Miller Dynasty 200 DX Owner's Manual
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Miller Dynasty 200 DX Owner's Manual

Including optional cart and cooler
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Dynasty 200 DX
(Including Optional Cart And Cooler)
CE Models
OM-245 730C
2010−04
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
115/230/400/460 Volt Models W/AutolineR
Arc Welding Power Source
R

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  • Page 1 OM-245 730C 2010−04 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description 115/230/400/460 Volt Models W/AutolineR Arc Welding Power Source Dynasty 200 DX (Including Optional Cart And Cooler) CE Models 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 5-15. Factory Parameter Defaults And Range And Resolution ........5-16.
  • Page 5 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 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 oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • 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-245 730 Page 10...

  • Page 17: Section 3 − Definitions (Ce Models)

    SECTION 3 − DEFINITIONS (CE Models) 3-1. Warning Label Definitions Warning! Watch Out! There are possible 2.2 Use forced ventilation or local exhaust welding helmet with correct shade of hazards as shown by the symbols. to remove the fumes. filter. Wear complete body protection. 2.3 Use ventilating fan to remove fumes.

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

    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: Symbols And Definitions

    3-3. Symbols And Definitions Gas Tungsten Arc Shielded Metal Arc Amperes Panel−Local Welding (GTAW) Welding (SMAW) 3 Phase Static Frequency Volts Voltage Input Converter-Transformer-Rectifier Lift-Arc Start Voltage Output Circuit Breaker Remote (GTAW) Protective Earth Postflow Timer Preflow Timer Seconds (Ground) Positive Negative Alternating...

  • Page 20: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Important Information Regarding CE Products (Sold Within The EU) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 21: Specifications

    4-3. Specifications Amperes Input At Rated Output, Welding Max. Rated Peak 50/60Hz Input Power Rated Output Amperage Open-Circuit Striking Range ** Voltage (Uo) Voltage (Up) 130 A @ 25.2 ∇ Three-Phase VDC, 12.3 1 − 200 15 KV*** -− 60% Duty 0.16* 0.24* 0.25*...

  • Page 22: Dc Volt-Ampere Curves

    4-4. DC Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amper- age output capabilities of welding 115VAC Input; DC Output power source. Curves of other set- tings fall between curves shown. Stick Max. TIG Max. Stick/TIG Min. DIG Max. Amperes 230VAC Single Phase Input;...

  • Page 23: Ac Volt-Ampere Curves

    4-5. AC Volt-Ampere Curves Volt-ampere curves show minimum 115VAC Input; AC Output and maximum voltage and amper- age output capabilities of welding power source. Curves of other set- tings fall between curves shown. Stick Max. TIG Max. Stick/TIG Min. Amperes 230VAC Single Phase Input;...

  • Page 24: Duty Cycle And Overheating

    4-6. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, output stops, a Help message is displayed (see Section 7-3), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.

  • Page 25: Selecting A Location

    4-7. Selecting A Location Line Disconnect Device Locate unit near correct input power supply. Dimensions And Weight Special installation may be required where gasoline or 48.5 lb (22.0 kg) volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 26: Weld Output Terminals And Selecting Cable Sizes

    4-8. Weld Output Terminals And Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 27: Remote 14 Receptacle Information

    4-9. Remote 14 Receptacle Information Socket* Socket Information Contactor control +15 volts DC. 15 VOLTS DC C L N OUTPUT Contact closure to A completes 15 volts DC CONTACTOR contactor control circuit and enables output. Output to remote control; +10 volts DC output to remote control.

  • Page 28: Tig Hf Impulse/ Lift-Arct Connections

    4-11. TIG HF Impulse/ Lift-Arct Connections Turn off power before mak- ing connections. Electrode Weld Output Terminal Connect TIG torch to weld output terminal labeled Electrode. Gas Out Connection Connect torch gas hose to gas out fitting. Work Weld Output Terminal Connect work lead to weld output terminal labeled Work.

  • Page 29: Tigrunner Connections

    4-13. TIGRunner Connections Cart and cooler are optional equip- ment. Gas Cylinder Chains Secure gas cylinder to cart with chains. Connect gas hose to welding power source (see Section 4-10). Connect work lead and torch to welding power source (see Section 4-11).

  • Page 30: Electrical Service Guide

    4-14. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. Actual input voltage should not fall below 103 volts AC or rise above 506 volts AC.

  • Page 31: Connecting Three-Phase Input Power

    4-15. 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 supply = GND/PE Earth Ground...

  • Page 32: Connecting Single-Phase Input Power

    4-16. 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. =GND/PE Earth Ground Always connect green or green/ yellow conductor supply...

  • Page 33: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls 207 694-A / 802 452 Polarity Control Sequencer Controls (DX, LX For all front panel switch pad controls: And All CE Models) press switch pad to turn on light and en- See Section 5-6. able function.

  • Page 34: 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.

  • Page 35: Voltmeter

    5-5. Voltmeter Volt Meter Displays output or open circuit volt- age. If output is off, the voltmeter will display a series of three dashes (-−−). Open circuit voltage is dis- played if power is on and output is available. 5-6. Polarity Control Polarity Control Press switch pad until desired LED is illuminated.

  • Page 36: Lift-Arc And Hf Tig Start Procedures

    5-7. 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 37: Process Control

    5-8. Process Control Process Control Press switch pad until desired pro- cess LED is illuminated: TIG HF Impulse - When selected, a pulsed HF (non-contact) (see Section 5-7) arc starting method is activated. This method can be used with either AC or DC TIG welding. Make connections according to Section 4-11.

  • Page 38: Pulser Control (Dx Models Only)

    5-10. Pulser Control (DX Models Only) Pulser Control Pulsing is available only while using the TIG process, it cannot be se- lected if the Stick process (see Sec- tion 5-8) is active. Controls can be ad- justed while welding. Press switch pad to enable pulser. ON - When illuminated, this LED in- dicates the pulser is on.

  • Page 39: Sequencer Controls (Dx Models Only)

    5-11. Sequencer Controls (DX Models Only) Sequencer Control Sequencing is available only while using the TIG process, but is dis- abled if a remote foot or finger cur- rent control is connected to the Re- mote receptacle while in the RMT STD mode.

  • Page 40: Adjust Controls (Preflow/Post Flow/Dig/Purge)

    5-12. Adjust Controls (Preflow/Post Flow/DIG/Purge) Adjust Press switch pad until desired function LED is illuminated. Encoder Control Ammeter Turn encoder (see Section 5-2) to set ap- propriate value for active Adjust parame- ter. Value selected is shown on the am- meter (see Section 5-4).

  • Page 41: Ac Waveshape

    5-13. AC Waveshape AC Waveshape Encoder Control Ammeter Turn encoder (see Section 5-2) to set appropriate value for active AC Waveshape parameter. Value se- lected is shown on the ammeter (see Section 5-4). See Section 5-15 for all AC Wave- shape parameter ranges.

  • Page 42: Factory Parameter Defaults And Range And Resolution

    5-15. Factory Parameter Defaults And Range And Resolution Parameter Default Range And Resolution Process TIG HF Impulse TIG HF Impulse / TIG Lift / Stick * Stick OCV Low OCV Low OCV / Normal OCV *Stick Stuck Check ScI (On) ScI (On) / Sc0 (Off) Output RMT STD...

  • Page 43: Resetting Unit To Factory Default Settings

    DYNASTY: *Tungsten .094 GEN, .020, .040, .062, .094, .125 **Polarity EP / EN **Amperage 1 − 200 Amps **Time 1 − 200 Milliseconds **Start Slope Time 0 − 250 Milliseconds **Preset Amperage Minimum 1 − 20 Amps *Tungsten .094 GEN, .020, .040, .062, .094, .125 **Polarity EP / EN **Amperage...

  • Page 44: Arc Timer/Counter Display

    5-17. Arc Timer/Counter Display 123 456 Rear Panel Output And Amperage Controls Arc Timer Display Arc Counter Upon power up as described above, the After 5 seconds, the meter A LED turns on, Power Switch meter S LED will turn on, and arc time will and the arc counter will be displayed for the To display the arc timer/counter, turn power be displayed for 5 seconds as [000 000] to...

  • Page 45: Section 6 − Advanced Functions

    SECTION 6 − ADVANCED FUNCTIONS 6-1. Accessing Advanced Functions Amperage Switch Pad tions (see Section 6-3) − For reconfigur- is turned off in an attempt to save the rod ing RMT 2T Hold for 3T, 4T Momentary, for reuse. Adjust or Mini Logic Encoder Control •...

  • Page 46: Programmable Tig Start Parameters

    6-2. Programmable TIG Start Parameters Tungsten Selection Current (A) Preset Amperage Minimum Start Time Start Slope Time Amperage Switch Pad size from the following: .020, .040, .062 separate set of parameters for AC and DC (1/16 in.), .094 (3/32 in.), or .125 (1/8 in.) (to select polarity see Section C).
  • Page 47 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 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 48 Changing Programmable TIG Start Polarity E− Current (A) Start Polarity Amperage Switch Pad To adjust TIG Start Polarity proceed as fol- [StP] [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 49 E. Changing Programmable Start 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 50 Changing Preset Amperage Minimum 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 51: 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 P & H Maintained Switch Foot Or Finger Remote Control P&H = Push trigger and hold R = Release trigger.
  • Page 52 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..When main amperage level is reached,...
  • Page 53 D. 4T Specific Trigger Method 4T (Specific Trigger Operation) Encoder Control To select 4T, turn Encoder control. Torch trigger operation is as = 4T shown. 4T allows the operator to toggle be- tween weld current and final cur- rent. When a remote switch is con- Current (A) nected to the welding power source, use the remote switch...
  • Page 54 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 power source, use the re- mote switch to control the weld cycle.
  • Page 55 G. Spot Control Operation Spot Function Meter Display While in Spot Control, Se- quencer settings will be ig- nored and will not be program- mable. When a remote switch is con- nected to the welding power Spot source, use the remote switch to control the weld cycle.
  • Page 56 H. On Trigger Operation Voltage (V) 2 Sec Current (A) Stick Touch Stick Lift Stick Electrode Electrode Current (A) Lift Main Amperage Initial Slope Initial Amperage Touch Current Touch Tungsten Lift Tungsten Lift Tungsten Slightly OM-245 730 Page 50...

  • Page 57: Ac Waveshape Selection

    6-4. AC Waveshape Selection = Soft Squarewave = Advanced Squarewave = Sine wave = Triangular wave Encoder To save changes and exit, press torch trig- puddle is desired. Use sine wave to simu- ger or turn power off. late a conventional power source. Use triangular waveshape when the effects of Use the Encoder to select between ad- Application: Use advance squarewave...

  • Page 58: Setting Preflow Time

    6-5. Setting Preflow Time Encoder Control Turn encoder to select from 0 to 25 seconds of preflow. The value selected is displayed on the am- meter. Application: Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting.

  • Page 59: Lockout Functions

    6-8. Lockout Functions A. Accessing Lockout Capability Toggle Select Lockout Level 1, 2, 3, or 4 Toggle Select Code Number 1 to 999 See Section 5-1 for explanation of controls referred to in all of Remember this code number, as you will need it to turn the lock- Section 6-8.
  • Page 60 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][L−1] is dis-...

  • Page 61: Setting Unit To Display Ppp While Pulse Welding (Dx Models Only)

    6-9. Setting Unit To Display PPP While Pulse Welding (DX Models Only) − − − Encoder Control When the [PPP] meter display feature is The [PPP] meter display feature will not ef- active while pulse welding, the [PPP] will fect the normal amperage display or Meter PPP Meter Display be displayed on the right meter display, and Hold capabilities when in a non-pulse weld-...

  • Page 62: Section 7 − Maintenance And Troubleshooting

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

  • Page 63: 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. 803 428-A OM-245 730 Page 57...

  • Page 64: Voltmeter/Ammeter Help Displays

    7-3. Voltmeter/Ammeter Help Displays Help 3 Display Help 9 Display All directions are in reference to the Indicates a short in the thermal protection front of the unit. All circuitry referred to Indicates the bottom heat sink has over- circuitry located on the top heat sink. Con- is located inside the unit.

  • Page 65: Troubleshooting

    7-4. Troubleshooting Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 4-15 or 4-16). inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-15 or 4-16). Check for proper input power connections (see Section 4-15 or 4-16). No weld output;...

  • Page 66: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram 237 567-A OM-245 730 Page 60...

  • Page 67: Section 9 − High Frequency (Hf)

    SECTION 9 − HIGH FREQUENCY (HF) 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 Weld Zone 9-2. Correct Installation 50 ft 50 ft (15 m) (15 m) Ground All...

  • Page 68: Section 10 − Setup Guides For (Gtaw) Tig Welding

    SECTION 10 − SETUP GUIDES FOR (GTAW) TIG WELDING 10-1. Typical GTAW Set-Ups A. AC − GTAW 1/8 in. Aluminum Set-Up Ammeter Encoder 207 694-A This symbol indicates which functions should be active for aluminum. • Turn power on (switch located on rear panel) Press Polarity switch pad until AC LED is lit •...
  • Page 69 B. DC - GTAW 16 Gauge Stainless Steel Set-Up Ammeter Encoder 207 694-A This symbol indicates which functions should be active for stainless steel. • Turn power on (switch located on rear panel) Press Polarity switch pad until DC LED is lit •...

  • Page 70: 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 71: 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 72: 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 73: Section 13 − Setup Guide For (Smaw) Stick Welding

    SECTION 13 − SETUP GUIDE FOR (SMAW) STICK WELDING 13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) Front Panel Correct front panel display for basic Stick DCEP welding. For all front panel switch pad controls: press switch pad to turn on light and enable function.

  • Page 74: 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 75 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 76 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 77 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 78 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 79 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 80 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 81 Notes OM-245 730 Page 75...

  • Page 82: Section 15 − Parts List

    SECTION 15 − PARTS LIST Hardware is common and not available unless listed. Figure 15-1. Main Assembly 805 464-A OM-245 730 Page 76...
  • Page 83 Item Dia. Part Mkgs. Description Quantity Figure 15-1. Main Assembly ... . . Fig 15-2 ..PANEL, FRONT W/CMPNT ........
  • Page 84 ..244027 ..MEMBRANE, SWITCH CONTROL DYNASTY 200 DX ......
  • Page 85 Hardware is common and not available unless listed. 803 392-A Figure 15-3.Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 15-3. Panel, Rear w/Components (Figure 15-1 Item 2) 210 158 ....194242 .
  • Page 86 Hardware is common and not available unless listed. 803 427-B Figure 15-4. Magnetics Assembly w/Components Item Dia. Part Mkgs. Description Quantity Figure 15-4. Magnetics Assembly w/Components (Figure 15-1 Item 3) ... . . 195649 .
  • Page 87 Item Dia. Part Mkgs. Description Quantity Figure 15-4. Magnetics Assembly w/Components (Figure 15-1 Item 3) (Continued) ..233191 ..COIL XFMR, COUPLING ......... .
  • Page 88 Hardware is common and not available unless listed. 803 425-A Figure 15-5. Windtunnel w/Components Item Dia. Part Mkgs. Description Quantity 210 162 Figure 15-5. Windtunnel w/Components (Figure 15-1 Item 4) ... . . 195645 .
  • Page 89 Hardware is common and not available unless listed. 803 426-D Figure 15-6. Heat Sink, Secondary Assembly Item Dia. Part Mkgs. Description Quantity Figure 15-6. Heat Sink, Secondary Assembly(Figure 15-5 Item 7) 232 851 ... . . 209984 .
  • Page 90 Hardware is common and not available unless listed. 803 394−A Figure 15-7. Base Assembly Item Dia. Part Mkgs. Description Quantity 207 689 Figure 15-7. Base Assembly (Figure 15-1 Item 5) ....207255 .
  • Page 91 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-245 730 Page 85...

  • Page 92: Section 16 − Cooler Parts List

    SECTION 16 − COOLER PARTS LIST Hardware is common and not available unless listed. 805 266-A Figure 16-1. Cooler Main Assembly OM-245 730 Page 86...
  • Page 93 ..........Nameplate, Miller Coolmate 1 (Order By Model And Serial Number) ..

  • Page 94: Section 17 − Cart Parts List

    SECTION 17 − CART PARTS LIST Hardware is common and not available unless listed. Item 4 can be mounted in alternative position if desired. 805 337-B Figure 17-1. Cart Main Assembly Item Dia. Part Mkgs. Description Quantity Figure 17-1. Cart Main Assembly .
  • Page 95 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 96: 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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