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MIG (GMAW) Welding Flux Cored (FCAW) Welding Description 208−575 Volt Models w/Autoline Arc Welding Power Source Dynasty 280, 280 DX Dynasty 280 DX Multiprocess Maxstar 280, 280 DX CE And Non-CE Models For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
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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.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
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........10-2. Accessing Tech Menu For Dynasty/Maxstar 280 DX Models .
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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 of the stated Council Directive(s) and Standard(s).
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EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number DYNASTY 280 DX (AUTO-LINE 208-575), CPS, CE 907514002 DYNASTY 280 DX (AUTO-LINE 208-575), CPS, VS, CE 907514008 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...
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EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number MAXSTAR 280 DX (AUTO-LINE 208-575), CPS, CE 907539002 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...
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2018−01 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 Indicates special instructions.
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D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.
D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.
H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2018−01_fre 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.
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D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...
D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.
A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves.
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A complete Parts List is available at www.MillerWelds.com Do not weld on drums or any closed containers. Safe16 2017−04 Do not remove or paint over (cover) the label. Safe20 2017−04 When power is applied failed parts can explode or cause other parts to explode. Safe26 2012−05 Flying pieces of parts can cause injury.
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A complete Parts List is available at www.MillerWelds.com Become trained and read the instructions before working on the machine or welding. Safe40 2012−05 Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait 60 seconds after power is turned off before working on unit, AND check input ca- pacitor voltage, and be sure it is near 0 before touching any parts.
A complete Parts List is available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Alternating Amperes Hertz Current Recall From Gas Input Panel−Local Memory Gas Tungsten Arc Gas Output Arc Force (DIG) Welding (GTAW) Shielded Metal Rated Welding Arc Striking Arc Welding Current without Contact (SMAW)
A complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for the power source is located on the top of the machine. Use the rating labels to determine input power requirements and/or rated output.
A complete Parts List is available at www.MillerWelds.com B. Maxstar Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-7, 5-8 and 5-9 for information on connecting input power. This equipment will deliver rated output at an ambient air temperature up to 1045 F ( 405 C). Welding Amperage Max Open Circuit Low Open-Circuit...
A complete Parts List is available at www.MillerWelds.com 4-4. Dimensions, Weights, And Mounting Options A. Welding Power Source Dimensions 13-5/8 in. (346 mm) 8-5/8 in. (219 mm) 22-1/2 in. (569 mm) Weight Maxstar: 47 lb (21.3 kg) w/CPS 50 lb (22.7 kg) Dynasty: 52 lb (23.6 kg) Ref.
A complete Parts List is available at www.MillerWelds.com C. Mounting Options Dimensions 15-7/16 in. (392 mm) 9-19/32 in. (244 mm) Center-To-Center 5/16 in. (8 mm) 17-15/32 in. (444 mm) 3-3/4 in. (95 mm) 13/64 in. (5 mm) 1. Mounting Hardware Remove hardware to separate power source from cooler.
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A complete Parts List is available at www.MillerWelds.com D. China EEP Hazardous Substance Information China EEP Hazardous Substance Information Ö Hazardous Substance Component Name × (if applicable) PBDE Ö Brass and Copper Parts Coupling Devices Switching Devices Ö...
A complete Parts List is available at www.MillerWelds.com 4-6. 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 11-2), and cooling fan runs.
A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Selecting a Location Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Movement, Location, and Airflow Section 20. Carry Strap Use strap to carry power source only.
A complete Parts List is available at www.MillerWelds.com 5-2. Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.
A complete Parts List is available at www.MillerWelds.com 5-4. Connections Turn off power before making connections. Remote Control Receptacle (See Section 5-10) Gas Out To Torch Connection Maxstar Front Panel Dynasty Front Panel Requires an 11/16 in. wrench. Work Weld Output Terminal Electrode Weld Output Terminal TIG Torch Stick Electrode Holder...
A complete Parts List is available at www.MillerWelds.com 5-5. Cooler Connections Cart and cooler are optional equipment. Coolmate 1.3 Power Receptacle Cooler Power Cord Provides 115 VAC to power cooler. Electrode Weld Output Terminal (−Weld Output Terminal On Maxstar Models) Connect TIG torch to electrode weld output terminal.
A complete Parts List is available at www.MillerWelds.com 5-6. Electrical Service Guide (Dynasty) Elec Serv 2017−01 A. Electrical Service Guide For Three-Phase Operation Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
A complete Parts List is available at www.MillerWelds.com 5-7. Electrical Service Guide (Maxstar) Elec Serv 2017−01 A. Electrical Service Guide For Three-Phase Operation Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
A complete Parts List is available at www.MillerWelds.com 5-8. Connecting Three-Phase Input Power = GND/PE Earth Ground Tools Needed: input2 2012−05 − 803766-C / Ref. 805496-A OM-253086 Page 25...
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A complete Parts List is available at www.MillerWelds.com 5-8. Connecting Three-Phase Input Power (Continued) primary voltage being applied. Check input Input Conductors (L1, L2 And L3) Installation must meet all National and voltage available at site. This unit can be con- Local Codes −...
A complete Parts List is available at www.MillerWelds.com 5-9. Connecting Single-Phase Input Power =GND/PE Earth Ground Tools Needed: input1 2012−05 − 803766-C / Ref. 805496-A OM-253086 Page 27...
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A complete Parts List is available at www.MillerWelds.com 5-9. Connecting Single-Phase Input Power (Continued) nected to any input power between 208−575 Disconnect Device (switch shown in the Installation must meet all National and VAC without removing cover to relink the OFF position) Local Codes −...
A complete Parts List is available at www.MillerWelds.com 5-10. Remote 14 Receptacle Information Socket Socket Information Contactor control +15 volts DC, referenced to G. 15 VOLTS DC OUTPUT Contact closure to A completes 15 volts DC CONTACTOR contactor control circuit and enables output. Output to remote control;...
A complete Parts List is available at www.MillerWelds.com 5-12. Software Updates A. Reasons For Downloads Of Software Updates • To get the latest feature and software improvements with future software updates. • For all circuit board replacements, a software update is required to ensure proper unit operation. •...
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A complete Parts List is available at www.MillerWelds.com D. Software Installation up to three minutes. Do Not re- Software updates may reset move card while LED is blinking machine back to default val- green. ues. After successfully reading from or Card Requirements: writing to the card, the LED Full size memory card required.
A complete Parts List is available at www.MillerWelds.com SECTION 6 − DYNASTY 280 OPERATION 6-1. Dynasty 280 Controls Standby Button Use to put machine into low power consumption mode. This button can also be used to clear some errors. See Section 11-3.
A complete Parts List is available at www.MillerWelds.com 6-2. Accessing Control Panel Menu: AC TIG Menu Button Press Menu button to cycle through parameters that can be set. Parameter Display Setting Display Encoder Rotate Encoder to adjust parameter setting. Parameter automatically returns to amperage setting 15 seconds after Encoder is inactive.
A complete Parts List is available at www.MillerWelds.com 6-3. Accessing Control Panel Menu: DC TIG Menu Button Press Menu button to cycle through paramet- ers that can be set. Parameter Display Setting Display Encoder Rotate Encoder to adjust parameter setting. Parameter automatically returns to am- perage setting 15 seconds after Encoder 150A...
A complete Parts List is available at www.MillerWelds.com 6-5. Accessing User Setup Menu: AC And DC TIG Menu Button Press and hold Menu button for ap- proximately two seconds to access machine configuration menus. Use Menu button to cycle through para- meters that can be set.
A complete Parts List is available at www.MillerWelds.com 6-6. Accessing User Setup Menu: AC And DC Stick Menu Button Press and hold Menu button for ap- proximately 2 seconds to access machine configuration menus. Use Menu button to cycle through para- meters that can be set.
A complete Parts List is available at www.MillerWelds.com SECTION 7 − DYNASTY 280 DX OPERATION 7-1. Dynasty 280 DX And Dynasty 280 DX Multiprocess Controls 280589-A Memory Card Port And Indicator Ammeter / Parameter For all front panel switch pad controls: Stick and TIG - Displays preset amperage press switch pad to turn on light and This port is used to add features to the ma-...
A complete Parts List is available at www.MillerWelds.com 7-2. Accessing Control Panel Menu Amperage Parameter Display Setting Display Encoder Rotate Encoder adjust parameter setting. Amperage (CC Mode) Controls the welding amperage output. Limits the maximum output of a remote amperage device. In AC, the user will be setting the rectified average value of the AC current, ( [AC AV] will be displayed).
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A complete Parts List is available at www.MillerWelds.com Pulse Control *PRO−SET provides PROfessionally developed SETtings for the weld process PRO−SET flashes one time and reveals the professional setting for the parameter. Pulsing is available in the TIG process. Controls can be ad- justed while welding.
A complete Parts List is available at www.MillerWelds.com 7-3. Accessing User Setup Menu Amperage Gas/Dig Button Parameter Display Setting Display Encoder To access the User Functions, press and hold the Amperage (A) and the Gas/DIG controls until [USER] [MENU] is displayed. To scroll through the user menu func- tions, press and release the Gas/ DIG control.
A complete Parts List is available at www.MillerWelds.com 7-4. AC Independent Expansion 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 7-3). A. AC Independent Amperage AC Waveshape Control Press switch pad until desired function is selected.
A complete Parts List is available at www.MillerWelds.com SECTION 8 − MAXSTAR 280 OPERATION 8-1. Maxstar 280 Controls LIFT ARC HF START Schedule 1 Schedule 2 247218-C Memory Card Port And Indicator Menu Button For all front panel switch pad controls:...
A complete Parts List is available at www.MillerWelds.com 8-2. Accessing Control Panel Menu: DC TIG HF And Lift Arc Menu Button Press Menu button to cycle through parameters that can be set. Parameter Display Setting Display Encoder Rotate Encoder to adjust paramet- er setting.
A complete Parts List is available at www.MillerWelds.com 8-3. Accessing Control Panel Menu: DC Stick Menu Button Press Menu button to cycle through parameters that can be set. Parameter Display Setting Display Encoder Rotate Encoder to adjust para- meter setting. Parameter automatically returns to amperage set- 110A...
A complete Parts List is available at www.MillerWelds.com 8-4. Accessing User Setup Menu: DC TIG HF And Lift-Arc Menu Button Press and hold Menu button for approximately 2 seconds to access machine configuration menus. Use Menu button to cycle through parameters that can be set.
A complete Parts List is available at www.MillerWelds.com 8-5. Accessing User Setup Menu: DC Stick Menu Button Press and hold Menu button for approximately 2 seconds to access machine configuration menus. Use Menu button to cycle through parameters that can be set. Parameter Display Setting Display Encoder...
A complete Parts List is available at www.MillerWelds.com SECTION 9 − MAXSTAR 280 DX OPERATION 9-1. Maxstar 280 DX Controls 247216-D Encoder Control Ammeter For all front panel switch pad controls: Use encoder control in conjunction with press switch pad to turn on light and...
A complete Parts List is available at www.MillerWelds.com 9-2. Accessing Control Panel Menu Amperage Button Parameter Display Setting Display Encoder Rotate Encoder to adjust parameter setting. The Amperage Control controls the welding amperage output, and limits the maximum output of a remote amperage device.
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A complete Parts List is available at www.MillerWelds.com *PRO−SET provides PROfessionally developed SETtings for the weld process. PRO−SET flashes one time and reveals the professional setting for the parameter. Pulse Control Pulsing is available while in the TIG process. Controls can be adjusted while welding. Reduces heat input to minimize distortion and increase travel speed.
A complete Parts List is available at www.MillerWelds.com 9-3. Accessing User Setup Menu Amperage Button Gas/Dig Button Parameter Display Setting Display Encoder To access the User functions, press and hold the Amperage (A) and the Gas/DIG controls until USER MENU is displayed. To scroll through the user menu functions, press and release the Gas/ DIG control.
A complete Parts List is available at www.MillerWelds.com SECTION 10 − ADVANCED MENU FUNCTIONS 10-1. Accessing Tech Menu For Dynasty/Maxstar 280 Models Menu Button Press and hold Menu button for ap- proximately four seconds to scroll past User Menu to Tech Menu. Use Menu button to cycle through para- meters that can be set.
A complete Parts List is available at www.MillerWelds.com 10-2. Accessing Tech Menu For Dynasty/Maxstar 280 DX Models Amperage Gas/Dig Button Press and hold Amperage and Gas/Dig buttons for approximately two seconds to scroll past User Menu to Tech Menu. Use...
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A complete Parts List is available at www.MillerWelds.com [ARC] [T/CY] Arc Timer: Monitors hours, minutes, and cycles of valid arc on. To view these different elements, rotate encoder. To reset, ro- tate encoder until [RESET] [YES] is displayed. Press Menu button to display [RESET] [Done]. Displays turn to [000] [000]. [ERR] [LOG] Error Log: Use to view last eight logged error events.
A complete Parts List is available at www.MillerWelds.com 10-3. Sequencer And Weld Timer For DX Model Sequencer Control With Weld Timers ON INTL This function is available while using the TIG process, but is disabled if a remote foot or fingertip control is connected while in the RMT STD mode.
A complete Parts List is available at www.MillerWelds.com 10-4. Output Control And Trigger Functions For DX Models A. Remote (Standard), 2T, And 4TE Torch Trigger Operation Current (A) Main Amps Initial Slope Final Slope Initial Amps Final Amps Postflow Preflow Time Standard Maintained Switch...
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A complete Parts List is available at www.MillerWelds.com 3T Specific Trigger Method Current (A) 3T 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. P/R = Push and Release (in less than 3/4 of a second) P/H = Push and Hold R = Release...
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A complete Parts List is available at www.MillerWelds.com C. 4T, 4Tm And 4TL Specific Trigger Method 4T and 4Tm Application: Use 4T and 4Tm (modified) trigger methods when the functions of a re- mote current control are desired, but only a remote on/off control is available. 4T* allows the operator to toggle be- tween weld current and final current.
A complete Parts List is available at www.MillerWelds.com 10-5. Lockout Functions See Section 10-2 for information on how to access Lockout Functions. There are four (1−4) different lockout levels. Each successive level allows the operator more flexibility. Before activating lockout levels, be sure that all procedures and para- meters are established.
A complete Parts List is available at www.MillerWelds.com SECTION 11 − MAINTENANCE AND TROUBLESHOOTING 11-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. A. Welding Power Source n = Check Z = Change ~ = Clean Δ...
A complete Parts List is available at www.MillerWelds.com 11-2. Voltmeter/Ammeter Display Messages Release Trigger Latching Errors: RELE CHEK INPT WELD CABL TRIG Latching Errors: O.M. Un Short Output COOL HORT UN S Not Valid OUTP VALD Over Temperature Error Lock Level OVER TEMP LOCK LEV1...
A complete Parts List is available at www.MillerWelds.com 11-3. Troubleshooting Table Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 5-8 or 5-9). inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-8 or 5-9). Check for proper input power connections (see Section 5-8 or 5-9).
A complete Parts List is available at www.MillerWelds.com 11-4. Blowing Out Inside of Unit Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. 805497-A 11-5. Coolant Maintenance Disconnect input power...
A complete Parts List is available at www.MillerWelds.com SECTION 12 − PARTS LIST 12-1. Recommended Spare Parts Dia. Part Mkgs. Description Quantity Recommended Spare Parts ....239494 .
SECTION 14 − HIGH FREQUENCY 14-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. high_freq 2018-01 14-2. Installation Showing Possible Sources Of HF Interference Weld Zone 11, 12 50 ft (15 m)
14-3. Recommended Installation To Reduce HF Interference Weld Zone 50 ft (15 m) 50 ft (15 m) Ground all metal ob- jects and all wiring in welding zone using #12 AWG wire. Ground workpiece if required by Nonmetal codes. Building Best Practices Followed Metal Building Ref.
SECTION 15 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2018-01 Whenever possible and practical, use DC weld output instead of AC weld output. 15-1. Selecting Tungsten Electrode ( Wear Clean Gloves To Prevent Contamination Of Tungsten A.
15-2. 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. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information.
SECTION 16 − TIG PROCEDURES gtaw_Inverter_2011-06 For additional resources on welding, visit http://www.millerwelds.com/resources/welding-resources/ 16-1. 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.
16-2. Pulser Control Pulser Control Pulsing is available while using the TIG process. Con- trols can be adjusted while welding. Press switch pad to enable pulser. ON - When illuminated, this LED indicates the pulser is Press switch pad until desired parameter LED is illumi- nated.
16-3. General (GEN) Tungsten Programmable TIG Starting Parameters (DX Models Only) Encoder Control Parameter Display Amperage Button Once inside the machine set up menu, tungsten parameter values can be manually changed by press- ing the Amperage switch pad to step through each adjustable para- meter.
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Effective January 1, 2019 (Equipment with a serial number preface of MK 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 Subarc Wire Drive Assemblies below, Miller Electric Mfg.
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