Miller Dynasty 200 Dx User Manual

Page 2 - To locate your nearest; Thank you; From Miller to You

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearest distributor or service agency call...

Page 3 - TABLE OF CONTENTS

TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1...

Page 5 - DECLARATION OF CONFORMITY; declares that the

DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions ofthe stated Council Directive(s) and Stand...

Page 11 - SECTION 2; CONSIGNES DE SÉCURITÉ

OM-2240 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010 − 03 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort...

Page 17 - SECTION 3

OM-2240 Page 11 SECTION 3 − DEFINITIONS (CE Models) 3-1. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols.1 Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet...

Page 20 - -2. Serial Number And Rating Label Location

OM-2240 Page 14 SECTION 4 − INSTALLATION 4-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) ! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equip...

Page 22 - Phase Voltage Input DC Output; 30VAC Single Phase Input DC Output; Amperes; 15VAC Input DC Output; Amperes

OM-2240 Page 16 4-4. DC Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amper- age output capabilities of welding power source. Curves of other set- tings fall between curves shown. 210 168-A 3 Phase Voltage Input; DC Output 0 20 40 60 80 100 120 140 0 50 100 150 200 250 A...

Page 23 - 15VAC Input AC Output; 30VAC Single Phase Input AC Output; Volts

OM-2240 Page 17 4-5. AC Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amper- age output capabilities of welding power source. Curves of other set- tings fall between curves shown. 210 168 115VAC Input; AC Output 0 20 40 60 80 100 120 140 0 50 100 150 200 250 Amperes Volt...

Page 24 - OUTPUT AMPERES; STICK

OM-2240 Page 18 4-6. Duty Cycle And Overheating 210 167 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 Section 7-3), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce am...

Page 28 - Connections

OM-2240 Page 22 4-11. TIG HF Impulse/ Lift-Arc t Connections 803 430-A ! Turn off power before mak- ing connections. 1 Electrode Weld Output Terminal Connect TIG torch to weld output terminal labeled Electrode.2 Gas Out Connection Connect torch gas hose to gas out fitting.3 Work Weld Output Terminal...

Page 30 - Notes

OM-2240 Page 24 4-14. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. . Actual in...

Page 41 - SPO

OM-2240 Page 35 5-13. AC Waveshape 1 AC Waveshape 2 Encoder Control 3 Ammeter 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 5-15 for all AC Wave- shape parameter ranges. Balance: AC Ba...

Page 42 - -15. Factory Parameter Defaults And Range And Resolution

OM-2240 Page 36 5-15. Factory Parameter Defaults And Range And Resolution Parameter Default Range And Resolution Process TIG HF Impulse TIG HF Impulse / TIG Lift / Stick * Stick OCV Low OCV Low OCV / Normal OCV *Stick Stuck Check ScI (On) ScI (On) / Sc0 (Off) Output *RMT 2T RMT STD 2T RMT STD / RMT ...

Page 43 - -16. Resetting Unit To Factory Default Settings

OM-2240 Page 37 DYNASTY: DC: *Tungsten **Polarity **Amperage **Time **Start Slope Time **Preset Amperage Minimum AC: *Tungsten **Polarity **Amperage **Time **Start Slope Time **Preset Amperage Minimum .094 EN 60 1 40 3 .094 EP 120 20 10 5 GEN, .020, .040, .062, .094, .125 EP / EN 1 − 200 Amps 1 − 20...

Page 45 - Accessing Advanced Functions

OM-2240 Page 39 SECTION 6 − ADVANCED FUNCTIONS 6-1. Accessing Advanced Functions 1 Amperage Switch Pad 2 Adjust 3 Encoder Control To access the advanced functions, press and hold the Amperage (A) switch pad and then press the Adjust switch pad. To scroll through the advanced functions, press and rel...

Page 46 - Tungsten Selection; tun

OM-2240 Page 40 6-2. Programmable TIG Start Parameters A. Tungsten Selection 2 3 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter Preset TIG Start Parameters Use Encoder control to select a tungsten size from the following: .020, .040, .062 (1/16 in.), .094 (3/32 in.), or .125 (1/8 in.) (.094 is...

Page 47 - Selecting GEN; GEn

OM-2240 Page 41 B. Selecting GEN 1 Encoder Control 2 Amps Meter 3 Amperage Switch Pad If [GEn] is selected and displayed on the amps meter, the TIG starting parameters for a .094 tungsten are the default, and for AC polarity they are: Start Polarity = EP, Start Am- perage = 120 A, Start Time = 20 ms...

Page 48 - Changing Programmable TIG Start Polarity; StP; Changing Programmable TIG Start Amperage; StA

OM-2240 Page 42 C. Changing Programmable TIG Start Polarity 2 StP E − 3 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust TIG Start Polarity proceed as fol- lows:Press Amperage switch pad. Switch pad LED turns on, and meter % LED turns on. The current Start Polarity, [StP] [E − ] or [St...

Page 49 - Stt; Changing Start Slope Time; StS

OM-2240 Page 43 E. Changing Programmable Start Time 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust Programmable Start Time pro- ceed as follows:Press Amperage switch pad, and meter S LED turns on. The current Start Time is dis- played in milliseconds on the amps meter, and can be adj...

Page 50 - Changing Preset Amperage Minimum

OM-2240 Page 44 G. Changing Preset Amperage Minimum 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust Preset Amperage Minimum pro- ceed as follows: Press Amperage switch pad. Switch pad LED turns on, and meter A LED turns on. The Preset Minimum Amperage is dis- played on the amps meter,...

Page 51 - -3. Output Control And Trigger Functions

OM-2240 Page 45 6-3. Output Control And Trigger Functions A. Remote (Standard) Torch Trigger Operation Current (A) Preflow Initial Amps Initial Slope Final Slope Postflow Main Amps Final Amps R R P & H Maintained Switch Foot Or Finger Remote Control P&H = Push trigger and holdR = Release tri...

Page 52 - T Specific Trigger Method; rt

OM-2240 Page 46 C. 3T Specific Trigger Method 1 3T (Specific Trigger Operation) Sequencer is required to reconfigure for 3T. 3T requires a specific type of remote con- trol with two independent momentary- contact switches. One will be designated initial switch, and it must be connected be- tween Rem...

Page 58 - AC Waveshape Selection; SEL

OM-2240 Page 52 6-4. AC Waveshape Selection 1 Encoder Use the Encoder to select between ad- vanced squarewave [ASq] , soft square- wave [SSq] (default), sine wave [SIN], or triangle wave [TRI]. To save changes and exit, press torch trig- ger or turn power off. Application: Use advance squarewave whe...

Page 59 - on

OM-2240 Page 53 6-5. Setting Preflow Time 1 Encoder Control Turn encoder to select from 0 to 25 seconds of preflow. The value selected is displayed on the am- meter. Application: Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting. PrE 0.2 1 6...

Page 60 - Lockout Functions; oFF

OM-2240 Page 54 6-8. Lockout Functions A. Accessing Lockout Capability 2 oFF cod 1 oFF Loc See Section 6-1 for explanation of controls referred to in all of Section 6-8. There are four (1 − 4) different lockout levels. Each successive level allows the operator more flexibility. . Before activating l...

Page 69 - -1. Welding Processes Requiring High Frequency; Best Practices

OM-2240 Page 63 SECTION 9 − HIGH FREQUENCY 9-1. Welding Processes Requiring High Frequency high_freq 5/10 − S-0693 1 High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. 1 TIG Work 9-2. Installation Showing Possible Sources Of HF Interference 50 ...

Page 70 - -3. Recommended Installation To Reduce HF Interference; Best Practices Followed

OM-2240 Page 64 9-3. Recommended Installation To Reduce HF Interference 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) Ground metal machine case (clean paint from around hole in case, and use case screw), work output terminal, line discon- nect device, input supp...

Page 73 - Welding With Inverter Machines

OM-2240 Page 67 SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2010-04 Whenever possible and practical, use DC weld output instead of AC weld output. 11-1. Selecting Tungsten Electrode ( Wear Clean gloves To Prevent Contamination Of Tungsten...

Page 75 - 2-3. Positioning Torch Tungsten For Various Weld Joints

OM-2240 Page 69 12-2. Torch Movement During Welding ST-162 002-B Tungsten Without Filler Rod Tungsten With Filler Rod Form pool Tilt torch Move torch to front of pool. Repeat process. 75 ° 75 ° Welding direction Form pool Tilt torch Add filler metal Move torch to front of pool. Repeat process. Remov...

Page 78 - 4-2. Electrode and Amperage Selection Chart

OM-2240 Page 72 14-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 6011 6013 7014 7018 7024 Ni-...

Page 80 - 4-7. Conditions That Affect Weld Bead Shape

OM-2240 Page 74 14-7. Conditions That Affect Weld Bead Shape S-0061 Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Small Angle Too Large Correct Angle Electrode Angle Arc Length Travel Speed . Weld bead shape is affectedby electrode angle, arc length, travel speed, and...

Page 84 - PARTS LIST

OM-2240 Page 78 SECTION 15 − PARTS LIST Figure 15-1. Main Assembly 805 464-B . Hardware is common andnot available unless listed. 28 25 12 11 28 13 402 8 40 6 2 10 32 44 4 29 5 39 42 600 614 1 17 15 3 403 43 14 400 401 7 16 18 19 41 615 46 45

Page 93 - Pros weld and cut

OM-2240 Page 87 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules atthe beginningof this manual.

Page 94 - COOLER PARTS LIST

OM-2240 Page 88 SECTION 16 − COOLER PARTS LIST . Hardware is common andnot available unless listed. 805 266-A 1 2 3 4 5 6 7 9 8 13 10 11 13 12 14 7 16 15 6 7 15 19 18 22 23 24 25 19 27 26 21 20 17 28 Figure 16-1. Cooler Main Assembly

Page 96 - CART PARTS LIST

OM-2240 Page 90 SECTION 17 − CART PARTS LIST 805 337-B . Hardware is common andnot available unless listed. 1 3 7 4 5 6 2 8 9 10 9 11 12 13 14 15 16 17 17 6 12 . Item 4 can be mounted inalternative position if desired. 7 Figure 17-1. Cart Main Assembly Quantity Description Part No. Dia. Mkgs. Item N...

Page 97 - (Equipment with a serial number preface of MA or newer)

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2010 − 01 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding ...

Page 98 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2010 Miller Electric Mfg. Co. 2010 − 01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 Internati...