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OM-275857 Page 22

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Complete Parts List is available at www.MillerWelds.com

5-2.

Weld Output Terminals

A complete Parts List is available at www.MillerWelds.com

SECTION 2   INSTALLATION

2-1.

Weld Output Terminals

804746-B

2

1

3

Turn off power before connecting
to weld output terminals.

Do not use worn, damaged, under-
sized, or repaired cables.

1

Work Weld Output Terminal (Dynasty
Models)

(+) Positive Weld Output Terminal (Max-
star Models)

2

Electrode Weld Output Terminal (Dynasty
Models)

(-) Negative Weld Output Terminal (Max-
star Models)

3

Remote 14 Receptacle (All Models)

See Sections 5-10 thru 5-12 for connection
diagrams.

5-3.

Selecting Cable Sizes

1

NOTICE –

The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source

is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.

Weld Cable Size

2

and Total Cable (Copper) Length in Weld Circuit Not Exceeding

100 ft (30 m) or Less

4

150 ft (45 m)

200 ft (60 m)

Welding Amperes

3

10 - 60% Duty Cycle

AWG (mm

2

)

60 - 100% Duty Cycle

AWG (mm

2

)

10 - 100% Duty Cycle

AWG (mm

2

)

100

4 (20)

4 (20)

4 (20)

3 (30)

150

3 (30)

3 (30)

2 (35)

1 (50)

200

3 (30)

2 (35)

1 (50)

1/0 (60)

250

2 (35)

1 (50)

1/0 (60)

2/0 (70)

300

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

350

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

400

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

500

2/0 (70)

3/0 (95)

4/0 (120)

2x2/0 (2x70)

600

3/0 (95)

4/0 (120)

2x2/0 (2x70)

2x3/0 (2x95)

700

4/0 (120)

2x2/0 (2x70)

2x3/0 (2x95)

2x4/0 (2x120)

800

4/0 (120)

2x2/0 (2x70)

2x3/0 (2x95)

2x4/0 (2x120)

900

2x2/0 (2x70)

2x3/0 (2x95)

2x4/0 (2x120)

3x3/0 (3x95)

1

This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

2

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

2

for metric use.

3

Select weld cable size for pulsing application at peak amperage value.

4

For distances longer than 100 ft (30 m) and up to 200 ft (60 m), use direct current (DC) output only. For distances longer than those shown in

this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding Society at

http://www.aws.org

.

Содержание Dynasty 400

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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