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OM-2240 Page 67

SECTION 12

−

STICK WELDING (SMAW) GUIDELINES

12-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)

207 694-A

Front Panel

Correct front panel display for basic

Stick DCEP welding.

For all front panel switch pad
controls: press switch pad to

turn on light and enable

function.

NOTE:

Gray on nameplate indi-

cates a Stick function (see Section

5-1 for description of controls).

Summary of Contents for DYNASTY 200 DX

Page 1: ...e at www MillerWelds com Processes Description TIG GTAW Welding Stick SMAW Welding OM 2240 207688K March 2005 115 230 400 460 Volt Models W AutolineR Arc Welding Power Source Dynasty 200 SD And DX R A...

Page 2: ...ue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the...

Page 3: ...eld Output Terminals And Selecting Cable Sizes 18 4 7 Remote 14 Receptacle Information 18 4 8 Gas Connections 19 4 9 TIG HF Impulse Lift Arct Connections 19 4 10 Stick Connections 20 4 11 Electrical S...

Page 4: ...Positioning The Torch 63 11 3 Lift ArcE And HF TIG Start Procedures 64 11 4 Torch Movement During Welding 65 11 5 Positioning Torch Tungsten For Various Weld Joints 66 SECTION 12 STICK WELDING SMAW GU...

Page 5: ...tromagnetic Capability Directives 89 336 92 31 EEC Standards Safety Requirements for Arc Welding Equipment part 1 EN 60974 1 1990 Arc Welding Equipment Part 1 Welding Power Sources IEC 974 1 December...

Page 6: ...Notes...

Page 7: ...hat cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power c...

Page 8: ...lding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane light...

Page 9: ...ng a qualified electrician prompt ly correct any interference problem resulting from the installa tion D If notified by the FCC about interference stop using the equipmentat once D Have the installati...

Page 10: ...e 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Su...

Page 11: ...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 D Pour ex cuter les branchements d entr e fixer d abord l...

Page 12: ...ue des gants en cuir une chemise en tissu pais des pantalons sans revers des chaussures montantes et un masque D Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au but...

Page 13: ...s et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de causer des interf rences D Le rayonnement haute fr quence peut causer des interf rences avec les quipements de radio navigat...

Page 14: ...andards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pitts...

Page 15: ...se 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 f...

Page 16: ...is applied failed parts can explode or cause other parts to explode 7 Flying pieces of parts can cause injury Always wear a face shield when servicing unit 8 Always wear long sleeves and button your c...

Page 17: ...8 16 18 X 2 U I 2 EN 60974 1 1A 10V 50 60 Hz 50 60 Hz 100 110 24 4 25 2 130 60 20 200 28 U 80V o 1A 20V 80V o U 32 25 16 35 eff max I I 1 1 IP23 1 1 f1 f2 10 21 3 50 60 Hz 6 12 3 50 60 Hz 5 10 3 50 60...

Page 18: ...ional Load Voltage U1 Primary Voltage IP Degree Of Protection I1max Rated Maximum Supply Current I1eff Maximum Effective Supply Current U0 Rated No Load Voltage Average Pulse Background Amperage Initi...

Page 19: ...A 16 VDC 60 Duty Cycle 1 200 80 5 10 15 8 0 23 7 9 25 3 6 0 05 3 6 0 02 Single Phase Stick Process 100 A 24 VDC 60 Duty Cycle 1 200 80 5 10 31 3 0 42 3 6 0 05 3 6 0 03 Single Phase TIG Process 140 A...

Page 20: ...20 40 60 80 100 120 140 0 50 100 150 200 250 Amperes Volts Dig Max Stick TIG Min Stick Max TIG Max 230VAC Single Phase Input DC Output 0 20 40 60 80 100 120 140 0 50 100 150 200 250 Amperes Volts Sti...

Page 21: ...0 20 40 60 80 100 120 140 0 50 100 150 200 250 Amperes Volts Stick Max TIG Max Stick TIG Min 230VAC Single Phase Input AC Output 0 20 40 60 80 100 120 140 0 50 100 150 200 250 Amperes Volts Stick Max...

Page 22: ...welding Y Exceeding duty cycle can damage unit and void warranty 130 A 60 Duty Cycle For Stick Process Other Voltages 6 Minutes Welding 4 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle M...

Page 23: ...803 428 A 2 21 in 533 mm 13 3 8 in 333 mm 7 9 16 in 192 mm Dimensions And Weight SERIAL NO STOCK NO EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY 48 5 lb 22 0 kg S S 20 60 100 120 150 200 14 8 16 18 X 2...

Page 24: ...ect weld cable size for pulsing application at peak amperage value S 0007 E 4 7 Remote 14 Receptacle Information Socket Socket Information A J B K I 15 VOLTS DC A Contactor control 15 volts dc B C L N...

Page 25: ...g on rear of unit Tools Needed 3 2 4 1 11 16 1 1 8 in 21 29 mm 4 9 TIG HF Impulse Lift Arct Connections 803 430 a Y Turn off power before mak ing connections 1 Electrode Weld Output Terminal Connect T...

Page 26: ...e Phase 60 Duty Cycle Three Phase 60 Duty Cycle Input Voltage 115 230 230 400 460 Input Amperes At Rated Output 28 20 12 3 7 6 6 0 Max Recommended Standard Fuse Rating In Amperes1 Normal Operating 2 3...

Page 27: ...moving cover to relink the power source For Three Phase Operation 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Green Or Green Yellow Grounding Conductor 4 Disconnect Devic...

Page 28: ...ver to relink the power source 1 Black And White Input Conductor L1 And L2 2 Red Input Conductor 3 Green Or Green Yellow Grounding Conductor 4 Insulation Sleeving 5 Electrical Tape Insulate and isolat...

Page 29: ...der control in conjunction with appli cable front panel function switch pads to change values for that function See Section 5 2 2 Ammeter And Parameter Display See Section 5 4 3 Voltmeter See Section...

Page 30: ...Press Amperage switch pad and turn Encoder control to set weld amperage Weld amperage setting is also peak amperage when Pulser function is active see Section 5 9 1 2 3 Or Or 5 4 Ammeter And Parameter...

Page 31: ...tage is dis played if power is on and output is available 1 5 6 Polarity Control Dynastyt Models Only 1 Polarity Control Press switch pad until desired LED is illuminated DC Machine is set to DCEN dir...

Page 32: ...te Trigger Standard when the operator desires to use a foot pedal or finger amperage control see Section 6 2A NOTE When a foot or finger remote current control is connected to the welding power source...

Page 33: ...rage which cools the weld puddle and af fects overall heat input Background Amps is set as a percentage of peak amperage 4 Pulsed Output Waveforms Example shows affect changing the Peak Time control h...

Page 34: ...while GTAW welding to assist in preheat ing cold material prior to depositing filler material or to ensure a soft start INITIAL t Initial Time LX Models Only Press control again and turn Encoder to se...

Page 35: ...event contamination of tungsten and weld Increase postflow time if tungsten or weld are dark in ap pearance DIG If the DC Stick process is active see Section 5 7 use control to set amount of DIG When...

Page 36: ...ct setting AC Frequency AC Frequency Control is enabled only if AC TIG process is selected Use control to set AC frequency cycles per sec ond Application AC frequency controls bead width and direction...

Page 37: ...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 n...

Page 38: ...the software version clears the meters and hold the switch pads until soft ware version clears the meters Upon power up as described the TIG Im pulse Postflow DIG and meter S LED s turn on and the fac...

Page 39: ...DC STICK 150 A 110 A 150 A 110 A 5 200 Amps 5 200 Amps 1 200 Amps 1 200 Amps Spot Time 1 0 S 0 1 25 0 Seconds PULSER PPS PEAK t BKGND A Off 100 Hz 40 25 ON OFF Dual Range And Resolution 0 1 9 9 10 500...

Page 40: ...ing Unit To Factory Default Settings 1 Process Switch Pad 2 Output Switch Pad 3 Adjust Switch Pad 4 Power Switch To reset all welding power source functions to original factory settings lockout featur...

Page 41: ...erage switch pads before the software version clears the meters Hold switch pads until software version clears the meters and SEL EP or SEL EN appears 4 Memory Switch Pad If Equipped Press Memory swit...

Page 42: ...an be adjusted see Section 5 16 by turning the Encoder control To change Start Amperage proceed to Section C Or Or 1 C Changing Programmable TIG Start Amperage All Models 1 Amperage Switch Pad 2 Encod...

Page 43: ...Pad 2 Encoder Control 3 Amps Meter To adjust Programmable Start Time pro ceed as follows Press Amperage switch pad and meter S LED turns on The current Start Time is displayed on the amps meter and ca...

Page 44: ...igger 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 not by the w...

Page 45: ...OM 2240 Page 39 Notes...

Page 46: ...the meters Hold the switch pads until software version clears the meters and SEL H 2 SEL SPO SEL H 4 SEL H4L SEL H 3 or SEL H4E appears 4 Encoder Control Turn Encoder to change functions Ac tive func...

Page 47: ...G 5 SEL H 4 SEL H4L SEL SPO 4T DX LX and CE Models SEL H4E 4T Momentary See Section 6 2F for operation for operation for operation for operation for operation See Section 6 2D See Section 6 2E DX LX a...

Page 48: ...te 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 Use 4T trigger method when the functio...

Page 49: ...mote 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 level...

Page 50: ...lled by the welding power source Application Use 4T Momentary trigger meth od when the functions of a re mote current control are desired but only a remote on off control is available SEL H4E 4T Momen...

Page 51: ...While in Spot Control Se quencer settings will be ignored and will not be programmable NOTE When a remote switch is connected to the welding power source use the remote switch to control the weld cycl...

Page 52: ...Trigger Operation Voltage V Current A Current A Touch Stick Lift Stick Touch Current Initial Amperage Initial Slope Main Amperage Touch Tungsten Lift Tungsten Slightly Lift Tungsten Electrode Electrod...

Page 53: ...f 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 ini...

Page 54: ...on power up as described above 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 m...

Page 55: ...ct any number from 001 thru 999 IMPORTANT remember this three digit number as you will need it to turn the lockout feature off Toggle Amperage A switch pad to light the meter S LED You may now select...

Page 56: ...t level 1 activation 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 lockout...

Page 57: ...ay L 3 as a re minder Pulser ON Off Control Gives operator the ability to turn on off the Pulser control When parameter change or selec tion is limited by lock level 3 L 3 is displayed as a reminder L...

Page 58: ...SEL or SEL PPP appears 4 Encoder Control 5 PPP Meter Display Turn Encoder to change between stan dard and PPP meter display When the PPP meter display feature is active while pulse welding the PPP wi...

Page 59: ...SEL noc appears 5 Encoder Control 6 Meter Display Turn Encoder to change between low OCV SEL Loc and normal OCV SEL noc Active selection is displayed on the meters When Stick low OCV is selected open...

Page 60: ...ean and tighten weld terminals Replace Damaged Gas Hose 3 Months Repair Or Replace Cracked Cables And Cords 6 Months Blow out inside During heavy service clean monthly Y Do not remove case when blowin...

Page 61: ...ntinue when the unit has cooled 4 Help 4 Display Indicates an open in the thermal protection circuitry located on the top heat sink Con tact a Factory Authorized Service Agent if this display is shown...

Page 62: ...air or replace remote control Unit overheated Allow unit to cool with fan On see Section 4 4 Erratic or improper weld output Use proper size and type of weld cable see Section 4 6 Clean and tighten al...

Page 63: ...OM 2240 Page 57 SECTION 8 ELECTRICAL DIAGRAMS Figure 8 1 Circuit Diagram 209 602 D...

Page 64: ...onduit sections using copper straps or braided wire Ground conduit every 50 ft 15 m 5 Water Pipes And Fixtures Ground water pipes every 50 ft 15 m 6 External Power Or Telephone Lines Locate HF source...

Page 65: ...200 320 3 16 500 750 55 80 400 500 290 390 1 4 750 1000 80 125 600 800 340 525 Typical argon shielding gas flow rates are 15 to 35 cfh cubic feet per hour Not Recommended The figures listed are intend...

Page 66: ...become contami nated causing lower weld quality 3 Ideal Tungsten Preparation Stable Arc 2 1 2 Times Electrode Diameter 1 2 1 Stable Arc 2 Flat Diameter of this flat determines amperage capacity 3 Grin...

Page 67: ...set 15 seconds of Post Flow time Press AC Waveshape switch pad until Balance LED is lit Turn Encoder control to set desired Balance 65 80 Press AC Waveshape switch pad until AC Frequency LED is lit Tu...

Page 68: ...til RMT STD LED is lit Press Adjust switch pad until Post Flow LED is lit Turn Encoder control to set 8 seconds of Post Flow time Press Amperage A switch pad until LED is lit Turn Encoder control to s...

Page 69: ...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 Se...

Page 70: ...de 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 contam...

Page 71: ...02 B Tungsten Without Filler Rod Tungsten With Filler Rod Form pool Tilt torch Move torch to front of pool Repeat process 75 75 Welding direction Form pool Tilt torch Add filler metal Move torch to fr...

Page 72: ...Om 2240 Page 66 11 5 Positioning Torch Tungsten For Various Weld Joints ST 162 003 S 0792 70 70 90 20 20 10 20 70 40 30 20 70 90 20 Butt Weld And Stringer Bead T Joint Lap Joint Corner Joint...

Page 73: ...ct Current Electrode Positive 207 694 A 1 Front Panel Correct front panel display for basic Stick DCEP welding For all front panel switch pad controls press switch pad to turn on light and enable func...

Page 74: ...7018 7024 Ni Cl 308L 50 100 150 200 250 300 350 400 450 ELECTRODE DC AC POSITION PENETRATION USAGE MIN PREP ROUGH HIGH SPATTER GENERAL SMOOTH EASY FAST LOW HYDROGEN STRONG SMOOTH EASY FASTER CAST IRO...

Page 75: ...th correct amperage will give a sharp crackling sound 7 Slag Use a chipping hammer and wire brush to remove slag Remove slag and check weld bead before mak ing another weld pass Tools Needed 1 4 3 5 2...

Page 76: ...12 7 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 12 8 Good Weld Bead Characteristics...

Page 77: ...orrect Angle 12 10 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a we...

Page 78: ...4 12 12 Lap Joint S 0063 S 0064 1 Electrode 2 Single LayerFillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fo...

Page 79: ...Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface bef...

Page 80: ...dirt from work surface before welding 12 18 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Caus...

Page 81: ...llel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 12 22 Troubleshooting Distortion Distortion contraction of weld met...

Page 82: ...e 76 SECTION 13 PARTS LIST Figure 13 1 Main Assembly 803 395 D Hardware is common and not available unless listed 5 29 4 1 17 600 614 31 14 10 32 2 6 8 402 615 13 25 28 11 12 3 400 401 7 19 18 16 403...

Page 83: ...IC 2 29 185835 LABEL WARNING ELECTRIC SHOCK EXPLODING PARTS 1 31 155436 LABEL GROUND PROTECTIVE EARTH 1 32 182826 LABEL WARNING ELECTRIC SHOCK POWER CORD 1 39 C9 213911 CAPACITOR ASSY CER DISC 0033 UF...

Page 84: ...LEADS PLUG 14 PIN 1 8 202553 RECEPTACLE TWIST LOCK FEMALE POWER 2 9 193649 FTG GAS BARBED 1 4 TBG 5 8 18 FEMALE 1 11 185712 INSULATOR BULKHEAD FRONT 2 12 185713 INSULATOR BULKHEAD REAR 2 13 185714 WAS...

Page 85: ...IEF 450 709 ID X1 608 MTG HOL 1 5 193649 FTG GAS BARBED 1 4 TBG 5 8 18 FEMALE 1 5 193650 FTG GAS BARBED 1 4 TBG 3 8 19 BSPP MALE CE MODELS ONLY 1 6 211165 BRACKET HEATSINK SUPPORT 1 600 198245 NUT CON...

Page 86: ...CT 1 5 197987 HOSE NPRN BRD NO 1 X 250 ID X 11 000 1 6 CR1 198549 RELAY ENCL 24VDC SPST 35A 300VAC 4PIN FLANGE MTG 1 7 112863 FTG HOSE BRS BARBED M 1 4 TBG X 5 8 18 SAE FLARE 1 8 209991 ASSY OUTPUT IN...

Page 87: ...608 602204 WASHER TOOTH 195IDX0 410ODX 025T STL PLD EXT 10 B 2 609 137761 NUT 750NPT 1 31HEX 27H NYL BLK 1 611 136343 SCREW K50X 20 PAN HD PHL STL PLD PT THREAD FORMING 2 612 099273 SCREW 008 18X 62 P...

Page 88: ...210568 COIL INDUCTOR 14T 1 12 109056 CORE FERRITE E 2 164 LG X 1 094 HIGH X 826 WIDE 1 13 196512 BRACKET INDUCTOR MOUNTING 1 14 196514 GASKET INDUCTOR MOUNTING 1 602 154408 BUSHING SNAP IN NYL 562 ID...

Page 89: ...2 PM3 213179 TRANSISTOR IGBT KIT 2 6 210278 BUS BAR POSITIVE 2 7 199952 DIODE POWER MODULE 50 AMP 600 V 1PH FAST RECOVE 1 8 210280 BUS BAR NEGITIVE 1 9 210279 BUS BAR OUTPUT 2 10 PC11 208060 CIRCUIT C...

Page 90: ...em 5 Quantity Description Part No Dia Mkgs 207 689 Item No 1 207255 BASE 1 2 019663 MOUNT NPRN 15 16ODX3 8REC 3 16X3 8 4 3 211478 INSULATOR BASE 1 To maintain the factory original performance of your...

Page 91: ...nd Blankets APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Co...

Page 92: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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