Miller Dynasty 400 Owner's Manual
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Miller Dynasty 400 Owner's Manual

Ce and non-ce models
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Dynasty
Maxstar
CE and Non-CE Models
OWNER'S MANUAL
OM-275857Q
Processes
Description
208/575 Volt Models w/Auto-Line™; 380/
575 Volt Three-Phase w/Auto-Line™
(CE) Arc Welding Power Source
400 And 800
®
400 And 800
®
2021-06
TIG (GTAW) Welding
Stick (SMAW) Welding

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Summary of Contents for Miller Dynasty 400

  • Page 1 OM-275857Q 2021-06 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description 208/575 Volt Models w/Auto-Line™; 380/ 575 Volt Three-Phase w/Auto-Line™ (CE) Arc Welding Power Source Dynasty 400 And 800 ® Maxstar 400 And 800 ® CE and Non-CE Models OWNER’S MANUAL For product information, Owner’s Manual translations, and more, visit...
  • 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 Symbol Usage .
  • Page 4 TABLE OF CONTENTS Lockout Functions ....................61 Lockout Levels Defined .
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. LLC, 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 of the stated Council Directive(s), Commission Regulation(s) and Standard(s).
  • Page 6 DECLARATION OF CONFORMITY For United Kingdom (UKCA marked) products. MILLER Electric Mfg. LLC, 1635 West Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Regulation(s) and Standard(s).
  • Page 7 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number DYNASTY 350 (AUTO-LINE 380-575)CE 907204021 DYNASTY 400 (AUTO-LINE 380-575)CE 907717002 SYNCROWAVE 400 380-400, CE 907783002 SYNCROWAVE 400 TIGRUNNER 380-400, CE 907783003 Compliance Information Summary Applicable regulation Directive 2014/35/EU...
  • Page 8 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number MAXSTAR 350 (AUTO-LINE 380-575) CE 907334021 MAXSTAR 400 (AUTO-LINE 380-575)CE 907716002 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822-1:2016, IEC 62822-2:2016 Intended use for occupational use for use by laymen...
  • Page 9 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number DYNASTY 700 (AUTO-LINE 380-575)CE 907101021 DYNASTY 800 (AUTO-LINE 380-575)CE 907719002 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822-1:2016, IEC 62822-2:2016 Intended use for occupational use for use by laymen...
  • Page 10 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number MAXSTAR 700 (AUTO-LINE 380-575)CE 907103021 MAXSTAR 800 AUTO-LINE 380-575)CE 907718002 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822-1:2016, IEC 62822-2:2016 Intended use for occupational use for use by laymen...

  • Page 11: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! – Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 12 HOT PARTS can burn. WELDING can cause fire or explosion. � Do not touch hot parts bare handed. � Allow cooling period before working on equipment. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. �...

  • Page 13: Additional Hazards For Installation, Operation, And Maintenance

    � Never weld on a pressurized cylinder — explosion will result. CYLINDERS can explode if � Use only correct compressed gas cylinders, regulators, hoses, damaged. and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 14: California Proposition 65 Warnings

    � Have the installation regularly checked and maintained. � Be sure all equipment in the welding area is electromagnetically compatible. � Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to �...

  • Page 15: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 16 � Porter un harnais de sécurité si l’on doit travailler au-dessus du � Ne pas souder des métaux munis d’un revêtement, tels que l’acier sol. galvanisé, plaqué en plomb ou au cadmium à moins que le revête- ment n’ait été enlevé dans la zone de soudure, que l’endroit soit �...

  • Page 17: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    � Ne pas couper ou souder des jantes ou des roues. Les pneus peu- Les CHAMPS vent exploser s’ils sont chauffés. Les jantes et les roues réparées ÉLECTROMAGNÉTIQUES (CEM) peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les peuvent affecter les implants normes de sécurité.
  • Page 18 � Suivre les consignes du Manuel des applications pour l’équation � Lorsque cela est nécessaire pour des travaux d’entretien et de dé- de levage NIOSH révisée (Publication Nº94– 110) lors du levage pannage, faire retirer les portes, panneaux, recouvrements ou dis- manuelle de pièces ou équipements lourds.

  • Page 19: Proposition Californienne 65 Avertissements

    2-4. Proposition californienne 65 Avertissements AVERTISSEMENT – Ce produit peut vous exposer à des pro- Pour plus d’informations, consulter www.P65Warnings.ca.gov. duits chimiques tels que le plomb, reconnus par l’État de Californie comme cancérigènes et sources de malforma- tions ou d’autres troubles de la reproduction. 2-5.

  • Page 20: Section 3 - Definitions

    Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Some symbols are found only on CE products. facility.
  • Page 21 Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift e Cutting sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Do not smoke while fueling or if near fuel. Do not work on unit if engine is running.

  • Page 22: Miscellaneous Symbols And Definitions

    Safe34 2012 05 � Complete Parts List is available at www.MillerWelds.com Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait 60 seconds Hazardous voltage remains on input capacitors after power is turned after power is turned off before working on unit, AND check input ca- Become trained and read the instructions and labels before working on machine.
  • Page 23 � Complete Parts List is available at www.MillerWelds.com Suitable for Welding Increase/Decrease Pulse Percent On in an Environment Of Quantity Time with Increased Risk of Electric Shock Remote Standard Sequence Initial Slope Remote 2T Hold AC Waveshape Background Control Amperage Gas/DIG Control Pulse AC Frequency...

  • Page 24: Section 4 - Specifications

    Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...
  • Page 25 � Complete Parts List is available at www.MillerWelds.com B. Maxstar 400 Models Rated Peak Striking Voltage Welding Amperage Range Max. Open Circuit Voltage (U Low Open-Circuit Voltage (U 3–400 A 8–15 V 75 V 14 kV Welding range for Stick process Low open-circuit voltage is is 5–400 amperes.

  • Page 26: Dimensions, Weights And Base Mounting Hole Layout

    � Complete Parts List is available at www.MillerWelds.com D. Maxstar 800 Models Rated Peak Striking Voltage Welding Amperage Range Max. Open Circuit Voltage (U Low Open-Circuit Voltage (U 5–800 A 8–15 V 75 V 14 kV Welding range for Stick process Low open-circuit voltage is is 5–750 amperes.

  • Page 27: Environmental Specifications

    -4 to 131°F (-20 to 55°C) *Output is derated at temperatures above 104°F (40°C). C. Information On Electromagnetic Compatibility (EMC) (Dynasty 400) This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system.
  • Page 28 � Complete Parts List is available at www.MillerWelds.com E. Information On Electromagnetic Compatibility (EMC) (Dynasty 800) This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
  • Page 29 H. EU Ecodesign Information Some symbols are found only on CE products. Minimum Power Source Maximum Idle State Model Input Efficiency Power Consumption Dynasty 400 400V Three Phase 80.0% 33.4 W Dynasty 800 400V Three Phase 82.2% 56.0 W Warning! Watch Out! There are possible hazards as shown by the symbols.

  • Page 30: Duty Cycle And Overheating

    1-4. Duty Cycle And Overheating � Complete Parts List is available at www.MillerWelds.com 4-7. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit weld rated load without overheating. If unit overheats, output stops, a Help mes- sage is displayed (see Section 11-3), and cooling fan runs.

  • Page 31: Section 5 - Installation

    A complete Parts List is available at www.MillerWelds.com � Writers: Remember to move unit dimension and weight and rating la- Complete Parts List is available at www.MillerWelds.com SECTION 5 – INSTALLATION bel location information to the appropriate sections. 5-1. Selecting A Location 1-3.

  • Page 32: Weld Output Terminals

    SECTION 2 INSTALLATION � Complete Parts List is available at www.MillerWelds.com Weld Output Terminals 5-2. Weld Output Terminals Turn off power before connecting to weld output terminals. Do not use worn, damaged, under- sized, or repaired cables. 1 Work Weld Output Terminal (Dynasty Models) (+) Positive Weld Output Terminal (Max- star Models)

  • Page 33: Remote 14 Receptacle Information

    � Complete Parts List is available at www.MillerWelds.com 5-4. Remote 14 Receptacle Information Remote 14 Socket Socket Information Contactor control +15 volts DC, referenced to G. 15 Volts DC Output Contact closure to A completes 15 volts DC con- Contactor tactor control circuit and enables output.

  • Page 34: Automation Connection For 28-Pin Receptacle (If Present)

    � Complete Parts List is available at www.MillerWelds.com 5-6. Automation Connection For 28-Pin Receptacle (If Present) A. Basic Automation Mode Use this mode when only the basic functions of the automation board are required. These functions include Start/Stop, Valid Arc Indication, Gas A complete Parts List is available at www.MillerWelds.com Control, High Frequency Arc Start Disable, and Remote Memory Select.
  • Page 35 � Complete Parts List is available at www.MillerWelds.com Output +10 volts DC With respect to pin 11 for use with an external potentiometer to vary the signal into pin 17 (Pin C of 14 pin). Input High Frequency Arc Start Disables the arc starter from being activated when connected to pin 8.
  • Page 36 � Complete Parts List is available at www.MillerWelds.com Amperage Control For pins 5, 6, 7, 17 and 18 (Pin D of 14 pin). Output Reference Earth ground. Connected only if common potentials are needed between user Output Welders Chassis equipment and the welder. Paired with Pin 14.

  • Page 37: Remote Memory Select Inputs For 28-Pin Receptacle (If Present)

    � Complete Parts List is available at www.MillerWelds.com Gas Control This input is used to control the gas flow outside the settings of the preflow Input and/or postflow set on the machine. Connection to pin 8 turns on gas. Valid Arc Indication Paired with Pin 9.

  • Page 38: 115 Volts Ac Cooler Receptacle, Supplementary Protector Cb1, And Power Switch

    � RC2 is a designated use receptacle in- tended only for supplying AC power to a Miller-approved cooler. 2 Supplementary Protector CB1 CB1 protects cooler receptacle from over- load. If circuit breaker opens, the receptacle does not work. Press button to reset protector.

  • Page 39: Gas Connections

    805593-A � Complete Parts List is available at www.MillerWelds.com 5-9. Gas Connections 2-7. Gas Connections 1 Gas Fitting Fittings have 5/8-18 right-hand threads. 2 Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. 3 Regulator/Flowmeter 4 Flow Adjust Typical flow rate is 15 cfh (cubic feet per hour).

  • Page 40: Cooler Connections

    1 AC Cooler Receptacle RC2 � RC2 is a designated use receptacle in- tended only for supplying AC power to a Miller-approved cooler. 2 115 VAC Cord Provides 115 VAC to power cooler. 3 Electrode Weld Output Terminal (– Weld...

  • Page 41: Dynasty Stick Connections

    A complete Parts List is available at www.MillerWelds.com � 2-10. Dynasty Stick Connections Complete Parts List is available at www.MillerWelds.com 5-12. Dynasty Stick Connections Turn off power before making connections. � Connections shown are for Dynasty models. 1 Work Weld Output Terminal Connect work lead to work weld output terminal.

  • Page 42: Electrical Service Guide

    Complete Parts List is available at www.MillerWelds.com 5-14. Electrical Service Guide A. Dynasty 400 Models Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommen- dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.
  • Page 43 � Complete Parts List is available at www.MillerWelds.com B. Maxstar 400 Models Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommen- dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.
  • Page 44 � Complete Parts List is available at www.MillerWelds.com C. Dynasty 800 Models Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommen- dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.
  • Page 45 � Complete Parts List is available at www.MillerWelds.com D. Maxstar 800 Models Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommen- dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.

  • Page 46: Connecting Input Power For 400 Models And 800 Ce Models

    � Complete Parts List is available at www.MillerWelds.com 5-15. Connecting Input Power For 400 Models And 800 CE Models A. Connecting 3-Phase Input Power 2-11. Connecting Input Power For 400 Models And 800 CE Models A. Connecting Three-Phase Input Power Installation must meet all National and Local Codes—have only quali- fied persons make this installation.
  • Page 47 A complete Parts List is available at www.MillerWelds.com B. Connecting Single-Phase Input Power � Complete Parts List is available at www.MillerWelds.com B. Connecting 1-Phase Input Power Installation must meet all National and Local Codes—have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input =GND/PE Earth Ground...

  • Page 48: Connecting Input Power For 800 Models

    � Complete Parts List is available at www.MillerWelds.com 5-16. Connecting Input Power For 800 Models A. Connecting 3-Phase Input Power tools/ tools/ flathead philips head wrench crescent wrench wrench allen_set flathead philips head wrench crescent wrench tools/ 5/16 in. Select size and length of conductors using Reinstall cover on welding power source.
  • Page 49 � Complete Parts List is available at www.MillerWelds.com B. Connecting Single-Phase Input Power A complete Parts List is available at www.MillerWelds.com B. Connecting Single-Phase Input Power =GND/PE Earth Ground tools/ tools/ flathead philips head wrench crescent wrench en_wrench allen_set flathead philips head wrench crescent wrench...

  • Page 50: Software Updates

    � Complete Parts List is available at www.MillerWelds.com 5-17. Software Updates Of Software Updates A. Downloading Software Updates 2-13. Software Updates A. Reasons For Downloads Of Software Updates Reasons To Download Software Updates: B. Requirements � To get the latest feature and software improvements with future...

  • Page 51: Section 6 - Dynasty Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 3 DYNASTY OPERATION SECTION 6 – DYNASTY OPERATION 6-1. Dynasty Controls 273670-B Port is used to add features to the machine, 5 Polarity Control � For all front panel button controls: and update software.

  • Page 52: Accessing Control Panel Menu

    3-1. Accessing Control Panel Menu 6-2. Accessing Control Panel Menu A complete Parts List is available at www.MillerWelds.com 1 Memory Button Select Memory 1-9 (See Section 10). 4-2. Accessing Control Panel Menu 2 Parameter Display 150A 3 Setting Display 4 Amperage Adjustment Control Rotate amperage adjustment control to ad- just parameter setting.
  • Page 53 Output (Trigger Mode Selection) 247220-D � See Section 9 for additional trigger function options. Parameter/Setting Description Display [RMT] [STD] Typical setting for a remote foot or hand control. RMT STD requires a maintained contact closure to enable weld output. Amperage can be controlled with a remote potentiometer, or it can be set at the control panel.
  • Page 54 AC Waveshape Control Parameter/Setting Description Display [ENEP] [150A] EN Amperage and EP Amperage TIG only: Controls both electrode negative and positive amperage value. � Both EN Amperage and EP Amperage LEDs will be lit. � See Section 6-3 to select Independent EN and EP Amperage control. [BAL] [75%] Balance Control (%EN) TIG Only: Controls oxide cleaning.

  • Page 55: Accessing User Setup Menu

    A complete Parts List is available at www.MillerWelds.com 6-3. Accessing User Setup Menu 3-2. Accessing User Setup Menu 1 Amperage Button 2 Gas/DIG Button 3 Parameter Display 4 Setting Display 5 Amperage Adjustment Control MENU USER To access the User Functions, press and hold the Amperage (A) and the Gas/DIG controls until [USER] [MENU] is displayed.

  • Page 56: Ac Independent

    6-4. AC Independent A. AC Independent Waveshape � AC Independent Expansion is available on DX models with SD expansion card and on CE models with feature enable through the user menu (see Section 6- 1 Parameter Display/Voltmeter MENU USER 2 Setting Display/Ammeter 3 Amperage Adjustment Control 4 Amperage Button 5 Gas/DIG Control...

  • Page 57: Section 7 - Maxstar Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 2 MAXSTAR OPERATION SECTION 7 – MAXSTAR OPERATION 2-1. Maxstar Controls 7-1. Maxstar Controls 275861-B / Ref. 803901-A Port is used to add features to the machine, terminals. It also show parameter descrip- �...

  • Page 58: Accessing Control Panel Menu

    A complete Parts List is available at www.MillerWelds.com 2-2. Accessing Control Panel Menu 7-2. Accessing Control Panel Menu Memory Button 4-2. Accessing Control Panel Menu Select Memory 1-9 (See Section 14) Parameter Display Setting Display Amperage Adjustment Control Rotate amperage adjustment control 1 Memory Button to adjust parameter setting.
  • Page 59 Output (Trigger Mode Selection) 247220-D � See Section 9 for additional trigger function options. Parameter/Setting Description Display [RMT] [STD] Typical setting for a remote foot or hand control. RMT STD requires a maintained contact closure to enable weld output. Amperage can be controlled with a remote potentiometer, or it can be set at the control panel.

  • Page 60: Accessing User Setup Menu

    A complete Parts List is available at www.MillerWelds.com 7-3. Accessing User Setup Menu 2-3. Accessing User Setup Menu 1 Amperage Button 2 Gas/DIG Button 3 Parameter Display 4 Setting Display USER MENU 5 Amperage Adjustment Control To access the User Functions, press and hold the Amperage (A) and the Gas/DIG controls until [USER] [MENU] is displayed.

  • Page 61: Section 8 - 28-Pin Advanced Automation Operation

    SECTION 4 28-PIN ADVANCED AUTOMATION OPERATION � Complete Parts List is available at www.MillerWelds.com SECTION 8 – 28-PIN ADVANCED AUTOMATION OPERATION 4-1. Controls 8-1. Controls 273670-B Use amperage adjustment control in con- Shows actual amperage while welding. It al- � To activate 28-pin Advanced Automa- junction with applicable front panel function so shows parameter selection options when...

  • Page 62: Controls

    4-2. Accessing Control Panel Menu � Complete Parts List is available at www.MillerWelds.com 8-2. Controls 1 Parameter Display A complete Parts List is available at www.MillerWelds.com 2 Setting Display 3 Amperage Adjustment Control Rotate amperage adjustment control to ad- just parameter setting. 150A 273670-B 247220-D...

  • Page 63: Accessing User Setup Menu

    A complete Parts List is available at www.MillerWelds.com � Complete Parts List is available at www.MillerWelds.com 8-3. Accessing User Setup Menu 4-3. Accessing User Setup Menu 1 Amperage Button 2 Gas/DIG Button 3 Parameter Display 4 Setting Display 5 Amperage Adjustment Control USER MENU To access the User Functions, press and hold...

  • Page 64: Programmable Tig Start Parameters

    � Complete Parts List is available at www.MillerWelds.com 8-4. Programmable TIG Start Parameters 1 Amperage Button 2 Encoder Control 3 Ammeter A. OFF/ON (Start Amperage And Time) A. Off/On (Start Amperage And Time) Current (A) Start Time A complete Parts List is available at www.MillerWelds.com A complete Parts List is available at www.MillerWelds.com B.

  • Page 65: Section 9 - Advanced Menu Functions

    SECTION 9 – ADVANCED MENU FUNCTIONS 9-1. Accessing Tech Menu 1 Amperage Button 2 Gas/DIG Button Press and hold Amperage and Gas/Dig but- tons for approximately two seconds to scroll past User Menu to Tech Menu. Use Gas/Dig button to cycle through parameters that can be set.

  • Page 66: Sequencer And Weld Timer

    9-2. Sequencer And Weld Timer Sequencer Control With Weld Timers ON This function is available while using the TIG process, but is disabled if a remote foot or fingertip con- trol is connected while in the RMT STD mode. When active, the sequencer controls the following pa- rameters of the weld cycle: Parameter/Setting Description...

  • Page 67: Output Control And Trigger Functions

    9-3. Output Control And Trigger Functions A. Remote (Standard), 2T, And 4TE Torch Trigger Operation Current (A) Current (A) Current (A) Current (A) Main Amps Initial Slope Main Amps Final Slope Main Amps Main Amps Initial Slope Final Slope Initial Amps Initial Slope Final Slope Initial Slope...
  • Page 68 B. 3T Specific Trigger Method 3T Trigger Operation Definitions: 2 Press initial switch to start arc at initial * Arc can be extinguished at any time by amps. Holding switch will change amper- pressing and releasing both initial and final Initial slope rate is the rate of amperage age at initial slope rate (release switch to switches, or by lifting the torch and breaking...
  • Page 69 Main Amps Initial Slope Final Slope C. 4T, 4Tm, And 4TL Specific Trigger Method C. 4T, 4Tm, And 4TL Specific Trigger Method Initial Amps Final Amps Postflow Preflow *P/R *P/R 4T And 4Tm Application: 4T And 4Tm Torch Trigger Operation Current (A) Use 4T or 4Tm (modified) trigger method when the functions of a remote current con-...
  • Page 70 A complete Parts List is available at www.MillerWelds.com A complete Parts List is available at www.MillerWelds.com D. On Trigger Operation D. On Trigger Operation D. On Trigger Operation D. On Trigger Operation Voltage (V) Voltage (V) Voltage (V) 2 Sec 2 Sec 2 Sec Stick...

  • Page 71: Lockout Functions

    9-4. Lockout Functions See Section 9-1 for information on how to access Lockout Functions. There are four (1-4) different lockout levels. Each successive level allows the operator LOCK more flexibility. � Before activating lockout levels, be CODE sure that all procedures and parame- ters are established.

  • Page 72: Lockout Levels Defined

    9-5. Lockout Levels Defined Minimum Adjustability Degree of Adjustability Maximum Adjustability Lock Level 1 Lock Level 2 Lock Level 3 Lock Level 4 Adjustable Locked Adjustable Locked Adjustable Locked Adjustable Locked Panel Amps Panel Amps Panel Amps Remote Amps ± 10% (min-panel) Panel Amps ±...

  • Page 73: Section 10 - Memory

    SECTION 4 MEMORY SECTION 10 – MEMORY Memory (Program Storage Locations 1-9) SECTION 3 MEMORY 10-1. Memory (Program Storage Locations 1–9) Memory (Program Storage 1-9) Switch Pad 3-1. Memory (Program Storage Locations 1-9) Polarity Switch Pad (Dynasty Only) Process Switch Pad To create, change, or recall a weld- 1 Memory (Program Storage 1–9) Button ing parameters program, proceed...

  • Page 74: Section 11 - Maintenance And Troubleshooting

    � Complete Parts List is available at www.MillerWelds.com SECTION 11 – MAINTENANCE AND TROUBLESHOOTING pliers needlenose knife steelbrush nutdriver chippinghammer 11-1. Routine Maintenance Disconnect power before maintaining. solderiron heavy-duty workclamp light-duty workclamp wirecutter frontcutter stripcrimp A complete Parts List is available at www.MillerWelds.com A complete Parts List is available at www.MillerWelds.com �...

  • Page 75: Voltmeter/Ammeter Display Messages

    � Complete Parts List is available at www.MillerWelds.com 11-3. Voltmeter/Ammeter Display Messages � All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Message Type Display Message Description Release Trigger [RELE] [ASE] / Remote 14 receptacle contactor control (Pins A-B) must be opened before [TRIG] [GER]...

  • Page 76: Troubleshooting Table

    � Complete Parts List is available at www.MillerWelds.com 11-4. Troubleshooting Table Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 5-15). inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-15). Check for proper input power connections (see Section 5-15).

  • Page 77: Section 12 - Electrical Diagrams

    SECTION 12 – ELECTRICAL DIAGRAMS Figure 12-1. Dynasty 400 Circuit Diagram (Page 1 of 2) OM-275857 Page 67...
  • Page 78 Figure 12-2. Dynasty 400 Circuit Diagram (Page 2 of 2) OM-275857 Page 68...
  • Page 79 SECTION 3 ELECTRICAL DIAGRAMS 275851-G Figure 11-1. Maxstar 400 Circuit Diagram (Page 1 of 2) Figure 12-3. Maxstar 400 Circuit Diagram (Page 1 of 2) OM-275857 Page 9 OM-275857 Page 69...
  • Page 80 Figure 12-4. Maxstar 400 Circuit Diagram (Page 2 of 2) OM-275857 Page 70...
  • Page 81 Figure 12-5. Dynasty 800 Circuit Diagram (Page 1 of 2) OM-275857 Page 71...
  • Page 82 Figure 12-6. Dynasty 800 Circuit Diagram (Page 2 of 2) OM-275857 Page 72...
  • Page 83 Figure 12-7. Maxstar 800 Circuit Diagram (Page 1 of 2) OM-275857 Page 73...
  • Page 84 275853-G Figure 11-4. Maxstar 800 Circuit Diagram (Page 2 of 2) Figure 12-8. Maxstar 800 Circuit Diagram (Page 2 of 2) OM-275857 Page 12 OM-275857 Page 74...

  • Page 85: Section 13 - High Frequency

    SECTION 13 – HIGH FREQUENCY SECTION 1 HIGH FREQUENCY 13-1. Welding Processes Requiring High Frequency SECTION 1 HIGH FREQUENCY 1 High-Frequency Voltage TIG – helps arc jump air gap between torch and workpiece and/or stabilize the arc. 13-2. Installation Showing Possible Sources Of HF Interference 11, 12 Best Practices Not Followed 11, 12...

  • Page 86: Recommended Installation To Reduce Hf Interference

    13-3. Recommended Installation To Reduce HF Interference Best Practices Followed 50 ft (15 m) 50 ft (15 m) 1 High-Frequency Source (welding power Conduit Joint Bonding and Grounding Ground workpiece if required by codes. source with built-in HF or separate HF Electrically join (bond) all conduit sections 9 Nonmetal Building unit)

  • Page 87: Section 14 - Selecting And Preparing A Tungsten For Dc Or Ac Welding With Inverter Machines

    SECTION 14 – SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES 14-1. Selecting Tungsten Electrode Whenever possible and practical, use DC weld output instead of AC weld output. NOTICE – Wear clean gloves to prevent contamination of tungsten. A.

  • Page 88: Preparing Tungsten Electrode For Dc Electrode Negative (Dcen) Welding Or Ac Welding With Inverter Machines

    1-1. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. 14-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Use local exhaust (forced ventilation) at the grinder or wear an approved respirator.

  • Page 89: Section 15 - Tig Procedures

    SECTION 5 TIG PROCEDURES SECTION 15 – TIG PROCEDURES SECTION 5 TIG PROCEDURES SECTION 5 TIG PROCEDURES Arc And HF TIG Start Procedures 15-1. Lift-Arc And HF TIG Start Procedures Arc And HF TIG Start Procedures Arc And HF TIG Start Procedures Lift-Arc Start Lift-Arc Start Method When Lift-Arc...

  • Page 90: Pulser Control

    15-2. Pulser Control (main amperage). Peak amperage is set 1 Pulser Control Percent with the Amperage control (see Operation (%) Peak Pulsed Output section). If one pulse per second is being Time Con- Waveforms Pulsing is available while using the TIG used, and peak time is set at 50%, one-half trol Setting process.

  • Page 91: General (Gen) Tungsten To Change Programmable Tig Starting Parameters

    15-3. General (GEN) Tungsten To Change Programmable TIG Starting Parameters 1 Amperage Adjustment Control 2 Parameter Display 3 Amperage Button Once inside the machine set up menu, tung- sten parameter values can be manually TUNG TUNG changed by pressing the Amperage switch pad to step through each adjustable parame- ter.

  • Page 92: Section 16 - Stick Welding (Smaw) Guidelines

    SECTION 16 – STICK WELDING (SMAW) GUIDELINES 16-1. Electrode And Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG...

  • Page 93: Warranty

    Effective January 1, 2021 (Equipment with a serial number preface of NB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions TIG Torches (No Labor) below, Miller Electric Mfg.
  • Page 94 Appleton, WI 54914 USA tact your distributor and/or equipment manu- facturer’s Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2021-06...

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