Miller Maxstar 400 Owner's Manual
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Miller Maxstar 400 Owner's Manual

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MANUAL
MAXSTAR 400
INGLÊS
ALUGUEL E VENDA DE MÁQUINAS DE
SOLDA E CORTE PLASMA
TODOS OS PROCESSOS DE SOLDAGEM
TRABALHAMOS EXCLUSIVAMENTE COM
AS MELHORES MÁQUINAS DO MUNDO
ASSESSORIA PARA PROCESSOS ESPECIAIS
TECNOLOGIA ATUALIZADA PARA
GARANTIR O MELHOR CUSTO BENEFÍCIO
AUMENTO DE PRODUTIVIDADE SOLDADOR-PEÇA
REDUÇÃO DE CUSTO COM ENERGIA
MIG MAG · TIG · ARCO SUBMERSO · MULTIPROCESSO · RETIFICADORAS CORTE PLASMA
INVERSORAS · ELETRODO · GERADORES DE ENERGIA · ROBÔS
www.aventa.com.br | contato@aventa.com.br
LOCAÇÃO E VENDA
MÁQUINAS DE SOLDA E CORTE

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  • Page 1 MANUAL MAXSTAR 400 LOCAÇÃO E VENDA MÁQUINAS DE SOLDA E CORTE INGLÊS ALUGUEL E VENDA DE MÁQUINAS DE SOLDA E CORTE PLASMA TODOS OS PROCESSOS DE SOLDAGEM TRABALHAMOS EXCLUSIVAMENTE COM AS MELHORES MÁQUINAS DO MUNDO ASSESSORIA PARA PROCESSOS ESPECIAIS TECNOLOGIA ATUALIZADA PARA GARANTIR O MELHOR CUSTO BENEFÍCIO...
  • Page 2 Stick (SMAW) Welding Description 208/575 Volt Models W/Auto-Linet 380/575 Volt Three-Phase W/Auto-Linet (CE) Arc Welding Power Source Dynasty 400, 800 Maxstar 400, 800 CE And Non-CE Models For product information, File: TIG (GTAW) Owner’s Manual translations, and more, visit www.MillerWelds.com...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 7 − MAXSTAR OPERATION ............7-1.
  • Page 5 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).
  • Page 6 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 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 7 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...
  • Page 8 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 9 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 10: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 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.
  • Page 11 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 12: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. 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 13: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 14: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 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 15 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

  • Page 16: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Tenir les bouteilles éloignées des circuits de soudage ou autres LE BRUIT peut endommager l’ouïe. circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. Le bruit des processus et des équipements peut affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec D Porter des protections approuvées pour les une bouteille.

  • Page 17: Proposition Californienne 65 Avertissements

    RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de FRÉQUENCE (H.F.) risque provoquer des interférences. provoquer des interférences. D L’énergie électromagnétique risque D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et l’équipement commandé...

  • Page 18: Section 3 − Definitions

    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.
  • Page 19 A complete Parts List is available at www.MillerWelds.com Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information. Safe37 2012−05 Environmental Protection Use Period (China) Safe123 2016−06...

  • Page 20: Miscellaneous Symbols And Definitions

    A complete Parts List is available at www.MillerWelds.com 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Impulse Starting Amperage Gas Output (GTAW) Rated Welding Output Final Slope Current Gas Tungsten Arc Duty Cycle Final Amperage Welding (GTAW) Shielded Metal Pulse Percent...

  • Page 21: Section 4 − Specifications

    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 front of the machine. Use the rating labels to determine input power requirements and/or rated output.
  • Page 22 A complete Parts List is available at www.MillerWelds.com B. Maxstar 400 Models Do not use information in unit specifications table to determine electrical service requirements. See Section 5-14B for information on connecting input power. Welding Amperage Max Open Circuit Low Open-Circuit...
  • Page 23 A complete Parts List is available at www.MillerWelds.com D. Maxstar 800 Models Do not use information in unit specifications table to determine electrical service requirements. See Section 5-14B for information on connecting input power. Welding Amperage Max Open Circuit Low Open-Circuit Rated Peak Striking IP Rating Range...

  • Page 24: Dimensions, Weights And Base Mounting Hole Layout

    A complete Parts List is available at www.MillerWelds.com 4-3. Dimensions, Weights And Base Mounting Hole Layout Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc. A. Welding Power Source Dimensions 400 Amp Models 800 Amp Models 24-3/4 in. (654 mm) 34-5/8 in.

  • Page 25: Environmental Specifications

    1 2014-07 D. Information On Electromagnetic Compatibility (EMC) (Maxstar 400) This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−...
  • Page 26 A complete Parts List is available at www.MillerWelds.com G. 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...

  • Page 27: Duty Cycle And Overheating

    Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding. NOTICE − Exceeding duty cycle can damage unit and void warranty. DUTY CYCLE DYNASTY MAXSTAR 400/800 MD800 3 PHASE MD800 1 PHASE MD400 1 PHASE MD400 3 PHASE...

  • Page 28: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Selecting A Location Movement Do not move or operate unit where it could tip. Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 29: Selecting Cable Sizes

    ****For distances longer than 100 ft (30 m) and up to 200 ft (60 m), use direct current (DC) output only. For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

  • Page 30: Remote 14 Receptacle Information

    Hot Wire, and Hot Start Adjust expansions. 5-5. Simple Automation Application (14-Pin Interface) This application requires the pur- chase of the automation expansion module, Miller Part No. 301151. Coil resistance plus To User Equipment should be chosen to limit current to 75 mA...

  • Page 31: Automation Connection (For 28-Pin Receptacle If Present)

    A 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 Con- trol, High Frequency Arc Start Disable, and Remote Memory Select.
  • Page 32 A complete Parts List is available at www.MillerWelds.com Continued from previous page Section A. 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 Disable = Disables the arc starter from being activated when connected to pin 8.
  • Page 33 A complete Parts List is available at www.MillerWelds.com Continued from previous page Section B. Output Arc Length Control Lockout Reference = Paired with Pin 13. Connect to user’s external voltage supply common (See Section 5-5 for typical application). Input Memory Select = Used to select between memory numbers. Used in conjunction with pin 10 and 16. (See Sections 5-7 and 14-1.) Input Memory Select = Used to select between memory numbers.

  • Page 34: Remote Memory Select Inputs (For 28-Pin Receptacle If Present)

    A complete Parts List is available at www.MillerWelds.com Continued from previous page, Section C. Output Control Reference for pins 5 and 6. Output Welders Chassis = Earth ground. Connected only if common potentials are needed between user equipment and the welder.

  • Page 35: 115 Volts Ac Cooler Receptacle, Supplementary Protector Cb1, And Power Switch

    Receptacle RC2 supplies 115 V 4A of single-phase power. RC2 is a designated use re- ceptacle intended only for sup- plying AC power to a Miller-ap- proved cooler. Supplementary Protector CB1 CB1 protects cooler receptacle from overload. If circuit breaker opens, the receptacle does not work.

  • Page 36: Tig Hf Impulse/ Lift-Arc Connections

    A complete Parts List is available at www.MillerWelds.com 5-10. TIG HF Impulse/ Lift-Arc Connections Turn off power before making connections. Electrode Weld Output Terminal Connect TIG torch to electrode weld output terminal. Gas Out Connection Connect torch gas hose to gas out fitting.

  • Page 37: Cooler Connections

    Cart and cooler are optional equipment. AC Cooler Receptacle RC2 RC2 is a designated use re- ceptacle intended only for sup- plying AC power to a Miller-ap- proved cooler. 115 VAC Cord Provides 115 VAC to power cooler. Electrode Weld Output Terminal (−Weld Output...

  • Page 38: Dynasty Stick Connections

    A 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. Work Weld Output Terminal Connect work lead to work weld output terminal. Electrode Weld Output Terminal Connect electrode holder to electrode weld output terminal.

  • Page 39: Electrical Service Guide

    A complete Parts List is available at www.MillerWelds.com Elec Serv 2017−01 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 recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated 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 40 A 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 recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
  • Page 41 A 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 recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated 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 42 A 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 recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated 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: Connecting Input Power For 400 Models And 800 Ce Models

    A complete Parts List is available at www.MillerWelds.com 5-15. 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. Disconnect and lockout/tagout in- put power before connecting input conductors from unit.
  • Page 44 A complete Parts List is available at www.MillerWelds.com B. Connecting Single-Phase Input Power Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.

  • Page 45: Connecting Input Power For 800 Models

    A complete Parts List is available at www.MillerWelds.com 5-16. Connecting Input Power For 800 Models A. Connecting Three-Phase Input Power = GND/PE Earth Ground Tools Needed: 5/16 in. Input 5 2016−06 / Ref. 805604-A Installation must meet all National and See rating label on unit and check input volt- Welding Power Source Line Terminals Local Codes −...
  • Page 46 A complete Parts List is available at www.MillerWelds.com B. Connecting Single-Phase Input Power =GND/PE Earth Ground Tools Needed: 5/16 in. Input9 2013−04 / Ref. 805604-A Installation must meet all National and Welding Power Source Input Power Disconnect Device Input Power Local Codes −...

  • Page 47: Software Updates

    A complete Parts List is available at www.MillerWelds.com 5-17. 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. •...

  • Page 48: Section 6 − Dynasty Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − DYNASTY OPERATION 6-1. Controls 273670-B Port is used to add features to the machine, Polarity Control (Dynasty Only) For all front panel switch pad controls: and update software. Indicator is lit while Process Controls press switch pad to turn on light and en- card is being accessed.

  • Page 49: Accessing Control Panel Menu

    A complete Parts List is available at www.MillerWelds.com 6-2. Accessing Control Panel Menu Memory Button Select Memory 1-9 (See Section 14) Parameter Display Setting Display Encoder Control Rotate Encoder to adjust parameter setting. Amperage Button Amperage Control Controls the welding amperage output. Limits the maximum output of a remote amperage device.
  • Page 50 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 in the TIG process. Controls can be adjusted while welding.

  • Page 51: Accessing User Setup Menu

    A complete Parts List is available at www.MillerWelds.com 6-3. Accessing User Setup Menu Amperage Button Gas/Dig Button Parameter Display Setting Display Encoder Control 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- MENU USER...

  • Page 52: Ac Independent

    A complete Parts List is available at www.MillerWelds.com 6-4. AC Independent 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 6-3). A. AC Independent Amperage AC Waveshape Control Press switch pad until desired function is selected.

  • Page 53: Controls

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − MAXSTAR OPERATION 7-1. Controls 275861-B / Ref. 803901-A Port is used to add features to the machine, terminals. It also show parameter descrip- For all front panel switch pad controls: and update software.
  • Page 54 A complete Parts List is available at www.MillerWelds.com Notes OM-275857 Page 45...

  • Page 55: Accessing Control Panel Menu

    A complete Parts List is available at www.MillerWelds.com 7-2. Accessing Control Panel Menu Memory Button Select Memory 1-9 (See Section 14) Parameter Display Setting Display Encoder Control Rotate Encoder to adjust parameter setting. Amperage Button Amperage Control Controls the welding amperage output. Limits the maximum output of a remote amperage device.
  • Page 56 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 in the TIG process. Controls can be ad- justed while welding.

  • Page 57: Accessing User Setup Menu

    A complete Parts List is available at www.MillerWelds.com 7-3. Accessing User Setup Menu Amperage Button Gas/Dig Button Parameter Display Setting Display Encoder Control 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- USER MENU...

  • Page 58: Section 8 − 28-Pin Advanced Automation Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 8 − 28-PIN ADVANCED AUTOMATION OPERATION 8-1. Controls 273670-B Memory Card Port And Indicator Shows actual rectified average voltage To activate 28−pin Advanced Automa- when voltage is present at the weld output tion, see Section 5-6C terminals.

  • Page 59: Controls

    A complete Parts List is available at www.MillerWelds.com 8-2. Controls Parameter Display Setting Display Encoder Control Rotate Encoder to adjust parameter setting. 273670-B Process Selection TIG HF Impulse is a non-contact arc starting method for AC and DC TIG welding (see Section 15-1). TIG Lift-Arc Is a contact arc starting method for AC and DC TIG welding (see Section 15-1).

  • Page 60: Accessing User Setup Menu

    A complete Parts List is available at www.MillerWelds.com 8-3. Accessing User Setup Menu Amperage Button Gas/Dig Button Parameter Display Setting Display Encoder Control To access the User Functions, press and hold the Amperage (A) and the Gas/DIG controls until [USER] [MENU] is displayed.

  • Page 61: Programmable Tig Start Parameters

    A complete Parts List is available at www.MillerWelds.com 8-4. Programmable TIG Start Parameters A. OFF/ON (Start Amperage And Time) Current (A) STAT OFF Start Time Off is the default setting. Use Encoder con- The AC and DC parameters are selected Preset Advanced Automation TIG Start trol to select On.
  • Page 62 A complete Parts List is available at www.MillerWelds.com C. Programmable Start Time Current (A) TIME Start Time Amperage Button To adjust Programmable Start Time pro- Start Time is displayed in milliseconds on ceed as follows: the amps meter, and can be adjusted by ro- Encoder Control tating the Encoder control.

  • Page 63: Section 9 − Advanced Functions

    A complete Parts List is available at www.MillerWelds.com SECTION 9 − ADVANCED FUNCTIONS 9-1. Accessing Tech Menu For Dynasty/Maxstar Models Amperage Button Gas/Dig Button Press and hold Amperage and Gas/Dig buttons 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 64 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, rotate 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.

  • Page 65: Sequencer And Weld Timer

    A complete Parts List is available at www.MillerWelds.com 9-2. Sequencer And Weld Timer Sequencer Control With Weld Timers ON INTL This function is available while using the TIG process, but is disabled if a remote foot or fin- gertip control is connected while in the RMT STD mode.

  • Page 66: Output Control And Trigger Functions

    A complete Parts List is available at www.MillerWelds.com 9-3. Output Control And Trigger Functions 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 P & H Foot Or Finger Maintained Switch Remote Control...
  • Page 67 A complete Parts List is available at www.MillerWelds.com 3T Specific Trigger Method 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 Application...
  • Page 68 A complete Parts List is available at www.MillerWelds.com C. 4T, 4Tm, And 4TL Specific Trigger Method 4T And 4Tm Application: Use 4T or 4Tm (modified) trigger method when the functions of a re- mote current control are desired, but only a remote on/off control is available.
  • Page 69 A complete Parts List is available at www.MillerWelds.com D. On Trigger Operation Voltage (V) 2 Sec Current (A) Stick Touch Stick Lift Stick Electrode Electrode Current (A) Lift Main Amperage *Final Slope Initial Slope Initial Amperage Touch Current *Final Amperage Touch Tungsten Lift Tungsten Lift Tungsten...

  • Page 70: Lockout Functions

    A complete Parts List is available at www.MillerWelds.com 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 more flexibility. Before activating lockout levels, be sure that all procedures and para- meters are established.

  • Page 71: Section 10 − Maintenance And Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 10 − MAINTENANCE AND TROUBLESHOOTING 10-1. Routine Maintenance Disconnect power before maintaining. n = Check Z = Change ~ = Clean Δ = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months ~ Weld Terminals...

  • Page 72: Voltmeter/Ammeter Display Messages

    A complete Parts List is available at www.MillerWelds.com 10-3. Voltmeter/Ammeter Display Messages Release Trigger Latching Errors: RELE CHEK INPT WELD CABL TRIG Latching Errors: O.M. Un Short Output HORT UN S Not Valid OUTP VALD Over Temperature Error Lock Level TEMP OVER LOCK...

  • Page 73: Troubleshooting Table

    A complete Parts List is available at www.MillerWelds.com 10-4. 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 74: Section 11 − Electrical Diagram

    SECTION 11 − ELECTRICAL DIAGRAM 275852-C Figure 11-1. Dynasty 400 Circuit Diagram OM-275857 Page 65...
  • Page 75 275851-C Figure 11-2. Maxstar 400 Circuit Diagram OM-275857 Page 66...
  • Page 76 275853-B Figure 11-3. Maxstar 800 Circuit Diagram (1 of 2) OM-275857 Page 67...
  • Page 77 275853-B Figure 11-4. Maxstar 800 Circuit Diagram (2 of 2) OM-275857 Page 68...
  • Page 78 275854-B Figure 11-5. Dynasty 800 Circuit Diagram (1 of 2) OM-275857 Page 69...
  • Page 79 275854-B Figure 11-6. Dynasty 800 Circuit Diagram (2 of 2) OM-275857 Page 70...

  • Page 80: Section 12 − High Frequency

    SECTION 12 − HIGH FREQUENCY 12-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Work high_freq 5/10 − S-0693 12-2. Installation Showing Possible Sources Of HF Interference Weld Zone 11, 12 50 ft...

  • Page 81: Recommended Installation To Reduce Hf Interference

    12-3. 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.

  • Page 82: Section 13 − Selecting And Preparing A Tungsten For Dc Or Ac Welding With Inverter Machines

    SECTION 13 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2016-10 Whenever possible and practical, use DC weld output instead of AC weld output. 13-1. Selecting Tungsten Electrode ( Wear Clean Gloves To Prevent Contamination Of Tungsten Not all tungsten electrode manufacturers use the same colors to identify tungsten type.

  • Page 83: Section 14 − Memory

    SECTION 14 − MEMORY 14-1. Memory (Program Storage Locations 1-9) Memory (Program Storage 1-9) Switch Pad Polarity Switch Pad (Dynasty Only) Process Switch Pad To create, change, or recall a weld- ing parameters program, proceed as follows: First, press Memory switch pad until the desired program storage location (1-9) is displayed.

  • Page 84: Section 15 − Tig Procedures

    SECTION 15 − TIG PROCEDURES 15-1. 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.

  • Page 85: Pulser Control

    15-2. Pulser Control Percent (%) Peak Time Pulsed Output Waveforms Control Setting Peak 50%/Background 50% Peak Amp Balanced 50% Bkg Amp More Time At Peak Amperage More Time At Background Amperage Pulser Control enced welder may have the PPS setting your puddle is on the background side of the much higher, depending on their personal pulse cycle.

  • Page 86: General (Gen) Tungsten To Change Programmable Tig Starting Parameters

    15-3. General (GEN) Tungsten To Change Programmable TIG Starting Parameters 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.

  • Page 87: 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 88 Effective January 1, 2017 (Equipment with a serial number preface of MH or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 89 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2017 Miller Electric Mfg. Co. 2017−01...

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Dynasty 800Dynasty 400Maxstar 800

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