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

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www.MillerWelds.com
Dynasty 350, 700
Maxstar 350, 700
Including Optional Cart And Cooler
CE And Non-CE Models
OM-216 869V
2010−11
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
208/575 Volt Models W/Auto-Linet
380/575 Volt Three-Phase
W/Auto-Linet (CE)
Arc Welding Power Source
R
R
File: TIG (GTAW)

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  • Page 1 Stick (SMAW) Welding Description 208/575 Volt Models W/Auto-Linet 380/575 Volt Three-Phase W/Auto-Linet (CE) Arc Welding Power Source Dynasty 350, 700 Maxstar 350, 700 Including Optional Cart And Cooler CE And Non-CE Models 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

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS 5-7. Process Control .................

  • Page 5: Declaration Of Conformity

    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).

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 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 8 D Keep your head out of the fumes. Do not breathe the fumes. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. 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 10: 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 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 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 12 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, elle peut exploser.

  • Page 14: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité...

  • Page 15: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 16 OM-216 869 Page 10...

  • Page 17: 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 18 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 19: Weee Label (For Products Sold Within The Eu)

    100 h. std. 043 810 (HF) 043 809 (AL) S-178 910 Warning! Watch Out! There are overheating and damage. Gas Tungsten Arc Welding possible hazards as shown by the applications. Use Aluminum Protecting Read Owner’s Manual. symbols. Coolant No. 043 809 where coolant Check and clean filter every 100 contacts aluminum parts or for Gas Disconnect input plug or power before...

  • Page 20: Symbols And Definitions

    3-3. 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 21: Section 4 − Installation

    Use mechanized welding operations when welding with AC or pulsed DC processes and power source settings are above 350 A. 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−...

  • Page 22: 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. 4-3. Specifications A. Dynasty 350 Models Rated Peak Amper- Open-...
  • Page 23 B. Maxstar 350 Models Rated Peak Amper- Open- Amperes Input at Rated Load Output 50/60 Hz Striking Circuit Rated Welding Voltage Rating 208 V 230 V 380 V 400 V 460 V 575 V Range Voltage Input (Up) Power Output DC (Uo) 250 A @ 30 Volts, 100% Duty...
  • Page 24 D. Maxstar 700 Models Rated Peak Amper- Open- Amperes Input at Rated Load Output 50/60 Hz Striking Circuit Voltage Rating Rated Welding 208 V 230 V 380 V 400 V 460 V 575 V Range Voltage Input (Up) Power Output DC (Uo) 500 A @ 40 Volts, 100% Duty...

  • Page 25: Duty Cycle And Overheating

    4-4. 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 26 Notes OM-216 869 Page 20...

  • Page 27: Volt-Ampere Curves

    4-5. 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 28 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 29: Selecting A Location

    4-6. 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 30: Dimensions, Weights And Base Mounting Hole Layout

    4-8. 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.

  • Page 31: Electrical Service Guide

    4-9. 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 32 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 33 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 34 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 35: Connecting Input Power For 350 Models

    4-10. 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 36 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 37: Connecting Input Power For 700 Models

    4-11. Connecting Input Power For 700 Models A. Connecting Three-Phase Input Power For Maxstar 700 Models 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.
  • Page 38 B. Connecting Three-Phase Input Power For Dynasty 700 Models 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 39 C. 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 40: Weld Output Terminals And Selecting Cable Sizes

    ****For distances longer than 100 ft (30 m) and up to 200 ft (60 m), use direct current (DC) output only. For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

  • Page 41: Remote 14 Receptacle Information (Used Without Automation Connection)

    4-13. Remote 14 Receptacle Information (Used Without Automation Connection) Socket* Socket Information Contactor control, 15 volts DC. 15 VOLTS DC Contact closure to A completes 15 volts DC contactor control circuit, and enables out- C L N put. +10 volts DC. REMOTE Remote control circuit common.

  • Page 42: Automation Connection (For 28-Pin Receptacle If Present)

    4-14. 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 43: Remote Memory Select Inputs (For 28-Pin Receptacle If Present)

    4-15. 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 4-16.

  • Page 44: Typical Automation Application

    4-17. 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 4-18. 115 Volts AC Duplex Receptacle, Supplementary Protector CB1, And Power Switch AC Duplex Receptacle Receptacle RC2 supplies 115 V 10...

  • Page 45: Gas Connections

    4-19. 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 46: Cooler Connections

    4-21. 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 47: Dynasty Stick Connections

    4-22. 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 4-13).

  • Page 48: 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 49: 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 50: 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 51: 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 4-20.

  • Page 52: Output Control

    5-9. Output Control Output Control NOTE: If an On/Off type trigger is used, it Mini Logic control See Sections 6-3C, must be a maintained switch. All Sequenc- D, E, or F) Press switch pad until desired parameter er functions become active, and must be LED is illuminated.

  • Page 53: 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 54: 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 55: 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 56: 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 57: 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 58: 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 59: Factory Parameter Defaults And Range And Resolution For 700 Models

    Factory Parameter Defaults And Range And Resolution For 350 Models (Continued) *TIG Start parameters for each program (1-9) *Tungsten .094 GEN, .020, .040, .062, .094, .125, .156, .187 ***Polarity (DYNASTY ONLY) EP / EN ***Amperage 60 A 1 − 200 Amps ***Time 1 ms 1 −...
  • Page 60 Factory Parameter Defaults And Range And Resolution For 700 Models (Continued) ADJUST PREFLOW 0.2 T 0.0 − 25.0 Seconds POST FLOW Auto Auto 1 − 50.0 Seconds @ 1 Second Resolution 0 − 100 Percent (DYNASTY ONLY) AC WAVESHAPE *Waveform Soft Square Soft Square, Advanced Square, Sine, Triangle EN Amps...

  • Page 61: 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 6-9). Turn power on and then press and hold the Pro- cess, Output, and Gas/DIG switch pads before the machine name...

  • Page 62: 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 63: Section 6 − Advanced Functions

    SECTION 6 − ADVANCED FUNCTIONS 6-1. Accessing Advanced Functions Amperage Switch Pad or Mini Logic  Stick Stuck Check Selection (See Sec- tion 6-8) − With Stick Stuck Check on and Gas/Dig  AC Waveshape Selection with Dynasty the welding electrode (rod) stuck, output Encoder Control models only (see Section 6-4) −...

  • Page 64: Programmable Tig Start Parameters

    6-2. Programmable TIG Start Parameters Each memory and polarity selection has their own programmable parameters. Tungsten Selection TUNG .094 Current (A) Preset Amperage Minimum Start Time Start Slope Time Amperage Switch Pad (1/16 in.), .094 (3/32 in.), or .125 (1/8 in.), um.
  • Page 65 Selecting GEN Encoder Control Amps Meter Amperage Switch Pad If [GEn] is selected and displayed on the amps meter, the TIG starting parameters for a .094 tungsten are TUNG GEN the default, and for AC polarity they are: Start Polarity = EP, Start Am- perage = 120 A, Start Time = 20 ms, Start Slope Time = 10 ms, Preset Minimum Amps = 5 A.
  • Page 66 Changing Programmable TIG Start Polarity (Dynasty Models Only) Current (A) Start Polarity Amperage Switch Pad To adjust TIG Start Polarity proceed as fol- [SEL] [EP] is displayed on meters, and can lows: be adjusted (see Section 5-15) by turning the Encoder control. Encoder Control Press Amperage switch pad.
  • Page 67 E. Changing Programmable Start Time TIME Current (A) Start Time Amperage Switch Pad ceed as follows: and can be adjusted by turning the Encoder control (see Section 5-15). Encoder Control Press Amperage switch pad, and meter S Amps Meter LED turns on. The current Start Time is dis- To change Start Slope Time, proceed to To adjust Programmable Start Time pro- played in milliseconds on the amps meter,...
  • Page 68 Changing Preset Amperage Minimum PMIN Current (A) Preset Amperage Minimum Amperage Switch Pad Press Amperage switch pad. Switch pad and DC. LED turns on, and meter A LED turns on. Encoder Control The Preset Minimum Amperage is dis- Whatever amperage is selected as the played on the amps meter, and can be ad- Amps Meter preset amperage minimum, is the min-...

  • Page 69: 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 70 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 71 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 72 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 73 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 67...

  • Page 74: 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 75: 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 76: Stick Stuck Check Selection

    6-8. Stick Stuck Check Selection STUC Encoder Control Application: For most Stick applications, when this function is desired. use Stick Stuck Check off. With Stick Ammeter Parameters Select Display Stuck Check on and the welding electrode Turn Encoder to change between Stick Some applications may require Stick (rod) stuck, output is turned off in an at- Stuck Check [ON and [OFF] meter display.

  • Page 77: Lockout Functions

    6-9. 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 6-9.
  • Page 78 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 When parameter change or selection is lim- 10% of preset amperage value, up to the Before activating lockout levels, be ited by lock level 1, [LOCK][LEV1] is dis-...

  • Page 79: Pulse Welding Display Options

    6-10. Pulse Welding Display Options METR Encoder Control voltage and amperage. While pulse weld- [AVG] ing in AC TIG, meter display may not be Ammeter Parameters Select Display Amperage preset displays average am- stable, and are for reference only. Turn Encoder to change between [V/A], perage for DC TIG pulser, and peak am- [OFF] [OFF], and [AVG] pulse welding display...

  • Page 80: 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 = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months ~ Weld Terminals...

  • Page 81: 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 Disconnect input power be- fore maintaining. Coolant Filter Unscrew housing to clean filter.

  • Page 82: 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 83 B. Troubleshooting Table Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 4-10). inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-10). Check for proper input power connections (see Section 4-10). No weld output;...

  • Page 84: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Dynasty 350 Models OM-216 869 Page 78...
  • Page 85 243 217-C OM-216 869 Page 79...
  • Page 86 Figure 8-2. Circuit Diagram For Maxstar 350 Models OM-216 869 Page 80...
  • Page 87 243 215-C OM-216 869 Page 81...
  • Page 88 Figure 8-3. Circuit Diagram For Dynasty 700 Models (Part 1 of 2) OM-216 869 Page 82...
  • Page 89 243 218-C OM-216 869 Page 83...
  • Page 90 Figure 8-4. Circuit Diagram For Dynasty 700 Models (Part 2 of 2) OM-216 869 Page 84...
  • Page 91 243 218-C OM-216 869 Page 85...
  • Page 92 Figure 8-5. Circuit Diagram For Maxstar 700 Models (Part 1 of 2) OM-216 869 Page 86...
  • Page 93 243 216-C OM-216 869 Page 87...
  • Page 94 Figure 8-6. Circuit Diagram For Maxstar 700 Models (Part 2 of 2) OM-216 869 Page 88...
  • Page 95 243 216-C OM-216 869 Page 89...
  • Page 96 228 525-B Figure 8-7. Circuit Diagram For Cooler OM-216 869 Page 90...

  • Page 97: 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 5/10 − S-0693 9-2. Installation Showing Possible Sources Of HF Interference Weld Zone 11, 12 50 ft...

  • Page 98: Recommended Installation To Reduce Hf Interference

    9-3. Recommended Installation To Reduce HF Interference 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 Nonmetal codes. Building Best Practices Followed Metal Building Ref.

  • Page 99: Section 10 − 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 100 226 868-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 101: Section 11 − Selecting And Preparing A Tungsten For Dc Or Ac Welding With Inverter Machines

    SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2010-04 Whenever possible and practical, use DC weld output instead of AC weld output. 11-1. Selecting Tungsten Electrode ( Wear Clean gloves To Prevent Contamination Of Tungsten ...

  • Page 102: Section 12 − Guidelines For Tig Welding (Gtaw)

    SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW) 12-1. 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 103: Torch Movement During Welding

    12-2. 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 104: 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 105: 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. Equipment Needed: Tools Needed: 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 106: Electrode And Amperage Selection Chart

    14-2. Electrode and Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG 3/32 FLAT SMOOTH, EASY, 7024 EP,EN HORIZ...

  • Page 107: Positioning Electrode Holder

    14-4. Positioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle     Groove Welds     Fillet Welds S-0060 14-5. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S-0053-A...

  • Page 108: Conditions That Affect Weld Bead Shape

    14-7. Conditions That Affect Weld Bead Shape Weld bead shape is affected electrode angle, length, travel speed, and thickness of base metal. Correct Angle  - Angle Too Large  Angle Too Small Electrode Angle Drag Spatter Arc Length Normal Too Long Too Short Travel Speed...

  • Page 109: Lap Joint

    14-9. Groove (Butt) Joints Tack Welds Prevent edges of joint from draw- ing together ahead of electrode by tack welding the materials in posi- tion before 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 110: Weld Test

    14-12. 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 14-13. Troubleshooting Porosity −...
  • Page 111 Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle.

  • Page 112: Section 15 − Parts List For 350 Models

    SECTION 15 − PARTS LIST FOR 350 MODELS Hardware is common and not available unless listed. Maxstar Qty 2 Dynasty Qty 1 Dynasty Only Dynasty 350 illustrated 805 471-B Figure 15-1. Main Assembly OM-216 869 Page 106...
  • Page 113 ..Figure 15-7 HEAT SINK, SECONDARY − DYNASTY 350 ......
  • Page 114 ..233 115 PLATE, INDICATOR FRONT − DYNASTY 350 ......
  • Page 115 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 116 Hardware is common and not available unless listed. 804 134-B 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 117 Hardware is common and not available unless listed. 804 135-C 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 118 Hardware is common and not available unless listed. 804 136-C 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 119 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 120 Hardware is common and not available unless listed. 804 177-B 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 121 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-216 869 Page 115...

  • Page 122: Section 16 − Parts List For 700 Models

    SECTION 16 − PARTS LIST FOR 700 MODELS Hardware is common and not available unless listed. 13Dynasty Maxstar 24 Dynasty Only Maxstar Only Dynasty 700 illustrated 805 472-B Figure 16-1. Main Assembly OM-216 869 Page 116...
  • Page 123 Item Dia. Part Mkgs. Description Quantity Figure 16-1. Main Assembly ... . . 223 785 LABEL, SIDE DYNASTY 700 ......... .
  • Page 124 Item Dia. Part Mkgs. Description Quantity Figure 16-1. Main Assembly (continued) . . . F8, F9 237 542 CORE, TOROIDAL .540 ID X .875 OD X .500 THK (MAXSTAR 700 ONLY) (CE) ... . . 235496 CABLE TIE, 0.06−2.000 BUNDLE DIA TREE STYLE PUSH MOUNT .
  • Page 125 ... . . 226 868 NAMEPLATE/SWITCH MEMBRANE, DYNASTY 350/700 STH/FF .....
  • Page 126 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 127 Hardware is common and not available unless listed. 804 134-B 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 128 Hardware is common and not available unless listed. 804 135-C 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 129 Hardware is common and not available unless listed. 804 136-C 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 130 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 233 157 CIRCUIT CARD ASSY, COMMUTATOR CONTROL .
  • Page 131 Hardware is common and not available unless listed. 804 177-B 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 132: 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 126...
  • Page 133 Item Dia. Part Mkgs. Description Quantity Figure 17-1. Main Assembly ... . . 228 551 Plug, W/Leads Fan ...........

  • Page 134: 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 135 Effective January 1, 2010 (Equipment with a serial number preface of MA 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 90 Days —...

  • Page 136: 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.  ORIGINAL INSTRUCTIONS − PRINTED IN USA 2010 Miller Electric Mfg. Co. 2010−01...

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