Miller | MK110021L | Owner Manual | Miller DYNASTY 800 User manual

Miller DYNASTY 800 User manual
OM-275857J
2019-02
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
208/575 Volt Models W/Auto-Linet
380/575 Volt Three-Phase
W/Auto-Linet (CE)
Arc Welding Power Source
R
Dynasty 400, 800
Maxstar 400, 800
R
CE And Non-CE Models
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: TIG (GTAW)
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety Precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller, you can count on
years of reliable service with proper
maintenance. And if for some reason the unit
needs repair, there’s a Troubleshooting
section that will help you figure out what the
problem is, and our extensive service
network is there to help fix the problem.
Warranty and maintenance information for
your particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
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_Thank1 2019−01
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
7
8
8
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Dimensions, Weights And Base Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Simple Automation Application (14-Pin Interface) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Automation Connection (For 28-Pin Receptacle If Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Remote Memory Select Inputs (For 28-Pin Receptacle If Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. 115 Volts AC Cooler Receptacle, Supplementary Protector CB1, And Power Switch . . . . . . . . . . . . .
5-9. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. TIG HF Impulse/ Lift-Arc Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Cooler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Dynasty Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Maxstar Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Connecting Input Power For 400 Models And 800 CE Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16. Connecting Input Power For 800 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17. Software Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − DYNASTY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Accessing Control Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Accessing User Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. AC Independent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
9
9
11
12
12
12
15
16
18
18
19
19
19
20
21
21
22
25
26
26
27
28
29
29
30
34
36
38
39
39
40
42
43
TABLE OF CONTENTS
SECTION 7 − MAXSTAR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Accessing Control Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Accessing User Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − 28-PIN ADVANCED AUTOMATION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Accessing User Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Programmable TIG Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Accessing Tech Menu For Dynasty/Maxstar Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Sequencer And Weld Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Lockout Levels Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Blowing Out Inside of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Voltmeter/Ammeter Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2. Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3. Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING
WITH INVERTER MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . .
13-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-1. Memory (Program Storage Locations 1-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 15 − TIG PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-1. Lift-Arc And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-2. Pulser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-3. General (GEN) Tungsten To Change Programmable TIG Starting Parameters . . . . . . . . . . . . . . . . . .
SECTION 16 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY
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48
49
49
50
51
52
54
54
56
57
61
61
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63
64
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74
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DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Stock Number
907717002
907716002
907719002
907718002
Product
Dynasty 400
Maxstar 400
Dynasty 800
Maxstar 800
Council Directives:
• 2014/35/EU Low voltage
• 2014/30/EU Electromagnetic compatibility
• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 60974-1: 2012 Arc welding equipment – Part 1: Welding power sources
• IEC 60974-3: 2013 Arc welding equipment – Part 3: Arc striking and stabilizing devices
• IEC 60974-10: 2014 Arc welding equipment – Part 10: Electromagnetic compatibility requirements
Signatory:
April 19, 2017
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
278454B
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
DYNASTY 350 (AUTO-LINE 380-575)CE
DYNASTY 400 (AUTO-LINE 380-575) CE
Stock Number
907204021
907717002
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☐ YES
☒ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory Ef­
fects
10 cm
0.21
Health Ef­
fects
10 cm
0.16
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.26
3 cm
0.15
3 cm
0.33
1 cm
1 cm
1 cm
1 cm
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
15 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
275611-B
Tony Samimi
Date tested:
2016-02-09
183 cm
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
MAXSTAR 350 (AUTO-LINE 380-575) CE
MAXSTAR 400 (AUTO-LINE 380-575)CE
Stock Number
907334021
907716002
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☐ YES
☒ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory Ef­
fects
10 cm
0.16
Health Ef­
fects
10 cm
0.12
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.19
3 cm
0.11
3 cm
0.24
1 cm
1 cm
1 cm
1 cm
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
9 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
275612-B
Tony Samimi
Date tested:
2016-02-10
198 cm
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
DYNASTY 700 (AUTO-LINE 380-575)CE
DYNASTY 800 (AUTO-LINE 380-575)CE
Stock Number
907101021
907719002
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☐ YES
☒ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory Ef­
fects
10 cm
0.31
Health Ef­
fects
10 cm
0.31
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.50
3 cm
0.29
3 cm
0.65
2 cm
2 cm
3 cm
1 cm
2 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
36 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
275613-B
Tony Samimi
Date tested:
2016-02-11
317 cm
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
MAXSTAR 700 (AUTO-LINE 380-575)CE
MAXSTAR 800 AUTO-LINE 380-575)CE
Stock Number
907103021
907718002
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☐ YES
☒ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory Ef­
fects
10 cm
0.24
Health Ef­
fects
10 cm
0.15
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.24
3 cm
0.14
3 cm
0.31
1 cm
1 cm
1 cm
1 cm
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
13 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
275614-B
Tony Samimi
Date tested:
2016-02-08
280 cm
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2018−01
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn off unit, disconnect input power, and discharge input capacitors according to instructions in Manual before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-275857 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D Ventilate the work area and/or use local forced ventilation at the arc
to remove welding fumes and gases. The recommended way to
determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
OM-275857 Page 2
D Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use correct procedures and equipment of adequate capacity to lift and support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
OM-275857 Page 3
H.F. RADIATION can cause interference.
ARC WELDING can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment
perform this installation.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D
D 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.
1-4. California Proposition 65 Warnings
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-275857 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som_2018−01_fre
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une
personne qualifiée est définie comme celle qui, par la
possession d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
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).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales 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 et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
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.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
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 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. Débrancher le
câble pour le procédé non utilisé.
Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Éteignez l’unité, débranchez le courant électrique, et déchargez
les condensateurs d’alimentation selon les instructions indiquées
dans le manuel avant de toucher les pièces.
OM-275857 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas couper ou souder des jantes ou des roues. Les pneus
peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans
les normes de sécurité.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
OM-275857 Page 6
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les
bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
OM-275857 Page 7
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-4. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 5060 Spec-
trum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N,
Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government
Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA
Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd,
Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-275857 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précédentes.
. A complete Parts List is available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2017−04
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2017−04
Disconnect input plug or power before working on machine.
Safe5 2017−04
Keep your head out of the fumes.
Safe6 2017−04
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−04
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2017−04
Do not remove or paint over (cover) the label.
Safe20 2017−04
OM-275857 Page 9
. A complete Parts List is available at www.MillerWelds.com
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2017−04
Environmental Protection Use Period (China)
Safe123 2016−06
Disconnect input plug or power before working on machine.
Safe30 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
After taking proper precautions as shown, connect power to unit.
Safe29 2012−05
Do not use one handle to lift or support unit.
Safe31 2017−04
= < 60°
Always lift and support unit using both handles. Keep angle of lifting
device less than 60 degrees.
Use a proper cart to move unit.
Safe44 2012−05
V
V
>60s
V
Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 60 seconds
after power is turned off before working on unit, OR check input capacitor voltage, and be sure it is near 0 before touching any parts.
Safe42 2017−04
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
OM-275857 Page 10
. A complete Parts List is available at www.MillerWelds.com
3-2.
Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
A
Gas Output
Arc Striking
without Contact
(HF and Impulse)
Rated Welding
Current
Final Slope
Duty Cycle
Final Amperage
Shielded Metal
Arc Welding
(SMAW)
Direct Current
Pulse Percent
On Time
Volts
Line Connection
Initial Slope
Amperage
Output
Gas Tungsten Arc
Welding (GTAW)
V
Input
3 Phase Static
Frequency
Converter-Transfo
rmer-Rectifier
Output
Supplementary
Protector
Remote
Lift-Arc (GTAW)
I2
X
U2
U1
IP
I1max
I1eff
U0
Conventional
Load Voltage
AC Waveshape
Control
Primary Voltage
Pulser
Degree Of
Protection
EP Amperage
Rated Maximum
Supply Current
Pulse Frequency
Maximum
Effective Supply
Current
Work
Rated No Load
Voltage (OCV)
Protective Earth
(Ground)
Polarity Control
Postflow Timer
Initial Amperage
Electrode
EN Amperage
Process
S
Preflow Timer
Increase/
Decrease Of
Quantity
Seconds
Remote Standard
On
Remote 2T Hold
Off
Gas/DIG Control
Positive
Percent
Unit may be used
in environments
with increased
hazard of electric
shock
Sequence
Background
Amperage
f
AC Frequency
Hertz
Water (Coolant)
Input
Alternating
Current
Recall From
Memory
Water (Coolant)
Output
Gas Input
Arc Force (DIG)
Circulating Unit
With Coolant
Pump
Negative
Hz
OM-275857 Page 11
. A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for the power source is located on the front of the machine. Use the rating labels to determine input power
requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Specifications
. Do not use information in unit specifications tables to determine electrical service requirements. See Sections 5-14 and 5-15 for information on
connecting input power.
. This equipment will deliver rated output at an ambient air temperature up to 104 F ( 40 C).
A. Dynasty 400 Models
. Do not use information in unit specifications table to determine electrical service requirements. See Section 5-14 A for information on connecting
input power.
Welding Amperage
Range
Max Open Circuit
Voltage (Uo)
Low Open-Circuit
Voltage (Uo)
Rated Peak Striking
Voltage (Up)
IP Rating
3-400*
75♦
8-15***
14KV**
23
*Welding range for Stick process is 5-400 amperes. For TIG, the amperage range is tungsten diameter dependent (see Section 6-3).
** Arc starting device is designed for manual guided operations.
*** Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected.
♦ Normal open-circuit voltage (75) is present while in Stick with normal open_circuit voltage selected.
Input
Power
Three
Phase
Single
Phase
Amperes Input at Rated Load Output 50/60 Hz
Rated Welding
Output
208 V
230 V
380 V
400 V
460 V
575 V
KVA
KW
250 A @ 30 Volts,
100% Duty Cycle
28
25
15
14
13
10
10.3
9.8
300 A @ 32 Volts,
60% Duty Cycle
36
33
19
19
16
13
13.1
12.5
400 A @ 36 Volts,
20% Duty Cycle
55
49
29
28
24
19
19.4
18.6
200 A @ 28 Volts,
100% Duty Cycle
40
36
−
20
17
13
8.2
7.5
250 A @ 30 Volts,
60% Duty Cycle
52
47
−
26
22
17
10.9
9.9
300 A @ 32 Volts,
20% Duty Cycle
67
60
−
33
28
22
13.9
12.7
. 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. It also adjusts for voltage spikes within the entire range.
Notes
OM-275857 Page 12
. A complete Parts List is available at www.MillerWelds.com
B. Maxstar 400 Models
. Do not use information in unit specifications table to determine electrical service requirements. See Section 5-14B for information on connecting
input power.
Welding Amperage
Range
Max Open Circuit
Voltage (Uo)
Low Open-Circuit
Voltage (Uo)
Rated Peak Striking
Voltage (Up)
IP Rating
3-400*
75♦
8-15***
14KV**
23
*Welding range for Stick process is 5-400 amperes. For TIG, the amperage range is tungsten diameter dependent (see Section 6-3).
** Arc starting device is designed for manual guided operations.
*** Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected.
♦ Normal open-circuit voltage (75) is present while in Stick with normal open_circuit voltage selected.
Input Power
Three Phase
Single Phase
Amperes Input at Rated Load Output 50/60 Hz
Rated Welding
Output
208 V
230 V
380 V
400 V
460 V
575 V
KVA
KW
250 A @ 30 Volts,
100% Duty Cycle
26
23
14
13
12
9
9.4
9.1
300 A @ 32 Volts,
60% Duty Cycle
33
30
18
17
15
12
12
11.6
400 A @ 36 Volts,
20% Duty Cycle
50
45
27
25
22
17
18.1
17.3
200 A @ 28 Volts,
100% Duty Cycle
37
33
−
18
18
12
7.4
6.9
250 A @ 30 Volts,
60% Duty Cycle
48
43
−
24
20
16
10.0
9.2
300 A @ 32 Volts,
20% Duty Cycle
62
55
−
30
28
20
12.8
11.8
. This unit is equipped with Auto-Linet. Auto-Line is an internal inverter power source circuit that automatically links the power source to any
primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.
C. Dynasty 800 Models
. Do not use information in unit specifications table to determine electrical service requirements. See Section 5-14 A for information on connecting
input power.
Welding Amperage
Range
Max Open Circuit
Voltage (Uo)
Low Open-Circuit
Voltage (Uo)
Rated Peak Striking
Voltage (Up)
IP Rating
5-800*
75♦
8-15***
14KV**
23
*Welding range for Stick process is 5-750 amperes. For TIG, the amperage range is tungsten diameter dependent (see Section 6-3).
** Arc starting device is designed for manual guided operations.
*** Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected.
♦ Normal open-circuit voltage (75) is present while in Stick with normal open_circuit voltage selected.
Input
Power
Three
Phase
Single
Phase
Amperes Input at Rated Load Output 50/60 Hz
Rated Welding
Output
208 V
230 V
380 V
400 V
460 V
575 V
KVA
KW
500 A @ 40 Volts,
100% Duty Cycle
73
66
39
37
32
25
26.3
25.2
600 A @ 44 Volts,
60% Duty Cycle
96
86
51
48
42
33
34.7
33.2
800 A @ 44 Volts,
20% Duty Cycle
123
118
69
65
57
45
46.9
45.0
400 A @ 36 Volts,
100% Duty Cycle
98
88
−
48
41
32
20.2
18.6
500 A @ 40 Volts,
60% Duty Cycle
136
122
−
66
56
44
28.0
25.8
. 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. It also adjusts for voltage spikes within the entire range.
OM-275857 Page 13
. A complete Parts List is available at www.MillerWelds.com
D. Maxstar 800 Models
. Do not use information in unit specifications table to determine electrical service requirements. See Section 5-14B for information on connecting
input power.
Welding Amperage
Range
Max Open Circuit
Voltage (Uo)
Low Open-Circuit
Voltage (Uo)
Rated Peak Striking
Voltage (Up)
IP Rating
5-800*
75♦
8-15***
14KV**
23
*Welding range for Stick process is 5-750 amperes. For TIG, the amperage range is tungsten diameter dependent (see Section 6-3).
** Arc starting device is designed for manual guided operations.
*** Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected.
♦ Normal open-circuit voltage (75) is present while in Stick with normal open_circuit voltage selected.
Three Phase
Amperes Input at Rated Load Output 50/60 Hz
Rated Welding
Input Power
Output
208 V
230 V
380 V
400 V
460 V
575 V
KVA
KW
500 A @ 40 Volts,
100% Duty Cycle
68
61
36
34
30
24
24.4
23.3
600 A @ 44 Volts,
60% Duty Cycle
90
80
48
45
39
31
32.4
31.1
800 A @ 44 Volts,
20% Duty Cycle
120
109
65
61
53
42
41.8
40.1
400 A @ 36 Volts,
100% Duty Cycle
89
80
−
44
38
30
18.5
17.1
500 A @ 40 Volts,
60% Duty Cycle
126
112
−
61
53
41
26.2
24.0
Single Phase
. This unit is equipped with Auto-Linet. Auto-Line is an internal inverter power source circuit that automatically links the power source to any
primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.
Notes
OM-275857 Page 14
. A complete Parts List is available at www.MillerWelds.com
4-3. 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
C
400 Amp Models
800 Amp Models
24-3/4 in. (654 mm)
34-5/8 in. (879 mm)
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
G
F
E
803914-A
Weight
Weight
134 lb (60.8 kg)
198 lb (89.8 kg)
B. Welding Power Source With Cart And Cooler
Dimensions
A
400 Models
800 Models
43-1/8 in. (1095 mm)
53-3/4 in. (1365 mm)
A
B
B
23-1/8 in. (587 mm)
C
43-3/4 in. (1111 mm)
C
Weight - 400 Models
Weight - 800 Models
250.5 lb (113.6 Kg)
313 lb (142 Kg)
804642-C
OM-275857 Page 15
. A complete Parts List is available at www.MillerWelds.com
4-4. Environmental Specifications
A. IP Rating (All Models)
IP Rating
IP23
This equipment is designed for outdoor use.
IP23 2017−02
B. Temperature Specifications
Operating Temperature Range*
Storage/Transportation Temperature Range
14 to 104 °F (-10 to 40°C)
−4 to 131 °F (−20 to 55°C)
*Output is derated at temperatures above 104°F (40°C).
Temp_2016- 07
C. Information On Electromagnetic Compatibility (EMC) (Dynasty 400)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 42.7mW (or the short−circuit power Ssc is greater than 3,746,329
VA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary,
that the system impedance complies with the impedance restrictions.
ce-emc 1 2014-07
D. Information On Electromagnetic Compatibility (EMC) (Maxstar 400)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 42.7mW (or the short−circuit power Ssc is greater than 3,746,329
VA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary,
that the system impedance complies with the impedance restrictions.
ce-emc 1 2014-07
E. Information On Electromagnetic Compatibility (EMC) (Dynasty 800)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 17.03mW (or the short−circuit power Ssc is greater than
9.4MVA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the system impedance complies with the impedance restrictions.
ce-emc 1 2014-07
F. Information On Electromagnetic Compatibility (EMC) (Maxstar 800)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 49.09mW (or the short−circuit power Ssc is greater than
3.3MVA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the system impedance complies with the impedance restrictions.
ce-emc 1 2014-07
OM-275857 Page 16
. A complete Parts List is available at www.MillerWelds.com
G. China EEP Hazardous Substance Information
质
量
China EEP Hazardous Substance Information
质
Hazardous Substance
部 Component Name
(适)
(if applicable)
铅
Pb
Hg
镉
Cd
铬
Cr6
苯
PBB
苯醚
PBDE
黄铜铜部
Brass and Copper Parts
X
O
O
O
O
O
装
Coupling Devices
X
O
O
O
O
O
!装
Switching Devices
O
O
X
O
O
O
"#"#配
Cable and Cable
Accessories
X
O
O
O
O
O
$
Batteries
X
O
O
O
O
O
%表&'*SJ/T 11364 规,-..
This table is prepared in accordance with China SJ/T 11364.
O:
表2该
质5该部7 8质9: 量85GB/T26572规, 限量要>?@.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.
X:
表2该
质AC5该部 DE8质9: 量超FGB/T26572规, 限量要>.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.
HIKL限'*SJ/Z11388 规,N,.
The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.
EEP_2016−06
Notes
OM-275857 Page 17
. A complete Parts List is available at www.MillerWelds.com
4-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 10-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
DUTY CYCLE DYNASTY MAXSTAR 400/800
900
MD800 3 PHASE
MD800 1 PHASE
800
MD400 1 PHASE
MD400 3 PHASE
OUTPUT CURRENT (A)
700
600
500
400
300
200
100
0
10
Overheating
20
% DUTY CYCLE
60
100
A or V
0
15
Minutes
OR
Reduce Duty Cycle
4-6. Static Characteristics
The static (output) characteristics of the welding power source can be described as drooping during the SMAW and GTAW processes. Static
characteristics are also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors. Contact
the factory for specific information on the static characteristics of the welding power source.
OM-275857 Page 18
. A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Selecting A Location
Movement
!
Do not move or operate unit
where it could tip.
1
OR
2
Location And Airflow
3
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
18 in.
(460 mm)
If using lifting forks, extend forks
beyond opposite side of unit.
3
Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
5-2.
loc_large 2018-08 / 804746-B
Weld Output Terminals
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
1
Work Weld Output Terminal
(Dynasty Models)
(+) Positive Weld Output Terminal
(Maxstar Models)
Electrode Weld Output Terminal
Dynasty Models)
(−) Negative Weld Output Terminal
(Maxstar Models)
Remote 14 Receptacle (All
Models)
2
3
3
See Sections 5-10 thru 5-13 for connection diagrams.
2
1
804746-B
OM-275857 Page 19
. A complete Parts List is available at www.MillerWelds.com
5-3. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100
ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding
150 ft
(45 m)
100 ft (30 m) or Less****
Welding Amperes***
10 − 60% Duty Cycle
AWG
(mm2)
60 − 100% Duty Cycle
AWG
200 ft
(60 m)
10 − 100% Duty Cycle
(mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
150
3 (30)
3 (30)
2 (35)
1 (50)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
600
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
700
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
800
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
900
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use.
***Select weld cable size for pulsing application at peak amperage value.
****For distances longer than 100 ft (30 m) and up to 200 ft (60 m), use direct current (DC) output only. For distances longer than those shown
in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding Society at http://www.aws.org.
Ref. S-0007-M 2017−08 (TIG)
Notes
OM-275857 Page 20
. A complete Parts List is available at www.MillerWelds.com
5-4. Remote 14 Receptacle Information
Socket
15 VOLTS DC
OUTPUT
CONTACTOR
A
B
K
J
I
REMOTE
OUTPUT
CONTROL
H
C L N
D M
G
E F
A
Contactor control +15 volts DC, referenced to G.
B
Contact closure to A completes 15 volts DC
contactor control circuit and enables output.
C
Output to remote control; +10 volts DC output to
remote control.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from
remote control.
*Reconfigurable as input for Output Enable (Weld
Stop) − used to remotely stop the weld outside the
normal welding cycle. Connection to the D socket
must be maintained at all times. If the connection
is broken, output stops, and Auto Stop is displayed.
F
Current feedback; +1 volt DC per 100 amps
output.
H
Voltage feedback; +1 volt DC per 10 volts output.
I*
Valid arc indication closed to socket G with valid
arc. Electrical specifications: open collector transistor (see Section 5-5 for connection example).
J*
Arc length control lockout closed to socket G during Initial and Final Amperage and Slope, and during the background time of a <=10 Hz pulse waveform. Electrical specifications: open collector transistor (see Section 5-5 for connection example).
**
Touch Sense Detection closed to Socket G, with
Modbus’s Touch Sense enabled and machine not
triggered for weld output.
G
Return for all output signals: F, H, I, J and A.
K
Chassis
Output
Signals
804746-B / 218 716-A
COMMON
CHASSIS
Serial
Communication
Bus
Socket Information
L**
Modbus Common (RS485 Common)
M**
Modbus D1 (RS485 B+)
N**
Modbus D0 (RS485 A-)
Sockets G and K are electrically isloated from each other.
. If a remote hand control like the RHC-14 is connected to the Remote 14 receptacle, some current value above min. must be set on the remote
control before the Panel or Remote contactor is turned on. Failure to do so will cause current to be controlled by the panel control, and the remote
hand control will not function.
*Available with optional Automation Expansion memory card.
**Available with optional Modbus Expansion memory card. Modbus serial communication provides access to all front panel parameters and
machine functionality. See Owner’s Manual 265415 for a list of Modbus registers. Modbus expansion also includes functionality of Automation,
Hot Wire, and Hot Start Adjust expansions.
5-5. Simple Automation Application (14-Pin Interface)
. This application
requires the purchase of the automation expansion
module, Miller Part No. 301151.
CR1
Pin I, J: Collector
R
Coil resistance plus
R
should be chosen to
limit current to 75 mA
CR1
To User Equipment
+
User supplied power
up to 27 volts DC peak
−
Pin G: Emitter
OM-275857 Page 21
. A complete Parts List is available at www.MillerWelds.com
5-6.
Automation Connection (For 28-Pin Receptacle If Present)
A. Basic Automation Mode
Use this mode when only the basic functions of the automation board are required. These functions include Start/Stop, Valid Arc Indication, Gas Control, High Frequency Arc Start Disable, and Remote Memory Select. The welding power source functions as a standard unit. Automation 2 mode should
be used when an externally controlled pulse waveform is needed, or if the welder’s amperage is affected by noise injected into the cabling between
the remote equipment and the welder.
2
3
8
14
20
7
1
6
5
4
13
12
11
10
9
19
18
17
16
15
25
28
24 23
27
22
21
26
804746-B / 218716-A
Pin
Signal
Direction
1
Input
Start/Stop = Maintained connection to pin 8 starts the weld cycle. Opening connection stops weld cycle. For
momentary closure operation, set unit to 2T. A momentary closure greater than 100 ms, but less than 3/4 of a second
starts and stops weld output.
3
Input
Gas Control = This input is used to control the gas flow outside the settings of the preflow and/or postflow set on the
machine. Connection to pin 8 turns on gas.
4
Output
Valid Arc Indication = Paired with Pin 9. This output is used to signal external fixtures that the machine has detected a
valid arc. Pin is closed to pin 9 when the output is on and there is less than 65 load volts. Electrical specifications: Open
collector transistor maximum values 27 volts DC peak @ 75mA. (See Section 5-5 for typical application).
5
Output
Scaled Actual Welding Voltage = +1 volt DC per 10 volts of output w/reference to pin 11.
6
Output
Scaled Actual Welding Amperage = +1 volt DC per 100 amperes of output w/reference to pin 11.
7
Output
+15volts DC with respect to pin 11 (Pin A of 14 pin).
8
Output
Reference PIN = This pin is the signal reference for pins 1, 2, 3, 10, 15, 16.
9
Output
Valid Arc Indication Reference = Paired with Pin 4. Connect to user’s external voltage supply common. (See Section
5-5 for typical application).
10
Input
Memory Select = Used to select between memory numbers. Used in conjunction with pin 15 and 16 (See Sections 5-7
and 14-1).
11
Output
Amperage Control Reference = for pins 5, 6, 7, 17 and 18 (Pin D of 14 pin).
12
Output
Welders Chassis = Earth ground. Connected only if common potentials are needed between user equipment and the
welder.
13
Output
Arc Length Control Lockout = Paired with Pin 14. Used to send signal to an automatic voltage control to ignore the
voltage during certain situations. Pin is closed to pin 14 when weld cycle is in Initial Amperage, Initial Slope, Final Slope,
Final Amperage, and Pulsed Background time. Electrical specifications: Open collector transistor maximum values 27
volts DC peak @ 75mA. (See Section 5-5 for typical application).
14
Output
Arc Length Control Lockout Reference = Paired with Pin 13. Connect to user’s external voltage supply common (See
Section 4-17 for typical application).
15
Input
Memory Select = Used to select between memory numbers. Used in conjunction with pins 10 and 16 (See Sections 5-7
and 14-1).
16
Input
Memory Select = Used to select between memory numbers. Used in conjunction with pins 10 and 15 (See Sections 5-7
and 14-1).
17
Input
Amperage Control = 0 to +10 volts DC with respect to pin 11. The 10 volts represents the amperage value set on machines meter (Pin E of 14 pin).
Pin Information For 28-Pin Receptacle RC28
Continued on next page
OM-275857 Page 22
. A complete Parts List is available at www.MillerWelds.com
Continued from previous page Section A.
18
Output
+10 volts DC with respect to pin 11 for use with an external potentiometer to vary the signal into pin 17 (Pin C of 14 pin).
19
Input
23
Output
High Frequency Arc Start Disable = Disables the arc starter from being activated when connected to pin 8.
Final Slope Sequence Indication = Paired with Pin 24. Pin is closed to pin 24 when in Final Slope. Electrical specifications: Open collector transistor maximum values 27 volts DC peak @ 75mA (See Section 5-5 for typical application).
24
Output
Final Slope Sequence Indication Reference = Paired with pin 23. Connect to user’s external voltage supply common.
(See Section 5-5 for typical application).
All other pins not used.
B. Welder Controlled Automation Mode (Pin 20 Connected To Pin 8) Automation 1
Use this mode when only the basic functions of the automation board are required, or if the welder needs to control the initial and final weld timers. These
functions include Start/Stop, Valid Arc Indication, Gas Control, High Frequency Arc Start Disable, Remote Memory Select, and Emergency weld stop.
The welding power source functions as a standard unit. Automation 2 mode should be used when an externally controlled pulse waveform is needed, or
if the welder’s amperage is affected by noise injected into the cabling between the remote equipment and the welder.
2
3
7
8
14
20
1
6
5
4
13
12
11
10
9
19
18
17
16
15
25
28
24 23
27
22
21
26
804746-B / 218716-A
Pin
Signal
Direction
1
Input
Start/Stop = Maintained connection to pin 8 starts the weld cycle. Opening connection stops weld cycle. For momentary
closure operation, set unit to 2T. A momentary closure greater than 100 ms, but less than 3/4 of a second starts and
stops weld output.
2
Input
Emergency Weld Stop = Used to remotely stop the weld outside the normal welding cycle (i.e. light curtains or external
E-Stop). Connection to pin 8 must be maintained at all times. If the connection is broken, output stops, Postflow begins,
and will be displayed on the meters.
3
Input
Gas Control = This input is used to control the gas flow outside the settings of the preflow and/or postflow set on the
machine. Connection to pin 8 turns on gas.
4
Output
Valid Arc Indication = Paired with Pin 9. This output is used to signal external fixtures that the machine has detected a
valid arc. Pin is closed to pin 9 when the output is on and there is less than 65 load volts. Electrical specifications: Open
collector transistor maximum values 27 volts DC peak @ 75mA. (See Section 5-5 for typical application).
5
Output
Scaled Actual Welding Voltage = +1 volt DC per 10 volts of output w/reference to pin 11.
6
Output
Scaled Actual Welding Amperage = +1 volt DC per 100 amperes of output w/reference to pin 11.
7
Output
+15 volts DC with respect to pin 11 (Pin A of 14 pin).
8
Output
Reference PIN= This pin is the signal reference for pins 1, 2, 3, 10, 15, 16.
9
Output
Valid Arc Indication Reference = Paired with Pin 4. Connect to user’s external voltage supply common (See Section
5-5 for typical application).
10
Input
11
Output
Amperage Control Reference = for pins 5, 6, 7, 17 and 18 (Pin D of 14 pin).
12
Output
Welders Chassis = Earth ground. Connected only if common potentials are needed between user equipment and the
welder.
13
Output
Arc Length Control Lockout = Paired with Pin 14. Used to send signal to an automatic voltage control to ignore the
voltage during certain situations. Pin is closed to pin 14 when the weld cycle is in Initial Amperage, Initial Slope, Final
Slope, Final Amperage, and Pulsed Background time. Electrical specifications: Open collector transistor maximum values 27volts DC peak @ 75mA (See Section 5-5 for typical application).
Pin Information For 28-Pin Receptacle RC28
Memory Select = Used to select between memory numbers. Used in conjunction with pins 15 and 16 (See Sections 5-7
and 14-1).
Continued on next page
OM-275857 Page 23
. A complete Parts List is available at www.MillerWelds.com
Continued from previous page Section B.
14
Output
Arc Length Control Lockout Reference = Paired with Pin 13. Connect to user’s external voltage supply common (See
Section 5-5 for typical application).
15
Input
Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 16 (See Sections 5-7
and 14-1).
16
Input
Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 15 (See Sections 5-7
and 14-1).
17
Input
Amperage Control = 0 to +10 volts DC with respect to pin 11. The 10 volts represents the amperage value set on machines meter (Pin E of 14 pin).
18
Output
19
Input
High Frequency Arc Start Disable = Disables the arc starter from being activated when connected to pin 8.
20
Input
Welder Control Select = Connect to pin 8 to activate this mode.
23
Output
Final Slope Sequence Indication = Paired with Pin 24. Pin is closed to pin 24 when in Final Slope. Electrical specifications: Open collector transistor maximum values 27 volts DC peak @ 75mA (See Section 5-5 for typical application).
24
Output
Final Slope Sequence Indication Reference = Paired with pin 23. Connect to user’s external voltage supply common
(See Section 5-5 for typical application).
+10 volts DC with respect to pin 11 for use with an external potentiometer to vary the signal into pin 17 (Pin C of 14 pin).
All other pins not used.
C. User Controlled Automation Mode (Pin 25 Connected To Pin 8) Automation 2
This mode includes all the basic functions of the automation board, plus gives the welder the option to control the pulse or AC waveforms, or to minimize
the noise that can be injected into the welder from the control and cables. These functions include Start/Stop, Valid Arc Indication, Gas Control, High
Frequency Arc Start Disable, and Emergency weld stop.
2
3
7
8
14
20
1
6
5
4
13
12
11
10
9
19
18
17
16
15
25
28
24 23
27
22
21
26
804746-B / 21816-A
Pin
Signal
Direction
1
Input
Start/Stop = Maintained connection to pin 8 starts the weld cycle. Opening connection stops weld cycle. For momentary
closure operation, set unit to 2T. A momentary closure greater than 100 ms, but less than 3/4 of a second starts and
stops weld output.
2
Input
Emergency Weld Stop = Used to remotely stop the weld outside the normal welding cycle (i.e. light curtains or external
E-Stop). Connection to pin 8 must be maintained at all times. If the connection is broken, output stops, Postflow begins,
and will be displayed on the meters.
3
Input
Gas Control = This input is used to control the gas flow outside the settings of the preflow and/or postflow set on the
machine. Connection to pin 8 turns on gas.
4
Output
Valid Arc Indication = Paired with Pin 9. This output is used to signal external fixtures that the machine has detected a
valid arc. Pin is closed to pin 9 when the output is on and there is less than 65 load volts. Electrical specifications: Open
collector transistor maximum values 27 volts DC peak @ 75mA (See Section 5-5 for typical application).
5
Output
Scaled Actual Welding Voltage = +1 volt DC per 10 volts of output w/respect to pin 11.
6
Output
Scaled Actual Welding Amperage = +1 volt DC per 100 amperes of output w/respect to pin 11.
7
Output
+15 volts DC with respect to pin 11 (Pin A of 14 pin).
8
Output
Reference PIN = This pin is the signal reference for pins 1,2,3,10,15,16.
9
Output
Valid Arc Indication Reference = Paired with Pin 4. Connect to user’s external voltage supply common (See Section
5-5 for typical application).
Pin Information For 28-Pin Receptacle RC28
Continued on next page
OM-275857 Page 24
. A complete Parts List is available at www.MillerWelds.com
Continued from previous page, Section C.
11
Output
Control Reference for pins 5 and 6.
12
Output
Welders Chassis = Earth ground. Connected only if common potentials are needed between user equipment and the
welder.
19
Input
High Frequency Arc Start Disable = Disables the arc starter from being activated when connected to pin 8.
21
Input
Isolated EN Amperage Common = Paired with Pin 22.
22
Input
Isolated EN Amperage Command = Paired with pin 21. Sets output amperage value for a Maxstar and the EN amperage value for a Dynasty. Value should be between 0.3 to 10V corresponding to the minimum to maximum of the
machine.
25
Input
User Controlled Automation Select = Connect to pin 8 to active this mode.
26
Input
Isolated EP Amperage Command (Dynasty models only) = Paired with Pin 27. Sets EP(cleaning) output amperage
value. Value should be between 0.3 to 10 volts corresponding to the minimum to maximum of the machine.
27
Input
Isolated EP Amperage Common (Dynasty models only) = Paired with Pin 26.
28
Input
AC waveform Generation (Dynasty models only) - User controlled polarity(EN or EP), frequency (20-400 HZ) and balance of an AC waveform. When this pin is not connected to pin 8 the weld output is EN. When this pin is connected to
pin 8 the weld output is EP. Alternating between connection and disconnection at different intervals creates the frequency and balance of the waveform.
All other pins not used.
5-7. Remote Memory Select Inputs (For 28-Pin Receptacle If Present)
28-Pin Receptacle RC28
Socket Designations 0 = No Connection / 1 = Connected To Ground (Pin 8)
3
Function
10
16
15
Off
0
0
0
Memory 1
0
0
1
Memory 2
0
1
0
Memory 3
0
1
1
Memory 4
1
0
0
Memory 5
1
0
1
Memory 6
1
1
0
Memory 7
1
1
1
1
8
4
9
14
15
20
25
21
28
26
Notes
OM-275857 Page 25
. A complete Parts List is available at www.MillerWelds.com
5-8.
115 Volts AC Cooler Receptacle, Supplementary Protector CB1, And Power Switch
1
AC Cooler Receptacle
Receptacle RC2 supplies 115 V 4A
of single-phase power.
. RC2 is a designated use recept-
acle intended only for supplying
AC power to a Miller-approved
cooler.
3
2
1
Supplementary Protector CB1
CB1 protects cooler receptacle from
overload. If circuit breaker opens,
the receptacle does not work. Press
button to reset protector.
3
Power On/Off Switch
2
805593-A
5-9.
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.
805593-A
OM-275857 Page 26
. A complete Parts List is available at www.MillerWelds.com
5-10.
TIG HF Impulse/ Lift-Arc Connections
!
Turn off power before making connections.
1
Electrode Weld Output
Terminal
Connect TIG torch to electrode
weld output terminal.
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
5
Remote 14 Receptacle
If desired, connect remote control
to Remote 14 receptacle (see
Section 5-4).
5
Gas In Connection
Connect gas hose from gas supply to gas in fitting (see Section
5-9).
4
Tools Needed:
1
11/16 in. (21 mm for CE units)
2
3
805594-A
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-275857 Page 27
. A complete Parts List is available at www.MillerWelds.com
5-11.
Cooler Connections
. Cart
and cooler
equipment.
1
1
are
optional
AC Cooler Receptacle RC2
. RC2 is a designated use receptacle
intended only for supplying AC
power to a Miller-approved cooler.
2
2
115 VAC Cord
Provides 115 VAC to power cooler.
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.
3
4
5
7
6
Tools Needed:
GTAW Or Where
HF* Is Used
Application
3-1/2
Gal
11/16 in. (21 mm for CE units)
Low Conductivity Coolant
No. 043 810**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
Coolant
*HF: High Frequency Current
**Coolant 043 810, a 50/50 solution, protect to -37° F (-38°C) and resist algae growth.
NOTICE − Use of any coolant other than those listed in the table voids the warranty
on any parts that come in contact with the coolant (pump, radiator, etc.).
OM-275857 Page 28
805595-A
. A complete Parts List is available at www.MillerWelds.com
5-12.
Dynasty Stick Connections
!
Turn off power before making
connections.
. Connections shown are for
Dynasty models.
1
Work Weld Output Terminal
Connect work lead to work weld output
terminal.
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 5-4).
3
2
1
805596-A
5-13.
Maxstar Stick Connections
!
Turn off power before making
connections.
. Connections shown are for
Maxstar models.
1
+ Weld Output Terminal
Connect electrode lead to positive (+)
weld output terminal.
2
− Weld Output Terminal
Connect work lead to negative (−) weld
output terminal.
3
Remote 14 Receptacle
If desired, connect remote control to Remote 14 receptacle (see Section 5-4).
3
2
1
803916-C
OM-275857 Page 29
. A complete Parts List is available at www.MillerWelds.com
Elec Serv 2017−01
5-14. Electrical Service Guide
A. Dynasty 400 Models
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral.
. 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.
Three-Phase
Input Voltage (V)
208
230
380
400
460
575
Rated Maximum Supply Current I1max (A)
55
49
29
28
24
19
Maximum Effective Supply Current I1eff (A)
28
25
15
14
13
10
Time-Delay Fuses2
60
60
35
35
30
20
Normal Operating Fuses3
80
70
45
40
35
30
Max Recommended Standard Fuse Rating In Amperes1
Min Input Conductor Size In AWG
(mm2) 4
10 (6)
10 (6)
14 (2.5)
14 (2.5)
14 (2.5)
14 (2.5)
Max Recommended Input Conductor Length In Feet (Meters)
56 (17)
70 (21)
77 (23)
83 (25)
111 (34)
175 (53)
Min Grounding Conductor Size In AWG (mm2) 4
10 (6)
10 (6)
14 (2.5)
14 (2.5)
14 (2.5)
14 (2.5)
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
Single-Phase
Input Voltage (V)
208
230
400
460
575
Rated Maximum Supply Current I1max (A)
67
60
33
28
22
Maximum Effective Supply Current I1eff (A)
40
36
20
17
13
80
70
40
35
25
100
90
50
40
35
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay Fuses2
Normal Operating
Min Input Conductor Size In AWG
Fuses3
(mm2) 4
8 (10)
8 (10)
12 (4)
12 (4)
14 (2.5)
Max Recommended Input Conductor Length In Feet (Meters)
63 (19)
78 (24)
96 (29)
129 (39)
132 (40)
Min Grounding Conductor Size In AWG (mm2) 4
8 (10)
8 (10)
12 (4)
12 (4)
14 (2.5)
1
2
3
4
Reference: 2017 National Electrical Code (NEC) (including article 630)
If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
“Time-Delay” fuses are UL class “RK5” . See UL 248.
“Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. 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-275857 Page 30
. A complete Parts List is available at www.MillerWelds.com
B. Maxstar 400 Models
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral.
. 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.
Three-Phase
Input Voltage (V)
208
230
380
400
460
575
Rated Maximum Supply Current I1max (A)
50
45
27
25
22
17
Maximum Effective Supply Current I1eff (A)
26
23
14
13
12
9
60
50
30
30
25
20
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses2
Normal Operating
Fuses3
80
70
40
35
35
25
Min Input Conductor Size In AWG (mm2) 4
10 (6)
10 (6)
14 (2.5)
14 (2.5)
14 (2.5)
14 (2.5)
Max Recommended Input Conductor Length In Feet (Meters)
62 (19)
76 (23)
81 (25)
92 (28)
121 (37)
196 (60)
Min Grounding Conductor Size In AWG (mm2) 4
10 (6)
10 (6)
14 (2.5)
14 (2.5)
14 (2.5)
14 (2.5)
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
Single-Phase
Input Voltage (V)
208
230
400
460
575
Rated Maximum Supply Current I1max (A)
62
55
30
26
20
Maximum Effective Supply Current I1eff (A)
37
33
18
18
12
70
60
35
30
25
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay Fuses2
Normal Operating
Fuses3
90
80
45
40
30
Min Input Conductor Size In AWG (mm2) 4
8 (10)
8 (10)
12 (4)
12 (4)
14 (2.5)
Max Recommended Input Conductor Length In Feet (Meters)
68 (21)
85 (26)
106 (32)
139 (42)
145 (44)
8 (10)
8 (10)
12 (4)
12 (4)
14 (2.5)
Min Grounding Conductor Size In AWG
(mm2) 4
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. 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-275857 Page 31
. A complete Parts List is available at www.MillerWelds.com
C. Dynasty 800 Models
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral.
. 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.
Three-Phase
Input Voltage (V)
208
230
380
400
460
575
Rated Maximum Supply Current I1max (A)
123
118
69
65
57
45
Maximum Effective Supply Current I1eff (A)
75
66
39
37
32
26
150
125
80
80
70
50
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses2
Normal Operating
Fuses3
175
175
100
90
80
60
4 (21.1)
4 (21.1)
8 (8.3)
8 (8.3)
8 (8.3)
10 (5.2)
Max Recommended Input Conductor Length In Feet (Meters)
93 (28)
107 (33)
124 (38)
138 (42)
183 (56)
190 (58)
Min Grounding Conductor Size In AWG (mm2) 4
6 (13.3)
6 (13.3)
8 (8.3)
8 (8.3)
8 (8.3)
10 (5.2)
Min Input Conductor Size In AWG (mm2) 4
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
Single-Phase
Input Voltage (V)
208
230
400
460
575
Rated Maximum Supply Current I1max (A)
136
122
66
57
44
Maximum Effective Supply Current I1eff (A)
105
94
51
44
34
150
150
80
70
50
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay Fuses2
Normal Operating
Fuses3
200
175
90
80
60
Min Input Conductor Size In AWG (mm2) 4
2 (33.6)
3 (26.6)
6 (13.3)
8 (8.3)
8 (8.3)
Max Recommended Input Conductor Length In Feet (Meters)
111 (34)
112 (34)
189 (58)
161 (49)
255 (78)
6 (13.3)
6 (13.3)
8 (8.3)
8 (8.3)
10 (5.2)
Min Grounding Conductor Size In AWG
(mm2) 4
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. 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-275857 Page 32
. A complete Parts List is available at www.MillerWelds.com
D. Maxstar 800 Models
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral.
. 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.
Three-Phase
Input Voltage (V)
208
230
380
400
460
575
Rated Maximum Supply Current I1max (A)
120
109
65
61
53
42
Maximum Effective Supply Current I1eff (A)
70
62
37
35
30
24
150
125
80
70
60
50
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses2
Normal Operating
Fuses3
Min Input Conductor Size In AWG (mm2) 4
175
150
90
90
70
60
4 (21.1)
6 (13.3)
8 (8.3)
8 (8.3)
10 (5.2)
10 (5.2)
Max Recommended Input Conductor Length In Feet (Meters)
96 (29)
75 (23)
132 (40)
148 (45)
129 (39)
203 (62)
Min Grounding Conductor Size In AWG (mm2) 4
6 (13.3)
6 (13.3)
8 (8.3)
8 (8.3)
10 (5.2)
10 (5.2)
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
Single-Phase
Input Voltage (V)
208
230
400
460
575
Rated Maximum Supply Current I1max (A)
126
112
61
53
41
Maximum Effective Supply Current I1eff (A)
97
87
48
41
32
150
125
70
60
50
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay Fuses2
Normal Operating
Fuses3
175
150
90
70
60
Min Input Conductor Size In AWG (mm2) 4
3 (26.6)
3 (26.6)
8 (8.3)
8 (8.3)
8 (8.3)
Max Recommended Input Conductor Length In Feet (Meters)
98 (30)
122 (37)
130 (40)
172 (52)
275 (84)
6 (13.3)
6 (13.3)
8 (8.3)
8 (8.3)
10 (5.2)
Min Grounding Conductor Size In AWG
(mm2) 4
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. 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-275857 Page 33
. A complete Parts List is available at www.MillerWelds.com
5-15.
Connecting Input Power For 400 Models And 800 CE 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. Follow established procedures regarding
the installation and removal of
lockout/tagout devices.
!
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
= GND/PE Earth Ground
4
7
. 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.
2
See rating label on unit and check input
voltage available at site.
For Three-Phase Operation
1
2
L1
3
L2
5
3
L3
6
4
1
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
Over-Current Protection
Select type and size of over-current
protection using Section 5-14 (fused disconnect switch shown).
Close and secure door on disconnect
device. Follow established lockout/tagout
procedures to put unit in service.
Tools Needed:
Ref. Input 2 2012−05 / Ref. 804746-B
OM-275857 Page 34
. A complete Parts List is available at www.MillerWelds.com
B. Connecting Single-Phase Input Power
!
Installation must meet all National
and Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout
input power before connecting
input conductors from unit. Follow
established procedures regarding
the installation and removal of
lockout/tagout devices.
!
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
1
=GND/PE Earth Ground
8
. The Auto-Line circuitry in this unit au-
10
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
9
L1
L2
See rating label on unit and check input
voltage available at site.
1
1
1
2
3
3
2
6
3
6
4
5
4
5
Black And White Input Conductor
(L1 And L2)
Red Input Conductor
Green Or Green/Yellow Grounding
Conductor
Insulation Sleeving
Electrical Tape
Insulate and isolate red conductor as
shown.
6 Input Power Cord
7 Disconnect Device (switch shown in
the OFF position)
8 Disconnect Device Grounding
Terminal
9 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 and L2 to
disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current
protection using Section 5-14 (fused disconnect switch shown).
Close and secure door on disconnect
device. Follow established lockout/tagout
procedures to put unit in service.
Tools Needed:
Input1 2012−05 / Ref. 804746-B / 803766-A
OM-275857 Page 35
. A complete Parts List is available at www.MillerWelds.com
5-16.
Connecting Input Power For 800 Models
A. Connecting Three-Phase Input Power
6
5
3
= GND/PE Earth Ground
4
8
10
7
1
2
L1
L2
L3
4
9
3
6
1
Tools Needed:
5/16 in.
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
Input 5 2016−06 / Ref. 805604-A
See rating label on unit and check input voltage available at site.
1
!
Input Power Conductors (Customer
Supplied)
Disconnect and lockout/tagout input
power before connecting input
conductors from unit. Follow established procedures regarding the installation and removal of lockout/
tagout devices.
Select size and length of conductors using
Section 5-14. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
!
Make input power connections to the
welding power source first.
Welding Power Source Input Power
Connections
!
Always connect green or green/yellow
conductor to supply grounding
terminal first, and never to a line
terminal.
NOTICE − The Auto-Line circuitry in this unit
automatically adapts the power source to the
primary voltage being applied. Check input
voltage available at site. This unit can be connected to any input power between 190 and
625 VAC without removing cover to relink the
power source.
OM-275857 Page 36
2
Strain Relief (Customer Supplied)
Install strain relief of proper size for unit and input conductors. Route conductors (cord)
through strain relief. Tighten strain relief.
3
Welding Power Source Grounding
Terminal
4
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to machine grounding terminal first.
5
Welding Power Source Line Terminals
(TE1)
6 Input Conductors L1 (U), L2 (V), L3 (W)
Connect input conductors L1 (U), L2 (V), and
L3 (W) to welding power source line terminals.
Reinstall cover on welding power source.
Disconnect
Device
Input
Power
Connections
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, L2, and L3 to
disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current protection using Section 5-14 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures
to put unit in service.
. A complete Parts List is available at www.MillerWelds.com
B. Connecting Single-Phase Input Power
5
6
1
4
=GND/PE Earth Ground
8
10
1
7
2
3
9
L1
L2
6
4
1
Tools Needed:
5/16 in.
Input9 2013−04 / Ref. 805604-A
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation.
!
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.
Welding Power Source Input Power
Connections
Disconnect
Connections
2
7
Disconnect Device (switch shown in
OFF position)
8
Disconnect Device (Supply) Grounding
Terminal
Strain Relief (Customer Supplied)
Install strain relief of proper size for unit and
conductors. Route conductors (cord) through
strain relief. Tighten strain relief.
3
Machine Grounding Terminal
4
Green Or Green/Yellow Grounding
Conductor
See rating label on unit and check input voltage available at site.
Connect green or green/yellow grounding
conductor to welding power source grounding
terminal first.
1
5
Welding Power Source Line Terminals
6
Input Conductors L1 And L2
Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section 5-14. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
Connect input conductors L1 and L2 to welding power source line terminals.
Reinstall cover on welding power source.
Device
Input
Power
Connect green or green/yellow grounding
conductor to disconnect device grounding terminal first.
9
Disconnect Device Line Terminals
Connect input conductors L1 and L2 to
disconnect device line terminals.
10 Overcurrent Protection
Select type and size of overcurrent protection
using Section 5-14 (fused disconnect switch
shown).
Close and secure door on line disconnect device. Follow established lockout/tagout procedures to put unit in service.
OM-275857 Page 37
. A complete Parts List is available at www.MillerWelds.com
5-17. Software Updates
A. Reasons For Downloads Of Software Updates
• To get the latest feature and software improvements with future software updates.
• For all circuit board replacements, a software update is required to ensure proper unit operation.
• A software update is required to ensure proper software expansion operation of all purchased feature expansions.
B. Requirements
. A computer with an SD memory card port, or SD
memory card reader is required to download software updates.
The SD logo is a registered trademark of SD-3C LLC.
C. How To Download Software Updates
1. On your web browser, go to http://www.millerwelds.com/support/system-setup-and-software/tig-software.
2. Select System Installation Instructions (PDF) and follow the instructions.
1
2
D. Software Installation
1
2
. Software
updates may reset
machine back to default values.
Card Requirements:
Full size memory card required.
1
2
Memory Card Port
Indicator LED
Insert card containing new software into
port while machine is on, (but not while
welding). Inserting card while welding
will interrupt the welding process.
LED indicator blinks green when machine is reading from or writing to the
card, and the meter displays go blank.
The update time may vary up to three
minutes. Do Not remove card while LED
is blinking green.
After successfully reading from or writing to the card, the LED switches from
blinking to continuous green, and the
meters illuminate. The machine is now
ready for use.
Troubleshooting:
Indicator LED is blinking red: Error updating software, or software is not compatible. Try removing and inserting card.
Indicator LED is continuous red: Cannot
read card. Card might be bad.
273670-B
OM-275857 Page 38
. A complete Parts List is available at www.MillerWelds.com
SECTION 6 − DYNASTY OPERATION
6-1.
Controls
3
2
4
1
14
12
13
5
6
7
8
9
11
10
273670-B
. For all front panel switch pad controls:
press switch pad to turn on light and enable normal function.
. Green on nameplate
indicates a TIG
function, Gray indicates a normal Stick
function.
1
Encoder Control
Use Encoder control in conjunction with applicable front panel function switch pads to
change values for that function.
2
Memory Card Port And Indicator
Port is used to add features to the machine,
and update software. Indicator is lit while
card is being accessed.
3 Ammeter And Parameter Display
Shows actual amperage while welding and
preset amperage while idle. It also shows
parameter selection options when in any
menu.
4 Voltmeter And Selected Parameter
Display
Shows actual rectified average voltage
when voltage is present at the weld output
terminals. It also show parameter descriptions when in any menu.
5
Polarity Control (Dynasty Only)
6
7
Process Controls
Output Controls
8
Pulser Controls
9 Sequencer Controls
10 Gas/DIG Controls
11 AC Waveshape (Dynasty Only)
12 Amperage And Spot Time Control
13 Memory
14 Memory Display
Displays active memory.
OM-275857 Page 39
. A complete Parts List is available at www.MillerWelds.com
6-2.
Accessing Control Panel Menu
1
Memory Button
Select Memory 1-9 (See Section 14)
2
3
4
2
3
4
5
Rotate Encoder to adjust parameter
setting.
5
1
Parameter Display
Setting Display
Encoder Control
Amperage Button
Amperage Control
Controls the welding amperage output.
Limits the maximum output of a remote
amperage device.
273670-B
Polarity Selection (Dynasty Only)
Select output type AC or DC. With DC selected, the electrode will be negative (DCEN) for TIG, and
positive (DCEP) for Stick.
Process Selection
TIG HF Impulse is a non-contact arc starting method for AC and DC TIG welding (see Section 15-1).
TIG Lift-Arc Is a contact arc starting method for AC and DC TIG welding (see Section 15-1).
Stick − Select AC or DC Stick (SMAW) welding.
Trigger Mode Selection (See Section 9-3 for additional trigger function options).
[RMT] [STD]
Typical setting for a remote foot or hand control. RMT STD requires a maintained contact closure to
enable weld output. Amperage can be controlled with a remote potentiometer, or it can be set at the
control panel.
[RMT] 2T [HOLD] (TIG Only)
Remote control required. Allows the operator to weld without holding the trigger closed. To start the
weld, operator presses and releases trigger. To stop the weld, the operator again presses and releases the trigger. In this mode, only the output contactor is controlled by the remote control. Amperage must be set on the control panel. (see Section 9-3).
[OUT] [ON]
Output on. (Stick and TIG Lift Only)
!
Weld output terminals are energized at all times when displays read [OUT] [ON].
No remote control or trigger required. Amperage can be controlled at the control panel or with a remote
potentiometer. Blue output on LED illuminates to indicate output is on.
OM-275857 Page 40
. A complete Parts List is available at www.MillerWelds.com
. *PRO−SET provides PROfessionally developed SETtings for the weld process.
PRO−SET flashes one time and reveals the professional setting for the parameter.
Pulse Control
PPS
PK T
BK A
100
40%
25%
Pulsing is available in the TIG process. Controls can be
adjusted while welding.
Reduces heat input to minimize distortion and increase travel
speed. Range is 01. to 500 pulses per second AC (Dynasty
only) or 01. to 5000 pulses per second DC.
Press switch pad to enable pulser.
[PPS]* Pulses Per Second: Range is 0.1− 500.
[BK A]* Background Amperage Time: Range is 5− 95% of peak
amperage value.
. See Section 15-2 for additional Pulser information,or
visit,http:/www.millerwelds.com/resources/
welding-resources/
Sequencer Control
INTL
ISLP
FSLP
FNL
20A
OFF
OFF
10A
The welding output can be programmed to specific amperages
and durations for repetitive applications. Sequencer is only
available in the TIG process. Sequencer is disabled if a remote
control with variable amperage is connected to the machine.
[INTL] Initial Amperage: Range is min − 400/800 amps.
[ISLP] Initial Slope Time: Range is OFF − 50.0T (seconds).
[FSLP] Final Slope Time: Range is OFF − 50.0T (seconds).
[FNL] Final Amperage: Range is min − 400/800 amps.
(See Sections 9-1 and 9-2 for setting weld time.)
Gas/DIG Control
PRE
POST
DIG
ENEP
BAL
FREQ
0.2T
AUTO
30%
150A
75%
120H
[PRE] Preflow Time:
Controls length of time gas flows prior to arc start.
Range is OFF−25T (seconds).
[POST] Post Flow Time:
Increasing setting increases length of time gas flows after
welding stops. Range is OFF − 50T (seconds). AUTO
calculates the time based on the maximum amperage of each
welding cycle. The minimum time is 8 seconds. Auto =
maximum amperage/10.
[DIG]* Arc Force Control:
Controls the amount of additional amperage at low voltage
(short arc length) conditions. Adjust the force of the arc for
different joint configurations and electrodes. Range is OFF −
100%. PRO-Set values available for both 6010 and 7018 electrodes
CARBon ARC Gouging can be selected at one step above
DIG’s 100%.
AC Waveshape Control (Dynasty Only)
[ENEP] EN Amperage and EP Amperage TIG only:
Controls both electrode negative and positive amperage value.
. Both EN Amperage and EP Amperage LEDs will be lit.
. See Section 6-3 to select Independent EN and EP Amper-
age control.
[BAL] Balance Control (%EN) TIG Only:
Controls oxide cleaning. Increasing the setting reduces cleaning. Range is BALL, 50 − 99%. Stick is fixed at 50%. “BALL”
sets the Balance to 30%. This is to allow the operator to form
a ball on the tip of the tungsten. It is not for normal welding
operation.
[FREQ] AC Frequency (Hz): Controls arc width. Increasing the
setting narrows the arc width. Range is 20 to 400 Hz.
OM-275857 Page 41
. A complete Parts List is available at www.MillerWelds.com
6-3.
Accessing User Setup Menu
3
5
4
1
1
2
3
4
5
Amperage Button
Gas/Dig Button
Parameter Display
Setting Display
Encoder Control
To access the User Functions,
press and hold the Amperage (A)
and the Gas/DIG controls until
[USER] [MENU] is displayed. To
scroll through the user menu functions, press and release the Gas/
DIG control.
USER MENU
Rotate Encoder to adjust parameter setting.
To exit user menu, press Amperage
and Gas/DIG controls at the same
time and then release, or turn power
off.
2
Tungsten Diameter Selection
TUNG
3/32
RMT
2T
ENEP SAME
AC
WAVE
AC
COM.A
HOTS
ON
Each tungsten size has preset starting parameters specific to that diameter for optimized starting. Range is
0.020−3/16 in. or 0.5−4.8 mm. To manually set starting
parameters, see Section 15-3.
Output Trigger Mode Functions
See Section 9-3 to reconfigure RMT functions.
Independent Amperage Control
[ENEP] [SAME] - standard mode of operation for controlling AC amperage setting.
[ENEP] [INDP] - for AC TIG welding allows the user to set
the EP amperage independently from the EN amperage.
When [INDP], the user can set the EP waveshape (sine,
square, triangle) independently from the EN waveshape
(see Section 6-4).
AC Waveshape Selection
Use Encoder to select between advanced squarewave
[ADVS], soft squarewave [SOFT], sine wave [SINE], or
triangle wave [TRI]. The default is Soft.
Application: Use advance squarewave when a more focused arc is required for better directional control. Use
soft squarewave when a softer arc with a more fluid
puddle is desired. Use sine wave to simulate a conventional power source. Use triangular waveshape when the
effects of peak amperage with reduced overall heat input
is required to help control distortion on thin materials.
AC Commutation Amperage Selection (Dynasty Only)
Use Encoder to select between [HIGH] or [LOW] AC commutation amperage. Default is High.
Application: Use High commutation amperage when a more aggressive arc is preferred. Use Low commutation amperage when a less
aggressive and quieter arc is preferred.
Arc Starting Mode Selection (Stick)
[HOTS] [ON]
Provides additional amperage while striking the electrode to prevent the electrode from sticking.
[HOTS] [OFF]
No additional starting amperage to assist in starting the electrode.
270536-A
OM-275857 Page 42
. A complete Parts List is available at www.MillerWelds.com
6-4. AC Independent
. AC Independent Expansion is available on
DX models with SD expansion card and on
CE models with feature enable through the
user menu (see Section 6-3).
A. AC Independent Amperage
1
4
3
EN
EP
AC Waveshape Control
Press switch pad until desired function is selected.
2
3
4
150 A
150 A
Encoder Control (Set Value)
Ammeter (Displays Value)
Voltmeter (Parameter Selection)
EN Amperage [EN] - Use with AC TIG only to select electrode negative amperage value.
EP Amperage [EP] - Use with AC TIG only to select
electrode positive amperage value.
2
5
5
Amperage Button
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 rotate the Encoder control. The changing average value is displayed on
the ammeter. Example: If EN Amperage is 150, EP
Amperage is 100, Balance is 75%, and Frequency
is 120, the average amperage is 138 amps. If you
press the Amperage switch pad and rotate the Encoder control until 69 amps is displayed, the EN amperage is now 75 and EP amperage is now 50. The
balance remains 75%, and the frequency is still
120, and the 1.5 to 1 EN amperage to EP amperage
ratio is maintained.
1
B. AC Independent Waveshape
3
4
5
1
. See Section 6-3 for additional information
on Accessing User Setup Menu. The
[ACEN], [ACEP] option replaces the [AC]
option.
USER
1
2
3
MENU
Amperage (A) Button
Gas/DIG Control
Parameter Display
Press Gas/DIG switch pad until [ACEN] is displayed. Press the A switch pad to toggle between [ACEN] and [ACEP].
4
5
Setting Display
Encoder Control
Use Encoder to select between advanced
squarewave [ADVS], soft squarewave
[SOFT], sine wave [SINE], or triangle wave
[TRI]. The default is [SOFT].
2
ACEN
SOFT
ACEP
SOFT
270536-A
OM-275857 Page 43
. A complete Parts List is available at www.MillerWelds.com
SECTION 7 − MAXSTAR OPERATION
7-1.
Controls
2
3
4
1
12
10
11
5
6
7
8
9
275861-B / Ref. 803901-A
. For all front panel switch pad controls:
Port is used to add features to the machine,
and update software. Indicator is lit while
card is being accessed.
. Green on nameplate
3
press switch pad to turn on light and enable normal function.
indicates a TIG
function, Gray indicates a normal Stick
function.
1
Encoder Control
Use Encoder control in conjunction with applicable front panel function switch pads to
change values for that function.
2
Memory Card Port And Indicator
OM-275857 Page 44
Ammeter And Parameter Display
Shows actual amperage while welding and
preset amperage while idle. It also shows
parameter selection options when in any
menu.
4
Voltmeter And Selected Parameter
Display
Shows actual rectified average voltage
when voltage is present at the weld output
terminals. It also show parameter descriptions when in any menu.
5
6
7
8
9
10
11
12
Process Controls
Output Controls
Pulser Controls
Sequencer Controls
Gas/DIG Controls
Amperage And Spot Time Control
Memory
Memory Display
Displays active memory.
. A complete Parts List is available at www.MillerWelds.com
Notes
Welding Tip:
Securely connect work clamp to a clean area
close to the weld joint.
OM-275857 Page 45
. A complete Parts List is available at www.MillerWelds.com
7-2.
Accessing Control Panel Menu
1
Memory Button
Select Memory 1-9 (See Section 14)
2
3
4
2
3
4
5
Rotate Encoder to adjust parameter
setting.
5
1
Parameter Display
Setting Display
Encoder Control
Amperage Button
Amperage Control
Controls the welding amperage output.
Limits the maximum output of a remote
amperage device.
275861-B
Polarity Selection (Dynasty Only)
Select output type AC or DC. With DC selected, the electrode will be negative (DCEN) for TIG, and
positive (DCEP) for Stick.
Process Selection
TIG HF Impulse is a non-contact arc starting method for AC and DC TIG welding (see Section 15-1).
TIG Lift-Arc Is a contact arc starting method for AC and DC TIG welding (see Section 15-1).
Stick − Select AC or DC Stick (SMAW) welding.
Trigger Mode Selection (See Section 9-3 for additional trigger function options).
[RMT] [STD]
Typical setting for a remote foot or hand control. RMT STD requires a maintained contact closure to
enable weld output. Amperage can be controlled with a remote potentiometer, or it can be set at the
control panel.
[RMT] 2T [HOLD] (TIG Only)
Remote control required. Allows the operator to weld without holding the trigger closed. To start the
weld, operator presses and releases trigger. To stop the weld, the operator again presses and releases the trigger. In this mode, only the output contactor is controlled by the remote control. Amperage must be set on the control panel. (see Section 9-3).
[OUT] [ON]
Output on. (Stick and TIG Lift Only)
!
Weld output terminals are energized at all times when displays read [OUT] [ON].
No remote control or trigger required. Amperage can be controlled at the control panel or with a remote
potentiometer. Blue output on LED illuminates to indicate output is on.
OM-275857 Page 46
. A complete Parts List is available at www.MillerWelds.com
. *PRO−SET provides PROfessionally developed SETtings for the weld process.
PRO−SET flashes one time and reveals the professional setting for the parameter.
Pulse Control
PPS
PK T
BK A
INTL
ISLP
FSLP
FNL
PRE
POST
DIG
100
40%
25%
20A
OFF
OFF
10A
0.2T
AUTO
30%
Pulsing is available in the TIG process. Controls can be adjusted while welding.
Reduces heat input to minimize distortion and increase travel
speed. Range is 01. to 5000 pulses per second.
Press switch pad to enable pulser.
[PPS]* Pulses Per Second: Range is 0.1− 500.
[BK A]* Background Amperage Time: Range is 5− 95% of
peak amperage value.
. See Section 15-2 for additional Pulser information,or
visit,http:/www.millerwelds.com/resources/
welding-resources/
Sequencer Control
The welding output can be programmed to specific amperages and durations for repetitive applications. Sequencer is
only available in the TIG process. Sequencer is disabled if a
remote control with variable amperage is connected to the
machine.
[INTL] Initial Amperage: Range is min − 400/800 amps.
[ISLP] Initial Slope Time: Range is OFF − 50.0T (seconds).
[FSLP] Final Slope Time: Range is OFF − 50.0T (seconds).
[FNL] Final Amperage: Range is min − 400/800 amps.
(See Sections 9-1 and 9-2 for setting weld time.)
Gas/DIG Control
[PRE] Preflow Time:
Controls length of time gas flows prior to arc start.
Range is OFF−25T (seconds).
[POST] Post Flow Time:
Increasing setting increases length of time gas flows after
welding stops. Range is OFF − 50T (seconds). AUTO calculates the time based on the maximum amperage of each
welding cycle. The minimum time is 8 seconds. Auto = maximum amperage/10.
[DIG]* Arc Force Control:
Controls the amount of additional amperage at low voltage
(short arc length) conditions. Adjust the force of the arc for different joint configurations and electrodes. Range is OFF −
100%. PRO-Set values available for both 6010 and 7018
electrodes.
CARBon ARC Gouging can be selected at one step above
DIG’s 100%.
OM-275857 Page 47
. A complete Parts List is available at www.MillerWelds.com
7-3.
Accessing User Setup Menu
3
5
4
USER MENU
1
1
2
3
4
5
Amperage Button
Gas/Dig Button
Parameter Display
Setting Display
Encoder Control
To access the User Functions,
press and hold the Amperage (A)
and the Gas/DIG controls until
[USER] [MENU] is displayed. To
scroll through the user menu functions, press and release the Gas/
DIG control.
Rotate Encoder to adjust parameter setting.
To exit user menu, press Amperage
and Gas/DIG controls at the same
time and then release, or turn power
off.
2
Tungsten Diameter Selection
TUNG
RMT
HOTS
3/32
2T
ON
Each tungsten size has preset starting parameters specific to that diameter for optimized starting. Range is
0.020−3/16 in. or 0.5−4.8 mm. To manually set starting
parameters, see Section 15-3.
Output Trigger Mode Functions
See Section 9-3 to reconfigure RMT functions.
Arc Starting Mode Selection (Stick)
[HOTS] [ON]
Provides additional amperage while striking the electrode to prevent the electrode from sticking.
[HOTS] [OFF]
No additional starting amperage to assist in starting the
electrode.
270536-A
OM-275857 Page 48
. A complete Parts List is available at www.MillerWelds.com
SECTION 8 − 28-PIN ADVANCED AUTOMATION
OPERATION
8-1.
Controls
3
2
4
1
. To activate 28−pin Advanced Automa-
2
. For all front panel switch pad controls:
Port is used to add features to the machine,
and update software. Indicator is lit while
card is being accessed.
tion, see Section 5-6C
press switch pad to turn on light and enable normal function.
. Green on nameplate
indicates a TIG
function, Gray indicates a normal Stick
function.
1 Encoder Control
Use Encoder control in conjunction with applicable front panel function switch pads to
change values for that function.
273670-B
6
5
3
Memory Card Port And Indicator
Ammeter And Parameter Display
Shows actual rectified average voltage
when voltage is present at the weld output
terminals. It also show parameter descriptions when in any menu.
5
6
Process Controls
Gas/DIG Controls
Shows actual amperage while welding. It also shows parameter selection options when
in any menu.
4
Voltmeter And Selected Parameter
Display
OM-275857 Page 49
. A complete Parts List is available at www.MillerWelds.com
8-2.
Controls
1
2
3
2
1
Parameter Display
Setting Display
Encoder Control
Rotate Encoder to adjust
parameter setting.
3
273670-B
Process Selection
TIG HF Impulse is a non-contact arc starting method for AC and DC TIG welding (see Section 15-1).
TIG Lift-Arc Is a contact arc starting method for AC and DC TIG welding (see Section 15-1).
Gas/DIG Control
PRE
POST
OM-275857 Page 50
0.2T
AUTO
[PRE] Preflow Time:
Controls length of time gas flows prior to arc start.
Range is OFF−25T (seconds).
[POST] Post Flow Time:
Increasing setting increases length of time gas flows after
welding stops. Range is OFF − 50T (seconds). AUTO
calculates the time based on the maximum amperage of
each welding cycle. The minimum time is 8 seconds.
Auto = maximum amperage/10.
. A complete Parts List is available at www.MillerWelds.com
8-3.
Accessing User Setup Menu
3
5
4
USER MENU
1
1
2
3
4
5
Amperage Button
Gas/Dig Button
Parameter Display
Setting Display
Encoder Control
To access the User Functions, press
and hold the Amperage (A) and the
Gas/DIG controls until [USER]
[MENU] is displayed. To scroll through
the user menu functions, press and release the Gas/DIG control.
Rotate Encoder to adjust parameter
setting.
To exit user menu, press Amperage
and Gas/DIG controls at the same time
and then release, or turn power off.
2
TIG Start Parameters
STAT
AC
OFF
COM.A
AC Communication Amperage Selection (Dynasty Only)
Use Encoder to select between [HIGH] OR [LOW] AC commutation amperage. Default is High.
Application: Use High commutation amperage when a more aggressive arc is preferred. Use Low commutation
amperage when a less aggressive and quieter arc is preferred.
273670-B
OM-275857 Page 51
. A complete Parts List is available at www.MillerWelds.com
8-4.
Programmable TIG Start Parameters
A. OFF/ON (Start Amperage And Time)
3
Current (A)
2
Start Amperage
STAT OFF
1
Start Time
Off is the default setting. Use Encoder control to select On. When On is selected, the
Amperage switch pad LED turns on.
Dynasty models have a separate set of
parameters for AC and DC.
The AC and DC parameters are selected
remotely through pin 28 of the 28-pin automation receptacle where EP (electrode
positive = AC, and EN (electrode negative)
= DC
1 Amperage Button
2 Encoder Control
3 Amps Meter
Preset Advanced Automation TIG Start
Parameters
Default values for Advanced Automation
TIG Start Amperage and Start Time are as
follows: AC Start Amperage = 50A, AC
Start Time = 30ms. DC Start Amperage =
30A and DC Start Time = 30ms.
If it is necessary or desired to change the
Advanced Automation TIG Start Amperage
and Start Time values from the default values, press the amperage switch pad to step
through each adjustable parameter (see
Sections B and C).
B. Programmable TIG Start Amperage
3
2
Current (A)
STRT
30A
Start
Amperage
1
Amperage Button
2
Encoder Control
3
Amps Meter
OM-275857 Page 52
1
To adjust TIG Start Amperage proceed as
follows:
Press Amperage switch pad until the
current start amperage is displayed. The
current Start Amperage is displayed on the
amps meter, and can be adjusted by
rotating the Encoder control.
To change Start Time, proceed to Section
C.
. A complete Parts List is available at www.MillerWelds.com
C. Programmable Start Time
3
2
Current (A)
TIME
30m
1
Start
Time
1
Amperage Button
2
Encoder Control
3
Amps Meter
To adjust Programmable Start Time proceed as follows:
Press Amperage switch pad until the current start time is displayed. The current
Start Time is displayed in milliseconds on
the amps meter, and can be adjusted by rotating the Encoder control.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-275857 Page 53
. A complete Parts List is available at www.MillerWelds.com
SECTION 9 − ADVANCED FUNCTIONS
9-1. Accessing Tech Menu For Dynasty/Maxstar Models
1
2
3
TECH
Press and hold Amperage and
Gas/Dig buttons for approximately
two seconds to scroll past User
Menu to Tech Menu. Use Gas/Dig
button to cycle through parameters
that can be set.
4
MENU
Amperage Button
Gas/Dig Button
5
3
4
5
Parameter Display
Setting Display
Encoder Control
1
Rotate Encoder to adjust parameter setting.
To exit tech menu, press Amperage
and Gas/DIG controls at the same
time.
2
ARC
T/CY
ERR
LOG
STUC
OFF
OCV
NORM
WELD
TMRS
OFF
COOL
AUTO
LOCK
OFF
EXPC
OFF
MACH
RSET
SOFT
WARE
SERL
NUM
270536-A
OM-275857 Page 54
. A complete Parts List is available at www.MillerWelds.com
[ARC] [T/CY] Arc Timer: Monitors hours, minutes, and cycles of valid arc on. To view these different elements, rotate Encoder. To reset,
rotate encoder until [RESET] [YES] is displayed. Press Menu button to display [RESET] [Done]. Displays turn to [000] [000].
[ERR] [LOG] Error Log: Use to view last eight logged error events. Each event may list multiple Error Codes. See Section 10-4.
[STUC] Stick Stuck: Detects if the electrode is stuck or shorted to the workpiece. Turns weld output off to aid in freeing the electrode. To
turn on, rotate Encoder. Not recommended for air carbon arc or large diameter electrodes.
[OCV] Open Circuit Voltage: Allows user to select between Normal (NORM) and Low open circuit voltage. Low reduces open circuit voltage
to between 8 and 15 volts. To select, rotate Encoder.
[WELD] [TMRS] Weld Timers: [ON] enable and [OFF] disable the feature. See Section 9-2 for information on setting weld timers. Weld
Timers work with or without Sequencer feature.
[COOL] Cooler Auxiliary Power (Optional): Selects between [OFF], [ON], and [AUTO]. [OFF] disables the power supply to the receptacle.
[ON] enables the power supply to the receptacle. [AUTO] provides power to the receptacle when the TIG process is active.
[LOCK]: Limits user control and adjustability of machine. See Section 9-4 For instructions and operation.
[EXPC] External Pulse Control Commands: Turn on when it is desired to control machine from an external source. When command is
on, a command voltage of 0−10 volts DC equals off − 400 amps.
[MACH] [RESET] Machine Reset:: Resets all machine values back to factory defaults. To reset, rotate Encoder to [RESET] [YES]. Then
press Amperage button. [RESET] [DONE] will be displayed when the reset is complete and factory defaults have been restored.
[SOFT] [WARE] Software Number: Software number and revision will be displayed.
[SERL] [NUM] Serial Number: If serial number displayed does not match serial number of machine, see Section 10-4.
OM-275857 Page 55
. A complete Parts List is available at www.MillerWelds.com
9-2. Sequencer And Weld Timer
Sequencer Control With Weld Timers ON
INTL
20A
INTL
OFF
OFF
ISLP
This function is available while using the TIG
process, but is disabled if a remote foot or fingertip control is connected while in the RMT
STD mode. When active, the sequencer controls the following parameters of the weld
cycle:
Initial Amperage
Range is 3−400/5−800 amps
Initial Time*
Range is OFF to 25.0T (seconds)
Initial Slope Time
Range is OFF to 50.0T (seconds)
FSLP
FNL
OFF
10A
Final Slope Time
Range is OFF to 50.0T (seconds)
Final Amperage
Range is 3−400/5−800 amps
Final Time*
Range is OFF to 25.0T (seconds)
. When a remote switch is connected to the
FNL
OFF
welding power source, use the remote
switch to control the weld cycle. Amperage
is controlled by the welding power source.
*
Enabled features with weld timer On (see
Section 9-1).
Weld Timer
WELD
OM-275857 Page 56
OFF
With Weld Timer enabled, press Amperage (A)
button, and rotate Encoder to set weld time.
Range is Off or 0.1−99.9 and 100−999 (sec)
(see Section 9-1).
. A complete Parts List is available at www.MillerWelds.com
9-3. Output Control And Trigger Functions
A. Remote (Standard), 2T, And 4TE Torch Trigger Operation
Current (A)
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Time
Postflow
Preflow
Standard
P/H
P/H = Push and hold trigger.
R
Maintained Switch
R
Foot Or Finger
Remote Control
R = Release trigger.
. When a foot or finger remote current control is connected to the welding power source, initial amps, initial
slope, final slope and final amps are controlled by the remote control, not by the welding power source.
Remote 2T
P/R
P/R
P/R = Push and release trigger.
. If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.
Remote 4TE
P/R
P/R
P/R
*P/R
P/R
P/R = Push and release trigger;
*Push and releasing during final slope will break the arc and go to postflow
. For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends.
. When a remote switch is connected to the welding power source, use the remote switch to control the weld cycle.
Amperage is controlled by the welding power source.
Application:
Use 4T Momentary trigger method when the functions of a remote current control are desired, but only a remote on/off
control is available.
OM-275857 Page 57
. A complete Parts List is available at www.MillerWelds.com
B.
3T Specific Trigger Method
Current (A)
3T Trigger Operation
*
*
*
*
*
*
A
Preflow
P/R
I
*
B
Initial Amps /Initial Slope
P/H
I
R
I
P/H
I
C
Main Amps
R
I
D
Final Slope /Final Amps
P/H
F
R
F
E
Postflow
P/H
F
* 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.
P/R = Push and Release (in less than 3/4 of a second)
P/H = Push and Hold
R = Release
I = Initial Switch
F = Final Switch
1 3T (Specific Trigger Operation)
Sequencer is required to reconfigure for 3T.
3T requires a specific type of remote control with two independent momentarycontact switches. One will be designated
initial switch, and it must be connected between Remote 14 receptacle pins A and B.
The second will be designated as the final
switch, and it must be connected between
Remote 14 receptacle pins D and E.
2 Encoder Control
To select 3T, turn Encoder control.
Definitions:
Initial slope rate is the rate of amperage
change determined by the initial amperage,
initial slope time, and main amperage.
Final slope rate is the rate of amperage
change determined by the main amperage, final slope time, and final amperage.
OM-275857 Page 58
Operation:
A. Press and release initial switch within 3/4
second to start shielding gas flow. To stop
the preflow sequence before preflow time
elapses (25 seconds), press and release
final switch. The preflow timer will reset
and the weld sequence can be started
again.
. If an initial switch closure is not made
again before preflow time ends, gas flow
stops, the timer resets, and an initial
switch press and release is necessary to
start the weld sequence again.
B. Press initial switch to start arc at initial
amps. Holding switch will change amperage at initial slope rate (release switch to
weld at desired amperage level).
C. When main amperage level is reached,
initial switch can be released.
D. Press and hold the final switch to decrease amperage at final slope rate (release switch to weld at desired amperage
level).
E. When final amperage has been reached,
the arc extinguishes and shielding gas
flows for the time set on the Postflow control.
Application:
With the use of two remote switches instead
of potentiometers, 3T gives the operator the
ability to infinitely increase, decrease, or
pause and hold amperage within the range
determined by the initial, main, and final amperages.
. A complete Parts List is available at www.MillerWelds.com
C. 4T, 4Tm, And 4TL Specific Trigger Method
4T And 4Tm Application:
Use 4T or 4Tm (modified) trigger
method when the functions of a
remote current control are desired,
but only a remote on/off control is
available.
4T* allows the operator to toggle
between weld current and final
current.
4T And 4Tm Torch Trigger Operation
Current (A)
. When a remote switch is con-
Main Amps
Initial Slope
nected to the welding power
source, use the remote switch
to control the weld cycle.
Amperage is controlled by the
welding power source.
Final Slope
Initial Amps
Final Amps
P/H
4TL Application:
Postflow
Preflow
R
*P/R
P/H
*P/R
The ability to change current levels
without either initial slope or final
slope, gives the operator the opportunity to adjust filler metal without
breaking the arc.
R
4TL (mini logic) allows the operator
to toggle between initial slope or
main amps and initial amps. Final
Amperage is not available. Final
slope always slopes to minimum
amperage and ends the cycle.
P/H = Push and hold trigger; R = Release trigger
*4T only: P/R = Push trigger and release in less than 0.75 second
. 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.
4TL Torch Trigger Operation
Current (A)
Main Amps
Final Slope
Initial Slope
**
Initial Amps
**
Preflow
P/H
R
P/R P/R
**
**
P/R
Postflow
P/R
P/R
P/H
P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 0.75 seconds
* * = Arc can be extinguished at final slope rate at any time by pushing and holding trigger
OM-275857 Page 59
. A complete Parts List is available at www.MillerWelds.com
D. On Trigger Operation
Voltage (V)
ON
2 Sec
Current (A)
Stick
Touch Stick
Electrode
Lift Stick
Electrode
Current (A)
Lift
Main Amperage
*Final Slope
Initial Amperage
Initial Slope
Touch Current
*Final Amperage
Touch Tungsten
Lift Tungsten
Slightly
*Becomes active with Spot Time enabled.
OM-275857 Page 60
Lift Tungsten
. A complete Parts List is available at www.MillerWelds.com
9-4.
Lockout Functions
See Section 9-1 for information on how to
access Lockout Functions.
There are four (1−4) different lockout levels.
Each successive level allows the operator
more flexibility.
. Before activating lockout levels, be sure
that all procedures and parameters are
established. Parameter adjustment is
limited while lockout levels are active.
To turn On lockout feature, proceed as
follows:
1
LOCK
OFF
1
2
2
CODE
Encoder Control
Amperage Button
Press Amperage (A) control to toggle
between the lock off and code off displays.
Toggle control until [CODE] [OFF] is
displayed
Rotate Encoder to select a lockout code
number. Select a number between 1 and
999. The number will appear on the
amperage, right, display.
. Remember
(write down) this code
number, as you will need this number to
turn this feature off, or make changes to
your settings.
Toggle Amperage control until [LOCK] is
displayed. You may now select a lockout
level. See table below for the degree of
adjustability associated with each lock level.
Exit Advanced Functions according to
Section 9-1.
To turn Off lockout feature, proceed as
follows:
Toggle Amperage control until Code is
displayed.
Use Encoder control to enter the same code
number that was used to turn on the lockout
feature.
Press the Amperage control. The amperage
meter display will turn to [OFF]. Lockout is
now off. Exit Advanced Functions according
to Section 9-1.
9-5. Lockout Levels Defined
Minimum Adjustability
Degree Of Adjustability
Lock Level 1
Adjustable
Locked
Lock Level 2
Adjustable
Panel Amps
Locked
Panel Amps
Maximum Adjustability
Lock Level 3
Adjustable
Locked
Panel Amps +/- 10%
Lock Level 4
Adjustable
Locked
Remote Amps
(min−panel)
Panel Amps +/- 10%
Polarity (Dyn Only)
Polarity (Dyn Only)
Polarity (Dyn Only)
Polarity (Dyn Only)
Process
Process
Process
Process
Output
Output
Output
Pulser (on/off only)
Pulser (on/off only)
Output
Pulser
Pulser
Sequencer
Sequencer
Sequencer
Sequencer
Gas/DIG
Gas/DIG
Gas/DIG
Gas/DIG
Waveshape
Waveshape
Waveshape
Waveshape
OM-275857 Page 61
. A complete Parts List is available at www.MillerWelds.com
SECTION 10 − MAINTENANCE AND TROUBLESHOOTING
10-1. Routine Maintenance
!
Disconnect power before maintaining.
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Δ = Repair
l = Replace
Every
3
Months
nl Labels
n l Gas Hoses
~ Weld Terminals
Every
3
Months
nΔ lCables And Cords
Every
6
Months
~:Durning heavy service, clean monthly.
10-2. 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.
804746-B
OM-275857 Page 62
. A complete Parts List is available at www.MillerWelds.com
10-3. Voltmeter/Ammeter Display Messages
1
4
Release Trigger
Latching Errors:
RELE
ASE
CHEK
INPT
TRIG
GER
WELD
CABL
SEE
O.M.
2
Un Short Output
UN S
}
Latching Errors
HORT
5
OUTP
Not Valid
UT
NOT
VALD
3
Over Temperature Error
OVER
6
Lock Level
TEMP
LOCK
LEV1
7
Software Not Valid
. All directions are in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
1
[RELE] [ASE] / [TRIG] [GER]
Remote 14 receptacle contactor control
(Pins A−B) must be opened before proceeding.
2
[UN S] [HORT] / [OUTP] [UT]
Short on weld output connections must be
removed before proceeding. See Section
10-4 if display shows after weld output connections have been verified as not having
a short.
3
[OVER] [TEMP]
Over temperature condition has occurred.
Error will clear after temperatures reach acceptable levels.
SOFT
WARE
8
NOT
VALD
9
REMO
TE
ADV
AUTO
4 Latching Errors:
When one of the following errors occurs,
the Standby LED flashes. To clear error,
press Standby button or turn off power. See
Section 10-4 if error does not clear or happens frequently.
[CHEK] [INPT] Check Input
High or low voltage has been sensed. Have
a qualified person check input voltage.
[WELD] [CABL] Weld Cable
An error relate to the weld cables has been
sensed. Straighten out or shorten weld
cables. If Carbon arc gouging, adjust DIG
setting to CARBon ARC. See Section 6-2
(Dynasty) or Section 7-2 (Maxstar).
[SEE] [O.M.] See Owner’s Manual: See
Section 10-4.
5 [NOT] [VALD]
Message is displayed when attempting an
incompatible setup; i.e., pressing AC
Waveshape while in DC.
6
[LOCK] [LEV1], 2, 3, 4
Is displayed when attempting adjustments
that are incompatible with the active selected lock level.
7
[SOFT] [WARE] [NOT] [VALD]
A software compatibility error has been detected. A software update is required (see
Section 5-17 Software Updates). See Section 10-4 if display shows after a software
update is performed.
8
[REMO] [TE]
Message is displayed when attempting an
incompatible setup with remote pendant
connected to 14-pin receptacle. Front panel is disabled with exception of access to
Tech Menu.
9
[ADV] [AUTO]
Message is displayed when attempting an
incompatible setup with 28-pin Advanced
Automation enabled.
OM-275857 Page 63
. A complete Parts List is available at www.MillerWelds.com
10-4. Troubleshooting Table
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 5-15).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-15).
Check for proper input power connections (see Section 5-15).
No weld output; meter display On.
If using remote control, be sure correct process is enabled to provide output control at Remote 14
receptacle (see Section 5-4 as applicable).
Input voltage outside acceptable range of variation (see Section 5-14).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-5).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 5-3).
Clean and tighten all weld connections (see Section 10-1).
Fan not operating.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Wandering arc.
Use proper size tungsten (see Section 13).
Use properly prepared tungsten (see Section 13).
Reduce gas flow rate.
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
Increase postflow time.
Check and tighten all gas fittings (see Section 10-1).
Water in torch. Refer to torch manual.
Blank Display.
Verify Power to machine.
A software update may be required (see Section 5-17, Software Updates). Contact factory if display remains blank after a software update is performed.
Error message [ERR] [LOG] is dis- Contact a Factory Authorized Service Agent for an explanation of the error code.
played.
Latching Errors see Section 10-3.
Contact a Factory Authorized Service Agent if error does not clear or happens frequently.
Error message [SEE] [O.M.] is dis- Contact a Factory Authorized Service Agent.
played.
Tech Menu (See Section 5-17) Contact a Factory Authorized Service Agent.
[SERL][NUM] is selected, and serial
number displayed does not match serial
number of machine.
Error message [UN S] [HORT] / [OUTP] Contact a Factory Authorized Service Agent if display shows after weld output connections have been
[UT] is displayed.
verified as not having a short.
Error message [SOFT] [WARE] [NOT] Contact a Factory Authorized Service Agent if display shows after a software update is performed.
[VALD] is displayed.
OM-275857 Page 64
. A complete Parts List is available at www.MillerWelds.com
Notes
OM-275857 Page 65
SECTION 11 − ELECTRICAL DIAGRAMS
Figure 11-1. Maxstar 400 Circuit Diagram (Page 1 of 2)
OM-275857 Page 66
275851-F
Figure 11-2. Maxstar 400 Circuit Diagram (Page 2 of 2)
275851-F
OM-275857 Page 67
Figure 11-3. Dynasty 400 Circuit Diagram (Page 1 of 2)
OM-275857 Page 68
275852-F
Figure 11-4. Dynasty 400 Circuit Diagram (Page 2 of 2)
275852-F
OM-275857 Page 69
Figure 11-5. Maxstar 800 Circuit Diagram (Page 1 of 2)
OM-275857 Page 70
275853-E
Figure 11-6. Maxstar 800 Circuit Diagram (Page 2 of 2)
275853-E
OM-275857 Page 71
Figure 11-7. Dynasty 800 Circuit Diagram (Page 1 of 2)
OM-275857 Page 72
275854-E
Figure 11-8. Dynasty 800 Circuit Diagram (Page 2 of 2)
275854-E
OM-275857 Page 73
SECTION 12 − HIGH FREQUENCY
12-1. 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
TIG
high_freq 2018-01
12-2. Installation Showing Possible Sources Of HF Interference
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
5
6
Best Practices
Not Followed
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
OM-275857 Page 3
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
12-3. Recommended Installation To Reduce HF Interference
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece if
required by
codes.
9
Best Practices Followed
Metal Building
8
8
11
10
Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case (clean paint
from around hole in case, and use case
screw), work output terminal, line disconnect device, input supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire.
Ground conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
Metal Building Requirements
9
Metal Building Panel Bonding
Methods
Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.
10 Windows and Doorways
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
11 Overhead Door Track
Ground the track.
OM-275857 Page 75
SECTION 13 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
Ref. gtaw_Inverter_2018-01
Whenever possible and practical, use DC weld output instead of AC weld output.
13-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten )
. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
(DCEN) − Argon
AC − Argon
Direct Current Electrode Negative
Unbalanced Wave
(For Use With Aluminum)
(For Use With Mild Or Stainless Steel)
2% Ceriated, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens
.010 in. (.25 mm)
Up to 15
Up to 15
.020 in. (.50 mm)
5-20
5-20
.040 in. (1 mm)
15-80
15-80
1/16 in. (1.6 mm)
70-150
70-150
3/32 in. (2.4 mm)
150-250
140-235
1/8 in. (3.2 mm)
250-400
225-325
5/32 in. (4.0 mm)
400-500
300-400
3/16 in (4.8 mm)
500-750
400-500
1/4 in. (6.4 mm)
750-1000
500-630
♦Typical argon shielding gas flow rates are 10 to 25 CFH (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS).
13-2. 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.
1
Radial Grinding
Causes Wandering Arc
2
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.
1-1/2 To 4 Times
Electrode Diameter
4
2
Tungsten Electrode
A 2% ceriated tungsten is recommended.
3
15° to 30°
3
Ideal Grind Angle Range: 15° to 30°
. 30 degrees is the recommended electrode grind angle.
4
1
Wrong Tungsten
Preparation
OM-275857 Page 76
Ideal Tungsten Preparation − Stable Arc
Straight Ground
Grind lengthwise, not radial.
SECTION 14 − MEMORY
14-1.
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:
First, press Memory switch pad until
the desired program storage location
(1-9) is displayed.
1
Second, press Polarity switch pad
until the desired polarity, AC or DC,
LED is lit
Third, press Process switch pad until
desired process, TIG HF Impulse,
TIG Lift Arc, or Stick, LED is lit.
1st
The program at the chosen location,
for the desired polarity and process, is
now the active program.
2
Fourth, change or set all desired
parameters.
2nd
3rd
3
. Polarity And AC Waveshape Controls Are
TIG (HF or Lift)
Available On Dynasty Models Only.
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-275857 Page 77
SECTION 15 − TIG PROCEDURES
15-1. Lift-Arc And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arct button light is On,
start arc as follows:
Lift-Arc Start Method
1
“Touch”
1−2
Seconds
2
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control. Hold
electrode to workpiece for 1-2 seconds, and slowly lift electrode. Arc is
formed when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low sensing voltage is present between electrode and workpiece. The solid-state
output contactor does not energize
until after electrode is touching workpiece. This allows a properly prepared electrode (see Section 13-2) to
touch workpiece without overheating,
sticking, or getting contaminated.
Application:
Lift-Arc is used for the DCEN or AC
GTAW process when HF Start method is not permitted, or to replace the
scratch method.
Do NOT Strike Like A Match!
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-275857 Page 78
15-2.
Pulser Control
3
2
4
1
Percent (%) Peak Time
Control Setting
Pulsed Output Waveforms
PPS
Peak 50%/Background 50%
Balanced 50%
Peak Amp
Bkg Amp
80%
More Time At Peak
Amperage
20%
More Time At Background
Amperage
1
Pulser Control
Pulsing is available while using the TIG process. Controls can be adjusted while welding.
Press switch pad to enable pulser.
ON - When lit, this LED indicates the pulser
is on.
Press switch pad until desired parameter
LED is lit.
To turn Pulser off, press and release switch
pad until the On LED turns off.
2
3
Encoder Control (Set Value)
Ammeter (Displays Value)
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 experi-
enced welder may have the PPS setting
much higher, depending on their personal
preferences, and on what they are trying to
accomplish.
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
6-1). If one pulse per second is being used,
and peak time is set at 50%, one-half second
is spent at peak amperage, and the other
50%, or one-half second, is spent at the
background amperage. Increasing peak
time increases time spent at peak amperage, which increases heat input into the part.
A good starting point for peak time is about
50-60%. To find a good ratio, you will have to
experiment a bit, but the idea is to decrease
heat input into the part, and increase the
cosmetics of the weld.
BKGND A - (Background amps) is set as a
percentage of the peak amps setting. If peak
amps is set at 200, and background amps at
50%, your background amps is 100 amps
when the machine pulses on the background side of the cycle. The lower background amperage helps reduce heat input.
Increasing or decreasing background amps
increases or decreases the overall average
amperage, which helps determine how fluid
your puddle is on the background side of the
pulse cycle. Overall, you want your puddle
to shrink to about one-half the size, but still
remain fluid. To start with, set background
amps at about 20-30% for stainless/carbon
steel, or at about 35-50% for aluminum alloys.
4
Pulsed Output Waveforms
Example shows affect changing the Peak
Time control has on the pulsed output waveform.
Application:
Pulsing refers to the alternating raising and
lowering of the weld output at a specific rate.
The raised portions of the weld output are
controlled in width, height, and frequency,
forming pulses of weld output. These pulses
and the lower amperage level between them
(called the background amperage) alternately heat and cool the molten weld puddle.
The combined effect gives the operator better control of penetration, bead width,
crowning, undercutting, and heat input.
Controls can be adjusted while welding.
Pulsing can also be used for filler material
addition technique training.
. Function is enabled when LED is lit.
OM-275857 Page 79
15-3. General (GEN) Tungsten To Change Programmable TIG Starting Parameters
1
2
3
2
1
TUNG
Encoder Control
Parameter Display
Amperage Button
Once inside the machine set up
menu, tungsten parameter values
can be manually changed by pressing the Amperage switch pad to
step through each adjustable parameter. Rotate encoder to change
the value.
GEN
3
Available Parameter Settings
Current (A)
Start Amperage
Preset Amperage Minimum
Start Time
Start Slope Time
Parameter
• Start Output Polarity (POL)
• Start Amperage (STRT)
• Start Time (TIME)
• Start Slope (SSLP)
• Preset Minimum
Amperage (PMIN)
OM-275857 Page 80
Default AC
Default DC
Range
• EP (Electrode Positive)
• EN (Electrode Negative)
• EP / EN
• 30 A
• 60 A
• 5−200 A
• 140 ms
• 30 ms
• 0−250 ms
• 10 ms
• 50 ms
• 0−250 ms
• 10 A
• 5A
• 1 (DC) 2 (AC) −25 A
SECTION 16 − STICK WELDING (SMAW) GUIDELINES
7014
7018
7024
Ni-Cl
308L
DEEP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
MED
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
FLAT
HORIZ*
LOW
SMOOTH, EASY,
FASTER
NI-CL
EP
ALL
LOW
CAST IRON
308L
EP
ALL
LOW
STAINLESS
USAGE
ALL
EP
AC
EP
6011
DC*
6010
ELECTRODE
450
400
350
300
AMPERAGE
RANGE
250
200
150
PENETRATION
6013
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
POSITION
6010
&
6011
100
50
DIAMETER
ELECTRODE
16-1. Electrode and Amperage Selection Chart
MIN. PREP, ROUGH
HIGH SPATTER
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087985-A
OM-270536 Page 81
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
Effective January 1, 2019
(Equipment with a serial number preface of MK 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.
* Subarc Wire Drive Assemblies
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to
* TIG Torches (No Labor)
authorized distributors that new Miller equipment sold after the
* Tregaskiss Guns (No Labor)
effective date of this limited warranty is free of defects in material
* Water Cooling Systems
and workmanship at the time it is shipped by Miller. THIS
* Wireless Remote Foot/Hand Controls and Receivers
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Work Stations/Weld Tables (No Labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
5. 6 Months — Parts
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Batteries
Within the warranty periods listed below, Miller will repair or replace 6. 90 Days — Parts
any warranted parts or components that fail due to such defects in
* Accessories (Kits)
material or workmanship. Miller must be notified in writing within
* Canvas Covers
thirty (30) days of such defect or failure, at which time Miller will
* Induction Heating Coils and Blankets, Cables, and
provide instructions on the warranty claim procedures to be
Non-Electronic Controls
followed. Notifications submitted as online warranty claims must
* M-Guns
provide detailed descriptions of the fault and troubleshooting steps
* MIG Guns, Subarc (SAW) Torches, and External
taken to diagnose failed parts. Warranty claims that lack the
Cladding Heads
required information as defined in the Miller Service Operation
* Remote Controls and RFCS-RJ45
Guide (SOG) may be denied by Miller.
* Replacement Parts (No labor)
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of a defect within the warranty coverage time
periods listed below. Warranty time periods start on the delivery Miller’s True Blue® Limited Warranty shall not apply to:
date of the equipment to the end-user purchaser, or 12 months 1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
after the equipment is shipped to a North American distributor, or
station table tops and welding curtains, or parts that
18 months after the equipment is shipped to an international
fail due to normal wear. (Exception: brushes and
distributor, whichever occurs first.
relays are covered on all engine-driven products.)
1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs, 2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
Diodes, and Discrete Rectifier Modules
covered by the manufacturer’s warranty, if any.
2. 3 Years — Parts and Labor Unless Specified
* Auto-Darkening Helmet Lenses (No Labor) (See 3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
Classic Series Exception Below)
improperly operated or misused based upon industry
* Engine Driven Welder/Generators
standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the
and necessary maintenance, or equipment which has
Engine Manufacturer.)
been used for operation outside of the specifications for
* Insight Welding Intelligence Products
the equipment.
* Inverter Power Sources
4. Defects caused by accident, unauthorized repair, or
* Plasma Arc Cutting Power Sources
improper testing.
* Process Controllers
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
* Semi-Automatic and Automatic Wire Feeders
AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
* Transformer/Rectifier Power Sources
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
3. 2 Years — Parts and Labor
The exclusive remedies for warranty claims are, at Miller’s
* Auto-Darkening Helmet Lenses − Classic Series Only option, either: (1) repair; or (2) replacement; or, if approved in
(No Labor)
writing by Miller, (3) the pre-approved cost of repair or
* Auto-Darkening Weld Masks (No Labor)
replacement at an authorized Miller service station; or (4)
* Fume Extractors − Capture 5, Filtair 400 and Industrial payment of or credit for the purchase price (less reasonable
Collector Series
depreciation based upon use). Products may not be returned
4. 1 Year — Parts and Labor Unless Specified
without Miller’s written approval. Return shipment shall be at
* AugmentedArc and LiveArc Welding Systems
customer’s risk and expense.
* Automatic Motion Devices
The above remedies are F.O.B. Appleton, WI, or Miller’s
* Bernard BTB Air-Cooled MIG Guns (No Labor)
authorized service facility. Transportation and freight are the
* CoolBelt and CoolBand Blower Unit (No Labor)
customer’s responsibility. TO THE EXTENT PERMITTED BY
LAW, THE REMEDIES HEREIN ARE THE SOLE AND
* Desiccant Air Dryer System
EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
* Field Options
(NOTE: Field options are covered for the remaining THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
SPECIAL,
INCIDENTAL OR
warranty period of the product they are installed in, DIRECT, INDIRECT,
or for a minimum of one year — whichever is CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
greater.)
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
* RFCS Foot Controls (Except RFCS-RJ45)
WARRANTY, GUARANTY, OR REPRESENTATION,
* Fume Extractors − Filtair 130, MWX and SWX Series
INCLUDING
ANY
IMPLIED
WARRANTY
OF
* HF Units
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* ICE/XT Plasma Cutting Torches (No Labor)
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
* Induction Heating Power Sources, Coolers
MILLER.
(NOTE: Digital Recorders are Warranted
Some US states do not allow limiting the duration of an implied
Separately by the Manufacturer.)
warranty or the exclusion of certain damages, so the above
* Load Banks
limitations may not apply to you. This warranty provides
* Motor-Driven Guns (except Spoolmate Spoolguns)
specific legal rights, and other rights may be available
* PAPR Blower Unit (No Labor)
depending on your state. In Canada, some provinces provide
* Positioners and Controllers
additional warranties or remedies, and to the extent the law
* Racks (For Housing Multiple Power Sources)
prohibits their waiver, the limitations set out above may not
* Running Gear/Trailers
apply. This Limited Warranty provides specific legal rights, and
* Spot Welders
other rights may be available, but may vary by province.
mil dom warr 2019-01
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. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2019 Miller Electric Mfg. LLC
2019−01
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