Miller DYNASTY 350 Owner's Manual
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Miller DYNASTY 350 Owner's Manual

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Dynasty 350, 700
Maxstar 350, 700
Including Optional Cart And Cooler
OM-216 869G
2008−02
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
208/575 Volt Models W/Auto-Linet
Arc Welding Power Source
R
R
File: TIG (GTAW)

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  • Page 1 OM-216 869G 2008−02 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description 208/575 Volt Models W/Auto-Linet Arc Welding Power Source Dynasty 350, 700 Maxstar 350, 700 Including Optional Cart And Cooler File: TIG (GTAW) Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    ............. 3-2. Manufacturer’s Rating Labels For Dynasty 350 Models .
  • Page 4 TABLE OF CONTENTS SECTION 5 − OPERATION ..............5-1.
  • Page 5 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Manufacturer: European Contact: Miller Electric Mg. Co. Mr. Danilo Fedolfi, 1635 W. Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
  • Page 6 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Manufacturer: European Contact: Miller Electric Mg. Co. Mr. Danilo Fedolfi, 1635 W. Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
  • Page 7 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Manufacturer: European Contact: Miller Electric Mg. Co. Mr. Danilo Fedolfi, 1635 W. Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
  • Page 8 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Manufacturer: European Contact: Miller Electric Mg. Co. Mr. Danilo Fedolfi, 1635 W. Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.

  • Page 9: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 10 D Do not use welder to thaw frozen pipes. FUMES AND GASES can be hazardous. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Welding produces fumes and gases. Breathing D Wear oil-free protective garments such as leather gloves, heavy these fumes and gases can be hazardous to your shirt, cuffless trousers, high shoes, and a cap.

  • Page 11: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 12: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 13: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 14 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un in les sources de soudage onduleur quand on a cendie ou une explosion. coupé l’alimentation. Le soudage effectué sur des conteneurs fermés tel D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peu décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

  • Page 15: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, ACCUMULATIONS des chocs mécaniques, des dommages physiques, du laitier, des risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs. ou même la mort. D Placer les bouteilles debout en les fixant dans un support station- D Fermer l’alimentation du gaz protecteur en cas naire ou dans un porte-bouteilles pour les empêcher de tomber ou de non-utilisation.

  • Page 16: Proposition Californienne 65 Avertissements

    LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ- provoquer des blessures. QUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Le rayonnement haute fréquence (H.F.) peut D Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe- sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica-...

  • Page 17: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org). Internet : www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, de American National Standards Institute, Recommended Safe Practices for the Preparation for Welding and Cut- 11 West 43rd Street, New York, NY 10036-8002 (téléphone :...
  • Page 18 OM-216 869 Page 10...

  • Page 19: Section 3 − Definitions (Ce Models Only)

    SECTION 3 − DEFINITIONS (CE Models Only) 3-1. Warning Label Definitions Warning! Watch Out! There are possible Breathing welding fumes can be 3.3 Do not weld on drums or any closed hazards as shown by the symbols. hazardous to your health. containers.
  • Page 20 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors.
  • Page 21 S-180 663 Warning! Watch Out! There are Moving parts, such as fans, can cut source, wire feeder, or other major fingers and hands and cause injury. equipment for welding safety possible hazards as shown by the Keep away from moving parts. information.

  • Page 22: Manufacturer's Rating Labels For Dynasty 350 Models

    3-2. Manufacturer’s Rating Labels For Dynasty 350 Models For label location see Section 4-4. Manufacture’s Rating Label For Manufacture’s Rating Label Dynasty 350 Non-CE Models For Dynasty 350 CE Models OM-216 869 Page 14...

  • Page 23: Manufacturer's Rating Labels For Maxstar 350 Models

    3-3. Manufacturer’s Rating Labels For Maxstar 350 Models For label location see Section 4-4. Manufacture’s Rating Label For Manufacture’s Rating Label Maxstar 350 Non-CE Models For Maxstar 350 CE Models OM-216 869 Page 15...

  • Page 24: Manufacturer's Rating Labels For Dynasty 700 Models

    3-4. Manufacturer’s Rating Labels For Dynasty 700 Models For label location see Section 4-4. Manufacture’s Rating Label For Manufacture’s Rating Label Dynasty 700 Non-CE Models Dynasty 700 Models OM-216 869 Page 16...

  • Page 25: Manufacturer's Rating Labels For Maxstar 700 Models

    3-5. Manufacturer’s Rating Labels For Maxstar 700 Models For label location see Section 4-4. Manufacture’s Rating Label For Manufacture’s Rating Label Maxstar 700 Non-CE Models For Maxstar 700 CE Models OM-216 869 Page 17...

  • Page 26: Symbols And Definitions

    3-6. Symbols And Definitions Gas Tungsten Arc Shielded Metal Arc Amperes Output Welding (GTAW) Welding (SMAW) 3 Phase Static Frequency Volts Input Converter-Transformer-Rectifier Supplementary Output Remote Lift-Arc (GTAW) Protector Protective Earth Postflow Timer Preflow Timer Seconds (Ground) Positive Negative Alternating Rated Welding Gas Input Gas Output...

  • Page 27: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Specifications A. Dynasty 350 Models Maximum Amper- Amperes Input at Rated Load Output 50/60 Hz Open-Cir- Open Cir Rated Welding Rated Welding Input cuit Volt- 208 V 230 V 380 V 400 V 460 V...
  • Page 28 C. Dynasty 700 Models Maximum Amper- Amperes Input at Rated Load Output 50/60 Hz Open-Cir- Open Cir Rated Welding Rated Welding Input cuit Volt- 208 V 230 V 380 V 400 V 460 V 575 V Range Power Output age DC 500 A @ 40 Volts, 100% Duty Cycle *(.08)

  • Page 29: Duty Cycle And Overheating

    4-2. 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 7-4), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.

  • Page 30: Volt-Ampere Curves

    4-3. Volt-Ampere Curves Dynasty 350 AC Dynasty 350 DC TIG Min TIG Max Stick Max Stick Min Stick Max DIG Min TIG Min TIG Max Stick Min DIG Max 50 100 150 200 250 300 350 400 50 100 150 200 250 300 350 400...
  • Page 31 Volt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. Dynasty 700 DC Dynasty 700 AC Stick Max TIG Min Stick Max TIG Max DIG Max Stick Min Stick Min DIG Max TIG Min TIG Max...

  • Page 32: Selecting A Location

    4-4. Selecting A Location Falling Unit Can Cause Injury. Use equipment of adequate capacity to lift and support unit. Movement Lifting Eye Lifting Forks Use lifting eye or lifting forks to move unit. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

  • Page 33: Dimensions, Weights And Base Mounting Hole Layout

    4-6. Dimensions, Weights And Base Mounting Hole Layout Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc. A. Welding Power Source Dimensions 24-3/4 in (654 mm) − 34-5/8 in (879 mm) − 350 Amp Models 700 Amp Models 13-3/4 in (349 mm) 22 in (559 mm) 20-1/2 in (521 mm)

  • Page 34: Electrical Service Guide

    4-7. Electrical Service Guide A. Dynasty 350 Models Actual input voltage should not be 10% less than minimum (5% for 380 volt CE models) and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available.
  • Page 35 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 −...
  • Page 36 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 −...
  • Page 37 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 −...

  • Page 38: Connecting Input Power For 350 Models

    4-8. Connecting Input Power For 350 Models A. Connecting Three-Phase Input Power 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. Always connect green or green/ yellow conductor...
  • Page 39 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 in- put power before connecting input conductors from unit. Always connect green or green/ yellow conductor supply grounding terminal first, and never...

  • Page 40: Connecting Input Power For 700 Models

    4-9. Connecting Input Power For 700 Models A. Connecting Three-Phase Input Power Installation must meet all National and Local Codes − have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input con- ductors from unit. Make input power connections to the welding power source first.
  • Page 41 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 in- put power before connecting input conductors from unit. Make input power connections to the welding power source first. Always connect green or green/ yellow conductor...

  • Page 42: Weld Output Terminals And Selecting Cable Sizes

    4-10. Weld Output Terminals And Selecting Cable Sizes* NOTICE − ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual.

  • Page 43: Remote 14 Receptacle Information (Used Without Automation Connection)

    4-11. Remote 14 Receptacle Information (Used Without Automation Connection) Socket* Socket Information Contactor control, 15 volts DC. 15 VOLTS DC 15 VOLTS DC Contact closure to A completes 15 volts DC contactor control circuit, and enables out- C L N put.

  • Page 44: Automation Connection (For 28-Pin Receptacle If Present)

    4-12. Automation Connection (For 28-Pin Receptacle If Present) 12 11 24 23 803 900-A / 218 716-A Pin Information For 28-Pin Receptacle RC28 Start/Stop - Closure to pin 8 starts the weld cycle. Opening closure stops weld cycle. During 2T operation, a momentary closure (greater than 100 ms, but less than 3/4 seconds) starts and stops weld output.

  • Page 45: Remote Memory Select Inputs (For 28-Pin Receptacle If Present)

    4-13. Remote Memory Select Inputs (For 28-Pin Receptacle If Present) 28-Pin Receptacle RC28 Socket Designations 0 = No Connection / 1 = Connected To Ground (Pin 8) Function Memory 1 Memory 2 Memory 3 Memory 4 Memory 5 Memory 6 Memory 7 4-14.

  • Page 46: Typical Automation Application

    4-15. Typical Automation Application Coil resistance plus R To User Equipment should be chosen to limit current to 75 mA User supplied power up to 27 volts DC peak − Typical 28-Pin Output Collector Emitter 4-16. 115 Volts AC Duplex Receptacle, Supplementary Protector CB1, And Power Switch AC Duplex Receptacle Receptacle RC2 supplies 115 V 10...

  • Page 47: Gas Connections

    4-17. Gas Connections Gas Fitting Fittings have 5/8-18 right-hand threads. Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. Regulator/Flowmeter Flow Adjust Typical flow rate is 15 cfh (cubic feet per hour). Connect customer supplied gas hose between regulator/flowmeter and gas fitting on rear of unit.

  • Page 48: Cooler Connections

    4-19. Cooler Connections Cart and cooler are optional equip- ment. AC Duplex Receptacle 115 VAC Cord Provides 115 vac to power cooler. Electrode Weld Output Terminal (−Weld Output Terminal On Maxstar Models) Connect TIG torch to electrode weld output terminal. Gas Out Connection Connect TIG torch gas hose to gas out fitting.

  • Page 49: Dynasty Stick Connections

    4-20. Dynasty Stick Connections Turn off power before making connections. Connections shown are for Dynas- ty models. Work Weld Output Terminal Connect work lead to work weld output terminal. Electrode Weld Output Terminal Connect electrode holder to electrode weld output terminal. Remote 14 Receptacle If desired, connect remote control to Re- mote 14 receptacle (see Section 4-11).

  • Page 50: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls Polarity And AC Waveshape Controls 226 868-B / Ref. 803 901-A Are Available On Dynasty Models Only. Rear Panel Polarity Control (Dynasty Only) 10 AC Waveshape (Dynasty Only) For all front panel switch pad controls: See Section 5-6.

  • Page 51: Encoder Control

    5-2. Encoder Control Encoder Control Use control in conjunction with ap- plicable front panel function switch pad to set values for that function. 5-3. Amperage Control A (Amperage Control) Encoder Control Ammeter See Section 5-15 for Amperage control range. Press Amperage switch pad, and turn Encoder control to set weld amperage, or peak amperage when Pulser function is active (see...

  • Page 52: Voltmeter And Selected Parameter Display

    5-5. Voltmeter And Selected Parameter Display Volt Meter Displays output or open circuit volt- age. Also displays word abbrevia- tions for selected parameters. 5-6. Polarity Control (Dynastyt Models Only) 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.

  • Page 53: Process Control

    5-7. Process Control Process Control Press switch pad until desired pro- cess LED is illuminated: TIG HF Impulse - is a pulsed HF (see Section 5-8) arc starting meth- od that can be used with either AC or DC TIG welding. Make connec- tions according to Section 4-18.

  • Page 54: Output Control

    5-9. Output Control Output Control er functions become active, and must be Mini Logic control See Sections 6-3C, set by the operator. D, E, or F) Press switch pad until desired parameter LED is illuminated. RMT 2T HOLD RMT STD (Remote Standard) Application: Use Remote Trigger Hold Output will energize two seconds after be- Application: Use Remote Trigger (Stan-...

  • Page 55: Pulser Control

    5-10. Pulser Control 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 Press switch pad until desired parameter LED is illumi- nated.

  • Page 56: Sequencer Controls

    5-11. Sequencer Controls 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.

  • Page 57: Gas/Dig Controls (Preflow/Post Flow/Dig/Purge)

    5-12. Gas/DIG Controls (Preflow/Post Flow/DIG/Purge) Gas/DIG Controls Press switch pad until desired function LED is illuminated. Encoder Control (Set Value) Ammeter (Displays Value) See Section 5-15 for all Adjust parameter ranges. Voltmeter Displays word abbreviations of selected parameters. PREFLOW [PRE] - If the TIG HF process is active (see Section 5-7) and Preflow is shown on the control panel, use control to set length of time gas flows before arc ini-...

  • Page 58: Ac Waveshape (Dynasty Models Only)

    5-13. AC Waveshape (Dynasty Models Only) AC Waveshape Control Press switch pad until desired function LED is illuminated. Encoder Control (Set Value) Ammeter (Displays Value) See Section 5-15 for all AC Waveshape param- eter ranges. EN Amperage [EN] - Use with AC TIG only to select electrode negative amperage value.

  • Page 59: Memory (Program Storage Locations 1-9)

    5-14. Memory (Program Storage Locations 1-9) Memory (Program Storage 1-9) Switch Pad Polarity Switch Pad (Dynasty Only) Process Switch Pad To create, change, or recall a welding parameters program, proceed as follows: First, press Memory switch pad until the desired program storage loca- tion (1-9) is displayed.

  • Page 60: Factory Parameter Defaults And Range And Resolution For 350 Models

    5-15. Factory Parameter Defaults And Range And Resolution For 350 Models Parameter Default Range And Resolution MEMORY 1−9 (DYNASTY ONLY) POLARITY AC / DC PROCESS TIG HF Impulse TIG HF Impulse / TIG Lift / Stick OUTPUT RMT STD RMT STD / RMT 2T / ON **RMT 2T RMT 2T can be reconfigured for: 2T / 3T / 4T / Mini Logic / 4T Momentary (see Section 6-3)

  • Page 61: Factory Parameter Defaults And Range And Resolution For 700 Models

    5-16. Factory Parameter Defaults And Range And Resolution For 700 Models Parameter Default Range And Resolution MEMORY 1−9 (DYNASTY ONLY) POLARITY AC / DC PROCESS TIG HF Impulse TIG HF Impulse / TIG Lift / Stick OUTPUT RMT STD RMT STD / RMT 2T / ON **RMT 2T RMT 2T can be reconfigured for: 2T / 3T / 4T / Mini Logic / 4T Momentary / Spot (see Section 6-3)

  • Page 62: Resetting Unit To Factory Default Settings

    5-17. Resetting Unit To Factory Default Settings Process Switch Pad Output Switch Pad Gas/DIG Switch Pad Power Switch To reset the active memory, polarity, and process to original factory set- tings, lockout feature must be off (see Section 6-8). Turn power on and then press and hold the Pro- cess, Output, and Gas/DIG switch pads before the machine name...

  • Page 63: Arc Timer/Counter Display

    5-19. Arc Timer/Counter Display 1234 Hour Rear Panel Output And Amperage Controls Arc Timer Display Arc Counter Power Switch After 5 seconds, the arc count will be dis- The arc time will be displayed for 5 seconds played for the next 5 seconds as To display the arc timer/counter, turn power as [0-9999][Hours] then [0-59][Mins].

  • Page 64: Section 6 − Advanced Functions

    SECTION 6 − ADVANCED FUNCTIONS 6-1. Accessing Advanced Functions • Output Remote Hold And Trigger Func- • Spot Enable (see Section 6-6) − Allows Amperage Switch Pad tions (see Section 6-3) − For reconfigur- you to turn the spot function on and be Gas/Dig ing RMT 2T Hold for 3T, 4T Momentary, available for all programs.

  • Page 65: Programmable Tig Start Parameters

    6-2. Programmable TIG Start Parameters Each memory and polarity selection has their own programmable parameters. Changing Programmable TIG Start Amperage STRT Amperage Switch Pad perage switch pad. Switch pad LED turns Amperage is displayed on the amps meter. on. If necessary, press Amperage switch The TIG start amperage can be adjusted Encoder Control pad to scroll through the programmable...

  • Page 66: Output Control And Trigger Functions

    6-3. Output Control And Trigger Functions A. Remote (Standard) Torch Trigger Operation Current (A) Main Amps Initial Slope Final Slope Initial Amps Final Amps Postflow Preflow 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.
  • Page 67 3T Specific Trigger Method = 3T Current (A) Remote Trigger Operation Preflow Initial Amps /Initial Slope Main Amps Final Slope /Final Amps Postflow * Arc can be extinguished at any time by pressing and releasing both initial and final switches, or by lifting the torch and breaking the arc. 3T (Specific Trigger Operation) Operation: C.
  • Page 68 D. 4T Specific Trigger Method 4T (Specific Trigger Operation) 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.
  • Page 69 F. 4T Momentary Operation 4T Momentary Meter Display Encoder Control To select 4T Momentary, turn Encoder control. 4T Momentary torch trigger operation is as shown. 4T Momentary Main When a remote switch is connected to the welding pow- er source, use the remote switch to control the weld cycle.
  • Page 70 G. On Trigger Operation Voltage (V) 2 Sec Current (A) Stick Touch Stick Lift Stick Electrode Electrode Current (A) Lift Main Amperage *Final Slope Initial Slope Initial Amperage Touch Current *Final Amperage Touch Tungsten Lift Tungsten Lift Tungsten Slightly *Becomes active with Spot Time enabled. OM-216 869 Page 62...

  • Page 71: Ac Waveshape Selection (Dynasty Models Only)

    6-4. AC Waveshape Selection (Dynasty Models Only) Soft = Soft Squarewave = Advanced Squarewave = Sine wave = Triangular wave Memory Switch Pad triangle wave [TRI]. Application: Use advance squarewave when a more focused arc is required for Each memory location can select any of better directional control.

  • Page 72: Independent Amplitude Selection

    6-5. Independent Amplitude Selection Encoder Control Ammeter Parameter Selection To change between same [Same] and independent [INDP] amplitude adjustment, turn encoder control. ENEP Same 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.

  • Page 73: Lockout Functions

    6-8. Lockout Functions A. Accessing Lockout Capability Toggle Lock Select Lockout Level 1, 2, 3, or 4 Toggle Code Select Code Number 1 to 999 See Section 5-1 for explanation of controls referred to in all of thru [999]. IMPORTANT: remember this code number, as you will Section 6-8.
  • Page 74 B. Lockout Levels Levels 1, 2, And 3 Use Encoder Control To Adjust Amperage +/− 10% Of Preset Value. Indicates which functions are available for the corresponding lockout level. Level 4 C L N ited by lock level 1, [LOCK][LEV1] is dis- limits of the machine.

  • Page 75: Setting Unit So Meters Are Blank While Pulse Welding

    6-9. Setting Unit So Meters Are Blank While Pulse Welding METR Encoder Control When the [OFF] meter display feature is The [OFF] meter display feature will not ef- active while pulse welding, [Puls][Weld] is fect the normal amperage display or meter Ammeter Parameters Select Display displayed, and the meter hold feature is hold capabilities when in a non-pulse weld-...

  • Page 76: Section 7 − Maintenance And Troubleshooting

    SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. A. Welding Power Source n = Check Z = Change ~ = Clean Δ = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months ~ Weld Terminals...

  • Page 77: Blowing Out Inside Of Unit

    7-2. Blowing Out Inside of Unit Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. 803 900-B 7-3. Coolant Maintenance And Oiling Motor Disconnect input power be- fore maintaining.

  • Page 78: Troubleshooting

    7-4. Troubleshooting A. Voltmeter/Ammeter And Cooler Help Displays HELP w Help 32 Display w Help 20 Display All directions are in reference to the Indicates a short or open in the thermal front of the unit. All circuitry referred to Indicates that the power supplies for the pri- protection circuitry located on the left side of is located inside the unit.
  • Page 79 B. Troubleshooting Table Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 4-8). inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-8). Check for proper input power connections (see Section 4-8). No weld output;...

  • Page 80: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Dynasty 350 Models OM-216 869 Page 72...
  • Page 81 215 133-D OM-216 869 Page 73...
  • Page 82 Figure 8-2. Circuit Diagram For Maxstar 350 Models OM-216 869 Page 74...
  • Page 83 224 526-E OM-216 869 Page 75...
  • Page 84 Figure 8-3. Circuit Diagram For Dynasty 700 Models (Part 1 of 2) OM-216 869 Page 76...
  • Page 85 213 338-E OM-216 869 Page 77...
  • Page 86 Figure 8-4. Circuit Diagram For Dynasty 700 Models (Part 2 of 2) OM-216 869 Page 78...
  • Page 87 213 338-E OM-216 869 Page 79...
  • Page 88 Figure 8-5. Circuit Diagram For Maxstar 700 Models (Part 1 of 2) OM-216 869 Page 80...
  • Page 89 215 121-E OM-216 869 Page 81...
  • Page 90 Figure 8-6. Circuit Diagram For Maxstar 700 Models (Part 2 of 2) OM-216 869 Page 82...
  • Page 91 215 121-E OM-216 869 Page 83...
  • Page 92 228 525-B Figure 8-7. Circuit Diagram For Cooler OM-216 869 Page 84...

  • Page 93: Section 9 − High Frequency

    SECTION 9 − HIGH FREQUENCY 9-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Work high_freq 12/96 − S-0693 9-2. Incorrect Installation Weld Zone 11, 12 50 ft (15 m) Sources of Direct High-Frequency...

  • Page 94: Correct Installation

    9-3. Correct Installation Weld Zone 50 ft (15 m) 50 ft (15 m) Ground all metal ob- jects and all wiring in welding zone using #12 AWG wire. Ground workpiece if required by codes. Nonmetal Building Metal Building Ref. S-0695 / Ref. S-0695 High-Frequency Source (welding Conduit Joint Bonding and Grounding Metal Building Requirements...

  • Page 95: Machines

    SECTION 10 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2007−05 Whenever possible and practical, use DC weld output instead of AC weld output. 10-1. Selecting Tungsten Electrode ( Wear Clean gloves To Prevent Contamination Of Tungsten ♦...

  • Page 96: Section 11 − Guidelines For Tig Welding (Gtaw)

    SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW) 11-1. Positioning The Torch Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information.

  • Page 97: Torch Movement During Welding

    11-2. Torch Movement During Welding Tungsten Without Filler Rod ° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod ° ° Welding direction Form pool Tilt torch Add filler metal Remove rod Move torch to front of pool.

  • Page 98: Section 12 − Setup Guides For (Gtaw) Tig Welding

    A. AC − GTAW 1/8 in. Aluminum Setup (Dynasty Models Only) This symbol indicates which functions should be active for aluminum welding 226 868-B Some of the controls shown above may not be on your machine (Dynasty 350/700 illustrated). • Turn power on (switch located on rear panel).
  • Page 99 226 868-B This symbol indicates which functions should be active for stainless or mild steel welding. Some of the controls shown above may not be on your machine (Dynasty 350/700 illustrated). • Turn power on (switch located on rear panel) •...

  • Page 100: Section 13 − Setup Guides For (Smaw) Stick Welding

    SECTION 13 − SETUP GUIDES FOR (SMAW) STICK WELDING 13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) Some of the controls shown above may not be on your machine (Dynasty 350/700 illus- trated). 216 869-B Gray on nameplate indicates a Stick function (see Section 5-1 for description of con- trols).

  • Page 101: Section 14 − Stick Welding (Smaw) Guidelines

    SECTION 14 − STICK WELDING (SMAW) GUIDELINES 14-1. Stick Welding Procedure Weld current starts when electrode touches work- piece. Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.

  • Page 102: Electrode And Amperage Selection Chart

    14-2. Electrode and Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 6010 DEEP MIN. PREP, ROUGH 1/16 HIGH SPATTER 6011 DEEP 5/64 6013 EP,EN GENERAL 3/32 SMOOTH, EASY, 6013 7014 EP,EN FAST 5/32 3/16 LOW HYDROGEN, 7018 STRONG 7/32 FLAT SMOOTH, EASY,...

  • Page 103: Positioning Electrode Holder

    14-5. Positioning Electrode Holder ° ° ° ° End View of Work Angle Side View of Electrode Angle GROOVE WELDS ° ° ° ° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 14-6. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding...

  • Page 104: Conditions That Affect Weld Bead Shape

    14-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Correct Angle ° - ° Angle Too Large Angle Too Small Drag ELECTRODE ANGLE Spatter Normal Too Long Too Short ARC LENGTH...

  • Page 105: Butt Joints

    14-10. Butt Joints Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. Single V-Groove Weld Good for materials 3/16 −...

  • Page 106: Weld Test

    14-13. Weld Test Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in (51-76 mm) 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) S-0057-B 14-14. Troubleshooting − Porosity Porosity −...
  • Page 107 14-16. Troubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
  • Page 108 14-19. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 14-20. Troubleshooting − Waviness Of Bead Waviness Of Bead −...
  • Page 109 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-216 869 Page 101...

  • Page 110: Section 15 − Parts List For 350 Models

    SECTION 15 − PARTS LIST FOR 350 MODELS Hardware is common and not available unless listed. Dynasty 350 illustrated 804 757-B Figure 15-1. Main Assembly OM-216 869 Page 102...
  • Page 111 ..Figure 15-7 HEAT SINK, SECONDARY − DYNASTY 350 ......
  • Page 112 ........PLG7 115 094 HOUSING PLUG+SKTS, (SERVICE KIT) (Dynasty 350 Models Only) ...
  • Page 113 Hardware is common and not available unless listed. 804 759-A Figure 15-3. Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity 215 128 Figure 15-3. Panel, Rear w/Components ... . +215 129 PANEL, REAR .
  • Page 114 Hardware is common and not available unless listed. 804 134-A Figure 15-4. Wind Tunnel, Right Hand w/Components Item Dia. Part Mkgs. Description Quantity 231 262 Figure 15-4. Wind Tunnel, Right Hand w/Components ..231 244 INDUCTOR, INPUT .
  • Page 115 Hardware is common and not available unless listed. 804 135-B Figure 15-5. Heat Sink, Primary Assembly Item Dia. Part Mkgs. Description Quantity 219 344 Figure 15-5. Heat Sink, Primary Assembly ... . . 213 346 HEAT SINK, POWER MODULE .
  • Page 116 Hardware is common and not available unless listed. 804 136-B Figure 15-6. Wind Tunnel, Left Hand w/Components Item Dia. Part Mkgs. Description 213 354 Figure 15-6. Wind Tunnel, Left Hand w/Components Quantity ... . . 170 647 BUSHING, SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE .
  • Page 117 Hardware is common and not available unless listed. 804 137-A Figure 15-7. Heat Sink, Secondary − Dynasty 350 Item Dia. Part Mkgs. Description Quantity 219 345 Figure 15-7. Heat Sink, Secondary − Dynasty 350 ..
  • Page 118 Hardware is common and not available unless listed. 804 177-A Figure 15-8. Heat Sink, Secondary − Maxstar 350 Item Dia. Part Mkgs. Description Quantity 221 730 Figure 15-8. Heat Sink, Secondary − Maxstar 350 ... . . 224 470 HEAT SINK, POWER MODULE .
  • Page 119 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-216 869 Page 111...

  • Page 120: Section 16 − Parts List For 700 Models

    SECTION 16 − PARTS LIST FOR 700 MODELS Hardware is common and not available unless listed. 14 15 22 21 Dynasty 700 illustrated 804 133-E Figure 16-1. Main Assembly OM-216 869 Page 112...
  • Page 121 Item Dia. Part Mkgs. Description Quantity Figure 16-1. Main Assembly ... . . 223 785 LABEL, SIDE DYNASTY 700 ......... .
  • Page 122 ... . . 226 868 NAMEPLATE/SWITCH MEMBRANE, DYNASTY 350/700 STH/FF .....
  • Page 123 Item Dia. Part Mkgs. Description Quantity 221 408 Figure 16-2. Panel, Front w/Components ... . . 185 713 INSULATOR, BULKHEAD REAR ........
  • Page 124 Hardware is common and not available unless listed. 804 139-A Figure 16-3. Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity 221 409 Figure 16-3. Panel, Rear w/Components ... . +213 054 PANEL, REAR .
  • Page 125 Hardware is common and not available unless listed. 804 134-A Figure 16-4. Wind Tunnel, Right Hand w/Components Item Dia. Part Mkgs. Description Quantity 213 345 Figure 16-4. Wind Tunnel, Right Hand w/Components ..231 244 INDUCTOR, INPUT .
  • Page 126 Hardware is common and not available unless listed. 804 135-B Figure 16-5. Heat Sink, Primary Assembly Item Dia. Part Mkgs. Description Quantity 219 344 Figure 16-5. Heat Sink, Primary Assembly ... . . 213 346 HEAT SINK, POWER MODULE .
  • Page 127 Hardware is common and not available unless listed. 804 136-B Figure 16-6. Wind Tunnel, Left Hand w/Components Item Dia. Part Mkgs. Description 213 354 Figure 16-6. Wind Tunnel, Left Hand w/Components Quantity ... . . 170 647 BUSHING, SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE .
  • Page 128 Hardware is common and not available unless listed. 804 137-A Figure 16-7. Heat Sink, Secondary − Dynasty 700 Item Dia. Part Mkgs. Description Quantity 219 345 Figure 16-7. Heat Sink, Secondary − Dynasty 700 . . . PC3,PC4 228 503 CIRCUIT CARD ASSY, COMMUTATOR CONTROL .
  • Page 129 Hardware is common and not available unless listed. 804 177-A Figure 16-8. Heat Sink, Secondary − Maxstar 700 Item Dia. Part Mkgs. Description Quantity 221 730 Figure 16-8. Heat Sink, Secondary − Maxstar 700 ... . . 224 470 HEAT SINK, POWER MODULE .

  • Page 130: Section 17 − Parts List For Cooler

    SECTION 17 − PARTS LIST FOR COOLER Hardware is common and not available unless listed. 804 813-B Figure 17-1. Main Assembly OM-216 869 Page 122...
  • Page 131 Item Dia. Part Mkgs. Description Quantity Figure 17-1. Main Assembly ... . . 228 551 Plug, W/Leads Fan ...........

  • Page 132: Section 18 − Parts List For Cart

    SECTION 18 − PARTS LIST FOR CART Hardware is common and not available unless listed. 804 812-A Figure 18-1. Main Assembly Item Dia. Part Mkgs. Description Quantity Figure 18-1 Complete Cart Assembly. 230 157 ....226 927 .
  • Page 133 Effective January 1, 2008 (Equipment with a serial number preface of LJ or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...

  • Page 134: Options And Accessories

    Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © PRINTED IN USA 2008 Miller Electric Mfg. Co. 2008−01...

This manual is also suitable for:

Dynasty 700Maxstar 350Maxstar 700

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