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1. AW f uis me P ERAN WARNING Do not touch live electrical parts 1 3 CAS ON A FFAA Disconnect input power or stop SIARZ SIOF HM la lar E DET engine before servicing 4 le Los OUTPUT ENABLE Do not operate with covers removed 5 ms AUTO ENABLE 1 ELECTRIC Have only qualified persons install 5 25 1 206 AUTO ENABLE 7 SHOCK HAZARD use or service this unit 7 78 um AC POLARITY a we REMOTE MEM SELO 9 76 203 REMOTE MEM SELI 10 70 270 REMOTE MEM EMABLE 11 4A NA 12 WA NA wA NA 14 27 274 P AMPS COMMON 75 z6 is EP AMPS COMMAND 76 2 216 EN AMPS COMMAND mme bm EN AMPS COMMON Es zs ISOLATED COMMON 19 74 279 PULSE LOCK E zo 3 ze PULSE LOCK 21 24 227 FINAL LOPE E 22 23 22 FINAL SLOPE C zie ze VALID ARC E sele 24 VALID ARC C ee RCI 1 ACIE ACZE MRE A DESCRIPTION 3 je EZ 1V 1004 uia i REZI SEE CHART ps JZ vw ROVPLO 5 47 CHASSIS poses Sp sS 2 470 VOG_ REFERENCE GUT 7 27 REMOTE REFERENCE O 10V0E 77 laz COMMON 72 _ 47 CHASSE 7 WA _ lt KPLGI m GROUND STRAP 5 N
2. lA REMOTE 14 Socket Socket Information A Contactor control 15 volts DC 15 VOLTS DC OUTPUT B Contact closure to A completes 15 volts DC CONTACTOR contactor control circuit and enables out put C 10 volts DC REMOTE D Remote control circuit common OUTPUT i CONTROL E 0 to 10 volts DC input command signal from remote control F Current feedback 1 volt DC per 100 am AN peres AMPERAGE VOLTAGE H Voltage feedback 1 volt DC per 10 output 803 900 A 218 716 A receptacle volts CHASSIS K Chassis common GND G 15 volts DC A common The remaining sockets are not used Note If a remote hand control like the RHC 14 is connected to the Remote 14 receptacle some current value above min must be set on the remote control before the Panel or Remote contactor is turned on Failure to do so will cause current to be controlled by the panel control and the remote hand control will not function OM 2250 Page 20 4 10 Automation Connection 803 900 A 218 716 A Pin Pin Information For 28 Pin Receptacle RC28 1 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 2 Output enable functional only in automation modes Closure to pin 8 must be maintained at all times If the closure between pins 2 an
3. a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed e e Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion wil
4. SECTION 5 OPERATION 5 1 Controls we ES NN Q O1 O2 22 11 12 V As te MEMORY f o JUL on o ER PPS INITIALA EN AMPERAGE 4 A o oll o Ju o WL o ha oH TIG HF IMPULSE RMT STD PEAKt INITIAL SLOPE t PREFLOW EP AMPERAGE at u O 2 O POST FLOW BALANCE o Dy i DIG AC FREQUENCY HRASIDIG AC NAVESHAPE 9 10 213 320 A 803 901 A Available On Dynasty Models Only Rear Panel See Section 5 12 4 Polarity Control Dynasty Only 10 AC Waveshape Dynasty Only gt For all front panel switch pad controls See Section 5 6 press switch pad to turn on light and en able normal function 5 Process Controls See Section 5 13 NOTE Green on nameplate indicates a TIG See Section 5 7 function Gray indicates a normal Stick func 6 Output Controls 11 Amperage And SpotTime Gontrol tion For Amperage Control see Section 5 3 See Section 5 9 j 1 Encoder Control For Spot Time Control see Section 5 14 7 Pulser Controls 2 Ammeter And Parameter Display See Section 5 10 12 Memory See Section 5 4 8 Sequencer Controls See Section 5 15 3 Voltmeter See Section 5 11 13 Power Switch See Section 5 5 9 Gas DIG Controls Use switch to turn unit On Off OM 2250 Page 28 5 2 Encoder Control AX 1 Encoder Control Use control in conjunction with ap pli
5. OM 2250 216 871F Emm su 200 Miller TIG GTAW Welding Stick SMAW Welding OWNER S MANUAL File TIG GTAW Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right 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 Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n 1 U E Bl E PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do 2 every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years NII 00012000 of reliable service with proper maintenance And if for some reason the unit needs repair
6. 1 Boss 215 117 NAMEPLATE IDENT REAR 1 giuste Mies 217297 COVER RECEPTACLE WEATHERPROOF DUPLEX RCPT 1 10 ese 221 164 LABEL WARNING ELECTRIC SHOCK INPUT POWER CONNECT 1 TO LIS 219842 LABEL WARNING INPUT CONNECTIONS ELECTRIC SHOCK CE 1 11 81 221 124 SWITCH TGL ASSY INCLUDES 1 veria idque te da 213060 SWITCH TGL 3 PST T When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2250 Page 73 LF Hardware is common and not available unless listed 804 134 A Figure 12 4 Wind Tunnel Right Hand w Components Item Dia Part No Mkgs No Description Quantity 213 345 Figure 12 4 Wind Tunnel Right Hand w Components 1 L1 213350 INDUCTOR INPUT sssssssssee e ms 1 2 T8 213326 XFMR COUPLING TOP 42 4 1 2 T4 215140 XFMR COUPLING BOTTOM 1 Sen d sucus 212 489 PANEL RIGHT WINDTUNNEL oooccccccoccccc e eee ees 1 d uox dues 195 666 SCREW 010 32X 50 TORX PANHD WGNDRN
7. 24V 108 2 2 mos B v 709 Mr RG144 gt gt iid rau gt gt 27 750 DEREN nous S Z RECRODE Ghee i 111 lt poner ruu VOR BACK HE ZOZ SIGNAL ON BUS La ZIE X NGA C O gt gt RE E A P WHITE HE 7 FN RG148 gt gt 113 lt lt nca grow STRAP CONTACT TOP z AG gt lt lt Rent 16 FB TOR 75 non E IB TOP COM 74 Roig IT P25 39 79 ans KREN 5 LAT POF A rce RC14 12 gt AMT NEG 38 _ 7271 MEMBRANE 3WITCH PANEL me C NOMAS PROCESS CONTROL RG gt ZA NOT READY TOP 76 nen 74 70 OC LATCH TOR Z lt lt RENT Ra gt gt aan TOR lt REIS RCI3PI COMMAND COMMON TOR 87 lt REM ROWPLG4 THERMISTOR PTOP 17 lt RONA roe La lt REHA RCIAPLGS TRE PUES PLG56 1 THERMISTOR SETOP 120 ren ESSE d AES7 27 PLOSE 2 THERMISTOR SCTOP 127 REIS A RTE FLGSS Ire PLG54 1 THERMISTOR INDTOP 12 nos RG142 gt gt I 127 A A ae SO ARTY A lt lt Rot le QUIPUT POLARITY COM 77 L not CAMP OVER Lad Croire gt 19 POR CAMP OVER COM 99 2A27 lt RGIT 1 CONTACT BOT 2 Less A OC LATCH BOT 37 k ra s12 AN 17 lt x peas E ma TO AZ COMMAND BOT Se ROI gt c finr COMMAND COMMON BOT E x en i THERWSTER PBOT JF lt lt ROIS Ram gt gt 22 E E lt E THERMISTOR PROT 2 ness ma 22 our RG18 7 rers L033 1 cg FLERE T nr 124 lt az mere so AVADIA EE E A m E 052 2 p pa KROIS0 m og 2 eu RoW X 25 VA I Ro gen FREE EE DE iiu RR E er Y MMMM V V V Y YX
8. Connect input conductors L1 U L2 V and L3 W to welding power source line terminals Install cover Disconnect Device Input Power Connec tions 7 Disconnect Device switch shown in OFF position 8 Disconnect Device Supply Grounding Terminal Connect green or green yellow grounding conductor to disconnect device grounding terminal first 9 Disconnect Device Line Terminals Connect input conductors L1 U L2 V And L3 W to disconnect device line terminals 10 Over Current Protection Select type and size of over current protec tion using Section 4 17 fused disconnect switch shown Close and secure door on line disconnect de vice Remove lockout tagout device and place switch in the On position 803 927 A OM 2250 Page 26 B Connecting Single Phase Input Power Her Tools Needed B A Installation must meet all National and Local Codes have only quali fied persons make this installation A Disconnect and lockout tagout in put power before connecting input conductors from unit A Make input power connections to the welding power source first A Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal See rating label on unit and check input volt
9. sonnes notamment les enfants de l appareil e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide doubl e UNE DECHARGE ELECTRIQUE peut e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le entra ner la mort champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes lectriques sous tension peut seit err A e Porter un harnais de s curit si l on doit travailler au us du sol provoquer des accidents mortels ou des br lures a un r r js t s gt mi dd s el e nt a i xn graves Le circuit de l lectrode et de la pi ce est dese el que tous GS PANNEAUX El couvercies sont correcementen sous tension lorsque le courant est d livr la place p sortie Le circuit d alimentation et les circuits internes de la machine e Fixerle c ble de retour de fa on obtenir un bon contact m tal m tal sont galement sous tension lorsque l alimentation est sur Marche avec la pi ce souder ou la table de travail le plus pr s possible de la Dans le mode de soudage avec du fil le fil le d rouleur le bloc de soudure commande du rouleau et toutes les parties m talliques en contact isoler la pince de masse quand pas mis la pi ce pour viter le contact avec le fil sont sous tension lectrique Un quipement install ou mis avec tout objet m tallique la terre de mani re
10. Duty Cycle 75V 75 68 39 34 27 27 26 Three Phase 5 700 600 A 44 Volts 60 Duty 10 154 Cycle 97 88 51 44 35 35 34 360 34 Volts 100 Duty Cycle 75V 82 74 37 30 17 16 Z sm 450 A 38 Volts DC 60 10 154 Duty Cycle 115 104 52 42 24 22 While idling 4 Low open circuit voltage while in TIG Lift Arc or while in Stick with low open circuit voltage selected see Section 6 7 VNormal open circuit voltage 75 volts is present while in Stick with normal open circuit voltage selected see Section 6 7 Note This unit is equipped with Auto Line Auto Line is an internal inverter power source circuit that automatically links the power source to any primary input voltage from 190 to 625 volts single or three phase 50 or 60 hertz Also adjusts for voltage spikes within the entire range B Maxstar 700 Md Amper Re Amperes Input at Rated Load Output 50 60 Hz age Open Cir Range cuitVoltage 208V 230V 400V 460V 575V KVA KW Input Power Rated Welding Output DC 500 40 Volts 100 Duty Cycle 75V 67 60 35 30 24 24 23 Three Phase 5 700 600 A 44 Volts 60 Duty 10 154 Cycle 89 80 46 40 32 32 31 360 A 34 Volts 100 Single Duty Cycle 75V 77 70 35 28 16 15 5 700 Phase 450 A 38 Volts DC 60 10 154 Duty Cycle 106 96 Zz 48 38 22 21 While idling 4 Low open circuit voltage while in TIG Lift Arc or while in Stick with low op
11. OD ma Ona OF m c To adjust Programmable Start Time press Amperage switch pad and meter S LED turns on The current Start Time is dis 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter played on the amps meter and can be ad justed by turning the Encoder control see Section 5 16 OM 2250 Page 42 6 2 Output Control And Trigger Functions A Remote Standard Torch Trigger Operation Current A Main Amps Initial Slope Final Slope Initial Amps Final Amps Preflow Postflow ___ __ _ _ _ gt gt P H R R Maintained Switch Foot Or Finger Remote Control P H Push trigger and hold R Release trigger NOTE When a foot or finger remote current control is connected to the welding power source initial amps initial slope final slope and final amps are controlled by the remote control B Remote 2T Torch Trigger Operation Current A Main Amps Initial Slope Final Slope Initial Amps Final Amps Preflow 4 P R Y P R P R Push trigger and release NOTE If torch trigger is held more than 3 seconds operation reverts to RMT STD Remote Standard mode OM 2250 Page 43 C Reconfiguring RMT 2T HOLD For 2T 3T Spot 4T 4T Momentary Or Mini Logic Control 4 TE L 2 SEL H c V A s H YO 1 o JUL O m PPS INITIALA o r a ob lof TIG
12. OM 2250 Page 40 6 1 SECTION 6 ADVANCED FUNCTIONS pm AR a EA ae 55 xu 9 NES Programmable TIG Start Parameters A Accessing Programmable TIG Start Parameters All Models wanes A O O1 O2 4 O3 O4 V A S H p MEMORY t o JUL AV PPS INITIALA Dp t 4 lj o E oM oh o ML o Ws TIG HF IMPULSE RMT STD PEAKt INITIAL SLOP t PREFLOW o Tk e BKGND A FINAL SLOPE t POST FLOW O 9 NA ON FINALA PULSER SEQUENCER GAS DIG AC WAVESHAPE Available On Dynasty Models Only NOTE The welding cycle can be executed while in programmable start mode Before accessing programmable TIG Start Polar ity Amperage and Time modes be sure that all procedures and parameters are es tablished 1 Process Switch Pad 2 Amperage Switch Pad 3 Power Switch To access the programmable TIG Start Amperage and Time screens turn power on and then press the Process and Amper age switch pads before the software ver sion clears the meters Hold switch pads CL until software version clears the meters and SEL EP or SEL EN appears 4 Memory Switch Pad Press Memory switch pad to select desired memory location see Section 5 15 5 Polarity Switch Pad Dynasty Models only Press Polarity switch pad to select AC or DC see Section 5 6 Note Each memory location and each po larity AC or DC has its o
13. QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in the U S A ta be registered to exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 121 Symbol Usage stor qe ER EA n e POUR nea UTE RE ea 1 122 Arc Welding Hazards tette a e d puce c ISSUE USE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 2 3 1 5 Principal Safety Standards 2 4 1 6 EME Information i atan een a mn rm px ese Fuld ER OE alls ne A oe PE 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILI
14. and it must be connected be tween Remote 14 receptacle pins A and B The second will be designated as the final switch and it must be connected between Remote 14 receptacle pins D and E Select 3T according to Section 6 2C Definitions Initial slope rate is the rate of amperage change determined by the initial amperage initial slope time and main amperage Final slope rate is the rate of amperage change determined by the main amperage fi nal slope time and final amperage Operation A Press and release initial switch within 3 4 second to start shielding gas flow To stop the preflow sequence before preflow time elapses 25 seconds press and release final switch The preflow timer will reset and the weld sequence can be started again L If an initial switch closure is not made again before preflow time ends gas flow stops the timer resets and an initial switch press and release is necessary to start the weld sequence again B Press initial switch to start arc at initial amps Holding switch will change amper age at initial slope rate release switch to weld at desired amperage level C When main amperage level is reached initial switch can be released D Press and hold the final switch to de crease amperage at final slope rate re lease switch to weld at desired amperage level E When final amperage has been reached the arc extinguishes and shielding gas flows for the time set on the Postflow
15. lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil SUR q nn L EMPLOI EXCESSIF peut CHAUFFER L QUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste An nn ee amp LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistati ques pour stocker d placer ou exp dier des cartes PC y amp DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d
16. output waveform NOTE Peak amperage is set using the Amperage control see Section 5 3 Peak amperage is the highest welding amperage allowed in the pulse cycle Weld penetration varies directly with peak amperage Application Pulsing is the alternating raising and lowering of the weld output at a spe cific rate The raised portions of the weld output are controlled in width height and frequency forming pulses of weld output These pulses and the lower amperage level be tween them called the background amperage alternately heat and cool the molten weld puddle The com bined effect gives better control of penetration bead width crowning undercutting and heat input OM 2250 Page 33 5 11 Sequencer Controls A INITIAL A o uv INITIAL SLOPE t o JX FINAL SLOPE t A FINALA SEQUENCER 1 Sequencer Control Sequencingis available while using the TIG process but is disabled if a remote foot or finger current control is connected to the Remote recep tacle while in the RMT STD mode Press switch pad until desired pa rameter LED is illuminated 2 Encoder Control Set Value 3 Ammeter Displays Value See Section 5 16 for all Sequencer parameter ranges INITIAL A Initial Amperage Use control to select a starting amper age that is different from the weld amperage Application Initial Amperage can be used to as sist in preheating cold material prior to deposit
17. 1 Main Assembly OM 2250 Page 70 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly d b aeterno 223785 LABEL SIDE DYNASTY 700 2 E lle cerita 223 784 LABEL SIDE MAXSTAR 700 2 leh EE RES 213 071 INSULATOR SIDE 00000430 ato ege eee nane a e 09 us 2 No eis MEM 213 057 gt PANEL SIDE 2202725 024 a HH Re 2 id iliius 213 056 WRAPPER TOP 24142838 or aan epe da RN alien nus 1 Ard A M id 203990 LABEL WARNING GENERAL PRECAUTIONARY STATIC 1 Deus 179310 LABEL GENERAL PRECAUTIONARY WORDLESS CE 1 ec O issus us 213073 2 SEAL LIFT EYE cia ae Set nada bte Deal nr ERR RE Eg 1 7 PC18 PC8207 157 CIRCUIT CARD ASSY CLAMP 2 O dns 080 509 GROMMET SCR NO 8 10 PANEL HOLE 312 SQ 375 HIGH 9 ON is 221708 BRACKET MTG PC BOARD DYNASTY 700 MODELS ONLY 1 e TO Sn etes 010493 BUSHING SNAP IN NYL 625 ID X 875 MTG HOLE 2 Ep 1 213058 LIFT EYE 202 ccs 2000 eR Rei RR a eae 1 12 T2 218059 XFMR 665 115 24 18 18 220 1 HAS ue a 155436 LABEL GROUND PROTECTIVE EARTH 1 ia ere es 218170 HOSE NPRN BRD NO 1 X 250 ID X 25 000 1 A ess 089 120 CLAMP HOSE 375 450 CLP DIA
18. 7596 30 99 Percent FREQUENCY 120Hz 20 400 Hertz Impulse HF Start parameters for each program 1 4 MAXSTAR Amperage 5 700 Amps Time 1 200 Milliseconds DYNASTY DC Polarity EP EN Amperage 5 700 Amps Time 1 200 Milliseconds Polarity EP EN Amperage 5 700 Amps Time 1 200 Milliseconds DYNASTY parameter selection only Parameter adjusted using a power up configuration only Parameter used with the automation option only OM 2250 Page 39 5 17 Resetting Unit To Factory Default Settings Process Switch Pad Output Switch Pad On im N Gas DIG Switch Pad S b 4 Power Switch Si To reset all welding power source oa functions to original factory settings lockout feature must be off see Sec 23 tion 6 5 Turn power on and then 04 V As um press and hold the Process Output O O O O and Gas DIG switch pads before the software version clears the meters MEMORY f o JUL o M V O Er PPS INITIAL A AMPERAGE iA O ra olt lof Q Oo bfa Oo d TIQ HF IMPULSE RMT STD PEAKt INITIAL SLOPE t PREFLOW EP AMPERAGE o o 1 out ode o rv o fa o pe TIG LIFT ARC RMT 2T HOLD BKGND A FINAL SLOPE t POST FLOW BALANCE o o ES O o o Jl o Dx O AP AC STICK ON ON FINAL A Dia AC FREQUENCY BW GJ tJ 9 A PA M Zz NC POLARITY PPCESS DN PULSER SEQUENCZA GAS DK AC WAVESHAPE N 7 NON N 7 4 Rear Panel
19. 900 DC Amperes 215 126 A 213 342 A 213 344 A OM 2250 Page 15 4 3 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 3 and cooling fan runs Wait fifteen minutes for unit to cool 800 Reduce amperage or voltage or duty cycle before welding 700 A Exceeding duty cycle can damage unit and void 600 warranty a 500 3 Phase 2 E ni 1 Phase lt 5 300 a 5 200 100 0 10 20 30 40 50 60 70 80 90 100 Duty Cycle Overheating EN a or v K amp gt 15 I E Minutes Reduce Duty Cycle sduty1 5 95 213 343 B 4 4 Dimensions Weights And Base Mounting Hole Layout NOTE Overall dimensions A B and C include lifting eye handles hardware etc Z Dimensions H E r A 34 1 2 in 876 mm B 13 3 4 in 349 mm C 22 in 559 mm D 20 1 2 in 521 mm I Li L amp E 1 in 25 mm F 11 3 4 in 298 mm G 1 2 in Dia 13 mm Dia 4 Holes A _ A s ya 2 L Weight r F HE 803 914 A 198 Ib 90 kg OM 2250 Page 16 4 5 Selecting A Location A Falling Unit Can Cause Injury Use equipment of a
20. Automation 1 1 0 Enables pin 2 function Sequencer and weld timers Automation 2 X 1 4 13 Typical Application Typical 28 Pin Output Collector K Emitter To User Equipment _ gt o Coil resistance plus R CR1 CR1 should be chosen to limit current to 75 mA yp L o User supplied power R up to 27 volts DC peak lt lt OM 2250 Page 22 4 14 Gas Connections gt dl 1 Gas Fitting Fittings have 5 8 18 right hand threads 2 Cylinder Valve Open valve slightly so gas flow blows dirt from valve Close valve 3 Regulator Flowmeter 4 Flow Adjust Typical flow rate is 15 cfh cubic feet per hour Connect customer supplied gas hose between regulator flowmeter and gas fitting on rear of unit Tools Needed IT 5 8 1 1 8 in Q00068080588009800000008896088800 000000888000000000000000088800000 080800000000080000008080000000008 000000898800000000000000088860009 O00688080888208800000088808828800 803 901 A 4 15 TIG HF Impulse Lift Arc Connections A Turn off power before mak ing connections 1 Electrode Weld Output Terminal Connect TIG torch to electrode weld output terminal 2 Gas Out Connection Connect torch gas hose to gas out fitting 3 Work Weld Output Terminal Connect work lead to work weld LA output terminal 4 Remote 14 Receptacle If desired co
21. Cable 10 Ungrounded Metal Objects power eia built in HF or 8 Line Disconnect Device 11 Lighting Soparaie unit 9 Input Supply Wiring 12 Wiring 2 Weld Cables 13 Water Pi d Fixt 3 Torch 3 Water Pipes and Fixtures 4 Work Clamp 14 External Phone and Power Lines 5 Workpiece 6 Work Table S 0694 OM 2250 Page 65 9 3 Correct Installation Ground all metal ob jects and all wiring in welding zone using 12 AWG wire Nonmetal e Building 1 High Frequency Source welding power source with built in HF or separate HF unit Ground metal machine case work output terminal line disconnect device input supply and worktable 2 Center Point of Welding Zone Midpoint between high frequency source and welding torch 3 Welding Zone A circle 50 ft 15 m from center point in all directions 4 Weld Output Cables Keep cables short and close together workpiece if required by codes 5 Conduit Joint Bonding and Grounding Electrically join bond all conduit sections using copper straps or braided wire Ground conduit every 50 ft 15 m 6 Water Pipes and Fixtures Ground water pipes every 50 ft 15 m 7 External Power or Telephone Lines Locate high frequency source at least 50 ft 15 m away from power and phone lines 8 Grounding Rod Consult the National Electrical Code for specifications Ref S 0695 Ref S 0695 Metal Building Requirements 9 Me
22. Control Dynastyt Models Only 29 5 7 Process Control o ns d ne m tc BE x petala death ele ata eet ae e e e ages 30 5 8 Lift ArcE And HF TIG Start Procedures 30 5 92 Output Control tes soeben wed OMe ga n erp Rl ec e o ba a e e d ex n E e 31 5510 Pulser Control za rune as GARY A DONS ER eL RBS ERR EA 32 5211 Sequencer Controls o RUE Gad a a RU Pa COL EAR AA DR DRE Le EAE CEN 33 5 12 Gas DIG Controls Preflow Post Flow DIG Purge 34 5 13 AC Waveshape Dynasty Models Only 35 5 14 Spot Time Control Reconfigured RMT 2T HOLD Output Selection 36 5 15 Memory Program Storage Locations 1 4 37 5 16 Factory Parameter Defaults And Range And Resolution 38 5 17 Resetting Unit To Factory Default Settings 39 SECTION 6 ADVANCED FUNCTIONS 0 cece cece eee acc c rece eee eee eee eee 40 6 1 Programmable TIG Start Parameters 40 6 2 Output Control And Trigger Functions 42 6 3 AC Waveshape Selection Dynasty Models Only 48 6 4 Arc Timer
23. Counter Display All Models 49 6 5 Lockout Functions ner mie reto ere Fs nct RR ek annee ea ERO PR RH federe 50 6 6 Setting Unit To Display PPP While Pulse Welding 52 6 7 Stick Open Circuit Voltage OCV Selection 53 SECTION 7 MAINTENANCE AND TROUBLESHOOTING 54 7 2 BlowingOutlnsideofUnit c occ cc ecce eee eee cerrar 54 7 3 Voltmeter Ammeter Help Displays 55 7 4 Troubleshooting u a 28 Bra bt ccevib ana lan rar inne 56 SECTION 8 ELECTRICAL DIAGRAM c c nennen cesser 58 SECTION 9 HIGH FREQUENCY 4 444 44444 esse hr s nnn ne 65 9 1 Welding Processes Requiring High Frequency 65 9 2 ncorrect Install tion 16 2 83 22 ue ite RE A an RER IR FLASH ach 65 9 3 Correct Installation pU da ATA d 66 SECTION 10 SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING 67 10 1 Selecting Tungsten Electrode Wear Clean gloves To Prevent Contamination Of Tungsten 67 10 2 Preparing Tungsten Electrode For Welding 68 SECTION 11 GUIDELINES FOR TIG WELDING GTAW 000 e cece eee eee crecer cr 68 1121 Positioning
24. I E E A SCTV E z s Be 8 ek ES TO PC2 3 N cre d ORNL i N pr E e cHassis 8 8 a 8 8 88 8 8 L x toe oi L L i Z X me 1 ams AUXPOWER c7 2 D 5 kres eus RCIZPLGI6 RC2 PLG17 RC5 PLG41 R67 1 Sb 7 2 RC7 PLGI9 p RC8 PLGE 0 VEL RC9 PLG21 CHASSIS Pp RCIO PLGee a RCIL PLGE3 RC9 10 gt lt RC6 70 ACG lt RC6 7 77 23 282322 2228222888 233 lt RC6 13 Mme von D US oc eo es p 1 o 2 11 D I D ZZ E ais 11 1111242 se titan u a lt lt RCE S NEVER VIE AVIV BW NAV VIN EN EV yyy GR 7258 RC6 14 EEE Risk als Z ee RC6 le i R kR Le ree 2 j IL A c RC6 6 TO PCS 10 Poa TO PCIE Thy TO Poe 79 de Ren 2209 1423 Azo 2 09 p RC6 10 1 m N N RCE 8 A Z K Rt6 9 D RR 17 SN lt RC6 3 Rt6 4 N ewe L SS 5 er ttes 1 fi 2 oe N n Ej a GEN YEL E CHASSIS ron a m 7 4 8 ES K RCe L 42 as 115 de RCe 4 A E amp Lise Ho YELLOW d lt RC6 L TZ 45 K diy n TZ 1 05 lt RC6 7 Ano E lt RC6 13 ReZ 119V REPT FE lt RC6 5 lt RCE 12 lt RC6 2 lt RC6 6 BRI lt RC6 11 RN 22 lt RC6 10 Me MODL 1 ak RC6 8 lt RC6 9 2 RC6 3 3 977 RC6 4 Q RC6 14 s r Valet A WARNING Do not touch live electrical parts N ES mex v Disconnect input power or stop RL p engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install
25. Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue amp for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary
26. RC7 PLG14 RCS PLGIS o Q ar RC7 3 7 xad 2 t RC7 1 gt i RGI 1 gt RTI r a RES lt 2 22 gt gt al 72 3 INVERTER MODULE TOP BIS ipe Rose gt Mr n TO pcs 2818 L e EN T8 Q 108 107 NEG 4 24 i 3 Tic n e ze 37 m H Opos E set ii I AAA N D i ii 2 E d g ill bi H mscm amp le iles IM ji E i j PC3 3 it i SNUBBER BOARD ar a Q i z m ml i pce o ar INTERCONNECT CONT ROL BOARD CT RCL PLGES RC3 PLG26 o RC amp PLG27 RC7 PLGe8 RC8 PLG62 O RC4 PLG63 RCE PLG46 432 1 O m REN BRE NS Re7 3 gt eue L Re7 2 gt BAK Rer gt RD A Reit gt RTS r er RC1 2 P gt gt 47 T gt Res 2 gt ReB 4 gt gt E 215 121 C OM 2250 Page 63 3 x RET ACTO MRE A DESCRIPTION 1 3 GAS ON OFF z le S ARI STO 3 19 203 HEF DISABLE 4 z m QUIPUT ENABLE 5 ms AUTO ENABLE 1 s z ms AUTO EMABLE Z 7 e Le AC POLARITY a Lwe REMOTE MEM SELO 9 6 209 REMOTE MEM SEL 1 10 70 z10 REMOTE MEM EMABLE H WA MA 12 WA NA 13 WA 274 EP AMPS COMMON 773 LP AMPS COMMAND JESESETESS A WARNING Do not touch live electrical parts Disconnect input power or stop engine before servicing FLECTRIC Have
27. SHOCK HAZARD use or service this unit Figure 8 1 Circuit Diagram For Dynasty 700 Models Part 1 of 2 OM 2250 Page 58 PCIS a PCS VOLTAGE CLAMP PCB mE L n Mer VOLTAGE CLAMP PCB RCI 1 gt gt 472 15 Yan RC1 PLG44 Z Ea I RCI PLG24 i LIE 774 RC2 PLG43 RE zg Qno 704 RC2 PLG33 RCL 2 Ss A20 z RC2 1 Rc3 PLG45 A A Az RCcl 422 7 13 Res z RC2 1 RC3 PLG348 A Z d 3 8 REI 4 gt JY AE eRe RC8 4 L 5 L 4 RCI 5 gt Z2 1828 ID PES 29 Rte 5 Lb 4 ras T Gee Y YY YY pa a 116 7181777 97 8E SLAMA vo 75 SYERVOLT UNIT odd Z grege um TD PLA BOT TG Pcia 10 PC3 1 524 1425 QA ree Y ee EDU ze zum Z4 1 1 2 a 4 ua CR1 WwW Eh s Z A F RRA aaa T 1 i Bow BUS BUs cme zi Dutput Fonverter RCZ z 8 2 Re A ser SIE y 3 rea J BS HF XFMR O PCS a 2 PCL O 8 E INTERCONNECT CONTROL _ o4 PC3 PMI 6 BOARD Ex COM
28. SLFTTNG GREEN 2 i26 ni Figure 12 8 PANEL REAR W COMPONENTS 1 sd f seeds Figure 12 5 HEAT SINK PRIMARY ASSY 2 co TO res Figure 12 4 WINDTUNNEL RIGHT HAND W COMPONENTS 2 19 PC7 214 712 CIRCUIT CARD ASSY HF INCLUDES 1 TEATER O E 189 786 CONTACT SPARK GAP 22 2 a ae 196455 POINT SPARK GAP ssssessss Is 2 i an 0 Re 219 055 BASE ios mei pre exe tee lap TR cip eda era Aloe LOGRO MUR ae 1 A NEN 213 074 CABLE LEM 23 Ni Hin 2 22 HD1 182918 TRANSDUCER CURRENT 400A MODULE SUPPLY V 15V 2 AOL sau Figure 12 7 HEAT SINK SECONDARY DYNASTY 700 2 ht OB raidir d Figure 12 8 HEAT SINK SECONDARY MAXSTAR 700 2 van LE EEE 213248 LUG UNIV W SCREW 2 0 14 WIRE 266STD 1 25 PC5 221722 CIRCUIT CARD ASSY AUX POWER W PROGRAM 1 ile OO uci cvs 215402 PANEL TOP WINDTUNNEL eee III e 1 UE V opcs 057 357 BUSHING SNAP IN NYL 937 ID X 1 125 MTG HOLE 1 O SEEN Figure 12 6 WINDTUNNEL LEFT HAND W COMPONENTS 2 29 C6 C7 222752 CAPACITOR ASSY 1 o suce 221721 PANEL WINDTUNNEL S
29. Start button light is On start arc as follows High frequency turns on to start arc when output is enabled High fre quency turns off when arc is started and turns on whenever arc is broken to help restart arc Application HF start is used for the DCEN GTAW process when a non con tact arc starting method is required OM 2250 Page 31 5 9 Output Control obl RMT STD B obw RMT 2T HOLD 1 1 Output Control Press switch pad until desired parameter LED is illuminated RMT STD Remote Standard Application Use Remote Trigger Stan dard with a foot pedal or finger amperage control see Section 6 24 NOTE When a foot or finger remote cur rent control is connected initial amps ini tial slope final slope and final amps are controlled by the remote control ON OUTPUT NOTE If an On Off type trigger is used it must be a maintained switch All Sequenc er functions become active and must be Set by the operator RMT 2T HOLD Application Use Remote Trigger Hold 2T for long extended welds If a foot or finger current control is con nected to the welding power source only trigger input is functional see Section 6 2B NOTE This switch function can be recon figured for 3T 4T 4T Momentary Mini Log ic or Spot control See Section 6 2C ON Output will energize two seconds after be ing selected Application Use Output On for Stick SMAW welding or f
30. The Toreh ir nt debe ree hier ga ee emere ree ER Uns MS ce 68 11 2 Torch Movement During Welding 69 11 3 Positioning Torch Tungsten For Various Weld Joints 69 SECTION 12 PARTS LIST A an re 70 OPTIONS AND ACCESSORIES WARRANTY Declaration of Conformity for European Community CE Products N OTE Ey This information is provided for units with CE certification see rating label on unit Manufacturer European Contact Miller Electric Mg Co Mr Danilo Fedolfi 1635 W Spencer St Managing Director Appleton WI 54914 USA ITW Welding Products Italy S r l Phone 920 734 9821 Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 ia European Contact Signature Declares that the product Dyn a sty 700 conforms to the following Directives and Standards dec_stat_6 05 Directives Low Voltage Directive 73 23 EEC Electromagnetic compatibility Directives 89 336 EEC 92 31 EEC Machinery Directives 98 37EEC 91 368 EEC 92 31 EEC 133 04 93 68 EEC Standards Arc Welding Equipment Part 10 Electromagnetic Compatibility EMC Requirements IEC 60974 10 August 2002 Arc Welding Equipment Part 1 Welding Power Sources IEC 60974 1 Ed 2 1 Degrees of Protection Provided By Enclosures IP Code IEC 60529 Ed 2 1 Insulation Coordination For Equipment Within
31. WASHER TOOTH 22MMID X 31 5MMOD 1 310 1MMT INTERN 3 ea Mir acte aces 185718 O RING 0 989 ID X 0 070 H 3 ee VO ar mes 185 713 INSULATOR BULKHEAD REAR 4 3 20 FMB FMT 213072 FAN MUFFIN 0 00 cece R9 2 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2250 Page 72 LF Hardware is common and not available unless listed UUU UU UU UU UU UU O O O C O O O O O O O O O O O O O O OEE CIL rM CUL F CD 804 139 A Figure 12 3 Panel Rear w Components Item Dia Part No Mkgs No Description Quantity 221 409 Figure 12 3 Panel Rear w Components l issue 218 054 5 PANEL REAR cuarta laa as Aci due utu Hasen esu se ng 1 2 G81 216607 VALVE 24VDC 2WAY CUSTOM PORT 1 8 ORF W FRICT 1 3 CB1 183 492 SUPPLEMENTARY PROTECTOR MAN RESET 1P 10A 250V FRIC 1 4 RC2 189033 RCPT STR DX GND 2P3W 15A 125V GRAY 1 D owes ed 115516 RIVET AL 187 DIA X 063 125 GRIP BLK BLIND DOME 1 MG see 010 467 CONN CLAMP CABLE 1 250 1 doi es at irait 137 761 NUT 750 NPT 1 31HEX 27H NYL BLK
32. always slope to minimum amperage Li n nz and end the cycle NOTE When a remote switch is connected to the welding power source use the remote switch to control the weld cycle Amperage is controlled by the welding power source Application This ability to change current levels without ei ther initial slope or final slope gives the operator the opportu nity to adjust filler metal without breaking the arc Torch Trigger Operation Main Amps Initial Slope Final Slope Initial a Postflow PlH R P R P R P R P R P R P H P H Push and hold trigger R Release trigger P R Push trigger and release in less than 3 4 seconds Arc can be extinguished at final slope rate at any time by pushing and holding trigger OM 2250 Page 46 G 4T Momentary Operation 1 4T Momentary Meter Display Select 4T Momentary according to Section 6 2C 4T Momentary torch trigger operation is as shown NOTE When a remote switch is connected to the welding power source use the remote switch to control the weld cycle Amperage is controlled by the welding power source Use 4T Momentary trigger method when the functions of a remote current control are desired but only a remote on off control is available Preflow gt 4 P R P R Final Slope SEL HUE _ 4T Momentary Main V A S Hz dicic Application Current A Main Amps Initial Slope Initial Amps Fin
33. and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label OM 2250 Page 9 Warning Watch Out There are possible hazards as shown by the symbols 1 2 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 Always wait 5 minutes after power is turned off before working on unit OR Check input capacitor voltage and be sure it is near O before touching any parts When power is applied failed parts can explode or cause other parts to explode Flying pieces of parts can cause injury Always wear a face shield when servicing unit Always wear long sleeves and button your collar when servicing unit After taking proper precautions as shown connect power to unit Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Read the Owner s Manual before working on this machine Disconnect input plug or power before working on
34. dessous concernant les mesures prendre pour supprimer LF Signifie NOTE n est pas relatif la s curit les dangers 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce manuel e V rifier fr quemment le cordon d alimentation afin de s assurer qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort instructions aff rentes pour viter tout risque Les instructions en e L quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu un e Ne pas utiliser des c bles us s endommag s de grosseur insuffisante sommaire des instructions de s curit plus compl tes fournies ou mal piss s dans les normes de piii hand mer dans la Section 2 5 Lire et amp Ne pas enrouler les c bles autour du corps e USA Pa 3 g e Sila pi ce soud e doit tre mise la terre le faire directement avec un A Seul un personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et r parer cet appareil Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre A Pendant le fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine H n n
35. m 3 38 WS lt 700 SEL Al P502 PLosO4 SE Y Y LI IE PLGEI 1 Rm SEIER 3 ie El OM 2250 Page 60 1 44 TO PEZ TO PCI IRI LEID Figure 8 2 Circuit Diagram For Dynasty 700 Models Part 2 of 2 213 338 C Notes OM 2250 Page 61 A WARNING Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed e mi ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit exo Tar i 27 sofo _ 2 peig 7 t 62 O NI T t D E OF J r G o o CAL ng a ne 4 AOZT s s iS N PAID 4 6 cov ZV Law a i LITE s 98 3 158 CE a a 1 E 71 198 91 108 fe7 8 gt p K Re2 1 BUS KRO2 4 BUS PC5 AUXPOWER A7 72p RCI PLGIE RC2 PLG17 RCS PLG41 7 Z ROB RC7 PLGI9 AS EU L RC8 PLG20 RC9 PLG21 GUESS p RC10 PLG22 REIL PLG23 REY 107 e lt RC6 1 70 71 x a S m lt RC6 7 lt RC6 13 27 534 10194 K 1 504 RE tamos 77 _ d RC6 14 X rce 12 K 02 638 K eau m Ke Kz is is Ks Kanu 77 71
36. m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Afin d liminer tout risque de feu tre vigilant et garder toujours un extincteur la port e de main Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit Brancher le c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque Avant de souder retirer toute substance combustible de ses poches telles qu un allumeur au butane ou des allumettes Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie e
37. only qualified persons install SHOCK HAZARD use or service this unit Do not operate with covers removed OM 2250 Page 64 Figure 8 4 Circuit Diagram For Maxstar 700 Models Part 2 of 2 16 2 6 EN AMPS COMMAND 17 277 EN AMPS COMMON 18 275 ISOLATED EOMMON 19 4e PUSE LOCK E zs 20 PUSE LOCK 21 ze 227 FINAL SLOPE E 22 25 zr FINAL SLOPE zo jm VALID ARE E 24 ae VALID ARE C Ves FCIS ROZE MRE DESCRIPTION 3 e TV 100A REI Sb 4 s 25 WY PCID ROLE SEE CHART 5 42 CHASSIS AUTOMATION CONTROL 5 8 ler 410 WE REFERENCE QUT Re 7 I Ir REMOTE REFERENCE 0 10V0C Rore sje COMMON zie CHASSIS 7 WA eKr PLG3 m ROUND STRAP 5 o 24V asa B z meua 24V 709 lt lt RCIBA ns TO POS 15V 110 X reisa mur SS Z E 1 03 15V 111 x ener mora A cow 172 L reine ponr gt BACK AE OUZ SIGNAL ON BUS TOR I Rog gt EE 1 22 lt REIS LROLND SIRAP L CONTACT TOP z ne Krone RS rh FB TOR 7 lt menan Roisi KB TOP COM 74 REIHE RG148 gt gt Pce REH MEMBRANE SWITCH PANEL OVER PONE 70 ET TE PROCESS CONTROL R6155 gt gt TO Pct NOT RE
38. qUe Lv Input V PIE Converter Transformer Rectifier gt Output Circuit Breaker Remote FR Lift Arc GTAW D d ems n ij t2 Postflow Timer L Preflow Timer S Seconds On O Off Positive Negative u we Gas Input gt Gas Output L d X Duty Cycle Direct Current io Line Connection U 2 oe Load Maximum Effective n A Remote Standard Alen U Primary Voltage P Degree Of Rated Maximum Protection Supply Current Supply Current 1 1max pply jeff pply Rated No Load T Increase Decrease U O Voliage Average E i Polarity Control A Initial Amperage Of Quantity Percent Wy Gas DIG Control Impulse Starting hazard of electric shock Recall From Hz Hertz gt Memory Dn il ii F GTAW t t Final Slope A Final Amperage F ies am t Initial Slope I f tL AC T Pulser EP Amperage Pulse Frequency Process Work Electi ENA A or N ectrode Lu mperage e e eo Unit may be used in environments o E with increased Sequence s diee An H AC Frequency OM 2250 Page 13 SECTION 4 INSTALLATION 4 1 Specifications A Dynasty 700 Maximum Amper Opere GIE Amperes Input at Rated Load Output 50 60 Hz age Range Cuit Voltage 208V 230V 400V 460V 575V KVA KW Input Power Rated Welding Output DC 500 A 40 Volts 100
39. than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventila
40. to simu late a conventional power source Use triangular waveshape when the effects of peak amperage with reduced overall heat input is required to help control distortion on thin materials OM 2250 Page 49 6 4 Arc Timer Counter Display All Models 1 Output And Amperage Controls 2 Power Switch To display the arc timer counter turn power Switch on press and hold the Amperage Control and Output switch pads until the Software version clears the meters 3 Arc Timer Display The meter S LED will turn on and arc time will be displayed for 5 seconds as 000 000 to 999 959 The first four numbers indicate hours and the last two numbers indicate minutes Example shown is read as 1 234 hours and 56 minutes Maximum arc time is 9 999 hours and 59 minutes 122 LIC f l IL V S H MO O TO Or t o JUL om O PPS INITIAL A y n oltre o Fr oi o PA b H RMT STD PEAK t INITIAL SLOPE t PREFLOW EP AMPERAGE o olan o JY o We o Ex Dc RMT 2T HOLD BKGNDA FINAL LOPE t o NY O O o NA AC ON ON FINALA a POLARITY PROCESS ourPlm PULSA SEQUENCER GAS DIG ACWAVESHAPE Z L Rear Panel 4 Arc Counter After 5 seconds the meter A LED turns on and the arc counter will be displayed for the next 5 seconds as 000 000 to 999 999 The maximum arc cycle count is 999 999 OM 2250 Page 50 6 5 Lockout F
41. to unit ee STATIC ESD can damage PC boards y e Puton grounded wrist strap BEFORE handling ASS boards or parts So e Use proper static proof bags and boxes to store move or ship PC boards amp MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire 453 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling P MOVING PARTS can cause injury Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before us
42. value EN Amperage and EP Amperage allow the op erator the ability to control the amount of am perage in the negative and positive half cycles independently A 2 to 1 or 3 to 1 ratio of EN to EP is a good starting point This provides cleaning action but directs more energy into the workpiece and provides faster travel speeds and deeper penetration 4 Amperage Control Average Amperage Control Setting EN Am perage EP Amperage Balance and Frequen cy values creates an average amperage The operator can change the average amperage value while maintaining the same EN amper age to EP amperage ratio at the existing bal ance and frequency To change the average amperage value press the Amperage switch pad and turn the Encoder control The chang ing average value is displayed on the ammeter Example If EN Amperage is 300 EP Amper age is 150 Balance is 60 and Frequency is 120 the average amperage is 240 amps If you press the Amperage switch pad and turn the Encoder control until 480 amps is displayed the EN amperage is now 600 and EP amper age is now 300 The balance remains 60 and the frequency is still 120 and the 2 to 1 EN am perage to EP amperage is maintained OM 2250 Page 36 5 14 Spot Time Control Reconfigured RMT 2T HOLD Output Selection 1 Spot Time Meter Display Select Spot function according to 3 Section 6 2C 2 Amperage Switch Pad 3 Encoder Control Y To set spot parameters pre
43. 00088898229800 803 901 A OM 2250 Page 18 4 8 Weld Output Terminals And Selecting Cable Sizes A ARC WELDING can cause Electromagnetic Interference To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Weld Cable Size and Total Cable Copper Length in Weld Circuit T Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100ft 30m orLess 45m 60m 70m 90m 105 m 120 m Weld Output Terminals A Turn off power before 10 6096 60 10096 connectingto weld out nn Duty Duty 10 100 Duty Cycle put terminals mps Cycle Cycle A Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2 ea 2 0 2 ea 2 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 a ca 2 ea 2 0 2 ea 3 0 2 ea 3 0 300 1 50
44. 1 6809293 6426888 6239407 6107602 6329636 6002103 EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY 5 5 MC 223 275 D OM 2250 Page 11 3 3 Manufacturer s Rating Labels CE Models LF For label location see Section 4 5 Manufacture s Rating Label Manufacture s Rating Label For Dynasty 700 Models Maxstar 700 Models N mer CE wie c MILLER ELECTRIC MFG CO APPLETON WI MILLER ELECTRIC MFG CO APPLETON WI SERIAL NO SERIAL STOCK NO 907102 IEC 60794 1 L__ sms War QA 0 60 100 30 700 600 5A 20V 700A 44V Nu x 3096 60 10094 __ 12 700 soo 500 SL ju ss Las Lo DD rm ner sad U1 400 se 90 res 2 X 12 60Hz 115V 10A X 100 2 X 1f 60Hz 115V 10A X 100 PROTECTED BY ONE OR MORE OF PROTECTED BY ONE OR MORE OF THE FOLLOWING US PATENTS THE FOLLOWING US PATENTS 6103994 6115273 6087628 6103994 6115273 6087628 6548784 6337789 5601471 6548784 6337789 5601471 6809293 6426888 6239407 6809293 6426888 6239407 6107602 6329636 6002103 6107602 6329636 6002103 EVIDENCE OF LABEL TAMPERING EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY 5 50 6 VOIDS WARRANTY 2o3077 0 ree y 223 260 C 223 277 C OM 2250 Page 12 3 4 Symbols And Definitions Gas Tungsten Arc Shielded Metal Arc s A Amperes gt Output AF Welding GTAW eh Welding SMAW m ao 3 Phase Static Frequency V
45. 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2 ea 2 0 2 ea 3 0 2 ea 3 0 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x95 2x120 2 ea 2 0 2 ea 3 0 2 ea 4 0 2 ea 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 2x120 2 ea 2 0 2 ea 3 0 2 ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 2ea 2 0 2ea 3 0 2 ea 4 0 3 ea 3 0 3 ea 4 0 3 ea 4 0 600 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x120 3x120 2 ea 2 0 2 ea 3 0 2ea 4 0 3 ea 3 0 3 ea 4 0 3 ea 4 0 4 ea 4 0 700 4 0 120 2x70 2x95 2x120 3x95 3x120 3x120 4x120 2 ea 2 0 2 ea 3 0 2ea 4 0 3 ea 4 0 3 ea 4 0 4 ea 4 0 4 ea 4 0 800 4 0 120 2x70 2x95 2x120 3x120 3x120 4x120 4x120 900 2 ea 2 0 2 ea 3 0 2ea 4 0 3ea 3 0 2x70 2x95 2x120 8x95 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use S 0007 E Select weld cable size for pulsing application at peak amperage value OM 2250 Page 19 4 9 Remote 14 Receptacle Information Used Without Automation Connection
46. 60974 3 Ed 1 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2 05 A Warning Protect yourself and others from injury read and follow these precautions 1 1 A Symbol Usage Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Marks a special safety message LF Means Note not safety related 1 2 Arc Welding Hazards A A A p The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipm
47. 826 RECEPTACLE THREAD LOCK 2 EC RE 186228 O RING 0 739 ID X 0 070H 3 La Miss Laits 185712 INSULATOR BULKHEAD FRONT 3 ra E Geo den mise 202 552 RECEPTACLE GAS FEMALE 0 00 c cece eee eee n 1 Eo 213051 PANEL FRONT TOP 20 2 242 2207 2378 ccc cee hans 1 RTE RIRES 216859 PLATE FRONT PANEL 444 444444 n 1 nin DB asas us 213069 PLATE INDICATOR FRONT DYNASTY 700 1 CERO mu benne 213518 PLATE INDICATOR FRONT MAXSTAR 700 1 sh ci CO green dentia 174991 KNOB POINTER 1 250 DIA X 250 ID W SPRING CLIP 21 1 ise NO sete ne 215294 BUSHING FLG 375 32X 511 1 MAT sente 212 490 PANEL FRONT 4444444 R NG Y RAR DORA C R R eee 1 wae A 213 320 NAMEPLATE SWITCH MEMBRANE DYNASTY 350 700 STH FF 1 Lu VZ ce act 215 119 NAMEPLATE SWITCH MEMBRANE MAXSTAR 350 700 STH FF 1 18 PC6 220755 CIRCUIT CARD ASSY CONTROL amp INTERFACE W PROGRAM 1 14 RC1 213327 RECEPTACLE W LEADS 8 PLUG 14PIN 1 bue TDI hh rs 185 717 NUT M20 1 5 1 00HEX 19H BRS LOCKING 3 tas WG ee A 2 178548 TERMINAL CONNECTOR FRICTION 1 AND 7743 E 185714
48. ADY TOP 76 lt M N BOARD ano QC LATCH TOP Z rent RCUPLOH Ra gt gt 7 ROIUPLGZ COMMAND TOP cra R COMAND COMMON TOR EI na mune THERMISTOR PTOP 17 K ROMA RCHPLGS THERMISTOR PTOP 18 rois RCIAPLGB RITE PUES PLGIO Y THERMISTOR SETOP 129 are TA NOTOP T Grants RTE ACSS PLES4 1 Rota PILSS 2 EE THERMISTOR NOTIF EM TO ptt ve 128 11310 Pm lt RG1143 CRETE CONTACT BOT Md k reisa RG OC LATCH BOT 51 Ta lt RG19 12 NA RD NOT READY BOT EIA lt a COMMAND BOT Eis misa 4 lt e COMAND COMMON BOT 5F lt noie P F3 m ee D ara lt r X Kreis ae 27 REN LEA lt n _ D RTA ALGES 7 qe PLOSE 1 TERMSTOR SCEN 128 617 Roa 5 JO ETS y Le Li ABRIR qg PUT THERMSTOR SCOOT 75 k nis10 T 25 ww zx 1810 OVER POWER BOT 4 Le noia i i i i i Ment GRNYLW VV V V VY V V V Y NS EE X S NS N 700 SEL N R 8 PLG50 2 PLOS0 1 NE vy PLOSI 2 PLGBI I SE TO Pea GRO 215 121 C SECTION 9 HIGH FREQUENCY 9 1 Welding Processes Requiring High Frequency 1 High Frequency Voltage TIG helps arc jump air gap between torch and workpiece and or stabilize the arc Work TIG high freq 12 96 S 0693 9 2 Incorrect Installation 11 12 m L 14 1 I I Sources of Direct High Frequency Sources of Conduction of High Sources of Reradiation of High Radiation Frequency Frequency 1 High Frequency Source welding 7 Input Power
49. B eme RC6 2 RC6 6 RCe 11 RC6 10 _ x RC6 8 _ 4 RC6 9 77 k re s l lt lt RC6 4 ZT TS TDR 3 33 en 3 3 WTI 1 2k N lov ne ne ant N Ep CHASSIS a 5 lt RC6 1 lt RC6 7 lt RC6 13 lt RC6 5 lt RC6 12 d RC6 2 58 RC6 6 amp RC6 11 2 K RC6 10 Fine 7 J aa RC6 8 f K RC6 9 lt RC6 3 l z r lt lt RC6 4 2x RC6 14 L 4 16 48 47 2009 Lt n MIET RCS 1 Figure 8 3 Circuit Diagram For Maxstar 700 Models Part 1 of 2 OM 2250 Page 62 Z4 Le c rs e m T STE SET i 70099 NR it a a a 8 i d i a NES BUS CIR 1 poma ur n 1 z i 5 p PC3 3 oT SNUBBER BOARD HF XPR O il g mr mer IP A Pci as INTERCONNECT CONTROL C BDARD 7 em RG1 PLG10 2 RC2 PLGIL RC4 PLG12 o RC6 PLGI3
50. EPARATOR 1 dl O s 221 707 3 CAPACITOR ASSY cub AR NER E e e Re 1 ids dese Figure 12 2 PANEL FRONT W CMPNTS 1 EE MER 215120 CONNECTION KIT DINSE 1 33 PC19 187264 CIRCUIT CARD ASSY FILTER CE MODELS ONLY 1 DD IMPR 222 760 BRACKET FILTER BOARD CE MODELS ONLY 1 sea DO create 226 878 BRACKET HARNESS SUPPORT MAXSTAR 700 MODELS ONLY 1 aid 195666 SCREW 010 32X 50 TORX PANHD W GNDRNG STL PLD 2 97 RT5 RT6 231 292 THERMISTOR NTC 30K OHM 25 DEG C 8IN W HEAT SHRINK 2 ia 88 x CIT ss 231486 CAPACITOR ASSY ss pec ue CUR RD eR La ob P PROS na 2 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2250 Page 71 LF Hardware is common and not available unless listed 2 804 138 A Figure 12 2 Panel Front w Components Item Dia Part No Mkas No Description Quantity 221 408 Figure 12 2 Panel Front w Components uoles A res 213053 PANEL LOUVER COVER ORDER SERIAL NO CARD ALSO 2 da 2 suit mama 214
51. G STL PLD 3 D af ren 216861 STAND OFF CAPACITOR 4 2 B ood 170 647 BUSHING SNAP IN NYL 1 312 ID X 1 500 MTG HOLE 1 Pere 216 860 GROMMET CAPACITOR 4 2 8 C4 C20 217941 CAPACITOR ELCTLT 1800 UF 500 VDC CAN 2 52 DIA 2 a T 207 418 SCREW K40X 20 PAN HD PHL STL PLD PT THREAD FORMING 2 10 C8 216700 CAPACITOR POLYP MET FILM 16 UF 400 VAC 1096 1 Ts omnis 218004 LABEL WARNING ELECTRIC SHOCK EXPLODING PARTS 1 HN pce 219844 LABEL WARNING ELECTRIC SHOCK EXPLODING PARTS CE 1 1 3262208244 010493 BUSHING SNAP IN NYL 625 ID X 875 MTG HOLE 1 h Ec bee uns 218566 GASKET INDUCTOR MOUNTING 1 14 L2 218348 COIL INDUCTOR PRE REGULATOR 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2250 Page 74 LF Hardware is common and not available unless listed 804 135 A Figure 12 5 Heat Sink Primary Assembly Item Dia Part No Mkgs No Description Quantity 219 344 Figur
52. HF IMPULSE RMT STD PEAKt E For RMT STD Remote Standard RMT 2T Hold Remote 2T Hold and On trigger op eration see Section 6 2A B and I 1 Process Switch Pad 2 Output Switch Pad 3 Power Switch PULSER SEQUENCER To access the RMT 2T HOLD turn power switch on press and hold the Process and Output switch pads before the software version clears the meters and SEL ap pears RMT 2T Hold LED will light 4 Encoder Control Set Value 5 Ammeter Displays Value H 2 2T see Section 6 2B Rear Panel SPO Spot see Section 6 2H H 3 3T see Section 6 2D H 4 4T see Section 6 2E H4L Mini Logic see Section 6 2F HYE 4T Momentary see Section 6 2G Press torch trigger or turn power Off to save setting OM 2250 Page 44 D 3T Specific Trigger Method zZ NN Zu BHAI 4 V A S Hz O O O O Current A Remote Trigger Operation A A B C D E 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 1 ST Specific Trigger Operation Sequencer is required to reconfigure for 3T 3T requires a specific type of remote con trol with two independent momentary contact switches One will be designated initial switch
53. Input Conductor Length In Feet Meters ys A a a es Min Grounding Conductor Size In AWG 4 6 6 8 8 10 Single Phase Input Voltage 208 230 460 575 Input Amperes At Rated Output 115 104 52 42 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 125 125 60 50 Normal Operating 3 175 150 80 60 Min Input Conductor Size In AWG 4 3 4 8 8 Max Recommended Input Conductor Length In Feet Meters 59 A Sd 86 Min Grounding Conductor Size In AWG 4 6 6 8 10 Reference 2005 National Electrical Code NEC includes article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 2250 Page 24 B Maxstar 700 NOTE ES Actual input voltage cannot exceed 10 of indicated required input voltage If actual input voltage is outside of this range no ou
54. LED You may now select a lockout level There are four lockout levels available Turn Encoder control to se lect a lockout level see Sections 6 5B for lockout level descriptions 6 Lockout On Once the desired three digits have been entered and a lockout level selected press torch trigger or turn Off power to complete lockout on sequence NOTE Setting a three digit lockout number of 200 or setting a lock out level of will cause a lockout off condition To turn Off the lockout feature proceed as follows To access lockout screens turn On power switch and then before the software version clears the meters push and hold the Amperage and Gas DIG switch pads until software version number clears me ters Upon power up as described the meter and Amperage A switch pad LED s will turn on and the meter display will be as shown for a lockout on see callout 6 condition Use Encoder control to enter the same three digits that were used to turn on the lockout feature Press the Amperage A switch pad The meter LED will turn off and the S LED will light The amperage right meter display will change to L The lockout feature is now off Press torch trigger or turn Off power to complete lock out Off sequence OM 2250 Page 51 B Lockout Levels Levels 1 2 And 3 FN o1 Use Encoder Control To Adjust 02 Amperage 10 Of Preset os Val
55. Low Voltage Systems Part 1 Principles Requirements And Tests IEC 60664 1 Ed 1 1 Arc Welding Equipment Part 3 Arc Striking And Stabilizing Devices IEC 60974 3 Ed 1 Declaration of Conformity for European Community CE Products N OTE Ey This information is provided for units with CE certification see rating label on unit Manufacturer European Contact Miller Electric Mg Co Mr Danilo Fedolfi 1635 W Spencer St Managing Director Appleton WI 54914 USA ITW Welding Products Italy S r l Phone 920 734 9821 Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 ia European Contact Signature Declares that the product M axsta r 700 conforms to the following Directives and Standards dec_stat_6 05 Directives Low Voltage Directive 73 23 EEC Electromagnetic compatibility Directives 89 336 EEC 92 31 EEC Machinery Directives 98 37EEC 91 368 EEC 92 31 EEC 133 04 93 68 EEC Standards Arc Welding Equipment Part 10 Electromagnetic Compatibility EMC Requirements IEC 60974 10 August 2002 Arc Welding Equipment Part 1 Welding Power Sources IEC 60974 1 Ed 2 1 Degrees of Protection Provided By Enclosures IP Code IEC 60529 Ed 2 1 Insulation Coordination For Equipment Within Low Voltage Systems Part 1 Principles Requirements And Tests IEC 60664 1 Ed 1 1 Arc Welding Equipment Part 3 Arc Striking And Stabilizing Devices IEC
56. MUTATOR DRIVER BOARD RC1 PLG10 RC20 PLG35 MOD 7 6 4 WHT RC2 PLGIL Oo RC21 PLG36 MOD 7 6 5 RED RC4 PLG12 O RC25 PLG37 MOG 6 _6 WHT RC6 PLG13 RC26 PLG38 RC7 PLG14 e20 MOD 6 7 RED RCS PLGIS q O 88 a8 22 8 amp SS SM SS TT T T T 4 mc m i el Y YY RCZ 4 gt le x a 3m lz RC7 3 gt LI L J p pa i Zac 2a 73 2 RC7 2 gt 3 E H a 33 Ef 26 RG7 1 gt Sg F 33 1 M Rol 1 gt gt r amp 1 RCI 2 I 22 xd gt 35 INVERTER MODULE TOP i OUTPUT SENSE rer gt c mr SENSE 2718 Le md 108 107 ELECTRODE i O y ue Ea 4 24 DAT TM YR Ve 37 en m Titane O ROR NG See i LEV STH 0 5 Y T F F e WORK RR m z p m am 8 e R Iii qu RM e IM m gt Bue BUS CTR d 16 illom ud a i mes gt Dutput chnver ter m GIR x ii rg mca um LEE og 3 4 qus HF XFMR 4 m pes MW 174 LU r pce PMI 6 INTERCONNECT CONTROL PC4 BOARD _1C4 3 COMMUTATOR DRIVER BOARD RC1 PLG25 M RC25 PLG31 MAHI 4 WT RC3 PLG26 RC26 PLG32 MOOI 6 5 RED RC6 PLG27 O INN MI E E MAT RG7 PLG28 RCB PLGE2 o c20 wy MOYI 6 7 RED RC4 PLG63 E RC2 PLG46 a mm 2 2 a 2 ou Blaza SS 8S BS SLY V V V TT TT TT Ha un SHADED CARE VV Y Y Y Y Ra gt a ale s is e R amp 7 3 gt CLA f bea la E Re7 2 gt gt per 8 BI 3 Sa te amp RG7 1 gt Sm va su E r fe Reti X RT 3 5 1 r RC1 2 gt gt 213 338 C OM 2250 Page 59
57. NSISTS OF 3 IGBT S 2 D ve D1 D2 213 521 4 KIT ULTRA FAST DIODE ur dre ea adi 2 6 RTZ RT4 213353 THERMISTOR NTC 30K OHM 25 DEG C 8IN LEAD 1 7 HEAT SINK POWER MODULE 1 8 SR1 201530 KIT DIODE FAST RECOVERY BRIDGE 1 9 BUS BAR NEGATIVE u a ea Saee peers RS 1 CIRCUIT CARD ASSEMBLY DIODE SNUBBER 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2250 Page 77 LF Hardware is common and not available unless listed 804 177 A Figure 12 8 Heat Sink Secondary Maxstar 700 Item Dia Part No Mkgs No Description Quantity 221 730 Figure 12 8 Heat Sink Secondary Maxstar 700 dde ra 213346 HEAT SINK POWER MODULE 1 2 D1 D2 213521 KIT ULTRA FAST DIODE 2 8 SR1 201 531 KIT DIODE POWER MODULE 1 4 RT2 RT4 213353 THERMISTOR NTC 30K OHM 25 DEG C 8IN LEAD 1 5 PC3 220987 CIRCUIT CARD ASSY DIODE SNUBBER 1 250 s ES 2139 519 BUS BAR 22 A Pe e REA RU EN A EE 1 To maintain the
58. O f o JUL o PPS INITIAL A t o oA off o Mn TIG HF IMPULSE RMT STD PEAKt INITIAL SLOPE t Hh o O 14 olani ode ove pe TIG LIFT ARC RMT 2T HOLD BKGND A FINAL SLOPE t o N Oo A ac STICK POLARITY PROCESS OUTPUX PUISER SEQUENCER GAS DIG AC WAVESHAPE 1 2 5 er Rear Panel 1 Output Switch Pad 4 Encoder Control The PPP meter display feature will not ef 2 Pulser Switch Pad 5 PPP Meter Display fect the normal amperage display or Meter 3 Power Switch Hold capabilities when in a non pulse y Turn Encoder to change between standard welding mode To access the PPP while welding display and PPP meter display turn power switch on press and hold the Press torch trigger or turn off power to save Output and Pulser switch pads until soft When the PPP meter display feature is ac setting ware version clears meters and SEL ap tive while pulse welding PPP is displayed pears A and Pulser On LED s will light and the meter hold feature is disabled OM 2250 Page 53 6 7 Stick Open Circuit Voltage OCV Selection 5 y gt qu LL H n 3 V A Hz ii MEMORY f o JUL 04 o ER PPS INITIAL A EN AMPERAGE gt O x ovr oJ o MV o X TIG HF IMPULSE RMT PEAKt INITIAL SLOP t PREFLOW EP AMPERAGE o O 1 olflurn_ o IM o u o Er pe TIG LIFT ARC RMT 2T HOLD BKGND A FINAL SLOPE t POST FLOW BALANCE o W O A l AC ON POLARITY PROCESS OU
59. ORY t o JUL o V PPS INITIAL A t o r a oli o Fi o WMV TIG HF IMPULSE RMT STD PEAKt INITIAL SLOPE t o IV FINAL SLOPEt o E EN AMPERAGE e EP AMPERAGE o Ex BALANCE lt POLARITY PROCESS OUTPUT Sine wave 1 Polarity Switch Pad 2 AC Waveshape Switch Pad 3 Power Switch To access the AC Waveshape selection Screen turn power on and then press the Polarity and Waveshape switch pads be fore the software version clears the meters and SEL 55q appears The active Memory LED AC LED and the EN and EP Amper age LED s will light 4 Memory Switch Pad Advanced Squarewave AL Each memory location can select any of four wave shapes 5 Encoder Use the Encoder at any of the four memory locations to select between advanced squarewave ASq soft squarewave 55qJ default sine wave 5 j or triangle wave TRI To save changes and exit press torch trig ger or turn power off Note During normal operation when EN or EP Amperage is selected the left parame Triangular wave PA Rear Panel Soft Squarewave ter screen will display the active wave shape A5q 55qJ SIM or TRI as a remind er Application Use advance squarewave when a more focused arc is required for better directional control Use soft square wave when a softer arc with a more fluid puddle is desired Use sine wave
60. SATION 5 2 1 Symboles titiliS6S1 cultam late it oath sited nU NC MOUE A N MU er he 4 D 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 7 2 5 Principales normes de s curit 8 2 6 Information EMF ci ea nt kr cep da s E EE em RE EA 8 SECTION 3 DEFINITIONS CE Models Only 9 3 1 Warning Label Definitions cccccccc ene hn 9 3 2 Manufacturers Rating Labels Non CE Models 11 3 3 Manufacturers Rating Labels CE Models 12 3 4 Symbols And Definitions 13 SECTION 4 INSTALLATION lt x Sa 05 0 AA ea FE GENS ck 14 451 Specifications zu ain AA A A ner EY GER E hr Hans 14 4 27 Volt Amper e CUES ceres eur ERU REPE A E Op Ye EY VOU GE VERRE Y EE 15 4 3 Duty Cycle and Overheating 42222 4 16 4 4 Dimensions Weights And Base Mounting Hole Layout 16 4 5 Selecting A Locations nca Dn AU R
61. T THREAD FORMING 2 MD uto On Lo 212 488 PANEL LEFT WINDTUNNEL 4422 1 6 T1 213361 XFMR HF LITZ LITZ W BOOST 1 7 Z4 213513 COIL INDUCTOR BOOST 1 8 Z1 213356 OUTPUT INDUCTOR ASSY 1 M gcc EN 010 498 BUSHING SNAP IN NYL 625 ID X 875 MTG HOLE 3 id redes 010381 CONNECTOR RECTIFIER oocccccccccccccc n 1 add e faste 227 746 GASKET INDUCTOR MOUNTING E55 FERRITE CORE 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2250 Page 76 LF Hardware is common and not available unless listed NN KREIEREN N ER A RAA 804 137 A Figure 12 7 Heat Sink Secondary Dynasty 700 Description Quantity Figure 12 7 Heat Sink Secondary Dynasty 700 1 PC3 PC4 222 753 CIRCUIT CARD ASSY COMMUTATOR CONTROL 1 2 a BUS BAR OUTPUT san nee ea Te cep eR wae 2 8 BUS BAR POSITIVE es eet Re ana a 1 4 PM1 6 213522 KIT IGBT CO
62. TPUT 1 NA a A L Rear Panel 1 Process Switch Pad ters Hold the switch pads until SEL Loc or When Stick low OCV is selected open cir SEL noci appears cuit voltage is between 9 and 14 volts 2 Gas DIG Shen Pad When Stick normal OCV is selected open 3 Amperage Switch Pad 5 Encoder Control circuit voltage is approximately 80 volts 4 Power Switch 6 Meter Display Application For most Stick applications To access the Stick OCV selection turn use low open circuit voltage Use normal power switch on and then press the Pro Turn Encoder to change between low OCV open circuit voltage for hard to start Stick cess Gas DIG and Amperage switch pads SEL Loc and normal OCV SEL noc Active electrodes or if required for your particular before the software version clears the me selection is displayed on the meters application OM 2250 Page 54 SECTION 7 MAINTENANCE AND TROUBLESHOOTING 7T 1 Routine Maintenance Her A Disconnect power before maintaining 3 Months Replace unreadable labels WARNI Clean and tighten weld gt terminals Al D Replace damaged gas hose N Repair or replace cracked cables and cords 6 Months B gg gt S gt Ay Blow out inside During heavy L service clean monthly 77 7 2 Blowing Out Inside of Unit adi A Do not remove case when blowing out inside of u
63. Y WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 2006 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Perso
64. age available at site see Section 4 5 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 4 17 Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief Route conductors cord through strain re lief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to welding power source grounding terminal first 5 Welding Power Source Line Terminals Switch S1 6 Input Conductors L1 U And L2 V Connect input conductors L1 U And L2 V to welding power source line terminals Install cover Disconnect Device Input Power Connections 7 Disconnect Device switch shown in OFF position 8 Disconnect Device Supply Grounding Terminal Connect green or green yellow grounding conductor to disconnect device grounding terminal first 9 Disconnect Device Line Terminals Connect input conductors L1 U And L2 V to disconnect device line terminals 10 Over Current Protection Select type and size of over current protection using Section 4 17 fused dis connect switch shown Close and secure door on line disconnect device Remove lockout tagout device and place switch in the On position 803 927 B OM 2250 Page 27
65. al Amps 1 P R P R P R Postflow P R Push and release trigger Push and releasing during final slope will break the arc and go to postflow NOTE For first torch trigger push amp release if trigger is held more than 3 seconds trigger cycle ends H Spot Control Operation 1 Spot Function Meter Display Select Spot function according to Section 6 2C See Section 5 14 for operation P H Push and hold trigger R Release Trigger I NOTE While in Spot Control Sequencer settings are not be CL CPI programmable _ 7 Spot NOTE When a remote switch is connected to the welding V A S Hz power source use the remote switch to control the weld O O O 0 cycle Amperage is controlled by the welding power source Torch trigger operation is as shown Application Used for tacking and thin sheet joining Current A Timed Spot Weld Amps Preflow Postflow P H R OM 2250 Page 47 I On Trigger Operation Voltage V ON 2 Sec O 9 oN oN OUTPUT OUTPUT Current A Stick Touch Stick p Electrode Ho Current A Lift Main Amperage Initial Amperage Initial Slope Touch Current t t Touch Tungsten Lift Tungsten Lift Tungsten Slightly OM 2250 Page 48 6 3 AC Waveshape Selection Dynasty Models Only CE l E EC L 559 Hz V A S O O O O MEM
66. ammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby A FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 2250 Page 2
67. ated Second press Polarity switch pad until the desired polarity AC or DC LED is illuminated Third press Process switch pad un til desired process TIG HF Impulse TIG Lift Arc or Stick LED is illumi nated The program at the chosen location for the desired polarity and process is now the active program Fourth change or set all desired pa rameters see Section 5 1 for pa rameters OM 2250 Page 38 5 16 Factory Parameter Defaults And Range And Resolution FOTO OUTPUT RMT STD RMT STD RMT 2T ON RMT 2T 2T RMT 2T can be reconfigured for 2T 3T 4T Mini Logic 4T Momentary Spot see Section 6 2C A MAIN PEAK AC TIG 5 700 Amps AC STICK 5 700 Amps DC TIG 5 700 Amps DC STICK 5 700 Amps Spot Time 0 1 25 0 Seconds Weld Time Dual Range And Resolution 0 0 99 9 100 999 Seconds PULSER ON OFF PPS Quad Range And Resolution DC 0 1 9 9 10 500 510 990 1K 5K Hertz AC 0 1 9 9 10 500 Hertz PEAKt 5 95 Percent BKGND A 5 95 Percent SEQUENCER INITIAL A 5 700 Amps Initial Time 0 0 25 0 Seconds INITIAL SLOPE t 0 0 25 0 Seconds FINAL SLOPE t 0 0 25 0 Seconds FINAL A 5 700 Amps Final Time 0 0 25 0 Seconds ADJUST PREFLOW 0 0 25 0 Seconds POST FLOW 0 0 50 0 Seconds 0 2 Second Resolution DIG 0 100 Percent AC WAVESHAPE Waveform Soft Square Soft Square Advanced Square Sine Triangle EN Amps 500A 5 700 Amps EP Amps 500A 5 700 Amps BALANCE
68. ber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifi que les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lors que la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suf fisamment de personnes pour soulever et d placer les bouteil les Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curi t 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation
69. bi 40 55 200 275 160 240 3 16 55 80 250 350 190 300 1 4 T 80 125 325 450 250 400 Zirconium Alloyed Tungsten Brown Band 010 i Up to 20 Up to 15 020 d 15 35 5 20 040 20 80 20 60 1 16 50 150 60 120 3 32 gt 130 250 100 180 1 8 x 225 360 160 250 5 32 300 450 200 320 3 16 id 400 550 290 390 1 4 600 800 340 525 Typical argon shielding gas flow rates are 15 to 35 cfh cubic feet per hour Not Recommended Figures listed are a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers OM 2250 Page 67 10 2 Preparing Tungsten Electrode For Welding R A Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires Use y local exhaust forced ventilation at the grinder or wear an approved respirator Read MSDS for safety infor G mation Consider using tungsten containing ceria lanthana or yttria instead of thoria Grinding dust from thoriated electrodes contains low level radioactive material Properly dispose of grinder dust in an environ mentally safe way Wear proper face hand and body protection Keep flammables away A Preparing Tungsten For DC Electrode Negative DCEN Welding Or AC Welding With Inverter Machines 2 1 2 Times 1 Grinding Wheel Electrode Diameter Grind end of tungsten on fine grit hard abrasive wheel before welding Do not use wh
70. cable front panel function switch pad to set values for that function 5 3 Amperage Control 2 N J O O O af 1 A Amperage Control 2 Encoder Control 3 Ammeter See Section 5 16 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 Section 5 10 Note See Section 5 13 for AC func tions 5 4 Ammeter And Parameter Display 1 Ammeter Ammeter displays actual amper age while welding It also displays preset parameters for any of the fol lowing amperage time percent age or frequency The LED located directly below the ammeter will also illuminate OM 2250 Page 29 5 5 Voltmeter 1 Volt Meter Displays output or open circuit volt age If output is off the voltmeter will display 5 6 Polarity Control Dynasty Models Only 1 Polarity Control Press switch pad until desired LED is illuminated DC Set machine to DCEN for TIG welding and to DCEP for Stick welding AC Use AC for TIG and Stick welding OM 2250 Page 30 5 7 Process Control o TIG HF IMPULSE o La TIG LIFT ARC of L PROCESS 1 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 w
71. con trol Application With the use of two remote switches instead of potentiometers 3T gives the operator the ability to infinitely increase decrease or pause and hold amperage within the range determined by the initial main and final am perages OM 2250 Page 45 E 4T Specific Trigger Method 1 1 4T Specific Trigger Operation Select 4T according to Section 6 2C TX Torch trigger operation is as shown current 4T NOTE When a remote switch is connected to the welding pow er source use the remote switch to control the weld cycle Am cr L LI 4T allows the operator to toggle between weld current and final S 9 perage is controlled by the welding power source Application Use 4T trigger method when the functions of a remote current Current A control are desired but only a remote on off control is available Torch Trigger Operation Main Amps Initial Slope Final Slope Final Amps Postflow P H R P R P R P H R P H Push and hold trigger R Release trigger P R Push trigger and release in less than 3 4 seconds Mini Logic Operation 1 1 Mini Logic Meter Display Select Mini Logic according to Section 6 2C SN Torch trigger operation is as shown ILI I Mini logic allows the operator to toggle between initial slope MiniLodi or main amps and initial amps Final Amperage is not avail lt Mn ogie able Final slope will
72. d 8 is broken an output disable occurs Postflow begins to time out and HELP 3 will be displayed on the meters 3 Gas Closure to pin 8 turns on gas This input will override Postflow but if a Preflow time is entered the Preflow cycle will time out before arc initiation 4 Valid arc collector Output is on when the contactor is on and there is less than 50 load volts see Section 4 13 5 Voltage feedback 1 volt DC per 10 volts w reference to pin 11 6 Current feedback 1 volt DC per 100 amperes w reference to pin 11 7 Not used 8 IGND isolation common 9 Valid arc emitter Output is on when the contactor is on and there is less than 50 load volts see Section 4 13 10 Memory enable See Section 4 11 11 Remote control circuit common 12 Chassis common 13 Pulse lockout collector Output is on when in Initial Amperage Initial Slope Final Slope Final Amperage and Pulsed Background time when the pulse frequency is less than 10 Hz see Section 4 13 14 Pulse lockout emitter Output is on when in Initial Amperage Initial Slope Final Slope Final Amperage and Pulse Background time when the pulse frequency is less than 10 Hz see Section 4 13 15 Memory select 0 See Section 4 11 16 Memory select 1 See Section 4 11 17 Command signal from remote control O to 10 volts DC input 18 10 volts DC 19 HF disable Disables high frequency when connected to pin 8 20 Automat
73. dequate capacity to lift and support unit 1 Lifting Eye 2 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 If using lifting forks extend forks beyond op posite side of unit 3 Serial Number Patent Label 4 Rating Label Use rating label to determine input power needs see Section 3 2 5 Line Disconnect Device Locate unit near correct input power supply A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 A Be careful when placing or moving unit over uneven surfaces Location And Airflow 18 in 460 mm Ref 117 264 C 803 900 A 223 259 A 223 275 A OM 2250 Page 17 A Be careful when placing or moving unit over uneven surfaces 4 7 115 Volts AC Duplex Receptacle Supplementary Protector CB1 And Power Switch 1 AC Duplex Receptacle Receptacle RC2 supplies 115 V 10 A of single phase power 2 Supplementary Protector CB1 CB1 protects duplex receptacle from overload If circuit breaker opens the receptacle does not work Press button to reset protector 3 Power On Off Switch 000069800869 008600000006008098800 000000888000000000000000088900000 060800000000080000008080000000008 000000888800000000000000088480008 0000880448880082000
74. e 12 5 Heat Sink Primary Assembly ur RER 213346 HEAT SINK POWER MODULE seee nennen nenn 1 2 RM1 205751 MODULE POWER RESISTOR W PLUG 1 CO 207 451 SCREW 008 32X 50 PAN HD PHL STL PLD SEMS 3 4 RT1 RT3 213 353 THERMISTOR NTC 30K OHM 25 DEG C 8IN LEAD 1 5 MOD1 2 217625 KIT INPUT PRE REGULATOR AND INVERTER MODULE 1 6 PC1 PC2 220 759 CIRCUIT CARD ASSY POWER INTERCONNECT 1 eU sx d sue 200565 SCREW M 5 8X 35 PAN HD PHL STL PLD SEMS 4 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2250 Page 75 LF Hardware is common and not available unless listed 804 136 B Figure 12 6 Wind Tunnel Left Hand w Components Item Dia Part No Mkgs No Description 213 354 Figure 12 6 Wind Tunnel Left Hand w Components Quantity lisser 170 647 BUSHING SNAP IN NYL 1 312 ID X 1 500 MTG HOLE 2 Le uh cedi 218004 LABEL WARNING ELECTRIC SHOCK EXPLODING PARTS 1 END EN 219844 LABEL WARNING ELECTRIC SHOCK EXPLODING PARTSCE 1 3 CR1 206258 RELAY ENCL 24VDC SPST 30A 240VAC 4PIN FLANGE MTG 1 pA ass EEE 145217 SCREW K40X 12 PAN HD PHL STL PLD P
75. e e Ne RE X ot a RC ehe dake A 17 4 6 115 Volts AC Duplex Receptacle Supplementary Protector CB1 And Power Switch 17 4 7 Weld Output Terminals And Selecting Cable Sizes 18 4 8 Remote 14 Receptacle Information Used Without Automation Connection 19 4 9 Automation Goninectionr s 22 RO nern ae he re LENCEREA eG Yd IRR RS 20 4 10 Remote Memory Select Inputs 21 4 11 Automation Selections 2218428284 RL a fn ae saine 21 4 12 Typical Application ocre pb he Late a dada ido 21 4 19 Ga Connections vista Ske lack eats ieee WG a th CII Re MARS Ta 22 4 14 TIG HF Impulse Lift Arct Connections 22 4 15 Stick Connections 4 halte TT M E A C R NA N A NERA CEN DIRE DEAE 23 4 16 Electrical Service Guide 23 4 17 Connecting Input Power 4444444 nennen ernennen nenn 25 TABLE OF CONTENTS SECTION 5 OPERATION oir aa a a aan te 27 Ds Controls coena 2274 RN 27 5 2 Encoder Gontrol esse WU LP Ee R E OPI ET CEA 28 5 3 Amperage Controle une ep A Y RE ERE ne nee ner en ne nn Yn 28 5 4 Ammeter And Parameter Display 22 0 28 5 5 NOltmeter sto eara enin cem A leans trate ficos tata A cm ten tuer ar oh 29 5 6 Polarity
76. eel for other jobs or tungsten can become contaminated causing lower weld quality 2 Tungsten Electrode 3 Flat Diameter of this flat determines amperage capacity Ideal Tungsten Preparation Stable Arc 4 Straight Ground Grind lengthwise not radial Radial Grinding Causes Wandering Arc B Preparing Tungsten For Conventional AC Welding 1 Tungsten Electrode t 2 Balled End e 1 1 1 2 Times Ball end of tungsten by applying AC amper Electrode Diameter age recommended for a given electrode diameter see Section 10 1 Let ball on end 1 5 ofthe tungsten take its own shape SECTION 11 GUIDELINES FOR TIG WELDING GTAW 11 1 Positioning The Torch LA AME Weld current can damage electronic parts in vehicles Discon e RIJ L YA nect both battery cables before welding on a vehicle Place work gt E 3 clamp as close to the weld as possible E L For additional information see your distributor for a handbook on the Gas Tungsten Arc Welding GTAW process 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten according to Sections 10 1 and 10 2 Guidelines The inside diameter of the gas cup should be at least three times the tungsten diameter to provide adequate shielding gas coverage For e
77. elding Make connec tions according to Section 4 15 TIG Lift Arc is an arc starting method in which the electrode must come in contact with the workpiece see Section 5 8 This method can be used with either AC or DC TIG welding Make connections ac cording to Section 4 15 Stick SMAW This method can be used with either AC or DC Stick welding Make connections ac cording to Section 4 16 5 8 Lift Arc And HF TIG Start Procedures Lift Arc Start Method 3 1 2 Touch Seconds Do NOT Strike Like Match Lift Arc Start When Lift Arc button light is On start arc as follows 1 TIG Electrode 2 Workpiece Touch tungsten electrode to work piece at weld start point enable out put and shielding gas with torch trig ger foot control or hand control Hold electrode to workpiece for 1 2 seconds and slowly lift elec trode Arc is formed when electrode is lifted Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output contactor does not energize until after electrode is touching workpiece This allows electrode to touch workpiece with out overheating sticking or getting contaminated Application Lift Arc is used for the DCEN or AC GTAW process when HF Start method is not permitted or to re place the scratch method HF Start When HF
78. en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geant le fil de soudage 43 DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels N que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettreles portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil e Utiliser uniquement des pi ces de rechange Miller Hobart LE RAYONNEMENT HAUTE FREQUENCE HF risque de provoquer des interf rences e Le rayonnement haute fr quence HF peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation e Lutilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr
79. en circuit voltage selected see Section 6 7 VNormal open circuit voltage 75 volts is present while in Stick with normal open circuit voltage selected see Section 6 7 Note This unit is equipped with Auto Line Auto Line is an internal inverter power source circuit that automatically links the power source to any primary input voltage from 190 to 625 volts single or three phase 50 or 60 hertz Also adjusts for voltage spikes within the entire range OM 2250 Page 14 4 2 Volt Ampere Curves Maxstar 700 Volt ampere curves show mini 80 mum and maximum voltage and amperage output capabilities of 70 unit Curves of other settings fall be Stick Max DIG Max tween curves shown 60 950 40 O 30 Ze 156 Dynasty 700 AC LA Stick Min DIG Max 20 Stick Mi 90 ick Min TIG Max 80 E 10 TIG Min 704 0 0 mL BB Stick Max O 100 200 300 400 500 600 700 800 900 60 C Amperes gt 50 N TIG Min O Dynasty 700 DC lt 40 N TIG Max 90 30 Stick Min 80 20 N 10 0 607 SSS 0 100 200 300 400 500 600 700 800 250 AC Amperes 2 40 Stick M Q30 ehr DIG Max 20 Stick Min DIG Max 10 i TIG Min LA TIG Max O 100 200 300 400 500 600 700 800
80. ength of time gas flows before arc ini tiation O O O O Application Preflow is used to purge the weld area and aids in arc starts POST FLOW If the TIG process is ac tive see Section 5 7 use control to set length of time gas flows after welding stops Application fh i Postflow is required to cool tungsten and nen weld and to prevent contamination of tungsten and weld Increase postflow 3 time if tungsten or weld are dark in ap LF Some features shown are OR MONI pearance not available on all models DIG If the DC Stick process is active O Da 1 see Section 5 7 use control to set Dia we amount of DIG When set at 0 short cir cuit amperage at low arc voltage is the K same as normal welding amperage When setting is increased short circuit amperage at low arc voltage increases GAS DIG Application Control helps arc starting or making verti cal or overhead welds by increasing am perage at low arc voltage and reduces electrode sticking while welding PURGE To activate the gas valve and start the purge function push and hold the Gas DIG switch pad for the desired amount of time To set from 1 to 50 sec onds of purge time hold the Gas DIG switch pad while turning the encoder con trol Default is O While Purge is active PUR is shown in the left display and purge time is shown in the right display Pressing any switch pad will end the purge display but gas will continue to flow until t
81. ent is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local c
82. equirements OM 2250 Page 25 4 18 Connecting Input Power Her A Connecting Three Phase Input Power SN Tools Needed a H Q 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 Always connect green or green yel low conductor to supply grounding terminal first and never to a line ter minal See rating label on unit and check input volt age available at site see Section 4 5 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 4 17 Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Con nections 2 Strain Relief Route conductors cord through strain relief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to welding power source ground ing terminal first 5 Welding Power Source Line Terminals Switch S1 6 Input Conductors L1 U L2 V And L3 W
83. essus des vapeurs Ne pas respirer ces va suivantes risques lectriques dans un environnement humide ou si l on peurs porte des v tements mouill s sur des structures m talliques telles que e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de Sols grilles ou chafaudages en position coinc e comme assise ge l arc pour l vacuation des fum es et des gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou Sila ventilation est m diocre porter un respirateur anti vapeurs approu accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser v les quipements suivants dans l ordre indiqu 1 un poste souder DC Lire et comprendre les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un poste souder AC tension vide r duite Dans la plupart des rev tements les nettoyants et les d graisseurs situations l utilisation d un poste souder DC fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir proximi
84. eur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxi ques en cas de soudage OM 2250 Page 5 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provo quer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants ap propri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous vo tre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection LE SOUDAGE peut provoquer un RIZ incendie o
85. factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2250 Page 78 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way C Miller Effective January 1 2006 Equipment with a serial number preface of LG or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY S EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in mate
86. he preset time has timed out Application Purge is used to clear the gas lines OM 2250 Page 35 5 13 AC Waveshape Dynasty Models Only y 4 AC WAVESHAPE 1 AC Waveshape Control Press switch pad until desired function LED is illuminated 2 Encoder Control Set Value 3 Ammeter Displays Value See Section 5 16 for all AC Waveshape param eter ranges Balance AC Balance control is enabled only in AC TIG to set percentage of time polarity is electrode negative Application When welding on oxide forming materials such as aluminum or magnesium excess cleaning is not necessary To produce a good weld only 0 10 in 2 5mm of etched zone along the weld toes is required Use AC Balance to control the etch zone width Joint configuration set up process variables and oxide thickness may affect setting AC Frequency AC Frequency control is en abled only in AC TIG Use control to set AC fre quency cycles per second Application AC Frequency controls arc width and direction al control As AC frequency decreases the arc becomes wider and less focused limiting di rectional control As AC frequency increases the arc becomes narrower and more focused increasing directional control Travel speed can increase as AC frequency increases EN Amperage Use control to select electrode negative amperage value EP Amperage Use control to select electrode positive amperage
87. incorrecte ou impropre constitue un danger e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e Ne pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou l o on risque de tomber Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip une m me borne de sortie de soudage Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indi qu es dans la partie Entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereuse pour la sant e D autres consignes de s curit sont n cessaires dans les conditions e Ne pas mettre sa t te au d
88. ing filler material or to en sure a soft start INITIAL t Initial Time Available with Automation option Only Press control again and turn En coder to set amount of time needed atthe beginning of the weld INITIAL SLOPE t Initial Slope Time Use control to set amount of time that it takes to slope from initial amperage to weld amperage To disable set to 0 4 Amperage Switch Pad Weld Time Available with Au tomation option Only Press Amperage switch pad twice Set desired weld time FINAL SLOPE t Final Slope Time Use control to set amount of time it takes to slope from weld amper age to final amperage To disable set to 0 Application Final Slope should be used while welding materials that are crack sensitive and or to eliminate the crater at the end of the weld FINAL A Final Amperage Used to set amperage to which weld am perage slopes to FINAL t Final Time Available with Automation option Only Press control again and turn En coder to set Final Amperage time OM 2250 Page 34 5 12 Gas DIG Controls Preflow Post Flow DIG Purge 1 Gas DIG Controls Press switch pad until desired function LED is illuminated F 3 2 Encoder Control Set Value 3 Ammeter Displays Value 2 See Section 5 16 for all Adjust parameter ranges PREFLOW If the TIG HF process is ac tive see Section 5 7 and Preflow is shown on the control panel use control to 96 A S Hz set l
89. ing or servic ing unit e Use only genuine Miller Hobart replacement parts H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables u
90. ion enable 1 See Section 4 12 21 Amperage EN common See Section 4 12 22 Amperage EN command See Section 4 12 23 Final slope collector Output is on when in Final Slope see Section 4 13 24 Final slope emitter Output is on when in Final Slope see Section 4 13 25 Automation enable 2 See Section 4 12 26 Amperage EP command Dynasty models only See Section 4 12 27 Amperage EP common Dynasty models only See Section 4 12 28 Polarity Dynasty models only See Section 4 12 OM 2250 Page 21 4 11 Remote Memory Select Inputs 28 Pin Receptacle RC28 Socket Designations 0 No Connection 1 Connected To Ground Pin 8 X Do Not Care Function 10 15 16 Off 0 X X Memory 1 1 0 0 Memory 2 1 1 0 Memory 3 1 0 1 Memory 4 1 1 1 4 12 Automation Selections 28 Pin Receptacle RC28 Socket Designations 0 No Connection 8 X Do Not Care 1 Connected To Ground Pin Connected to pin 8 EP H H Open EN Pin 28 Enables pin 2 functions Balance Final Slope and Pulse outputs are not functional Pin 22 to pin 21 O to 10 volts DC EN amplitude Pin 26 to pin 27 0 to 10 volts DC EP amplitude Pin 28 to pin 8 EP polarity Frequency and Balance Pin 28 not connected to pin 8 EN polarity Frequency and Pin Function 20 21 No automation functions selected 0 0
91. l result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A FIRE OR EXPLOSION hazard d Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit nn LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle z e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow
92. machine Become trained and read the instructions before working on the machine or welding OM 2250 Page 10 3 2 Manufacturer s Rating Labels Non CE Models Manufacture s Rating Label For Dynasty 700 Models Mie G SERIAL NO SERIAL STOCK NO 907101 INPUT PHASE 3 VOLTS 208 230 460 575 AMPS 98 88 43 33 KW 35 Hz 50 60 PHASE 1 VOLTS 208 230 460 575 AMPS 119 105 50 38 KW21 Hz50 60 RATED WELD N OUTPUT PHASE 3 VOLTS 44 AMPS 600 AC DC PHASE 1 VOLTS 38 AMPS 450 AC DC DUTY CYCLE 60 MAX OCV 75 VDC AUXILIARY gt OUTPUT 2 x 1 u60Hz 115V 10A 100 PROTECTED BY ONE OR MORE OF THE FOLLOWING US PATENTS 6103994 6115273 6087628 6548784 6337789 5601471 6809293 6426888 6239407 6107602 6329636 6002103 EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY 223259 D CMM 223 259 D LF For label location see Section 4 5 Manufacture s Rating Label Maxstar 700 Models 7 O Q Miller SERIAL NO SERIAL STOCK NO 907103 INPUT PHASE 3 VOLTS 208 230 460 575 AMPS 89 80 40 31 KW 32 Hz 50 60 PHASE 1 VOLTS 208 230 460 575 AMPS 108 95 45 35 KW 20 Hz 50 60 RATED WELD OUTPUT PHASE 3 VOLTS 44 AMPS 600 DC PHASE 1 VOLTS 38 AMPS 450 DC DUTY CYCLE 60 MAX OCV 75 VDC AUXILIARY gt OUTPUT 2 x 1 u60Hz 115V 10A 100 PROTECTED BY ONE OR MORE OF THE FOLLOWING US PATENTS 6103994 6115273 6087628 6548784 6337789 560147
93. maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEOR
94. miques dont l Etat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres pro bl mes de procr ation A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l tat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l Etat de Californie reconnait qu ils provoquent des can cers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipulation OM 2250 Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Principales normes de s curit Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 si
95. nal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller File a claim for loss or damage during shipment Contact the Delivering Carrier to For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2006 Miller Electric Mfg Co 2006 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com C Miller
96. nit To blow out unit direct airflow through front and back louvers as shown 803 900 A OM 2250 Page 55 7 3 Voltmeter Ammeter Help Displays 30 Series Display Top Module LF All directions are in reference to the front of the unit All circuitry referred to is located inside the unit 1 Typical Voltmeter Ammeter Help Display A 30 series message refers to the top power Source and a 40 series message refers to the bottom power source Only one series message 30 or 40 will be displayed at a time e Help 35 40 Display Indicates a failure in the thermal protection circuitry located in the input inductor of the unit Contact a Factory Authorized Service Agent if this display is shown Help 31 41 Display Indicates a malfunction in the primary pow er circuit caused by an overcurrent condi tion in the primary IGBT switching circuit Contact a Factory Authorized Service Agent if this display is shown Help 32 42 Display Indicates a failure in the thermal protection circuitry located on the left side of the unit Contact a Factory Authorized Service Agent if this display is shown Help 33 43 Display Indicates the left side of the unit has over heated The unit has shut down to allow the fan to cool it see Section 4 3 Operation will continue when the unit has cooled 40 Series Display Bottom Module Help 34 44 Display Indicates a failure in the thermal protection circuitr
97. nnect remote control to Remote 14 receptacle see Sec tion 4 9 5 Gas In Connection Connect gas hose from gas supply to gas in fitting see Section 4 14 Tools Needed SIG 11 16 in 21 mm for CE units 803 915 A OM 2250 Page 23 4 16 Stick Connections Her A Turn off power before making connections LF Connections shown are for Dynas ty models For Maxstar models re verse work and electrode connec tions 1 Work Weld Output Terminal Connect work lead to work weld output terminal 2 Electrode Weld Output Terminal Connect electrode holder to electrode weld output terminal 3 Remote 14 Receptacle If desired connect remote control to Re mote 14 receptacle see Section 4 9 803 916 A 4 17 Electrical Service Guide A Dynasty 700 NOTE gt Actual input voltage cannot exceed 1096 of indicated required input voltage If actual input voltage is outside of this range no output is available Three Phase Input Voltage 208 230 400 460 575 Input Amperes At Rated Output 97 88 51 44 35 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 110 100 60 50 40 Normal Operating 3 150 125 80 70 50 Min Input Conductor Size In AWG 4 4 4 8 8 10 Max Recommended
98. nput voltage outside acceptable range of variation see Section 4 17 Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 4 3 Erratic or improper weld output Use proper size and type of weld cable see Section 4 8 Clean and tighten all weld and gas connections No 115 volts ac output at duplex recep tacle Reset circuit breaker CB1 see Section 4 7 Fan not operating Note Fan only runs when cooling is necessary Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor Wandering arc Use proper size tungsten see Section 10 1 Use properly prepared tungsten see Section 10 2 Reduce gas flow rate Tungsten electrode oxidizing and not re maining bright after conclusion of weld Shield weld zone from drafts Increase postflow time see Section 5 12 Check and tighten all gas fittings Water in torch Refer to torch manual OM 2250 Page 57 SECTION 8 ELECTRICAL DIAGRAM D sepu ihe RC Rofo i 62 E zZ 1 i 50 0 Ld t Ge
99. odes Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections APA This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more
100. ol is not available in level 2 Includes all the functions of level 1 plus Memory Polarity and Process Selection see Sections 5 6 and 5 7 When parameter change or selection is lim ited by lock level 2 L 4 is displayed as a re minder Level 3 NOTE Remote amperage control is not available in level 3 Includes all the functions of levels 1 and 2 plus the following 10 adjustment of preset TIG or Stick Weld Amps Select desired process TIG or Stick and use Encoder control to adjust amperage 10 of preset amperage value up to the limits of the machine If operator tries to go beyond the 10 the amperage right meter will display 3 as a reminder Pulser ON Off Control Gives operator the ability to turn on off the Pulser control When parameter change or selection is lim ited by lock level 3 L J is displayed as a re minder Level 4 Includes all the functions of levels 1 2 and 3 plus the following Remote Amperage Control Allows operator to use remote amperage control if desired Remote control operates from minimum to maximum of preset am perage value Connect remote control de vice according to Section 4 9 When parameter change or selection is lim ited by lock level 4 L 4 is displayed as a re minder OM 2250 Page 52 6 6 Setting Unit To Display PPP While Pulse Welding 5 4 cr xum xe IL V S H O O O
101. or Lift Arc without the use of a remote control see Section 6 21 2 OnLED Blue On LED is lit whenever Output is on OM 2250 Page 32 5 10 Pulser Control O O O O zt Percent Peak Time Control Setting Pulsed Output Waveforms ea PPS Balanced 50 Bkg Amp Peak Amp More Time At Peak Amperage 80 More Time At A Background 20 Amperage 1 Pulser Control Pulsing is available while using the TIG process Controls can be ad justed while welding Press switch pad to enable pulser ON When illuminated this LED in dicates the pulser is on Press switch pad until desired pa rameter LED is illuminated To turn Pulser off press and release switch pad until the On LED turns off 2 Encoder Control Set Value 3 Ammeter Displays Value See Section 5 16 for all Pulser pa rameter ranges PPS Pulses Per Second or Pulse Frequency Used to determine ap pearance of weld bead PEAK t The percentage of each pulse cycle at the peak amperage level BKGND A Background Amps Use Background Amps to set the low pulse of the weld amperage which cools the weld puddle and affects overall heat input Background Amps is a percentage of peak amperage 4 Pulsed Output Waveforms Example shows affect changing the Peak Time control has on the pulsed
102. ow Help 74 Display Unit not ready Primary circuit bus not up to full power Help 15 Display Indicates a primary overpower condition Output current is decreased to limit primary power draw Depress any switch pad and turn encoder or strike an arc to clear the last help condition Help 16 Display Secondary clamp voltage too high Help 20 Display Indicates that the power supplies for the pri mary drives have failed Contact a Factory Authorized Service Agent if this display is shown e Help 27 Display Indicates voltage or current feedback has been detected with contactor off Contact a Factory Authorized Service Agent if this display is shown e Help ze Display Voltage and current not present with con tactor on Contact a Factory Authorized Service Agent if this display is shown e Help 24 Display Indicates a power supplies for the control and interface board PC6 failure OM 2250 Page 56 7 4 Troubleshooting Trouble Remedy No weld output unit completely inoperative Place line disconnect switch in On position see Section 4 18 Check and replace line fuse s if necessary or reset circuit breaker see Section 4 18 Check for proper input power connections see Section 4 18 No weld output meter display On If using remote control be sure correct process is enabled to provide output control at Remote 14 receptacle see Sections 5 1 and 4 9 I
103. rial or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated ntellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HFUnits Grids Spot Welders Load Banks Arc Stud
104. ry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body Boo m Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre_som _3 05 Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s Symbole graphique d avertissement Attention Cette pro A c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints A Indique un message de s curit particulier Ce groupe de symboles signifie Avertissement Attention Risques a d p d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci
105. s autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de VOUS 5 Connecter la pince sur la piece aussi pr s que possible de la sou dure En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur medecin avant de souder ou d approcher des op rations de soudage Si le m de cin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 DEFINITIONS CE Models Only 3 1 Warning Label Definitions Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from welding electrode or wiring can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 8 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes
106. sing line filters or shielding the work area For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm OM 2250 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magne
107. ss Am lt perage switch pad once meter A l i LED turns on and turn Encoder to set spot amperage Press Amperage switch pad again meter S LED S Hz lights and turn Encoder to set spot O O time 1 25 seconds Default is 1 second Application To provide a timed weld for tacking and thin sheet joining OM 2250 Page 37 5 15 Memory Program Storage Locations 1 4 TES lt AN 01 Ji DO O4 V A S m e o o o o ist ofl oan E SEL But L gans E ite 2 e CM LM ut BKGND A EA A Cor rm oz al lak jel Ich thy ias Na a Gm EG p p ris OUTPUT PULSER SEQUENCER GASDIQ AC WAVESHAPE Memory Locations 1 4 Available On Dynasty Models Only LF Some features shown are not available on all models TIG HF or Lift AC And Stick And TIG HF or Lift DC And Stick Each memory location 1 thru 4 can store parameters for both polarities and each polarity can store parameters for both pro cess TIG or Stick for a total of 16 programs 1 Memory Program Storage 1 4 Switch Pad 2 Polarity Switch Pad Dynasty Only 3 Process Switch Pad To create change or recall a welding parameters program proceed as follows First press Memory switch pad until the desired program storage loca tion 1 4 LED is illumin
108. t Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l air et abaisser le niveau d oxyg ne provo l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de quant des blessures ou des accidents mortels S assurer que l air de s curit respiration ne pr sente aucun danger e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situ s proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de pulv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute EN 3 RR ment toxiques et irritants Toujours v rifier la terre du cordon d alimentation V rifier et s assurer Ne pas souder des m taux munis d un rev tement tels que l acier gal que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions vanis plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirat
109. t tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes OM 2250 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 telephone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Maintenir les c bles ensemble en les tordant ou en les enveloppant 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c ble
110. t un ex tincteur proximit DES PARTICULES VOLANTES peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 2250 Page 6 distance e Les porteurs d un stimulateur cardiaque doi vent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma gee elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessi ve des chocs m caniques des dommages physiques du lai tier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support sta tionnaire ou dans un porte bouteilles pour les emp cher de tom
111. tal Building Panel Bonding Methods Bolt or weld building panels together install copper straps or braided wire across seams and ground frame 10 Windows and Doorways Cover all windows and doorways with grounded copper screen of not more than 1 4 in 6 4 mm mesh 11 Overhead Door Track Ground the track OM 2250 Page 66 SECTION 10 SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING ac dc gtaw 2 2004 gt o A Whenever possible and practical use DC weld output instead of AC weld output 10 1 Selecting Tungsten Electrode Wear Clean gloves To Prevent Contamination Of Tungsten Amperage Range Gas Types Polarity Electrode Diameter DC Argon Electrode DC Argon Elec AC Argon AC Argon ER Po rn Balanced Wave 2 Ceria Orange Band 1 5 Lan thanum Gray Band Or 2 Thorium Red Band Alloy Tungstens 010 Up to 25 x Up to 20 Up to 15 020 15 40 15 35 5 20 040 25 85 20 80 20 60 1 16 50 160 10 20 50 150 60 120 3 32 135 235 15 30 130 250 100 180 1 8 250 400 25 40 225 360 160 250 5 32 400 500 40 55 300 450 200 320 3 16 500 750 55 80 400 500 290 390 1 4 750 1000 80 125 600 800 340 525 Pure Tungsten Green Band 010 e Up to 15 Up to 10 020 i 5 20 10 20 040 Ei 10 60 20 30 1 16 10 20 50 100 30 80 3 32 15 30 100 160 60 130 1 8 x 25 40 150 210 100 180 5 32
112. te Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de souda ge causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soien
113. ted and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 2250 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike fl
114. ter imm diatement l appareil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique peut g ner le fonctionnement d appareils lectroniques comme des ordinateurs et des robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chi
115. tic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 2250 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus t
116. tput is available Three Phase Input Voltage 208 230 400 460 575 Input Amperes At Rated Output 89 80 46 40 32 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 110 100 50 50 40 Normal Operating 3 125 125 70 60 50 Min Input Conductor Size In AWG 4 4 6 8 8 10 Max Recommended Input Conductor Length In Feet Meters es in id e 60 Min Grounding Conductor Size In AWG 4 6 6 8 10 10 Single Phase Input Voltage 208 230 460 575 Input Amperes At Rated Output 106 96 48 38 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 125 110 50 45 Normal Operating 3 150 150 70 60 Min Input Conductor Size In AWG 4 4 4 8 10 Max Recommended Input Conductor Length In Feet Meters 28 35 ES i5 Min Grounding Conductor Size In AWG 4 6 6 8 10 Reference 2005 National Electrical Code NEC includes article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable r
117. u une explosion Le soudage effectu sur des conteneurs ferm s tels DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche e Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter les br lures que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peuvent provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion une surchauffe ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque rester danger EF D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soi gneusementavec des protections homologu es Ne pas souder dans un endroit o des tincelles peuvent tomber sur des substances inflammables Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le
118. ue O4 v As te O O O O L2 o In oL o ae PPS INTALA EN AMPERAGE o ra oBut o FL lour o Ku o TP TIG HF IMPULSE RMT STD PEAKt INITIAL SLOPE t EP AMPERAGE o ot oat of lon lo lom Press switch pads in the d TEE EON n osent gt S ect ON S s parce hand combinations shown to oV Jo amp o l o 1 oda D PARA ON access the different lockout levels L1 L2 or L3 EI am a gB Euge ee Level 4 NOTE Before activating lock out levels be sure that all procedures and parameters are established Parameter adjustment is limit ed while lock out levels are active Level 1 NOTE Remote amperage control is not available in level 1 TIG Output Selection If either the TIG HF Impulse or TIG Lift Arc process see Section 5 7 was active when lockout level 1 was activated the operator can choose between RMT STD Remote Standard or RMT 2T HOLD Remote 2T Hold see Section 5 9 The On function is also available if TIG Lift Arc was active If RMT 2T HOLD was reconfigured see Section 6 2C prior to lockout level 1 activa tion the reconfigured output mode 4T 4T momentary mini logic or spot is available to the operator instead of RMT 2T Stick Output Selection If the Stick process was active when lock out level 1 was activated the operator can choose between RMT STD or On When parameter change or selection is lim ited by lock level 1 is displayed as a reminder Level 2 NOTE Remote amperage contr
119. unctions A Accessing Lockout Capability See Section 5 1 for explanation of controls referred to in all of Section 6 5 There are four 1 4 different lockout levels Each successive level allows the operator more flexibility NOTE Before activating lockout levels be sure that all procedures and parameters are established Parameter adjustment is limited while lockout levels are active 1 Amperage A Switch Pad 2 Gas DIG Switch Pad 3 Power Switch To access lockout screens turn On power switch and then before the software version clears the meters push and hold the Amperage and Gas DIG switch pads until software version number clears me ters 4 Lockout Off Upon power up as described the meter and Amperage A switch pad LED s light and the meter display will be as shown for a lockout off condition 5 Encoder Control To turn On the lockout feature proceed as follows Pressing Amperage A switch pad will toggle between the meter and S LED s Toggle switch pad until LED is on Turn Encoder control to select a three digit lockout number Number will appear on the voltage left meter Select any number from 227 thru 552 IMPORTANT remember this three digit number as you will need it to turn the lockout feature off 000 bos V A S Hz Qv O O ux 7 i 000 LL 8 3 GRY V A S Hz Gr doe Q ud Lu Rear Panel Toggle Amperage A switch pad to light the meter S
120. wn set of start parameters Rear Panel Press the Process switch pad to select the desired process TIG HF Impulse or TIG Lift Arc for your application see Section 5 7 The parameter values are the same for both processes and any changes made to the values in one process are duplicated in the other process 6 Output Switch Pad Press Output switch pad to select desired type of control see Section 5 9 Proceed to Section B C and or D To save changes and exit Advanced Func tions turn power off OM 2250 Page 41 B Changing Programmable TIG Start Polarity Dynasty Models Only 1 Amperage Switch Pad To adjust TIG Start Polarity press Amper 3 un 2 CE eee JLL V S e OO O O 1 played on meters and can be changed age switch pad Switch pad LED turns on see Section 5 16 by turning the Encoder Encoder Gonirol and meter LED turns on The current control Amps Meter Start Polarity SELI E J or SEL EP is dis Changing Programmable TIG Start Amperage 3 CE 5n Se JILL LL we A 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust TIG Start Amperage press Am perage switch pad Switch pad LED turns on and meter A LED turns on The current Start Amperage is displayed on the amps meter and can be adjusted see Section 5 16 by turning the Encoder control D Changing Programmable Start Time um 5EL Li 1
121. xample if tungsten is 1 16 in diameter gas cup should be a minimum of 3 16 in diameter Tungsten extension is the distance the tungsten extends out gas cup of torch The tungsten extension should be no greater than the inside diameter of the gas cup 1 16 in 3 16 in Bottom View Of Gas Cup Arc length is the distance from the tungsten to the workpiece Ref ST 161 892 OM 2250 Page 68 11 2 Torch Movement During Welding Tungsten Without Filler Rod Welding direction y EA 75 gt lt lt U pd 1 Z LID A 7 ZZZ A Y ZL A Form pool Tilt torch Move torch to front of pool Repeat process Tungsten With Filler Rod Welding direction Leaf er amp D y gan 1 7 ZZ A lt gt Z ZZA VZ Form pool Tilt torch Add filler metal ZZZZZZ2ZZZA UZAZZADIZA Remove rod Move torch to front of pool Repeat process ST 162 002 B 11 3 Positioning Torch Tungsten For Various Weld Joints Butt Weld And Stringer Bead T Joint 20 90 E Me Ae Y 159 10 Lap Joint Corner Joint 20 40 90 A de LA 3 Y 3 yd 15 15 30 ST 162 003 S 0792 OM 2250 Page 69 SECTION 12 PARTS LIST LF Hardware is common and not available unless listed Dynasty 700 illustrated 804 133 C Figure 12
122. y located on the right side of the unit Contact a Factory Authorized Service Agent if this display is shown Help 35 45 Display Indicates the right side of the unit has over heated The unit has shut down to allow the fan to cool it see Section 4 3 Operation will continue when the unit has cooled Help 5 Display Indicates that the input voltage is too low and the unit has automatically shut down Operation will continue when the voltage is within the operating range 10 Have an electrician check the input voltage if this dis play is shown e Help 7 Display Indicates that the input voltage is too high and the unit has automatically shut down Operation will continue when the voltage is within the operating range 10 Have an electrician check the input voltage if this dis play is shown Help 8 Display Indicates a malfunction in the secondary power circuit of the unit There is a high open circuit condition Contact a Factory Authorized Service Agent if this display is shown Help 39 49 Display Indicates the input inductor of the unit has overheated Contact a Factory Authorized Service Agent if this display is shown Help 10 Display Indicates torch trigger is depressed Re lease trigger to continue Help 12 Display Indicates a non allowable set up on the front panel Help 13 Display Automation Models Only Output disable open causing weld output to Stop but gas continues to fl

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