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— answers from the official manualAI-powered answers from the official manual. Verify critical info.
Common questions
Common Questions
44 totalWhat input voltages does the Dynasty 350 accept?
The Dynasty 350 is equipped with Auto-Line, which 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. No manual voltage switching is required. (Page 12)
What is the maximum open-circuit voltage on the Dynasty 350?
The maximum open-circuit DC voltage (Uo) is 75 volts when in Stick mode with normal open-circuit voltage selected. A low open-circuit voltage of 10–15 volts is present while in TIG Lift Arc mode or while in Stick with low open-circuit voltage selected. (Page 12)
Is there significant voltage present inside the machine after I turn it off?
Yes — significant DC voltage exists in inverter welding power sources after removal of input power. You must turn off the inverter, disconnect input power, and discharge the input capacitors according to the instructions in the Maintenance Section before touching any internal parts. Always wait at least 60 seconds after power is turned off, or check that input capacitor voltage is near 0 before touching any parts. (Page 10)
What maintenance should I perform on the inside of the Dynasty 350?
The manual covers blowing out the inside of the unit in Section 8-2 and coolant maintenance in Section 8-3. These procedures are detailed in the Maintenance and Troubleshooting section starting on page 66.
What safety precautions should I follow to reduce EMF exposure while welding?
Keep cables close together by twisting, taping, or using a cable cover, and do not place your body between welding cables. Keep your head and trunk as far from the equipment as possible, and connect the work clamp to the workpiece as close to the weld as possible. Do not coil or drape cables around your body, and do not weld while carrying the welding power source. (Page 12)
Can I use the Dynasty 350 if I have a pacemaker or other implanted medical device?
Wearers of pacemakers and other implanted medical devices should keep away from arc welding operations. Implanted medical device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. (Page 10)
Show 38 more questions
What should I do if overheating occurs on the Dynasty 350?
What is the rated output and duty cycle of the Dynasty 350?
What is the maximum open-circuit voltage (OCV) on the Dynasty 350?
How do I reset the Dynasty 350 to factory default settings?
Is it safe to touch internal parts immediately after turning off the Dynasty 350?
What safety gear should I wear when operating the Dynasty 350?
Can the Dynasty 350 be used by people with pacemakers or other implanted medical devices?
How do I minimize EMF exposure when using the Dynasty 350?
What maintenance does the Dynasty 350 require?
What welding processes does the Dynasty 350 support?
What is the maximum amperage output for the Dynasty 350 welder?
What input voltages does the Dynasty 350 support?
What should I do before installing or servicing the welder?
What is the maximum open-circuit voltage (OCV) for the Dynasty 350?
How do I safely handle compressed gas cylinders used with this welder?
What duty cycle rating does the Dynasty 350 have?
What precautions should I take regarding fumes and gases when welding?
How should I protect myself from electric shock when using this welder?
What safety equipment should I wear when welding?
Where is the serial number and rating label located on the Dynasty 350?
What gas connections does the Dynasty 350 require for TIG welding?
Are there European safety certifications for the Dynasty 350?
What are the voltage requirements for the Dynasty 350 welder?
What safety hazards should I be aware of before using the Dynasty 350?
What should I consider when selecting a location for my Dynasty 350?
What welding processes does the Miller Dynasty 350 support?
How do I connect a cooler to my Dynasty 350?
How do I select the correct cable size for my Dynasty 350?
Where should I locate the serial number and rating label on my Dynasty 350?
What does the 28-pin receptacle on the Dynasty 350 do?
What should I know about connecting input power for the 350 model?
What does the TIG HF Impulse/Lift-Arc connection do on the Dynasty 350?
What voltage and phase options are available for the Dynasty 350?
What are the main safety precautions I need to read before using this welder?
How do I connect the gas for TIG welding on the Dynasty 350?
Are there specific safety standards that the Dynasty 350 complies with?
How do I properly select a location for my Dynasty 350?
What are the weld output terminal options and how do I select the correct cable size?
Full Manual
88 pages
Processes Description TIG (GTAW) Welding Stick (SMAW) Welding Arc Welding Power Source
Om-216869Al
2016−10 Dynasty 350, 700 208/575 Volt Models W/Auto-Line Maxstar 350, 700 File: TIG (GTAW) Including Optional Cart And Cooler CE And Non-CE Models 380/575 Volt Three-Phase W/Auto-Line (CE) For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com
Declaration Of Conformity
for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number Dynasty 350 907204021 Maxstar 350 907334021 Dynasty 700 907101021 Maxstar 700 907103021 Council Directives: • 2014/35/EU Low Voltage • 2014/30/EU Electromagnetic Compatibility • 2011/65/EU Restriction of the use of certain Hazardous Substances in electrical and electronic equipment Standards: • IEC 60974-1: 2012 Arc Welding Equipment – Part 1: Welding Power Sources • IEC 60974-3: 2007 Arc Welding Equipment – Part 3: Arc Striking and Stabilizing Devices • IEC 60974-10: 2007 Arc Welding Equipment – Part 10: Electromagnetic Compatibility Requirements Signatory: _____________________________________ ___________________________________________ David A. Werba Date of DeclarationManager, Product Design Compliance
July 21, 2015241512G
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 Symbols 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. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7 . . . . . 2-4. Proposition californienne 65 Avertissements 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. Informations relatives aux CEM 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 3 − Definitions
9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Additional Safety Symbols And Definitions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Miscellaneous Symbols And Definitions 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 4 − Specifications
12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Serial Number And Rating Label Location 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Specifications 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Dimensions, Weights And Base Mounting Hole Layout 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Environmental Specifications 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Duty Cycle And Overheating 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Volt-Ampere Curves 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 5 − Installation
18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Selecting A Location 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Weld Output Terminals And Selecting Cable Sizes* 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Weld Output Terminals 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Remote 14 Receptacle Information (Used Without Automation Connection) 20 . . . . . . . . . . . . . . . . . . . . 5-5. Automation Connection (For 28-Pin Receptacle If Present) 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Remote Memory Select Inputs (For 28-Pin Receptacle If Present) 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Typical Automation Application For Valid Arc Length Control Lockout And Final Slope Indication 25 . . . 5-8. 115 Volts AC Cooler Receptacle, Supplementary Protector CB1, And Power Switch 25 . . . . . . . . . . . . . 5-9. Gas Connections 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10. TIG HF Impulse/ Lift-Arc Connections 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11. Cooler Connections 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12. Dynasty Stick Connections 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13. Maxstar Stick Connections 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14. Electrical Service Guide 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15. Connecting Input Power For 350 Models 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16. Connecting Input Power For 700 Models 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 6 − Operation
38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Controls 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Encoder Control 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Amperage Control 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Ammeter And Parameter Display And Voltmeter And Selected Parameter Display 39 . . . . . . . . . . . . . . . 6-5. Polarity Control (Dynasty Models Only) 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6. Process Control 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7. Lift-Arc And HF TIG Start Procedures 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table Of Contents
6-8. Output Control 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9. Pulser Control 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10. Sequencer Controls 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11. Gas/DIG Controls (Preflow/Post Flow/DIG/Purge) 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12. AC Waveshape (Dynasty Models Only) 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13. Memory (Program Storage Locations 1-9) 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14. Factory Parameter Defaults And Range And Resolution For 350 Models 47 . . . . . . . . . . . . . . . . . . . . . . 6-15. Factory Parameter Defaults And Range And Resolution For 700 Models 48 . . . . . . . . . . . . . . . . . . . . . . 6-16. Resetting Unit To Factory Default Settings 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17. Software And Revision Viewing 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18. Arc Timer/Counter Display 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 7 − Advanced Functions
52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Accessing Advanced Functions 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Programmable TIG Start Parameters 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Programmable TIG Start Parameters For Models With Advanced Automation Capabilities 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Output Control And Trigger Functions 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. AC Waveshape Selection (Dynasty Models Only) 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Independent Amplitude Selection 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Spot Enable 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8. Stick Open-Circuit Voltage (OCV) Selection 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9. Stick Stuck Check Selection 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10. Lockout Functions 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11. Pulse Welding Display Options 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12. DC Meter Calibration 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 8 − Maintenance And Troubleshooting
65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Blowing Out Inside of Unit 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Coolant Maintenance 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4. Troubleshooting 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 9 − Parts List
68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Recommended Spare Parts 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 10 − Electrical Diagram
69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 11 − High Frequency
76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1. Welding Processes Requiring High Frequency 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2. Installation Showing Possible Sources Of HF Interference 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3. Recommended Installation To Reduce HF Interference 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 12 − Selecting And Preparing A Tungsten For Dc Or Ac Welding With
Inverter Machines
78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) 78 . . . . . . 12-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPLETE PARTS LIST − Available at www.MillerWelds.comWarranty
Emf Data Sheet For Arc Welding Power Source
Product/Apparatus Identification Product Stock NumberMaxstar 700 (Auto-Line 380-575)Ce
907103021 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-A
Emf Data Sheet For Arc Welding Power Source
Product/Apparatus Identification Product Stock NumberDynasty 700 (Auto-Line 380-575)Ce
907101021 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-A
Emf Data Sheet For Arc Welding Power Source
Product/Apparatus Identification Product Stock NumberMaxstar 350 (Auto-Line 380-575) Ce
907334021 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-A
Emf Data Sheet For Arc Welding Power Source
Product/Apparatus Identification Product Stock NumberDynasty 350 (Auto-Line 380-575)Ce
907204021 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 0.21 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: 2016-02-09275611-A
OM- 216869 Page 1
Section 1 − Safety Precautions - Read Before Using
som 2015−09 7 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or ex- plained in the text. NOTICE − Indicates statements not related to personal injury. Indicates special instructions. This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym- bols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. ELECTRIC SHOCK can kill. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Additional safety precautions are required when any of the follow- ing electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of 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! Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes. Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conduc- tor first − double-check connections. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or repaired cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Do not touch electrode holders connected to two welding ma- chines at the same time since double open-circuit voltage will be present. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use. Use GFCI protection when operating auxiliary equipment in damp or wet locations. SIGNIFICANT DC VOLTAGE exists in inverter weld- ing power sources AFTER removal of input power. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. HOT PARTS can burn. Do not touch hot parts bare handed. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insu- lated welding gloves and clothing to prevent burns.
OM- 216869 Page 2 Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch- person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breath- ing air is safe. Do not weld in locations near degreasing, cleaning, or spraying op- erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. Wear body protection made from durable, flame−resistant mate- rial (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. ARC RAYS can burn eyes and skin. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. WELDING can cause fire or explosion. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards). Do not weld where the atmosphere can contain flammable dust, gas, or liquid vapors (such as gasoline). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or by- pass them. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. FLYING METAL or DIRT can injure eyes. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. BUILDUP OF GAS can injure or kill. Shut off compressed gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator.
Electric And Magnetic Fields (Emf)
can affect Implanted Medical Devices. Wearers of Pacemakers and other Implanted Medical Devices should keep away. Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise lev- el is high. NOISE can damage hearing. Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. CYLINDERS can explode if damaged. Protect compressed gas cylinders from excessive heat, mechani- cal shocks, physical damage, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder − explosion will result. Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Use the right equipment, correct procedures, and sufficient num- ber of persons to lift and move cylinders. Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.
OM- 216869 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manu- ally lifting heavy parts or equipment. OVERUSE can cause OVERHEATING Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. FLYING SPARKS can injure. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. Sparks can cause fires — keep flammables away. STATIC (ESD) can damage PC boards. Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. MOVING PARTS can injure. Keep away from moving parts. Keep away from pinch points such as drive rolls. WELDING WIRE can injure. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. BATTERY EXPLOSION can injure. 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. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.
Read Instructions.
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. Use only genuine replacement parts from the manufacturer. Perform installation, maintenance, and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting from the installa- tion. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference. Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive elec- tronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.
OM- 216869 Page 4 1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Glob- al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Com- bustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protec- tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga- net.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- site: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org). OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Super- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Applications Manual for the Revised NIOSH Lifting Equation, The Na- tional Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). 1-6. EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied pro- cesses 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. pace- makers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or con- duct 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-216869 Page 5
Section 2 − Consignes De Sécurité − Lire Avant Utilisation
fre_som_2015−09 7 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dan- gers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. AVIS − Indique des déclarations pas en relation avec des blessures personnelles. Indique des instructions spécifiques. Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger. 2-2. Dangers relatifs au soudage à l’arc Les symboles représentés ci-dessous sont utilisés dans ce ma- nuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Sec- tion 2-5. Lire et observer toutes les normes de sécurité. Seul un personnel qualifié est autorisé à installer, faire fonc- tionner, entretenir et réparer cet appareil. Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil. Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimen- tation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger. UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort. Ne pas toucher aux pièces électriques sous tension. Porter des gants isolants et des vêtements de protection secs et sans trous. S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol. Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber. Se servir d’une source électrique à courant électrique UNIQUE- MENT si le procédé de soudage le demande. Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé. D’autres consignes de sécurité sont nécessaires dans les condi- tions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante (à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est re- commandée. En outre, ne pas travailler seul ! Couper l’alimentation ou arrêter le moteur avant de procéder à l’in- stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor- mes de sécurité). Installez, mettez à la terre et utilisez correctement cet équipement conformément à son Manuel d’Utilisation et aux réglementations nationales, gouvernementales et locales. Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. En effectuant les raccordements d’entrée, fixer d’abord le conduc- teur de mise à la terre approprié et contre-vérifier les connexions. Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes. Vérifier fréquemment le cordon d’alimentation et le conducteur de mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −, le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî- ner la mort. L’équipement doit être hors tension lorsqu’il n’est pas utilisé. Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi- sante ou mal épissés. Ne pas enrouler les câbles autour du corps. Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct. Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine. Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide dou- blée. 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. Porter un harnais de sécurité si l’on doit travailler au-dessus du sol. S’assurer que tous les panneaux et couvercles sont correctement en place. Fixer le câble de retour de façon à obtenir un bon contact métal- métal avec la pièce à souder ou la table de travail, le plus près pos- sible de la soudure. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé. Utiliser une protection différentielle lors de l’utilisation d’un équi- pement auxiliaire dans des endroits humides ou mouillés. Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces.
OM-216869 Page 6 LES PIÈCES CHAUDES peuvent provoquer des brûlures. Ne pas toucher à mains nues les parties chaudes. Prévoir une période de refroidissement avant de travailler à l’équipement. Ne pas toucher aux pièces chaudes, utiliser les outils recomman- dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé. Eloigner votre tête des fumées. Ne pas respirer les fumées. À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Pour déterminer la bonne ventilation, il est recommandé de procéder à un prélèvement pour la composition et la quantité de fumées et de gaz auxquels est exposé le personnel. Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé. Lire et comprendre les fiches de données de sécurité et les instruc- tions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux. 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. 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. 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 RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets e infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). Porter des lunettes de sécurité avec écrans latéraux même sous votre casque. Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc. Porter un équipement de protection pour le corps fait d’un matériau résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette. LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incen- dies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un sur- chauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués. Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables. Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 et AWS A6.0 (voir les Normes de Sécurité). Ne pas souder là où l’air ambiant pourrait contenir des poussières, gaz ou émanations inflammables (vapeur d’essence, par exemple). Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provo- quant des risques d’électrocution, d’étincelles et d’incendie. Ne pas utiliser le poste de soudage pour dégeler des conduites ge- lées. En cas de non utilisation, enlever la baguette d’électrode du porte- électrode ou couper le fil à la pointe de contact. Porter un équipement de protection pour le corps fait d’un matériau résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette. Avant de souder, retirer toute substance combustible de vos po- ches telles qu’un allumeur au butane ou des allumettes. Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes. Utiliser exclusivement des fusibles ou coupe−circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter. 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. Lire et comprendre les fiches de données de sécurité et les instruc- tions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux. DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux. 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 ref- roidissement des soudures, elles risquent de projeter du laitier. Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
Les
Accumulations
De
Gaz
risquent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz comprimé en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance. 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.
OM-216869 Page 7 LE BRUIT peut endommager l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. LES BOUTEILLES peuvent exploser si elles sont endommagées. 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. 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. Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. Ne jamais placer une torche de soudage sur une bouteille à gaz. Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurisée − risque d’explosion. 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. Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors de l’ouverture de la vanne. Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur. Utiliser les équipements corrects, les bonnes procédures et suffi- samment de personnes pour soulever et déplacer les bouteilles. Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité. 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. Ne pas installer l’appareil à proximité de pro- duits inflammables. Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service. LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures. Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire. Utiliser un équipement de levage de capacité suffisante pour lever l’appareil. En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur. Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds. L’EMPLOI EXCESSIF peut
Surchauffer L’Équipement.
Prévoir une période de refroidissement ; res- pecter le cycle opératoire nominal. Réduire le courant ou le facteur de marche avant de poursuivre le soudage. Ne pas obstruer les passages d’air du poste.Les Étincelles Projetées
peuvent provoquer des blessures. Porter un écran facial pour protéger le visage et les yeux. Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exé- cuter dans un endroit sûr lorsque l’on porte l’équipement ho- mologué de protection du visage, des mains et du corps. Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.Les Charges Électrostati-
QUES peuvent endommager les cir- cuits imprimés. Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistatiques pour stocker, dé- placer ou expédier des cartes de circuits imprimes. Les PIÈCES MOBILES peuvent causer des blessures. Ne pas s’approcher des organes mobiles. Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.L’Explosion
De
La
Batterie
peut provoquer des blessures. 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. S’abstenir de toucher des organes mobiles tels que des ventilateurs. Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection. Lorsque cela est nécessaire pour des travaux d’entretien et de dé- pannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié. Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.Lire Les Instructions.
Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’instal- lation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. N’utiliser que les pièces de rechange recommandées par le constructeur. Effectuer l’installation, l’entretien et toute intervention selon les manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie, ainsi que les codes municipaux.
OM-216869 Page 8
Le
Rayonnement
Haute
Fréquence
(H.F.)
risque de provoquer des interférences. Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équi- pements de radio−navigation et de communication, les services de sécurité et les ordinateurs. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation. L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. Si le FCC signale des interférences, arrêter immédiatement l’appareil. Effectuer régulièrement le contrôle et l’entretien de l’installation. Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- ce correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles. LE SOUDAGE À L’ARC risque de provoquer des interférences. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots. Veiller à ce que tout l’équipement de la zone de soudage soit com- patible électromagnétiquement. Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. 2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants) Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après utilisation. 2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Glob- al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Com- bustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protec- tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga- net.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- site: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org). OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Super- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Applications Manual for the Revised NIOSH Lifting Equation, The Na- tional Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). 2-6. Informations relatives aux CEM Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant issu d’un soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations de chauffage par induction) crée un champ électromagnétique (CEM) autour du circuit de soudage. Les champs électromagnétiques produits peuvent causer interférence à certains implants médicaux, p. ex. les stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: Limiter par exemple tout accès aux passants ou procéder à une évaluation des risques individuels pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage:
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 9
Section 3 − Definitions
3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground. Safe3 2012−05 Disconnect input plug or power before working on machine. Safe5 2012−05 Keep your head out of the fumes. Safe6 2012−05 Use forced ventilation or local exhaust to remove the fumes. Safe8 2012−05 Use ventilating fan to remove fumes. Safe10 2012−05 Keep flammables away from welding. Do not weld near flammables. Safe12 2012−05 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe14 2012−05 Do not weld on drums or any closed containers. Safe16 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 10 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information. Safe37 2012−05 Environmental Protection Use Period (China) Safe123 2016−06 Disconnect input plug or power before working on machine. Safe30 2012−05 When power is applied failed parts can explode or cause other parts to explode. Safe26 2012−05 Always wear long sleeves and button your collar when servicing unit. Safe28 2012−05 After taking proper precautions as shown, connect power to unit. Safe29 2012−05 Do not use one handle to lift or support unit. Safe31 2012−05 =< 60° Always lift and support unit using both handles. Keep angle of lifting device less than 60 degrees. Use a proper cart to move unit. Safe44 2012−05 >60s
V
V
V
Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait 60 seconds after power is turned off before working on unit, OR check input ca- pacitor voltage, and be sure it is near 0 before touching any parts. Safe42 2012−05 Become trained and read the instructions before working on the machine or welding. Safe40 2012−05 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. Safe38 2012−05
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 11 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products.
A
Amperage Output Gas Tungsten Arc Welding (GTAW) Shielded Metal Arc Welding(Smaw)
V
Volts Input 3 Phase Static Frequency Converter-Transfo rmer-Rectifier Output Supplementary Protector Remote Lift-Arc (GTAW) Protective Earth (Ground) Postflow Timer Preflow TimerS
Seconds On Off Positive Negative Alternating Current Gas Input Gas OutputI2
Rated Welding CurrentX
Duty Cycle Direct Current Line ConnectionU2
Conventional Load VoltageU1
Primary VoltageIp
Degree Of Protection I1max Rated Maximum Supply Current I1eff Maximum Effective Supply CurrentU0
Rated No Load Voltage (OCV) Polarity Control Initial Amperage Increase/ Decrease Of Quantity Remote Standard Remote 2T Hold Gas/DIG Control Percent Hz Hertz Recall From Memory Arc Force (DIG) Impulse Starting(Gtaw)
Final Slope Final Amperage Pulse Percent On Time Initial Slope AC Waveshape Control Pulser EP Amperage Pulse Frequency Work Electrode EN Amperage Process Unit may be used in environments with increased hazard of electric shock Sequence Background Amperage f AC Frequency Water (Coolant) Input Water (Coolant) Output Circulating Unit With Coolant Pump
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 12
Section 4 − Specifications
4-1. Serial Number And Rating Label Location The serial number and rating information for the power source is located on the front of the machine. Use the rating labels to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2. Specifications This equipment will deliver rated output at an ambient air temperature up to 104F ( 40C).A.
Dynasty 350 Models Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-14A and 5-15A or B for information on connecting input power. Input Power Rated Welding Output Amper- age Range Max Open- Circuit Voltage DC (Uo) Rated Peak Striking Voltage (Up) Amperes Input at Rated Load Output 50/60 Hz208 V
230 V
380 V
400 V
460 V
575 V
Kva
Kw
Three Phase 250 A @ 30 Volts, 100% Duty Cycle 3−350 75∇ 10−15♦15 Kv**
29 26 16 15 13 10 10.3 9.9 *(.06) 300 A @ 32 Volts, 60% Duty Cycle 36 32 19 18 16 13 12.7 12.1 *(.06) Single Phase 180 A @ 27.2 Volts, 100% Duty Cycle 3−350 75∇ 10−15♦15 Kv**
35 32 −− −− 15 12 7.4 6.8 *(.06) 225 A @ 29 Volts, 60% Duty Cycle 47 43 −− −− 21 16 9.8 9.1 *(.06) *While idling ** Arc starting device is designed for manual guided operations. ♦Low open-circuit voltage while in TIG Lift Arc, or while in Stick with low open-circuit voltage selected (see Section 7-8). ∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 7-8). This unit is equipped with Auto-Line. Auto-Line is an internal inverter power source circuit that automatically links the power source to any primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.B.
Maxstar 350 Models Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-14B and 5-15A or B for information on connecting input power. Input Power Rated Welding Output Amper- age Range Max Open- Circuit Voltage DC (Uo) Rated Peak Striking Voltage (Up) Amperes Input at Rated Load Output 50/60 Hz208 V
230 V
380 V
400 V
460 V
575 V
Kva
Kw
Three Phase 250 A @ 30 Volts, 100% Duty Cycle 3−350 75∇ 10−15♦15 Kv**
27 24 15 14 12 9 9.7 9.3 *(.06) 300 A @ 32 Volts, 60% Duty Cycle 33 30 18 17 15 12 12 11.5 *(.06) Single Phase180 A @ 27.2
Volts, 100% Duty Cycle 3−350 75∇ 10−15♦15 Kv**
32 29 −− −− 14 11 6.4 6 *(.06) 225 A @ 29 Volts, 60% Duty Cycle 43 39 −− −− 19 14 8.6 8.2 *(.06) *While idling ** Arc starting device is designed for manual guided operations. ♦Low open-circuit voltage while in TIG Lift Arc, or while in Stick with low open-circuit voltage selected (see Section 7-8). ∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 7-8). This unit is equipped with Auto-Line. Auto-Line is an internal inverter power source circuit that automatically links the power source to any primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 13
C.
Dynasty 700 Models Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-14C and 5-16B or C for information on connecting input power. Input Power Rated Welding Output Amper- age Range Max Open- Circuit Voltage DC (Uo) Rated Peak Striking voltage (Up) Amperes Input at Rated Load Output 50/60 Hz208 V
230 V
380 V
400 V
460 V
575 V
Kva
Kw
Three Phase 500 A @ 40 Volts, 100% Duty Cycle 5−700 75∇ 10−15♦15 Kv **
75 68 41 39 34 27 27 26 *(.08) 600 A @ 44 Volts, 60% Duty Cycle 98 88 53 51 43 33 35 34 *(.08) Single Phase 360 A @ 34 Volts, 100% Duty Cycle 5−700 75∇ 10−15♦15 Kv **
82 74 −− −− 37 30 17 16 *(.08) 450 A @ 38 Volts, 60% Duty Cycle 119 105 −− −− 50 38 24 22 *(.08) *While idling ** Arc starting device is designed for manual guided operations. ♦Low open-circuit voltage while in TIG Lift Arc, or while in Stick with low open-circuit voltage selected (see Section 7-8). ∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 7-8). This unit is equipped with Auto-Line. Auto-Line is an internal inverter power source circuit that automatically links the power source to any primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.D.
Maxstar 700 Models Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-14D and 5-16A or C for information on connecting input power. Input Power Rated Welding Output Amper- age Range Max Open- Circuit Voltage DC (Uo) Rated Peak Striking Voltage (Up) Amperes Input at Rated Load Output 50/60 Hz208 V
230 V
380 V
400 V
460 V
575 V
Kva
Kw
Three Phase 500 A @ 40 Volts, 100% Duty Cycle 5−700 75∇ 10−15♦15 Kv**
67 60 36 35 30 24 24 23 *(.08) 600 A @ 44 Volts, 60% Duty Cycle 89 80 49 46 40 31 32 31 *(.08) Single Phase 360 A @ 34 Volts, 100% Duty Cycle 5−700 75∇ 10−15♦15 Kv**
77 70 −− −− 35 28 16 15 *(.08) 450 A @ 38 Volts, 60% Duty Cycle 108 95 −− −− 45 35 22 21 *(.08) *While idling ** Arc starting device is designed for manual guided operations. ♦Low open-circuit voltage while in TIG Lift Arc, or while in Stick with low open-circuit voltage selected (see Section 7-8). ∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 7-8). This unit is equipped with Auto-Line. Auto-Line is an internal inverter power source circuit that automatically links the power source to any primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 14 4-3. Dimensions, Weights And Base Mounting Hole Layout Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.
A.
Welding Power SourceB
A
C
803 914-A
C
D
F
G
E
DimensionsA
24-3/4 in (654 mm) − 350 Amp Models 34-5/8 in (879 mm) − 700 Amp ModelsB
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 Weight 135.5 lb (61.5 kg) 198 lb (89.8 kg)B.
Welding Power Source With Cart And CoolerB
A
C
804 642-C
DimensionsA
350 Models 43-3/4 in. (1111 mm) 700 Models 53-3/4 in. (1365 mm)B
23-1/8 in. (587 mm)C
41-3/4 in. (1060 mm) Weight For 350 Models Weight For 700 Models 250.5 lb (113.6 Kg) 313 lb (142 Kg)
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 15 4-4. Environmental Specifications
A.
IP Rating (All Models) IP Rating Operating Temperature Range Storage Temperature RangeIp23
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered. 14 to 104 °F (-10 to 40°C) −4 to 131 °F (−20 to 55°C)Ip23 2014−06
B.
Information On Electromagnetic Compatibility (EMC) (Dynasty 350) ! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low− voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con- ducted as well as radiated disturbances. This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public low-voltage system impedance Zmax at the point of common coupling is less than 38.63m (or the short−circuit power Ssc is greater than 4.1MVA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if neces- sary, that the system impedance complies with the impedance restrictions. ce-emc 1 2014-07C.
Information On Electromagnetic Compatibility (EMC) (Maxstar 350) ! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low− voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con- ducted as well as radiated disturbances. This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public low-voltage system impedance Zmax at the point of common coupling is less than 119.38m (or the short−circuit power Ssc is greater than 1.3MVA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if neces- sary, that the system impedance complies with the impedance restrictions. ce-emc 1 2014-07D.
Information On Electromagnetic Compatibility (EMC) (Dynasty 700) ! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low− voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con- ducted as well as radiated disturbances. This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public low-voltage system impedance Zmax at the point of common coupling is less than 17.03m (or the short−circuit power Ssc is greater than 9.4MVA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if neces- sary, that the system impedance complies with the impedance restrictions. ce-emc 1 2014-07E.
Information On Electromagnetic Compatibility (EMC) (Maxstar 700) ! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low− voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con- ducted as well as radiated disturbances. This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public low-voltage system impedance Zmax at the point of common coupling is less than 49.09m (or the short−circuit power Ssc is greater than 3.3MVA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if neces- sary, that the system impedance complies with the impedance restrictions. ce-emc 1 2014-07
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 16
F.
China EEP Hazardous Substance Information China EEP Hazardous Substance Information Component Name () (if applicable)Hazardous Substance Pb Hg Cd Cr6
Pbb
Pbde
Brass and Copper PartsX
O
O
O
O
O
Coupling Devices
X
O
O
O
O
O
! Switching DevicesO
O
X
O
O
O
"# "# Cable and Cable AccessoriesX
O
O
O
O
O
$ BatteriesX
O
O
O
O
O
%&'*Sj/T 11364 ,-..
This table is prepared in accordance with China SJ/T 11364.O:
257 89: 85Gb/T26572, >?@.
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:
2Ac5 De89: FGb/T26572, >.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of China GB/T 26572.HikL'*Sj/Z11388 ,N,.
The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.Eep_2016−06
4-5. Duty Cycle And Overheating Duty Cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops, a Help message is displayed (see Section 8-4), 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. Overheating 0 15 A or VOr
Reduce Duty Cycle Minutes Output Amperes %Duty Cycle 10 100 0 100 200 300 400 500 600 700 350 1 Phase 350 3 Phase 700 1 Phase 700 3 Phase 20 30 40 50 60 70 80 90
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 17 4-6. Volt-Ampere Curves 0 50 100 150 200 250 300 350 400 0 10 20 30 40 50 60 70 80 Maxstar 350 DC
215 138-A
Dynasty 350 DC Dynasty 350 AC AC Volts TIG Max Stick Max TIG Min Stick Min Stick Max DIG Min TIG Max Stick Min DIG Max TIG Min 0 50 100 150 200 250 300 350 400 0 50 100 150 200 250 300 350 400 0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80 AC Amperes DC Amperes DC Volts DIG Max Stick Max TIG Max TIG Min Stick Min DIG Max224 527-A
Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown.213 342-A
Dynasty 700 DC Dynasty 700 AC AC Volts 0 100 200 300 400 500 600 700 800 0 10 20 30 40 50 60 70 80 90 100 0 100 200 300 400 500 600 700 800 900 0 10 20 30 40 50 60 70 80 90 DC Amperes DC Volts AC Amperes TIG Max Stick Max TIG Min Stick Min Stick Max DIG Max TIG Max Stick Min DIG Max TIG Min213 344-A
215 139-A
Maxstar 700 DC DC Amperes 0 100 200 300 400 500 600 700 800 900 0 10 20 30 40 50 60 70 80 DC Volts Stick Max DIG Max TIG Max TIG Min Stick Min DIG Max215 126-A
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 18
Section 5 − Installation
! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 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 opposite side of unit. 3 Line Disconnect Device Locate unit near correct input power supply. 5-1. Selecting A Location 3 18 in. (460 mm) 18 in. (460 mm)Or
1 2 Movement Location And Airflow loc_large 2015-04 / 803 900-B ! Do not move or operate unit where it could tip. Notes
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 19 5-2. Weld Output Terminals And Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size. Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding 100 ft (30 m) or Less**** 150 ft (45 m) 200 ft (60 m) Welding Amperes*** 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)
803 900-B
! Turn off power before connecting to weld output terminals. ! Do not use worn, damaged, un- dersized, or repaired cables. 1 Work Weld Output Terminal (Dynasty Models) (+) Positive Weld Output Terminal (Maxstar Models) 2 Electrode Weld Output Terminal Dynasty Models) (−) Negative Weld Output Terminal (Maxstar Models) 3 Remote 14 Receptacle (All Models) See Sections 5-10 thru 5-13 for connec- tion diagrams. 2 1 3
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 20 5-4. Remote 14 Receptacle Information (Used Without Automation Connection)
803 900-A / 218 716-A
A
J
B
K
I
C
L
N
H
D
M
G
E
F
Socket* Socket Information15 Volts Dc
A
Contactor control, 15 volts DC.B
Contact closure to A completes 15 volts DC contactor control circuit, and enables out- put.Remote
Output
Control
C
+10 volts DC.D
Remote control circuit common.E
0 to +10 volts DC input command signal from remote control.A/V
Amperage
Voltage
F
Current feedback; +1 volt DC per 100 am- peres.H
Voltage feedback; +1 volt DC per 10 output receptacle volts.Chassis
K
Chassis common.Gnd
G
+15 volts DC (A) common. If a remote hand control, like the RHC-14, is connected to the Remote 14 receptacle, some current value above min. must be set on the remote control before the Panel or Remote contactor is turned on. Failure to do so will cause current to be controlled by the panel control, and the remote hand control will not function.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 21 5-5. 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.803 900-A / 218 716-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 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 moment- ary closure operation, set unit to 2T, A momentary closure greater than 100 ms, but less than 3/4 of a second starts and stops weld output. 3 Input Gas Control = This input is used to control the gas flow outside the settings of the preflow and/or postflow set on the machine. Connection to pin 8 turns on gas. 4 Output Valid Arc Indication = Paired with Pin 9. This output is used to signal external fixtures that the machine has detected a valid arc. Pin is closed to pin 9 when the output is on and there is less than 65 load volts. Electrical specifications: Open collector transistor maximum values 27volts DC peak @ 75mA. (See Section 5-7 for typical application). 5 Output Scaled Actual Welding Voltage = +1 volt DC per 10 volts of output w/reference to pin 11. 6 Output Scaled Actual Welding Amperage = +1 volt DC per 100 amperes of output w/reference to pin 11. 7 Output +15volts DC with respect to pin 11 (Pin A of 14 pin) 8 Output Reference PIN = This pin is the signal reference for pins 1,2,3,10,15,16 9 Output Valid Arc Indication Reference = Paired with Pin 4. Connect to user’s external voltage supply common. (See Section 5-7 for typical application). 10 Input Memory Select = Used to select between memory numbers. Used in conjunction with pin 15 and 16. (See Sections 4-14 and 5-14. ) 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 val- ues 27 volts DC peak @ 75mA. (See Section 5-7 for typical application) 14 Output Arc Length Control Lockout Reference = Paired with Pin 13. Connect to user’s external voltage supply common (See Section 4-17 for typical application). 15 Input Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 16.(See Sections 4-15 and 5-14.) 16 Input Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 15.(See Sections 4-15 and 5-14.) 17 Input Amperage Control = 0 to +10 volts DC with respect to pin 11. The 10 volts represents the amperage value set on ma- chines meter. (Pin E of 14 pin) Continued on next page
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 22 Continued from previous page Section A. 18 Output +10 volts DC = with respect to pin 11 for use with an external potentiometer to vary the signal into pin 17 (Pin C of 14 pin) 19 Input 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 specifica- tions: Open collector transistor maximum values 27 volts DC peak @ 75mA. (See Section 5-7 for typical application). 24 Output Final Slope Sequence Indication Reference = Paired with pin 23. Connect to user’s external voltage supply common. (See Section 5-7 for typical application). All other pins not used.
B.
Welder Controlled Automation Mode (Pin 20 Connected To Pin 8) Automation 1 Use this mode when only the basic functions of the automation board are required, or if the welder needs to control the initial and final weld timers. These functions include Start/Stop, Valid Arc Indication, Gas Control, High Frequency Arc Start Disable, Remote Memory Select, and Emergency weld stop. The welding power source functions as a standard unit. Automation 2 mode should be used when an externally controlled pulse waveform is needed, or if the welder’s amperage is affected by noise injected into the cabling between the remote equipment and the welder.803 900-A / 218 716-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 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 moment- ary closure operation, set unit to 2T. A momentary closure greater than 100 ms, but less than 3/4 of a second starts and stops weld output. 2 Input Emergency Weld Stop = Used to remotely stop the weld outside the normal welding cycle (i.e. light curtains or external E-Stop). Connection to pin 8 must be maintained at all times. If the connection is broken, output stops, Postflow begins, and AUTO STOP will be displayed on the meters. 3 Input Gas Control = This input is used to control the gas flow outside the settings of the preflow and/or postflow set on the machine. Connection to pin 8 turns on gas. 4 Output Valid Arc Indication = Paired with Pin 9. This output is used to signal external fixtures that the machine has detected a valid arc. Pin is closed to pin 9 when the output is on and there is less than 65 load volts. Electrical specifications: Open collector transistor maximum values 27 volts DC peak @ 75mA. (See Section 5-7 for typical application). 5 Output Scaled Actual Welding Voltage = +1 volt DC per 10 volts of output w/reference to pin 11. 6 Output Scaled Actual Welding Amperage = +1 volt DC per 100 amperes of output w/reference to pin 11. 7 Output +15 volts DC = with respect to pin 11 (Pin A of 14 pin) 8 Output Reference PIN= This pin is the signal reference for pins 1,2,3,10,15,16 9 Output Valid Arc Indication Reference = Paired with Pin 4. Connect to user’s external voltage supply common. (See Section 5-7 for typical application). 10 Input Memory Select = Used to select between memory numbers. Used in conjunction with pins 15 and 16. (See Sections 4-14 and 5-14. ) 11 Output Amperage Control Reference = for pins 5,6,7,17 and 18. (Pin D of 14 pin) 12 Output Welders Chassis = Earth ground. Connected only if common potentials are needed between user equipment and the welder. 13 Output Arc Length Control Lockout = Paired with Pin 14. Used to send signal to an automatic voltage control to ignore the voltage during certain situations. Pin is closed to pin 14 when the weld cycle is in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and Pulsed Background time. Electrical specifications: Open collector transistor maximum val- ues 27volts DC peak @ 75mA. (See Section 5-7 for typical application) Continued on next page
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 23 Continued from previous page Section B. 14 Output Arc Length Control Lockout Reference = Paired with Pin 13. Connect to user’s external voltage supply common (See Section 5-7 for typical application). 15 Input Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 16.(See Sections 4-15 and 5-14.) 16 Input Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 15.(See Sections 4-15 and 5-14.) 17 Input Amperage Control = 0 to +10 volts DC with respect to pin 11. The 10 volts represents the amperage value set on ma- chines 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 specifica- tions: Open collector transistor maximum values 27 volts DC peak @ 75mA. (See Section 5-7 for typical application). 24 Output Final Slope Sequence Indication Reference = Paired with pin 23. Connect to user’s external voltage supply common. (See Section 5-7 for typical application). 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.803 900-A / 218 716-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 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 momentary closure greater than 100 ms, but less than 3/4 of a second starts and stops weld output. 2 Input Emergency Weld Stop = Used to remotely stop the weld outside the normal welding cycle (i.e. light curtains or extern- al E-Stop). Connection to pin 8 must be maintained at all times. If the connection is broken, output stops, Postflow be- gins, and AUTO STOP will be displayed on the meters. 3 Input Gas Control = This input is used to control the gas flow outside the settings of the preflow and/or postflow set on the machine. Connection to pin 8 turns on gas. 4 Output Valid Arc Indication = Paired with Pin 9. This output is used to signal external fixtures that the machine has detected a valid arc. Pin is closed to pin 9 when the output is on and there is less than 65 load volts. Electrical specifications: Open collector transistor maximum values 27 volts DC peak @ 75mA. (See Section 5-7 for typical application). 5 Output Scaled Actual Welding Voltage = +1 volt DC per 10 volts of output w/reference to pin 11. 6 Output Scaled Actual Welding Amperage = +1 volt DC per 100 amperes of output w/reference to pin 11. 7 Output +15 volts DC = with respect to pin 11 (Pin A of 14 pin) 8 Output Reference PIN = This pin is the signal reference for pins 1,2,3,10,15,16 9 Output Valid Arc Indication Reference = Paired with Pin 4. Connect to user’s external voltage supply common. (See Section 5-7 for typical application). Continued on next page
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 24 Continued from previous page Section C. 11 Output Control Reference for pins 5 and 6. 12 Output Welders Chassis = Earth ground. Connected only if common potentials are needed between user equipment and the welder. 19 Input High Frequency Arc Start Disable = Disables the arc starter from being activated when connected to pin 8. 21 Input Isolated EN Amperage Common = Paired with Pin 22. 22 Input Isolated EN Amperage Command = Paired with pin 21. Sets output amperage value for a Maxstar and the EN amper- age value for a Dynasty. Value should be between .3 to 10V corresponding to the minimum to maximum of the machine. 25 Input User Controlled Automation Select = Connect to pin 8 to active this mode. 26 Input Isolated EP Amperage Command (Dynasty models only) = Paired with Pin 27. Sets EP(cleaning) output amperage value. Value should be between .3 to 10 volts corresponding to the minimum to maximum of the machine. 27 Input Isolated EP Amperage Common (Dynasty models only) = Paired with Pin 26. 28 Input AC waveform Generation (Dynasty models only) - User controlled polarity(EN or EP), frequency (20-400 HZ) and balance of an AC waveform. When this pin is not connected to pin 8 the weld output is EN. When this pin is connected to pin 8 the weld output is EP. Alternating between connection and disconnection at different intervals creates the fre- quency and balance of the waveform. All other pins not used. 5-6. Remote Memory Select Inputs (For 28-Pin Receptacle If Present) 1 4 9 15 21 26 28 25 20 14 8 3 28-Pin Receptacle RC28 Socket Designations 0 = No Connection / 1 = Connected To Ground (Pin 8)
Function 10 16 15 Off 0 0 0 Memory 1 0 0 1 Memory 2 0 1 0 Memory 3 0 1 1 Memory 4 1 0 0 Memory 5 1 0 1 Memory 6 1 1 0 Memory 7 1 1 1 Notes
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 25 5-7. Typical Automation Application For Valid Arc Length Control Lockout And Final Slope Indication
R
Cr1
+ −Cr1
To User Equipment Typical 28-Pin Output Collector Emitter Coil resistance plus R should be chosen to limit current to 75 mA User supplied power up to 27 volts DC peak Pins 4, 13, 23 Pins 9, 14, 24 5-8. 115 Volts AC Cooler Receptacle, Supplementary Protector CB1, And Power Switch803 901-A
1 AC Cooler Receptacle Receptacle RC2 supplies 115 V 10 A of single-phase power. RC2 is a designated use re- ceptacle intended only for sup- plying AC power to a Miller-ap- proved cooler. 2 Supplementary Protector CB1 CB1 protects cooler receptacle from overload. If circuit breaker opens, the receptacle does not work. Press button to reset protector. 3 Power On/Off Switch 1 2 3
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 26 5-9. Gas Connections
803 901-A
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 between regulator/flowmeter and gas fitting on rear of unit. Tools Needed: 11/16, 1-1/8 in. 3 2 4 1 5-10. TIG HF Impulse/ Lift-Arc Connections803 915-B
! Turn off power before making connections. 1 Electrode Weld Output Terminal Connect TIG torch to electrode weld output terminal. 2 Gas Out Connection Connect torch gas hose to gas out fitting. 3 Work Weld Output Terminal Connect work lead to work weld output terminal. 4 Remote 14 Receptacle If desired, connect remote con- trol to Remote 14 receptacle (see Section 5-4). 5 Gas In Connection Connect gas hose from gas sup- ply to gas in fitting (see Section 5-9). Tools Needed: 11/16 in. (21 mm for CE units) 2 3 5 4 1
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 27 5-11. Cooler Connections Cart and cooler are optional equip- ment. 1 AC Cooler Receptacle RC2 RC2 is a designated use re- ceptacle intended only for sup- plying AC power to a Miller-ap- proved 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 Output Terminal On Maxstar Models) Connect work lead to work weld output terminal. 6 Water-Out (To Torch) Connection Connect torch water-in (blue) hose to welding power source water-out connection. 7 Water-In (From Torch) Connection Connect torch water-out (red) hose to welding power source water-in connection. 1 Low Conductivity Coolant No. 043 810**; Distilled Or Deionized Water OK Above 32° F (0° C) GTAW Or Where HF* Is Used Application *HF: High Frequency Current **Coolant 043 810, a 50/50 solution, protect to -37° F (-38°C) and resist algae growth. NOTICE − Use of any coolant other than those listed in the table voids the warranty on any parts that come in contact with the coolant (pump, radiator, etc.). Coolant 3 4 5 6 7
804 753-C
3-1/2 Gal 2 Tools Needed: 11/16 in. (21 mm for CE units)
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 28 5-12. Dynasty Stick Connections
803 916-C
! Turn off power before making connections. Connections shown are for Dynas- ty models. 1 Work Weld Output Terminal Connect work lead to work weld output terminal. 2 Electrode Weld Output Terminal Connect electrode holder to electrode weld output terminal. 3 Remote 14 Receptacle If desired, connect remote control to Re- mote 14 receptacle (see Section 5-4). 2 1 3 5-13. Maxstar Stick Connections803 916-C
! Turn off power before making connections. Connections shown are for Max- star models. 1 + Weld Output Terminal Connect electrode lead to positive (+) weld output terminal. 2 − Weld Output Terminal Connect work lead to negative (−) weld output terminal. 3 Remote 14 Receptacle If desired, connect remote control to Re- mote 14 receptacle (see Section 5-4). 2 1 3
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 29 5-14. Electrical Service Guide Elec Serv 2015−05
A.
Dynasty 350 Models Actual input voltage should not be 10% less than minimum (5% for 380 volt CE models) and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available. NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12. CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral. Three-Phase Input Voltage (V) 208 230 380 400 460 575 Input Amperes (A) At Rated Output - 300 amps @ 32 volts 36 32 19 18 16 13 Max Recommended Standard Fuse Rating In Amperes1 Time-Delay Fuses2 40 35 20 20 20 15 Normal Operating Fuses3 50 45 30 25 25 20 Min Input Conductor Size In AWG4 10 10 12 14 14 14 Max Recommended Input Conductor Length In Feet (Meters) 88 (27) 107 (33) 177 (54) 127 (39) 168 (51) 262 (80) Min Grounding Conductor Size In AWG4 10 10 12 14 14 14 Reference: 2014 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12. Single-Phase Input Voltage (V) 208 230 460 575 Input Amperes (A) At Rated Output - 225 amps @ 29 volts 47 43 21 16 Max Recommended Standard Fuse Rating In Amperes1 Time-Delay Fuses2 50 50 25 20 Normal Operating Fuses3 70 60 30 25 Min Input Conductor Size In AWG4 8 8 12 14 Max Recommended Input Conductor Length In Feet (Meters) 88 (27) 108 (33) 172 (52) 174 (53) Min Grounding Conductor Size In AWG4 8 10 12 14 Reference: 2014 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 30
B.
Maxstar 350 Models Actual input voltage should not be 10% less than minimum (5% for 380 volt CE models) and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available. NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12. CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral. Three-Phase Input Voltage (V) 208 230 380 400 460 575 Input Amperes (A) At Rated Output - 300 amps @ 32 volts 33 30 18 17 15 12 Max Recommended Standard Fuse Rating In Amperes1 Time-Delay Fuses2 40 35 20 20 15 15 Normal Operating Fuses3 50 45 25 25 20 20 Min Input Conductor Size In AWG4 10 10 14 14 14 14 Max Recommended Input Conductor Length In Feet (Meters) 93 (28) 113 (35) 121 (37) 134 (41) 177 (54) 276 (84) Min Grounding Conductor Size In AWG4 10 10 14 14 14 14 Reference: 2014 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12. Single-Phase Input Voltage (V) 208 230 460 575 Input Amperes (A) At Rated Output - 225 amps @ 29 volts 43 39 19 14 Max Recommended Standard Fuse Rating In Amperes1 Time-Delay Fuses2 50 45 20 15 Normal Operating Fuses3 60 60 30 20 Min Input Conductor Size In AWG4 8 10 14 14 Max Recommended Input Conductor Length In Feet (Meters) 99 (30) 79 (24) 124 (38) 194 (59) Min Grounding Conductor Size In AWG4 10 10 14 14 Reference: 2014 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 31
C.
Dynasty 700 Models Actual input voltage should not be 10% less than minimum (5% for 380 volt CE models) and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available. NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12. CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral. Three-Phase Input Voltage (V) 208 230 380 400 460 575 Input Amperes (A) At Rated Output - 600 amps @ 44 volts 98 88 53 51 44 33 Max Recommended Standard Fuse Rating In Amperes1 Time-Delay Fuses2 110 100 60 60 50 40 Normal Operating Fuses3 150 125 80 80 70 50 Min Input Conductor Size In AWG4 4 4 8 8 8 10 Max Recommended Input Conductor Length In Feet (Meters) 118 (36) 144 (44) 160 (49) 177 (54) 235 (72) 240 (73) Min Grounding Conductor Size In AWG4 6 6 8 8 8 10 Reference: 2014 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12. Single-Phase Input Voltage (V) 208 230 460 575 Input Amperes (A) At Rated Output - 450 amps @ 38 volts 119 105 50 38 Max Recommended Standard Fuse Rating In Amperes1 Time-Delay Fuses2 125 125 60 50 Normal Operating Fuses3 175 150 80 60 Min Input Conductor Size In AWG4 3 4 8 8 Max Recommended Input Conductor Length In Feet (Meters) 107 (33) 107 (33) 178 (54) 279 (85) Min Grounding Conductor Size In AWG4 6 6 8 10 Reference: 2014 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 32
D.
Maxstar 700 Models Actual input voltage should not be 10% less than minimum (5% for 380 volt CE models) and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available. NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input volt- age. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12. CE-marked equipment shall only be used on a supply network that is a three-phase, four-wire system with an earthed neutral. Three-Phase Input Voltage (V) 208 230 380 400 460 575 Input Amperes (A) At Rated Output - 600 amps @ 44 volts 89 80 49 46 40 31 Max Recommended Standard Fuse Rating In Amperes1 Time-Delay Fuses2 110 100 60 50 50 40 Normal Operating Fuses3 125 125 70 70 60 50 Min Input Conductor Size In AWG4 4 6 8 8 8 10 Max Recommended Input Conductor Length In Feet (Meters) 129 (39) 101 (31) 175 (53) 194 (59) 257 (78) 263 (80) Min Grounding Conductor Size In AWG4 6 6 8 8 10 10 Reference: 2014 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12. Single-Phase Input Voltage (V) 208 230 460 575 Input Amperes (A) At Rated Output - 450 amps @ 38 volts 108 95 45 35 Max Recommended Standard Fuse Rating In Amperes1 Time-Delay Fuses2 125 110 50 45 Normal Operating Fuses3 150 150 70 60 Min Input Conductor Size In AWG4 4 4 8 10 Max Recommended Input Conductor Length In Feet (Meters) 94 (29) 115 (35) 189 (58) 194 (59) Min Grounding Conductor Size In AWG4 6 6 8 10 Reference: 2014 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 33 5-15. Connecting Input Power For 350 Models
L1
2 1L2
L3
3 4 5 6 7A.
Connecting Three-Phase Input Power Tools Needed: Ref. Input 2 2012−12 / Ref. 804 746-B ! 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. The Auto-Line circuitry in this unit au- tomatically adapts the power source to the primary voltage being applied. Check input voltage available at site. This unit can be connected to any in- put power between 208 and 575 VAC without removing cover to relink the power source. See rating label on unit and check input voltage available at site. For Three-Phase Operation 1 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 protection using Section 5-14 (fused dis- connect switch shown). Close and secure door on disconnect device. Follow established lockout/tagout procedures to put unit in service. = GND/PE Earth Ground 3
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B.
Connecting Single-Phase Input Power ! 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 conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices. ! Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. The Auto-Line circuitry in this unit au- tomatically adapts the power source to the primary voltage being applied. Check input voltage available at site. This unit can be connected to any in- put power between 208 and 575 VAC without removing cover to relink the power source. See rating label on unit and check input voltage 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 disconnect device line terminals. 10 Over-Current Protection Select type and size of over-current protection using Section 5-14 (fused dis- connect switch shown). Close and secure door on disconnect device. Follow established lockout/tagout procedures to put unit in service. 1 6 5 4 2 7 6L1
L2
1 =GND/PE Earth Ground 3 3 1 8 9 10 Tools Needed: Input1 2012−05 / Ref. 804 746-B / 803 766-A
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 35 5-16. Connecting Input Power For 700 Models 4 9 8 11 6 10 3
A.
Connecting Three-Phase Input Power For Maxstar 700 Models Tools Needed: Ref. Input3 2012−12 / 805 473-A ! Installation must meet all National and Lo- cal Codes − have only qualified persons make this installation. ! Disconnect and lockout/tagout input power before connecting input conduc- tors from unit. Follow established proced- ures regarding the installation and remov- al of lockout/tagout devices. ! Make input power connections to the welding power source first. ! Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. See rating label on unit and check input voltage available at site (see Section 5-1). 1 Input Power Conductors (Customer Supplied Cord) Select size and length of conductors using Section 5-14. Conductors must comply with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size. Welding Power Source Input Power Connec- tions 2 Strain Relief Route conductors (cord) through strain relief and tighten screws. 3 Machine Grounding Terminal 4 Green Or Green/Yellow Grounding Conductor Connect green or green/yellow grounding con- ductor to welding power source grounding termi- nal first. 5 Welding Power Source Line Terminals (Switch S1) 6 Input Conductors L1 (U), L2 (V) And L3 (W) Connect input conductors L1 (U), L2 (V) and L3 (W) to welding power source line terminals. 7 Cable Tie (CE Only) Secure wires with supplied cable tie. Install cover. Disconnect Device Input Power Connections 8 Disconnect Device (switch shown in OFF position) 9 Disconnect Device (Supply) Grounding Terminal Connect green or green/yellow grounding con- ductor to disconnect device grounding terminal first. 10 Disconnect Device Line Terminals Connect input conductors L1 (U), L2 (V) And L3 (W) to disconnect device line terminals. 11 Over-Current Protection Select type and size of over-current protection us- ing Section 5-14 (fused disconnect switch shown). Close and secure door on line disconnect device. Follow established lockout/tagout procedures to put unit in service. 5 6 1 3 4 = GND/PE Earth Ground 2 7
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B.
Connecting Three-Phase Input Power For Dynasty 700 Models Tools Needed: Input3 2012−12 / 805 470-B ! Installation must meet all National and Lo- cal Codes − have only qualified persons make this installation. ! Disconnect and lockout/tagout input power before connecting input conduc- tors from unit. Follow established proced- ures regarding the installation and remov- al of lockout/tagout devices. ! Make input power connections to the welding power source first. ! Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal. See rating label on unit and check input voltage available at site (see Section 5-1). 1 Input Power Conductors (Customer Supplied Cord) Select size and length of conductors using Section 5-14. Conductors must comply with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size. Welding Power Source Input Power Connec- tions 2 Strain Relief Route conductors (cord) through strain relief and tighten screws. 3 Machine Grounding Terminal 4 Green Or Green/Yellow Grounding Conductor Connect green or green/yellow grounding con- ductor to welding power source grounding termi- nal first. 5 Ferrite Core F9 (CE Only) For Dynasty models, wrap green/yellow grounding conductor through supplied ferrite F9 4 times as shown. 6 Welding Power Source Line Terminals (Switch S1) 7 Input Conductors L1 (U), L2 (V) And L3 (W) Connect input conductors L1 (U), L2 (V) and L3 (W) to welding power source line terminals. 8 Cable Tie (CE Only) Secure wires with supplied cable tie. Install cover. Disconnect Device Input Power Connections 9 Disconnect Device (switch shown in OFF position) 10 Disconnect Device (Supply) Grounding Terminal Connect green or green/yellow grounding con- ductor to disconnect device grounding terminal first. 11 Disconnect Device Line Terminals Connect input conductors L1 (U), L2 (V) And L3 (W) to disconnect device line terminals. 12 Over-Current Protection Select type and size of over-current protection us- ing Section 5-14 (fused disconnect switch shown). Close and secure door on line disconnect device. Follow established lockout/tagout procedures to put unit in service. 6 7 1 3 4 10 9 12 6 11 3 = GND/PE Earth Ground 2 5 8 4
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C.
Connecting Single-Phase Input Power Ref. 803 927-D Tools Needed: ! 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. ! Make input power connections to the welding power source first. ! Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. See rating label on unit and check input voltage available at site (see Section 5-1). 1 Input Power Conductors (Customer Supplied Cord) Select size and length of conductors using Section 5-14. Conductors must comply with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size. Welding Power Source Input Power Connections 2 Strain Relief Route conductors (cord) through strain re- lief and tighten screws. 3 Machine Grounding Terminal 4 Green Or Green/Yellow Grounding Conductor Connect green or green/yellow grounding conductor to welding power source grounding terminal first. 5 Welding Power Source Line Terminals (Switch S1) 6 Input Conductors L1 (U) And L2 (V) Connect input conductors L1 (U) And L2 (V) to welding power source line terminals. Install cover. Disconnect Device Input Power Connections 7 Disconnect Device (switch shown in 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 (U) And L2 (V) to disconnect device line terminals. 10 Over-Current Protection Select type and size of over-current protection using Section 5-14 (fused dis- connect switch shown). Close and secure door on line disconnect device. Follow established lockout/tagout procedures to put unit in service. 2 35 6 7 4 8 10 9 6 1 =GND/PE Earth Ground 1 4 2
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Section 6 − Operation
226 868-B / Ref. 803 901-A 1 2 3 4 5 11 8 6 7 For all front panel switch pad controls: press switch pad to turn on light and en- able normal function. Green on nameplate indicates a TIG function, Gray indicates a normal Stick function. 1 Encoder Control 2 Ammeter And Parameter Display See Section 6-4. 3 Voltmeter And Selected Parameter Display See Section 6-4. 4 Polarity Control (Dynasty Only) See Section 6-5. 5 Process Controls See Section 6-6. 6 Output Controls See Section 6-8. 7 Pulser Controls See Section 6-9. 8 Sequencer Controls See Section 6-10. 9 Gas/DIG Controls See Section 6-11. 10 AC Waveshape (Dynasty Only) See Section 6-12. 11 Amperage And Spot Time Control For Amperage Control see Section 6-3. For Spot Time Control see Section 7-7. 12 Memory See Section 6-13. 13 Memory Display Displays active memory. 14 Power Switch Use switch to turn unit On/Off. Rear Panel 9 10 12 6-1. Controls 13 14 Polarity And AC Waveshape Controls Are Available On Dynasty Models Only.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 39 6-2. Encoder Control 1 Encoder Control Use control in conjunction with ap- plicable front panel function switch pad to set values for that function. 1 6-3. Amperage Control 1 A (Amperage Control) 2 Encoder Control 3 Ammeter See Section 6-14 for Amperage control range. Press Amperage switch pad, and turn Encoder control to set weld amperage, or peak amperage when Pulser func- tion is active (see Section 6-9). See Section 6-12 for AC functions. 2 3 1 6-4. Ammeter And Parameter Display And Voltmeter And Selected Parameter Display 1 Ammeter Ammeter displays actual amperage while welding. It also displays ad- justable parameters for all functions 2 Volt Meter Displays output or open circuit volt- age. Also displays word abbrevia- tions for selected parameters. 1 2 6-5. Polarity Control (Dynasty Models Only) 1 Polarity Control Press switch pad until desired LED is illuminated. DC - Select DC for DC welding. Ma- chines electrode output is DCEN for TIG, and DCEP for Stick. AC - Select AC for AC welding. 1
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 40 6-6. Process Control 1 1 Process Control Press switch pad until desired pro- cess LED is illuminated: TIG HF Impulse - is a pulsed HF (see Section 6-7) arc starting meth- od that can be used with either AC or DC TIG welding. Make connec- tions according to Section 5-10. TIG Lift-Arc - is an arc starting method in which the electrode must come in contact with the workpiece (see Section 6-7). This method can be used with either AC or DC TIG welding. Make connections ac- cording to Section 5-10. Stick (SMAW) - This method can be used with either AC or DC Stick welding. Make connections ac- cording to Section 5-12. 6-7. Lift-Arc And HF TIG Start Procedures Lift-Arc Start When Lift-Arc button light is On, start arc as follows: 1 TIG Electrode 2 Workpiece Touch tungsten electrode to work- piece at weld start point, enable out- put and shielding gas with torch trig- ger, foot control, or hand control. Hold electrode to workpiece for 1-2 sec- onds, and slowly lift electrode. Arc is formed when electrode is lifted. Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sens- ing voltage is present between elec- trode and workpiece. The solid-state output contactor does not energize until after electrode is touching work- piece. This allows a properly pre- pared electrode (see Section 12-2) to touch workpiece without overheating, sticking, or getting contaminated. Application: Lift-Arc is used for the DCEN or AC GTAW process when HF Start meth- od is not permitted, or to replace the scratch method. HF Start When HF Start button light is On, start arc as follows: High frequency turns on to start arc when output is enabled. High fre- quency 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. 1 1 − 2 Seconds “Touch” Do NOT Strike Like A Match! 2 Lift-Arc Start Method
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 41 6-8. Output Control 1 1 Output Control Press switch pad until desired parameter LED is illuminated. RMT STD (Remote Standard) Application: Use Remote Trigger (Stan- dard) with a foot pedal or finger amperage control (see Section 7-47-4A). When a foot or finger remote current control is connected, initial amps, ini- tial slope, final slope, and final amps are controlled by the remote control. NOTE: If an On/Off type trigger is used, it must be a maintained switch. All Sequenc- er functions become active, and must be set by the operator.
Rmt 2T Hold
Application: Use Remote Trigger Hold (2T) for long extended welds. If a foot or finger current control is con- nected to the welding power source, only trigger input is functional (see Section7-4B).
This switch function can be reconfi- gured for 3T, 4T, 4T Momentary, or Mini Logic control See Sections 7-4C, D, E, or F)On
Output will energize two seconds after be- ing selected. Application: Use Output On for Stick (SMAW) welding, or for Lift-Arc without the use of a remote control (see Section7-4H).
2 On LED Blue On LED is lit whenever Output is on. 2 Notes
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 42 6-9. Pulser Control 1 3 2 Peak Amp Bkg Amp Peak 50%/Background 50% Balanced 50% More Time At Peak Amperage More Time At Background Amperage Pulsed Output Waveforms Percent (%) Peak Time Control Setting (80%) (20%)
Pps
4 1 Pulser Control Pulsing is available while using the TIG process. Con- trols can be adjusted while welding. Press switch pad to enable pulser. ON - When illuminated, this LED indicates the pulser is on. Press switch pad until desired parameter LED is illumi- nated. To turn Pulser off, press and release switch pad until the On LED turns off. 2 Encoder Control (Set Value) 3 Ammeter (Displays Value) See Section 6-14 for all Pulser parameter ranges. PPS - Pulse frequency or pulses per second, is the num- ber of pulse cycles per second. Pulse frequency helps reduce heat input, part warpage, and helps weld bead cosmetics. The higher the PPS setting, the smoother the ripple effect, the narrower the weld bead, and the more cooling you get. By setting PPS on the lower end, the pulse is slower, and the weld bead wider. This slow puls- ing helps agitate the weld puddle to help release gas trapped in the weldment, and help reduce porosity (very useful in aluminum welding). Some beginners use a slower pulse rate (2-4 pps) to help them with their timing on adding filler material. An experienced welder may have the PPS setting much higher, depending on their personal preferences, and on what they are trying to ac- complish. PEAK t - (PEAK t) is the percentage of time in each cycle, spent at peak amperage (main amperage). Peak amper- age is set with the Amperage control (see Section 6-3). If one pulse per second is being used, and peak time is set at 50%, one-half second is spent at peak amperage, and the other 50%, or one-half second, is spent at the background amperage. Increasing peak time increases time spent at peak amperage, which increases heat input into the part. A good starting point for peak time is about 50-60%. To find a good ratio, you will have to experiment a bit, but the idea is to decrease heat input into the part, and increase the cosmetics of the weld. BKGND A - (Background amps) is set as a percentage of the peak amps setting. If peak amps is set at 200, and background amps at 50%, your background amps is 100 amps when the machine pulses on the background side of the cycle. The lower background amperage helps re- duce heat input. Increasing or decreasing background amps increases or decreases the overall average am- perage, which helps determine how fluid your puddle is on the background side of the pulse cycle. Overall, you want your puddle to shrink to about one-half the size, but still remain fluid. To start with, set background amps at about 20-30% for stainless/carbon steel, or at about 35-50% for aluminum alloys. 4 Pulsed Output Waveforms Example shows affect changing the Peak Time control has on the pulsed output waveform. Application: Pulsing refers to the alternating raising and lowering of the weld output at a specific rate. The raised portions of the weld output are controlled in width, height, and fre- quency, forming pulses of weld output. These pulses and the lower amperage level between them (called the back- ground amperage) alternately heat and cool the molten weld puddle. The combined effect gives the operator bet- ter control of penetration, bead width, crowning, under- cutting, and heat input. Controls can be adjusted while welding. Pulsing can also be used for filler material addition tech- nique training. Function is enabled, when LED is lit
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 43 6-10. Sequencer Controls 2 3 1 5 1 Sequencer Control Sequencing is available while using the TIG process, but is disabled if a remote foot or finger current control is connected to the Remote recep- tacle while in the RMT STD mode. Press switch pad until desired pa- rameter LED is illuminated. 2 Encoder Control (Set Value) Turn control to set values for the se- quencer parameters. 3 Ammeter (Displays Value) See Section 6-14 for all Sequencer parameter ranges. 4 Voltmeter Displays word abbreviations of se- lected parameters. INITIAL A (Initial Amperage) [INTL]
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 44 6-11. Gas/DIG Controls (Preflow/Post Flow/DIG/Purge) 1 2 3 1 Gas/DIG Controls Press switch pad until desired function LED is illuminated. 2 Encoder Control (Set Value) 3 Ammeter (Displays Value) See Section 6-14 for all Adjust parameter ranges. 4 Voltmeter Displays word abbreviations of selected parameters. PREFLOW [PRE] - If the TIG HF process is active (see Section 6-6) and Preflow is shown on the control panel, use control to set length of time gas flows before arc ini- tiation. Application: Preflow is used to purge the weld area and aids in arc starts. POST FLOW [POST] - If the TIG process is active (see Section 6-6), use control to set length of time gas flows after welding stops. AUTO POST FLOW - Creates a post flow time scaled at 1 second per 10 amps of the peak weld amperage for a given weld cycle. Auto post flow is limited to a 8 second minimum, or to the maximum preset post flow time. Application: Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in ap- pearance. DIG - If Stick process is active (see Sec- tion 6-6), use control to set amount of DIG. When set at 0, short-circuit amper- age at low arc voltage is the same as nor- mal welding amperage. When setting is increased, short-circuit amperage at low arc voltage increases. Application: Control helps arc starting or making verti- cal or overhead welds by increasing am- perage at low arc voltage, and reduces electrode sticking while welding. PURGE [PURG] - To activate the gas valve and start the purge function, push and hold the Gas/DIG switch pad for the desired amount of time. To set from 1 to 50 seconds of purge time, hold the Gas/ DIG switch pad while turning the encoder control. Default is 0. While Purge is active, [PURG] is shown in the left display, and purge time is shown in the right display. Pressing any switch pad will end the purge display, but gas will continue to flow until the preset time has timed out. Application: Purge is used to clear the gas lines. 4
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 45 6-12. AC Waveshape (Dynasty Models Only) 1 2 3 1 AC Waveshape Control Press switch pad until desired function LED is illuminated. 2 Encoder Control (Set Value) 3 Ammeter (Displays Value) See Section 6-14 for all AC Waveshape param- eter ranges. EN Amperage [EN] - Use with AC TIG only to select electrode negative amperage value. EP Amperage [EP] - Use with AC TIG only to select electrode positive amperage value. Note: See Section 7-1 to set same Amplitude control [ENEP]. EN Amperage and EP Amperage allow the op- erator the ability to control the amount of am- perage in the negative and positive half cycles independently. A 1.5 to 1 ratio of EN to EP is a good starting point. This provides cleaning ac- tion, but directs more energy into the workpiece and provides faster travel speeds. 4 Amperage Control Average Amperage Control: Setting EN Am- perage, EP Amperage, Balance, and Frequen- cy values creates an average amperage. The operator can change the average amperage value while maintaining the same EN amper- age to EP amperage ratio at the existing bal- ance and frequency. To change the average amperage value, press the Amperage switch pad and turn the Encoder control. The chang- ing average value is displayed on the ammeter. Example: If EN Amperage is 300, EP Amper- age is 150, Balance is 60%, and Frequency is 120, the average amperage is 240 amps. If you press the Amperage switch pad and turn the Encoder control until 480 amps is displayed, the EN amperage is now 600 and EP amper- age is now 300. The balance remains 60%, and the frequency is still 120, and the 2 to 1 EN am- perage to EP amperage is maintained. Balance [BAL] - AC Balance control is enabled only in AC TIG to set percentage of time polarity is electrode negative. Set control at about 75%, and fine tune from there. 5 Voltmeter Displays word abbreviations of selected pa- rameters. Application: When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. To produce a good weld, only 0.10 in (2.5mm) of etched zone along the weld toes is required. Use AC Balance to control the etch zone width. Joint configuration, set-up, process variables, and oxide thickness may affect setting. AC Frequency [FREQ] - Use control to set AC frequency (cycles per second). Application: AC Frequency controls arc width and direction- al control. As AC frequency decreases, the arc becomes wider and less focused, limiting di- rectional control. As AC frequency increases, the arc becomes narrower and more focused, increasing directional control. Travel speed can increase as AC frequency increases. 5 f 4
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 46 6-13. Memory (Program Storage Locations 1-9) 1 Memory (Program Storage 1-9) Switch Pad 2 Polarity Switch Pad (Dynasty Only) 3 Process Switch Pad To create, change, or recall a welding parameters program, proceed as follows: First, press Memory switch pad until the desired program storage loca- tion (1-9) is displayed. Second, press Polarity switch pad until the desired polarity, AC or DC, LED is illuminated Third, press Process switch pad un- til desired process, TIG HF Impulse, TIG Lift Arc, or Stick, LED is illumi- nated. The program at the chosen location, for the desired polarity and process, is now the active program. Fourth, change or set all desired pa- rameters (see Section 6-14 for parameters). Memory Locations 1−9
Ac
Dc
TIG (HF or Lift) TIG (HF or Lift) Stick Stick For Dynasty Models, each memory location (1 thru 9) can store parameters for both polarities (AC and DC), and each polarity can store parameters for both process (TIG and Stick) for a total of 36 programs. And And And 1 2 3 2nd 3rd 1st Polarity And AC Waveshape Controls Are Available On Dynasty Models Only. Memory Locations 1−9Dc
TIG (HF or Lift) Stick For Maxstar Models, each memory location (1 thru 9) can store parameters for both process (TIG and Stick) for a total of 18 programs. And
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 47 6-14. Factory Parameter Defaults And Range And Resolution For 350 Models Parameter Default Range And Resolution
Memory
1 1−9(Dynasty Only) Polarity
Ac
Ac / Dc
Process
TIG HF Impulse TIG HF Impulse / TIG Lift / StickOutput
**Rmt 2T
Rmt Std
2T
Rmt Std / Rmt 2T / On
RMT 2T can be reconfigured for: 2T / 3T / 4T / Mini Logic / 4T Momentary (see Section 7-4)A Main / Peak
(Dynasty Only) Ac Tig
(Dynasty Only) Ac Stick
Dc Tig
Dc Stick
150 A
110 A
150 A
110 A
3 − 350 Amps 3− 350 Amps 3 − 350 Amps 3 − 350 Amps *Spot *Spot Time **Weld TimeOff
0 T
0T
On/Off
0 − 999 Seconds 0 − 999 SecondsPulser
Pps
PEAK tBkgnd A
Off 100 Hz 40% 25%On / Off
Dc: 0.1 - 5000 Pps
Ac: 0.1 − 500 Pps
5 − 95 Percent 5 − 95 PercentSequencer
Initial A
**Initial Time INITIAL SLOPE t FINAL SLOPE tFinal A
**Final Time20 A
0 T
0 T
0 T
5 A
0 T
3 − 350 Amps 0.0 − 25.0 Seconds 0.0 − 50.0 Seconds 0.0 − 50.0 Seconds 3 − 350 Amps 0.0 − 25.0 SecondsAdjust
Preflow
Post Flow
Dig
0.2 T
Auto 30% 0.0 − 25.0 Seconds Auto 1 − 50 Seconds 0 − 100 Percent(Dynasty Only) Ac Waveshape
*Waveform EN Amps EP AmpsBalance
Frequency
En/Ep
Soft Square150A
150A
75% 120 Hz Independent Soft Square, Advanced Square, Sine, Triangle 3 - 350 Amps 3 - 350 Amps 30 − 99 Percent 20 − 400 Hertz Same/Independent
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 48 Factory Parameter Defaults And Range And Resolution For 350 Models (Continued) *TIG Start parameters for each program (1-9)
Dc:
*Tungsten ***Polarity (DYNASTY ONLY) ***Amperage ***Time ***Start Slope Time ***Preset Amperage MinimumAc: (Dynasty Only)
*Tungsten ***Polarity ***Amperage ***Time ***Start Slope Time ***Preset Amperage Minimum .094En
60 A
1 ms 40 ms5 A
.094Ep
130 A
20 ms 20 ms5 A
Gen, .020, .040, .062, .094, .125, .156, .187
Ep / En
3 − 200 Amps 1 − 200 Milliseconds 0 − 250 Milliseconds 3 − 25 AmpsGen, .020, .040, .062, .094, .125, .156, .187
Ep / En
3 − 200 Amps 1 − 200 Milliseconds 0 − 250 Milliseconds 3 − 25 Amps *TIG Start parameters for Advanced AutomationDc:
**Off
**Amperage **TimeAc: (Dynasty Only)
**Off/On
**Amperage **TimeOff
50 A
30 msOff
30 A
30 msOn
3 − 200 Amps 10 − 200 MillisecondsOn
3 − 200 Amps 10 − 200 MillisecondsMemory
1 1−9(Dynasty Only) Polarity
Ac
Ac / Dc
Process
TIG HF Impulse TIG HF Impulse / TIG Lift / StickOutput
**Rmt 2T
Rmt Std
2T
Rmt Std / Rmt 2T / On
RMT 2T can be reconfigured for: 2T / 3T / 4T / Mini Logic / 4T Momentary / Spot (see Section 7-4)A Main / Peak
(Dynasty Only) Ac Tig
(Dynasty Only) Ac Stick
Dc Tig
Dc Stick
500 A
110 A
500 A
110 A
5 − 700 Amps 5 − 700 Amps 5 − 700 Amps 5 − 700 Amps *Spot Spot Time **Weld Time Off0 T
0T
On/Off 0.0 − 999 Seconds 0.0 − 999 SecondsPulser
Pps
PEAK tBkgnd A
Off 100 Hz 40% 25%On / Off
Dc: 0.1 − 5000 Pps
Ac: 0.1 − 500 Pps
5 − 95 Percent 5 − 95 Percent
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 49 Factory Parameter Defaults And Range And Resolution For 700 Models (Continued)
Sequencer
Initial A
**Initial Time INITIAL SLOPE t FINAL SLOPE tFinal A
**Final Time20 A
0 T
0 T
0 T
5 A
0 T
5 − 700 Amps 0.0 − 25.0 Seconds 0.0 − 50.0 Seconds 0.0 − 50.0 Seconds 5 − 700 Amps 0.0 − 25.0 SecondsAdjust
Preflow
Post Flow
Dig
0.2 T
Auto 30% 0.0 − 25.0 Seconds Auto 1 − 50.0 Seconds @ 1 Second Resolution 0 − 100 Percent(Dynasty Only) Ac Waveshape
*Waveform EN Amps EP AmpsBalance
Frequency
*En/Ep
Soft Square500A
500A
75% 120 Hz Independent Soft Square, Advanced Square, Sine, Triangle 5 - 700 Amps 5 - 700 Amps 30 − 99 Percent 20 − 400 Hertz Same/Independent *TIG Start parameters for each program (1-9)Dc:
*Tungsten ***Polarity (DYNASTY ONLY) ***Amperage ***Time **Start Slope Time ***Preset Amperage MinimumAc: (Dynasty Only)
*Tungsten ***Polarity ***Amperage ***Time ***Start Slope Time ***Preset Amperage Minimum .094En
60 A
1 ms 40 ms5 A
.094Ep
130 A
20 ms 20 ms 5 msGen, .040, .062, .094, .125, .156, .187, .250
Ep / En
5 − 200 Amps 1 − 200 Milliseconds 0 − 250 Milliseconds 5 − 25 AmpsGen, .040, .062, .094, .125, .156, .187, .250
Ep / En
5 − 200 Amps 1 − 200 Milliseconds 0 − 250 Milliseconds 5 − 25 Amps *TIG Start parameters for Advanced AutomationDc:
**Off
**Amperage **TimeAc: (Dynasty Only)
**Off/On
**Amperage TimeOff
50 A
30 msOff
30 A
30 msOn
5 − 200 Amps 10 − 200 MillisecondsOn
5 − 200 Amps 10 − 200 Milliseconds
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 50 6-16. Resetting Unit To Factory Default Settings 1 Process Switch Pad 2 Output Switch Pad 3 Gas/DIG Switch Pad 4 Power Switch To reset the active memory, polarity, and process to original factory set- tings, lockout feature must be off (see Section 7-10). Turn power on and then press and hold the Pro- cess, Output, and Gas/DIG switch pads before the machine name clears the meters. 1 2 3 Rear Panel 4
V
6-17. Software And Revision Viewing 1 Power Switch 2 Process Switch Pad To access software numbers, turn power on and then press and hold Process switch pad until machine name clears. First [SOFT][NUM] will appear for two seconds fol- lowed by the software number for five seconds. 2 Rear Panel 1V
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 51 f 6-18. Arc Timer/Counter Display 1 Output And Amperage Controls 2 Power Switch To display the arc timer/counter, turn power switch on, press and hold the Amperage Control and Output switch pads until the machine name clears the meters. 3 Arc Timer Display The arc time will be displayed for 5 seconds as [0-9999][Hours] then [0-59][Mins]. 4 Arc Counter After 5 seconds, the arc count will be dis- played for the next 5 seconds as [0cy] to [9999][99cy]. And 1 1234 Hour 3/4 Rear Panel 2
V
1
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 52
Section 7 − Advanced Functions
f 7-1. Accessing Advanced Functions 1 Amperage Switch Pad 2 Gas/Dig 3 Encoder Control To access the advanced functions, press and hold the Amperage (A) switch pad and then press the Gas/Dig switch pad. To scroll through the advanced functions, press and release the Gas/Dig switch pad. Use the Encoder control to change param- eters for each function. Advanced Functions:
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 53 7-2. Programmable TIG Start Parameters Each memory and polarity selection has their own programmable parameters. A. Tungsten Selection 2
Tung
.094 3 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter Preset TIG Start Parameters Use Encoder control to select a tungsten size from the following: .020, .040, .062 (1/16 in.), .094 (3/32 in.), or .125 (1/8 in.), .156 (5/32 in.), .187 (3/16 in.), [.250 (1/4 in.) 700 Models only], (.094 is the default). When one of the listed tungsten sizes is se- lected, the following TIG starting paramet- ers are preset: Amperage, Start Time, Start Slope Time, and Preset Amperage Minim- um. There are a separate set of parameters for AC and DC (to select polarity see Sec- tion C). If it is necessary or desired to manually set the TIG starting parameters, turn the en- coder until GEN is displayed on the amps meter and Amperage (A) switch pad LED turns on (see Section B). 1 Current (A) Start Time Start Slope Time Preset Amperage Minimum Start Amperage B. Selecting GEN 1 Encoder Control 2 Amps Meter 3 Amperage Switch Pad If [GEn] is selected and displayed on the amps meter, the TIG starting parameters for a .094 tungsten are the default, and for AC polarity they are: Start Polarity = EP, Start Amperage = 120 A, Start Time = 20 ms, Start Slope Time = 10 ms, Preset Minimum Amps = 5 A. For DC polarity they are: Start Polarity = EN, Start Amperage = 60 A, Start Time = 1 ms, Start Slope Time = 40 ms, Preset Min- imum Amps = 5 A. These parameters can be manually changed by pressing the Am- perage switch pad to step through each ad- justable parameter. To change parameters, see Sections C, D, E, F, and G. 1 2 3 Current (A) Start Time Start Slope Time Preset Amperage Minimum Start Amperage 20 ms 120 Amps 10 ms 5 Amps GEN Default AC TIG Start Parameter Relationships Current (A) Start Time Start Slope Time Preset Amperage Minimum Start Amperage 1 ms 60 Amps 40 ms 5 Amps GEN Default DC TIG Start Parameter RelationshipsTung
Gen
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 54 C. Changing Programmable TIG Start Polarity (Dynasty Models Only) 2
Pol
3 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust TIG Start Polarity proceed as fol- lows: Press Amperage switch pad until the cur- rent Start Polarity, (SEL] [E−] or [SEL] [EP] is displayed on meters, and can be ad- justed (see Section 6-14) by turning the En- coder control. To change Start Amperage, proceed to Section D. 1 Current (A) Start Polarity En D. Changing Programmable TIG Start Amperage 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust TIG Start Amperage proceed as follows: Press Amperage switch pad until the cur- rent Start Amperage is displayed on the amps meter, and can be adjusted (see Sec- tion 6-14) by turning the Encoder control. To change Start Time, proceed to SectionD.
1 2Strt
20A
3 Current (A) Start Amperage
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 55
E.
Changing Programmable Start Time 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust Programmable Start Time pro- ceed as follows: Press Amperage switch pad until the cur- rent Start Time is displayed in milliseconds on the amps meter, and can be adjusted by turning the Encoder control (see Section 6-14). To change Start Slope Time, proceed to Section F. 3 2Time
10m 1 Current (A) Start Time F. Changing Start Slope Time 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust Start Slope Time proceed as fol- lows: Press Amperage switch pad until the Start Slope Time is displayed in milliseconds on the amps meter, and can be adjusted (see Section 6-14) by turning the Encoder con- trol. To change Preset Amperage Minimum, proceed to Section G. 1 2Sslp
20m 3 Current (A) Start Slope Time G. Changing Preset Amperage Minimum 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust Preset Amperage Minimum pro- ceed as follows: Press Amperage switch pad until the Pre- set Minimum Amperage is displayed on the amps meter, and can be adjusted (see Sec- tion 6-14) by turning the Encoder control. The preset amperage minimum can be in- dependently set for AC and DC. Whatever amperage is selected as the preset amperage minimum, is the min- imum amperage that the machine will provide in either AC or DC. 1 2Pmin
5A
3 Current (A) Preset Amperage Minimum
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 56 7-3. Programmable TIG Start Parameters For Models With Advanced Automation Capabilities A. OFF/ON (Start Amperage And Time) For Models W/Advanced Automation Capabilities 2
Stat
Off
3 When pin 25 of the 28-pin automation con- nection receptacle (see Section 5-5) is se- lected, Advanced Automation TIG Start Amperage and Start Time may be turned on. Off is the default setting. Use Encoder con- trol to select On. When On is selected, the Amperage switch pad LED turns on. Dynasty models have a separate set of parameters for AC and DC. The AC and DC parameters are selected remotely through pin 28 of the 28-pin auto- mation receptacle where EP (electrode positive = AC, and EN (electrode negative)= Dc
1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter Preset Advanced Automation TIG Start Parameters Default values for Advanced Automation TIG Start Amperage and Start Time are as follows: AC Start Amperage = 50A, AC Start Time = 30ms. DC Start Amperage = 30A and DC Start Time = 30ms. If it is necessary or desired to change the Advanced Automation TIG Start Amperage and Start Time values from the default val- ues, press the amperage switch pad to step through each adjustable parameter (see Sections B and C). 1 Current (A) Start Time Start AmperageB.
Changing Programmable TIG Start Amperage For Models With Advanced Automation Capabilities 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust TIG Start Amperage proceed as follows: Press Amperage switch pad until the cur- rent start amperage is displayed. The cur- rent Start Amperage is displayed on the amps meter, and can be adjusted (see Sec- tion 6-14) by turning the Encoder control. To change Start Time, proceed to SectionC.
1 2Strt
20A
3 Current (A) Start Amperage
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 57
C.
Changing Programmable Start Time For Models With Advanced Automation Capabilities 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust Programmable Start Time pro- ceed as follows: Press Amperage switch pad until the cur- rent start time is displayed. The current Start Time is displayed in milliseconds on the amps meter, and can be adjusted by turning the Encoder control (see Section 6-14). 3 2Time
10m 1 Current (A) Start Time 7-4. Output Control And Trigger FunctionsA.
Remote (Standard) Torch Trigger Operation Current (A) Preflow Initial Amps Initial Slope Final Slope Postflow Main Amps Final AmpsR
R
P/H
Maintained Switch Foot Or Finger Remote Control P/H = Push trigger and hold R = Release trigger. When a foot or finger remote current control is connected to the welding power source, initial amps, initial slope, final slope and final amps are controlled by the remote control.B.
Remote 2T Torch Trigger Operation Current (A) Preflow Initial Amps Initial Slope Final Slope PostflowP/R
Main Amps Final AmpsP/R
P/R = Push trigger and release. If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 58 C. 3T Specific Trigger Method 1 3T (Specific Trigger Operation) Sequencer is required to reconfigure for 3T. 3T requires a specific type of remote con- trol with two independent momentary- contact switches. One will be designated initial switch, and it must be connected be- tween Remote 14 receptacle pins A and B. The second will be designated as the final switch, and it must be connected between Remote 14 receptacle pins D and E. 2 Encoder Control To select 3T, turn Encoder control. Definitions: Initial slope rate is the rate of amperage change determined by the initial amperage, initial slope time, and main amperage. Final slope rate is the rate of amperage change determined by the main amperage, fi- nal slope time, and final amperage. Operation: A. Press and release initial switch within 3/4 second to start shielding gas flow. To stop the preflow sequence before preflow time elapses (25 seconds), press and release final switch. The preflow timer will reset and the weld sequence can be started again. If an initial switch closure is not made again before preflow time ends, gas flow stops, the timer resets, and an initial switch press and release is necessary to start the weld sequence again. B. Press initial switch to start arc at initial amps. Holding switch will change amper- age at initial slope rate (release switch to weld at desired amperage level). C. When main amperage level is reached, initial switch can be released. D. Press and hold the final switch to de- crease amperage at final slope rate (re- lease switch to weld at desired amperage level). E. When final amperage has been reached, the arc extinguishes and shielding gas flows for the time set on the Postflow con- trol. Application: With the use of two remote switches instead of potentiometers, 3T gives the operator the ability to infinitely increase, decrease, or pause and hold amperage within the range determined by the initial, main, and final am- perages. 1
Rmt
3T
Current (A) Remote Trigger OperationA
B
C
D
E
Preflow Initial Amps/Initial Slope Main Amps Final Slope/Final Amps Postflow= 3T
2D.
4T Specific Trigger Method 1 4T (Specific Trigger Operation) 2 Encoder Control To select 4T, turn Encoder control. Torch trigger operation is as shown. 4T allows the operator to toggle between weld current and final current. When a remote switch is connected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source. Application: Use 4T trigger method when the functions of a remote current control are desired, but only a remote on/off control is available. =Rmt
4T
4T
1 Current (A) Preflow Initial Amps Initial Slope Final Slope PostflowP/H
R
P/H
R
P/R
Main Amps Final Amps Torch Trigger OperationP/R
P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds 2
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 59
E.
Mini Logic Operation =Rmt
4Tl
Mini Logic 1 1 Mini Logic Meter Display 2 Encoder Control To select Mini Logic, turn Encoder control. Torch trigger operation is as shown. Mini logic allows the operator to toggle between ini- tial slope or main amps and initial amps. Final Am- perage is not available. Final slope will always slope to minimum amperage and end the cycle. When a remote switch is connected to the welding power source, use the remote switch to control the weld cycle. Amperage is con- trolled by the welding power source. Application: This ability to change current levels without either initial slope or final slope, gives the operator the opportunity to adjust filler metal with- out breaking the arc. Preflow Initial Amps Initial Slope Final Slope Postflow Main Amps Torch Trigger OperationP/H
R
P/R
P/R
P/R
P/R
P/R
P/H
P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 secondsF.
4T Momentary Operation 1 4T Momentary Meter Display 2 Encoder Control To select 4T Momentary, turn Encoder control. 4T Momentary torch trigger operation is as shown. When a remote switch is connected to the welding pow- er source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source. Application: Use 4T Momentary trigger method when the functions of a remote current control are desired, but only a remote on/off control is available. =Rmt
4Te
4T Momentary Main Current (A) Preflow Initial Amps Initial Slope Final Slope Postflow Main Amps Final Amps 1 For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends.P/R
P/R
P/R
P/R
P/R = Push and release trigger; * = Push and releasing during final slope will break the arc and go to postflowP/R
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 60 G. 4T Modified Specific Trigger Method 1 4T Modified (Specific Trigger Operation) 2 Encoder Control To select 4T Modified, turn Encoder control. Torch trigger operation is as shown. When a remote switch is connected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source. Application: Use 4T Modified trigger method when the func- tions of a remote current control are desired, but only a remote on/off control is available. =
Rmt
4Tm 4TModified 1 Current (A) Preflow Initial Amps Initial Slope Final Slope PostflowP/H
R
P/H
R
Main Amps Final Amps Torch Trigger Operation P/H = Push and hold trigger; R = Release trigger 2H.
On Trigger Operation Voltage (V) Current (A) Current (A) Touch Stick Lift Stick Touch Current Initial Amperage Initial Slope Main Amperage Touch Tungsten Lift Tungsten Slightly Lift Tungsten Electrode ElectrodeOn
2 Sec Stick Lift *Final Slope *Final Amperage *Becomes active with Spot Time enabled.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 61 7-5. AC Waveshape Selection (Dynasty Models Only) 1 Memory Switch Pad Each memory location can select any of four wave shapes. 2 Encoder Use the Encoder, at any of the nine memory locations, to select between advanced squarewave [ADVS], soft squarewave [SOFT] (default), sine wave [Sine], or triangle wave [TRI]. During normal operation, when EN or EP Amperage is selected, the left pa- rameter screen will display the active waveshape [ADVS],, [Soft], [Sine], or [TRI] and the independent amplitude selection (see Section 7-6) as a re- minder. Application: Use advance squarewave when a more focused arc is required for better directional control. Use soft square- wave when a softer arc with a more fluid puddle is desired. Use sine wave to simu- late a conventional power source. Use triangular waveshape when the effects of peak amperage with reduced overall heat input is required to help control distortion on thin materials. 2 1
Ac
= Advanced Squarewave = Soft Squarewave = Sine wave = Triangular wave Soft 1 7-6. Independent Amplitude Selection 1 Encoder Control 2 Ammeter Parameter Selection To change between same [Same] and independent [INDP] amplitude adjustment, turn encoder control. Application: Use same if it is de- sired to have the same amperage set for both the electrode negative (EN) and electrode positive (EP) halves of the cycle. Use indepen- dent if you wish to set a different amperage for each half of the weld cycle for more control of the clean- ing action and longer tungsten life (see Section 6-12).Enep
Same 1 2 7-7. Spot Enable 1 Encoder 2 Ammeter Parameter Selection 3 Amperage Switch Pad Turn Encoder control to turn Spot on and off. Once on, exit set-up and press Amperage control switch pad twice and turn Encoder control to set spot time. The spot time default is zero for each program. Spot Enable works in RMT STD and RMT 2T Hold only. When a foot control is con- nected, amperage is controlled at the machine, not by a remote control. Application: Used for tacking and thin sheet joining. Spot Off 1 2 3
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 62 7-8. Stick Open-Circuit Voltage (OCV) Selection 1 Encoder Control 2 Meter Display Turn Encoder to change between low OCV and normal OCV. Active selection is dis- played on the meters. When Stick low OCV is selected, open-cir- cuit voltage is between 9 and 14 volts. When Stick normal OCV is selected, open- circuit voltage is approximately 72 volts. Application: For most Stick applications use low open-circuit voltage. Use normal open-circuit voltage for hard to start Stick electrodes, or if required for your particular application.
Ocv
1Low
2 7-9. Stick Stuck Check Selection 1 Encoder Control 2 Ammeter Parameters Select Display Turn Encoder to change between Stick Stuck Check [ON and [OFF] meter display. When Stick Stuck Check is on and the welding electrode (rod) is stuck, output is turned off. Application: For most Stick applications, use Stick Stuck Check off. With Stick Stuck Check on and the welding electrode (rod) stuck, output is turned off in an at- tempt to save the rod for reuse. This allows the operator time to un-stick the rod, or dis- connect the rod holder from the rod without arc occurring. Turn Stick Stuck Check on when this function is desired. Some applications may require Stick Stuck Check to be turned off. For ex- ample: Large stick electrodes operat- ing at high amperages would require Stick Stuck Check to be turned off.On
Stuc
1 2 7-10. Lockout FunctionsA.
Accessing Lockout Capability 2Off
Code 1Off
Lock See Section 6-1 for explanation of controls referred to in all of Section 7-10. There are four (1−4) different lockout levels. Each successive level allows the operator more flexibility. Before activating lockout levels, be sure that all procedures and parameters are established. Parameter adjustment is limited while lockout levels are active. To turn On the lockout feature, proceed as follows: 1 Encoder Control 2 Amperage (A) Switch Pad Press Amperage (A) switch pad to toggle between the lock and code displays. Toggle switch pad until code is displayed. Turn Encoder control to select a lockout code number. The code number will appear on the amp meter. Select any number from [1] thru [999]. IMPORTANT: remember this code number, as you will need it to turn the lockout feature off. Toggle Amperage (A) switch pad until lock is displayed. You may now select a lockout level. There are four lockout levels available. Turn Encoder control to se- lect a lockout level (see Sections 7-10B for lockout level descrip- tions). Once the desired three digits have been entered and a lockout level selected, exit advanced functions mode (see Section 7-1). To turn Off the lockout feature, proceed as follows: Use Encoder control to enter the same code number that was used to turn on the lockout feature. Press the Amperage (A) switch pad. The amperage (right) meter dis- play will change to [OFF]. The lockout feature is now off. Toggle Select Code Number Select Lockout Level 1, 2, 3, or 4 Toggle 1 to 999
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 63
B.
Lockout Levels Before activating lockout levels, be sure that all procedures and parame- ters are established. Parameter adjust- ment is limited while lockout levels are active. Level 1 Remote amperage control is not avail- able in level 1. TIG Output Selection If either the TIG HF Impulse or TIG Lift Arc process (see Section 6-6) was active when lockout level 1 was activated, the operator can choose between RMT STD (Remote Standard) or RMT 2T HOLD (Remote 2T Hold) (see Section 6-8). The On function is also available if TIG Lift Arc was active. Stick Output Selection If the Stick process was active when lock- out level 1 was activated, the operator can choose between RMT STD or On. When parameter change or selection is lim- ited by lock level 1, [LOCK][LEV1] is dis- played as a reminder. Level 2 Remote amperage control is not avail- able in level 2. Includes all the functions of level 1 plus Memory, Polarity and Process Selection (see Sections 6-5 and 6-6). When parameter change or selection is lim- ited by lock level 2, [LOCK][LEV2] is dis- played as a reminder. Level 3 Remote amperage control is not avail- able in level 3. Includes all the functions of levels 1 and 2 plus the following: 10% adjustment of preset TIG or Stick Weld Amps Select desired process, TIG or Stick, and use Encoder control to adjust amperage +/− 10% of preset amperage value, up to the limits of the machine. If operator tries to go beyond the ±10%, the amperage (right) me- ter will display [LOCK][LEV3] as a reminder. Pulser ON/Off Control Gives operator the ability to turn on/off the Pulser control. When parameter change or selection is lim- ited by lock level 3, [LOCK][LEV3] is dis- played as a reminder. Level 4 Includes all the functions of levels 1, 2, and 3 plus the following: Remote Amperage Control Allows operator to use remote amperage control if desired. Remote control operates from minimum to maximum of preset am- perage value. Connect remote control de- vice according to Section 5-4. When parameter change or selection is lim- ited by lock level 4, [LOCK][LEV4] is dis- played as a reminder.L2
L2
L2
L1
L3
Use Encoder Control To Adjust Amperage ±10% Of Preset Value.L3
Levels 1, 2, And 3 Level 4A
J
B
K
I
C
L
N
H
D
M
G
E
F
Indicates which functions are available for the corresponding lockout level.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 64 7-11. Pulse Welding Display Options 1 Encoder Control 2 Ammeter Parameters Select Display Turn Encoder to change between [V/A], [OFF], and [AVG] pulse welding display options.
[V/A]
Amperage preset displays peak amperage for both AC and DC TIG pulser. While pulse welding at one pulse per second and above in DC TIG, meters display average voltage and amperage. While pulse weld- ing in AC TIG, meter display may not be stable, and are for reference only.[Off]
Amperage preset displays peak amperage for both AC and DC TIG pulser. Meters dis- play [PULS] [WELD] while pulse welding. Meter Hold function is disabled. While in a non-pulse welding mode, weld voltage and amperage display and meter hold capabili- ties are not effected.[Avg]
Amperage preset displays average am- perage for DC TIG pulser, and peak am- perage for AC TIG pulser. While pulse welding at one pulse per second and above in DC TIG, meters display average voltage and amperage. While pulse weld- ing in AC TIG, meter display may not be stable, and are for reference only.V/A
Metr
1 2 1 Encoder Control 2 Ammeter Parameters Select Display Amperage Calibration: The amperage calibration range is ±10 amps. To calibrate the machine’s amperage meter to a load bank’s amperage meter, add or subtract the difference between the amperage found on the machine’s amperage meter and the am- perage meter on the load bank. For example: MachineMeter LoadBankMeter SetMCAL Amps100 A
105 A
+5 A
100 A
95 A
−5 A
3 Amperage Switch Pad 4 Voltage Parameters Select Display Voltage Calibration: The voltage calibration range is ±9.9 volts. To calibrate voltage, press the Amperage switch pad and [MCAL] [OV] will be displayed. To calibrate the machine’s voltage meter to a load bank’s voltage meter, add or subtract the difference between the voltage found on the machine’s voltage meter and the voltage me- ter on the load bank. For example: MachineMeter LoadBankMeter SetMCAL Volts10.0 V
10.5 V
+0.5 V
10.0 V
9.5 V
−0.5 V
7-12. DC Meter CalibrationOa
Mcal
1 2Mcal
Ov
3 4
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 65
Section 8 − Maintenance And Troubleshooting
8-1. Routine Maintenance ! Disconnect power before maintaining.A.
Welding Power Source = Check = Change = Clean Δ = Repair = ReplaceB.
Cooler = Check = Change = Clean Δ = Repair = Replace
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 66 8-2. Blowing Out Inside of Unit
803 900-B
! Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. m30 Torx Tools Needed: 8-3. Coolant Maintenance 804 649-A / Ref. 801 194 ! Disconnect input power be- fore maintaining. 1 Coolant Filter Unscrew housing to clean filter. Changing coolant: Drain coolant by tipping unit to rear, or use suction pump. Fill with clean water and run for 10 minutes. Drain and refill with coolant (see section 5-11). If replacing hoses, use hoses compatible with ethylene gly- col, such as Buna-n, Neo- prene, or Hypalon. Oxy-acety- lene hoses are not compatible with any product containing ethylene glycol. 1
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 67 8-4. Troubleshooting
A.
Voltmeter/Ammeter And Cooler Help Displays All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. 1 Typical Voltmeter/Ammeter Numbered Help Displays - 30 Numbers are for 350 Models Or Top Engine Of 700 Models. 40 Numbers Are For Bottom Engine Of 700 Models. Help 30 Display Indicates a short or open in the thermal protection circuitry located in the input in- ductor of the unit. Contact a Factory Autho- rized Service Agent if this display is shown. Help 31 Display Indicates a malfunction in the primary pow- er circuit caused by an overcurrent condi- tion in the primary IGBT switching circuit. Contact a Factory Authorized Service Agent if this display is shown. Help 32 Display Indicates a short or open in the thermal protection circuitry located on the left side of the unit. Contact a Factory Authorized Ser- vice Agent if this display is shown. Help 34 Display Indicates a short or open in the thermal protection circuitry located on the right side of the unit. Contact a Factory Authorized Service Agent if this display is shown. Help 8 Display Indicates a malfunction in the secondary power circuit of the unit. There is a high open circuit condition. Contact a Factory Authorized Service Agent if this display is shown. Help 14 Display Unit not ready. Primary circuit bus not up to full power. Help 16 Display Secondary clamp voltage too high. Straighten out or shorten weld cables. If this does not correct the problem, contact a Factory Authorized Service Agent. Help 20 Display Indicates that the power supplies for the pri- mary drives have failed. Contact a Factory Authorized Service Agent if this display is shown. Help 21 Display Indicates voltage or current feedback has been detected with contactor off. Contact a Factory Authorized Service Agent if this display is shown. Help 22 Display Voltage and current not present with con- tactor on. Contact a Factory Authorized Service Agent if this display is shown. Help 24 Display Indicates a power supply to the control and interface board PC6 failure. Possible cause is a short in Pin A or Pin B of the remote control. 1V
Help
30A
2 Typical Voltmeter/Ammeter Worded Help Displays. [TOP] or [BOT] will display after the message to identify the affected engine on 700 models. [Over][Temp] On for two seconds then flashes: [Sec] − Indicates the left side of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 4-5). Op- eration will continue when the unit has cooled. [PRI] − Indicates the right side of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 4-5). Operation will continue when the unit has cooled. [InD] − Indicates that the input inductor has overheated. The unit has shut down to allow the fans to cool it (see Section 4-5). Operation will continue when the unit has cooled.[Low][Line]
Indicates that the input voltage is too low, and the unit has automatically shut down. Operation will continue when the voltage is within the operating range (±10%). Have an electrician check the input voltage if this dis- play is shown.[High][Line]
Indicates that the input voltage is too high, and the unit has automatically shut down. Operation will continue when the voltage is within the operating range (±10%). Have an electrician check the input voltage if this dis- play is shown.[Rel][Rmt]
Indicates that the torch trigger is de- pressed. Release trigger to continue. [not][VALD] Indicates a non-allowable set-up on the front panel. [AUTO][STop] Output disable open causing weld output to stop, but gas continues to flow. [Out][LIMT] Indicates a primary overpower condition. Output current is decreased to limit primary power draw. Depress any switch pad and turn encoder or strike an arc to clear the last help condition.[Adv][Auto]
Indicates a non-allowable setup on the front panel due to an Advanced Automation selection being active (see Section 7). [LOCK][LEV 1] 2, 3, or 4 Indicates a non-allowable setup on the front panel due to the current lockout selection (see Section 7-10).[Err][Gnd]
Turn Off input power and have qualified per- son inspect unit. To clear error, turn power Off and back On. Error is displayed only if option is installed and error occurs. Err GND indicates current is present on green or green/yellow grounding conductor. As a result, machine weld output is disabled. ERR GND may be caused by a live conduc- tor contacting the chassis. ERR GND may be caused by work clamp not connected to work piece.
A complete Parts List is available at www.MillerWelds.com OM-216869 Page 68
B.
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 receptacle (see Sections 6-1 and 5-4). Input voltage outside acceptable range of variation (see Section 5-14). Check, repair, or replace remote control. Unit overheated and [Over][Temp] is displayed. Allow unit to cool with fan On (see Section 4-5). Erratic or improper weld output. Use proper size and type of weld cable (see Section 5-2). Clean and tighten all weld and gas connections. No 115 volts AC output at cooler receptacle. Reset circuit breaker CB1 (see Section 5-8). Fan not operating. Fan only runs when cooling is necessary. Check for and remove anything blocking fan movement. Have Factory Authorized Service Agent check fan motor. Wandering arc Use proper size tungsten (see Section 12-1). Use properly prepared tungsten (see Section 12-2). Reduce gas flow rate. Tungsten electrode oxidizing and not re- maining bright after conclusion of weld. Shield weld zone from drafts. Increase postflow time (see Section 6-11). Check and tighten all gas fittings. Water in torch. Refer to torch manual.Section 9 − Parts List
9-1. Recommended Spare Parts Description Part No. Dia. Mkgs. Recommended Spare Parts Quantity 257415 Screen, Filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A complete Parts List is available on-line at www.MillerWelds.com
OM-216869 Page 69
Section 10 − Electrical Diagram
Figure 10-1. Circuit Diagram For Dynasty 350 Models243 217-D
OM-216869 Page 70
243 215-D
Figure 10-2. Circuit Diagram For Maxstar 350 Models
OM-216869 Page 71 Figure 10-3. Circuit Diagram For Dynasty 700 Models (Part 1 of 2)
243 218-D
OM-216869 Page 72 Figure 10-4. Circuit Diagram For Dynasty 700 Models (Part 2 of 2)
243 218-D
OM-216869 Page 73 Figure 10-5. Circuit Diagram For Maxstar 700 Models (Part 1 of 2)
243 216-D
OM-216869 Page 74 Figure 10-6. Circuit Diagram For Maxstar 700 Models (Part 2 of 2)
243 216-D
OM-216869 Page 75
228 525-C
Figure 10-7. Circuit Diagram For Cooler
OM-216869 Page 76
Section 11 − High Frequency
11-1. Welding Processes Requiring High Frequency high_freq 5/10 − S-0693 1 High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. 1Tig
Work 11-2. Installation Showing Possible Sources Of HF Interference 50 ft (15 m)S-0694
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 Weld Zone 13 9 8 7 1 2 4 5 6 3 10 11, 12 14 Best Practices Not Followed
OM-216869 Page 77 11-3. Recommended Installation To Reduce HF Interference 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 discon- nect device, input supply, and worktable. 2 Center Point of Welding Zone Midpoint between high-frequency source and welding torch. 3 Welding Zone A circle 50 ft (15 m) from center point in all directions. 4 Weld Output Cables Keep cables short and close together. 5 Conduit Joint Bonding and Grounding Electrically join (bond) all conduit sections using copper straps or braided wire. Ground conduit every 50 ft (15 m). 6 Water Pipes and Fixtures Ground water pipes every 50 ft (15 m). 7 External Power or Telephone Lines Locate high-frequency source at least 50 ft (15 m) away from power and phone lines. 8 Grounding Rod Consult the National Electrical Code for specifications. Metal Building Requirements 9 Metal Building Panel Bonding Methods Bolt or weld building panels together, install copper straps or braided wire across seams, and ground frame. 10 Windows and Doorways Cover all windows and doorways with grounded copper screen of not more than 1/4 in (6.4 mm) mesh. 11 Overhead Door Track Ground the track. Ref. S-0695 / Ref. S-0695 1 2 3 50 ft (15 m) Weld Zone 4 7 50 ft (15 m) 8 5 8 6 Ground workpiece if required by codes. Ground all metal ob- jects and all wiring in welding zone using #12 AWG wire. Nonmetal Building 9 11 10 Metal Building 8 8 Best Practices Followed
OM-216869 Page 78
Section 12 − Selecting And Preparing A
Tungsten For Dc Or Ac Welding With
Inverter Machines
gtaw_Inverter_2013-10 Whenever possible and practical, use DC weld output instead of AC weld output. 12-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference the product packaging to identify the tungsten you are using. Amperage Range - Gas Type♦ - Polarity Electrode Diameter (DCEN) − Argon Direct Current Electrode Negative (For Use With Mild Or Stainless Steel) AC − Argon Balance Control @ 65% Electrode Negative (For Use With Aluminum) 2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens .010 in. (.25 mm) Up to 25 Up to 20 .020 in. (.50 mm) 15-40 15-35 .040 in. (1 mm) 25-85 20-80 1/16 in. (1.6 mm) 50-160 50-150 3/32 in. (2.4 mm) 130-250 135-235 1/8 in. (3.2 mm) 250-400 225-360 5/32 in. (4.0 mm) 400-500 300-450 3/16 in (4.8 mm) 500-750 400-500 1/4 in. (6.4 mm) 750-1000 600-800 ♦Typical argon shielding gas flow rates are 11 to 35 CFH (cubic feet per hour). Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers. 12-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away. Ideal Tungsten Preparation − Stable Arc 2-1/2 Times Electrode Diameter 1 Grinding Wheel Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality. 2 Tungsten Electrode A 2% ceriated tungsten is recommended. 3 Flat Diameter of this flat determines amperage capacity. 4 Straight Ground Grind lengthwise, not radial. 1 3 4 Causes Wandering Arc 2 Wrong Tungsten Radial Grinding Preparation
Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser 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 Lieu Of All Other Warranties, Express
Or
Implied,
Including
The
Warranties
Of
Merchantability And Fitness.
Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. If notification is submitted as an online warranty claim, the claim must include a detailed description of the fault and the troubleshooting steps taken to identify failed components and the cause of their failure. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed twelve months after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor.Miller Products Are Intended For Purchase And
Use By Commercial/Industrial Users And Persons
Trained
And
Experienced
In
The
Use
And
Maintenance Of Welding Equipment.
In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.To The Extent Permitted By Law, The Remedies
Provided Herein Are The Sole And Exclusive
Remedies. In No Event Shall Miller Be Liable For
Direct,
Indirect,
Special,
Incidental
Or
Consequential Damages (Including Loss Of Profit),
Whether Based On Contract, Tort Or Any Other
Legal Theory.
Any Express Warranty Not Provided Herein And Any
Implied Warranty, Guaranty Or Representation As
To Performance, And Any Remedy For Breach Of
Contract Tort Or Any Other Legal Theory Which,
But For This Provision, Might Arise By Implication,
Operation Of Law, Custom Of Trade Or Course Of
Dealing,
Including
Any
Implied
Warranty
Of
Merchantability
Or
Fitness
For
Particular
Purpose, With Respect To Any And All Equipment
Furnished By Miller Is Excluded And Disclaimed By
Miller.
Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. Warranty Questions? Call1-800-4-A-Miller
for your local Miller distributor. miller_warr 2016-01 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.
Original Instructions − Printed In Usa
© 2016 Miller Electric Mfg. Co. 2016−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Please complete and retain with your personal records. Always provide Model Name and Serial/Style Number. Contact a DISTRIBUTOR or SERVICE AGENCY near you. Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to: For Service Owner’s Record File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. Contact your Distributor for:To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller