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Miller DYNASTY DX, Technical Manual

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Miller DYNASTY DX Technical Manual Download Page 21

TM-357 Page 19

Dynasty DX

5-7.

Contactors W1, W2 (230/460 V Models Only)

ST-801 550 / SC-183 621-A

Y

Read and follow safety
information in  Section  5-1
before proceeding.

1

Check normally-open
contacts of W1 and W2 to be
sure contacts are not stuck
shut (ohms position).

Normally-Open

Contacts Of 460 V

Input Contactor W1

Normally-Open

 Contacts Of 230 V

 Auto-Link Contactor W2

Interconnecting Board PC2

Summary of Contents for DYNASTY DX

Page 1: ...TM 357A June 1999 Eff w Serial Number KH384382 Processes Description TIG GTAW Welding Stick SMAW Welding Arc Welding Power Source Dynasty DX With Auto Link Visit our website at www MillerWelds com...

Page 2: ...TROUBLESHOOTING 20 6 1 Troubleshooting Table 20 6 2 Troubleshooting Circuit Diagram 22 6 3 Waveforms for Sections 6 2 24 6 4 Control Board PC1 Testing Information Use with Section 6 5 26 6 5 Control...

Page 3: ...uctors from deenergized supply line BEFORE moving a welding power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters D Turn Off inverter disconnect input power and discharg...

Page 4: ...his unit D Consult the Owner s Manual for welding safety precautions D Use only genuine MILLER replacement parts 1 3 EMF Information Considerations About Welding And The Effects Of Low Frequency Elect...

Page 5: ...ngle Phase 200 A 28 Volts DC 40 Duty Cycle 5 300 90 44 33 25 8 18 11 9 1 8 1 07 While idling 2 2 Duty Cycle and Overheating 4 Minutes Welding 6 Minutes Resting Duty Cycle is percentage of 10 min utes...

Page 6: ...Page 4 Dynasty DX 2 3 Volt Ampere Curves SA 185 793 SA 186 294 Volt amperecurves show minimum and maximum voltage and amper age output capabilities of unit Curves of other settings fall be tween curve...

Page 7: ...determine input power needs 4 Line Disconnect Device Locate unit near correct input power supply Y Special installation may be required where gasoline or volatile liquids are present see NEC Article...

Page 8: ...mils per ampere Contact your distributor for the mm2 equivalent weld cable sizes NOTE For proper installation of gas hose the use of a quick connect torch such as Weldcraft QWP 17 or QWP 20 is recomm...

Page 9: ...15 of indicated required input voltage If actual input voltage is outside of this range no output is available NOTE Three Phase Single Phase Input Voltage 230 460 230 460 AC 26 5 17 9 62 6 32 2 Input...

Page 10: ...lectrical Tape Insulate and isolate red conductor as shown Y Always connect green wire to supply grounding termi nal never to a line terminal For three phase operation Connect black white and red wire...

Page 11: ...h in Panel position For remote control make connections to remote 14 receptacle and place switch in Remote 14 position 8 Trigger Hold To start weld press and release gun trigger within three seconds a...

Page 12: ...elding On V A Actual Volts OCV Preset Amps 80 0 85 Actual Volts Actual Amps V A 24 5 85 Lift On Actual Volts Preset Amps V A 7 0 85 Actual Volts Actual Amps V A 10 3 85 HF Remote Blank Preset Amps V A...

Page 13: ...ce Touch tungsten electrode to work piece at weld start point hold electrode to workpiece for 1 2 seconds and slowly lift electrode An arc will form when electrode is lifted Normal open circuit voltag...

Page 14: ...Motor FM Provides cooling of internal compo nents 12 Display Board PC3 See Section 3 1 Consists of voltmeter V ammeter A Amperage Adjustment control R5 Amperage Control switch S1 AC Frequency control...

Page 15: ...t of T1 21 Stabilizer Z1 Smooths out welding current 22 Hall Device HD1 Provides weld or secondary current feedback signal to PC1 23 IGBT Switching Modules PM3 And PM4 Use very fast on off switching a...

Page 16: ...s are based on in circuit measurements 1 Visually inspect SR1 for damage 2 Check 6 diodes diode test Check from each ac terminal to the positive terminal and from each ac terminal to the negative term...

Page 17: ...either C3 or C4 is shorted re move interconnecting board PC2 and check IGBT s PM1 and PM2 1 Check C1 C3 and C4 for a short ohms position Tank Capacitor C1 Input Capacitors C3 C4 5 4 Output Diodes D1...

Page 18: ...ed to top of next page to test PM3 and PM4 Alternate Test For PM1 And PM2 Use stan dard digital meter set to ohms position Y Read and follow safety information in Section 5 1 before proceeding It is n...

Page 19: ...in 9 Connect PLG7 to RC7 Alternate Test For PM3 And PM4 Use standard digital meter set to ohms position Continued Y Read and follow safety information in Section 5 1 before proceeding 1 Visually inspe...

Page 20: ...and follow safety information in Section 5 1 before proceeding 1 Check D1 and D2 on PC2 for 2000 ohms 10 in 230 460 volt models or 400 ohms 10 in 460 575 volt models ohms position 2 Check D3 and D4 o...

Page 21: ...ead and follow safety information in Section 5 1 before proceeding 1 Check normally open contacts of W1 and W2 to be sure contacts are not stuck shut ohms position Normally Open Contacts Of 460 V Inpu...

Page 22: ...on 6 2 Replace HD1 if necessary Check output diodes D1 and D2 and replace if necessary see Section 5 4 Check input integrated rectifier SR1 and replace if necessary see Section 5 2 Check IGBT modules...

Page 23: ...wiring and connections No 115 volts ac output at optional du Reset circuit breaker CB1 if necessary see Section 2 7 plex receptacle Check receptacle s wiring and connections Fan motor does not run af...

Page 24: ...Y Discharge input capacitors according to Section 7 5 and be sure voltage is near zero before touching any parts No calibration available for voltmeter V or ammeter A V8 V7 V1 V2 460 V Input Contacto...

Page 25: ...with 230 volts ac input power 650 volts dc with 460 volts ac input power V9 V10 325 volts dc V11 0 volts dc with 230 volts ac input power 3 8 volts dc with 460 volts ac input power V12 3 8 volts dc wi...

Page 26: ...C Open Circuit Voltage 86 7 VDC B AC Maximum Cleaning 30 Volts AC 250 Amperes 140 Hertz Resistive Load 2 5 ms 20 V C AC Maximum Penetration 30 Volts AC 250 Amperes 140 Hertz Resistive Load 2 5 s 20V D...

Page 27: ...TM 357 Page 25 Dynasty DX Notes...

Page 28: ...near zero before touching any parts Be sure plugs are secure before testing See Section 6 5 for specific values during testing 1 Control Board PC1 2 Receptacle RC1 3 Receptacle RC2 4 Receptacle RC3 5...

Page 29: ...tion 14 15 volts dc input during normal operation 0 volts dc input when HELP 6 screen is displayed 15 15 volts dc input with Process switch S3 in Stick position 0 volts dc input with S3 in Tig positio...

Page 30: ...7 10 10 Circuit common for pin RC7 9 11 15 volts dc with respect to pin RC7 12 12 Circuit common for pin RC7 11 RC8 1 0 volts dc with 230 volts ac input power 3 8 volts dc with 460 volts ac input powe...

Page 31: ...6 7 for specific values during testing 1 Display Board PC3 2 Receptacle RC1 3 Receptacle RC2 4 Receptacle RC4 Connection point for thermistor RT1 5 Receptacle RC5 Connection point for thermistor RT2 6...

Page 32: ...t when HELP 6 screen is displayed 15 15 volts dc output with Process switch S3 in Stick position 0 volts dc input with S3 in Tig position 16 15 volts dc input during normal operation 0 volts dc input...

Page 33: ...sure voltage is near zero before touching any parts Be sure to use torque values in dicated on PC2 when servi cing Use component to heat sink torque value of 26 in lb when servicing SR1 and IGBT s PM1...

Page 34: ...ors according to Section 7 5 and be sure voltage is near zero before touching any parts Be sure plugs are secure before testing See Section 6 10 for specific values during testing 1 High Frequency Boa...

Page 35: ...pin RC1 5 3 325 volts dc with respect to pin RC1 8 4 325 volts dc with respect to pin RC1 8 5 220 volts ac with respect to pin RC1 1 6 220 volts ac with respect to pin RC1 1 7 325 volts dc with respe...

Page 36: ...SC 182 189 B Y Discharge input capacitors according to Section 7 5 and be sure voltage is near zero before touching any parts Be sure plugs are secure before testing See Section 6 12 for specific val...

Page 37: ...amp voltage with respect to pin RC1 3 3 Clamp voltage with respect to pin RC1 2 4 15 volts dc with contactor energized 0 volts dc with contactor deenergized 5 325 volts dc with respect to pin RC1 6 6...

Page 38: ...ST 802 037 SC 182 193 A Y Discharge input capacitors according to Section 7 5 and be sure voltage is near zero before touching any parts Be sure plugs are secure before testing See Section 6 14 for sp...

Page 39: ...RC1 Test without contactor energized and without any load 1 Circuit common for pin RC1 6 2 Circuit common for pin RC1 3 3 15 volts dc with respect to pin RC1 2 4 Clamp voltage signal to board PC6 5 C...

Page 40: ...g Out Inside of Unit ST 801 708 A Y Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown 7 3 Overload Protection ST 801 866 1 Circ...

Page 41: ...over heated The unit has shut down to allow the fan to cool it see Section 2 2 Operation will continue when the unit has cooled 7 Help 6 Display Indicates that the input voltage is too low and the uni...

Page 42: ...nit Turn Off welding power source and disconnect input power Remove case 1 Input Capacitor C3 2 Input Capacitor C4 3 Voltmeter Check input capacitors as shown Measure the dc voltage across the positiv...

Page 43: ...rces of Direct High Frequency Radiation 1 High Frequency Source welding power source with built in HF or separate HF unit 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table Sources of Conduct...

Page 44: ...ipes 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 N...

Page 45: ...lowing SD 189 922 SD 183 037 B Circuit Board PC1 Control Board KH384382 thru KH518627 SD 182 179 KH518628 thru KJ037292 SD 186 803 KJ037293 and following SD 188 732 A Circuit Board PC2 Interconnect in...

Page 46: ...TM 357 Page 44 Dynasty DX Figure 9 1 Circuit Diagram For Dynasty DX Effective With Serial No KH384382 Thru KJ037292...

Page 47: ...TM 357 Page 45 Dynasty DX SD 183 036 C...

Page 48: ...TM 357 Page 46 Dynasty DX Figure 9 2 Circuit Diagram For Dynasty DX Effective With Serial No KJ037293 And Following...

Page 49: ...TM 357 Page 47 Dynasty DX SD 189 922...

Page 50: ...TM 357 Page 48 Dynasty DX Figure 9 3 Wiring Diagram For Dynasty DX Effective With Serial No KJ037293 And Following...

Page 51: ...TM 357 Page 49 Dynasty DX SD 183 037 B...

Page 52: ...TM 357 Page 50 Dynasty DX Figure 9 4 Circuit Diagram For Main Control Board PC1 Effective With Serial No KJ037293 And Following Part 1 Of 3...

Page 53: ...TM 357 Page 51 Dynasty DX SD 183 732 A...

Page 54: ...TM 357 Page 52 Dynasty DX Figure 9 5 Circuit Diagram For Main Control Board PC1 Effective With Serial No KJ037293 And Following Part 2 Of 3...

Page 55: ...TM 357 Page 53 Dynasty DX SD 183 732 A...

Page 56: ...TM 357 Page 54 Dynasty DX Figure 9 6 Circuit Diagram For Main Control Board PC1 Effective With Serial No KJ037293 And Following Part 3 Of 3...

Page 57: ...TM 357 Page 55 Dynasty DX SD 183 732 A...

Page 58: ...TM 357 Page 56 Dynasty DX SD 183 623 Figure 9 7 Circuit Diagram For Interconnecting Board PC2 Effective With Serial No KH384382 And Following...

Page 59: ...TM 357 Page 57 Dynasty DX Notes...

Page 60: ...TM 357 Page 58 Dynasty DX Figure 9 8 Circuit Diagram For Front Board PC3 Effective With Serial No KH384382 And Following Part 1 Of 2...

Page 61: ...TM 357 Page 59 Dynasty DX SD 189 540...

Page 62: ...TM 357 Page 60 Dynasty DX Figure 9 9 Circuit Diagram For Front Board PC3 Effective With Serial No KH384382 And Following Part 2 Of 2...

Page 63: ...TM 357 Page 61 Dynasty DX SD 189 540...

Page 64: ...TM 357 Page 62 Dynasty DX SD 188 015 Figure 9 10 Circuit Diagram For IGBT Single Board PC4 PC5 Effective With Serial No KH518630 And Following...

Page 65: ...TM 357 Page 63 Dynasty DX SD 182 195 Figure 9 11 Circuit Diagram For IGBT Double Board PC6 Effective With Serial No KH384382 And Following...

Page 66: ...TM 357 Page 64 Dynasty DX SD 186 810 Figure 9 12 Circuit Diagram For HF Board PC7 Effective With Serial No KH517737 And Following...

Page 67: ...TM 357 Page 65 Dynasty DX SD 182 191 A Figure 9 13 Circuit Diagram For Clamp Board PC8 Effective With Serial No KH384382 And Following...

Page 68: ...TM 357 Page 66 Dynasty DX Notes...

Page 69: ...Processes Description TIG GTAW Welding Stick SMAW Welding Arc Welding Power Source Dynasty DX With Auto Link Eff w KH384382 Thru KJ150395 For OM 357 188 291 Revisions A thru D Visit our website at ww...

Page 70: ...4382 Thru KJ150395 Figure 10 1 Main Assembly ST 801 870 A Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 PC3 31 32...

Page 71: ...Prior to KJ003565 1 11 T2 187 574 TRANSFORMER control Eff w KJ003565 and on 1 11 T2 174 981 TRANSFORMER control Prior to KJ003565 1 11 T2 187 757 TRANSFORMER control Eff w KJ003565 and on 1 RC10 166...

Page 72: ...R SOCKETS 1 PLG18 131 054 CONNECTOR SOCKETS 1 31 FM 175 084 MOTOR fan 24VDC 3000RPM 1 135 635 CONNECTOR SOCKETS fan motor 1 32 191 571 PANEL front 1 33 187 198 NAMEPLATE order by model and serial numb...

Page 73: ...5 TM 357 Page 71 Dynasty DX Figure 10 2 Windtunnels w Components ST 801 871 A Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 23 24 25 26 27 PC...

Page 74: ...1 250 lg 2 19 CT1 175 199 TRANSFORMER current 1 20 177 547 BUSHING snap in CT mount 1 21 175 140 BRACKET DI DT 1 22 181 197 GASKET DI DT rubber 1 23 L3 4 175 482 COIL DI DT 2 24 109 056 CORE 2 25 187...

Page 75: ...1999 Processes Description TIG GTAW Welding Stick SMAW Welding Arc Welding Power Source Dynasty DX With Auto Link Eff w KJ150396 And Following For OM 357 188 291 Revision E Visit our website at www Mi...

Page 76: ...50396 And Following Figure 11 1 Main Assembly ST 801 870 B Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 PC3 31 32 33...

Page 77: ...y 1 13 189 033 RECEPTACLE str dx grd 2P 3W 15A 1 14 CB1 083 432 CIRCUIT BREAKER 1P 10A 250VAC 1 16 605 227 NUT 750 14 knurled 1 17 182 205 PANEL rear 1 18 PLATE identification rear order by model seri...

Page 78: ...emale 1 39 C7 8 186 543 CAPACITOR cer disc 1uf 500VDC 2 40 183 332 KNOB pointer 570 6 41 174 991 KNOB pointer 1 250 1 42 Fig 11 2 WINDTUNNELS w COMPONENTS 1 When ordering a component originally displa...

Page 79: ...49 CAPACITOR polyp 27uf 1000VDC 1 18 025 248 STAND OFF insul 250 20 x 1 250 lg 2 19 CT1 175 199 TRANSFORMER current 1 20 177 547 BUSHING snap in CT mount 1 21 175 140 BRACKET DI DT 1 22 181 197 GASKET...

Page 80: ...y 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA Phone 920 735 4505 USA Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone...

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