Ask AI
— answers from the official manualAnswers from the official manual.
Common questions
Common Questions
52 totalWhat should I do if my electrode gets stuck to the workpiece during Stick welding?
The Dynasty 400 includes a Stick-Stuck feature that automatically detects if the electrode is stuck to the part and turns the welding output off, allowing you to safely and easily remove the electrode. This feature is menu selectable and can be turned on or off as needed. (Page 2)
What should I do if the Dynasty 400 won't initiate an arc?
First, check that the power connections are secure and the machine is powered on. Verify that the torch connections are properly attached and the electrode is in good condition. Ensure the correct welding process is selected on the control panel, as selecting the wrong process will prevent arc initiation.
What does error code E-1 mean on the Dynasty 400?
Error code E-1 indicates that overcurrent protection has been activated. This typically means the machine has detected an excessive current condition and has shut down to protect itself.
How do I troubleshoot an inconsistent arc with the Dynasty 400?
For AC welding, adjust the balance and frequency settings to improve arc stability. Additionally, check for gas flow issues or contamination in the torch and coolant system, as these can cause arc inconsistency.
What cooling system is recommended for the Dynasty 400?
The Coolmate™ 3.5 is the recommended cooling system for the Dynasty 400. It connects to the integrated 120-volt dedicated-use Cooler Power Supply (CPS) receptacle and provides efficient cooling for water-cooled torches.
How can I save and recall my welding settings on the Dynasty 400?
The Dynasty 400 features nine independent program memories that allow you to save and recall your favorite weld settings easily. You can also use the USB front panel port to backup your settings and transfer weld programs between units.
Show 46 more questions
What is the maximum welding amperage and duty cycle rating for the Dynasty 400?
What input voltage range does the Dynasty 400 accept?
How do I reduce audible noise when pulse TIG welding with the Dynasty 400?
What is the rated output and duty cycle of the Dynasty 400?
What processes can the Dynasty 400 perform?
What is the maximum carbon arc gouging electrode size for the Dynasty 400?
What are the electrical input requirements for the Dynasty 400?
What generator size is required to run the Dynasty 400?
What type of coolant should I use with the Coolmate 3.5 cooler on the Dynasty 400?
What is the DIG control used for during Stick welding on the Dynasty 400?
How do I reduce audible noise when pulse TIG welding?
How do I save and recall my favorite weld settings?
What happens if my electrode gets stuck to the workpiece during Stick welding?
What is the maximum stick electrode diameter the Dynasty 400 can run?
Can I use the Dynasty 400 with a wireless foot pedal, and what is the operating range?
What type of coolant should I use with the Coolmate 3.5 water cooler?
What DIG control setting should I use for E7018 versus E6010 electrodes?
What welding processes does the Miller Dynasty 400 support?
How do I set up and connect the Dynasty 400 for the first time?
How do I properly store welding cables?
What should I do if the welder experiences overheating?
How do I safely lift the Dynasty 400?
What protective gear is recommended to prevent electromagnetic interference from the welder?
What are the safety guidelines when welding in humid environments?
What should I do if the Dynasty 400 doesn't turn on?
How do I safely change tungsten electrodes?
What are the grounding requirements for welding equipment?
How should I handle compressed gas cylinders?
What are the warning codes displayed on the voltmeter/ammeter?
How do I save and recall my favorite weld settings on the Dynasty 400?
How do I start a TIG weld with the Dynasty 400?
What should I do if I experience an inconsistent arc while welding?
What power sources can the Miller Dynasty 400 connect to?
What does error code E-4 mean and what should I do?
How can I save and recall my favorite welding settings?
What should I do if the arc won't initiate?
How do I set up the water cooling system on the Dynasty 400?
Can I use the Pro-Set™ feature to automatically set welding parameters?
What is the maximum welding amperage the Dynasty 400 can produce?
Is wireless remote control compatible with the Dynasty 400?
What is the Pro-Set™ feature and how does it help?
How many weld programs can I save on the Dynasty 400?
What cooling system should I use with the Dynasty 400?
How do I fix an inconsistent arc during welding?
What should I do if I receive an E-4 error code?
What does the Cooler-On-Demand™ feature do?
Full Manual
94 pages
Owner’S Manual
Om-290047D
2022-07 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description 208/575 Volt Models w/Auto-Line™; 380/ 575 Volt Three-Phase w/Auto-Line™ (CE) Arc Welding Power Source For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com Dynasty ® 400 And 800 Maxstar ® 400 And 800 CE and Non-CE Models
Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the
Iso
9001 Quality System Standard. Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business. 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 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.
Table Of Contents
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2 Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3 Additional Hazards For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1-4 California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1-5 Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1-6 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2-2 Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2-3 Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . 7 2-4 Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2-5 Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2-6 Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SECTION 3 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3-1 Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3-2 Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SECTION 4 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4-1 Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4-2 Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4-3 Information About Default Weld Parameters And Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4-4 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4-5 Dimensions, Weights, And Base Mounting Hole Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 4-6 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4-7 Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4-8 Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SECTION 5 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5-1 Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 5-2 Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5-3 Selecting Cable Sizes1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5-4 Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5-5 Simple Automation Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5-6 Automation Connection For 28-Pin Receptacle (If Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5-7 Remote Memory Select Inputs For 28-Pin Receptacle (If Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5-8 115 Volts AC Cooler Receptacle, Supplementary Protector CB1, And Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 5-9 Gas Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5-10 TIG HF Impulse/Lift-Arc Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5-11 Cooler Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5-12 Dynasty Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5-13 Maxstar Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5-14 Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5-15 Connecting Input Power For 400 Models And 800 CE Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 5-16 Connecting Input Power For 800 Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 5-17 Software Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SECTION 6 – DYNASTY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6-1 Dynasty Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6-2 Accessing Control Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 6-3 Accessing User Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6-4 AC Independent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 SECTION 7 – MAXSTAR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7-1 Maxstar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7-2 Accessing Control Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 7-3 Accessing User Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 SECTION 8 – 28-PIN ADVANCED AUTOMATION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 8-1 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 8-2 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 8-3 Accessing User Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 8-4 Programmable TIG Start Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 SECTION 9 – ADVANCED MENU FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 9-1 Accessing Tech Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 9-2 Sequencer And Weld Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 9-3 Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Table Of Contents
9-4 Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 9-5 Lockout Levels Defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 SECTION 10 – MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 10-1 Memory (Program Storage Locations 1–9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 SECTION 11 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 11-1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 11-2 Blowing Out Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 11-3 Voltmeter/Ammeter Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 11-4 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 SECTION 12 – ELECTRICAL DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 SECTION 13 – HIGH FREQUENCY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 13-1 Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 13-2 Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 13-3 Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 SECTION 14 – SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES. . . . . . . . . . . . . . . . 77 14-1 Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 14-2 Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines. . . . . . . . . . . . . . 78 SECTION 15 – TIG PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 15-1 Lift-Arc And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 15-2 Pulser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 15-3 General (GEN) Tungsten To Change Programmable TIG Starting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 SECTION 16 – STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 16-1 Electrode And Amperage Selection Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Declaration Of Conformity
for European Community (CE marked) products. MILLER Electric Mfg. LLC, 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), Commission Regulation(s) and Standard(s). Product/Apparatus Identification:Product Stock Number Maxstar 400 907716002 Dynasty 400 907717002 Maxstar 800 907718002 Dynasty 800 907719002
Council Directives and Commission Regulations: • 2014/35/EU Low voltage • 2014/30/EU Electromagnetic compatibility • 2009/125/EC and regulation 2019/1784 Ecodesign requirements for energy-related products • 2011/65/EU and amendment 2015/863 Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards: • EN IEC 60974-1:2018/A1:2019 Arc welding equipment – Part 1: Welding power sources • EN IEC 60974-3:2019 Arc welding equipment – Part 3: Arc striking and stabilizing devices • EN 60974-10:2014/A1:2015 Arc welding equipment – Part 10: Electromagnetic compatibility requirements • EN IEC 63000:2018 – Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances
Signatory:
_____________________________________ ___________________________________________ David A. Werba Date of Declaration
Manager, Product Design Compliance
July 14, 2022
278454E
Declaration Of Conformity
For United Kingdom (UKCA marked) products. MILLER Electric Mfg. LLC, 1635 West 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 Regulation(s) and Standard(s). Product/Apparatus Identification:
Product Stock Number Maxstar 400 907716002 Dynasty 400 907717002 Maxstar 800 907718002 Dynasty 800 907719002
Regulations: • S.I. 2016/1101 Electrical Equipment (Safety) Regulations 2016 • S.I. 2016/1091 Electromagnetic Compatibility Regulations 2016 • S.I. 2021/745 Ecodesign for Energy-Related Products and Energy Regulations 2021 • S.I. 2012/3032 Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012
Standards: • EN IEC 60974-1:2018/A1:2019 Arc welding equipment – Part 1 Welding power sources • EN IEC 60974-3:2019 Arc welding equipment – Part 3: Arc striking and stabilizing devices • EN 60974-10:2014/A1:2015 Arc welding equipment – Part 10: Electromagnetic compatibility requirements • EN IEC 63000:2018 Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances
Signatory:
_____________________________________ ___________________________________________ David A. Werba Date of Declaration
Manager, Product Design Compliance
July 14, 2022
290429B
Emf Data Sheet For Arc Welding Power Source
Product/Apparatus Identification Product Stock NumberDynasty 350 (Auto-Line 380-575)Ce
907204021Dynasty 400 (Auto-Line 380-575)Ce
907717002Syncrowave 400 380-400, Ce
907783002Syncrowave 400 Tigrunner 380-400, Ce
907783003Compliance 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)☒ Yes
☐ No
for health effects at the standardized configurations (if NO, specific required minimum distances apply) Occupational exposure is below the Exposure Limit Values (ELVs) ☐ n.a☒ Yes
☐ No
for sensory effects at the standardized configurations (if applicable and NO, specific measures are needed) Occupational exposure is below the Action Levels (ALs) at the☐ n.a
☐ Yes
☒ No
standardized configurations (if applicable and NO, specific signage is needed) EMF Data for Non-thermal Effects Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)Head
Trunk
Limb (hand)
Limb (thigh) Sensory Effects Health Effects Standardized distance 10 cm 10 cm 10 cm 3 cm 3 cm ELV EI @ standardized distance 0.21 0.16 0.26 0.15 0.33 Required minimum distance 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%) 183 cm Tested by: Tony Samimi Date tested: 2016-02-09
275611-C
Emf Data Sheet For Arc Welding Power Source
Product/Apparatus Identification Product Stock NumberMaxstar 350 (Auto-Line 380-575) Ce
907334021Maxstar 400 (Auto-Line 380-575)Ce
907716002 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standardsIec 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 assessmentYes
No
Thermal effects need to be considered for workplace assessmentYes
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)Yes
No
for health effects at the standardized configurations (if NO, specific required minimum distances apply) Occupational exposure is below the Exposure Limit Values (ELVs) n.aYes
No
for sensory effects at the standardized configurations (if applicable and NO, specific measures are needed) Occupational exposure is below the Action Levels (ALs) at the n.aYes
No
standardized configurations (if applicable and NO, specific signage is needed) EMF Data for Non-thermal Effects Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable) Head Trunk Limb (hand) Limb (thigh) Sensory Ef fects Health Ef fects Standardized distance 10 cm 10 cm 10 cm 3 cm 3 cm ELV EI @ standardized distance 0.16 0.12 0.19 0.11 0.24 Required minimum distance 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%) 198 cm Tested by: Tony Samimi Date tested: 2016-02-10275612-B
Emf Data Sheet For Arc Welding Power Source
Product/Apparatus Identification Product Stock NumberDynasty 700 (Auto-Line 380-575)Ce
907101021Dynasty 800 (Auto-Line 380-575)Ce
907719002 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standardsIec 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 assessmentYes
No
Thermal effects need to be considered for workplace assessmentYes
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)Yes
No
for health effects at the standardized configurations (if NO, specific required minimum distances apply) Occupational exposure is below the Exposure Limit Values (ELVs) n.aYes
No
for sensory effects at the standardized configurations (if applicable and NO, specific measures are needed) Occupational exposure is below the Action Levels (ALs) at the n.aYes
No
standardized configurations (if applicable and NO, specific signage is needed) EMF Data for Non-thermal Effects Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable) Head Trunk Limb (hand) Limb (thigh) Sensory Ef fects Health Ef fects Standardized distance 10 cm 10 cm 10 cm 3 cm 3 cm ELV EI @ standardized distance 0.31 0.31 0.50 0.29 0.65 Required minimum distance 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%) 317 cm Tested by: Tony Samimi Date tested: 2016-02-11275613-B
Emf Data Sheet For Arc Welding Power Source
Product/Apparatus Identification Product Stock NumberMaxstar 700 (Auto-Line 380-575)Ce
907103021Maxstar 800 Auto-Line 380-575)Ce
907718002 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standardsIec 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 assessmentYes
No
Thermal effects need to be considered for workplace assessmentYes
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)Yes
No
for health effects at the standardized configurations (if NO, specific required minimum distances apply) Occupational exposure is below the Exposure Limit Values (ELVs) n.aYes
No
for sensory effects at the standardized configurations (if applicable and NO, specific measures are needed) Occupational exposure is below the Action Levels (ALs) at the n.aYes
No
standardized configurations (if applicable and NO, specific signage is needed) EMF Data for Non-thermal Effects Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable) Head Trunk Limb (hand) Limb (thigh) Sensory Ef fects Health Ef fects Standardized distance 10 cm 10 cm 10 cm 3 cm 3 cm ELV EI @ standardized distance 0.24 0.15 0.24 0.14 0.31 Required minimum distance 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%) 280 cm Tested by: Tony Samimi Date tested: 2016-02-08275614-B
OM-290047 Page 1
Section 1 – Safety Precautions – Read Before Using
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 haz- ards are shown in the adjoining symbols or explained in the text. NOTICE – Indicates statements not related to personal injury. F 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 these 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 instruc- tions to avoid the hazard. The safety information given be- low is only a summary of the more complete safety information found in the Principal Safety Standards. 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 the 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 cir- cuits 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. l Do not touch live electrical parts. l Wear dry, hole-free insulating gloves and body protection. l Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. l Do not use AC weld output in damp, wet, or confined spaces, or if there is a danger of falling. l Use AC output ONLY if required for the welding process. l If AC output is required, use remote output control if present on unit. l Additional safety precautions are required when any of the follow- ing electrically hazardous conditions are present: in damp loca- tions 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 unavoid- able 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 volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! l Disconnect input power or stop engine before installing or servic- ing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). l Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes. l 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. l When making input connections, attach proper grounding conduc- tor first—double-check connections. l Keep cords dry, free of oil and grease, and protected from hot met- al and sparks. l Frequently inspect input power cord and ground conductor for damage or bare wiring—replace immediately if damaged—bare wiring can kill. l Turn off all equipment when not in use. l Do not use worn, damaged, undersized, or repaired cables. l Do not drape cables over your body. l If earth grounding of the workpiece is required, ground it directly with a separate cable. l Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. l Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. l Do not touch electrode holders connected to two welding ma- chines at the same time since double open-circuit voltage will be present. l Wear a safety harness if working above floor level. l Keep all panels and covers securely in place. l Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. l Insulate work clamp when not connected to workpiece to prevent contact with any metal object. l Do not connect more than one electrode or work cable to any sin- gle weld output terminal. Disconnect cable for process not in use. l Use GFCI protection when operating auxiliary equipment in damp or wet locations.
OM-290047 Page 2 HOT PARTS can burn. l Do not touch hot parts bare handed. l Allow cooling period before working on equipment. l To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. FLYING METAL OR DIRT can injure eyes. l Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. l Wear approved safety glasses with side shields even under your welding helmet. FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. l Keep your head out of the fumes. Do not breathe the fumes. l 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. l If ventilation is poor, wear an approved air-supplied respirator. l Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, con- sumables, coolants, degreasers, fluxes, and metals. l Work in a confined space only if it is well ventilated, or while wear- ing 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. l 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. l Do not weld on coated metals, such as galvanized, lead, or cadmi- um plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respi- rator. The coatings and any metals containing these elements can give off toxic fumes if welded. BUILDUP OF GAS can injure or kill. l Shut off compressed gas supply when not in use. l Always ventilate confined spaces or use approved air-supplied respirator. 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. l Wear an approved welding helmet fitted with a proper shade of fil- ter 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). l Wear approved safety glasses with side shields under your helmet. l Use protective screens or barriers to protect others from flash, glare, and sparks; warn others not to watch the arc. l Wear body protection made from leather or flame-resistant cloth- ing (FRC). Body protection includes oil-free clothing such as leath- er 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, ex- plosion, overheating, or fire. Check and be sure the area is safe be- fore doing any welding. l Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. l Do not weld where flying sparks can strike flammable material. l Protect yourself and others from flying sparks and hot metal. l Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. l Watch for fire, and keep a fire extinguisher nearby. l Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. l 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. l 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 (see Safety Standards). l Do not weld where the atmosphere can contain flammable dust, gas, or liquid vapors (such as gasoline). l 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. l Do not use welder to thaw frozen pipes. l Remove stick electrode from holder or cut off welding wire at con- tact tip when not in use. l Wear body protection made from leather or flame-resistant cloth- ing (FRC). Body protection includes oil-free clothing such as leath- er gloves, heavy shirt, cuffless trousers, high shoes, and a cap. l Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. l After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. l Use only correct fuses or circuit breakers. Do not oversize or by- pass them. l Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. l Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, con- sumables, coolants, degreasers, fluxes, and metals. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. l Wear approved ear protection if noise level is high.
Electric And Magnetic Fields
(EMF) can affect Implanted Medical Devices. l Wearers of Pacemakers and other Implanted Med- ical Devices should keep away. l Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot weld- ing, gouging, plasma arc cutting, or induction heating operations.
OM-290047 Page 3 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 weld- ing process, be sure to treat them carefully. l Protect compressed gas cylinders from excessive heat, mechani- cal shocks, physical damage, slag, open flames, sparks, and arcs. l Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. l Keep cylinders away from any welding or other electrical circuits. l Never drape a welding torch over a gas cylinder. l Never allow a welding electrode to touch any cylinder. l Never weld on a pressurized cylinder—explosion will result. l Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. l Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the valve. l Keep protective cap in place over valve except when cylinder is in use or connected for use. l Use the proper equipment, correct procedures, and sufficient number of persons to lift, move, and transport cylinders. l Read and follow instructions on compressed gas cylinders, asso- ciated equipment, and Compressed Gas Association (CGA) publi- cation P-1 listed in Safety Standards. 1-3. Additional Hazards For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. l Do not install or place unit on, over, or near com- bustible surfaces. l Do not install unit near flammables. l Do not overload building wiring — be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. l Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. l Use correct procedures and equipment of ad- equate capacity to lift and support unit. l If using lift forks to move unit, be sure forks are long enough to ex- tend beyond opposite side of unit. l Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. l Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94-110) when manually lifting heavy parts or equipment. OVERUSE can cause
Overheating.
l Allow cooling period; follow rated duty cycle. l Reduce current or reduce duty cycle before start- ing to weld again. l Do not block or filter airflow to unit. FLYING SPARKS can injure. l Wear a face shield to protect eyes and face. l Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. l Sparks can cause fires—keep flammables away. STATIC (ESD) can damage PC boards. l Put on grounded wrist strap BEFORE handling boards or parts. l Use proper static-proof bags and boxes to store, move, or ship PC boards. MOVING PARTS can injure. l Keep away from moving parts. l Keep away from pinch points such as drive rolls. WELDING WIRE can injure. l Do not press gun trigger until instructed to do so. l Do not point gun toward any part of the body, other people, or any metal when threading welding wire. BATTERY EXPLOSION can injure. l 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. l Keep away from moving parts such as fans. l Keep all doors, panels, covers, and guards closed and securely in place. l Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. l Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.Read Instructions.
l 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. l Use only genuine replacement parts from the manufacturer. l Perform installation, maintenance, and service according to the Owner’s Manuals, industry standards, and national, state, and lo- cal codes. H.F. RADIATION can cause interference. l High-frequency (H.F.) can interfere with radio navi- gation, safety services, computers, and communi- cations equipment. l Have only qualified persons familiar with electronic equipment per- form this installation. l The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. l If notified by the FCC about interference, stop using the equipment at once. l Have the installation regularly checked and maintained. l 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.
OM-290047 Page 4 ARC WELDING can cause interference. l Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such as robots. l Be sure all equipment in the welding area is electromagnetically compatible. l To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. l Locate welding operation 100 meters from any sensitive electronic equipment. l Be sure this welding machine is installed and grounded according to this manual. l 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 in- cluding 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, American Welding Society standard ANSI Standard Z49.1. Website: http://www.aws.org. Safe Practice For Occupational And Educational Eye And Face Pro- tection, ANSI Standard Z87.1, from American National Standards In- stitute. Website: www.ansi.org. Safe Practices for the Preparation of Containers and Piping for Weld- ing and Cutting, American Welding Society Standard AWS F4.1. Website: http://www.aws.org. National Electrical Code, NFPA Standard 70 from National Fire Pro- tection Association. Website: www.nfpa.org. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P- 1 from Compressed Gas Association. Website: www.cganet.com. Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2 from Canadian Standards Association. Website: www. csagroup.org. Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B from National Fire Protection Association. Website: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub- part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov. OSHA Important Note Regarding the ACGIH TLV, Policy Statement on the Uses of TLVs and BEIs. Website: www.osha.gov. Applications Manual for the Revised NIOSH Lifting Equation from the National Institute for Occupational Safety and Health (NIOSH). Web- site: www.cdc.gov/NIOSH.
Som 2022–01
1-6. EMF Information Electric current flowing through any conductor causes localized elec- tric and magnetic fields (EMF). The current from arc welding (and al- lied 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:
OM-290047 Page 5
Section 2 – Consignes De Sécurité - Lire Avant
Utilisation
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’é- vite 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 pos- sibles sont montrés par les symboles joints ou sont expli- qués dans le texte. AVIS – Indique des déclarations pas en relation avec des blessures personnelles. F Indique des instructions spécifiques. Ce groupe de symboles veut dire Avertissement! Attention! DAN- GER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIE- CES CHAUDES. Reportez-vous aux symboles et aux directives ci- dessous afin de connaître les mesures à prendre pour éviter tout 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 pos- sibles. En présence de ce symbole, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les consignes de sécurité présentées ci-après ne font que résu- mer l’information contenue dans les Normes de sécurité principales. Lire et suivre toutes les Normes de sécurité. L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. Une per- sonne qualifiée est définie comme celle qui, par la posses- sion 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 re- connaître et d’éviter les risques inhérents. Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants. 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’ali- mentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de sou- dage 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 ten- sion électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger. l Ne pas toucher aux pièces électriques sous tension. l Porter des gants isolants et des vêtements de protection secs et sans trous. l 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. l Ne pas utiliser de sortie de soudage CA dans des zones humides ou confinées ou s’il y a un risque de chute. l Se servir d’une source électrique à courant électrique UNIQUE- MENTsi le procédé de soudage le demande. l 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. l D’autres consignes de sécurité sont nécessaires dans les condi- tions suivantes : risques électriques dans un environnement hu- mide 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 situ- ations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul ! l Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déver- rouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). l Brancher correctement la mise à la terre et utiliser cet appareil conformément à son manuel d’utilisateur et aux codes nationaux, provinciaux et municipaux. l Toujours vérifier la mise à la terre — vérifier et assurez-vous que le conducteur de mise à la terre du cordon d’alimentation est bien raccordé à la borne de mise à la terre dans le boîtier de déconne- xion ou que la fiche du cordon est raccordée à une prise correcte- ment mise à la terre. l En effectuant les raccordements d’entrée, fixer d’abord le conduc- teur de mise à la terre approprié et contre-vérifier les connexions. l Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez-les contre les étincelles et les pièces métalliques chaudes. l 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 entraî- ner la mort. l L’équipement doit être hors tension lorsqu’il n’est pas utilisé. l Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi- sante ou mal épissés. l Ne pas enrouler les câbles autour du corps. l Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct. l Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine. l Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée. l N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le- champ les pièces endommagées. Entretenir l’appareil conformé- ment à ce manuel. l Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
OM-290047 Page 6 l S’assurer que tous les panneaux et couvercles sont correctement en place. l Fixer le câble de retour de façon à obtenir un bon contact métal- métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure. l Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. l 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. l Utiliser une protection différentielle lors de l’utilisation d’un équipe- ment auxiliaire dans des endroits humides ou mouillés. LES PIÈCES CHAUDES peuvent provoquer des brûlures. l Ne pas toucher des parties chaudes à mains nues. l Prévoir une période de refroidissement avant de travailler à l’équipement. l Ne pas toucher aux pièces chaudes, utiliser les outils recomman- dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux. l 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 proje- ter du laitier. l Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé. l Eloigner votre tête des fumées. Ne pas respirer les fumées. l 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 sou- dage. 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. l Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé. l Lire et comprendre les fiches de données de sécurité et les ins- tructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidisse- ment, les dégraisseurs, les flux et les métaux. l 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. l 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 for- mer des gaz hautement toxiques et irritants. l Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revête- ment 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 Accumulations De Gaz
risquent de provoquer des blessures ou même la mort. l Fermer l’alimentation du gaz comprimé en cas de non utilisation. l Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. 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 et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. l Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). l Porter des lunettes de sécurité avec écrans latéraux même sous votre casque. l Avoir recours à des écrans protecteurs ou à des rideaux pour pro- téger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas re- garder l’arc. l Porter une protection corporelle en cuir ou des vêtements ignifu- ges (FRC). La protection du corps comporte des vêtements sans huile, comme des gants de cuir, une chemise solide, des panta- lons sans revers, des chaussures hautes et une casquette. LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. l 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. l Ne pas souder dans un endroit là où des étincelles peuvent tom- ber sur des substances inflammables. l Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. l Des étincelles et des matériaux chauds du soudage peuvent faci- lement passer dans d’autres zones en traversant de petites fissu- res et des ouvertures. l Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. l Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. l Ne pas couper ou souder des jantes ou des roues. Les pneus peu- vent 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. l Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les Nor- mes de Sécurité). l Ne pas souder là où l’air ambiant pourrait contenir des poussières, gaz ou émanations inflammables (vapeur d’essence, par exemple).
OM-290047 Page 7 l 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 lon- gue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie. l Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. l En cas de non utilisation, enlever la baguette d’électrode du porte- électrode ou couper le fil à la pointe de contact. l Porter une protection corporelle en cuir ou des vêtements ignifu- ges (FRC). La protection du corps comporte des vêtements sans huile, comme des gants de cuir, une chemise solide, des panta- lons sans revers, des chaussures hautes et une casquette. l Avant de souder, retirer toute substance combustible de vos po- ches telles qu’un allumeur au butane ou des allumettes. l Une fois le travail achevé, assurez-vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes. l Utiliser exclusivement des fusibles ou coupe-circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter. l 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. l Lire et comprendre les fiches de données de sécurité et les ins- tructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidisse- ment, les dégraisseurs, les flux et les métaux. Le BRUIT peut endommager l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. l Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé. Les CHAMPS
Électromagnétiques (Cem)
peuvent affecter les implants médicaux. l Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance. l 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. Si des BOUTEILLES sont endommagées, elles pourront exploser. Des bouteilles de gaz comprimé protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteil- les de gaz font normalement partie du procédé de soudage, les mani- puler avec précaution. l 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. l Placer les bouteilles debout en les fixant dans un support station- naire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser. l Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. l Ne jamais placer une torche de soudage sur une bouteille à gaz. l Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. l Ne jamais souder une bouteille pressurisée - risque d’explosion. l 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. l 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 lerégulateur lors de l’ouverture de la vanne. l Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille. l Utilisez les équipements corrects, les bonnes procédures et suffi- samment de personnes pour soulever, déplacer et transporter les bouteilles. l 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. Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OUD’Explosion.
l Ne pas placer l’appareil sur, au-dessus ou à proxi- mité de surfaces inflammables. l Ne pas installer l’appareil à proximité de produits inflammables l Ne pas surcharger l’installation électrique – s’assurer que l’alimen- tation est correctement dimensionné et protégé avant de mettre l’appareil en service. LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures. l Utiliser l’anneau de levage uniquement pour soule- ver l’appareil, NON PAS les organes de roulement, les bouteilles de gaz ou tout autre accessoire. l Utilisez les procédures correctes et des équipements d’une capa- cité appropriée pour soulever et supporter l’appareil. l En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. l Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur. l 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 peutSurchauffer L’Équipement.
l Laisser l’équipement refroidir ; respecter le facteur de marche nominal. l Réduire le courant ou le cycle opératoire avant de recommancer le soudage. l Ne pas obstruer les passages d’air du poste.Les Étincelles Projetées
peuvent provoquer des blessures. l Porter un écran facial pour protéger le visage et les yeux.
OM-290047 Page 8 l 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 vi- sage, des mains et du corps. l Les étincelles risquent de causer un incendie - éloigner toute sub- stance inflammable.
Les Charges
ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. l Établir la connexion avec la barrette de terre AVANT de manipuler des cartes ou des pièces. l Utiliser des pochettes et des boîtes antistatiques pour stocker, dé- placer ou expédier des cartes de circuits imprimes. Les PIÈCES MOBILES peuvent causer des blessures. l Ne pas s’approcher des organes mobiles. l Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. l Ne pas appuyer sur la gachette avant d’en avoir reçu l’instruction. l Ne pas diriger le pistolet vers soi, d’autres person- nes ou toute pièce mécanique en engageant le fil de soudage. L’EXPLOSION DE LA BATTERIE peut provoquer des blessures. l 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. l S’abstenir de toucher des organes mobiles tels que des ventilateurs. l Maintenir fermés et verrouillés les portes, pan- neaux, recouvrements et dispositifs de protection. l Lorsque cela est nécessaire pour des travaux d’entretien et de dé- pannage, faire retirer les portes, panneaux, recouvrements ou dis- positifs de protection uniquement par du personnel qualifié. l Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’a- limentation électrique.Lire Les Instructions.
l 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. l N’utiliser que des pièces de remplacement provenant du fabricant. l 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. l Le rayonnement haute fréquence (H.F.) peut pro- voquer des interférences avec les équipements de radio-navigation et de communication, les services de sécurité et les ordinateurs. l Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation. l L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. l Si le FCC signale des interférences, arrêter immédiatement l’appareil. l Effectuer régulièrement le contrôle et l’entretien de l’installation. l Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une dis- tance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles. LE SOUDAGE À L’ARC risque de provoquer des interférences. l 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. l Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement. l 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). l Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. l Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. l 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.
OM-290047 Page 9 2-4. Proposition californienne 65 Avertissements AVERTISSEMENT – Ce produit peut vous exposer à des pro- duits chimiques tels que le plomb, reconnus par l’État de Californie comme cancérigènes et sources de malforma- tions 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, American Welding Society standard ANSI Standard Z49.1. Website: http://www.aws.org. Safe Practice For Occupational And Educational Eye And Face Pro- tection, ANSI Standard Z87.1, from American National Standards In- stitute. Website: www.ansi.org. Safe Practices for the Preparation of Containers and Piping for Weld- ing and Cutting, American Welding Society Standard AWS F4.1. Website: http://www.aws.org. National Electrical Code, NFPA Standard 70 from National Fire Pro- tection Association. Website: www.nfpa.org. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P- 1 from Compressed Gas Association. Website: www.cganet.com. Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2 from Canadian Standards Association. Website: www. csagroup.org. Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B from National Fire Protection Association. Website: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub- part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov. OSHA Important Note Regarding the ACGIH TLV, Policy Statement on the Uses of TLVs and BEIs. Website: www.osha.gov. Applications Manual for the Revised NIOSH Lifting Equation from the National Institute for Occupational Safety and Health (NIOSH). Web- site: www.cdc.gov/NIOSH. SOM_fre 2022–01 2-6. Informations relatives aux CEM Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant is- su d’un soudage à l’arc (et de procédés connexes, y compris le sou- dage 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 pro- duits 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: par exemple, des restrictions d’accès pour les passants ou une évaluation indivi- duelle des risques pour les soudeurs. Tous les soudeurs doivent ap- pliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage:
OM-290047 Page 10 F Complete Parts List is available at www.MillerWelds.com
Section 3 – Definitions
3-1. Additional Safety Symbol Definitions F Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Protect yourself from electric shock by insulating yourself from work and ground. Disconnect input plug or power before working on machine. Keep your head out of the fumes. Use forced ventilation or local exhaust to remove the fumes. Use ventilating fan to remove fumes. Keep flammables away from welding. Do not weld near flammables. Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
OM-290047 Page 11 F Complete Parts List is available at www.MillerWelds.com Do not weld on drums or any closed containers. Do not remove or paint over (cover) the label. 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. Environmental Protection Use Period (China) Disconnect input plug or power before working on machine. When power is applied failed parts can explode or cause other parts to explode. Always wear long sleeves and button your collar when servicing unit. After taking proper precautions as shown, connect power to unit. Do not use one handle to lift or support unit. =< 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.
OM-290047 Page 12 F Complete Parts List is available at www.MillerWelds.com
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, AND check input ca- pacitor voltage, and be sure it is near 0 before touching any parts. Become trained and read the instructions before working on the ma- chine or welding. Wear hat and safety glasses. Use ear protection and button shirt col- lar. Use welding helmet with correct shade of filter. Wear complete body protection made from leather or flame-resistant clothing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. 3-2. Miscellaneous Symbols And Definitions F Some symbols are found only on CE products. Amperage Output Gas Tungsten Arc Welding (GTAW) / Tungsten Inert Gas (TIG) Welding Voltage Input Voltage Three Phase Static Frequency Convert- er-Transformer- Rectifier Output Voltage Circuit Breaker Remote Lift-Arc (GTAW) Protective Earth (Ground) Gas Postflow Gas Preflow Seconds On Off Positive Negative Alternating Current
(Ac)
Gas Input Gas Output Rated Welding Current Duty Cycle Direct Current (DC) Line Connection Conventional Load Voltage Primary Voltage Degree of Protection Rated Maximum Supply Current Maximum Effective Supply Current Rated No Load Volt- age (OCV) Polarity Control Initial Amperage
OM-290047 Page 13 F Complete Parts List is available at www.MillerWelds.com Increase/Decrease Of Quantity Remote Standard Remote 2T Hold Gas/DIG Control Percent Hertz Recall From Memory Arc Force (DIG) Arc Striking without Contact (HF And Impulse) Final Slope Final Amperage Pulse Percent On Time Initial Slope AC Waveshape Control Pulse EP Amperage Pulse Frequency Work Connection Electrode Connection EN Amperage Process (Welding) Suitable for Welding in an Environment with Increased Risk of Electric Shock Sequence Background Amperage f AC Frequency Water (Coolant) Input Water (Coolant) Output Circulating Unit With Coolant Pump
OM-290047 Page 14 F 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. Software Licensing Agreement The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at https://www.millerwelds.com/eula and are incorporated by reference herein. 4-3. Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriate- ness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific require- ments. The end user is solely responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld parameters and settings, and ultimate quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warran- ties including any implied warranty of fitness for a particular purpose. 4-4. Specifications F 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. F This equipment will deliver rated output at an ambient air temperature up to 104° F ( 40° C). A. Dynasty 400 Models Welding Amperage Range Max. Open Circuit Voltage (U0) Low Open-Circuit Voltage (U0) Rated Peak Striking Voltage (Up)3-400 A
Welding range for Stick process is 5-400 amperes. For TIG, the amperage range is tungsten di- ameter dependent. See Section .75 V
Normal open-circuit voltage is present while in Stick with normal open-circuit voltage selected.8-15 V
Low open-circuit voltage is present while in TIG Lift-Arc, or while in Stick with low open-cir- cuit voltage selected. 14 kV Arc starting device is designed for manual guided operations. Input Power Rated Welding Output Amperes Input at Rated Load Output 50/60 Hz208 V
230 V
380 V
400 V
460 V
575 V
Three Phase 250 A @ 30 Volts, 100% Duty Cycle 28 25 15 14 13 10 300 A @ 32 Volts, 60% Duty Cycle 36 33 19 19 16 13 400 A @ 36 Volts, 20% Duty Cycle 55 49 29 28 24 19 Single Phase 200 A @ 28 Volts, 100% Duty Cycle 40 36 — 20 17 13 250 A @ 30 Volts, 60% Duty Cycle 52 47 — 26 22 17 300 A @ 32 Volts, 20% Duty Cycle 67 60 — 33 28 22 F 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-290047 Page 15 F Complete Parts List is available at www.MillerWelds.com B. Maxstar 400 Models Welding Amperage Range Max. Open Circuit Voltage (U0) Low Open-Circuit Voltage (U0) Rated Peak Striking Voltage (Up)
3-400 A
Welding range for Stick process is 5-400 amperes. For TIG, the amperage range is tungsten di- ameter dependent. See Section .75 V
Normal open-circuit voltage is present while in Stick with normal open-circuit voltage selected.8-15 V
Low open-circuit voltage is present while in TIG Lift-Arc, or while in Stick with low open-cir- cuit voltage selected. 14 kV Arc starting device is designed for manual guided operations. Input Power Rated Welding Output Amperes Input at Rated Load Output 50/60 Hz208 V
230 V
380 V
400 V
460 V
575 V
Three Phase 250 A @ 30 Volts, 100% Duty Cycle 26 23 14 13 12 9 300 A @ 32 Volts, 60% Duty Cycle 33 30 18 17 15 12 400 A @ 36 Volts, 20% Duty Cycle 50 45 27 25 22 17 Single Phase 200 A @ 28 Volts, 100% Duty Cycle 37 33 — 18 18 12 250 A @ 30 Volts, 60% Duty Cycle 48 43 — 24 20 16 300 A @ 32 Volts, 20% Duty Cycle 62 55 — 30 28 20 F 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. C. Dynasty 800 Models Welding Amperage Range Max. Open Circuit Voltage (U0) Low Open-Circuit Voltage (U0) Rated Peak Striking Voltage (Up)5-800 A
Welding range for Stick process is 5-750 amperes. For TIG, the amperage range is tungsten di- ameter dependent. See Section .75 V
Normal open-circuit voltage is present while in Stick with normal open-circuit voltage selected.8-15 V
Low open-circuit voltage is present while in TIG Lift-Arc, or while in Stick with low open-cir- cuit voltage selected. 14 kV Arc starting device is designed for manual guided operations. Input Power Rated Welding Output Amperes Input at Rated Load Output 50/60 Hz208 V
230 V
380 V
400 V
460 V
575 V
Three Phase 500 A @ 40 Volts, 100% Duty Cycle 73 66 39 37 32 25 600 A @ 44 Volts, 60% Duty Cycle 96 86 51 48 42 33 800 A @ 44 Volts, 20% Duty Cycle 123 118 69 65 57 45 Single Phase 400 A @ 36 Volts, 100% Duty Cycle 98 88 — 48 41 32 500 A @ 40 Volts, 60% Duty Cycle 136 122 — 66 56 44 F 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-290047 Page 16 F Complete Parts List is available at www.MillerWelds.com D. Maxstar 800 Models Welding Amperage Range Max. Open Circuit Voltage (U0) Low Open-Circuit Voltage (U0) Rated Peak Striking Voltage (Up)
5-800 A
Welding range for Stick process is 5-750 amperes. For TIG, the amperage range is tungsten di- ameter dependent. See Section .75 V
Normal open-circuit voltage is present while in Stick with normal open-circuit voltage selected.8-15 V
Low open-circuit voltage is present while in TIG Lift-Arc, or while in Stick with low open-cir- cuit voltage selected. 14 kV Arc starting device is designed for manual guided operations. Input Power Rated Welding Output Amperes Input at Rated Load Output 50/60 Hz208 V
230 V
380 V
400 V
460 V
575 V
Three Phase 500 A @ 40 Volts, 100% Duty Cycle 68 61 36 34 30 24 600 A @ 44 Volts, 60% Duty Cycle 90 80 48 45 39 31 800 A @ 44 Volts, 20% Duty Cycle 120 109 65 61 53 42 Single Phase 400 A @ 36 Volts, 100% Duty Cycle 89 80 — 44 38 30 500 A @ 40 Volts, 60% Duty Cycle 126 112 — 61 53 41 F 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. 4-5. Dimensions, Weights, And Base Mounting Hole Layout F Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc. A. Welding Power SourceB
A
C
803914-A
C
D
F
G
E
DimensionsA
400 Amp Models 24-3/4 in. (654 mm) 800 Amp Models 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 Weight 400 Amp Models 134 lb (60.8 kg) 800 Amp Models 198 lb (89.8 kg)
OM-290047 Page 17 F Complete Parts List is available at www.MillerWelds.com B. Welding Power Source With Cart And Cooler
B
A
C
804642-C
DimensionsA
400 Amp Models 43-1/8 in. (1095 mm) 800 Amp Models 53-3/4 in. (1365 mm)B
23-1/8 in. (587 mm)C
43-3/4 in. (1111 mm) Weight 400 Amp Models 250.5 lb (113.6 kg) 800 Amp Models 313 lb (142 kg) 4-6. Environmental Specifications A. IP Rating IP RatingIp23
This equipment is designed for outdoor use. 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). 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 pub- lic low-voltage system impedance Zmax at the point of common coupling is less than 47.2 mΩ (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. 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 pub- lic low-voltage system impedance Zmax at the point of common coupling is less than 47.2 mΩ (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.
OM-290047 Page 18 F Complete Parts List is available at www.MillerWelds.com 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 pub- lic low-voltage system impedance Zmax at the point of common coupling is less than 17.03 mΩ (or the short-circuit power Ssc is greater than 9.4 MVA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if nec- essary, that the system impedance complies with the impedance restrictions. 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 pub- lic low-voltage system impedance Zmax at the point of common coupling is less than 49.09 mΩ (or the short-circuit power Ssc is greater than 3.3 MVA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if nec- essary, that the system impedance complies with the impedance restrictions. G. China EEP Hazardous Substance Information 中国电器电子产品中有害物质的名称及含量 China EEP Hazardous Substance Information 部件名称 Component Name (如果适用) (if applicable) 有害物质 Hazardous Substance 铅 Pb 汞 Hg 镉 Cd 六价铬 Cr6 多溴联苯
Pbb
多溴二苯醚Pbde
黄铜和铜部件 Brass and Cop- per PartsX
O
O
O
O
O
耦合装置 Coupling DevicesX
O
O
O
O
O
开关装置 Switching DevicesO
O
X
O
O
O
线缆和线缆配件 Cable and Cable AccessoriesX
O
O
O
O
O
电池 BatteriesX
O
O
O
O
O
本表格依据中国Sj/T 11364的规定编制.
This table is prepared in accordance with China SJ/T 11364.O:
表示该有害物质在该部件所有均质材料中的含量均在中国Gb/T26572规定的限量要求以下.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of ChinaGb/T 26572.
X:
表示该有害物质至少在该部件的某一均质材料中的含量超出中国Gb/T26572规定的限量要求.
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.器电子产品的环保使用期限依据中国Sj/Z11388的规定确定.
The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.
OM-290047 Page 19 F Complete Parts List is available at www.MillerWelds.com H. EU Ecodesign Information Model Input Minimum Power Source Efficiency Maximum Idle State Power Consumption Dynasty 400 400V Three Phase 84.0%
44.4 W
Dynasty 800 400V Three Phase 84.7%37.7 W
Maxstar 400 400V Three Phase 86.8%45.5 W
Maxstar 800 400V Three Phase 88.8%37.3 W
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. Critical raw materials possibly present in indicative amounts higher than 1 gram at component level Component Critical Raw Material Printed circuit boards Baryte, Bismuth, Cobalt, Gallium, Germanium, Hafnium, Indium, Heavy Rare Earth, Light Rare Earth, Niobium, Platinum Group Metals, Scandium, Silicon Metal, Tantalum, Vanadium Plastic components Antimony, Baryte Electrical and electronic components Antimony, Beryllium, Magnesium Metal components Beryllium, Cobalt, Magnesium, Tungsten, Vanadium Cables and cable assemblies Borate, Antimony, Baryte, Beryllium, Magnesium Display panels Gallium, Indium, Heavy Rare Earth, Light Rare Earth,Niobium, Platinum Group Metals, Scandium Batteries Fluorspar, Heavy Rare Earth, Light Rare Earth, Magnesium
OM-290047 Page 20 F Complete Parts List is available at www.MillerWelds.com 4-7. 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 mes- sage is displayed (see Section ), 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. 200
Output Current (A)
100 0 300 400 500 600 700 800 900% Duty Cycle
10 20 60 100Duty Cycle Dynasty Maxstar 400/800
Md800 3 Phase
Md800 1 Phase
Md400 1 Phase
Md400 3 Phase
Overheating 0 15 A or VOr
Reduce Duty Cycle Minutes 4-8. 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-290047 Page 21 F Complete Parts List is available at www.MillerWelds.com
Section 5 – Installation
5-1. Selecting A Location Movement 1 2 Location And Airflow 3 18 in. (460 mm) 18 in. (460 mm) Do not move or operate unit where it could tip. Special installation may be re- quired where gasoline or volatile liquids are present - see NEC Ar- ticle 511 or CEC Section 20. 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond op- posite side of unit. 3 Line Disconnect Device Locate unit near correct input power supply.
OM-290047 Page 22 F Complete Parts List is available at www.MillerWelds.com 5-2. Weld Output Terminals
804746-B
2 1 3 Turn off power before connecting to weld output terminals. Do not use worn, damaged, under- sized, or repaired cables. 1 Work Weld Output Terminal (Dynasty Models) (+) Positive Weld Output Terminal (Max- star Models) 2 Electrode Weld Output Terminal (Dynasty Models) (–) Negative Weld Output Terminal (Max- star Models) 3 Remote 14 Receptacle (All Models) See Sections 5-10 thru for connection diagrams. 5-3. Selecting Cable Sizes1 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 Size2 and Total Cable (Copper) Length in Weld Circuit Not Exceeding 100 ft (30 m) or Less4 150 ft (45 m) 200 ft (60 m) Welding Amperes3 10 - 60% Duty Cycle AWG (mm2) 60 - 100% Duty Cycle AWG (mm2) 10 - 100% Duty Cycle 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) 1 This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable. 2 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. 3 Select weld cable size for pulsing application at peak amperage value. 4 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.
OM-290047 Page 23 F Complete Parts List is available at www.MillerWelds.com 5-4. Remote 14 Receptacle Information
804746-B / 218716-A
A
J
B
K
I
C
L
N
H
D
M
G
E
F
Remote 14 Socket Socket Information 15 Volts DC Output ContactorA
Contactor control +15 volts DC, referenced to G.B
Contact closure to A completes 15 volts DC con- tactor control circuit and enables output. Remote Output ControlC
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 re- mote control. 1 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. Output SignalsF
Current feedback; +1 volt DC per 100 amps output.H
Voltage feedback; +1 volt DC per 10 volts output.I1
Valid arc indication closed to socket G with valid arc. Electrical specifications: open collector tran- sistor (see Section 5-5 for connection example).J1
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 connec- tion example). 2 Touch Sense Detection closed to Socket G, with Modbus’s Touch Sense enabled and machine not triggered for weld output. CommonG
Return for all output signals: F, H, I, J and A. ChassisK
Chassis Serial Communication BusL2
Modbus Common (RS485 Common)M2
Modbus D1 (RS485 B+)N2
Modbus D0 (RS485 A-) Sockets G and K are electrically isolated from each other. 1 Available with optional Automation Expansion memory card. 2 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 Automa- tion, Hot Wire, and Hot Start Adjust expansions. F 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 con- trol, and the remote hand control will not function. 5-5. Simple Automation Application Pin I, J: Collector Pin G: Emitter To User Equipment Coil CR1 resistance plus R should be chos- en to limit current to 75 mA. User supplied power up to 27 volts DC peak.
OM-290047 Page 24 F 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.
804746-B / 21816-A
1 4 9 15 21 26 28 25 20 14 8 3 2 7 6 5 13 12 11 10 19 18 17 16 24 23 22 27 Pin Signal Direction Description Pin Information For 28–Pin Receptacle RC28 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 momen- tary 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 ma- chine 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 . 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 . 10 Input Memory Select Used to select between memory numbers. Used in conjunction with pin 15 and 16. See Sections 5-7 and 10. 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 . 14 Output Arc Length Control Lock- out Reference Paired with Pin 13. Connect to user’s external voltage supply common. See Section 5-5 . 15 Input Memory Select Used to select between memory numbers. Used in conjunction with pins 10 and 16. See Sections 5-7 and 10. 16 Input Memory Select Used to select between memory numbers. Used in conjunction with pins 10 and 15. See Sections 5-7 and 10. 17 Input Amperage Control 0 to +10 volts DC with respect to pin 11. The 10 volts represents the amper- age value set on machines meter (Pin E of 14 pin).
OM-290047 Page 25 F Complete Parts List is available at www.MillerWelds.com 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 High Frequency Arc Start Disable Disables the arc starter from being activated when connected to pin 8. 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 . 24 Output Final Slope Sequence Indi- cation Reference Paired with pin 23. Connect to user’s external voltage supply common. See Section 5-5 . 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.
804746-B / 21816-A
1 4 9 15 21 26 28 25 20 14 8 3 2 7 6 5 13 12 11 10 19 18 17 16 24 23 22 27 Pin Signal Direction Description Pin Information For 28–Pin Receptacle RC28 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 momen- tary 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 cur- tains 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 dis- played 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 ma- chine 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 . 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. 10 Input Memory Select Used to select between memory numbers. Used in conjunction with pins 15 and 16. See Section 5-7.
OM-290047 Page 26 F Complete Parts List is available at www.MillerWelds.com 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 transis- tor maximum values 27volts DC peak @ 75mA. See Section 5-5 . 14 Output Arc Length Control Lock- out Reference Paired with Pin 13. Connect to user’s external voltage supply common. See Section 5-5 . 15 Input Memory Select Used to select between memory numbers. Used in conjunction with pin 10 and 16. See Sections 5-7 and 10. 16 Input Memory Select Used to select between memory numbers. Used in conjunction with pin 10 and 15. See Sections 5-7 and 10. 17 Input Amperage Control 0 to +10 volts DC with respect to pin 11. The 10 volts represents the amper- age value set on machines meter (Pin E of 14 pin). 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 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 . 24 Output Final Slope Sequence Indi- cation Reference Paired with pin 23. Connect to user’s external voltage supply common. See Section 5-5 . 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.
804746-B / 21816-A
1 4 9 15 21 26 28 25 20 14 8 3 2 7 6 5 13 12 11 10 19 18 17 16 24 23 22 27 Pin Signal Direction Description Pin Information For 28–Pin Receptacle RC28 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 momen- tary 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 cur- tains 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 dis- played on the meters.
OM-290047 Page 27 F Complete Parts List is available at www.MillerWelds.com 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 ma- chine 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 . 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 . 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 am- perage value for a Dynasty. Value should be between 0.3 to 10V correspond- ing to the minimum to maximum of the machine. 25 Input User Controlled Automa- tion Select Connect to pin 8 to activate this mode. 26 Input Isolated EP Amperage Command (Dynasty models only) Paired with Pin 27. Sets EP (cleaning) output amper- age value. Value should be between 0.3 to 10 volts corresponding to the mini- mum 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 Function Pin 10 Pin 16 Pin 15 1 4 9 15 21 26 28 25 20 14 8 3 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 Socket Designations: 0 = No Connection / 1 = Connected To Ground (Pin 8)
OM-290047 Page 28 F Complete Parts List is available at www.MillerWelds.com 5-8. 115 Volts AC Cooler Receptacle, Supplementary Protector CB1, And Power Switch
805593-A
1 2 3 1 AC Cooler Receptacle Receptacle RC2 supplies 115 V 4A of single- phase power. F RC2 is a designated use receptacle in- tended only for supplying AC power to a Miller-approved cooler. 2 Supplementary Protector CB1 CB1 protects cooler receptacle from over- load. If circuit breaker opens, the receptacle does not work. Press button to reset protector. 3 Power On/Off Switch
OM-290047 Page 29 F Complete Parts List is available at www.MillerWelds.com 5-9. Gas Connections
805593-A
3 2 4 1 11/16, 1-1/8 in. 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. 3 Regulator/Flowmeter 4 Flow Adjust Typical flow rate is 15 cfh (cubic feet per hour). Connect customer supplied gas hose be- tween regulator/flowmeter and gas fitting on rear of unit. 5-10. TIG HF Impulse/Lift-Arc Connections805594-A
2 3 5 4 1 11/16 in. (21 mm for CE units) Turn off power before making connections. 1 Electrode Weld Output Terminal (–) Weld Output Terminal (Maxstar Models) 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 (+) Weld Output Terminal (Maxstar Models) Connect work lead to work weld output terminal. 4 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).
OM-290047 Page 30 F Complete Parts List is available at www.MillerWelds.com 5-11. Cooler Connections 3 4 5 6 7
805595-A
2 1 11/16 in. (21 mm for CE units) F Cart and cooler are optional equipment. 1 AC Cooler Receptacle RC2 F RC2 is a designated use receptacle in- tended only for supplying AC power to a Miller-approved cooler. 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 Out- put 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 weld- ing power source water-out connection. 7 Water-In (From Torch) Connection Connect torch water-out (red) hose to weld- ing power source water-in connection. Coolant Specifications Application GTAW or where HF (high frequency current) is used Coolant (3-1/2 gal) Low Conductivity Coolant 043810 l 50/50 solution l Protects to –37°F(–38°C)
l Resists algae growth Distilled or dionized water okay above 32°F (0°C) 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-290047 Page 31 F Complete Parts List is available at www.MillerWelds.com 5-12. Dynasty Stick Connections
805596-A
2 1 3 Turn off power before making connections. F 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). 5-13. Maxstar Stick Connections803916-C
2 1 3 Turn off power before making connections. F Connections shown are for Maxstar models. 1 (+) Weld Output Terminal Connect electrode holder 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).
OM-290047 Page 32 F Complete Parts List is available at www.MillerWelds.com 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 recommen- dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch 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. F 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 available. NOTICE – INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral. 60 Hz 3-Phase Rated Supply Voltage (V) 208 230 380 400 460 575 Rated Maximum Supply Current I1max (A) 55.0 49.0 29.0 28.0 24.0 19.0 Rated Effective Supply Current I1eff (A) 28.0 25.0 15.0 14.0 13.0 10.0 Maximum Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses2 60 60 35 35 30 20 Normal Operating Fuses3 80 70 40 40 35 25 Maximum Recommended Supply Conductor Length In Feet (Me- ters)4 56 (17) 70 (21) 77 (23) 83 (25) 111 (34) 175 (53) Raceway Installation Minimum Supply Conductor Size In AWG (mm2)5 10 (6) 10 (6) 14 (2.5) 14 (2.5) 14 (2.5) 14 (2.5) Minimum Grounding Conductor Size In AWG (mm2) 5 10 (6) 10 (6) 14 (2.5) 14 (2.5) 14 (2.5) 14 (2.5) Flexible Cord Installation Minimum Supply Conductor Size In AWG (mm2)6 8 (10) 10 (6) 14 (2.5) 14 (2.5) 14 (2.5) 14 (2.5) Reference: 2020 National Electrical Code (NEC) (including article 630) 60 Hz 1-Phase Rated Supply Voltage (V) 208 230 400 460 575 Rated Maximum Supply Current I1max (A) 67.0 60.0 33.0 28.0 22.0 Rated Effective Supply Current I1eff (A) 40.0 36.0 20.0 17.0 13.0 Maximum Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses 2 80 70 40 35 25 Normal Operating Fuses3 100 90 45 40 30 Maximum Recommended Supply Conductor Length In Feet (Meters)4 63 (19) 78 (24) 96 (29) 129 (39) 132 (40) Raceway Installation Minimum Supply Conductor Size In AWG (mm2)5 8 (10) 8 (10) 12 (4) 12 (4) 14 (2.5) Minimum Grounding Conductor Size In AWG (mm2) 5 8 (10) 8 (10) 12 (4) 12 (4) 14 (2.5) Flexible Cord Installation Minimum Supply Conductor Size In AWG (mm2)6 8 (10) 8 (10) 12 (4) 14 (2.5) 14 (2.5) Reference: 2020 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 Maximum total length of copper input conductors in entire installation, raceway and/or flexible cord. 5 Raceway 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 75°C (167°F) with not more than three single current-carrying conductors in a raceway. 6 Flexible cord conductor size is based on NEC Table 400.5(A)(1) for SOOW 600V 90°C (194°F) jacketed cable in a 30°C (86°F) ambient tem- perature. See NEC Table 310.15(B)(2)(a) for ambient temperature correction factors. Flexible cord used for connection to the power supply sys- tem shall comply with the requirements of CSA C22.2 No. 49.
OM-290047 Page 33 F 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 recommen- dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch 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. F 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 available. NOTICE – INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral. 60 Hz 3-Phase Rated Supply Voltage (V) 208 230 380 400 460 575 Rated Maximum Supply Current I1max (A) 50.0 45.0 27.0 25.0 22.0 17.0 Rated Effective Supply Current I1eff (A) 26.0 23.0 14.0 13.0 12.0 9.0 Maximum Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses2 60 50 30 30 25 20 Normal Operating Fuses3 70 60 40 35 30 25 Maximum Recommended Supply Conductor Length In Feet (Me- ters)4 62 (19) 76 (23) 81 (25) 92 (28) 121 (37) 196 (60) Raceway Installation Minimum Supply Conductor Size In AWG (mm2)5 10 (6) 10 (6) 14 (2.5) 14 (2.5) 14 (2.5) 14 (2.5) Minimum Grounding Conductor Size In AWG (mm2) 5 10 (6) 10 (6) 14 (2.5) 14 (2.5) 14 (2.5) 14 (2.5) Flexible Cord Installation Minimum Supply Conductor Size In AWG (mm2)6 8 (10) 10 (6) 14 (2.5) 14 (2.5) 14 (2.5) 14 (2.5) Reference: 2020 National Electrical Code (NEC) (including article 630) 60 Hz 1-Phase Rated Supply Voltage (V) 208 230 400 460 575 Rated Maximum Supply Current I1max (A) 62.0 55.0 30.0 26.0 20.0 Rated Effective Supply Current I1eff (A) 37.0 33.0 18.0 18.0 12.0 Maximum Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses 2 70 60 35 30 25 Normal Operating Fuses3 90 80 45 35 30 Maximum Recommended Supply Conductor Length In Feet (Meters)4 68 (21) 85 (26) 106 (32) 139 (42) 145 (44) Raceway Installation Minimum Supply Conductor Size In AWG (mm2)5 8 (10) 8 (10) 12 (4) 12 (4) 14 (2.5) Minimum Grounding Conductor Size In AWG (mm2) 5 8 (10) 8 (10) 12 (4) 12 (4) 14 (2.5) Flexible Cord Installation Minimum Supply Conductor Size In AWG (mm2)6 8 (10) 8 (10) 14 (2.5) 14 (2.5) 14 (2.5) Reference: 2020 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 Maximum total length of copper input conductors in entire installation, raceway and/or flexible cord. 5 Raceway 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 75°C (167°F) with not more than three single current-carrying conductors in a raceway. 6 Flexible cord conductor size is based on NEC Table 400.5(A)(1) for SOOW 600V 90°C (194°F) jacketed cable in a 30°C (86°F) ambient tem- perature. See NEC Table 310.15(B)(2)(a) for ambient temperature correction factors. Flexible cord used for connection to the power supply sys- tem shall comply with the requirements of CSA C22.2 No. 49.
OM-290047 Page 34 F 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 recommen- dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch 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. F 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 available. NOTICE – INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral. 3-Phase Rated Supply Voltage (V) 208 230 380 400 460 575 Rated Maximum Supply Current I1max (A) 123.0 118.0 69.0 65.0 57.0 45.0 Rated Effective Supply Current I1eff (A) 75.0 66.0 39.0 37.0 32.0 26.0 Maximum Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses2 150 125 80 80 70 50 Normal Operating Fuses3 175 175 100 90 80 60 Maximum Recommended Supply Conductor Length In Feet (Me- ters)4 93 (28) 107 (33) 124 (38) 138 (42) 183 (56) 190 (58) Raceway Installation Minimum Supply Conductor Size In AWG (mm2)5 4 (25) 4 (25) 8 (10) 8 (10) 8 (10) 10 (6) Minimum Grounding Conductor Size In AWG (mm2) 5 6 (16) 6 (16) 8 (10) 8 (10) 8 (10) 10 (6) Flexible Cord Installation Minimum Supply Conductor Size In AWG (mm2)6 2 (35) 2 (35) 6 (16) 6 (16) 8 (10) 8 (10) Reference: 2020 National Electrical Code (NEC) (including article 630) 1-Phase Rated Supply Voltage (V) 208 230 400 460 575 Rated Maximum Supply Current I1max (A) 136.0 122.0 66.0 57.0 44.0 Rated Effective Supply Current I1eff (A) 105.0 94.0 51.0 44.0 34.0 Maximum Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses 2 150 150 80 70 50 Normal Operating Fuses3 200 175 90 80 60 Maximum Recommended Supply Conductor Length In Feet (Meters)4 111 (34) 112 (34) 189 (58) 161 (49) 255 (78) Raceway Installation Minimum Supply Conductor Size In AWG (mm2)5 2 (35) 3 (35) 6 (16) 8 (10) 8 (10) Minimum Grounding Conductor Size In AWG (mm2) 5 6 (16) 6 (16) 8 (10) 8 (10) 8 (10) Flexible Cord Installation Minimum Supply Conductor Size In AWG (mm2)6
OM-290047 Page 35 F 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 recommen- dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch 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. F 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 available. NOTICE – INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral. 3-Phase Rated Supply Voltage (V) 208 230 380 400 460 575 Rated Maximum Supply Current I1max (A) 120.0 109.0 65.0 61.0 53.0 42.0 Rated Effective Supply Current I1eff (A) 70.0 62.0 37.0 35.0 30.0 24.0 Maximum Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses2 150 125 80 70 60 50 Normal Operating Fuses3 175 150 90 90 70 60 Maximum Recommended Supply Conductor Length In Feet (Me- ters)4 96 (29) 75 (23) 132 (40) 148 (45) 129 (39) 203 (62) Raceway Installation Minimum Supply Conductor Size In AWG (mm2)5 4 (25) 6 (16) 8 (10) 8 (10) 10 (6) 10 (6) Minimum Grounding Conductor Size In AWG (mm2) 5 6 (16) 6 (16) 8 (10) 8 (10) 10 (6) 10 (6) Flexible Cord Installation Minimum Supply Conductor Size In AWG (mm2)6 2 (35) 2 (35) 6 (16) 8 (10) 8 (10) 10 (6) Reference: 2020 National Electrical Code (NEC) (including article 630) 1-Phase Rated Supply Voltage (V) 208 230 400 460 575 Rated Maximum Supply Current I1max (A) 126.0 112.0 61.0 53.0 41.0 Rated Effective Supply Current I1eff (A) 97.0 87.0 48.0 41.0 32.0 Maximum Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses 2 150 125 70 60 50 Normal Operating Fuses3 175 150 90 70 60 Maximum Recommended Supply Conductor Length In Feet (Meters)4 98 (30) 122 (37) 130 (40) 172 (52) 275 (84) Raceway Installation Minimum Supply Conductor Size In AWG (mm2)5 3 (35) 3 (35) 8 (10) 8 (10) 8 (10) Minimum Grounding Conductor Size In AWG (mm2) 5 6 (16) 6 (16) 8 (10) 8 (10) 10 (6) Flexible Cord Installation Minimum Supply Conductor Size In AWG (mm2)6
OM-290047 Page 36 F Complete Parts List is available at www.MillerWelds.com 5-15. Connecting Input Power For 400 Models And 800 CE Models A. Connecting 3-Phase Input Power
L1
2 1L2
L3
3 4 5 6 7 = GND/PE Earth Ground 3 Installation must meet all National and Local Codes—have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Follow es- tablished 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. F The Auto-Line circuitry in this unit auto- matically 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 with- out removing cover to relink the power source. See rating label on unit and check input volt- age available at site. For Three-Phase Operation 1 Input Power Cord 2 Disconnect Device (switch shown in the OFF position) 3 Green Or Green/Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors (L1, L2, And L3) 6 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 protec- tion using Electrical Service Guide (fused disconnect switch shown). Close and secure door on disconnect device. Follow established lockout/tagout proce- dures to put unit in service.
OM-290047 Page 37 F Complete Parts List is available at www.MillerWelds.com B. Connecting 1-Phase Input Power 1 6 5 4 2 7 6
L1
L2
1 =GND/PE Earth Ground 3 3 1 8 9 10 Installation must meet all National and Local Codes—have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Follow es- tablished 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. F The Auto-Line circuitry in this unit auto- matically 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 with- out removing cover to relink the power source. See rating label on unit and check input volt- age available at site. 1 Black And White Input Conductor (L1 And L2) 2 Red Input Conductor 3 Green Or Green/Yellow Grounding Conductor 4 Insulation Sleeving 5 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 dis- connect device line terminals. 10 Over-Current Protection Select type and size of over-current protec- tion using Electrical Service Guide (fused disconnect switch shown). Close and secure door on disconnect device. Follow established lockout/tagout proce- dures to put unit in service.
OM-290047 Page 38 F Complete Parts List is available at www.MillerWelds.com 5-16. Connecting Input Power For 800 Models A. Connecting 3-Phase Input Power 5/16 in. Installation must meet all National and Local Codes—have only quali- fied persons make this installation. Disconnect and lockout/tagout input power before connecting input con- ductors from unit. Follow estab- lished procedures regarding the installation and removal of lockout/ tagout devices. Make input power connections to the welding power source first. Always connect green or green/yel- low 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 in- put voltage available at site. This unit can be connected to any input power between 190 and 625 VAC without removing cover to re- link the power source. See rating label on unit and check input volt- age available at site. 1 Input Power Conductors (Customer Sup- plied Cord) Select size and length of conductors using Electrical Service Guide. Conductors must comply with national, state, and local electri- cal codes. If applicable, use lugs of proper amperage capacity and correct hole size. Welding Power Source Input Power Connections 2 Strain Relief (Customer Supplied) Install strain relief of proper size for unit and 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 6 Input Conductors (L1, L2, And L3) Connect input conductors L1, L2, and L3 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 protec- tion using Electrical Service Guide (fused disconnect switch shown). Close and secure door on disconnect de- vice. Follow established lockout/tagout pro- cedures to put unit in service.
OM-290047 Page 39 F Complete Parts List is available at www.MillerWelds.com B. Connecting Single-Phase Input Power 7 1 1 =GND/PE Earth Ground 4 8 9 10
L1
L2
6 6 5 Input9 2013 04 / Ref. 805604-A 2 3 4 1 5/16 in. Installation must meet all National and Local Codes—have only quali- fied persons make this installation. Disconnect and lockout/tagout input power before connecting input con- ductors from unit. Follow estab- lished procedures regarding the installation and removal of lockout/ tagout devices. Make input power connections to the welding power source first. Always connect green or green/yel- low conductor to supply grounding terminal first, and never to a line terminal. See rating label on unit and check input volt- age available at site. 1 Input Power Conductors (Customer Sup- plied Cord) Select size and length of conductors using Electrical Service Guide. Conductors must comply with national, state, and local electri- cal codes. If applicable, use lugs of proper amperage capacity and correct hole size. Welding Power Source Input Power Connections 2 Strain Relief (Customer Supplied) Install strain relief of proper size for unit and 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 6 Black And White Input Conductor (L1 And L2) Connect input conductors L1 and L2 to welding power source line terminals. Close and secure access door on welding power source. Disconnect Device Input Power Connections 7 Disconnect Device (switch shown in the OFF position) 8 Disconnect Device (Supply) Grounding Terminal Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. 9 Disconnect Device Line Terminals Connect input conductors L1 and L2 to dis- connect device line terminals. 10 Over-Current Protection Select type and size of over-current protec- tion using Electrical Service Guide (fused disconnect switch shown). Close and secure door on disconnect de- vice. Follow established lockout/tagout pro- cedures to put unit in service.
OM-290047 Page 40 F Complete Parts List is available at www.MillerWelds.com 5-17. Software Updates A. Downloading Software Updates 1 2 Reasons To Download Software Updates: l To get the latest feature and software improvements with future software updates. l For all circuit board replacements, a software update is required to ensure proper unit operation. l A software update is required to ensure proper software expansion operation of all purchased feature expansions. Requirements A computer with an SD memory card port, or SD memory card reader is required to down- load software updates. 32 GB max SD memory card. The SD logo is a registered trademark of
Sd-3C Llc.
How To Download Software Updates 1 In a web browser, go to https://www.miller- welds.com/support/software/tig-software 2 Click Installation Instructions (PDF) and follow the instructions. B. Installing Software Updates273670-B
F Software updates may reset machine back to default values. Card Requirements: 32 GB max capacity SD memory card required. 1 Memory Card Port 2 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 re- move 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.
OM-290047 Page 41
Section 6 – Dynasty Operation
6-1. Dynasty Controls273670-B
1 2 5 12 8 6 7 9 10 13 14 11 3 4 F For all front panel button controls: press button to turn on light and ena- ble normal function. F Green on nameplate indicates a TIG function. Gray indicates a normal Stick function. 1 Amperage Adjustment Control Use amperage adjustment control in con- junction with applicable front panel function buttons 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 descrip- tions when in any menu. 5 Polarity Control 6 Process Controls 7 Output Controls 8 Pulser Controls 9 Sequencer Controls 10 Gas/DIG Controls 11 AC Waveshape 12 Amperage And Spot Time Control 13 Memory 14 Memory Display Displays active memory.
OM-290047 Page 42 6-2. Accessing Control Panel Menu
273670-B
1 Memory Button Select Memory 1-9 (See Section 10). 2 Parameter Display 3 Setting Display 4 Amperage Adjustment Control Rotate amperage adjustment control to ad- just parameter setting. 5 Amperage Button Amperage Control Controls the welding amperage output. Limits the maximum output of a remote amperage device. *PRO-SET provides PROfessionally devel- oped SETtings for the weld process. To use PRO-SET, press the menu button to display the parameter and adjust the amperage ad- justment control until PRO-SET flashes on the display. PRO-SET flashes one time and reveals the professional setting for the parameter. Polarity Selection (Dynasty Only) Select output type AC or DC. With DC selected, the electrode will be negative (DCEN) for TIG, and posi- tive (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.
OM-290047 Page 43 Output (Trigger Mode Selection) F See Section 9 for additional trigger function options. Parameter/Setting Display Description
[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.[Out] [On]
Output on. (Stick and Lift-Arc TIG 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 out- put is on. Pulse Control Pulsing is available in the TIG process. Controls can be adjusted while welding. Reduces heat input to minimize distortion and increase travel speed. Press button to enable pulser. F See Section 15 for additional Pulser information, or visit http:/www. millerwelds. com/resources/welding- guides. Parameter/Setting Display Description[Pps] [100]
*Pulses Per Second: range is 0.1 - 500 for AC polarity and 0.1 - 5000 for DC polarity.[Pk T] [40%]
*Peak Amperage Time: range is 5 - 95%.[Bk A] [25%]
*Background Amperage Time: range is 5 - 95% of peak amperage value. Sequencer Control The welding output can be programmed to specific amperages and durations for repetitive applications. Se- quencer is only available in the TIG process. Sequencer is disabled if a remote control with variable amperage is connected to the machine. F See Section 9 for setting weld time. Parameter/Setting Display Description[Intl] [20A]
Initial Amperage: Range is min - 400/800 amps.[Islp] [Off]
Initial Slope Time: Range is OFF - 50.0T (seconds).[Fslp] [Off]
Final Slope Time: Range is OFF - 50.0T (seconds).[Fnl] [10A]
Final Amperage: Range is min - 400/800 amps. Gas/DIG Control Parameter/Setting Display Description[Pre] [0.2T]
Preflow Time: Controls length of time gas flows prior to arc start. Range is OFF-25T (seconds).[Post] [Auto]
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/[Dig] [30%]
OM-290047 Page 44 AC Waveshape Control Parameter/Setting Display Description
[Enep] [150A]
EN Amperage and EP Amperage TIG only: Controls both electrode negative and positive amperage value. F Both EN Amperage and EP Amperage LEDs will be lit. F See Section to select Independent EN and EP Amperage control.[Bal] [75%]
Balance Control (%EN) TIG Only: Controls oxide cleaning. Increasing the setting reduces cleaning. Range is BALL, 50[Freq] [120H]
AC Frequency (Hz): Controls arc width. Increasing the setting narrows the arc width. Range is 20 to 400 Hz.
OM-290047 Page 45 6-3. Accessing User Menu
270536-A
Menu
3 5User
2 1 4 1 Amperage Button 2 Gas/DIG Button 3 Parameter Display 4 Setting Display 5 Amperage Adjustment Control To access the User Menu 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 amperage adjustment control to ad- just parameter setting. To exit User Menu, press Amperage and Gas/DIG controls at the same time and then release, or turn power off. User Menu Function Parameter/Setting Display Example Description Tungsten Diameter Selection[Tung] [3/32]
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, select [GEN] and press Amperage to cycle through start parameters. Output Trigger Mode Functions[Rmt] [2T]
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[Ac] [Wave]
Use Encoder to select between advanced squarewave [ADVS], soft square- wave [SOFT], sine wave [SINE], or triangle wave [TRI]. The default is Soft. Application: Use advanced squarewave when a more focused arc is re- quired for better directional control. Use soft squarewave when a softer arc with a more fluid puddle is desired. Use sine wave to simulate a convention- al power source. Use triangular waveshape when the effects of peak amper- age with reduced overall heat input is required to help control distortion on thin materials. AC Commutation Amperage Selec- tion (Dynasty Only)[Ac] [Com.A]
Use Encoder to select between [HIGH] or [LOW] AC commutation amper- age. 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.
OM-290047 Page 46 6-4. AC Independent
Menu
1 3User
5 4 2270536-A
6 F 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 ). 1 Parameter Display/Voltmeter 2 Setting Display/Ammeter 3 Amperage Adjustment Control 4 Amperage Button 5 Gas/DIG Control 6 AC Waveshape Control AC Independent Amperage Press AC Waveshape control until desired function is selected. Parameter/Setting Display Example Description[En] [150A]
EN Amperage: Use with AC TIG only to select electrode negative amperage value.[Ep] [150A]
EP Amperage: Use with AC TIG only to select electrode positive amperage value. 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 button and rotate the Encoder control. The changing average value is displayed on the am- meter. 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 button 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. AC Independent Waveshape F See Section for additional information on Accessing User Setup Menu. The [ACEN], [ACEP] option replaces the [AC] option. Parameter/Setting Display Example Description[Acen] [Soft]
Press Gas/DIG control until [ACEN] is displayed. Press the Amperage button to toggle between [ACEN] and [ACEP]. Use Encoder to select between advanced squarewave [ADVS], soft squarewave [SOFT], sine wave [SINE], or triangle wave [TRI]. The default is [SOFT].[Acep] [Soft]
OM-290047 Page 47
Section 7 – Maxstar Operation
7-1. Maxstar Controls 275861-B / Ref. 803901-A 1 2 10 7 5 6 8 9 11 12 4 3 F For all front panel button controls: press button to turn on light and ena- ble normal function. F Green on nameplate indicates a TIG function. Gray indicates a normal Stick function. 1 Amperage Adjustment Control Use amperage adjustment control in con- junction with applicable front panel function buttons 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 descrip- tions when in any menu. 5 Process Controls 6 Output Controls 7 Pulser Controls 8 Sequencer Controls 9 Gas/DIG Controls 10 Amperage And Spot Time Control 11 Memory 12 Memory Display Displays active memory.
OM-290047 Page 48 7-2. Accessing Control Panel Menu
275861-B
2 3 4 5 1 1 Memory Button Select Memory 1-9 (See Section 10). 2 Parameter Display 3 Setting Display 4 Amperage Adjustment Control Rotate amperage adjustment control to ad- just parameter setting. 5 Amperage Button Amperage Control Controls the welding amperage output. Limits the maximum output of a remote amperage device. *PRO-SET provides PROfessionally devel- oped SETtings for the weld process. To use PRO-SET, press the menu button to display the parameter and adjust the amperage ad- justment control until PRO-SET flashes on the display. PRO-SET flashes one time and reveals the professional setting for the parameter. 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.
OM-290047 Page 49 Output (Trigger Mode Selection) F See Section 9 for additional trigger function options. Parameter/Setting Display Description
[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.[Out] [On]
Output on. (Stick and Lift-Arc TIG 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 out- put is on. Pulse Control Pulsing is available in the TIG process. Controls can be adjusted while welding. Reduces heat input to minimize distortion and increase travel speed. Press button to enable pulser. F See Section 15 for additional Pulser information, or visit http:/www. millerwelds. com/resources/welding- guides. Parameter/Setting Display Description[Pps] [100]
*Pulses Per Second: range is 0.1 - 5000.[Pk T] [40%]
*Peak Amperage Time: range is 5 - 95%.[Bk A] [25%]
*Background Amperage Time: range is 5 - 95% of peak amperage value. Sequencer Control The welding output can be programmed to specific amperages and durations for repetitive applications. Se- quencer is only available in the TIG process. Sequencer is disabled if a remote control with variable amperage is connected to the machine. F See Section 9 for setting weld time. Parameter/Setting Display Description[Intl] [20A]
Initial Amperage: Range is min - 400/800 amps.[Islp] [Off]
Initial Slope Time: Range is OFF - 50.0T (seconds).[Fslp] [Off]
Final Slope Time: Range is OFF - 50.0T (seconds).[Fnl] [10A]
Final Amperage: Range is min - 400/800 amps. Gas/DIG Control Parameter/Setting Display Description[Pre] [0.2T]
Preflow Time: Controls length of time gas flows prior to arc start. Range is OFF-25T (seconds).[Post] [Auto]
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/[Dig] [30%]
OM-290047 Page 50 7-3. Accessing User Menu
270536-A
1 Amperage Button 2 Gas/DIG Button 3 Parameter Display 4 Setting Display 5 Amperage Adjustment Control To access the User Menu 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 amperage adjustment control to ad- just parameter setting. To exit User Menu, press Amperage and Gas/DIG controls at the same time and then release, or turn power off. User Menu Function Parameter/Setting Display Example Description Tungsten Diameter Selection[Tung] [3/32]
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, select [GEN] and press Amperage to cycle through start parameters. Output Trigger Mode Functions[Rmt] [2T]
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.
OM-290047 Page 51 F Complete Parts List is available at www.MillerWelds.com
Section 8 – 28-Pin Advanced Automation Operation
8-1. Controls273670-B
1 2 6 5 3 4 F To activate 28-pin Advanced Automa- tion, see Section 5-6C.. F For all front panel switch pad controls: press button to turn on light and ena- ble normal function. F Green on nameplate indicates a TIG function. Gray indicates a normal Stick function. 1 Amperage Adjustment Control Use amperage adjustment control in con- junction with applicable front panel function buttons 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. It al- so 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 descrip- tions when in any menu. 5 Process Controls 6 Gas/DIG Controls
OM-290047 Page 52 F Complete Parts List is available at www.MillerWelds.com 8-2. Controls
273670-B
1 Parameter Display 2 Setting Display 3 Amperage Adjustment Control Rotate amperage adjustment control to ad- just parameter setting. Process Selection TIG HF Impulse is a non-contact arc starting method for AC and DC TIG welding. TIG Lift-Arc Is a contact arc starting method for AC and DC TIG welding. See Section 15. Gas/DIG Control Parameter/Setting Display Example Description[Pre] [0.2T]
Preflow Time: Controls length of time gas flows prior to arc start. Range is OFF-25T (seconds).[Post] [Auto]
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 maxi- mum amperage of each welding cycle. The minimum time is 8 seconds. Auto = max- imum amperage/10.
OM-290047 Page 53 F Complete Parts List is available at www.MillerWelds.com 8-3. Accessing User Setup Menu
273670-B
Menu
3 5User
2 1 4 1 Amperage Button 2 Gas/DIG Button 3 Parameter Display 4 Setting Display 5 Amperage Adjustment 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 amperage adjustment control to ad- just parameter setting. To exit user menu, press Amperage and Gas/ DIG controls at the same time and then re- lease, or turn power off. TIG Start Parameters Parameter/Setting Display Example Description[Stat] [Off]
[Ac] [Com.A]
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 commu- tation amperage when a less aggressive and quieter arc is preferred.
OM-290047 Page 54 F Complete Parts List is available at www.MillerWelds.com 8-4. Programmable TIG Start Parameters 1 Amperage Button 2 Encoder Control 3 Ammeter A. Off/On (Start Amperage And Time) Current (A) Start Time Start Amperage Off is the default setting. Use Encoder con- trol to select On. When On is selected, the Amperage button LED turns on. Dynasty models have a separate set of pa- rameters for AC and DC. The AC and DC parameters are selected re- motely through pin 28 of the 28-pin automation receptacle where EP (electrode positive = AC, and EN (electrode negative)
= Dc
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 val- ues, press the amperage button to step through each adjustable parameter (see Sections B. and C.). B. Programmable TIG Start Amperage Start Amperage Current (A) To adjust TIG Start Amperage proceed as follows: Press Amperage button until the current start amperage is displayed. The current Start Amperage is displayed on the ammeter, and can be adjusted by rotating the amperage adjustment control. To change Start Time, proceed to Section C. C. Programmable Start Time Current (A) Start Time To adjust Programmable Start Time proceed as follows: Press Amperage button 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 amper- age adjustment control.
OM-290047 Page 55
Section 9 – Advanced Menu Functions
9-1. Accessing Tech Menu 1 Amperage Button 2 Gas/DIG Button Press and hold Amperage and Gas/Dig but- tons for approximately two seconds to scroll past User Menu to Tech Menu. Use Gas/Dig button to cycle through parameters that can be set. 3 Parameter Display 4 Setting Display 5 Amperage Adjustment Control Rotate amperage adjustment control to ad- just parameter setting. To exit tech menu, press Amperage and Gas/ DIG controls at the same time. Tech Menu Function Parameter/Setting Display Example Description Arc Timer[Arc] [T/Cy]
Monitors hours, minutes, and cycles of valid arc on. To view these different elements, rotate amperage adjustment control. To reset, rotate amperage adjustment control until [RESET] [YES] is displayed. Press Menu button to display [RESET] [Done]. Displays turn to [000] [000]. Error Log[Err] [Log]
Use to view last eight logged error events. Each event may list multiple Error Codes. See Section 11-4. Sleep Timer[Slep] [Off]
Turns power off after the machine exceeds the programmed idle time with- out operation. Press the Standby button to turn power on. To set or change time, rotate amperage adjustment control to desired time. Timer range: 1, 5, 10, 20, 30, 45 minutes or one hour. Stick Stuck[Stuc] [Off]
Detects if the electrode is stuck or shorted to the workpiece. Turns weld out- put off to aid in freeing the electrode. To turn on, rotate amperage adjust- ment control. Not recommended for air carbon arc or large diameter electrodes. Open Circuit Voltage[Ocv] [Norm]
Allows user to select between Normal (NORM) and Low open circuit volt- age. Low reduces open circuit voltage to between 8 and 15 volts. To select, rotate amperage adjustment control. Weld Timers[Weld] [Tmrs]
[ON] enables and [OFF] disables the feature. See Section 9-2 for informa- tion on setting weld timers. Weld Timers work with or without Sequencer feature. Cooler Auxiliary Power (Optional)[Cool] [Auto]
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[Lock] [Off]
Limits user control and adjustability of machine. See Section 9-4 for instruc- tions and operation. External Pulse Control Commands[Expc] [Off]
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. Machine Reset[Mach] [Rset]
Resets all machine values back to factory defaults. To reset, rotate amper- age adjustment control to [RESET] [YES]. Then press Amperage button. [RESET] [DONE] will be displayed when the reset is complete and factory defaults have been restored. Software Number[Soft] [Ware]
Software number and revision will be displayed. Serial Number[Serl] [Num]
If serial number displayed does not match serial number of machine, see Section 11-4.
OM-290047 Page 56 9-2. Sequencer And Weld Timer Sequencer Control With Weld Timers ON This function is available while using the TIG process, but is disabled if a remote foot or fingertip con- trol is connected while in the RMT STD mode. When active, the sequencer controls the following pa- rameters of the weld cycle: Parameter/Setting Display Example Description
[Intl] [20A]
Initial Amperage: Range is 3-400/5-800 amps.[Intl] [Off]
*Initial Time: Range is OFF to 25.0T (seconds).[Islp] [Off]
Initial Slope Time: Range is OFF to 50.0T (seconds).[Fslp] [Off]
Final Slope Time: Range is OFF to 50.0T (seconds).[Fnl] [10A]
Final Amperage: Range is 3-400/5-800 amps.[Fnl] [Off]
*Final Time: Range is OFF to 25.0T (seconds). F 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.[Weld] [Off]
Weld Timer: With Weld Timer enabled, press Amperage (A) button, and ro- tate amperage adjustment control to set weld time. Range is Off or 0.1-99.9 and 100-999 (sec) (see Section 9-1). *Enabled features with weld timer On (see Section 9-1).
OM-290047 Page 57 9-3. Output Control And Trigger Functions A. Remote (Standard), 2T, And 4TE Torch Trigger Operation Current (A) Preflow Initial Amps Initial Slope Final Slope Postflow Main Amps Final Amps Time Standard
R
R
P/H
Maintained Switch Foot Or Finger Remote Control P/H = Push and hold trigger; R = Release trigger. F 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 2TP/R
P/R
P/R = Push and release trigger. F If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode. Remote 4TEP/R
P/R
P/R
P/R
*P/R
P/R = Push and release trigger. *Pushing and releasing during final slope will break the arc and go to postflow. F For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends. F When a remote switch is connected to the welding power source, use the remote switch to control the weld cycle. Amperage is con- trolled 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-290047 Page 58 B. 3T Specific Trigger Method 3T Trigger Operation
OM-290047 Page 59 C. 4T, 4Tm, And 4TL Specific Trigger Method 4T And 4Tm Torch Trigger Operation Current (A) Preflow Initial Amps Initial Slope Final Slope Postflow
P/H
R
P/H
R
*P/R
Main Amps Final Amps*P/R
P/H = Push and hold trigger; R = Release trigger *4Tonly: P/R = Push trigger and release in less than 0.75 second 4TL Torch Trigger Operation Preflow Initial Amps Initial Slope Final Slope Postflow Main AmpsP/H
R
P/R
P/R
P/R
P/R
P/R
P/H
Current (A) 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. 4T And 4Tm Application: Use 4T or 4Tm (modified) trigger method when the functions of a remote current con- trol are desired, but only a remote on/off con- trol is available. 4T* allows the operator to toggle between weld current and final current. F When a remote switch is connected to the welding power source, use the re- mote switch to control the weld cycle. Amperage is controlled by the welding power source. 4TL Application: The ability to change current levels without either initial slope or final slope, gives the op- erator the opportunity to adjust filler metal without breaking the arc. 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. F When a remote switch is connected to the welding power source, use the re- mote switch to control the weld cycle. Amperage is controlled by the welding power source.
OM-290047 Page 60 D. On Trigger Operation
On
Voltage (V) 2 Sec Stick Current (A) Touch Stick Lift Stick Electrode Electrode Lift Current (A) Touch Current Initial Amperage Initial Slope Main Amperage Touch Tungsten Lift Tungsten Slightly Lift Tungsten *Final Slope *Final Amperage *Becomes active with Spot Time enabled.
OM-290047 Page 61 9-4. Lockout Functions
Lock
Code
Off
1 2 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. F Before activating lockout levels, be sure that all procedures and parame- ters are established. Parameter adjust- ment is limited while lockout levels are active. To turn On lockout feature, proceed as follows: 1 Amperage Adjustment Control 2 Amperage Button Press Amperage (A) control to toggle be- tween the lock off and code off displays. Tog- gle control until [CODE] [OFF] is displayed Rotate amperage adjustment control to se- lect a lockout code number. Select a number between 1 and 999. The number will appear on the amperage, right, display. F Remember (write down) this code num- ber, as you will need this number to turn this feature off, or make changes to your settings. Toggle Amperage control until [LOCK] is dis- played. You may now select a lockout level. See table below for the degree of adjustabil- ity associated with each lock level. Exit Ad- vanced Functions according to Section 9-1. To turn Off lockout feature, proceed as follows: Toggle Amperage control until Code is displayed. Use amperage adjustment 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.
OM-290047 Page 62 9-5. Lockout Levels Defined Minimum Adjustability Degree of Adjustability Maximum Adjustability Lock Level 1 Lock Level 2 Lock Level 3 Lock Level 4 Adjustable Locked Adjustable Locked Adjustable Locked Adjustable Locked Panel Amps Panel Amps Panel Amps ± 10% Remote Amps (min-panel) Panel Amps ± 10% Polarity (Dy- nasty Only) Polarity (Dy- nasty Only) Polarity (Dy- nasty Only) Polarity (Dy- nasty Only) Process Process Process Process Output Output Output Output Pulser Pulser Pulser (on/off only) Pulser (on/off only) Sequencer Sequencer Sequencer Sequencer Gas/DIG Gas/DIG Gas/DIG Gas/DIG Waveshape Waveshape Waveshape Waveshape
OM-290047 Page 63
Section 10 – Memory
10-1. Memory (Program Storage Locations 1–9) 2 3 2nd 3rd 1st 1 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. For Maxstar Models, each memory location (1 thru 9) can store parameters for both process (TIG and Stick) for a total of 18 programs. Memory Locations 1 9Dc
TIG (HF or Lift) Stick And 1 Memory (Program Storage 1–9) Button 2 Polarity Button (Dynasty Only) 3 Process Button F Polarity and AC Waveshape controls are available on Dynasty models only. To create, change, or recall a welding pa- rameters program, proceed as follows: First, press Memory button until the desired program storage location (1-9) is displayed. Second, press Polarity button until the de- sired polarity, AC or DC, LED is lit. Third, press Process button until desired process, TIG HF Impulse, TIG Lift Arc, or Stick, LED is lit. The program at the chosen location, for the desired polarity and process, is now the ac- tive program. Fourth, change or set all desired parameters. 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.
OM-290047 Page 64 F Complete Parts List is available at www.MillerWelds.com
Section 11 – Maintenance And Troubleshooting
11-1. Routine Maintenance Disconnect power before maintaining. F Maintain more often during severe conditions. ü = Check ◇= Change m = Clean ¶ = Replace Every 3 Months ü ¶ Labels ü ¶ Gas Hoses m Weld Terminals ü ¶ Cables And Cords Every 6 Months m During heavy service, clean monthly. 11-2. Blowing Out Unit Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown.
OM-290047 Page 65 F Complete Parts List is available at www.MillerWelds.com 11-3. Voltmeter/Ammeter Display Messages F All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Message Type Display Message Description Release Trigger
[Rele] [Ase] /
[Trig] [Ger]
Remote 14 receptacle contactor control (Pins A-B) must be opened before proceeding. Un Short Output[Un S] [Hort] /
[Outp] [Ut]
Short on weld output connections must be removed before proceeding. See Section 11-4 if display shows after weld output connections have been veri- fied as not having a short. Over Temperature Error[Over] [Temp]
Over temperature condition has occurred. Error will clear after temperatures reach acceptable levels. Latching Error When one of the following errors occurs, the Standby LED flashes. To clear error, press Standby button or turn off power. See Section 11-4 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 related to the weld cables has been sensed. Straighten out or shorten weld cables. If Carbon arc gouging, adjust DIG setting to Car- bon ARC. See Section (Dynasty) or (Maxstar).[See] [O.M.]
See Owner’s Manual: See Section 11-4. Not Valid[Not] [Vald]
Message is displayed when attempting an incompatible setup; i.e., pressing AC Waveshape while in DC. Lock Level[Lock] [Lev1]
Is displayed when attempting adjustments that are incompatible with the ac- tive selected lock level. Software Not Valid[Soft] [Ware] /
[Not] [Vald]
A software compatibility error has been detected. A software update is re- quired (see Section 5-17). See Section 11-4 if display shows after a software update is performed.[Remo] [Te]
Message is displayed when attempting an incompatible setup with remote pendant connected to 14-pin receptacle. Front panel is disabled with excep- tion of access to Tech Menu.[Adv] [Auto]
Message is displayed when attempting an incompatible setup with 28-pin Ad- vanced Automation enabled.
OM-290047 Page 66 F Complete Parts List is available at www.MillerWelds.com 11-4. Troubleshooting Table Trouble Remedy No weld output; unit completely inoperative. 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 re- ceptacle (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 4-7). 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 11-1). 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 14). Use properly prepared tungsten (see Section 14). Reduce gas flow rate. Tungsten electrode oxidizing and not remaining bright after conclusion of weld. Shield weld zone from drafts. Increase postflow time. Check and tighten all gas fittings (see Section 11-1). Water in torch. Refer to torch manual. Blank display. Verify Power to machine. A software update may be required (see Section 5-17). Contact factory if display remains blank after a software update is performed. Error message [ERR] [LOG] is displayed. Contact a Factory Authorized Service Agent for an explanation of the error code. Latching Errors (see Section 11-3). Contact a Factory Authorized Service Agent if error does not clear or happens frequently. Error message [SEE] [O.M.] is displayed. Contact a Factory Authorized Service Agent. Tech Menu [SERL][NUM] is selected, and serial number displayed does not match serial number of machine (see Section 9-1). Contact a Factory Authorized Service Agent. Error message [UN S] [HORT] / [OUTP] [UT] is displayed. Contact a Factory Authorized Service Agent if display shows after weld output connections have been verified as not having a short. Error message [SOFT] [WARE] [NOT] [VALD] is displayed. Contact a Factory Authorized Service Agent if display shows after a software update is performed.
OM-290047 Page 67
Section 12 – Electrical Diagrams
290105-C
Figure 12-1. Dynasty 400 Circuit Diagram (Page 1 of 2)
OM-290047 Page 68
290105-C
Figure 12-2. Dynasty 400 Circuit Diagram (Page 2 of 2)
OM-290047 Page 69
291939-B
Figure 12-3. Maxstar 400 Circuit Diagram (Page 1 of 2)
OM-290047 Page 70
291939-B
Figure 12-4. Maxstar 400 Circuit Diagram (Page 2 of 2)
OM-290047 Page 71
290148-D
Figure 12-5. Dynasty 800 Circuit Diagram (Page 1 of 2)
OM-290047 Page 72
290148-D
Figure 12-6. Dynasty 800 Circuit Diagram (Page 2 of 2)
OM-290047 Page 73
290975-B
Figure 12-7. Maxstar 800 Circuit Diagram (Page 1 of 2)
OM-290047 Page 74
290975-B
Figure 12-8. Maxstar 800 Circuit Diagram (Page 2 of 2)
OM-290047 Page 75
Section 13 – High Frequency
13-1. Welding Processes Requiring High Frequency 1Tig
1 High-Frequency Voltage TIG – helps arc jump air gap between torch and workpiece and/or stabilize the arc. 13-2. Installation Showing Possible Sources Of HF Interference Best Practices Not Followed 13 9 8 7 1 2 4 5 6 3 10 11, 12 14 Sources of Direct High Frequency Radiation 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table Sources of Conduction of High Frequency 7 Input Power Cable 8 Line Disconnect Device 9 Input Supply Wiring Sources of Reradiation of High Frequency 10 Ungrounded Metal Objects 11 Lighting 12 Wiring 13 Water Pipes And Fixtures 14 External Phone And Power Lines
OM-290047 Page 76 13-3. Recommended Installation To Reduce HF Interference Best Practices Followed 1 2 3 50 ft (15 m) 4 7 50 ft (15 m) 8 5 8 6 9 11 13 12 8 8 10 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. Ground all metal objects and all wiring in welding zone using #12 AWG wire. Ground workpiece if required by codes. 9 Nonmetal Building Metal Building Requirements 10 Metal Building 11 Metal Building Panel Bonding Methods Bolt or weld building panels together, install copper straps or braided wire across seams, and ground frame. 12 Windows and Doorways Cover all windows and doorways with grounded copper screen of not more than 1/ 4 in (6.4 mm) mesh. 13 Overhead Door Track Ground the track.
OM-290047 Page 77
Section 14 – Selecting And Preparing A Tungsten
For Dc Or Ac Welding With Inverter Machines
14-1. Selecting Tungsten Electrode Whenever possible and practical, use DC weld output instead of AC weld output. NOTICE – Wear clean gloves to prevent contamination of tungsten. A. Select Tungsten Electrode Amperage Range By Gas Type* And Polarity Electrode Diameter DCEN – Argon AC – Argon (2% Ceriated or 1.5% Lanthanum Alloy Tungstens) Direct Current Electrode Negative Unbalanced Wave (75% EN Balance) (For Use With Mild Or Stainless Steel) (For Use With Aluminum) 0.010 in. (0.25 mm) Up to 15 Up to 15 0.020 in. (0.50 mm) 5–20 5–20 0.040 in. (1 mm) 15–80 15–80 1/16 in. (1.6 mm) 70–150 70–150 3/32 in. (2.4 mm) 150–200 140–235 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). B. Electrode Composition Tungsten Type Application Notes 2% Cerium (Gray) Good all-around tungsten for both AC and DC welding. 1.5–2% Lanthanum (Yellow/Blue) Excellent low amp starts for AC and DC welding. Pure Tungsten (Green) Not recommended for inverters! For best results in most applications, use a sharpened cerium or lanthanum electrode for AC or DC welding. F 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.
OM-290047 Page 78 14-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines Wrong Tungsten Preparation — Radial Grinding Causes Wandering Arc Better Tungsten Preparation — Stable Arc ° ° 6 Best Tungsten Preparation — Dedicated Tungsten Grinder Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use appropriate local ex- haust (forced ventilation) at the grinder or wear an approved respi- rator. Read SDS for safety informa- tion. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away. Do not use thoriated tungsten. Use tungsten containing ceria, lantha- na, or yttria instead of thoria. Grinding dust from thoriated elec- trodes contains low-level radioac- tive material. F It is recommended to prepare tungsten with a tungsten grinder designed for that purpose whenever possible. 1 Grinding Wheel Grind end of tungsten on fine grit, hard abra- sive wheel before welding. Do not use wheel for other jobs or tungsten can become conta- minated causing lower weld quality. 2 Tungsten Electrode A 2% ceriated tungsten is recommended. 3 Ideal Grind Angle Range: 15° to 30° F 30 degrees is the recommended elec- trode grind angle. 4 Straight Ground Grind lengthwise, not radial. 5 1–1/2 to 4 Times Electrode Diameter 6 Straight Ground Tip F Blunting the tip of the electrode is sometimes done to help maintain con- sistent geometry and resist tungsten erosion. This is especially helpful in AC when melt-back of the tungsten elec- trode is common.
OM-290047 Page 79
Section 15 – Tig Procedures
15-1. Lift-Arc And HF TIG Start Procedures Lift-Arc Start Method 1 2 “Touch” 1–2 Seconds Do NOT Strike Like A Match! Lift-Arc Start When Lift-Arc ™button light is On, start arc as follows: 1 TIG Electrode 2 Workpiece Touch tungsten electrode to workpiece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control. Hold electrode to workpiece for 1- 2 seconds, and slowly lift electrode. Arc is formed when electrode is lifted. Normal open-circuit voltage is not present before tungsten electrode touches work- piece; 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 14) to touch workpiece without over- heating, sticking, or getting contaminated. Application: Lift-Arc is used for the DCEN or AC GTAW process when HF Start method is not permit- ted, or to replace the scratch method. HF Start When HF Start button light is On, start arc as follows: High frequency turns on to start arc when output is enabled. High frequency turns off when arc is started, and turns on whenever arc is broken to help restart arc. Application: HF start is used for the DCEN GTAW, or the AC GTAW process when a non-contact arc starting method is required.
OM-290047 Page 80 15-2. Pulser Control 1 3 2 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 Encoder Control (Set Value) 3 Ammeter (Displays Value) PPS - Pulse frequency or pulses per sec- ond, is the number of pulse cycles per sec- ond. 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 alumi- num 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 Operation section). 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 amper- age, 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 in- crease 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 back- ground side of the cycle. The lower back- ground 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. Table shows effect changing the Peak Time control has on the pulsed output waveform. Percent (%) Peak Time Con- trol Setting Pulsed Output Waveforms Peak 50%/ Background 50% Balanced 50% Bkg Amp Peak Amp
Pps
80% More Time At Peak Amperage 20% More Time At Back- ground Amperage 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) alter- nately heat and cool the molten weld puddle. The combined effect gives the operator bet- ter control of penetration, bead width, crowning, undercutting, and heat input. Con- trols can be adjusted while welding. Pulsing can also be used for filler material addition technique training. F Function is enabled when LED is lit.
OM-290047 Page 81 15-3. General (GEN) Tungsten To Change Programmable TIG Starting Parameters 1 2 3
Gen
Tung
Available Parameter Settings Current (A) Start Time Start Slope Time Preset Amperage Minimum Start Amperage 1 Amperage Adjustment Control 2 Parameter Display 3 Amperage Button Once inside the machine set up menu, tung- sten parameter values can be manually changed by pressing the Amperage switch pad to step through each adjustable parame- ter. Rotate encoder to change the value. Parameter Default AC Default DC Range Start Output Polarity (POL) EP (Electrode Positive) EN (Electrode Negative)Ep/En
Start Amperage (STRT)30 A
60 A
5–200 A
Start Time (TIME) 140 ms 30 ms 0–250 ms Start Slope (SSLP) 10 ms 50 ms 0–250 ms Preset Minimum Amperage(Pmin)
10 A
5 A
1–25 A (Dc)
2–25 A (Ac)
OM-290047 Page 82
Section 16 – Stick Welding (Smaw) Guidelines
16-1. Electrode And Amperage Selection Chart 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 6010 & 6011 6013 7014 7018 7024 Ni-Cl308L
50 100 150 200 250 300 350 400 450Electrode
Dc*
Ac
Position
Penetration
Usage
Min. Prep, Rough
High Spatter
General
Smooth, Easy,
Fast
Low Hydrogen,
Strong
Smooth, Easy,
Faster
Cast Iron
Stainless
Deep
Deep
Low
Med
Low
Low
Low
All
All
All
All
All
Flat
Horiz*
All
All
Ep
Ep
Ep,En
Ep,En
Ep
Ep,En
Ep
Ep
6010 6011 6013 7014 7018 7024Ni-Cl
308L
*Ep = Electrode Positive (Reverse Polarity)
En = Electrode Negative (Straight Polarity)
Electrode
Amperage
Range
Diameter
Med
Effective January 1, 2022 (Equipment with a serial number preface of NC or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. LIMITED WARRANTY - Subject to the terms and conditions below, Miller Electric Mfg. LLC, Apple- ton, Wisconsin, warrants to authorized distributors that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
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