Miller Dynasty 200 DX
Miller Dynasty 200 DX
Miller Dynasty 200 DX
2005−10
Processes
TIG (GTAW) Welding
Description
Mil_Thank 4/05
TABLE OF CONTENTS
Directives
Standards
dec_stat_6/05
Notes
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
Y Warning: Protect yourself and others from injury — read and follow these precautions.
Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
D 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). HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
D Use protective screens or barriers to protect others from flash,
torch.
glare and sparks; warn others not to watch the arc.
D To handle hot parts, use proper tools and/or
D Wear protective clothing made from durable, flame-resistant mate-
wear heavy, insulated welding gloves and
rial (leather, heavy cotton, or wool) and foot protection.
clothing to prevent burns.
OM-2240 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
OVERUSE can cause OVERHEATING D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
D Allow cooling period; follow rated duty cycle. communications equipment.
D Reduce current or reduce duty cycle before D Have only qualified persons familiar with
starting to weld again. electronic equipment perform this installation.
D Do not block or filter airflow to unit. D The user is responsible for having 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
STATIC (ESD) can damage PC boards. equipment at once.
D Have the installation regularly checked and maintained.
D Put on grounded wrist strap BEFORE handling D Keep high-frequency source doors and panels tightly shut, keep
boards or parts. spark gaps at correct setting, and use grounding and shielding to
D Use proper static-proof bags and boxes to minimize the possibility of interference.
store, move, or ship PC boards.
OM-2240 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som _3/05
Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
Y Indique un message de sécurité particulier Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
. Signifie NOTE ; n’est pas relatif à la sécurité. les dangers.
OM-2240 Page 6
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
OM-2240 Page 8
SECTION 3 − DEFINITIONS (CE Models)
Warning! Watch Out! There are possible 2 Breathing welding fumes can be 3.3 Do not weld on drums or any closed
hazards as shown by the symbols. hazardous to your health. containers.
2.1 Keep your head out of the fumes. 4 Arc rays can burn eyes and injure
1 Electric shock from welding electrode skin.
or wiring can kill. 2.2 Use forced ventilation or local exhaust
to remove the fumes. 4.1 Wear hat and safety glasses. Use ear
1.1 Wear dry insulating gloves. Do not 2.3 Use ventilating fan to remove fumes. protection and button shirt collar. Use
touch electrode with bare hand. Do welding helmet with correct shade of
not wear wet or damaged gloves. 3 Welding sparks can cause explosion
or fire. filter. Wear complete body protection.
1.2 Protect yourself from electric shock by 3.1 Keep flammables away from welding. 5 Become trained and read the
insulating yourself from work and Do not weld near flammables. instructions before working on the
ground. machine or welding.
3.2 Welding sparks can cause fires. Have
1.3 Disconnect input plug or power before a fire extinguisher nearby, and have a 6 Do not remove or paint over (cover)
working on machine. watchperson ready to use it. the label.
S-179 310-A
OM-2240 Page 9
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1 Electric shock from wiring can
kill.
2 Disconnect input plug or
power before working on
machine.
1 2 3 4 5 3 Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
V 4 Always wait 60 seconds after
V power is turned off before
working on unit, OR
> 60 s V 5 Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
6 When power is applied failed
S-185 836 parts can explode or cause
other parts to explode.
7 Flying pieces of parts can
cause injury. Always wear a
6 7 8 9 face shield when servicing
unit.
8 Always wear long sleeves and
button your collar when
servicing unit.
9 After taking proper
precautions as shown,
connect power to unit.
S-179 309-A
2 3 4 5
1/96
OM-2240 Page 10
3-2. Manufacturer’s Rating Label
f2 f2 EN 60974−1
. Use rating label to de-
termine input power
1A 10V 200A 18V U 1 =115V requirements.
X 20% 60% 100% 40% 100%
I 1 max I 1 eff
1 50/60 Hz U 1 =115V 32 25
1 50/60 Hz U 1 =230V 35 16
3 50/60 Hz U 1 =230V 21 10
3 50/60 Hz U 1 =400V 12 6
3 50/60 Hz U 1 =460V 10 5
IP23
OM-2240 Page 11
3-3. Symbols And Definitions
A Amperes Panel−Local
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
Lift-Arc Start
Voltage Output Circuit Breaker Remote
(GTAW)
S
Protective Earth
Postflow Timer Preflow Timer Seconds
(Ground)
Alternating
Current
Gas Input Gas Output
I2 Rated Welding
Current
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
Initial Amperage
Increase/Decrease
Of Quantity
Hz Hertz
Recall From
Memory
Arc Force (DIG)
HF Impulse Start-
ing (GTAW)
Pulse Percent
Final Slope Final Amperage Initial Slope
On Time
S
Suitable For Areas
Output Adjust Of Increased
Shock Hazard
OM-2240 Page 12
SECTION 4 − INSTALLATION
4-1. Specifications
Welding Max. Amperes Input At Rated Output, 50/60Hz
Input Power Rated Output Amperage Open-Circuit KVA KW
Range ** Voltage 115 230 400 460
Three-Phase 130 A @ 25.2 VDC, 80∇ 12.3 7.6 6.0 4.8 4.6
1 − 200 -−
Stick Process 60% Duty Cycle 5-10♦ 0.16* 0.24* 0.25* 0.06* 0.03*
80
Three-Phase 150 A @ 16 VDC, 9.4 6.0 4.7 3.8 3.6
60% Duty Cycle
1 − 200 5-10♦
TIG Process -− 0.16* 0.24* 0.25* 0.06* 0.03*
80∇
Three-Phase 200 A @ 28 VDC, 20.8 13.0 10.2 8.1 7.8
Stick Process 20% Duty Cycle
1 − 200 5-10♦
0.16* 0.24* 0.25* 0.06* 0.03*
80
Three-Phase 200 A @ 18 VDC, 13.7 8.7 6.9 5.5 5.2
TIG Process 20% Duty Cycle
1 − 200 5-10♦
0.16* 0.24* 0.25* 0.06* 0.03*
80∇
Single-Phase 130 A @ 25.2 VDC, 20.0 10.0 4.7 4.7
60% Duty Cycle
1 − 200 5-10♦ -−
0.23*
-−
0.05* 0.02*
Stick Process .25*
80
Single-Phase 150 A @ 16 VDC, 15.8 7.9 3.6 3.6
60% Duty Cycle
1 − 200 5-10♦ -−
TIG Process -− 0.23* .25* 0.05* 0.02*
80∇
Single-Phase 100 A @ 24 VDC, 31.3 3.6 3.6
60% Duty Cycle
1 − 200 5-10♦ 0.42*
-− -− -−
0.05* 0.03*
Stick Process
80∇
Single-Phase 90 A @ 23.6 VDC, 27.6 3.2 3.2
100% Duty Cycle
1 − 200 5-10♦ 0.42*
-− -− -−
Stick Process 0.05* 0.03*
80
Single-Phase 100 A @ 14 VDC, 20.7 2.3 2.3
100% Duty Cycle
1 − 200 5-10♦ 0.42*
-− -− -−
TIG Process 0.05* 0.03*
*While idling
** Welding range for AC output is 5−200 amperes
♦Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected.
∇Normal open-circuit voltage (80 volts) is present while in Stick with normal open-circuit voltage selected.
NOTE: Duty cycle limitations on units with 115 volt input power are due to the input power cord supplied with the unit.
NOTE: This unit is equipped with Auto-Linet. The Auto-Line circuitry automatically connects to 120−460 VAC, single- or three-phase power without
removing the cover to relink the power source.
OM-2240 Page 13
4-2. DC Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amper-
age output capabilities of welding
115VAC Input; DC Output power source. Curves of other set-
tings fall between curves shown.
140
Stick Max.
120
100 TIG Max.
*
Volts
80
60
40 Stick/TIG Min.
DIG Max.
20
0
0 50 100 150 200 250
Amperes
80
60
40
Stick/TIG Min. DIG Max.
20
0
0 50 100 150 200 250
Amperes
100
TIG Max.
*
Volts
80
60
40 Stick/TIG Min. Dig Max.
20
0
0 50 100 150 200 250
Amperes
*Amperage setting must be reduced to obtain currents less than highlighted data* point.
210 168-A
OM-2240 Page 14
4-3. AC Volt-Ampere Curves
Volt-ampere curves show minimum
115VAC Input; AC Output and maximum voltage and amper-
age output capabilities of welding
power source. Curves of other set-
140 tings fall between curves shown.
Stick Max.
120
100 TIG Max.
*
Volts
80
60
40
Stick/TIG Min.
20
0
0 50 100 150 200 250
Amperes
80
60
40 Stick/TIG Min.
20
0
0 50 100 150 200 250
Amperes
100
* TIG Max.
Volts
80
60
40
Stick/TIG Min.
20
0
0 50 100 150 200 250
Amperes
*Amperage setting must be reduced to obtain currents less than highlighted data* point.
210 168
OM-2240 Page 15
4-4. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed (see
250 Section 7-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
OUTPUT AMPERES
100
STICK (115V INPUT)
50
0
10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE
100%dutycycle
Continuous Welding
Overheating
0 A or V
15
OR
Minutes Reduce Duty Cycle
210 167
OM-2240 Page 16
4-5. Selecting A Location
1 Identification Plate
2 Rating Label
3 Line Disconnect Device
Dimensions And Weight Locate unit near correct input
48.5 lb (22.0 kg) power supply.
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
21 in
(533 mm)
13-3/8 in
(333 mm)
7-9/16 in
(192 mm)
SERIAL NO. 1
Location And Air flow
3 STOCK NO.
f1 f1
f2 f2 EN 60974−1
18 in (460 mm) S 60 Hz
U o 80V
I2
U2
200
28
130
25.2
110
24.4
100
24 23.6
90
Clearance
I1 max I 1 eff
1 50/60 Hz U 1 =115V 32 25
1 50/60 Hz U 1 =230V 35 16
3 50/60 Hz U 1 =230V 21 10
3 50/60 Hz U 1 =400V 12 6
3 50/60 Hz U 1 =460V 10 5
IP23
803 428-A
OM-2240 Page 17
4-6. Weld Output Terminals And Selecting Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding
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)
+
−
Output Receptacles
* 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.
( ) = mm2 for metric use
***Select weld cable size for pulsing application at peak amperage value. S-0007-E−
REMOTE
OUTPUT D Remote control circuit common.
CONTROL
E 0 to +10 volts dc input command signal from
remote control.
OM-2240 Page 18
4-8. Gas Connections
1 Gas Fitting
Fittings have 5/8-18 right-hand
threads (3/8-19 BSPP on CE units).
2 Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
3 Regulator/Flowmeter
4 3 2
4 Flow Adjust
Typical flow rate is 15 cubic feet per
hour (7.1 liters per minute).
1 Connect customer supplied gas
hose between regulator/flowmeter
and gas fitting on rear of unit.
Tools Needed:
802 452
2
1
4
Tools Needed:
803 430-a
OM-2240 Page 19
4-10. Stick Connections
Y Turn off power before mak-
ing connections.
1 Electrode Weld Output
Terminal
Connect electrode holder to weld
output terminal labeled Electrode.
2 Work Weld Output Terminal
Connect work lead to weld output
terminal labeled Work.
3 Remote 14 Receptacle
If desired, connect remote control
to Remote 14 receptacle (see Sec-
tion 4-7).
803 429-a
NOTE Actual input voltage should not fall below 103 volts AC or rise above 506 volts AC.
If actual input voltage is outside this range, unit may not operate according to
specifications.
Single-Phase, Single-Phase,
Three-Phase, 60% Duty
100% Duty 60% Duty
Cycle
Cycle Cycle
Input Voltage
115 230 230 400 460
Normal Operating 3 40 30 20 10 10
Tools Needed:
2/04 - Ref. 802 136-A / 803 428-A
OM-2240 Page 21
4-13. Connecting Single-Phase Input Power
Y Installation must meet all National
and Local Codes − have only quali-
fied persons make this installation.
1
Y Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
8 =GND/PE Earth Ground Y Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
10 to a line terminal.
Tools Needed:
OM-2240 Page 22
SECTION 5 − OPERATION
NOTE Section 5 in this manual covers operation of all models of 200 and 300 ampere
inverter based TIG machines. Features and options referenced may not be
available on your machine. Verify the model you have before using this section.
5-1. Controls
3 2 1
11
4 5 6 7 8 9 10
12
. For all front panel switch pad controls: 4 Polarity Control 8 Sequencer Controls (DX, LX
And All CE Models)
press switch pad to turn on light and en-
able function. See Section 5-6. See Section 5-10.
NOTE: Green on nameplate indicates a TIG 9 Adjust Controls
5 Process Controls
function, Gray indicates a Stick function.
See Section 5-11.
1 Encoder Control See Section 5-7.
10 AC Waveshape Control
Use encoder control in conjunction with appli-
cable front panel function switch pads to 6 Output Controls See Section 5-12.
change values for that function. See Section 11 Amperage And Spot Time Control
5-2. See Section 5-8.
For Amperage control, see Section 5-3.
2 Ammeter And Parameter Display
See Section 5-4. 7 Pulser Controls (DX And For Spot Time control, see Section 5-13.
LX Models)
3 Voltmeter 12 Power Switch
See Section 5-5. See Section 5-9. Use switch to turn unit On/Off.
OM-2240 Page 23
5-2. Encoder Control
1 Encoder Control
Use control in conjunction with ap-
1 plicable front panel function switch
pad to set values for that function.
Or Or
OM-2240 Page 24
5-5. Voltmeter
1 Volt Meter
Displays output or open circuit volt-
age. If output is off, the voltmeter will
1
display a series of three dashes
(-−−). Open circuit voltage is dis-
played if power is on and output is
available.
OM-2240 Page 25
5-7. Process Control
1 Process Control
Press switch pad until desired pro-
cess LED is illuminated:
TIG HF Impulse - When selected,
a pulsed HF (non-contact) (see
Section 11-3) arc starting method is
activated. This method can be used
with either AC or DC TIG welding.
Make connections according to
Section 4-9.
1 TIG Lift-Arct - When selected, is
an arc starting method in which the
electrode must come in contact
with the workpiece to initiate an arc
(see Section 11-3). This method
can be used with either AC or DC
TIG welding. Make connections ac-
cording to Section 4-9.
Stick (SMAW) - This method can
be used with either AC or DC Stick
welding. Make connections ac-
cording to Section 4-10.
1 Output Control are controlled at the remote control, only trigger input is functional (see
not at the welding power source. Section 6-2B).
Press switch pad until desired param-
eter LED is illuminated. NOTE: If On/Off only type trigger is NOTE: This switch function can be re-
used, it must be a maintained switch. configured for 4T, 4T Momentary, Mini
RMT STD (Remote Standard) All Sequencer functions become ac- Logic, or Spot control See Section
tive, and must be set by the operator. 6-2C)
Application: Use Remote Trigger
(Standard) when the operator desires RMT 2T HOLD ON
to use a foot pedal or finger amperage Application: Use Remote Trigger Output will energize two seconds after
control (see Section 6-2A). Hold (2T) when long extended welds being selected.
are made. Remote Trigger Hold (2T)
NOTE: When a foot or finger remote Application: Use Output On for Stick
can help to reduce operator fatigue.
current control is connected to the (SMAW) welding, or for Lift-Arc with-
welding power source, initial amps, If a foot or finger current control is con- out the use of a remote control (see
initial slope, final slope, and final amps nected to the welding power source, Section 6-2H).
OM-2240 Page 26
5-9. Pulser Control (DX And LX Models)
1 Pulser Control
3 Pulsing is available only while using
the TIG process, it cannot be se-
lected if the Stick process (see Sec-
2 tion 5-7) is active. 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
3 Ammeter
Turn encoder (see Section 5-2) to se-
lect appropriate value for active pulse
parameter. Value selected is shown
on the ammeter (see Section 5-4).
Also, the ammeter LED for the corre-
1 sponding unit of measure (%, A, s,
Hz) of the active parameter will be il-
luminated.
See Section 5-16 for all Pulser pa-
rameter ranges.
PPS (Pulses Per Second or Pulse
Frequency) - Control is used to de-
termine appearance of weld bead.
PEAK t - The percentage of each
pulse cycle that can be spent at the
4 peak amperage level.
OM-2240 Page 27
5-10. Sequencer Controls (DX, LX And All CE Models)
1 Sequencer Control
Sequencing is available only while
using the TIG process, but is dis-
abled if a remote foot or finger cur-
3 rent control is connected to the Re-
mote receptacle while in the RMT
STD mode. Sequencer parameters
2 cannot be selected if the Stick pro-
cess (see Section 5-7) is active.
Press switch pad until desired pa-
rameter LED is illuminated.
4 2 Encoder Control
3 Ammeter
Turn encoder (see Section 5-2) to
set appropriate value for active se-
Or Or quence parameter. Value selected
is shown on the ammeter (see Sec-
tion 5-4). Also, the ammeter LED for
the corresponding unit of measure
(A, S) of the active parameter will be
illuminated.
See Section 5-16 for all Sequencer
parameter ranges.
INITIAL A (Initial Amperage) - Use
1 control to select a starting amper-
age that is different from the weld
amperage.
Application:
Initial Amperage can be used 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 select amount of time
that is needed at the beginning of
the weld.
INITIAL SLOPE t (Initial Slope
Time) Use control to select amount
of time that it takes to slope up/
down from initial amperage to weld
amperage. To disable, set to 0.
4 Amperage Switch Pad
Weld Time (LX Models Only) -
Press Amperage switch pad twice.
Set desired length of weld time.
FINAL SLOPE t (Final Slope Time)
- Use control to select amount of
time that it takes to slope up/down
from weld amperage to final amper-
age. To disable, set to 0.
Application:
Final Slope should be used while
GTAW welding materials that are
crack sensitive, and/or the operator
wants to eliminate the crater at the
end of the weld.
FINAL A (Final Amperage) - Use
control to select amperage to which
weld amperage has sloped up/
down to.
FINAL t (Final Time)(LX Models
Only) - Press control again and turn
Encoder to select amount of time
that is needed at the end of the
weld.
OM-2240 Page 28
5-11. Adjust Controls (Preflow/Post Flow/DIG/Purge)
1 Adjust
Press switch pad until desired function
LED is illuminated.
3 2 Encoder Control
3 Ammeter
Turn encoder (see Section 5-2) to set ap-
2 propriate value for active Adjust parame-
ter. Value selected is shown on the am-
meter (see Section 5-4). Also, the am-
meter LED for the corresponding unit of
measure (S, %) of the active parameter
will be illuminated.
See Section 5-16 for all Adjust parame-
ter 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 set length of time gas flows before arc
initiation. To set Preflow time for models
that do not have Preflow Time control on
the front panel, see Section 5-15.
Application: Preflow is used to purge
. Some features shown are the immediate weld area of atmosphere.
not available on all models. Preflow also aids in consistent arc starts.
POST FLOW - If the TIG process is ac-
tive (see Section 5-7), use control to set
1 length of time gas flows after welding
stops.
Application:
Postflow is required to cool tungsten and
weld, and to prevent 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 set at 0, short-cir-
cuit amperage at low arc voltage is the
same as normal welding amperage.
When setting is increased, short-circuit
amperage at low arc voltage increases.
Application:
Control helps arc starting or making ver-
tical or overhead welds by increasing
amperage at low arc voltage, and re-
duces electrode sticking while welding.
PURGE - While in the TIG process (see
Section 5-7), to activate the gas valve
and start the purge function, push and
hold the Adjust switch pad for the desired
amount of purge time. To set from 1 to 50
seconds of additional purge time, contin-
ue to hold the Adjust switch pad while
turning the encoder control. Factory de-
fault setting is 0.
While Purge is active, (PUR) is shown in
the left display, and purge time is shown
in the right display.
Pressing any front panel switch pad will
end the purge time display, but gas will
continue to flow until the preset time has
timed out.
Application: Purge is used to clear the
shielding gas lines of contaminates.
OM-2240 Page 29
5-12. AC Waveshape (Dynasty Models Only)
1 AC Waveshape
3
2 Encoder Control
3 Ammeter
2 Turn encoder (see Section 5-2) to
set appropriate value for active AC
Waveshape parameter. Value se-
lected is shown on the ammeter
(see Section 5-4).
See Section 5-16 for all AC Wave-
shape parameter ranges.
Balance: AC Balance Control is
enabled only if AC TIG process is
selected. Use control to set per-
centage of time polarity is electrode
negative.
Application:
When welding on oxide forming ma-
terials such as aluminum or magne-
sium, excess cleaning is not neces-
sary. To produce a good weld, only
a minimal amount, approximately a
0.10 in (2.5mm) of etched zone
along the weld toes is required.
Or Or
OM-2240 Page 30
5-14. Memory (Program Storage Locations 1-4) (DX And LX Models If Available)
1 Memory (Program Storage
1-4) Switch Pad
2 Polarity Switch Pad
3 Process Switch Pad
To create, change, or recall a
welding parameters program,
1 proceed as follows:
First, press Memory switch pad until
the desired program storage loca-
tion (1-4) LED is illuminated
Second, press Polarity switch pad
until the desired polarity, AC or DC,
1st LED is illuminated
Third, press Process switch pad un-
til desired process, TIG HF Impulse,
2 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.
2nd 3rd Fourth, change or set all desired pa-
rameters (see Section 5-1 for pa-
3 . Some features shown are rameters).
not available on all models.
AC And
Stick
Memory Locations
And
1−4
TIG (HF or Lift)
DC And
Stick
OM-2240 Page 31
5-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A
Preflow Control On The Front Panel
SEL 0.2
1 2
And
3
V Or
Rear Panel
1 Process Control Pad Upon power up as described, the TIG Im- 4 Encoder Control
2 Adjust Control Pad pulse, Postflow, DIG, and meter S LED’s Turn encoder to select from 0 to 25 seconds
3 Power Switch turn on, and the factory default setting [SEL] of preflow. The value selected is displayed
[0.2] will be displayed. on the ammeter.
To adjust preflow, turn power switch on, and
then press the Process and Adjust switch Application: Preflow is used to purge the
pads before the software version clears the immediate weld area of atmosphere. Pre-
meters, and hold the switch pads until soft- flow also aids in consistent arc starting.
ware version clears the meters.
OM-2240 Page 32
5-16. Factory Parameter Defaults And Range And Resolution
A MAIN / PEAK
SEQUENCER
1 − 200 Amps DC
1 − 200 Amps DC
ADJUST
AC WAVESHAPE
OM-2240 Page 33
DYNASTY:
DC:
Polarity EN EP / EN
AC:
Polarity EP EP / EN
3 4
1 2
V Or
Rear Panel
OM-2240 Page 34
SECTION 6 − ADVANCED FUNCTIONS
NOTE Section 6 in this manual covers operation of all models of 200 and 300 ampere
inverter based TIG machines. Features and options referenced may not be
available on your machine. Verify the model you have before using this section.
4
2
Or Or
5 1 6 3
And
V Or
Rear Panel
NOTE: The welding cycle can be execut- pads until software version clears the Press the Process switch pad to select
ed while in programmable start mode. meters and [SEL] [EP] or [SEL] [EN] appears. the desired process, TIG HF Impulse or
Before accessing programmable TIG TIG Lift Arc, for your application (see
Start Polarity, Amperage, and Time 4 Memory Switch Pad (If Equipped) Section 5-7). The parameter values are
modes, be sure that all procedures and Press Memory switch pad to select de- the same for both processes, and any
parameters are established. sired memory location (see Section changes made to the values in one pro-
1 Process Switch Pad 5-14). cess, are duplicated in the other process.
2 Amperage Switch Pad 5 Polarity Switch Pad (If Equipped) 6 Output Switch Pad
3 Power Switch Press Output switch pad to select de-
Press Polarity switch pad to select AC or
To access the programmable TIG Start sired type of control (see Section 5-8).
DC (see Section 5-6).
Amperage and Time screens, turn power Proceed to Section B, C and/or D.
on, and then press the Process and Am- Note: Each memory location and each
perage switch pads before the software polarity (AC or DC) has its own set of start To save changes and exit Advanced
version clears the meters. Hold switch parameters. Functions, turn power off.
OM-2240 Page 35
B. Changing Programmable TIG Start Polarity (Dynasty Models Only)
SEL E−
Or Or
1 Amperage Switch Pad To adjust TIG Start Polarity proceed as [EP] is displayed on meters, and can be
follows: adjusted (see Section 5-16) by turning
2 Encoder Control Press Amperage switch pad. Switch pad the Encoder control.
LED turns on, and meter % LED turns on. To change Start Amperage, proceed to
3 Amps Meter The current Start Polarity, (SEL] [E−] or [SEL] Section C.
SEL 20
Or Or
1 Amperage Switch Pad To adjust TIG Start Amperage proceed on the amps meter, and can be adjusted
as follows: (see Section 5-16) by turning the
2 Encoder Control Press Amperage switch pad. Switch pad Encoder control.
LED turns on, and meter A LED turns on. To change Start Time, proceed to Section
3 Amps Meter The current Start Amperage is displayed D.
OM-2240 Page 36
D. Changing Programmable Start Time (All Models)
SEL 10
Or Or
1 Amperage Switch Pad To adjust Programmable Start Time pro- displayed on the amps meter, and can be
ceed as follows: adjusted by turning the Encoder control
2 Encoder Control (see Section 5-16).
Press Amperage switch pad, and meter
3 Amps Meter S LED turns on. The current Start Time is
OM-2240 Page 37
6-2. Output Control And Trigger Functions
Current (A)
Main Amps
Initial Amps
Final Amps
Preflow Postflow
P&H R R
Maintained Switch Foot Or Finger
Remote Control
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 welding power source.
Current (A)
Main Amps
Initial Amps
Final Amps
Preflow Postflow
P&R
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-2240 Page 38
Notes
OM-2240 Page 39
C. Reconfiguring RMT 2T HOLD For 2T, 3T, Spot, 4T, 4T Momentary, Or Mini Logic Control
SEL H−2
Or Or
And 3
V Or
Rear Panel
For RMT STD (Remote Standard), RMT To access the RMT 2T HOLD reconfi- 5 Meter Displays
2T Hold (Remote 2T Hold), and On trig- guration screen, turn power switch on
ger operation, see Section 6-2A, B, and and then press the Process and Output Meter displays for the different functions
H. switch pads before the software version will be as shown.
clears the meters. Hold the switch pads
1 Process Switch Pad Press torch trigger or turn power Off to
until software version clears the meters
and [SEL] [H-2], [SEL] [SPO], [SEL] [H-4], [SEL] save setting.
[H4L], (SEL) (H-3), or [SEL] [H4E] appears. NOTE: After 2T has been reconfigured
2 Output Switch Pad 4 Encoder Control and one of the reconfigured functions is
Turn Encoder to change functions. Ac- selected during normal operation, H−4,
tive function will be displayed on amper- H4L, H4E, H-3, or SPO will be displayed for 1
3 Power Switch age (right) meter. second as a reminder to the operator.
OM-2240 Page 40
SEL H−2 = 2T (See Section 6-2B
for operation)
SEL H-3 = 3T
(DX, LX and CE Models)
(See Section 6-2I
for operation)
OM-2240 Page 41
D. 4T Specific Trigger Method (DX, LX And All CE Models)
1 4T (Specific Trigger
1 Operation)
Sequencer is required to reconfi-
gure for 4T.
Select 4T according to Section
SEL H−4
6-2C.
Torch trigger operation is as shown.
= 4T
4T allows the operator to toggle be-
tween weld current and final current
without breaking the arc.
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:
Use 4T trigger method when the
Current (A) functions of a remote current con-
trol are desired, but only a remote
Torch Trigger Operation on/off control is available.
Main Amps
Initial Amps
Final Amps
Preflow Postflow
OM-2240 Page 42
E. Mini Logic Operation (DX, LX And All CE Models)
SEL H4L
While in mini logic, the operator
may use the trigger on the remote
= Mini Logic device to toggle between initial
slope or main amps and initial amps
as illustrated.
During Mini Logic, Final Amperage
is not available. Final slope will al-
ways slope to minimum amperage
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 either initial
slope or final slope, gives the oper-
ator the opportunity to adjust filler
metal without breaking the arc.
Main Amps
Final Slope
Initial Slope
*
Initial Amps
* * *
Preflow Postflow
OM-2240 Page 43
F. 4T Momentary Operation (DX, LX And All CE Models)
1 4T Momentary Meter
Display
Select 4T Momentary according
to Section 6-2C.
4T Momentary torch trigger op-
1 eration is as shown.
NOTE: When a remote switch is
connected to the welding power
source, use the remote switch to
control the weld cycle. Amper-
SEL H4E
age is controlled by the welding
power source.
= 4T Momentary Main
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.
Current (A)
Main Amps
Initial Amps
Final Amps
*
Preflow Postflow
NOTE: For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends
OM-2240 Page 44
G. Spot Control Operation
1 Spot Function Meter Display
1 Select Spot function according to
Section 6-2C.
NOTE: While in Spot Control, Se-
quencer settings will be ignored
and will not be programmable.
Current (A)
Preflow Postflow
OM-2240 Page 45
H. On Trigger Operation
Voltage (V)
ON
2 Sec
Current (A)
Stick
Touch Stick
Electrode Lift Stick
Electrode
Current (A)
Lift
Main Amperage
Touch Current
Touch Tungsten
Lift Tungsten Lift Tungsten
Slightly
OM-2240 Page 46
I. 3T Specific Trigger Method (DX, LX And All CE Models)
SEL H-3
Current (A)
Remote Trigger Operation
*
*
*
*
*
* *
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.
OM-2240 Page 47
6-3. Arc Timer/Counter Display
3/4
123 456
Or
Or Or
2
1
And V Or
Rear Panel
OM-2240 Page 48
6-4. Lockout Functions
000 LL−0
−−
1
3
2
V
Or
Rear Panel
See Section 5-1 for explanation of controls referred to in all of Toggle Amperage (A) switch pad to light the meter S LED. You may
Section 6-4. now select a lockout level.
There are four (1−4) different lockout levels. Each successive level There are four lockout levels available. Turn Encoder control to se-
allows the operator more flexibility. lect a lockout level (see Sections B for lockout level descriptions).
NOTE: Before activating lockout levels, be sure that all procedures 6 Lockout On
and parameters are established. Parameter adjustment is limited
while lockout levels are active. Once the desired three digits have been entered and a lockout level
selected, press torch trigger or turn Off power to complete lockout on
1 Amperage (A) Switch Pad sequence.
2 Adjust Switch Pad
NOTE: Setting a three digit lockout number of [000], or setting a lock-
3 Power Switch out level of [L−−] will cause a lockout off condition.
To access lockout screens, turn On power switch, and then before
To turn Off the lockout feature, proceed as follows:
the software version clears the meters, push and hold the Amperage
and Adjust switch pads until software version number clears meters. To access lockout screens, turn On power switch, and then before
4 Lockout Off the software version clears the meters push and hold the Amperage
and Adjust switch pads until software version number clears meters.
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 Upon power up as described, the meter % and Amperage (A) switch
off condition. pad LED’s will turn on, and the meter display will be as shown for a
lockout on (see callout 6) condition.
5 Encoder Control
To turn On the lockout feature, proceed as follows: Use Encoder control to enter the same three digits that were used
to turn on the lockout feature.
Pressing Amperage (A) switch pad will toggle between the meter %
and S LED’s. Toggle switch pad until % LED is on. Press the Amperage (A) switch pad. The meter % LED will turn off,
and the S LED will light. The amperage (right) meter display will
Turn Encoder control to select a three digit lockout number. Number change to [L−−]. The lockout feature is now off.
will appear on the voltage (left) meter. Select any number from [001]
thru [999 ]. IMPORTANT: remember this three digit number, as you Press torch trigger or turn Off power to complete lock out Off
will need it to turn the lockout feature off. sequence.
OM-2240 Page 49
B. LockOut Levels
Level 1 NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
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 (Re-
mote Standard) or RMT 2T HOLD
(Remote 2T Hold). The On function
is also available if TIG Lift Arc was
Use Output Switch Pad To active.
Select A Trigger Method If RMT 2T HOLD was reconfigured
(see Section 6-2C) prior to lockout
For The TIG Process 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 level 1 was activated,
the operator can choose between
RMT STD or On.
When parameter change or selec-
tion is limited by lock level 1, [L-1 ] is
displayed as a reminder.
Level 2
NOTE: Remote amperage control
is not available in level 2.
Includes all the functions of level 1
plus Polarity and Process Selection
(see Sections 5-6 and 5-7).
When parameter change or selec-
Use Output Switch Pad To tion is limited by lock level 2, [L-2] is
displayed as a reminder.
Select A Trigger Method
Level 2
Select Process
Process Selection
OM-2240 Page 50
B. Lock Out Levels (Continued)
Level 3 Level 3
NOTE: Remote amperage control is
not available in level 3.
Use Encoder Control To Includes all the functions of levels 1
Adjust Amperage +/− 10% and 2 plus the following:
Of Preset Value. +/− 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 [L-3 ] as a re-
minder.
Pulser ON/Off Control
Gives operator the ability to turn on/
Select Process off the Pulser control.
When parameter change or selec-
+/− 10 % Amperage Adjust Control tion is limited by lock level 3, [L-3] is
displayed as a reminder.
Level 4
Includes all the functions of levels 1,
2, and 3 plus the following:
Remote Amperage Control
Allows operator to use remote am-
perage control if desired. Remote
control operates from minimum to
maximum of preset amperage val-
ue. Connect remote control device
according to Section 4-7.
When parameter change or selec-
tion is limited by lock level 4, [L-4] is
displayed as a reminder.
Level 4
A J
K I
B
C L N H
D M G
E F
OM-2240 Page 51
6-5. Setting Unit To Display PPP While Pulse Welding (DX And LX Models Only)
PPP
4
sel −−−
1 2
3
And
V
Or
Rear Panel
1 Output Switch Pad clears the meters. Hold the switch pads be displayed on the right meter display,
until [SEL] [−−−] or [SEL] [PPP] appears. and the Meter Hold feature is disabled.
2 Pulser Switch Pad
4 Encoder Control The (PPP) meter display feature will not
3 Power Switch 5 PPP Meter Display effect the normal amperage display or
Turn Encoder to change between stan- Meter Hold capabilities when in a non-
To access the PPP while welding dis-
dard and (PPP) meter display. pulse welding mode.
play, turn power switch on, and then
press the Output and Pulser switch When the (PPP) meter display feature is Press torch trigger or turn off power to
pads before the software version active while pulse welding, the (PPP) will save setting and end this set-up.
OM-2240 Page 52
6-6. Stick Open-Circuit Voltage (OCV) Selection (All Models)
6 5
sel loc
3
1 2
V
And
Or
Rear Panel
1 Process Switch Pad sion clears the meters. Hold the switch When Stick low OCV is selected, open-
pads until [SEL] [Loc] or [SEL] [noc) appears. circuit voltage is between 9 and 14
2 Adjust Switch Pad volts. When Stick normal OCV is se-
5 Encoder Control lected, open-circuit voltage is approxi-
3 Amperage Switch Pad
6 Meter Display mately 80 volts.
4 Power Switch
Application: For most Stick applica-
To access the Stick OCV selection, Turn Encoder to change between low tions use low open-circuit voltage. Use
turn power switch on and then press OCV [SEL] [Loc] and normal OCV [SEL] normal open-circuit voltage for hard to
the Process, Adjust and Amperage [noc]. Active selection is displayed on start Stick electrodes, or if required for
switch pads before the software ver- the meters. your particular application.
OM-2240 Page 53
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING
3 Months
3 Months
Repair Or Replace
Cracked Cables
And Cords
6 Months
Y Do not remove case when
blowing out inside of unit
(see Section 7-2) .
Blow out inside. During
heavy service clean
monthly.
803 428-A
OM-2240 Page 54
7-3. Voltmeter/Ammeter Help Displays
V A V A
0 5
OM-2240 Page 55
7-4. Troubleshooting
Trouble Remedy
No weld output; unit completely Place line disconnect switch in On position (see Section 4-12 or 4-13).
inoperative.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-12 or 4-13).
Check for proper input power connections (see Section 4-12 or 4-13).
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 Section 4-7 as applicable).
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).
Fan not operating. Check for and remove anything blocking fan movement.
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
weld
Increase postflow time (see Section 5-1).
OM-2240 Page 56
SECTION 8 − ELECTRICAL DIAGRAMS
OM-2240 Page 57
SECTION 9 − HIGH FREQUENCY (HF)
9-1. Welding Processes Requiring High Frequency
1 High-Frequency Voltage
TIG − helps arc jump air gap
1 between torch and workpiece and/
or stabilize the arc.
Work
TIG
6
Weld Zone
50 ft 50 ft
(15 m) (15 m)
1
5
2
7
3
7
Ground All
Metal Objects
And All Wiring
In Welding Zone 8
Using #12 AWG Ground
Wire Workpiece
If Required
Nonmetal By Codes
Building
7
7
10
Metal Building
9
1 HF Source (Welder With Built-In HF Or Electrically join (bond) all conduit sections 8 Metal Building Panel Bonding Methods
Separate HF Unit) using copper straps or braided wire. Ground
conduit every 50 ft (15 m). Bolt or weld building panels together, install
Ground metal machine case, work output copper straps or braided wire across seams,
terminal, line disconnect device, input 5 Water Pipes And Fixtures and ground frame.
supply, and worktable.
Ground water pipes every 50 ft (15 m). 9 Windows And Doorways
2 Welding Zone And Centerpoint
6 External Power Or Telephone Lines Cover all windows and doorways with
A circle 50 ft (15 m) from centerpoint
grounded copper screen of not more than
between HF source and welding torch in all Locate HF source at least 50 ft (15 m) away 1/4 in (6.4 mm) mesh.
directions. from power and phone lines.
3 Weld Output Cables 10 Overhead Door Track
7 Grounding Rod
Keep cables short and close together. Ground the track.
Consult the National Electrical Code for
4 Conduit Joint Bonding And Grounding specifications.
OM-2240 Page 58
SECTION 10 − SELECTING AND PREPARING TUNGSTEN
ELECTRODE
gtaw5_8/8/03
NOTE For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent
contamination of tungsten electrode.
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
Ref. S-0161
OM-2240 Page 59
10-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding
1 Tungsten Electrode
1 2 2 Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld-
ing. Do not use wheel for other jobs
or tungsten can become contami-
nated causing lower weld quality.
2-1/2 Times
Electrode Diameter
1 Stable Arc
2 Flat
1
Diameter of this flat determines
amperage capacity.
2
3 Grinding Wheel
3 Grinding wheel should be dedi-
cated to grinding tungsten only.
4 Straight Ground
4
Ideal Tungsten Preparation − Stable Arc
1 Arc Wander
2 Point
1 3 Grinding Wheel
Grinding wheel should be dedi-
2 cated to grinding tungsten only.
4 Radial Ground
Om-2240 Page 60
SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW)
Ammeter Encoder
207 694-A
This symbol indicates which functions should be active for aluminum.
Ammeter Encoder
207 694-A
This symbol indicates which functions should be active for stainless steel.
Om-2240 Page 62
11-2. Positioning The Torch
Y Grinding the tungsten elec-
trode produces dust and fly-
ing sparks which can cause
injury and start fires. Use lo-
cal exhaust (forced ventila-
tion) at the grinder or wear an
3
approved respirator. Read
MSDS for safety information.
Consider using cerium or
2
lanthanum based tungsten
instead of thoriated. Tho-
rium dust contains low-level
radioactive material. Proper-
4 ly dispose of grinder dust in
an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flam-
90°
mables away.
1 1 Workpiece
Make sure workpiece is clean
before welding.
2 Work Clamp
Place as close to the weld as
possible.
10−15°
3 Torch
4 4 Filler Rod (If Applicable)
5 Gas Cup
5 6 Tungsten Electrode
10−25° 6 Select and prepare tungsten
according to Sections 10-1 and
10-3.
Guidelines:
5 The inside diameter of the gas cup
6 should be at least three times the
tungsten diameter to provide ade-
quate shielding gas coverage. (For
example, if tungsten is 1/16 in
diameter, gas cup should be a
minimum of 3/16 in diameter.
1/16 in
Tungsten extension is the distance
the tungsten extends out gas cup of
3/16 in torch.
Bottom View Of Gas Cup The tungsten extension should be
no greater than the inside diameter
of the gas cup.
Arc length is the distance from the
tungsten to the workpiece.
OM-2240 Page 63
11-3. Lift-Arc™ And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arct 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-
Lift-Arc Start Method ger, foot control, or hand control.
1 2 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
1−2 touches workpiece; only a low
“Touch” Seconds 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-
Do NOT Strike Like A Match! place the scratch method.
HF Start
When HF Start button light is On,
start arc as follows:
High frequency turns on to help
start arc when output is enabled.
High frequency 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-2240 Page 64
11-4. Torch Movement During Welding
Tungsten Without Filler Rod
75° 15°
Welding direction
OM-2240 Page 65
11-5. Positioning Torch Tungsten For Various Weld Joints
90°
Butt Weld And Stringer Bead
70°
20°
20°
“T” Joint
70°
20°
10°
40°
Lap Joint
70°
20°
30°
90°
Corner Joint
70°
20°
Om-2240 Page 66
SECTION 12 − STICK WELDING (SMAW) GUIDELINES
12-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)
1 Front Panel
Correct front panel display for basic
1 Stick DCEP welding.
207 694-A
OM-2240 Page 67
12-2. Electrode and Amperage Selection Chart
AMPERAGE
RANGE
ELECTRODE
DIAMETER
100
150
200
250
300
350
400
450
PENETRATION
50
ELECTRODE
POSITION
USAGE
3/32
DC*
AC
1/8
6010
5/32
& 3/16
6011 7/32
1/4 6010 EP ALL DEEP MIN. PREP, ROUGH
1/16 HIGH SPATTER
6011 EP ALL DEEP
5/64
3/32 6013 EP,EN ALL LOW GENERAL
1/8 SMOOTH, EASY,
6013 7014 EP,EN ALL MED FAST
5/32
3/16 LOW HYDROGEN,
7018 EP ALL LOW STRONG
7/32
1/4 FLAT
7024 EP,EN HORIZ LOW SMOOTH, EASY,
3/32 FASTER
FILLET
1/8
5/32 NI-CL EP ALL LOW CAST IRON
7014
3/16 308L EP ALL LOW STAINLESS
7/32 *EP = ELECTRODE POSITIVE (REVERSE POLARITY)
1/4 EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
3/32
1/8
5/32
7018
3/16
7/32
1/4
3/32
1/8
5/32
7024
3/16
7/32
1/4
3/32
1/8
Ni-Cl
5/32
3/16
3/32
308L 1/8
5/32
Ref. S-087 985-A
OM-2240 Page 68
12-3. Stick Welding Procedure
Y Weld current starts when
electrode touches work-
piece.
5
Y Weld current can damage
4 electronic parts in vehicles.
Disconnect both battery
2
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
1 Workpiece
Make sure workpiece is clean be-
fore welding.
2 Work Clamp
3
3 Electrode
A small diameter electrode requires
6
less current than a large one. Fol-
low electrode manufacturer’s
1 7 instructions when setting weld am-
perage (see Section 12-2).
4 Insulated Electrode Holder
5 Electrode Holder Position
6 Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
Tools Needed: arc with 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.
stick 12/96 − ST-151 593
S-0050
OM-2240 Page 69
12-6. Positioning Electrode Holder
10°-30°
90° 90°
GROOVE WELDS
10°-30°
45°
45°
2 3 4
5 S-0053-A
S-0052-B
OM-2240 Page 70
12-9. Conditions That Affect Weld Bead Shape
NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.
Correct Angle
Angle Too Small 10° - 30° Angle Too Large
Drag
ELECTRODE ANGLE
Spatter
NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads work better.
S-0054-A
OM-2240 Page 71
12-11. Butt Joints
1 1 Tack Welds
Prevent edges of joint from drawing
2 together ahead of electrode by tack
welding the materials in position be-
fore final weld.
2 Square Groove Weld
Good for materials up to 3/16 in (5
mm) thick.
3 Single V-Groove Weld
30° Good for materials 3/16 − 3/8 in (5-9
1/16 in mm) thick. Cut bevel with oxyacety-
(1.6 mm) lene or plasma cutting equipment.
Remove scale from material after
cutting. A grinder can also be used
to prepare bevels.
3 4 Create 30 degree angle of bevel on
materials in V-groove welding.
4 Double V-Groove Weld
Good for materials thicker than 3/8
in (9 mm).
S-0662
3
S-0060 / S-0058-A / S-0061
OM-2240 Page 72
12-14. Weld Test
1 Vise
3 2 Weld Joint
3 Hammer
Strike weld joint in direction shown.
3 A good weld bends over but does
not break.
2 To 3 in
(51-76 mm)
2 To 3 in
(51-76 mm)
2 2
1/4 in
(6.4 mm) 1 1
S-0057-B
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Amperage too high for electrode. Decrease amperage or select larger electrode.
Arc length too long or voltage too high. Reduce arc length or voltage.
OM-2240 Page 73
12-17. Troubleshooting − Incomplete Fusion
Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.
Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.
OM-2240 Page 74
12-20. Troubleshooting − Burn-Through
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
Excessive heat input. Use restraint (clamp) to hold base metal in position.
OM-2240 Page 75
SECTION 13 − PARTS LIST
11
. Hardware is common and
not available unless listed.
12
13
28
25 615
41
19 2
18
10
28 16
402 8
6
40
401 32
400
14
403
3
15 31 4
17
1
29
614
39
600
OM-2240 Page 76
Item Dia. Part
No. Mkgs. No. Description Quantity
OM-2240 Page 77
400
604
. Hardware is common and
not available unless listed.
1
3 603
14
13
12
9 602
15
11
16
8
803 391-A
207 698 Figure 13-2. Panel Front w/Components (Figure 13-1 Item 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-2240 Page 78
. Hardware is common and
not available unless listed.
601 4
600 1
6
605
803 392-A
Figure 13-3.Panel, Rear w/Components
Item Dia. Part
No. Mkgs. No. Description Quantity
210 158 Figure 13-3. Panel, Rear w/Components (Figure 13-1 Item 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-2240 Page 79
. Hardware is common and 604 613
not available unless listed. 608
1
3
609
7
19
5
4 21
21
17 618
617
614
611
15 600
2
12
400
9 11
612
14 8
6
13
605
20
10
18
803 427-A
Figure 13-4. Magnetics Assembly w/Components
209 936 Figure 13-4. Magnetics Assembly w/Components (Figure 13-1 Item 3)
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-2240 Page 81
. Hardware is common and
not available unless listed.
606
605
13 1 10
14
11
12 4
602
607
8 6
803 425-A
Figure 13-5. Windtunnel w/Components
+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-2240 Page 82
. Hardware is common and
12 not available unless listed.
601
11
3
10
6
9
8
7
2
5
1
803 426-B
210 163 Figure 13-6. Heat Sink, Secondary Assembly(Figure 13-5 Item 7)
♦For models prior to Serial No. LE200084, order kit 220 384 (kit contains PC board 207826 and clips 220384).
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-2240 Page 83
. Hardware is common and
not available unless listed.
803 394−A
Figure 13-7. Base Assembly
Item Dia. Part
No. Mkgs. No. Description Quantity
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 equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2240 Page 84
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
Call LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
for your local the effective date of this limited warranty is free of defects in * Remote Controls
material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory Kits
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
Your distributor also gives replace any warranted parts or components that fail due to such
* Canvas Covers
you ... defects in material or workmanship. Miller must be notified in Miller’s True Blue® Limited Warranty shall not apply to:
Service writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings,
reliable response you relays or parts that fail due to normal wear. (Exception:
need. Most replacement Miller shall honor warranty claims on warranted equipment brushes, slip rings, and relays are covered on Bobcat,
parts can be in your listed below in the event of such a failure within the warranty Trailblazer, and Legend models.)
time periods. All warranty time periods start on the date that the
hands in 24 hours. equipment was delivered to the original retail purchaser, or one 2. Items furnished by Miller, but manufactured by others,
Support year after the equipment is sent to a North American distributor such as engines or trade accessories. These items are
Need fast answers to the or eighteen months after the equipment is sent to an covered by the manufacturer’s warranty, if any.
International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
Contact your distributor. 1. 5 Years Parts — 3 Years Labor Miller, or equipment that has been improperly installed,
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
distributor and Miller is * Inverters (input and output rectifiers only)
standards, or equipment which has not had reasonable
there to help you, every and necessary maintenance, or equipment which has
step of the way. 2. 3 Years — Parts and Labor been used for operation outside of the specifications for the
equipment.
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Semi-Automatic and Automatic Wire Feeders PERSONS TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated) In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Maxstar 150 replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods at
3. 1 Year — Parts and Labor Unless Specified customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
* Motor Driven Guns (w/exception of Spoolmate Miller. Therefore no compensation or reimbursement for
Spoolguns) transportation costs of any kind will be allowed.
* Process Controllers TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Positioners and Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* RFCS Foot Controls CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources and Coolers
ANY OTHER LEGAL THEORY.
* Water Coolant Systems (Non-Integrated)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Flowgauge and Flowmeter Regulators (No Labor) ANY IMPLIED WARRANTY, GUARANTY OR
* HF Units REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Maxstar 85, 140 PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Spot Welders OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Load Banks MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Arc Stud Power Sources & Arc Stud Guns PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Racks FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
Models)
special or consequential damages, so the above limitation or
* Field Options exclusion may not apply to you. This warranty provides specific
(NOTE: Field options are covered under True legal rights, and other rights may be available, but may vary
Blue® for the remaining warranty period of the from state to state.
product they are installed in, or for a minimum of
one year — whichever is greater.) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
5. 90 Days — Parts Warranty provides specific legal rights, and other rights may be
* MIG Guns/TIG Torches available, but may vary from province to province.
miller_warr 1/05
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.