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Miller Dynasty 400, Owner'S Manual

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Miller Dynasty 400 Owner'S Manual Download Page 83

OM-275857 Page 73

Figure 12-7. Maxstar 800 Circuit Diagram (Page 1 of 2)

Summary of Contents for Dynasty 400

Page 1: ...MAW Welding Description 208 575 Volt Models w Auto Line 380 575 Volt Three Phase w Auto Line CE Arc Welding Power Source For product information Owner s Manual translations and more visit www MillerWe...

Page 2: ...hat meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety Precautio...

Page 3: ...CTION 5 INSTALLATION 21 5 1 Selecting A Location 21 5 2 Weld Output Terminals 22 5 3 Selecting Cable Sizes1 22 5 4 Remote 14 Receptacle Information 23 5 5 Simple Automation Application 23 5 6 Automati...

Page 4: ...ossible Sources Of HF Interference 75 13 3 Recommended Installation To Reduce HF Interference 76 SECTION 14 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES 77 14 1 Selec...

Page 5: ...on 2019 1784 Ecodesign requirements for energy related products 2011 65 EU and amendment 2015 863 Restriction of the use of certain hazardous substances in electrical and electronic equipment Standard...

Page 6: ...Regulations 2016 S I 2012 3032 Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012 Standards EN IEC 60974 1 2018 A1 2019 Arc welding equipme...

Page 7: ...d until setting options welding programs are changed Occupational exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required...

Page 8: ...are changed Occupational exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required minimum distances apply Occupational expo...

Page 9: ...re changed Occupational exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required minimum distances apply Occupational expos...

Page 10: ...re changed Occupational exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required minimum distances apply Occupational expos...

Page 11: ...is required use remote output control if present on unit Additional safety precautions are required when any of the follo wing electrically hazardous conditions are present in damp loca tions or whil...

Page 12: ...trousers high shoes and a cap 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 flyin...

Page 13: ...guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manually lifting heavy parts or equipment OVERUSE can cause OVERHEATING Allow cooling period fo...

Page 14: ...ressed Gas Association Website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Website www csagroup org Standard for Fire Preventi...

Page 15: ...isolants et des v tements de protection secs et sans trous 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 cou...

Page 16: ...age ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants Ne pas souder des m taux munis d un rev tement tels q...

Page 17: ...asma ou une op ration de chauffage par induction LES BOUTEILLES peuvent exploser si elles sont endommag es Les bouteilles de gaz comprim contiennent du gaz sous haute pression Si une bouteille est en...

Page 18: ...eaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l a limentation lectrique LIRE LES INSTRUCTIONS Lire et appliquer les instructions sur les tiquettes...

Page 19: ...Policy Statement on the Uses of TLVs and BEIs Website www osha gov Applications Manual for the Revised NIOSH Lifting Equation from the National Institute for Occupational Safety and Health NIOSH Web...

Page 20: ...umes Safe7 201 Use forced ventilation or local exhaust to remove the fumes Safe8 201 Use forced ventilation or local exhaust to remove the fumes Safe9 201 Disconnect input plug or power before working...

Page 21: ...e Do not smoke while fueling or if near fuel Saf Stop engine before fueling Safe Do not fuel a hot engine Safe Use lift eye to lift unit and properly installed accessories only not gas cylinders Do no...

Page 22: ...ing crate Remove Owner s Manual from unit Follow instructions to install muffler Safe46 2012 05 Safe51 2012 05 Every 100 hours check and clean filter and check condition of hoses Safe54 2017 04 During...

Page 23: ...without Contact HF And Impulse Final Slope Final Amperage Pulse Percent On Time Initial Slope AC Waveshape Control Pulse EP Amperage Pulse Frequency Work Connection Electrode Connection EN Amperage Pr...

Page 24: ...ric expressly disclaims any and all implied warran ties including any implied warranty of fitness for a particular purpose 4 4 Specifications Do not use information in unit specifications tables to de...

Page 25: ...ower source to any primary input voltage from 190 to 625 volts single or three phase 50 or 60 hertz It also adjusts for voltage spikes within the entire range C Dynasty 800 Models Welding Amperage Ran...

Page 26: ...800 A 44 Volts 20 Duty Cycle 120 109 65 61 53 42 41 8 40 1 Single Phase 400 A 36 Volts 100 Duty Cycle 89 80 44 38 30 18 5 17 1 500 A 40 Volts 60 Duty Cycle 126 112 61 53 41 26 2 24 0 This unit is equi...

Page 27: ...can be connected to public low voltage systems provided that the pub lic low voltage system impedance Zmax at the point of common coupling is less than 47 2 m or the short circuit power Ssc is greater...

Page 28: ...as well as radiated disturbances This equipment complies with IEC61000 3 11 and IEC 61000 3 12 and can be connected to public low voltage systems provided that the pub lic low voltage system impedance...

Page 29: ...Safe Disconnect input plug or power before working on machine Safe Keep your head out of the fumes Safe Keep your head out of the fumes Safe Use forced ventilation or local exhaust to remove the fumes...

Page 30: ...1 4 Duty Cycle And Overheating 200 OUTPUT CURRENT A 100 0 300 400 500 600 700 800 900 DUTY CYCLE 10 20 60 100 DUTY CYCLE DYNASTY MAXSTAR 400 800 MD800 3 PHASE MD800 1 PHASE MD400 1 PHASE MD400 3 PHAS...

Page 31: ...c_large 2018 08 Location And Airflow A complete Parts List is available at www MillerWelds com Writers Remember to move unit dimension and weight and rating la el location information to the appropria...

Page 32: ...00 ft 30 m or Less4 150 ft 45 m 200 ft 60 m Welding Amperes3 10 60 Duty Cycle AWG mm2 60 100 Duty Cycle AWG mm2 10 100 Duty Cycle AWG mm2 100 4 20 4 20 4 20 3 30 150 3 30 3 30 2 35 1 50 200 3 30 2 35...

Page 33: ...ee Section 5 5 for connection example J1 Arc length control lockout closed to socket G during Initial and Final Amperage and Slope and during the background time of a 10 Hz pulse waveform Electrical s...

Page 34: ...is less than 65 load volts Electrical specifications Open collector transistor maximum values 27 volts DC peak 75mA See Section 5 5 5 Output Scaled Actual Welding Voltage 1 volt DC per 10 volts of ou...

Page 35: ...mory Select Inputs For 28 Pin Receptacle If Present 1 4 9 15 21 26 28 25 20 14 8 3 Pin Signal Direction Description Pin Information For 28 Pin Receptacle RC28 1 Input Start Stop Maintained connection...

Page 36: ...tput Final Slope Sequence Indication Paired with Pin 24 Pin is closed to pin 24 when in Final Slope Electrical specifications Open collector transistor maximum values 27 volts DC peak 75mA See Section...

Page 37: ...mmand Paired with pin 21 Sets output amperage value for a Maxstar and the EN am perage value for a Dynasty Value should be between 0 3 to 10V correspond ing to the minimum to maximum of the machine 25...

Page 38: ...er Switch 805593 A 1 2 3 Gas Connections 805593 A 3 2 4 1 1 AC Cooler Receptacle Receptacle RC2 supplies 115 V 4A of single phase power RC2 is a designated use receptacle in tended only for supplying...

Page 39: ...s hose be tween regulator flowmeter and gas fitting on rear of unit 5 10 TIG HF Impulse Lift Arc Connections A complete Parts List is available at www MillerWelds com 2 8 TIG HF Impulse Lift Arc Conne...

Page 40: ...ection Connect TIG torch gas hose to gas out fitting 5 Work Weld Output Terminal Weld Out put Terminal On Maxstar Models Connect work lead to work weld output terminal 6 Water Out To Torch Connection...

Page 41: ...ections A complete Parts List is available at www MillerWelds com 1 1 Maxstar Stick Connections 803916 C Turn off power before making connections Connections shown are for Maxstar models 1 Weld Output...

Page 42: ...pply Conductor Size In AWG mm2 6 8 10 10 6 14 2 5 14 2 5 14 2 5 14 2 5 Reference 2020 National Electrical Code NEC including article 630 60 Hz 1 Phase Rated Supply Voltage V 208 230 400 460 575 Rated...

Page 43: ...ize In AWG mm2 6 8 10 10 6 14 2 5 14 2 5 14 2 5 14 2 5 Reference 2020 National Electrical Code NEC including article 630 60 Hz 1 Phase Rated Supply Voltage V 208 230 400 460 575 Rated Maximum Supply C...

Page 44: ...m2 6 2 35 2 35 6 16 6 16 8 10 8 10 Reference 2020 National Electrical Code NEC including article 630 1 Phase Rated Supply Voltage V 208 230 400 460 575 Rated Maximum Supply Current I1max A 136 0 122 0...

Page 45: ...m2 6 2 35 2 35 6 16 8 10 8 10 10 6 Reference 2020 National Electrical Code NEC including article 630 1 Phase Rated Supply Voltage V 208 230 400 460 575 Rated Maximum Supply Current I1max A 126 0 112 0...

Page 46: ...itry in this unit auto matically adapts the power source to the primary voltage being applied Check input voltage available at site This unit can be connected to any input power between 208 and 575 VA...

Page 47: ...auto matically adapts the power source to the primary voltage being applied Check input voltage available at site This unit can be connected to any input power between 208 and 575 VAC with out removi...

Page 48: ...able at site This unit can be connected to any input power between 190 and 625 VAC without removing cover to re link the power source See rating label on unit and check input volt age available at sit...

Page 49: ...to supply grounding terminal first and never to a line terminal See rating label on unit and check input volt age available at site 1 Input Power Conductors Customer Sup plied Cord Select size and le...

Page 50: ...lerwelds com support system setup and software tig software Click System Installation Instructions PDF and follow the instructions B Installing Software Updates 2 1 C Software Installation 1 2 Softwar...

Page 51: ...at function 2 Memory Card Port And Indicator Port is used to add features to the machine and update software Indicator is lit while card is being accessed 3 Ammeter And Parameter Display Shows actual...

Page 52: ...play the parameter and adjust the amperage ad justment control until PRO SET flashes on the display PRO SET flashes one time and reveals the professional setting for the parameter Polarity Selection D...

Page 53: ...welding guides Parameter Setting Display Description PPS 100 Pulses Per Second range is 0 1 500 PK T 40 Peak Amperage Time range is 5 95 BK A 25 Background Amperage Time range is 5 95 of peak amperage...

Page 54: ...6 3 to select Independent EN and EP Amperage control BAL 75 Balance Control EN TIG Only Controls oxide cleaning Increasing the setting reduces cleaning Range is BALL 50 99 Stick is fixed at 50 BALL s...

Page 55: ...ge setting ENEP INDP For AC TIG welding allows the user to set the EP amperage independently from the EN amperage When INDP the user can set the EP waveshape sine square triangle independently from th...

Page 56: ...maintaining the same EN amperage to EP amperage ratio at the existing balance and frequency To change the average amperage value press the Amperage button and rotate the Encoder control The changing a...

Page 57: ...function buttons to change values for that function 2 Memory Card Port And Indicator Port is used to add features to the machine and update software Indicator is lit while card is being accessed 3 Am...

Page 58: ...To stop the weld the operator again presses and re leases the trigger In this mode only the output contactor is controlled by the remote control Amper age must be set on the control panel see Section...

Page 59: ...welding guides Parameter Setting Display Description PPS 100 Pulses Per Second range is 0 1 500 PK T 40 Peak Amperage Time range is 5 95 BK A 25 Background Amperage Time range is 5 95 of peak amperage...

Page 60: ...just parameter setting To exit user menu press Amperage and Gas DIG controls at the same time and then re lease or turn power off User Menu Function Parameter Setting Display Example Description Tung...

Page 61: ...Amperage Adjustment Control Use amperage adjustment control in con junction with applicable front panel function buttons to change values for that function 2 Memory Card Port And Indicator Port is us...

Page 62: ...for AC and DC TIG welding TIG Lift Arc Is a contact arc starting method for AC and DC TIG welding See Section 15 Gas DIG Control A complete Parts List is available at www MillerWelds com Parameter Set...

Page 63: ...yed To scroll through the user menu functions press and release the Gas DIG control Rotate amperage adjustment control to ad just parameter setting To exit user menu press Amperage and Gas DIG control...

Page 64: ...ation TIG Start Amperage and Start Time values from the default val ues press the amperage button to step through each adjustable parameter see Sections B and C B Programmable TIG Start Amperage A com...

Page 65: ...large diameter electrodes Open Circuit Voltage OCV NORM Allows user to select between Normal NORM and Low open circuit volt age Low reduces open circuit voltage to between 8 and 15 volts To select ro...

Page 66: ...l Time Range is OFF to 25 0T seconds ISLP OFF Initial Slope Time Range is OFF to 50 0T seconds FSLP OFF Final Slope Time Range is OFF to 50 0T seconds FNL 10A Final Amperage Range is 3 400 5 800 amps...

Page 67: ...nitial Slope Final Slope Postflow Main Amps Final Amps R R P H Maintained Switch Foot Or Finger Remote Control P R P R P R P R P R P R P R Time P R Push and release trigger If torch trigger is held mo...

Page 68: ...tion 1 Press and release initial switch within 3 4 second to start shielding gas flow To stop the preflow sequence before pre flow time elapses 25 seconds press and release final switch The preflow ti...

Page 69: ...ed at final slope rate at any time by pushing and holding trigger 4T And 4Tm Application Use 4T or 4Tm modified trigger method when the functions of a remote current con trol are desired but only a re...

Page 70: ...ration 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 Electrode 2 Sec Fin...

Page 71: ...e amperage adjustment control to se lect a lockout code number Select a number between 1 and 999 The number will appear on the amperage right display Remember write down this code num ber as you will...

Page 72: ...Locked Adjustable Locked Panel Amps Panel Amps Panel Amps 10 Remote Amps min panel Panel Amps 10 Polarity Dy nasty Only Polarity Dy nasty Only Polarity Dy nasty Only Polarity Dy nasty Only Process Pro...

Page 73: ...d until desired process TIG HF Impulse TIG Lift Arc or Stick LED is lit The program at the chosen location for the desired polarity and process is now the active program Fourth change or set all desir...

Page 74: ...hs 6 1 Blowing Out Inside of Unit 804746 B Cables And Cords Every 6 Months OM 222 Page 1 pliers knife heavy duty workclamp light duty workclamp wirecutter frontcutter needlenose steelbrush nutdriver c...

Page 75: ...ens frequently CHEK INPT Check Input High or low voltage has been sensed Have a qualified person check input voltage WELD CABL Weld Cable An error related to the weld cables has been sensed Straighten...

Page 76: ...rly prepared tungsten see Section 14 Reduce gas flow rate Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from drafts Increase postflow time Check and t...

Page 77: ...OM 275857 Page 67 SECTION 12 ELECTRICAL DIAGRAMS 275852 H Figure 12 1 Dynasty 400 Circuit Diagram Page 1 of 2...

Page 78: ...OM 275857 Page 68 275852 H Figure 12 2 Dynasty 400 Circuit Diagram Page 2 of 2...

Page 79: ...OM 275857 Page 69 OM 275857 Page 9 SECTION 3 ELECTRICAL DIAGRAMS Figure 11 1 Maxstar 400 Circuit Diagram Page 1 of 2 275851 G Figure 12 3 Maxstar 400 Circuit Diagram Page 1 of 2...

Page 80: ...OM 275857 Page 70 Figure 12 4 Maxstar 400 Circuit Diagram Page 2 of 2...

Page 81: ...OM 275857 Page 71 275854 G Figure 12 5 Dynasty 800 Circuit Diagram Page 1 of 2...

Page 82: ...OM 275857 Page 72 275854 G Figure 12 6 Dynasty 800 Circuit Diagram Page 2 of 2...

Page 83: ...OM 275857 Page 73 Figure 12 7 Maxstar 800 Circuit Diagram Page 1 of 2...

Page 84: ...OM 275857 Page 74 OM 275857 Page 12 Figure 11 4 Maxstar 800 Circuit Diagram Page 2 of 2 275853 G Figure 12 8 Maxstar 800 Circuit Diagram Page 2 of 2...

Page 85: ...Practices Not Followed SECTION 1 HIGH FREQUENCY 1 TIG S 0694 13 9 8 7 1 2 4 5 6 3 10 11 12 14 Sources of Direct High Frequency Radiation 1 High Frequency Source welding power source with built in HF o...

Page 86: ...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 Telep...

Page 87: ...2 4 mm 150 200 140 235 1 8 in 3 2 mm 250 400 225 325 5 32 in 4 0 mm 400 500 300 400 3 16 in 4 8 mm 500 750 400 500 1 4 in 6 4 mm 750 1000 500 630 Typical argon shielding gas flow rates are 10 to 25 C...

Page 88: ...ury and start fires Use appropriate local ex haust forced ventilation at the grinder or wear an approved respi rator Read SDS for safety informa tion Properly dispose of grinder dust in an environment...

Page 89: ...ed when electrode is lifted Normal open circuit voltage is not present before tungsten electrode touches work piece only a low sensing voltage is present between electrode and workpiece The solid stat...

Page 90: ...eak time is about 50 60 To find a good ratio you will have to experiment a bit but the idea is to decrease heat input into the part and in crease the cosmetics of the weld BKGND A Background amps is s...

Page 91: ...age Adjustment Control 2 Parameter Display 3 Amperage Button Once inside the machine set up menu tung sten parameter values can be manually changed by pressing the Amperage switch pad to step through...

Page 92: ...10 6011 6013 7014 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 EAS...

Page 93: ...No Labor Water Cooling Systems Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts 12 Volt Automotive Style Batteries 6 90 Days Parts Accessories Kits...

Page 94: ...d 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 We...

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