Miller DYNASTY 200 DX Owner's Manual
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Miller DYNASTY 200 DX Owner's Manual

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www.MillerWelds.com
Dynasty 200 SD And DX
R
OM-2240
207688K
March 2005
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
115/230/400/460 Volt Models W/AutolineR
Arc Welding Power Source
And Non-CE Models

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Summary of Contents for Miller DYNASTY 200 DX

  • Page 1 OM-2240 207688K March 2005 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description 115/230/400/460 Volt Models W/AutolineR Arc Welding Power Source Dynasty 200 SD And DX And Non-CE Models Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 6 − ADVANCED FUNCTIONS ............6-1.
  • Page 5 Declaration of Conformity For European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit.) Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Dynasty...
  • Page 6 Notes...

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 8 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 10: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- (phone: 305-443-9353, website: www.aws.org). ternational.org).

  • Page 11: Section 2 − Consignes De Sécurité − À Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- lance.
  • Page 12 LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et D Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation.

  • Page 13: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil

    2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. D Ne pas placer l’appareil sur une surface inflam- D Se tenir à l’écart des organes mobiles comme les mable, ni au−dessus ou à...

  • Page 14: Principales Normes De Sécurité

    2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna- (téléphone : (305) 443−9353, site Web : www.aws.org).

  • Page 15: Section 3 − Definitions (Ce Models)

    SECTION 3 − DEFINITIONS (CE Models) 3-1. Warning Label Definitions Warning! Watch Out! There are possible 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.
  • Page 16 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors.

  • Page 17: Manufacturer's Rating Label

    3-2. Manufacturer’s Rating Label See Section 4-5 for location. EN 60974−1 Use rating label to de- termine input power requirements. 1A 10V 200A 18V =115V 100% 100% 20−250 Hz 14.8 15.6 1A 20V 200A 28V =115V 100% 100% 60 Hz 25.2 24.4 23.6...

  • Page 18: Symbols And Definitions

    3-3. Symbols And Definitions Gas Tungsten Arc Shielded Metal Arc Amperes Panel−Local Welding (GTAW) Welding (SMAW) 3 Phase Static Frequency Volts Voltage Input Converter-Transformer-Rectifier Lift-Arc Start Voltage Output Circuit Breaker Remote (GTAW) Protective Earth Postflow Timer Preflow Timer Seconds (Ground) Positive Negative Alternating...

  • Page 19: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Specifications Amperes Input At Rated Output, 50/60Hz Welding Max. Input Power Input Power Rated Output Rated Output Amperage Amperage Open-Circuit Open-Circuit Range ** Voltage ∇ Three-Phase 130 A @ 25.2 VDC, 12.3 1 − 200 -−...

  • Page 20: Dc Volt-Ampere Curves

    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. Stick Max. TIG Max. Stick/TIG Min. DIG Max. Amperes 230VAC Single Phase Input;...

  • Page 21: Ac Volt-Ampere Curves

    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- tings fall between curves shown. Stick Max. TIG Max. Stick/TIG Min. Amperes 230VAC Single Phase Input;...

  • Page 22: Duty Cycle And Overheating

    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 Section 7-3), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.

  • Page 23: Selecting A Location

    4-5. Selecting A Location Identification Plate Rating Label Line Disconnect Device Dimensions And Weight Locate unit near correct input power supply. 48.5 lb (22.0 kg) Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 24: Weld Output Terminals And Selecting Cable Sizes

    4-6. Weld Output Terminals And Selecting Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding Y Turn off power before 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft connecting to weld out- 100 ft (30 m) Or Less (45 m) (60 m)

  • Page 25: Gas Connections

    4-8. Gas Connections Gas Fitting Fittings have 5/8-18 right-hand threads (3/8-19 BSPP on CE units). Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. Regulator/Flowmeter Flow Adjust Typical flow rate is 15 cubic feet per hour (7.1 liters per minute).

  • Page 26: Stick Connections

    4-10. Stick Connections Y Turn off power before mak- ing connections. Electrode Weld Output Terminal Connect electrode holder to weld output terminal labeled Electrode. Work Weld Output Terminal Connect work lead to weld output terminal labeled Work. Remote 14 Receptacle If desired, connect remote control to Remote 14 receptacle (see Sec- tion 4-7).

  • Page 27: Connecting Three-Phase Input Power

    4-12. Connecting Three-Phase Input Power Y Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Y Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Y Always connect green or green/ yellow conductor supply...

  • Page 28: Connecting Single-Phase Input Power

    4-13. Connecting Single-Phase Input Power Y Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Y Disconnect and lockout/tagout in- put power before connecting input conductors from unit. =GND/PE Earth Ground Y Always connect green or green/ yellow conductor supply...

  • Page 29: Section 5 − Operation

    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.

  • Page 30: Encoder Control

    5-2. Encoder Control Encoder Control Use control in conjunction with ap- plicable front panel function switch pad to set values for that function. 5-3. Amperage Control A (Amperage Control) Encoder Control Ammeter See Section 5-16 for Amperage control range. Press Amperage switch pad and turn Encoder control to set weld amperage.

  • Page 31: Voltmeter

    5-5. Voltmeter Volt Meter Displays output or open circuit volt- age. If output is off, the voltmeter will display a series of three dashes (-−−). Open circuit voltage is dis- played if power is on and output is available. 5-6. Polarity Control (Dynastyt Models Only) Polarity Control Press switch pad until desired LED is illuminated.

  • Page 32: Process Control

    5-7. Process Control 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.

  • Page 33: Pulser Control (Dx And Lx Models)

    5-9. Pulser Control (DX And LX Models) Pulser Control Pulsing is available only while using the TIG process, it cannot be se- lected if the Stick process (see Sec- tion 5-7) is active. Controls can be ad- justed while welding. Press switch pad to enable pulser.

  • Page 34: Sequencer Controls (Dx, Lx And All Ce Models)

    5-10. Sequencer Controls (DX, LX And All CE Models) Sequencer Control Sequencing is available only while using the TIG process, but is dis- abled if a remote foot or finger cur- rent control is connected to the Re- mote receptacle while in the RMT STD mode.

  • Page 35: Adjust Controls (Preflow/Post Flow/Dig/Purge)

    5-11. Adjust Controls (Preflow/Post Flow/DIG/Purge) Adjust Press switch pad until desired function LED is illuminated. Encoder Control Ammeter Turn encoder (see Section 5-2) to set ap- propriate value for active Adjust parame- ter. Value selected is shown on the am- meter (see Section 5-4).

  • Page 36: Ac Waveshape (Dynasty Models Only)

    5-12. AC Waveshape (Dynasty Models Only) AC Waveshape Encoder Control 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 5-16 for all AC Wave- shape parameter ranges.

  • Page 37: Memory (Program Storage Locations 1-4) (Dx And Lx Models If Available)

    5-14. Memory (Program Storage Locations 1-4) (DX And LX Models If Available) Memory (Program Storage 1-4) Switch Pad Polarity Switch Pad Process Switch Pad To create, change, or recall a welding parameters program, 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...

  • Page 38: Setting Preflow Time For Use With Tig Hf Impulse On Models That Do Not Have A Preflow Control On The Front Panel

    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 Rear Panel Process Control Pad Upon power up as described, the TIG Im- Encoder Control pulse, Postflow, DIG, and meter S LED’s Adjust Control Pad Turn encoder to select from 0 to 25 seconds...

  • Page 39: Factory Parameter Defaults And Range And Resolution

    5-16. Factory Parameter Defaults And Range And Resolution Parameter Default Range And Resolution POLARITY AC / DC PROCESS TIG HF Impulse TIG HF Impulse / TIG Lift / Stick * Stick OCV Low OCV Low OCV / Normal OCV OUTPUT RMT STD RMT STD / RMT 2T / ON *RMT 2T...

  • Page 40: Resetting Unit To Factory Default Settings

    DYNASTY: Polarity EP / EN Amperage 25 A 1 − 200 Amps Time 1 mS 1 − 200 Milliseconds Polarity EP / EN Amperage 40 A 5 − 200 Amps Time 40 mS 1 − 200 Milliseconds * Parameter adjusted using a power up configuration only 5-17.

  • Page 41: Section 6 − Advanced Functions

    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. 6-1.
  • Page 42 Changing Programmable TIG Start Polarity (Dynasty Models Only) E− 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 the Encoder control. Encoder Control Press Amperage switch pad. Switch pad LED turns on, and meter % LED turns on.
  • Page 43 D. Changing Programmable Start Time (All Models) 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 Encoder Control (see Section 5-16). Press Amperage switch pad, and meter Amps Meter S LED turns on.

  • Page 44: Output Control And Trigger Functions

    6-2. Output Control And Trigger Functions A. Remote (Standard) Torch Trigger Operation Current (A) Main Amps Initial Slope Final Slope Initial Amps Final Amps Postflow Preflow P & H Maintained Switch Foot Or Finger Remote Control P&H = Push trigger and hold R = Release trigger.
  • Page 45 Notes OM-2240 Page 39...
  • Page 46 C. Reconfiguring RMT 2T HOLD For 2T, 3T, Spot, 4T, 4T Momentary, Or Mini Logic Control H−2 Rear Panel For RMT STD (Remote Standard), RMT To access the RMT 2T HOLD reconfi- Meter Displays 2T Hold (Remote 2T Hold), and On trig- guration screen, turn power switch on Meter displays for the different functions ger operation, see Section 6-2A, B, and...
  • Page 47 H−2 (See Section 6-2B for operation) Spot (See Section 6-2G for operation) H−4 (DX, LX and CE Models) (See Section 6-2D for operation) Mini Logic (DX, LX and CE Models) (See Section 6-2E for operation) 4T Momentary (DX, LX and CE Models) (See Section 6-2F for operation) (DX, LX and CE Models)
  • Page 48 D. 4T Specific Trigger Method (DX, LX And All CE Models) 4T (Specific Trigger Operation) Sequencer is required to reconfi- gure for 4T. Select 4T according to Section H−4 6-2C. Torch trigger operation is as shown. 4T allows the operator to toggle be- tween weld current and final current without breaking the arc.
  • Page 49 E. Mini Logic Operation (DX, LX And All CE Models) Mini Logic Meter Display Select Mini Logic according to Sec- tion 6-2C. Torch trigger operation is as shown. 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...
  • Page 50 F. 4T Momentary Operation (DX, LX And All CE Models) 4T Momentary Meter Display Select 4T Momentary according to Section 6-2C. 4T Momentary torch trigger op- 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.
  • Page 51 G. Spot Control Operation Spot Function Meter Display Select Spot function according to Section 6-2C. NOTE: While in Spot Control, Se- quencer settings will be ignored and will not be programmable. NOTE: When a remote switch is connected to the welding power Spot source, use the remote switch to control the weld cycle.
  • Page 52 H. On Trigger Operation Voltage (V) 2 Sec Current (A) Stick Touch Stick Lift Stick Electrode Electrode Current (A) Lift Main Amperage Initial Slope Initial Amperage Touch Current Touch Tungsten Lift Tungsten Lift Tungsten Slightly OM-2240 Page 46...
  • Page 53 3T Specific Trigger Method (DX, LX And All CE Models) Current (A) Remote Trigger Operation 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. 3T (Specific Trigger Operation) Operation: C..When main amperage level is reached,...

  • Page 54: Arc Timer/Counter Display

    6-3. Arc Timer/Counter Display 123 456 Rear Panel Output And Amperage Controls Arc Timer Display Arc Counter Upon power up as described above, the After 5 seconds, the meter A LED turns Power Switch meter S LED will turn on, and arc time will on, and the arc counter will be displayed be displayed for 5 seconds as [000 000 ] to for the next 5 seconds as [000 000 ] to [999...

  • Page 55: Lockout Functions

    6-4. Lockout Functions A. Accessing Lockout Capability L − − L−0 L L1 or 2,3,4 L−0 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.
  • Page 56 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)
  • Page 57 B. Lock Out Levels (Continued) Level 3 Level 3 NOTE: Remote amperage control is not available in level 3. Includes all the functions of levels 1 Use Encoder Control To and 2 plus the following: Adjust Amperage +/− 10% Of Preset Value. +/−...

  • Page 58: Setting Unit To Display Ppp While Pulse Welding (Dx And Lx Models Only)

    6-5. Setting Unit To Display PPP While Pulse Welding (DX And LX Models Only) − − − Rear Panel 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.

  • Page 59: Stick Open-Circuit Voltage (Ocv) Selection (All Models)

    6-6. Stick Open-Circuit Voltage (OCV) Selection (All Models) Rear Panel Process Switch Pad sion clears the meters. Hold the switch When Stick low OCV is selected, open- pads until [SEL] [L ] or [SEL] [ ) appears. circuit voltage is between 9 and 14 Adjust Switch Pad volts.

  • Page 60: Section 7 − Maintenance And Troubleshooting

    SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. Maintain more often during severe conditions. 3 Months Replace Clean and tighten Replace Damaged unreadable weld terminals. Gas Hose labels. 3 Months Repair Or Replace Cracked Cables And Cords 6 Months Y Do not remove case when...

  • Page 61: Voltmeter/Ammeter Help Displays

    7-3. Voltmeter/Ammeter Help Displays P−0 P−5 P−1 P−8 P−2 P−9 P−3 P−4 Contact a Factory Authorized Service Help 8 Display All directions are in reference to the Agent if this display is shown. Indicates a malfunction in the secondary front of the unit. All circuitry referred to power circuit of the unit.

  • Page 62: Troubleshooting

    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;...

  • Page 63: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram 209 602-D OM-2240 Page 57...

  • Page 64: Section 9 − High Frequency (Hf)

    SECTION 9 − HIGH FREQUENCY (HF) 9-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Work 9-2. Correct Installation Weld Zone 50 ft 50 ft (15 m) (15 m) Ground All...

  • Page 65: Section 10 − Selecting And Preparing Tungsten Electrode

    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. 10-1. Selecting Tungsten Electrode ♦ Amperage Range - Gas Type - Polarity Electrode Diameter...

  • Page 66: Preparing Tungsten For Ac Or Dc Electrode Negative (Dcen) Welding

    10-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding Tungsten Electrode 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.

  • Page 67: Section 11 − Guidelines For Tig Welding (Gtaw)

    SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW) 11-1. Typical GTAW Set-Ups A. AC − GTAW 1/8 in. Aluminum Set-Up Ammeter Encoder 207 694-A This symbol indicates which functions should be active for aluminum. • Turn power on (switch located on rear panel) Press Polarity switch pad until AC LED is lit •...
  • Page 68 B. DC - GTAW 16 Gauge Stainless Steel Set-Up Ammeter Encoder 207 694-A This symbol indicates which functions should be active for stainless steel. • Turn power on (switch located on rear panel) Press Polarity switch pad until DC LED is lit •...

  • Page 69: Positioning The Torch

    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 approved respirator. Read MSDS for safety information. Consider using cerium or lanthanum based tungsten instead of thoriated.

  • Page 70: Lift-Arce And Hf Tig Start Procedures

    11-3. Lift-Arc™ And HF TIG Start Procedures Lift-Arc Start When Lift-Arct button light is On, start arc as follows: TIG Electrode Workpiece Touch tungsten electrode to work- piece at weld start point, enable out- put and shielding gas with torch trig- ger, foot control, or hand control.

  • Page 71: Torch Movement During Welding

    11-4. Torch Movement During Welding Tungsten Without Filler Rod ° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod ° ° Welding direction Form pool Tilt torch Add filler metal Remove rod Move torch to front of pool.

  • Page 72: Positioning Torch Tungsten For Various Weld Joints

    11-5. Positioning Torch Tungsten For Various Weld Joints ° Butt Weld And Stringer Bead ° ° ° “T” Joint ° ° ° ° Lap Joint ° ° ° ° Corner Joint ° ° ST-162 003 / S-0792 Om-2240 Page 66...

  • Page 73: Section 12 − Stick Welding (Smaw) Guidelines

    SECTION 12 − STICK WELDING (SMAW) GUIDELINES 12-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) Front Panel Correct front panel display for basic Stick DCEP welding. For all front panel switch pad controls: press switch pad to turn on light and enable function.

  • Page 74: Electrode And Amperage Selection Chart

    12-2. Electrode and Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 6010 DEEP MIN. PREP, ROUGH 1/16 HIGH SPATTER 6011 DEEP 5/64 6013 EP,EN GENERAL 3/32 SMOOTH, EASY, 6013 7014 EP,EN FAST 5/32 3/16 LOW HYDROGEN, 7018 STRONG 7/32 FLAT SMOOTH, EASY,...

  • Page 75: Stick Welding Procedure

    12-3. Stick Welding Procedure Y Weld current starts when electrode touches work- piece. Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Workpiece Make sure workpiece is clean be- fore welding.

  • Page 76: Positioning Electrode Holder

    12-6. Positioning Electrode Holder ° ° ° ° End View of Work Angle Side View of Electrode Angle GROOVE WELDS ° ° ° ° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 12-7. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding...

  • Page 77: Conditions That Affect Weld Bead Shape

    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 Large Angle Too Small Drag ELECTRODE ANGLE Spatter Normal Too Long Too Short...

  • Page 78: Butt Joints

    12-11. Butt Joints Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. Single V-Groove Weld Good for materials 3/16 −...

  • Page 79: Weld Test

    12-14. Weld Test Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in (51-76 mm) 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) S-0057-B 12-15. Troubleshooting − Porosity Porosity −...

  • Page 80: Troubleshooting − Incomplete Fusion

    12-17. Troubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions 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.

  • Page 81: Troubleshooting − Burn-Through

    12-20. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 12-21. Troubleshooting − Waviness Of Bead Waviness Of Bead −...

  • Page 82: Section 13 − Parts List

    SECTION 13 − PARTS LIST Hardware is common and not available unless listed. Figure 13-1. Main Assembly 803 395-D OM-2240 Page 76...
  • Page 83 Item Dia. Part Mkgs. Description Quantity Figure 13-1. Main Assembly ... . . Fig 13-2 ..PANEL,FRONT W/CMPNT ........
  • Page 84 ..207694 ..NAMEPLATE/SWITCH MEMBRANE,DYNASTY 200 DX ......
  • Page 85 Hardware is common and not available unless listed. 803 392-A Figure 13-3.Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 13-3. Panel, Rear w/Components (Figure 13-1 Item 2) 210 158 ....194242 .
  • Page 86 Hardware is common and not available unless listed. 803 427-A Figure 13-4. Magnetics Assembly w/Components Item Dia. Part Mkgs. Description Quantity Figure 13-4. Magnetics Assembly w/Components (Figure 13-1 Item 3) 209 936 ... . . 195649 .
  • Page 87 Item Dia. Part Mkgs. Description Quantity Figure 13-4. Magnetics Assembly w/Components (Figure 13-1 Item 3) (Continued) ... . . 089120 ..CLAMP,HOSE .375 − .450 CLP DIA SLFTTNG GREEN .
  • Page 88 Hardware is common and not available unless listed. 803 425-A Figure 13-5. Windtunnel w/Components Item Dia. Part Mkgs. Description Quantity 210 162 Figure 13-5. Windtunnel w/Components (Figure 13-1 Item 4) ... . . 195645 .
  • Page 89 Hardware is common and not available unless listed. 803 426-B Figure 13-6. Heat Sink, Secondary Assembly Item Dia. Part Mkgs. Description Quantity Figure 13-6. Heat Sink, Secondary Assembly(Figure 13-5 Item 7) 210 163 ... . . 209984 .
  • Page 90 Hardware is common and not available unless listed. 803 394−A Figure 13-7. Base Assembly Item Dia. Part Mkgs. Description Quantity 207 689 Figure 13-7. Base Assembly (Figure 13-1 Item 5) ....207255 .
  • Page 91 Effective January 1, 2004 (Equipment with a serial number preface of “LE” 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.

  • Page 92: Options And Accessories

    Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

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