Miller Dynasty 400 Owner's Manual
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Miller Dynasty 400 Owner's Manual

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www.MillerWelds.com
Dynasty 400
Maxstar 400
CE And Non-CE Models
OM-275857A
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)
2017−01-18

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Summary of Contents for Miller Dynasty 400

  • Page 1 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 Dynasty 400 Maxstar 400 CE And Non-CE Models For product information, File: TIG (GTAW) Owner’s Manual translations, and more, visit...

  • Page 2: 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 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS 7-2. AC Independent ..............7-3.
  • Page 5 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number DYNASTY 350 (AUTO-LINE 380-575)CE 907204021 DYNASTY 400 (AUTO-LINE 380-575) CE 907717002 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822-1:2016, IEC 62822-2:2016...
  • Page 6 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number MAXSTAR 350 (AUTO-LINE 380-575) CE 907334021 MAXSTAR 400 (AUTO-LINE 380-575)CE 907716002 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822-1:2016, IEC 62822-2:2016 Intended use for occupational use for use by laymen...

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 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 Indicates special instructions.
  • Page 8 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • 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 Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 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.
  • Page 12 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

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

    D Tenir les bouteilles éloignées des circuits de soudage ou autres LE BRUIT peut endommager l’ouïe. circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. Le bruit des processus et des équipements peut affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec D Porter des protections approuvées pour les une bouteille.

  • Page 14: Proposition Californienne 65 Avertissements

    RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de FRÉQUENCE (H.F.) risque provoquer des interférences. provoquer des interférences. D L’énergie électromagnétique risque D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et l’équipement commandé...

  • Page 15: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves.
  • Page 16 A complete Parts List is available at www.MillerWelds.com Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information. Safe37 2012−05 Environmental Protection Use Period (China) Safe123 2016−06...

  • Page 17: Miscellaneous Symbols And Definitions

    A complete Parts List is available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Impulse Starting Amperage Gas Output (GTAW) Rated Welding Output Final Slope Current Gas Tungsten Arc Duty Cycle Final Amperage Welding (GTAW) Shielded Metal Pulse Percent...

  • Page 18: Section 4 − Specifications

    This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C). A. Dynasty 400 Models Do not use information in unit specifications table to determine electrical service requirements. See Section 5-14 A for information on connecting input power.

  • Page 19: Dimensions, Weights And Base Mounting Hole Layout

    A complete Parts List is available at www.MillerWelds.com B. Maxstar 400 Models Do not use information in unit specifications table to determine electrical service requirements. See Section 5-14B for information on connecting input power. Welding Amperage Max Open Circuit Low Open-Circuit Rated Peak Striking IP Rating Range...

  • Page 20: Environmental Specifications

    A complete Parts List is available at www.MillerWelds.com B. Welding Power Source With Cart And Cooler Dimensions 43.125 in. (1095 mm) 23.125 in. (587 mm) 43.75 in. (1111 mm) Weight 250.5 lb (113.6 Kg) 804 642-C 4-4. Environmental Specifications A. IP Rating (All Models) IP Rating IP23 This equipment is designed for outdoor use.

  • Page 21: Static Characteristics

    A complete Parts List is available at www.MillerWelds.com D. China EEP Hazardous Substance Information   ‡ China EEP Hazardous Substance Information Ö Hazardous Substance Component Name × (if applicable) PBDE Ö Brass and Copper Parts Coupling Devices Switching Devices Ö...

  • Page 22: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Selecting A Location Movement Do not move or operate unit where it could tip. Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 23: 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 24: Remote 14 Receptacle Information

    Hot Wire, and Hot Start Adjust expansions. 5-5. Simple Automation Application (14-Pin Interface) This application requires the pur- chase of the automation expansion module, Miller Part No. 301151. Coil resistance plus To User Equipment should be chosen to limit current to 75 mA...

  • Page 25: Automation Connection (For 28-Pin Receptacle If Present)

    A complete Parts List is available at www.MillerWelds.com 5-6. Automation Connection (For 28-Pin Receptacle If Present) A. Basic Automation Mode Use this mode when only the basic functions of the automation board are required. These functions include Start/Stop, Valid Arc Indication, Gas Con- trol, High Frequency Arc Start Disable, and Remote Memory Select.
  • Page 26 A complete Parts List is available at www.MillerWelds.com Continued from previous page Section A. 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) Input High Frequency Arc Start Disable = Disables the arc starter from being activated when connected to pin 8.
  • Page 27 A complete Parts List is available at www.MillerWelds.com Continued from previous page Section B. Output Arc Length Control Lockout Reference = Paired with Pin 13. Connect to user’s external voltage supply common (See Section 5-5 for typical application). Input Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 16. (See Sections 5-7 and 6-6.) Input Memory Select = Used to select between memory numbers.

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

    A complete Parts List is available at www.MillerWelds.com Continued from previous page Section C. Output Control Reference for pins 5 and 6. Output Welders Chassis = Earth ground. Connected only if common potentials are needed between user equipment and the welder.

  • Page 29: 115 Volts Ac Cooler Receptacle, Supplementary Protector Cb1, And Power Switch

    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. Supplementary Protector CB1 CB1 protects cooler receptacle from overload. If circuit breaker opens, the receptacle does not work.

  • Page 30: Tig Hf Impulse/ Lift-Arc Connections

    A complete Parts List is available at www.MillerWelds.com 5-10. TIG HF Impulse/ Lift-Arc Connections Turn off power before making connections. Electrode Weld Output Terminal Connect TIG torch to electrode weld output terminal. Gas Out Connection Connect torch gas hose to gas out fitting.

  • Page 31: Cooler Connections

    Cart and cooler are optional equip- ment. AC Cooler Receptacle RC2 RC2 is a designated use re- ceptacle intended only for sup- plying AC power to a Miller-ap- proved cooler. 115 VAC Cord Provides 115 vac to power cooler. Electrode Weld Output Terminal (−Weld Output...

  • Page 32: Dynasty Stick Connections

    A complete Parts List is available at www.MillerWelds.com 5-12. Dynasty Stick Connections Turn off power before making connections. Connections shown are for Dynasty models. Work Weld Output Terminal Connect work lead to work weld output terminal. Electrode Weld Output Terminal Connect electrode holder to electrode weld output terminal.

  • Page 33: Electrical Service Guide

    Elec Serv 2017−01 5-14. Electrical Service Guide A. Dynasty 400 Models Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
  • Page 34 A complete Parts List is available at www.MillerWelds.com B. Maxstar 400 Models Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These 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.

  • Page 35: Connecting Input Power For 400 Models

    A complete Parts List is available at www.MillerWelds.com 5-15. Connecting Input Power For 400 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.
  • Page 36 A complete Parts List is available at www.MillerWelds.com B. Connecting Single-Phase Input Power Installation must meet all National and Local Codes − have only 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.
  • Page 37 A complete Parts List is available at www.MillerWelds.com Notes OM-275857 Page 31...

  • Page 38: Section 6 − Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATION 6-1. Software Updates A. Reasons For Downloads Of Software Updates • To get the latest feature and software improvements with future software updates. • For all circuit board replacements, a software update is required to ensure proper unit operation. •...

  • Page 39: Controls

    A complete Parts List is available at www.MillerWelds.com 6-2. Controls Polarity and AC Waveshape controls are available on Dynasty Models only. Rear Panel 273670-A / Ref. 803 901-A Ammeter And Parameter Display Pulser Controls For all front panel switch pad controls: Sequencer Controls press switch pad to turn on light and en- Shows actual amperage while welding and...

  • Page 40: Accessing Control Panel Menu

    A complete Parts List is available at www.MillerWelds.com 6-3. Accessing Control Panel Menu Amperage Button Parameter Display Setting Display Encoder Control Rotate Encoder to adjust paramet- er setting. Amperage Control Controls the welding amperage output. Limits the maximum output of a remote amperage device. 273 670-A Polarity Selection (Dynasty Only) Select output type AC or DC.
  • Page 41 A complete Parts List is available at www.MillerWelds.com *PRO−SET provides PROfessionally developed SETtings for the weld process. PRO−SET flashes one time and reveals the professional setting for the parameter. Pulse Control Pulsing is available in the TIG process. Controls can be ad- justed while welding.

  • Page 42: Lift-Arc And Hf Tig Start Procedures

    A complete Parts List is available at www.MillerWelds.com 6-4. Lift-Arc And HF TIG Start Procedures Lift-Arc Start When Lift-Arct button light is On, start arc as follows: TIG Electrode 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.

  • Page 43: Pulser Control

    A complete Parts List is available at www.MillerWelds.com 6-5. Pulser Control Percent (%) Peak Time Pulsed Output Waveforms Control Setting Peak 50%/Background 50% Peak Amp Balanced 50% Bkg Amp More Time At Peak Amperage More Time At Background Amperage Pulser Control enced welder may have the PPS setting your puddle is on the background side of the much higher, depending on their personal...

  • Page 44: Memory (Program Storage Locations 1-9)

    A complete Parts List is available at www.MillerWelds.com 6-6. 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 45: Section 7 − User Functions

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − USER FUNCTIONS 7-1. Accessing User Setup Menu Amperage Button Gas/Dig Button Parameter Display Setting Display Encoder Control To access the User Functions, press and hold the Amperage (A) and the Gas/DIG controls until [USER] [MENU] is displayed.

  • Page 46: Ac Independent

    A complete Parts List is available at www.MillerWelds.com 7-2. AC Independent AC Independent Expansion is available on DX models with SD expansion card and on CE models with feature enable through the user menu (see Section 7-1). A. AC Independent Amperage AC Waveshape Control Press switch pad until desired function is selected.

  • Page 47: General (Gen) Tungsten To Change Programmable Tig Starting Parameters

    A complete Parts List is available at www.MillerWelds.com 7-3. General (GEN) Tungsten To Change Programmable TIG Starting Parameters Encoder Control Parameter Display Amperage Button Once inside the machine set up menu, tungsten parameter values can be manually changed by press- ing the Amperage switch pad to step through each adjustable para- meter.

  • Page 48: Programmable Tig Start Parameters For Models With 28-Pin Advanced Automation Capabilities

    A complete Parts List is available at www.MillerWelds.com 7-4. Programmable TIG Start Parameters For Models With 28-Pin Advanced Automation Capabilities A. OFF/ON (Start Amperage And Time) For Models W/28-Pin Advanced Automation Capabilities Current (A) STAT OFF Start Time Off is the default setting. Use Encoder con- The AC and DC parameters are selected Preset Advanced Automation TIG Start trol to select On.
  • Page 49 A complete Parts List is available at www.MillerWelds.com C. Changing Programmable Start Time For Models With Advanced Automation Capabilities Current (A) TIME Start Time Amperage Button To adjust Programmable Start Time pro- Start Time is displayed in milliseconds on ceed as follows: the amps meter, and can be adjusted by ro- Encoder Control tating the Encoder control.

  • Page 50: Output Control And Trigger Functions

    A complete Parts List is available at www.MillerWelds.com 7-5. Output Control And Trigger Functions A. Remote (Standard), 2T, And 4TE Torch Trigger Operation Current (A) Main Amps Initial Slope Final Slope Initial Amps Final Amps Postflow Preflow Time Standard P & H Foot Or Finger Maintained Switch Remote Control...
  • Page 51 A complete Parts List is available at www.MillerWelds.com 3T Specific Trigger Method 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 Application...
  • Page 52 A complete Parts List is available at www.MillerWelds.com C. 4T, 4Tm, And 4TL Specific Trigger Method 4T And 4Tm Application: Use 4T or 4Tm (modified) trigger method when the functions of a re- mote current control are desired, but only a remote on/off control is available.
  • Page 53 A complete Parts List is available at www.MillerWelds.com D. 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...

  • Page 54: Section 8 − Advanced Functions

    A complete Parts List is available at www.MillerWelds.com SECTION 8 − ADVANCED FUNCTIONS 8-1. Accessing Tech Menu For Dynasty/Maxstar Models Amperage Button Gas/Dig Button Press and hold Amperage and Gas/Dig buttons for approximately two seconds to scroll past User Menu to Tech Menu. Use Gas/Dig button to cycle through parameters that can be set.
  • Page 55 A complete Parts List is available at www.MillerWelds.com [ARC] [T/CY] Arc Timer: Monitors hours, minutes, and cycles of valid arc on. To view these different elements, rotate Encoder. To reset, rotate encoder until [RESET] [YES] is displayed. Press Menu button to display [RESET] [Done]. Displays turn to [000] [000]. [ERR] [LOG] Error Log: Use to view last eight logged error events.

  • Page 56: Sequencer And Weld Timer For Dx Model

    A complete Parts List is available at www.MillerWelds.com 8-2. Sequencer And Weld Timer For DX Model Sequencer Control With Weld Timers ON INTL This function is available while using the TIG process, but is disabled if a remote foot or fin- gertip control is connected while in the RMT STD mode.

  • Page 57: Lockout Functions

    A complete Parts List is available at www.MillerWelds.com 8-3. Lockout Functions See Section 8-1 for information on how to access Lockout Functions. There are four (1−4) different lockout levels. Each successive level allows the operator more flexibility. Before activating lockout levels, be sure that all procedures and para- meters are established.

  • Page 58: Section 9 − Maintenance And Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 9 − MAINTENANCE AND TROUBLESHOOTING 9-1. Routine Maintenance Disconnect power before maintaining. Δ = Repair n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent Every Months ~ Weld Terminals...

  • Page 59: Voltmeter/Ammeter Display Messages

    A complete Parts List is available at www.MillerWelds.com 9-3. Voltmeter/Ammeter Display Messages Release Trigger Latching Errors: RELE CHEK INPT WELD CABL TRIG Latching Errors: O.M. Un Short Output HORT UN S Not Valid OUTP VALD Over Temperature Error Lock Level OVER TEMP LOCK...

  • Page 60: Troubleshooting Table

    A complete Parts List is available at www.MillerWelds.com 9-4. Troubleshooting Table Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 5-15). inoperative. 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).

  • Page 61: Section 10 − Electrical Diagram

    SECTION 10 − ELECTRICAL DIAGRAM 275852-A Figure 10-1. Dynasty 400 Circuit Diagram OM-275857 Page 55...
  • Page 62 275851-A Figure 10-2. Maxstar 400 Circuit Diagram OM-275857 Page 56...

  • Page 63: Section 11 − High Frequency

    SECTION 11 − HIGH FREQUENCY 11-1. 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 11-2. Installation Showing Possible Sources Of HF Interference Weld Zone 11, 12 50 ft...

  • Page 64: Recommended Installation To Reduce Hf Interference

    11-3. 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 65: Section 12 − Selecting And Preparing A Tungsten For Dc Or Ac Welding With Inverter Machines

    SECTION 12 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2016-10 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.
  • Page 66 Notes...
  • Page 67 Effective January 1, 2017 (Equipment with a serial number preface of MH or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 68 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 2017 Miller Electric Mfg. Co. 2017−01...

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