Miller Dynasty 200 SD Owner's Manual
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Miller Dynasty 200 SD Owner's Manual

Miller Dynasty 200 SD Owner's Manual

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Dynasty 200 SD And DX
R
OM-2240
207688U
2008−07
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 SD

  • Page 1 OM-2240 207688U 2008−07 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 TABLE OF CONTENTS SECTION 15 − PARTS LIST ..............OPTIONS AND ACCESSORIES WARRANTY...
  • Page 6 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Manufacturer: European Contact: Miller Electric Mg. Co. Mr. Danilo Fedolfi, 1635 W. Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 8 D Do not use welder to thaw frozen pipes. FUMES AND GASES can be hazardous. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Welding produces fumes and gases. Breathing D Wear oil-free protective garments such as leather gloves, heavy these fumes and gases can be hazardous to your shirt, cuffless trousers, high shoes, and a cap.

  • 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: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 12 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un in les sources de soudage onduleur quand on a cendie ou une explosion. coupé l’alimentation. Le soudage effectué sur des conteneurs fermés tel D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peu décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, ACCUMULATIONS des chocs mécaniques, des dommages physiques, du laitier, des risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs. ou même la mort. D Placer les bouteilles debout en les fixant dans un support station- D Fermer l’alimentation du gaz protecteur en cas naire ou dans un porte-bouteilles pour les empêcher de tomber ou de non-utilisation.

  • Page 14: Proposition Californienne 65 Avertissements

    LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ- provoquer des blessures. QUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Le rayonnement haute fréquence (H.F.) peut D Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe- sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica-...

  • Page 15: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org). Internet : www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, de American National Standards Institute, Recommended Safe Practices for the Preparation for Welding and Cut- 11 West 43rd Street, New York, NY 10036-8002 (téléphone :...
  • Page 16 OM-2240 Page 10...

  • Page 17: 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 18 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 19: 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 20: Symbols And Definitions

    3-4. 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 21: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Specifications Amperes Input At Rated Output, 50/60Hz Welding Max. Input Power Rated Output Amperage Open-Circuit Range ** Voltage ∇ Three-Phase 130 A @ 25.2 VDC, 12.3 1 − 200 -− 60% Duty Cycle 0.16* 0.24* 0.25* 0.06* 0.03*...

  • Page 22: 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 23: 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 24: 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 25: 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) Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 26: 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 Turn off power before connecting to weld output terminals. 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) Or Less (45 m)

  • Page 27: 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 28: Stick Connections

    4-10. Stick Connections 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 29: Connecting Three-Phase Input Power

    4-12. 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. Always connect green or green/ yellow conductor supply = GND/PE Earth Ground...

  • Page 30: Connecting Single-Phase Input Power

    4-13. 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 in- put power before connecting input conductors from unit. =GND/PE Earth Ground Always connect green or green/ yellow conductor supply...

  • Page 31: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls 207 694-A / 802 452 Polarity Control Sequencer Controls (DX, LX For all front panel switch pad controls: And All CE Models) press switch pad to turn on light and en- See Section 5-6. able function.

  • Page 32: 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 33: 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 Polarity Control Press switch pad until desired LED is illuminated.

  • Page 34: Lift-Arce And Hf Tig Start Procedures

    5-7. 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 35: Process Control

    5-8. 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 5-7) 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 36: Pulser Control (Dx Models Only)

    5-10. Pulser Control (DX Models Only) Pulser Control Pulsing is available only while using the TIG process, it cannot be se- lected if the Stick process (see Sec- tion 5-8) is active. Controls can be ad- justed while welding. Press switch pad to enable pulser. ON - When illuminated, this LED in- dicates the pulser is on.

  • Page 37: Sequencer Controls (Dx And Ce Models)

    5-11. Sequencer Controls (DX And 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 38: Adjust Controls (Preflow/Post Flow/Dig/Purge)

    5-12. 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 39: Ac Waveshape

    5-13. AC Waveshape 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 40: 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 41: Factory Parameter Defaults And Range And Resolution

    5-16. Factory Parameter Defaults And Range And Resolution Parameter Default Range And Resolution PROCESS TIG HF Impulse TIG HF Impulse / TIG Lift / Stick * Stick OCV Low OCV Low OCV / Normal OCV *Stick Stuck Check ScI (On) ScI (On) / Sc0 (Off) OUTPUT RMT STD...

  • Page 42: Resetting Unit To Factory Default Settings

    DYNASTY: *Tungsten .094 GEN, .020, .040, .062, .094, .125 **Polarity EP / EN **Amperage 1 − 200 Amps **Time 1 − 200 Milliseconds **Start Slope Time 0 − 250 Milliseconds **Preset Amperage Minimum 1 − 20 Amps *Tungsten .094 GEN, .020, .040, .062, .094, .125 **Polarity EP / EN **Amperage...
  • Page 43 Notes OM-2240 Page 37...

  • Page 44: Section 6 − Advanced Functions

    SECTION 6 − ADVANCED FUNCTIONS 6-1. Programable TIG Start, And Preset Amperage Minimum Parameters Accessing Programmable TIG Start Parameters Rear Panel parameter screens, turn power on, and Press the Process switch pad to select The welding cycle can be executed then press the Process and Amperage the desired process, TIG HF Impulse or while in programmable start mode.
  • Page 45 Tungsten Selection Eun 094 Current (A) Preset Amperage Minimum Start Time Start Slope Time Amperage Switch Pad size from the following: .020, .040, .062 are a seperate set of parameters for AC (1/16 in.), .094 (3/32 in.), or .125 (1/8 in.) and DC (to select polarity see Section D).
  • Page 46 Selecting GEN Encoder Control Amps Meter Amperage Switch Pad If [GEn] is selected and displayed on the amps meter, the TIG starting parameters for a .094 tungsten are the default, and for AC polarity they are: Start Polarity = EP, Start Am- perage = 120 A, Start Time = 20 ms, Start Slope Time = 10 ms, Preset Minimum Amps = 5 A.
  • Page 47 Changing Programmable TIG Start Polarity Current (A) Start Polarity 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 48 F. Changing Programmable Start Time Current (A) Start Time Amperage Switch Pad ceed as follows: meter, and can be adjusted by turning the Encoder control (see Section 5-16). Encoder Control Press Amperage switch pad, and meter Amps Meter S LED turns on. The current Start Time is To change Start Slope Time, proceed to To adjust Programmable Start Time pro- displayed in milliseconds on the amps...
  • Page 49 Changing Preset Amperage Minimum Current (A) Preset Amperage Minimum Amperage Switch Pad Press Amperage switch pad. Switch pad for AC and DC. LED turns on, and meter A LED turns on. Encoder Control The Preset Minimum Amperage is dis- Whatever amperage is selected as played on the amps meter, and can be Amps Meter the preset amperage minimum, is the...

  • Page 50: Ac Waveshape Selection

    6-2. AC Waveshape Selection Rear Panel = Soft Squarewave = Advanced Squarewave = Sine wave = Triangular wave Polarity Switch Pad Application: Use advance squarewave when a more focused arc is required for AC Waveshape Switch Pad Encoder better directional control. Use soft square- Power Switch wave when a softer arc with a more fluid Use the Encoder to select between ad-...

  • Page 51: Output Control And Trigger Functions

    6-3. 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 52 C. Reconfiguring RMT 2T HOLD For 2T, 3T, Spot, 4T, 4T Momentary, Or Mini Logic Control Rear Panel For RMT STD (Remote Standard), RMT guration screen, turn power switch on Meter Displays 2T Hold (Remote 2T Hold), and On trig- and then press the Process and Output Meter displays for the different functions ger operation, see Section 6-3A, B, and...
  • Page 53 (See Section 6-3B for operation) Spot (See Section 6-3G for operation) (DX, LX and CE Models) (See Section 6-3D for operation) Mini Logic (DX, LX and CE Models) (See Section 6-3E for operation) 4T Momentary (DX, LX and CE Models) (See Section 6-3F for operation) H‐3...
  • Page 54 D. 4T Specific Trigger Method (DX And CE Models) 4T (Specific Trigger Operation) Sequencer is required to reconfi- gure for 4T. Select 4T according to Section 6-3C. Torch trigger operation is as shown. 4T allows the operator to toggle be- tween weld current and final current without breaking the arc.
  • Page 55 E. Mini Logic Operation (DX And CE Models) Mini Logic Meter Display Select Mini Logic according to Sec- tion 6-3C. 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 as illustrated.
  • Page 56 F. 4T Momentary Operation (DX And CE Models) 4T Momentary Meter Display Select 4T Momentary according to Section 6-3C. 4T Momentary torch trigger op- eration is as shown. When a remote switch is connected to the welding power source, use the re- mote switch to control the weld cycle.
  • Page 57 G. Spot Control Operation Spot Function Meter Display Select Spot function according to Section 6-3C. While in Spot Control, Se- quencer settings will be ig- nored and will not be program- mable. Spot When a remote switch is con- nected to the welding power source, use the remote switch to control the weld cycle.
  • Page 58 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 52...
  • Page 59 3T Specific Trigger Method (DX And CE Models) H‐3 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 60: Arc Timer/Counter Display

    6-4. 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 61: Lockout Functions

    6-5. 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 6-5.
  • Page 62 B. LockOut Levels Level 1 Before activating lock out lev- els, be sure that all procedures and parameters are estab- lished. Parameter adjustment is limited while lock out levels are active. Level 1 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 5-8)
  • Page 63 B. Lock Out Levels (Continued) Level 3 Level 3 Remote amperage control is not available in level 3. Use Encoder Control To Includes all the functions of levels 1 Adjust Amperage +/− 10% and 2 plus the following: Of Preset Value. +/−...

  • Page 64: Setting Unit To Display Ppp While Pulse Welding (Dx Models Only)

    6-6. Setting Unit To Display PPP While Pulse Welding (DX 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 65: Stick Open-Circuit Voltage (Ocv) Selection

    6-7. Stick Open-Circuit Voltage (OCV) Selection 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 66: Stick Stuck Check Selection

    6-8. Stick Stuck Check Selection Rear Panel Process Switch Pad i) appears. Application: For most Stick applica- tions, use Stick Stuck Check off. With Output Switch Pad Encoder Control Stick Stuck Check on and the welding Meter Display Amperage Switch Pad electrode (rod) stuck, output is turned Power Switch Turn Encoder to change between Stick...

  • Page 67: Section 7 − Maintenance And Troubleshooting

    SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. Δ = Repair n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent Every Months nl Labels...

  • Page 68: Voltmeter/Ammeter Help Displays

    7-3. Voltmeter/Ammeter Help Displays Help 3 Display Help 9 Display All directions are in reference to the Indicates a short in the thermal protection front of the unit. All circuitry referred to Indicates the bottom heat sink has over- circuitry located on the top heat sink. Con- is located inside the unit.

  • Page 69: 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 70: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram 237 567-A OM-2240 Page 64...

  • Page 71: 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 72: Section 10 − Setup Guides For (Gtaw) Tig Welding

    SECTION 10 − SETUP GUIDES FOR (GTAW) TIG WELDING 10-1. 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 73 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 74: Section 11 − Selecting And Preparing A Tungsten For Dc Or Ac Welding With Inverter Machines

    SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2007_05 Whenever possible and practicle, use DC weld output instead of AC weld output. 11-1. Selecting Tungsten Electrode ( Wear Clean gloves To Prevent Contamination Of Tungsten ♦...

  • Page 75: Section 12 − Guidelines For (Gtaw) Tig Welding

    SECTION 12 − GUIDELINES FOR (GTAW) TIG WELDING gtaw 7/2006 12-1. Positioning The Torch 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.

  • Page 76: Torch Movement During Welding

    12-2. 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 77: Section 13 − Setup Guide For (Smaw) Stick Welding

    SECTION 13 − SETUP GUIDE FOR (SMAW) STICK WELDING 13-1. 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 78: Section 14 − Guidelines For (Smaw) Stick Welding

    SECTION 14 − GUIDELINES FOR (SMAW) STICK WELDING 14-1. 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...

  • Page 79: Stick Welding Procedure

    14-2. Stick Welding Procedure NOTICE − Weld current starts when electrode touches work- piece. NOTICE − Weld current can dam- age electronic parts in vehicles. Disconnect both battery cables be- fore welding on a vehicle. Place work clamp as close to the weld as possible.

  • Page 80: Positioning Electrode Holder

    14-5. 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 14-6. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding...

  • Page 81: Conditions That Affect Weld Bead Shape

    14-8. Conditions That Affect Weld Bead Shape 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 ARC LENGTH...

  • Page 82: Butt Joints

    14-10. 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 83: Weld Test

    14-13. 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 14-14. Troubleshooting − Porosity Porosity −...

  • Page 84: Troubleshooting − Incomplete Fusion

    14-16. 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 85: Troubleshooting − Burn-Through

    14-19. 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. 14-20. Troubleshooting − Waviness Of Bead Waviness Of Bead −...
  • Page 86 SECTION 15 − PARTS LIST Hardware is common and not available unless listed. Figure 15-1. Main Assembly 803 395-F OM-2240 Page 80...
  • Page 87 Item Dia. Part Mkgs. Description Quantity Figure 15-1. Main Assembly ... . . Fig 15-2 ..PANEL, FRONT W/CMPNT ........
  • Page 88 ......NAMEPLATE/SWITCH MEMBRANE, DYNASTY 200 SD ......
  • Page 89 Hardware is common and not available unless listed. 803 392-A Figure 15-3.Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 15-3. Panel, Rear w/Components (Figure 15-1 Item 2) 210 158 ....194242 .
  • Page 90 Hardware is common and not available unless listed. 803 427-B Figure 15-4. Magnetics Assembly w/Components Item Dia. Part Mkgs. Description Quantity Figure 15-4. Magnetics Assembly w/Components (Figure 15-1 Item 3) 209 936 ... . . 195649 .
  • Page 91 Item Dia. Part Mkgs. Description Quantity Figure 15-4. Magnetics Assembly w/Components (Figure 15-1 Item 3) (Continued) ..233191 ..COIL XFMR, COUPLING ......... .
  • Page 92 Hardware is common and not available unless listed. 803 425-A Figure 15-5. Windtunnel w/Components Item Dia. Part Mkgs. Description Quantity 210 162 Figure 15-5. Windtunnel w/Components (Figure 15-1 Item 4) ... . . 195645 .
  • Page 93 Hardware is common and not available unless listed. 803 426-C Figure 15-6. Heat Sink, Secondary Assembly Item Dia. Part Mkgs. Description Quantity Figure 15-6. Heat Sink, Secondary Assembly(Figure 15-5 Item 7) 232 851 ... . . 209984 .
  • Page 94 Hardware is common and not available unless listed. 803 394−A Figure 15-7. Base Assembly Item Dia. Part Mkgs. Description Quantity 207 689 Figure 15-7. Base Assembly (Figure 15-1 Item 5) ....207255 .
  • Page 95 Effective January 1, 2008 (Equipment with a serial number preface of LJ or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...
  • Page 96 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. © PRINTED IN USA 2008 Miller Electric Mfg. Co. 2008−01...

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Dynasty 200 dx

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