OM-2250 216 871E

2006−03

Processes
TIG (GTAW) Welding

Stick (SMAW) Welding

Description

208/575 Volt Models W/Auto-Linet

Arc Welding Power Source

Dynasty 700
R

Maxstar 700
R

File: TIG (GTAW)

Visit our website at

www.MillerWelds.com
 From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. particular model are also provided.

Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 4/05
 TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − DEFINITIONS (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Manufacturer’s Rating Labels (Non CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-3. Manufacturer’s Rating Labels (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-4. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-3. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-4. Dimensions, Weights And Base Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-5. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-6. 115 Volts AC Duplex Receptacle, Supplementary Protector CB1, And Power Switch . . . . . . . . . . . . . 17
4-7. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-8. Remote 14 Receptacle Information (Used Without Automation Connection) . . . . . . . . . . . . . . . . . . . . . 19
4-9. Automation Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-10. Remote Memory Select Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-11. Automation Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-12. Typical Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-13. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-14. TIG HF Impulse/ Lift-Arct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-15. Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-16. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-17. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
 TABLE OF CONTENTS

SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-2. Encoder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-3. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-4. Ammeter And Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-5. Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-6. Polarity Control (Dynastyt Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-7. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-8. Lift-ArcE And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-9. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5-10. Pulser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5-11. Sequencer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-12. Gas/DIG Controls (Preflow/Post Flow/DIG/Purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5-13. AC Waveshape (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5-14. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5-15. Memory (Program Storage Locations 1-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5-16. Factory Parameter Defaults And Range And Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5-17. Resetting Unit To Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SECTION 6 − ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6-1. Programmable TIG Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6-2. Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6-3. AC Waveshape Selection (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6-4. Arc Timer/Counter Display (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6-5. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6-6. Setting Unit To Display PPP While Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6-7. Stick Open-Circuit Voltage (OCV) Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7-2. Blowing Out Inside of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SECTION 9 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SECTION 10 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING . . 67
10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . . 67
10-2. Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
OPTIONS AND ACCESSORIES
WARRANTY
 Declaration of Conformity for
European Community (CE) Products
NOTE 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.
Phone: (920) 734-9821 Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203

European Contact Signature:

Declares that the product: Dynasty R 700

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC

Standards

Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.

IEC 60974-10 August 2002

Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1

Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1

Insulation Coordination For Equipment Within Low-Voltage Systems:

Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1

Arc Welding Equipment − Part 3: Arc Striking And Stabilizing Devices. IEC 60974-3 Ed. 1

dec_stat_6/05
 Declaration of Conformity for
European Community (CE) Products
NOTE 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.
Phone: (920) 734-9821 Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203

European Contact Signature:

Declares that the product: Maxstar R 700

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC

Standards

Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.

IEC 60974-10 August 2002

Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1

Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1

Insulation Coordination For Equipment Within Low-Voltage Systems:

Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1

Arc Welding Equipment − Part 3: Arc Striking And Stabilizing Devices. IEC 60974-3 Ed. 1

dec_stat_6/05
 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2/05
Y Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

This group of symbols means Warning! Watch Out! possible

Y Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to D Frequently inspect input power cord for damage or bare wiring −
call attention to and identify possible hazards. When you see replace cord immediately if damaged − bare wiring can kill.
the symbol, watch out, and follow the related instructions to D Turn off all equipment when not in use.
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in D Do not use worn, damaged, undersized, or poorly spliced cables.
the Safety Standards listed in Section 1-5. Read and follow all D Do not drape cables over your body.
Safety Standards. D If earth grounding of the workpiece is required, ground it directly
Y Only qualified persons should install, operate, maintain, and with a separate cable.
repair this unit. D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Y During operation, keep everybody, especially children, away.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
ELECTRIC SHOCK can kill. D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is D Clamp work cable with good metal-to-metal contact to workpiece
electrically live whenever the output is on. The input or worktable as near the weld as practical.
power circuit and machine internal circuits are also D Insulate work clamp when not connected to workpiece to prevent
live when power is on. In semiautomatic or automatic wire welding, the contact with any metal object.
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly D Do not connect more than one electrode or work cable to any
grounded equipment is a hazard. single weld output terminal.
D Do not touch live electrical parts. SIGNIFICANT DC VOLTAGE exists in inverter-type
D Wear dry, hole-free insulating gloves and body protection. welding power sources after removal of input
D Insulate yourself from work and ground using dry insulating mats power.
or covers big enough to prevent any physical contact with the work D Turn Off inverter, disconnect input power, and discharge input
or ground. capacitors according to instructions in Maintenance Section
D Do not use AC output in damp areas, if movement is confined, or if before touching any parts.
there is a danger of falling.
D Use AC output ONLY if required for the welding process. FUMES AND GASES can be hazardous.
D If AC output is required, use remote output control if present on
unit. Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
D Additional safety precautions are required when any of the follow- health.
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such D Keep your head out of the fumes. Do not breathe the fumes.
as floors, gratings, or scaffolds; when in cramped positions such D If inside, ventilate the area and/or use local forced ventilation at the
as sitting, kneeling, or lying; or when there is a high risk of unavoid- arc to remove welding fumes and gases.
able or accidental contact with the workpiece or ground. For these D If ventilation is poor, wear an approved air-supplied respirator.
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual D Read and understand the Material Safety Data Sheets (MSDSs)
(stick) welder, or 3) an AC welder with reduced open-circuit volt- and the manufacturer’s instructions for metals, consumables,
age. In most situations, use of a DC, constant voltage wire welder coatings, cleaners, and degreasers.
is recommended. And, do not work alone! D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
D Disconnect input power or stop engine before installing or
person nearby. Welding fumes and gases can displace air and
servicing this equipment. Lockout/tagout input power according to
lower the oxygen level causing injury or death. Be sure the breath-
OSHA 29 CFR 1910.147 (see Safety Standards).
ing air is safe.
D Properly install and ground this equipment according to its
D Do not weld in locations near degreasing, cleaning, or spraying op-
Owner’s Manual and national, state, and local codes.
erations. The heat and rays of the arc can react with vapors to form
D Always verify the supply ground − check and be sure that input highly toxic and irritating gases.
power cord ground wire is properly connected to ground terminal in D Do not weld on coated metals, such as galvanized, lead, or
disconnect box or that cord plug is connected to a properly cadmium plated steel, unless the coating is removed from the weld
grounded receptacle outlet. area, the area is well ventilated, and while wearing an air-supplied
D When making input connections, attach proper grounding conduc- respirator. The coatings and any metals containing these elements
tor first − double-check connections. can give off toxic fumes if welded.
OM-2250 Page 1
 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill.

Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
D Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
D Use protective screens or barriers to protect others from flash,
torch.
glare and sparks; warn others not to watch the arc.
D To handle hot parts, use proper tools and/or
D Wear protective clothing made from durable, flame-resistant mate-
wear heavy, insulated welding gloves and
rial (leather, heavy cotton, or wool) and foot protection.
clothing to prevent burns.

WELDING can cause fire or explosion.

MAGNETIC FIELDS can affect pacemakers.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks D Pacemaker wearers keep away.
can fly off from the welding arc. The flying sparks, hot D Wearers should consult their doctor before
workpiece, and hot equipment can cause fires and going near arc welding, gouging, or spot
burns. Accidental contact of electrode to metal objects can cause welding operations.
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. NOISE can damage hearing.
D Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can
D Protect yourself and others from flying sparks and hot metal. damage hearing.
D Be alert that welding sparks and hot materials from welding can D Wear approved ear protection if noise level is
easily go through small cracks and openings to adjacent areas. high.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side. CYLINDERS can explode if damaged.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see Shielding gas cylinders contain gas under high
Safety Standards). pressure. If damaged, a cylinder can explode. Since
D Connect work cable to the work as close to the welding area as gas cylinders are normally part of the welding
practical to prevent welding current from traveling long, possibly process, be sure to treat them carefully.
unknown paths and causing electric shock, sparks, and fire D Protect compressed gas cylinders from excessive heat, mechani-
hazards. cal shocks, physical damage, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes. D Install cylinders in an upright position by securing to a stationary
D Remove stick electrode from holder or cut off welding wire at support or cylinder rack to prevent falling or tipping.
contact tip when not in use. D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy D Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap.
D Never allow a welding electrode to touch any cylinder.
D Remove any combustibles, such as a butane lighter or matches,
D Never weld on a pressurized cylinder − explosion will result.
from your person before doing any welding.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
tings designed for the specific application; maintain them and
for hot work and have a fire watcher and extinguisher nearby.
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
FLYING METAL can injure eyes. D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Welding, chipping, wire brushing, and grinding D Use the right equipment, correct procedures, and sufficient num-
cause sparks and flying metal. As welds cool, ber of persons to lift and move cylinders.
they can throw off slag.
D Read and follow instructions on compressed gas cylinders,
D Wear approved safety glasses with side associated equipment, and Compressed Gas Association (CGA)
shields even under your welding helmet. publication P-1 listed in Safety Standards.

OM-2250 Page 2
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. closed and securely in place.
D Do not overload building wiring − be sure power supply system is D Have only qualified persons remove doors,
properly sized, rated, and protected to handle this unit. panels, covers, or guards for maintenance as
necessary.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running READ INSTRUCTIONS.
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and D Read Owner’s Manual before using or servic-
support unit. ing unit.
D If using lift forks to move unit, be sure forks are D Use only genuine Miller/Hobart replacement
long enough to extend beyond opposite side of parts.
unit.

H.F. RADIATION can cause interference.

OVERUSE can cause OVERHEATING D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
D Allow cooling period; follow rated duty cycle. communications equipment.
D Reduce current or reduce duty cycle before D Have only qualified persons familiar with
starting to weld again. electronic equipment perform this installation.
D Do not block or filter airflow to unit. D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
STATIC (ESD) can damage PC boards. equipment at once.
D Have the installation regularly checked and maintained.
D Put on grounded wrist strap BEFORE handling D Keep high-frequency source doors and panels tightly shut, keep
boards or parts. spark gaps at correct setting, and use grounding and shielding to
D Use proper static-proof bags and boxes to minimize the possibility of interference.
store, move, or ship PC boards.

ARC WELDING can cause interference.

MOVING PARTS can cause injury. D Electromagnetic energy can interfere with
sensitive electronic equipment such as
D Keep away from moving parts. computers and computer-driven equipment
D Keep away from pinch points such as drive such as robots.
rolls. D Be sure all equipment in the welding area is
electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
WELDING WIRE can cause injury. D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Do not press gun trigger until instructed to do D Be sure this welding machine is installed and grounded
so. according to this manual.
D Do not point gun toward any part of the body, D If interference still occurs, the user must take extra measures
other people, or any metal when threading such as moving the welding machine, using shielded cables,
welding wire. using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases which For Gasoline Engines:
contain chemicals known to the State of California to cause Y Engine exhaust contains chemicals known to the State of
birth defects and, in some cases, cancer. (California Health & California to cause cancer, birth defects, or other reproductive
Safety Code Section 25249.5 et seq.) harm.
Y Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of Y Diesel engine exhaust and some of its constituents are known
California to cause cancer and birth defects or other to the State of California to cause cancer, birth defects, and
reproductive harm. Wash hands after handling. other reproductive harm.
OM-2250 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-
www.global.ihs.com). ternational.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, American Welding Society Standard ANSI Standard Z87.1, from American National Standards Institute, 11
AWS F4.1 from Global Engineering Documents (phone: West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
1-877-413-5184, website: www.global.ihs.com). website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec- Standard for Fire Prevention During Welding, Cutting, and Other Hot
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, from National Fire Protection Association,
02269−9101 (phone: 617−770−3000, website: www.nfpa.org). P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway, OSHA, Occupational Safety and Health Standards for General Indus-
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
site: www.cganet.com). and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
Code for Safety in Welding and Cutting, CSA Standard W117.2, from are 10 Regional Offices−−phone for Region 5, Chicago, is
Canadian Standards Association, Standards Sales, 178 Rexdale 312−353−2220,website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from opera-
Research Council concluded that: “The body of evidence, in the
tor as practical.
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.” 5. Connect work clamp to workpiece as close to the weld as possi-
However, studies are still going forth and evidence continues to be
ble.
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when About Pacemakers:
welding or cutting. Pacemaker wearers consult your doctor before welding or going near
To reduce magnetic fields in the workplace, use the following welding operations. If cleared by your doctor, then following the above
procedures: procedures is recommended.

OM-2250 Page 4
 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som _3/05
Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.

2-1. Symboles utilisés

Symbole graphique d’avertissement ! Attention ! Cette pro-
cédure comporte des risques possibles ! Les dangers éven-
tuels sont représentés par les symboles graphiques joints.

Y Indique un message de sécurité particulier Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
. Signifie NOTE ; n’est pas relatif à la sécurité. les dangers.

2-2. Dangers relatifs au soudage à l’arc

Y Les symboles représentés ci-dessous sont utilisés dans ce manuel D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
pour attirer l’attention et identifier les dangers possibles. En n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu
présence de l’un de ces symboles, prendre garde et suivre les peut entraîner la mort.
instructions afférentes pour éviter tout risque. Les instructions en D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
matière de sécurité indiquées ci-dessous ne constituent qu’un D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante
sommaire des instructions de sécurité plus complètes fournies ou mal épissés.
dans les normes de sécurité énumérées dans la Section 2-5. Lire et D Ne pas enrouler les câbles autour du corps.
observer toutes les normes de sécurité.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
Y Seul un personnel qualifié est autorisé à installer, faire fonction- câble distinct.
ner, entretenir et réparer cet appareil. D Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre
Y Pendant le fonctionnement, maintenir à distance toutes les per- ou une électrode provenant d’une autre machine.
sonnes, notamment les enfants de l’appareil. D Ne pas toucher des porte électrodes connectés à deux machines en
même temps à cause de la présence d’une tension à vide doublée.
UNE DÉCHARGE ÉLECTRIQUE peut D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
entraîner la mort. champ les pièces endommagées. Entretenir l’appareil conformément à
ce manuel.
Le contact d’organes électriques sous tension peut D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est D S’assurer que tous les panneaux et couvercles sont correctement en
sous tension lorsque le courant est délivré à la place.
sortie. Le circuit d’alimentation et les circuits internes de la machine D Fixer le câble de retour de façon à obtenir un bon contact métal-métal
sont également sous tension lorsque l’alimentation est sur Marche. avec la pièce à souder ou la table de travail, le plus près possible de la
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de soudure.
commande du rouleau et toutes les parties métalliques en contact D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec le fil sont sous tension électrique. Un équipement installé ou mis avec tout objet métallique.
à la terre de manière incorrecte ou impropre constitue un danger. D Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à
une même borne de sortie de soudage.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et sans
Il reste une TENSION DC NON NÉGLIGEABLE dans
trous. les sources de soudage onduleur quand on a coupé
D S’isoler de la pièce à couper et du sol en utilisant des housses ou des l’alimentation.
tapis assez grands afin d’éviter tout contact physique avec la pièce à D Arrêter les convertisseurs, débrancher le courant électrique et
couper ou le sol. décharger les condensateurs d’alimentation selon les instructions indi-
D Ne pas se servir de source électrique à courant électrique dans les zo- quées dans la partie Entretien avant de toucher les pièces.
nes humides, dans les endroits confinés ou là où on risque de tomber. LES FUMÉES ET LES GAZ peuvent
D Se servir d’une source électrique à courant électrique UNIQUEMENT si être dangereux.
le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère né- Le soudage génère des fumées et des gaz. Leur
cessaire, se servir de la fonction de télécommande si l’appareil en est inhalation peut être dangereuse pour la santé.
équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces va-
suivantes : risques électriques dans un environnement humide ou si l’on peurs.
porte des vêtements mouillés ; sur des structures métalliques telles que D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de
sols, grilles ou échafaudages ; en position coincée comme assise, à ge- l’arc pour l’évacuation des fumées et des gaz de soudage.
noux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou D Si la ventilation est médiocre, porter un respirateur anti-vapeurs approu-
accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser vé.
les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC D Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et
à tension constante (à fil), 2) un poste à souder DC manuel (électrode) les instructions du fabricant concernant les métaux, les consommables, les
ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des revêtements, les nettoyants et les dégraisseurs.
situations, l’utilisation d’un poste à souder DC à fil à tension constante D Travailler dans un espace fermé seulement s’il est bien ventilé ou en
est recommandée. En outre, ne pas travailler seul ! portant un respirateur à alimentation d’air. Demander toujours à un sur-
D Couper l’alimentation ou arrêter le moteur avant de procéder veillant dûment formé de se tenir à proximité. Des fumées et des gaz de
à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provo-
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de quant des blessures ou des accidents mortels. S’assurer que l’air de
sécurité). respiration ne présente aucun danger.
D Installer le poste correctement et le mettre à la terre convenablement D Ne pas souder dans des endroits situés à proximité d’opérations de dé-
selon les consignes du manuel de l’opérateur et les normes nationales, graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
provinciales et locales. l’arc peuvent réagir en présence de vapeurs et former des gaz haute-
ment toxiques et irritants.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer D Ne pas souder des métaux munis d’un revêtement, tels que l’acier gal-
que le fil de terre du cordon d’alimentation est bien raccordé à la borne vanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait
de terre du sectionneur ou que la fiche du cordon est raccordée à une été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en
prise correctement mise à la terre. portant un respirateur à alimentation d’air. Les revêtements et tous les
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur métaux renfermant ces éléments peuvent dégager des fumées toxi-
de mise à la terre approprié et contre-vérifier les connexions. ques en cas de soudage.
OM-2250 Page 5
 LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ
ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures
Le rayonnement de l’arc du procédé de soudage ou même la mort.
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provo- D Fermer l’alimentation du gaz protecteur en cas
quer des brûlures dans les yeux et sur la peau. de non-utilisation.
Des étincelles sont projetées pendant le soudage. D Veiller toujours à bien aérer les espaces confi-
nés ou se servir d’un respirateur d’adduction
D Porter un casque de soudage approuvé muni de verres filtrants ap- d’air homologué.
proprié pour protéger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous vo- DES PIÈCES CHAUDES peuvent
tre casque.
provoquer des brûlures graves.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements et D Ne pas toucher des parties chaudes à mains
les étincelles ; prévenir toute personne sur les lieux de ne pas nues.
regarder l’arc. D Prévoir une période de refroidissement avant
D Porter des vêtements confectionnés avec des matières résistantes d’utiliser le pistolet ou la torche.
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection. D Ne pas toucher aux pièces chaudes, utiliser les outils recom-
mandés et porter des gants de soudage et des vêtements épais
LE SOUDAGE peut provoquer un pour éviter les brûlures.
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut LES CHAMPS MAGNÉTIQUES peuvent
provoquer leur éclatement. Des étincelles peuvent affecter les stimulateurs cardiaques.
être projetées de l’arc de soudure. La projection D Porteurs de stimulateur cardiaque, rester
d’étincelles, des pièces chaudes et des équipements chauds peuvent
provoquer des incendies et des brûlures. Le contact accidentel de à distance.
l’électrode avec des objets métalliques peut provoquer des étincelles, D Les porteurs d’un stimulateur cardiaque doi-
une explosion, une surchauffe ou un incendie. Avant de commencer vent d’abord consulter leur médecin avant de
le soudage, vérifier et s’assurer que l’endroit ne présente pas de s’approcher des opérations de soudage à l’arc,
danger. de gougeage ou de soudage par points.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soi- LE BRUIT peut endommager l’ouïe.
gneusement avec des protections homologuées.
D Ne pas souder dans un endroit où des étincelles peuvent tomber sur Le bruit des processus et des équipements peut
des substances inflammables. affecter l’ouïe.
D Se protéger, ainsi que toute autre personne travaillant sur les lieux, D Porter des protections approuvées pour les
contre les étincelles et le métal chaud.
oreilles si le niveau sonore est trop élevé.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Afin d’éliminer tout risque de feu, être vigilant et garder toujours un
LES BOUTEILLES peuvent exploser
extincteur à la portée de main. si elles sont endommagées.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation Des bouteilles de gaz protecteur contiennent du gaz
peut déclencher un incendie de l’autre côté. sous haute pression. Si une bouteille est endomma-
D Ne pas effectuer le soudage sur des conteneurs fermés tels que des gée, elle peut exploser. Du fait que les bouteilles de
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été prépa- gaz font normalement partie du procédé de soudage,
rés correctement conformément à AWS F4.1 (voir les normes de les manipuler avec précaution.
sécurité).
D Brancher le câble de masse sur la pièce le plus près possible de la D Protéger les bouteilles de gaz comprimé d’une chaleur excessi-
zone de soudage pour éviter le transport du courant sur une longue ve, des chocs mécaniques, des dommages physiques, du lai-
distance par des chemins inconnus éventuels en provoquant des tier, des flammes ouvertes, des étincelles et des arcs.
risques d’électrocution, d’étincelles et d’incendie. D Placer les bouteilles debout en les fixant dans un support sta-
D Ne pas utiliser le poste de soudage pour dégeler des conduites tionnaire ou dans un porte-bouteilles pour les empêcher de tom-
gelées. ber ou de se renverser.
D En cas de non-utilisation, enlever la baguette d’électrode du porte- D Tenir les bouteilles éloignées des circuits de soudage ou autres
électrode ou couper le fil à la pointe de contact. circuits électriques.
D Porter des vêtements de protection exempts d’huile tels que des D Ne jamais placer une torche de soudage sur une bouteille à gaz.
gants en cuir, une veste résistante, des pantalons sans revers, des D Une électrode de soudage ne doit jamais entrer en contact avec
bottes et un casque. une bouteille.
D Avant de souder, retirer toute substance combustible de ses poches D Ne jamais souder une bouteille pressurisée − risque d’explosion.
telles qu’un allumeur au butane ou des allumettes. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B tuyaux et raccords convenables pour cette application spécifi-
pour travaux de soudage et prévoir un détecteur d’incendie et un ex- que ; les maintenir ainsi que les éléments associés en bon état.
tincteur à proximité. D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
DES PARTICULES VOLANTES D Le couvercle du détendeur doit toujours être en place, sauf lors-
peuvent blesser les yeux. que la bouteille est utilisée ou qu’elle est reliée pour usage ulté-
rieur.
D Le soudage, l’écaillement, le passage de la
pièce à la brosse en fil de fer, et le meulage D Utiliser les équipements corrects, les bonnes procédures et suf-
génèrent des étincelles et des particules fisamment de personnes pour soulever et déplacer les bouteil-
les.
métalliques volantes. Pendant la période de
refroidissement des soudures, elles risquent D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
de projeter du laitier. l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécuri-
D Porter des lunettes de sécurité avec écrans latéraux ou un écran té.
facial.

OM-2250 Page 6
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent

SION. provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou D S’abstenir de toucher des organes mobiles tels
à proximité de surfaces inflammables. que des ventilateurs.
D Ne pas installer l’appareil à proximité de D Maintenir fermés et verrouillés les portes,
produits inflammables. panneaux, recouvrements et dispositifs de
D Ne pas surcharger l’installation électrique − s’assurer que protection.
l’alimentation est correctement dimensionnée et protégée avant D Seules des personnes qualifiées sont autorisées à enlever les
de mettre l’appareil en service. portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
LA CHUTE DE L’APPAREIL peut l’alimentation électrique.
blesser.
D Utiliser l’anneau de levage uniquement pour LIRE LES INSTRUCTIONS.
soulever l’appareil, NON PAS les chariots, les D Lire le manuel d’utilisation avant d’utiliser ou
bouteilles de gaz ou tout autre accessoire. d’intervenir sur l’appareil.
D Utiliser un équipement de levage de capacité D Utiliser uniquement des pièces de rechange
suffisante pour lever l’appareil. Miller/Hobart.
D En utilisant des fourches de levage pour déplacer l’unité, s’assu-
rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil. LE RAYONNEMENT HAUTE
FRÉQUENCE (HF) risque de provoquer
des interférences.
L’EMPLOI EXCESSIF peut SUR- D Le rayonnement haute fréquence (HF) peut
CHAUFFER L’ÉQUIPEMENT. provoquer des interférences avec les équipe-
D Prévoir une période de refroidissement ; ments de radio-navigation et de communica-
respecter le cycle opératoire nominal. tion, les services de sécurité et les ordinateurs.
D Réduire le courant ou le facteur de marche D Demander seulement à des personnes qualifiées familiarisées
avant de poursuivre le soudage. avec des équipements électroniques de faire fonctionner l’instal-
lation.
D Ne pas obstruer les passages d’air du poste.
D L’utilisateur est tenu de faire corriger rapidement par un électri-
cien qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement
LES CHARGES ÉLECTROSTATIQUES l’appareil.
peuvent endommager les circuits D Effectuer régulièrement le contrôle et l’entretien de l’installation.
imprimés. D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une
D Établir la connexion avec la barrette de terre distance correcte et utiliser une terre et un blindage pour réduire
avant de manipuler des cartes ou des pièces. les interférences éventuelles.
D Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes PC. LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D L’énergie électromagnétique peut gêner le
DES ORGANES MOBILES peuvent fonctionnement d’appareils électroniques
provoquer des blessures. comme des ordinateurs et des robots.
D Ne pas s’approcher des organes mobiles. D Veiller à ce que tout l’équipement de la zone de
soudage soit compatible électromagnétiquement.
D Ne pas s’approcher des points de coincement
D Pour réduire la possibilité d’interférence, maintenir les câbles de
tels que des rouleaux de commande. soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipe-
LES FILS DE SOUDAGE peuvent ment électronique sensible.
provoquer des blessures. D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction. D En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
D Ne pas diriger le pistolet vers soi, d’autres mentaires telles que le déplacement du poste, l’utilisation de
personnes ou toute pièce mécanique en enga- câbles blindés, l’utilisation de filtres de ligne ou la pose de protec-
geant le fil de soudage. teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

Y Les équipements de soudage et de coupage produisent des Pour les moteurs à essence :
fumées et des gaz qui contiennent des produits chimiques dont Y Les gaz d’échappement des moteurs contiennent des produits
l’État de Californie reconnaît qu’ils provoquent des malformations chimiques dont l’État de Californie reconnaît qu’ils provoquent
congénitales et, dans certains cas, des cancers. (Code de santé et des cancers et des malformations congénitales ou autres pro-
de sécurité de Californie, chapitre 25249.5 et suivants) blèmes de procréation.
Y Les batteries, les bornes et autres accessoires contiennent du Pour les moteurs diesel :
plomb et des composés à base de plomb, produits chimiques Y Les gaz d’échappement des moteurs diesel et certains de leurs
dont l’État de Californie reconnaît qu’ils provoquent des can- composants sont reconnus par l’État de Californie comme
cers et des malformations congénitales ou autres problèmes de provoquant des cancers et des malformations congénitales ou au-
procréation. Se laver les mains après manipulation. tres problèmes de procréation.
OM-2250 Page 7
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet :
ternet : www.global.ihs.com). www.csa-international.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, American Welding Society Standard AWS ANSI Standard Z87.1, de American National Standards Institute, 11 West
F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site 42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.global.ihs.com). Internet : www.ansi.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection Standard for Fire Prevention During Welding, Cutting, and Other Hot
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org). Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite OSHA, Occupational Safety and Health Standards for General Industry,
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
: www.cganet.com). Part 1926, Subpart J, de U.S. Government Printing Office, Superinten-
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
Code for Safety in Welding and Cutting, CSA Standard W117.2, de bureaux régionaux−−le téléphone de la région 5, Chicago, est
Canadian Standards Association, Standards Sales, 178 Rexdale 312-353-2220, site Internet : www.osha.gov).

2-6. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des 1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de souda- 2. Disposer les câbles d’un côté et à distance de l’opérateur.
ge, causera des champs électromagnétiques. Il y a eu et il y a encore un
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
certain souci à propos de tels champs. Cependant, après avoir examiné
plus de 500 études qui ont été faites pendant une période de recherche votre corps.
de 17 ans, un comité spécial ruban bleu du National Research Council a
4. Garder le poste de soudage et les câbles le plus loin possible de
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
vous.
pas démontré que l’exposition aux champs magnétiques et champs élec-
triques à haute fréquence représente un risque à la santé humaine ». 5. Connecter la pince sur la pièce aussi près que possible de la sou-
Toutefois, des études sont toujours en cours et les preuves continuent à
dure.
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux En ce qui concerne les stimulateurs cardiaques
champs électromagnétiques pendant le soudage ou le coupage. Les porteurs de stimulateur cardiaque doivent consulter leur médecin
Pour réduire les champs magnétiques sur le poste de travail, appliquer avant de souder ou d’approcher des opérations de soudage. Si le méde-
les procédures suivantes : cin approuve, il est recommandé de suivre les procédures précédentes.

OM-2250 Page 8
 SECTION 3 − DEFINITIONS (CE Models Only)

3-1. Warning Label Definitions

Warning! Watch Out! There are possible 2 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.
2.1 Keep your head out of the fumes. 4 Arc rays can burn eyes and injure
1 Electric shock from welding electrode skin.
or wiring can kill. 2.2 Use forced ventilation or local exhaust
to remove the fumes. 4.1 Wear hat and safety glasses. Use ear
1.1 Wear dry insulating gloves. Do not 2.3 Use ventilating fan to remove fumes. protection and button shirt collar. Use
touch electrode with bare hand. Do welding helmet with correct shade of
not wear wet or damaged gloves. 3 Welding sparks can cause explosion
or fire. filter. Wear complete body protection.
1.2 Protect yourself from electric shock by 3.1 Keep flammables away from welding. 5 Become trained and read the
insulating yourself from work and Do not weld near flammables. instructions before working on the
ground. machine or welding.
3.2 Welding sparks can cause fires. Have
1.3 Disconnect input plug or power before a fire extinguisher nearby, and have a 6 Do not remove or paint over (cover)
working on machine. watchperson ready to use it. the label.

1 1.1 1.2 1.3 4 4.1

2 2.1 2.2 2.3 5

3 3.1 3.2 3.3 6

OM-2250 Page 9
 Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1 Electric shock from wiring can
kill.
2 Disconnect input plug or
power before working on
machine.
1 2 3 4 5 3 Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
4 Always wait 5 minutes after
power is turned off before
working on unit, OR
5 Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
6 When power is applied failed
parts can explode or cause
other parts to explode.
7 Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
6 7 8 9 8 Always wear long sleeves and
button your collar when
servicing unit.
9 After taking proper
precautions as shown,
connect power to unit.

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.
2 Electric shock from wiring can
kill.
2 1 3 4
3 Read the Owner’s Manual
before working on this
machine.
4 Disconnect input plug or
power before working on
machine.
5 Become trained and read the
instructions before working on
the machine or welding.

OM-2250 Page 10
3-2. Manufacturer’s Rating Labels (Non CE Models)

. For label location

see Section 4-5.

Manufacture’s Rating Label Manufacture’s Rating Label

For Dynasty 700 Models Maxstar 700 Models

223 259-D 223 275-D

OM-2250 Page 11
3-3. Manufacturer’s Rating Labels (CE Models)

. For label location

see Section 4-5.

Manufacture’s Rating Label Manufacture’s Rating Label

For Dynasty 700 Models Maxstar 700 Models

223 260-C 223 277-C

OM-2250 Page 12
3-4. Symbols And Definitions

A Amperes Output
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)

V Volts Input
3 Phase Static Frequency
Converter-Transformer-Rectifier

Output Circuit Breaker Remote Lift-Arc (GTAW)

S
Protective Earth
Postflow Timer Preflow Timer Seconds
(Ground)

On Off Positive Negative

Alternating
Current
Gas Input Gas Output
I2 Rated Welding
Current

X Duty Cycle Direct Current Line Connection

U2 Conventional Load
Voltage

U1 Primary Voltage
IP Degree Of
Protection I1max Rated Maximum
Supply Current
I1eff
Maximum Effective
Supply Current

U0 Rated No Load
Voltage (Average)
Polarity Control Initial Amperage
Increase/Decrease
Of Quantity

Remote Standard Gas/DIG Control Percent

Hz Hertz
Recall From
Memory
Arc Force (DIG)
Impulse Starting
(GTAW)

Pulse Percent
Final Slope Final Amperage Initial Slope
On Time

AC Waveshape
Pulser EP Amperage Pulse Frequency
Control

Process
Work Electrode EN Amperage

Unit may be used

in environments
with increased Sequence
Background Am-
perage
f AC Frequency
hazard of electric
shock

OM-2250 Page 13
 SECTION 4 − INSTALLATION
4-1. Specifications
A. Dynasty 700

Amper- Maximum
Open Cir
Open-Cir- Amperes Input at Rated Load Output 50/60 Hz
age
Range cuit Voltage 208 V 230 V 400 V 460 V 575 V KVA KW
Input Power Rated Welding Output DC
500 A @ 40 Volts, 100%
Duty Cycle 75 68 39 34 27 27 26
75∇
Three Phase 5−700
600 A @ 44 Volts, 60% Duty 10−15♦
Cycle 97 88 51 44 35 35 34

360 A @ 34 Volts, 100%

Single Duty Cycle 75∇ 82 74 −− 37 30 17 16
5−700
Phase 10−15♦
450 A @ 38 Volts DC, 60%
Duty Cycle 115 104 −− 52 42 24 22
*While idling
♦Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected (see Section 6-7).
∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-7).
Note: This unit is equipped with Auto-Linet. Auto-Line is an internal inverter power source circuit that automatically links the power source to
any primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.

B. Maxstar 700

Amper- Maximum
Open Cir
Open-Cir- Amperes Input at Rated Load Output 50/60 Hz
age
Range cuit Voltage 208 V 230 V 400 V 460 V 575 V KVA KW
Input Power Rated Welding Output DC
500 A @ 40 Volts, 100%
Duty Cycle 67 60 35 30 24 24 23
75∇
Three Phase 5−700
600 A @ 44 Volts, 60% Duty 10−15♦
Cycle 89 80 46 40 32 32 31

360 A @ 34 Volts, 100%

Single Duty Cycle 75∇ 77 70 −− 35 28 16 15
5−700
Phase 10−15♦
450 A @ 38 Volts DC, 60%
Duty Cycle 106 96 −− 48 38 22 21
*While idling
♦Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected (see Section 6-7).
∇Normal open-circuit voltage (75 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-7).
Note: This unit is equipped with Auto-Linet. Auto-Line is an internal inverter power source circuit that automatically links the power source to
any primary input voltage from 190 to 625 volts, single-or-three-phase, 50 or 60 hertz. Also adjusts for voltage spikes within the entire range.

OM-2250 Page 14
4-2. Volt-Ampere Curves
Maxstar 700 Volt-ampere curves show mini-
80 mum and maximum voltage and
amperage output capabilities of
70 unit. Curves of other settings fall be-
Stick Max DIG Max tween curves shown.
60
50
DC Volts

40
Dynasty 700 AC
30 100
Stick Min DIG Max
20 90
Stick Min
TIG Max 80
10 TIG Min
70
0 Stick Max
60

AC Volts
0 100 200 300 400 500 600 700 800 900
DC Amperes 50 TIG Min

Dynasty 700 DC 40 TIG Max

90 30 Stick Min
80 20
70 10
60 0
0 100 200 300 400 500 600 700 800
50 AC Amperes
DC Volts

40
30 Stick Max
DIG Max
Stick Min DIG Max
20
10 TIG Min
TIG Max
0
0 100 200 300 400 500 600 700 800 900
DC Amperes 215 126-A / 213 342-A / 213 344-A

OM-2250 Page 15
 4-3. Duty Cycle and Overheating
Duty Cycle is the percentage of 10
minutes 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.
800 Reduce amperage or voltage, or
duty cycle before welding.
700 Y Exceeding duty cycle can
damage unit and void
600 warranty.

500 3-Phase
Output Amperes

400
1-Phase
300

200

100
0
10 20 30 40 50 60 70 80 90 100
% Duty Cycle

Overheating
0 A or V

15
OR
Minutes Reduce Duty Cycle
sduty1 5/95 / 213 343-B

4-4. Dimensions, Weights And Base Mounting Hole Layout

NOTE Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.

Dimensions

A 34-1/2 in (876 mm)

B 13-3/4 in (349 mm)

A
C 22 in (559 mm)

C D 20-1/2 in (521 mm)

B D C
E 1 in (25 mm)

F 11-3/4 in (298 mm)

1/2 in Dia. (13 mm Dia.)

G
4 Holes

Weight
G
F E 803 914-A 198 lb (90 kg)

OM-2250 Page 16
4-5. Selecting A Location
Y Falling Unit Can Cause Injury.
Use equipment of adequate capacity to lift
and support unit.
1 Lifting Eye
Movement
2 Lifting Forks
Use lifting eye or lifting forks to move unit.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
1 If using lifting forks, extend forks beyond op-
posite side of unit.
3 Serial Number/Patent Label
4 Rating Label
Use rating label to determine input power
needs (see Section 3-2).
OR
2 5 Line Disconnect Device
Locate unit near correct input power supply.
Y Special installation may be required
where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
Location And Airflow
Y Be careful when placing or moving
5
unit over uneven surfaces.

18 in (460 mm)
4

18 in (460 mm) Ref. 117 264-C / 803 900-A / 223 259-A / 223 275-A

OM-2250 Page 17
4-6. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.

4-7. 115 Volts AC Duplex Receptacle, Supplementary Protector CB1, And Power
Switch
1 AC Duplex Receptacle
Receptacle RC2 supplies 115 V 10
3
1 A of single-phase power.
2 Supplementary Protector CB1
CB1 protects duplex receptacle
from overload. If circuit breaker
2 opens, the receptacle does not
work. Press button to reset
protector.
3 Power On/Off Switch

803 901-A

OM-2250 Page 18
4-8. Weld Output Terminals And Selecting Cable Sizes*

Y ARC WELDING can cause Electromagnetic Interference.

To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding****
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y Turn off power before 10 − 60% 60 − 100%
connecting to weld out- Welding
Duty Duty 10 − 100% Duty Cycle
put terminals. Amps***
Cycle Cycle
Y Do not use worn, dam-
aged, undersized, or
poorly spliced cables.

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x70)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95)

Electrode 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x95) (2x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (2x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
W k
Work
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0
600 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0
700 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120) (4x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0 4 ea. 4/0
800 4/0 (120)
(2x70) (2x95) (2x120) (3x120) (3x120) (4x120) (4x120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0

900
(2x70) (2x95) (2x120) (3x95)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-E−

***Select weld cable size for pulsing application at peak amperage value.

OM-2250 Page 19
 4-9. Remote 14 Receptacle Information (Used Without Automation Connection)

Socket* Socket Information

A Contactor control, 15 volts DC.

A J 15 VOLTS DC
K I B Contact closure to A completes 15 volts DC
B
contactor control circuit, and enables out-
C L N H put.
D M G
E F C +10 volts DC.

REMOTE D Remote control circuit common.

OUTPUT
CONTROL E 0 to +10 volts DC input command signal
from remote control.

F Current feedback; +1 volt DC per 100 am-

A/V peres.
AMPERAGE
VOLTAGE H Voltage feedback; +1 volt DC per 10 output
803 900-A / 218 716-A receptacle volts.

CHASSIS K Chassis common.

GND G +15 volts DC (A) common.

*The remaining sockets are not used.

Note: If a remote hand control, like the RHC-14, is connected to the Remote 14 receptacle, some current value above min. must be set on the
remote control before the Panel or Remote contactor is turned on. Failure to do so, will cause current to be controlled by the panel control and
the remote hand control will not function.

OM-2250 Page 20
4-10. Automation Connection

3 2 1
8 7 6 5 4
14 13 12 11 10 9

20 19 18 17 16 15

25 24 23 22 21

28 27 26

803 900-A / 218 716-A

Pin Pin Information For 28-Pin Receptacle RC28

1 Start/Stop - Closure to pin 8 starts the weld cycle. Opening closure stops weld cycle. During 2T operation, a momentary closure
(greater than 100 ms, but less than 3/4 seconds) starts and stops weld output.
2 Output enable - functional only in automation modes - Closure to pin 8 must be maintained at all times. If the closure between pins 2
and 8 is broken, an output disable occurs, Postflow begins to time out, and HELP 13 will be displayed on the meters.
3 Gas - Closure to pin 8 turns on gas. This input will override Postflow, but if a Preflow time is entered, the Preflow cycle will time out
before arc initiation.
4 Valid arc, collector - Output is on when the contactor is on and there is less than 50 load volts (see Section 4-13).
5 Voltage feedback - +1 volt DC per 10 volts w/reference to pin 11.

6 Current feedback - +1 volt DC per 100 amperes w/reference to pin 11.

7 Not used
8 IGND isolation common
9 Valid arc, emitter - Output is on when the contactor is on and there is less than 50 load volts (see Section 4-13).
10 Memory enable - See Section 4-11.
11 Remote control circuit common
12 Chassis common
13 Pulse lockout, collector - Output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and Pulsed Background
time when the pulse frequency is less than 10 Hz (see Section 4-13).
14 Pulse lockout, emitter - Output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and Pulse Background
time, when the pulse frequency is less than 10 Hz (see Section 4-13).
15 Memory select 0 - See Section 4-11.
16 Memory select 1 - See Section 4-11.
17 Command signal from remote control - 0 to +10 volts DC input.
18 +10 volts DC
19 HF disable - Disables high frequency when connected to pin 8.
20 Automation enable 1 - See Section 4-12.
21 Amperage EN common - See Section 4-12.
22 Amperage EN command - See Section 4-12.
23 Final slope, collector - Output is on when in Final Slope (see Section 4-13).
24 Final slope, emitter - Output is on when in Final Slope (see Section 4-13).
25 Automation enable 2 - See Section 4-12.
26 Amperage EP command (Dynasty models only) - See Section 4-12.
27 Amperage EP common (Dynasty models only) - See Section 4-12.
28 Polarity (Dynasty models only) - See Section 4-12.
OM-2250 Page 21
4-11. Remote Memory Select Inputs
28-Pin Receptacle RC28

Socket Designations 0 = No Connection / 1 = Connected To Ground (Pin 8)

3 1 X= Do Not Care
8 4
Function 10 15 16
14 9

20 15 Off 0 X X

25 Memory 1 1 0 0
21
28 26
Memory 2 1 1 0

Memory 3 1 0 1

Memory 4 1 1 1

4-12. Automation Selections

28-Pin Receptacle RC28

Socket Designations 0 = No Connection / 1 = Connected To Ground (Pin

3 1 8)
8 4
X= Do Not Care
14 9

15 Pin
20
25 Function 20 21
21
28 26 No automation functions selected 0 0

Automation 1 1 0

Enables pin 2 function, Sequencer and weld timers

Automation 2 X 1

Enables pin 2 functions

Pin 22 to pin 21 - 0 to +10 volts DC EN amplitude

Connected to pin 8 (EP)
Pin 26 to pin 27 - 0 to +10 volts DC EP amplitude
Open (EN)
Pin 28 to pin 8 - EP polarity (Frequency and Balance)
Pin 28
Pin 28 not connected to pin 8 - EN polarity (Frequency and
Balance)

Final Slope and Pulse outputs are not functional

4-13. Typical Application

Coil resistance plus R CR1 To User Equipment

CR1 should be chosen to
limit current to 75 mA
+
User supplied power
up to 27 volts DC peak
R
Typical 28-Pin Output −
Collector

Emitter

OM-2250 Page 22
4-14. 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.
4 3 2 3 Regulator/Flowmeter
1
4 Flow Adjust
Typical flow rate is 15 cfh (cubic feet
per hour).
Connect customer supplied gas
hose between regulator/flowmeter
and gas fitting on rear of unit.

Tools Needed:
5/8, 1-1/8 in

803 901-A

4-15. TIG HF Impulse/ Lift-Arct Connections

Y Turn off power before mak-
ing connections.
1 Electrode Weld Output
Terminal
Connect TIG torch to electrode
weld output terminal.
2 Gas Out Connection
5 Connect torch gas hose to gas out
fitting.
3 Work Weld Output Terminal
Connect work lead to work weld
output terminal.
4 4 Remote 14 Receptacle
1 If desired, connect remote control
to Remote 14 receptacle (see Sec-
tion 4-9).
5 Gas In Connection
Connect gas hose from gas supply
to gas in fitting (see Section 4-14).

Tools Needed:
2 3
11/16 in, (21 mm for CE units)

803 915-A

OM-2250 Page 23
4-16. Stick Connections
Y Turn off power before making
connections.

. Connections shown are for Dynas-

ty models. For Maxstar models, re-
verse work and electrode connec-
tions
3 1 Work Weld Output Terminal
2 Connect work lead to work weld output
terminal.
2 Electrode Weld Output Terminal
Connect electrode holder to electrode
weld output terminal.
3 Remote 14 Receptacle
If desired, connect remote control to Re-
mote 14 receptacle (see Section 4-9).
1

803 916-A

4-17. Electrical Service Guide

A. Dynasty 700

NOTE Actual input voltage cannot exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, no output is available.

Three-Phase
Input Voltage 208 230 400 460 575
Input Amperes At Rated Output 97 88 51 44 35
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2 110 100 60 50 40
Normal Operating 3 150 125 80 70 50
Min Input Conductor Size In AWG 4 4 4 8 8 10
118 144 177 235 240
Max Recommended Input Conductor Length In Feet (Meters)
(36) (44) (54) (72) (73)
Min Grounding Conductor Size In AWG 4 6 6 8 8 10

Single-Phase
Input Voltage 208 230 460 575
Input Amperes At Rated Output 115 104 52 42
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2 125 125 60 50
Normal Operating 3 175 150 80 60
Min Input Conductor Size In AWG 4 3 4 8 8
107 107 178 279
Max Recommended Input Conductor Length In Feet (Meters)
(33) (33) (54) (85)
Min Grounding Conductor Size In AWG 4 6 6 8 10
Reference: 2005 National Electrical Code (NEC) (includes article 630)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-2250 Page 24
B. Maxstar 700

NOTE Actual input voltage cannot exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, no output is available.

Three-Phase
Input Voltage 208 230 400 460 575
Input Amperes At Rated Output 89 80 46 40 32
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2 110 100 50 50 40
Normal Operating 3 125 125 70 60 50
Min Input Conductor Size In AWG 4 4 6 8 8 10
129 101 194 257 263
Max Recommended Input Conductor Length In Feet (Meters)
(39) (31) (59) (78) (80)
Min Grounding Conductor Size In AWG 4 6 6 8 10 10

Single-Phase
Input Voltage 208 230 460 575
Input Amperes At Rated Output 106 96 48 38
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay 2 125 110 50 45
Normal Operating 3 150 150 70 60
Min Input Conductor Size In AWG 4 4 4 8 10
94 115 189 194
Max Recommended Input Conductor Length In Feet (Meters)
(29) (35) (58) (59)
Min Grounding Conductor Size In AWG 4 6 6 8 10
Reference: 2005 National Electrical Code (NEC) (includes article 630)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” (65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

OM-2250 Page 25
4-18. Connecting Input Power

A. Connecting Three-Phase Input Power

Y Installation must meet all National
5 and Local Codes − have only qualified
6 persons make this installation.
Y Disconnect and lockout/tagout input
power before connecting input con-
ductors from unit.
Y Make input power connections to the
welding power source first.
Y Always connect green or green/yel-
low conductor to supply grounding
terminal first, and never to a line ter-
4 minal.
2 See rating label on unit and check input volt-
age available at site (see Section 4-5).
1 Input Power Conductors (Customer
Supplied Cord)
1 Select size and length of conductors using
Section 4-17. Conductors must comply with
national, state, and local electrical codes. If
3 applicable, use lugs of proper amperage
capacity and correct hole size.
Welding Power Source Input Power Con-
3 nections
8 = GND/PE Earth Ground 2 Strain Relief
Route conductors (cord) through strain relief
and tighten screws.
10
3 Machine Grounding Terminal
4 Green Or Green/Yellow Grounding
7 Conductor
Connect green or green/yellow grounding
conductor to welding power source ground-
ing terminal first.
5 Welding Power Source Line Terminals
(Switch S1)
9 6 Input Conductors L1 (U), L2 (V) And L3
(W)
Connect input conductors L1 (U), L2 (V) and
6
L3 (W) to welding power source line
4
terminals.
Install cover.
Disconnect Device Input Power Connec-
tions
7 Disconnect Device (switch shown in
OFF position)
8 Disconnect Device (Supply) Grounding
Terminal
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
9 Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V) And
L3 (W) to disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current protec-
tion using Section 4-17 (fused disconnect
switch shown).
Close and secure door on line disconnect de-
Tools Needed: vice. Remove lockout/tagout device, and
place switch in the On position.
803 927-A

OM-2250 Page 26
B. Connecting Single-Phase Input Power
Y Installation must meet all National
5 and Local Codes − have only quali-
6 fied persons make this installation.
Y Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
Y Make input power connections to
2
the welding power source first.
Y Always connect green or green/
yellow conductor to supply
4 grounding terminal first, and never
to a line terminal.
2 See rating label on unit and check input
voltage available at site (see Section 4-5).
1 Input Power Conductors (Customer
Supplied Cord)
1
Select size and length of conductors using
Section 4-17. Conductors must comply
1 with national, state, and local electrical
3 codes. If applicable, use lugs of proper
amperage capacity and correct hole size.
Welding Power Source Input Power
8 Connections
=GND/PE Earth Ground
2 Strain Relief
Route conductors (cord) through strain re-
10 lief and tighten screws.
3 Machine Grounding Terminal
7 4 Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to welding power source
grounding terminal first.
9 5 Welding Power Source Line
Terminals (Switch S1)
6 Input Conductors L1 (U) And L2 (V)
6
Connect input conductors L1 (U) And L2
(V) to welding power source line terminals.
4 Install cover.
Disconnect Device Input Power
Connections
7 Disconnect Device (switch shown in
OFF position)
8 Disconnect Device (Supply)
Grounding Terminal
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
9 Disconnect Device Line Terminals
Connect input conductors L1 (U) And L2
(V) to disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current
protection using Section 4-17 (fused dis-
connect switch shown).
Close and secure door on line disconnect
device. Remove lockout/tagout device,
Tools Needed:
and place switch in the On position.

803 927-A

OM-2250 Page 27
 SECTION 5 − OPERATION

5-1. Controls

3 1

11

12

4* 5 6 7 8 9 10*

213 320-A / 803 901-A

*Available On Dynasty Models Only.

13

Rear Panel

. For all front panel switch pad controls: 4 Polarity Control (Dynasty Only) See Section 5-12.
press switch pad to turn on light and en- See Section 5-6. 10 AC Waveshape (Dynasty Only)
able normal function. 5 Process Controls See Section 5-13.
NOTE: Green on nameplate indicates a TIG See Section 5-7. 11 Amperage And Spot Time Control
function, Gray indicates a normal Stick func-
6 Output Controls
tion. For Amperage Control see Section 5-3.
See Section 5-9.
1 Encoder Control For Spot Time Control see Section 5-14.
7 Pulser Controls
2 Ammeter And Parameter Display 12 Memory
See Section 5-10.
See Section 5-4. 8 Sequencer Controls See Section 5-15.
3 Voltmeter See Section 5-11. 13 Power Switch
See Section 5-5. 9 Gas/DIG Controls Use switch to turn unit On/Off.

OM-2250 Page 28
5-2. Encoder Control
1 Encoder Control
Use control in conjunction with ap-
1 plicable front panel function switch
pad to set values for that function.

5-3. Amperage Control

1 A (Amperage Control)
3 2 Encoder Control
3 Ammeter
See Section 5-16 for Amperage
2 control range.
Press Amperage switch pad, and
turn Encoder control to set weld
amperage, or peak amperage
when Pulser function is active (see
Section 5-10).
1
Note: See Section 5-13 for AC func-
tions.

5-4. Ammeter And Parameter Display

1 Ammeter
Ammeter displays actual amper-
age while welding. It also displays
1 preset parameters for any of the fol-
lowing: amperage, time, percent-
age or frequency. The LED located
directly below the ammeter will also
illuminate.

OM-2250 Page 29
5-5. Voltmeter
1 Volt Meter
Displays output or open circuit volt-
age. If output is off, the voltmeter will
1
display (-−−).

5-6. Polarity Control (Dynastyt Models Only)

1 Polarity Control
Press switch pad until desired LED
is illuminated.
DC - Set machine to DCEN for TIG
welding, and to DCEP for Stick
welding.
AC - Use AC for TIG and Stick
welding.

OM-2250 Page 30
5-7. Process Control
1 Process Control
Press switch pad until desired pro-
cess LED is illuminated:
TIG HF Impulse - is a pulsed HF
(see Section 5-8) arc starting meth-
od that can be used with either AC
or DC TIG welding. Make connec-
tions according to Section 4-15.
TIG Lift-Arct - is an arc starting
method in which the electrode must
1 come in contact with the workpiece
(see Section 5-8). This method can
be used with either AC or DC TIG
welding. Make connections ac-
cording to Section 4-15.
Stick (SMAW) - This method can
be used with either AC or DC Stick
welding. Make connections ac-
cording to Section 4-16.

5-8. Lift-Arc™ And HF TIG Start Procedures

Lift-Arc Start
When Lift-Arct button light is On,
start arc as follows:
1 TIG Electrode
2 Workpiece
Touch tungsten electrode to work-
piece at weld start point, enable out-
put and shielding gas with torch trig-
Lift-Arc Start Method ger, foot control, or hand control.
1 2 Hold electrode to workpiece for
1-2 seconds, and slowly lift elec-
trode. Arc is formed when electrode
is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
1−2 touches workpiece; only a low
“Touch” Seconds sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece with-
out overheating, sticking, or getting
contaminated.
Application:
Lift-Arc is used for the DCEN or AC
GTAW process when HF Start
method is not permitted, or to re-
Do NOT Strike Like A Match! place the scratch method.
HF Start
When HF Start button light is On,
start arc as follows:
High frequency turns on to start arc
when output is enabled. High fre-
quency turns off when arc is
started, and turns on whenever arc
is broken to help restart arc.
Application:
HF start is used for the DCEN
GTAW process when a non-con-
tact arc starting method is required.

OM-2250 Page 31
5-9. Output Control

2
1

1 Output Control NOTE: If an On/Off type trigger is used, it NOTE: This switch function can be recon-
must be a maintained switch. All Sequenc- figured for 3T, 4T, 4T Momentary, Mini Log-
Press switch pad until desired parameter
er functions become active, and must be ic, or Spot control See Section 6-2C)
LED is illuminated.
set by the operator.
ON
RMT STD (Remote Standard)
RMT 2T HOLD Output will energize two seconds after be-
Application: Use Remote Trigger (Stan- ing selected.
dard) with a foot pedal or finger amperage Application: Use Remote Trigger Hold
control (see Section 6-2A). (2T) for long extended welds. Application: Use Output On for Stick
(SMAW) welding, or for Lift-Arc without the
NOTE: When a foot or finger remote cur- If a foot or finger current control is con- use of a remote control (see Section 6-2I).
rent control is connected, initial amps, ini- nected to the welding power source, only
tial slope, final slope, and final amps are trigger input is functional (see Section 2 On LED
controlled by the remote control. 6-2B). Blue On LED is lit whenever Output is on.

OM-2250 Page 32
5-10. Pulser Control
1 Pulser Control
3 Pulsing is available while using the
TIG process. Controls can be ad-
justed while welding.
2 Press switch pad to enable pulser.
ON - When illuminated, this LED in-
dicates the pulser is on.
Press switch pad until desired pa-
rameter LED is illuminated.
To turn Pulser off, press and release
switch pad until the On LED turns off.
2 Encoder Control (Set Value)
3 Ammeter (Displays Value)
See Section 5-16 for all Pulser pa-
rameter ranges.
PPS Pulses Per Second or (Pulse
Frequency) Used to determine ap-
pearance of weld bead.
PEAK t - The percentage of each
1 pulse cycle at the peak amperage
level.

BKGND A (Background Amps) - Use

Background Amps to set the low
pulse of the weld amperage, which
cools the weld puddle and affects
overall heat input. Background Amps
is a percentage of peak amperage.
4 Pulsed Output Waveforms
4 Example shows affect changing the
Peak Time control has on the pulsed
output waveform.
NOTE: Peak amperage is set using
the Amperage control (see Section
Percent (%) Peak
Pulsed Output Waveforms 5-3). Peak amperage is the highest
Time Control Setting
welding amperage allowed in the
PPS pulse cycle. Weld penetration varies
Balanced (50%) directly with peak amperage.
Bkg Amp Application:
Peak Amp Pulsing is the alternating raising and
lowering of the weld output at a spe-
cific rate. The raised portions of the
weld output are controlled in width,
height, and frequency, forming
More Time pulses of weld output. These pulses
At Peak and the lower amperage level be-
(80%) tween them (called the background
Amperage
amperage) alternately heat and cool
the molten weld puddle. The com-
bined effect gives better control of
penetration, bead width, crowning,
undercutting, and heat input.
More Time
At (20%)
Background
Amperage

OM-2250 Page 33
5-11. Sequencer Controls
1 Sequencer Control
Sequencing is available while using
the TIG process, but is disabled if a
remote foot or finger current control
3
is connected to the Remote recep-
tacle while in the RMT STD mode.
2 Press switch pad until desired pa-
rameter LED is illuminated.
2 Encoder Control (Set Value)
3 Ammeter (Displays Value)
See Section 5-16 for all Sequencer
parameter ranges.
4
INITIAL A (Initial Amperage) - Use
control to select a starting amper-
age that is different from the weld
amperage.
Application:
Initial Amperage can be used to as-
sist in preheating cold material prior
to depositing filler material, or to en-
sure a soft start.
INITIAL t (Initial Time)(Available
with Automation option Only) -
1 Press control again and turn En-
coder to set amount of time needed
at the beginning of the weld.
INITIAL SLOPE t (Initial Slope
Time) Use control to set amount of
time that it takes to slope from initial
amperage to weld amperage. To
disable, set to 0.
4 Amperage Switch Pad
Weld Time (Available with Au-
tomation option Only) - Press
Amperage switch pad twice. Set
desired weld time.
FINAL SLOPE t (Final Slope Time)
- Use control to set amount of time
it takes to slope from weld amper-
age to final amperage. To disable,
set to 0.
Application:
Final Slope should be used while
welding materials that are crack
sensitive, and/or to eliminate the
crater at the end of the weld.
FINAL A (Final Amperage) - Used
to set amperage to which weld am-
perage slopes to.
FINAL t (Final Time)(Available
with Automation option Only) -
Press control again and turn En-
coder to set Final Amperage time.

OM-2250 Page 34
5-12. Gas/DIG Controls (Preflow/Post Flow/DIG/Purge)
1 Gas/DIG Controls
Press switch pad until desired function
LED is illuminated.
3
2 Encoder Control (Set Value)
3 Ammeter (Displays Value)

2 See Section 5-16 for all Adjust parameter

ranges.
PREFLOW - If the TIG HF process is ac-
tive (see Section 5-7) and Preflow is
shown on the control panel, use control to
set length of time gas flows before arc ini-
tiation.
Application: Preflow is used to purge
the weld area and aids in arc starts.
POST FLOW - If the TIG process is ac-
tive (see Section 5-7), use control to set
length of time gas flows after welding
stops.
Application:
Postflow is required to cool tungsten and
weld, and to prevent contamination of
tungsten and weld. Increase postflow
time if tungsten or weld are dark in ap-
. Some features shown are pearance.
not available on all models. DIG - If the DC Stick process is active
1 (see Section 5-7), use control to set
amount of DIG. When set at 0, short-cir-
cuit amperage at low arc voltage is the
same as normal welding amperage.
When setting is increased, short-circuit
amperage at low arc voltage increases.
Application:
Control helps arc starting or making verti-
cal or overhead welds by increasing am-
perage at low arc voltage, and reduces
electrode sticking while welding.
PURGE - To activate the gas valve and
start the purge function, push and hold
the Gas/DIG switch pad for the desired
amount of time. To set from 1 to 50 sec-
onds of purge time, hold the Gas/DIG
switch pad while turning the encoder con-
trol. Default is 0.
While Purge is active, (Pur) is shown in
the left display, and purge time is shown
in the right display.
Pressing any switch pad will end the
purge display, but gas will continue to flow
until the preset time has timed out.
Application: Purge is used to clear the
gas lines.

OM-2250 Page 35
5-13. AC Waveshape (Dynasty Models Only)

3 1 AC Waveshape Control
Press switch pad until desired function LED is
illuminated.
2 2 Encoder Control (Set Value)
3 Ammeter (Displays Value)
See Section 5-16 for all AC Waveshape param-
eter ranges.
Balance: AC Balance control is enabled only
in AC TIG to set percentage of time polarity is
4 electrode negative.
Application:
When welding on oxide forming materials such
as aluminum or magnesium, excess cleaning
is not necessary. To produce a good weld, only
0.10 in (2.5mm) of etched zone along the weld
toes is required.
Use AC Balance to control the etch zone width.
Joint configuration, set-up, process variables,
and oxide thickness may affect setting.
AC Frequency: AC Frequency control is en-
abled only in AC TIG. Use control to set AC fre-
quency (cycles per second).
Application:
AC Frequency controls arc width and direction-
f
al control. As AC frequency decreases, the arc
1 becomes wider and less focused, limiting di-
rectional control. As AC frequency increases,
the arc becomes narrower and more focused,
increasing directional control. Travel speed
can increase as AC frequency increases.
EN Amperage: Use control to select electrode
negative amperage value.
EP Amperage: Use control to select electrode
positive amperage value.
EN Amperage and EP Amperage allow the op-
erator the ability to control the amount of am-
perage in the negative and positive half cycles
independently. A 2 to 1 or 3 to 1 ratio of EN to
EP is a good starting point. This provides
cleaning action, but directs more energy into
the workpiece and provides faster travel
speeds and deeper penetration.
4 Amperage Control
Average Amperage Control: Setting EN Am-
perage, EP Amperage, Balance, and Frequen-
cy values creates an average amperage. The
operator can change the average amperage
value while maintaining the same EN amper-
age to EP amperage ratio at the existing bal-
ance and frequency. To change the average
amperage value, press the Amperage switch
pad and turn the Encoder control. The chang-
ing average value is displayed on the ammeter.
Example: If EN Amperage is 300, EP Amper-
age is 150, Balance is 60%, and Frequency is
120, the average amperage is 240 amps. If you
press the Amperage switch pad and turn the
Encoder control until 480 amps is displayed,
the EN amperage is now 600 and EP amper-
age is now 300. The balance remains 60%, and
the frequency is still 120, and the 2 to 1 EN am-
perage to EP amperage is maintained.

OM-2250 Page 36
5-14. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection)
1 Spot Time Meter Display
Select Spot function according to
1 3 Section 6-2C.
2 Amperage Switch Pad
3 Encoder Control
To set spot parameters, press Am-

SPO 1.0
perage switch pad once (meter A
LED turns on) and turn Encoder to set
spot amperage. Press Amperage
switch pad again, (meter S LED
lights) and turn Encoder to set spot
time (.1−25 seconds). Default is 1
second.
2 Application: To provide a timed weld
for tacking and thin sheet joining.

OM-2250 Page 37
5-15. Memory (Program Storage Locations 1-4)
1 Memory (Program Storage
1-4) Switch Pad
2 Polarity Switch Pad (Dynasty
Only)
3 Process Switch Pad
To create, change, or recall a
welding parameters program,
1 proceed as follows:
First, press Memory switch pad until
the desired program storage loca-
tion (1-4) LED is illuminated
Second, press Polarity switch pad
1st until the desired polarity, AC or DC,
LED is illuminated
Third, press Process switch pad un-
til desired process, TIG HF Impulse,
TIG Lift Arc, or Stick, LED is illumi-
f nated.
2*
The program at the chosen location,
for the desired polarity and process,
is now the active program.
Fourth, change or set all desired pa-
2nd 3rd rameters (see Section 5-1 for pa-
rameters).
3

. Some features shown are

*Available On Dynasty Models Only. not available on all models.

TIG (HF or Lift)

AC And

Stick
Memory Locations
And
1−4
TIG (HF or Lift)

DC And

Stick

Each memory location (1 thru 4) can store parameters for both

polarities, and each polarity can store parameters for both pro-
cess (TIG or Stick) for a total of 16 programs.

OM-2250 Page 38
5-16. Factory Parameter Defaults And Range And Resolution
Parameter Default Range And Resolution
MEMORY 1 1−4
*POLARITY AC AC / DC
PROCESS TIG HF Impulse TIG HF Impulse / TIG Lift / Stick
OUTPUT RMT STD RMT STD / RMT 2T / ON
**RMT 2T 2T RMT 2T can be reconfigured for: 2T / 3T / 4T / Mini Logic
/ 4T Momentary / Spot (see Section 6-2C)
A MAIN / PEAK
*AC TIG 500 A 5 − 700 Amps
*AC STICK 110 A 5 − 700 Amps
DC TIG 500 A 5 − 700 Amps
DC STICK 110 A 5 − 700 Amps
Spot Time 1.0 S 0.1 − 25.0 Seconds
***Weld Time 0S Dual Range And Resolution
0.0 − 99.9 / 100 − 999 Seconds
PULSER Off ON / OFF
PPS 100 Hz Quad Range And Resolution
DC: 0.1 − 9.9 / 10 − 500 / 510 − 990 / 1K − 5K Hertz
AC: 0.1 − 9.9 / 10 − 500 Hertz
PEAK t 40% 5 − 95 Percent
BKGND A 25% 5 − 95 Percent
SEQUENCER
INITIAL A 20 A 5 − 700 Amps
***Initial Time 0 S 0.0 − 25.0 Seconds
INITIAL SLOPE t 0S 0.0 − 25.0 Seconds
FINAL SLOPE t 0S 0.0 − 25.0 Seconds
FINAL A 5A 5 − 700 Amps
***Final Time 0S 0.0 − 25.0 Seconds
ADJUST
PREFLOW 0.2 S 0.0 − 25.0 Seconds
POST FLOW 10.0 S 0.0 − 50.0 Seconds @ 0.2 Second Resolution
DIG 30% 0 − 100 Percent
*AC WAVESHAPE
Waveform Soft Square Soft Square, Advanced Square, Sine, Triangle
EN Amps 500A 5 - 700 Amps
EP Amps 500A 5 - 700 Amps
BALANCE 75% 30 − 99 Percent
FREQUENCY 120 Hz 20 − 400 Hertz
**Impulse HF Start parameters for each program (1-4)
MAXSTAR:
Amperage 30 A 5 − 700 Amps
Time 3 mS 1 − 200 Milliseconds
*DYNASTY:
DC:
Polarity EN EP / EN
Amperage 30 A 5 − 700 Amps
Time 3 mS 1 − 200 Milliseconds
AC:
Polarity EP EP / EN
Amperage 40 A 5 − 700 Amps
Time 40 mS 1 − 200 Milliseconds
* DYNASTY parameter selection only
** Parameter adjusted using a power up configuration only
*** Parameter used with the automation option only

OM-2250 Page 39
5-17. Resetting Unit To Factory Default Settings
1 Process Switch Pad
2 Output Switch Pad
3 Gas/DIG Switch Pad
4 Power Switch
To reset all welding power source
functions to original factory settings,
lockout feature must be off (see Sec-
tion 6-5). Turn power on and then
press and hold the Process, Output,
and Gas/DIG switch pads before the
software version clears the meters.

4
1 2 3

Rear Panel

OM-2250 Page 40
 SECTION 6 − ADVANCED FUNCTIONS

6-1. Programmable TIG Start Parameters

A. Accessing Programmable TIG Start Parameters (All Models)

4
2

5* 1 6
3

And
V
*Available On Dynasty Models Only.
Rear Panel

NOTE: The welding cycle can be executed until software version clears the meters Press the Process switch pad to select the
while in programmable start mode. Before and [SEL] [EP] or [SEL] [EN] appears. desired process, TIG HF Impulse or TIG
accessing programmable TIG Start Polar- Lift Arc, for your application (see Section
4 Memory Switch Pad
ity, Amperage, and Time modes, be sure 5-7). The parameter values are the same
that all procedures and parameters are es- Press Memory switch pad to select desired for both processes, and any changes made
tablished. memory location (see Section 5-15). to the values in one process, are duplicated
1 Process Switch Pad in the other process.
5 Polarity Switch Pad (Dynasty Models
2 Amperage Switch Pad only) 6 Output Switch Pad
3 Power Switch Press Output switch pad to select desired
Press Polarity switch pad to select AC or
To access the programmable TIG Start DC (see Section 5-6). type of control (see Section 5-9).
Amperage and Time screens, turn power
Proceed to Section B, C and/or D.
on, and then press the Process and Amper- Note: Each memory location and each po-
age switch pads before the software ver- larity (AC or DC) has its own set of start To save changes and exit Advanced Func-
sion clears the meters. Hold switch pads parameters. tions, turn power off.

OM-2250 Page 41
B. Changing Programmable TIG Start Polarity (Dynasty Models Only)
3

SEL E−
1

1 Amperage Switch Pad To adjust TIG Start Polarity, press Amper- played on meters, and can be changed
age switch pad. Switch pad LED turns on, (see Section 5-16) by turning the Encoder
2 Encoder Control
and meter % LED turns on. The current control.
3 Amps Meter Start Polarity, SEL] [E−] or [SEL] [EP] is dis-

C. Changing Programmable TIG Start Amperage

SEL 20
1

1 Amperage Switch Pad To adjust TIG Start Amperage, press Am- Start Amperage is displayed on the amps
2 Encoder Control perage switch pad. Switch pad LED turns meter, and can be adjusted (see Section
3 Amps Meter on, and meter A LED turns on. The current 5-16) by turning the Encoder control.

D. Changing Programmable Start Time

SEL 10
1

1 Amperage Switch Pad To adjust Programmable Start Time, press played on the amps meter, and can be ad-
2 Encoder Control Amperage switch pad, and meter S LED justed by turning the Encoder control (see
3 Amps Meter turns on. The current Start Time is dis- Section 5-16).

OM-2250 Page 42
6-2. Output Control And Trigger Functions

A. Remote (Standard) Torch Trigger Operation

Current (A)

Main Amps

Initial Slope Final Slope

Initial Amps

Final Amps
Preflow Postflow

P/H R R
Maintained Switch Foot Or Finger
Remote Control

P/H = Push trigger and hold

R = Release trigger.

NOTE: When a foot or finger remote current control is connected to the welding power source, initial amps, initial slope, final slope
and final amps are controlled by the remote control.

B. Remote 2T Torch Trigger Operation

Current (A)

Main Amps

Initial Slope Final Slope

Initial Amps
Final Amps

Preflow Postflow

P/R
P/R

P/R = Push trigger and release. NOTE: If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.

OM-2250 Page 43
C. Reconfiguring RMT 2T HOLD For 2T, 3T, Spot, 4T, 4T Momentary, Or Mini Logic Control

SEL H−2

And
3

Rear Panel

For RMT STD (Remote Standard), RMT 2T To access the RMT 2T HOLD, turn power SPO = Spot (see Section 6-2H)
Hold (Remote 2T Hold), and On trigger op- switch on, press and hold the Process and
eration, see Section 6-2A, B, and I. Output switch pads before the software H-3 = 3T (see Section 6-2D)

1 Process Switch Pad version clears the meters and [SEL] ap- H-4 = 4T (see Section 6-2E)
pears. RMT 2T Hold LED will light.
H4L = Mini Logic (see Section 6-2F)
4 Encoder Control (Set Value)
2 Output Switch Pad H4E = 4T Momentary (see Section 6-2G).
5 Ammeter (Displays Value)
Press torch trigger or turn power Off to
3 Power Switch H-2 = 2T (see Section 6-2B) save setting.

OM-2250 Page 44
D. 3T Specific Trigger Method

SEL H-3

Current (A)
Remote Trigger Operation

*
*
*
*
*
* *

A B C D E
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.

1 3T (Specific Trigger Operation) Operation: C..When main amperage level is reached,

Sequencer is required to reconfigure for 3T. initial switch can be released.
A..Press and release initial switch within 3/4
3T requires a specific type of remote con- second to start shielding gas flow. To stop D..Press and hold the final switch to de-
trol with two independent momentary- the preflow sequence before preflow time crease amperage at final slope rate (re-
contact switches. One will be designated elapses (25 seconds), press and release lease switch to weld at desired amperage
initial switch, and it must be connected be- final switch. The preflow timer will reset level).
tween Remote 14 receptacle pins A and B. and the weld sequence can be started
The second will be designated as the final E.. When final amperage has been reached,
again.
switch, and it must be connected between the arc extinguishes and shielding gas
Remote 14 receptacle pins D and E. . If an initial switch closure is not made flows for the time set on the Postflow con-
again before preflow time ends, gas flow trol.
Select 3T according to Section 6-2C.
stops, the timer resets, and an initial Application:
Definitions:
switch press and release is necessary to
Initial slope rate is the rate of amperage start the weld sequence again. With the use of two remote switches instead
change determined by the initial amperage, of potentiometers, 3T gives the operator the
initial slope time, and main amperage. B..Press initial switch to start arc at initial ability to infinitely increase, decrease, or
Final slope rate is the rate of amperage amps. Holding switch will change amper- pause and hold amperage within the range
change determined by the main amperage, fi- age at initial slope rate (release switch to determined by the initial, main, and final am-
nal slope time, and final amperage. weld at desired amperage level). perages.

OM-2250 Page 45
E. 4T Specific Trigger Method

1 1 4T (Specific Trigger Operation)

Select 4T according to Section 6-2C.
Torch trigger operation is as shown.

SEL H−4
4T allows the operator to toggle between weld current and final
current.
= 4T
NOTE: When a remote switch is connected to the welding pow-
er source, use the remote switch to control the weld cycle. Am-
perage is controlled by the welding power source.
Application:
Use 4T trigger method when the functions of a remote current
Current (A) control are desired, but only a remote on/off control is available.
Torch Trigger Operation
Main Amps
Initial Slope
Final Slope

Initial Amps
Final Amps

Preflow Postflow

P/H R P/R P/R P/H R

P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds

F. Mini Logic Operation

1 1 Mini Logic Meter Display

Select Mini Logic according to Section 6-2C.
Torch trigger operation is as shown.

SEL H4L = Mini Logic

Mini logic allows the operator to toggle between initial slope
or main amps and initial amps. Final Amperage is not avail-
able. Final slope will always slope to minimum amperage
and end the cycle.
NOTE: When a remote switch is connected to the welding
power source, use the remote switch to control the weld
cycle. Amperage is controlled by the welding power source.
Application: This ability to change current levels without ei-
ther initial slope or final slope, gives the operator the opportu-
nity to adjust filler metal without breaking the arc.

Torch Trigger Operation

Main Amps

Initial Slope Final Slope

*
Initial Amps

* * *
Preflow Postflow

P/H R P/R P/R P/R P/R P/R P/H

P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds
* = Arc can be extinguished at final slope rate at any time by pushing and holding trigger

OM-2250 Page 46
G. 4T Momentary Operation

1 1 4T Momentary Meter Display

Select 4T Momentary according to Section 6-2C.
4T Momentary torch trigger operation is as shown.

SEL H4E = 4T Momentary Main

NOTE: When a remote switch is connected to the welding
power source, use the remote switch to control the weld
cycle. Amperage is controlled by the welding power source.
Application:
Use 4T Momentary trigger method when the functions of a
remote current control are desired, but only a remote on/off
control is available.

Current (A)
Main Amps

Initial Slope Final Slope

Initial Amps
Final Amps
*
Preflow Postflow

P/R P/R P/R P/R P/R

P/R = Push and release trigger; * = Push and releasing during final slope will break the arc and go to postflow
NOTE: For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends

H. Spot Control Operation

1 1 Spot Function Meter Display

Select Spot function according to Section 6-2C.
See Section 5-14 for operation.
NOTE: While in Spot Control, Sequencer settings are not be

SEL SPO = Spot

programmable.
NOTE: When a remote switch is connected to the welding
power source, use the remote switch to control the weld
cycle. Amperage is controlled by the welding power source.
Torch trigger operation is as shown.
Application: Used for tacking and thin sheet joining.

Current (A)

Timed Spot Weld Amps

Preflow Postflow

P/H R

P/H = Push and hold trigger; R = Release Trigger

OM-2250 Page 47
I. On Trigger Operation

Voltage (V)

ON

2 Sec

Current (A)

Stick

Touch Stick
Electrode Lift Stick
Electrode

Current (A)
Lift

Main Amperage

Initial Amperage Initial Slope

Touch Current

Touch Tungsten
Lift Tungsten Lift Tungsten
Slightly

OM-2250 Page 48
6-3. AC Waveshape Selection (Dynasty Models Only)

4
SEL SS

1 2

3
And

Rear Panel

= Advanced Squarewave = Soft Squarewave

= Sine wave = Triangular wave

1 Polarity Switch Pad Each memory location can select any of ter screen will display the active wave-
four wave shapes. shape (ASq), (SSq), (Sin), or (tri) as a remind-
2 AC Waveshape Switch Pad er.
5 Encoder
3 Power Switch
Use the Encoder, at any of the four memory Application: Use advance squarewave
To access the AC Waveshape selection locations, to select between advanced when a more focused arc is required for
screen, turn power on, and then press the squarewave [ASq], soft squarewave [ssq] better directional control. Use soft square-
Polarity and Waveshape switch pads be- (default), sine wave (Sin), or triangle wave wave when a softer arc with a more fluid
fore the software version clears the meters (Tri). puddle is desired. Use sine wave to simu-
and [SEL] [ssq) appears. The active Memory late a conventional power source. Use
To save changes and exit, press torch trig-
LED, AC LED, and the EN and EP Amper- triangular waveshape when the effects of
ger or turn power off.
age LED’s will light. peak amperage with reduced overall heat
Note: During normal operation, when EN or input is required to help control distortion on
4 Memory Switch Pad EP Amperage is selected, the left parame- thin materials.

OM-2250 Page 49
6-4. Arc Timer/Counter Display (All Models)

3/4

123 456
Or

2
And

Rear Panel

1 Output And Amperage Controls 3 Arc Timer Display 4 Arc Counter

The meter S LED will turn on, and arc time After 5 seconds, the meter A LED turns on,
2 Power Switch will be displayed for 5 seconds as [000 000 and the arc counter will be displayed for the
] to [999 959 ]. The first four numbers indicate next 5 seconds as [000 000 ] to [999 999 ].
To display the arc timer/counter, turn power hours, and the last two numbers indicate The maximum arc cycle count is 999 999.
switch on, press and hold the Amperage minutes. Example shown is read as 1,234
Control and Output switch pads until the hours and 56 minutes. Maximum arc time is
software version clears the meters. 9,999 hours and 59 minutes.

OM-2250 Page 50
6-5. Lockout Functions

A. Accessing Lockout Capability

000 L−−
1

And 000 LL! 2, 3, or 4

2
3

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. now select a lockout level.
There are four (1−4) different lockout levels. Each successive level There are four lockout levels available. Turn Encoder control to se-
allows the operator more flexibility. lect a lockout level (see Sections 6-5B for lockout level descriptions).
NOTE: Before activating lockout levels, be sure that all procedures 6 Lockout On
and parameters are established. Parameter adjustment is limited
while lockout levels are active. Once the desired three digits have been entered and a lockout level
selected, press torch trigger or turn Off power to complete lockout on
1 Amperage (A) Switch Pad sequence.
2 Gas/DIG Switch Pad
NOTE: Setting a three digit lockout number of [000], or setting a lock-
3 Power Switch out level of [L−−] will cause a lockout off condition.
To access lockout screens, turn On power switch, and then before
To turn Off the lockout feature, proceed as follows:
the software version clears the meters, push and hold the Amperage
and Gas/DIG switch pads until software version number clears me- To access lockout screens, turn On power switch, and then before
ters. the software version clears the meters push and hold the Amperage
4 Lockout Off and Gas/DIG switch pads until software version number clears me-
ters.
Upon power up as described, the meter % and Amperage (A) switch
pad LED’s light, and the meter display will be as shown for a lockout Upon power up as described, the meter % and Amperage (A) switch
off condition. pad LED’s will turn on, and the meter display will be as shown for a
lockout on (see callout 6) condition.
5 Encoder Control
To turn On the lockout feature, proceed as follows: Use Encoder control to enter the same three digits that were used
to turn on the lockout feature.
Pressing Amperage (A) switch pad will toggle between the meter %
and S LED’s. Toggle switch pad until % LED is on. Press the Amperage (A) switch pad. The meter % LED will turn off,
and the S LED will light. The amperage (right) meter display will
Turn Encoder control to select a three digit lockout number. Number
change to [L−−]. The lockout feature is now off.
will appear on the voltage (left) meter. Select any number from [001]
thru [999 ]. IMPORTANT: remember this three digit number, as you Press torch trigger or turn Off power to complete lock out Off
will need it to turn the lockout feature off. sequence.

OM-2250 Page 51
B. Lockout Levels
Levels 1, 2, And 3

Use Encoder Control To Adjust

Amperage +/− 10% Of Preset
L3
Value.

L2

Press switch pads in the

hand combinations shown to
access the different lockout
levels, L1, L2, or L3.

L2 L2 L1 L3

Level 4

A J
K I
B
C L N H
D M G
E F

NOTE: Before activating lock out levels, be When parameter change or selection is lim- 10% of preset amperage value, up to the
sure that all procedures and parameters are ited by lock level 1, [L-1 ] is displayed as a limits of the machine. If operator tries to go
established. Parameter adjustment is limit- reminder. beyond the +/− 10%, the amperage (right)
ed while lock out levels are active. meter will display [L-3 ] as a reminder.
Level 2
Level 1 Pulser ON/Off Control
NOTE: Remote amperage control is not
NOTE: Remote amperage control is not available in level 2. Gives operator the ability to turn on/off the
available in level 1. Pulser control.
TIG Output Selection Includes all the functions of level 1 plus
Memory, Polarity and Process Selection When parameter change or selection is lim-
If either the TIG HF Impulse or TIG Lift Arc (see Sections 5-6 and 5-7). ited by lock level 3, [L-3] is displayed as a re-
process (see Section 5-7) was active when minder.
lockout level 1 was activated, the operator When parameter change or selection is lim-
can choose between RMT STD (Remote ited by lock level 2, [L-2] is displayed as a re- Level 4
Standard) or RMT 2T HOLD (Remote 2T minder.
Includes all the functions of levels 1, 2, and
Hold) (see Section 5-9). The On function is 3 plus the following:
also available if TIG Lift Arc was active. Level 3

If RMT 2T HOLD was reconfigured (see NOTE: Remote amperage control is not Remote Amperage Control
Section 6-2C) prior to lockout level 1 activa- available in level 3.
Allows operator to use remote amperage
tion, the reconfigured output mode (4T, 4T control if desired. Remote control operates
Includes all the functions of levels 1 and 2
momentary, mini logic, or spot) is available from minimum to maximum of preset am-
plus the following:
to the operator instead of RMT 2T. perage value. Connect remote control de-
Stick Output Selection +/− 10% adjustment of preset TIG or vice according to Section 4-9.
Stick Weld Amps
If the Stick process was active when lock- When parameter change or selection is lim-
out level 1 was activated, the operator can Select desired process, TIG or Stick, and ited by lock level 4, [L-4] is displayed as a re-
choose between RMT STD or On. use Encoder control to adjust amperage +/− minder.

OM-2250 Page 52
6-6. Setting Unit To Display PPP While Pulse Welding

PPP
4

sel −−−

1 2

And
3

Rear Panel

1 Output Switch Pad 4 Encoder Control The (PPP) meter display feature will not ef-
2 Pulser Switch Pad fect the normal amperage display or Meter
5 PPP Meter Display
3 Power Switch Hold capabilities when in a non-pulse
Turn Encoder to change between standard welding mode.
To access the PPP while welding display, and (PPP) meter display.
turn power switch on, press and hold the Press torch trigger or turn off power to save
Output and Pulser switch pads until soft- When the (PPP) meter display feature is ac- setting.
ware version clears meters and [SEL] ap- tive while pulse welding, (PPP) is displayed,
pears. A and Pulser On LED’s will light. and the meter hold feature is disabled.

OM-2250 Page 53
6-7. Stick Open-Circuit Voltage (OCV) Selection

5
6

sel loc 3

1 2

And V

Rear Panel

1 Process Switch Pad ters. Hold the switch pads until [SEL] [Loc] or When Stick low OCV is selected, open-cir-
2 Gas/DIG Switch Pad [SEL] [noc) appears. cuit voltage is between 9 and 14 volts.
When Stick normal OCV is selected, open-
3 Amperage Switch Pad 5 Encoder Control circuit voltage is approximately 80 volts.
4 Power Switch 6 Meter Display Application: For most Stick applications
To access the Stick OCV selection, turn use low open-circuit voltage. Use normal
power switch on and then press the Pro- Turn Encoder to change between low OCV open-circuit voltage for hard to start Stick
cess, Gas/DIG and Amperage switch pads [SEL] [Loc] and normal OCV [SEL] [noc]. Active electrodes, or if required for your particular
before the software version clears the me- selection is displayed on the meters. application.

OM-2250 Page 54
 SECTION 7 − MAINTENANCE AND TROUBLESHOOTING
7-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Replace Clean and

unreadable Replace damaged
tighten weld
labels. gas hose.
terminals.

Repair or replace cracked

cables and cords.

6 Months

Blow out inside. During heavy

service, clean monthly.

7-2. Blowing Out Inside of Unit

Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.

803 900-A

OM-2250 Page 55
 7-3. Voltmeter/Ammeter Help Displays

V A V A
1 1

HE.L P30 HE.L P40

30 Series Display 40 Series Display
Top Module Bottom Module

. All directions are in reference to the w Help 34/44 Display w Help 13 Display (Automation Models
Only)
front of the unit. All circuitry referred to Indicates a failure in the thermal protection
is located inside the unit. circuitry located on the right side of the unit.
Output disable open causing weld output to
Contact a Factory Authorized Service
stop, but gas continues to flow.
1 Typical Voltmeter/Ammeter Help Agent if this display is shown.
Display w Help 35/45 Display w Help 14 Display
Indicates the right side of the unit has over-
A 30 series message refers to the top power heated. The unit has shut down to allow the Unit not ready. Primary circuit bus not up to
source, and a 40 series message refers to fan to cool it (see Section 4-3). Operation full power.
the bottom power source. Only one series will continue when the unit has cooled.
message (30 or 40) will be displayed at a w Help 15 Display
w Help 6 Display
time
Indicates that the input voltage is too low Indicates a primary overpower condition.
and the unit has automatically shut down. Output current is decreased to limit primary
w Help 30/40 Display power draw. Depress any switch pad and
Operation will continue when the voltage is
within the operating range (±10%). Have an turn encoder or strike an arc to clear the last
Indicates a failure in the thermal protection electrician check the input voltage if this dis- help condition.
circuitry located in the input inductor of the play is shown.
unit. Contact a Factory Authorized Service w Help 16 Display
w Help 7 Display
Agent if this display is shown.
Indicates that the input voltage is too high Secondary clamp voltage too high.
and the unit has automatically shut down.
w Help 31/41 Display Operation will continue when the voltage is w Help 20 Display
within the operating range (±10%). Have an
electrician check the input voltage if this dis- Indicates that the power supplies for the pri-
Indicates a malfunction in the primary pow-
play is shown. mary drives have failed. Contact a Factory
er circuit caused by an overcurrent condi-
Authorized Service Agent if this display is
tion in the primary IGBT switching circuit. w Help 8 Display shown.
Contact a Factory Authorized Service
Indicates a malfunction in the secondary
Agent if this display is shown. w Help 21 Display
power circuit of the unit. There is a high
open circuit condition. Contact a Factory
w Help 32/42 Display Authorized Service Agent if this display is Indicates voltage or current feedback has
shown. been detected with contactor off. Contact a
Factory Authorized Service Agent if this
Indicates a failure in the thermal protection w Help 39/49 Display display is shown.
circuitry located on the left side of the unit. Indicates the input inductor of the unit has
Contact a Factory Authorized Service overheated. Contact a Factory Authorized w Help 22 Display
Agent if this display is shown. Service Agent if this display is shown.
Voltage and current not present with con-
w Help 10 Display tactor on. Contact a Factory Authorized
w Help 33/43 Display
Indicates torch trigger is depressed. Re- Service Agent if this display is shown.
lease trigger to continue.
Indicates the left side of the unit has over- w Help 24 Display
heated. The unit has shut down to allow the w Help 12 Display
fan to cool it (see Section 4-3). Operation Indicates a non-allowable set-up on the Indicates a power supplies for the control
will continue when the unit has cooled. front panel. and interface board PC6 failure.

OM-2250 Page 56
7-4. Troubleshooting

Trouble Remedy

No weld output; unit completely Place line disconnect switch in On position (see Section 4-18).
inoperative.

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-18).

Check for proper input power connections (see Section 4-18).

No weld output; meter display On. If using remote control, be sure correct process is enabled to provide output control at Remote 14
receptacle (see Sections 5-1 and 4-9).

Input voltage outside acceptable range of variation (see Section 4-17).

Check, repair, or replace remote control.

Unit overheated. Allow unit to cool with fan On (see Section 4-3).

Erratic or improper weld output. Use proper size and type of weld cable (see Section 4-8).

Clean and tighten all weld and gas connections.

No 115 volts ac output at duplex recep- Reset circuit breaker CB1 (see Section 4-7).
tacle.

Fan not operating. Note: Fan only runs Check for and remove anything blocking fan movement.
when cooling is necessary.

Have Factory Authorized Service Agent check fan motor.

Wandering arc Use proper size tungsten (see Section 10-1).

Use properly prepared tungsten (see Section 10-2).

Reduce gas flow rate.

Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
weld
Increase postflow time (see Section 5-12).

Check and tighten all gas fittings.

Water in torch. Refer to torch manual.

OM-2250 Page 57
 SECTION 8 − ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram For Dynasty 700 Models (Part 1 of 2)

OM-2250 Page 58
 213 338-C

OM-2250 Page 59
 213 338-C

Figure 8-2. Circuit Diagram For Dynasty 700 Models (Part 2 of 2)

OM-2250 Page 60
Notes

OM-2250 Page 61
 Figure 8-3. Circuit Diagram For Maxstar 700 Models (Part 1 of 2)

OM-2250 Page 62
 215 121-C

OM-2250 Page 63
 215 121-C

Figure 8-4. Circuit Diagram For Maxstar 700 Models (Part 2 of 2)

OM-2250 Page 64
 SECTION 9 − HIGH FREQUENCY
9-1. Welding Processes Requiring High Frequency
1 High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1

Work
TIG high_freq 12/96 − S-0693

9-2. Incorrect Installation

Weld Zone
11, 12

50 ft
(15 m)

10
9 14
8

13 2

4 5 6

Sources of Direct High-Frequency Sources of Conduction of High Sources of Reradiation of High

Radiation Frequency Frequency
1 High-Frequency Source (welding 7 Input Power Cable 10 Ungrounded Metal Objects
power source with built-in HF or 8 Line Disconnect Device 11 Lighting
separate HF unit)
9 Input Supply Wiring 12 Wiring
2 Weld Cables
13 Water Pipes and Fixtures
3 Torch
4 Work Clamp 14 External Phone and Power Lines
5 Workpiece
6 Work Table

S-0694

OM-2250 Page 65
9-3. Correct Installation

Weld Zone 7

3 50 ft
(15 m) 50 ft
(15 m)

1
6

2
8

8
Ground all metal ob-
jects and all wiring in
welding zone using
#12 AWG wire. Ground
workpiece
if required
Nonmetal by codes.
Building

Metal Building

8
8
11

10

Ref. S-0695 / Ref. S-0695

1 High-Frequency Source (welding 5 Conduit Joint Bonding and Grounding Metal Building Requirements
power source with built-in HF or
Electrically join (bond) all conduit sections 9 Metal Building Panel Bonding Methods
separate HF unit)
using copper straps or braided wire. Ground
Ground metal machine case, work output Bolt or weld building panels together, install
conduit every 50 ft (15 m).
terminal, line disconnect device, input copper straps or braided wire across seams,
supply, and worktable. 6 Water Pipes and Fixtures and ground frame.
2 Center Point of Welding Zone Ground water pipes every 50 ft (15 m). 10 Windows and Doorways
Midpoint between high-frequency source Cover all windows and doorways with
7 External Power or Telephone Lines
and welding torch. grounded copper screen of not more than
3 Welding Zone Locate high-frequency source at least 50 ft 1/4 in (6.4 mm) mesh.
A circle 50 ft (15 m) from center point in all (15 m) away from power and phone lines.
11 Overhead Door Track
directions. 8 Grounding Rod
4 Weld Output Cables Ground the track.
Consult the National Electrical Code for
Keep cables short and close together. specifications.

OM-2250 Page 66
 SECTION 10 − SELECTING AND PREPARING TUNGSTEN
ELECTRODE FOR DC OR AC WELDING
ac/dc_gtaw 2/2004

Y Whenever possible and practical, use DC weld output instead of AC weld output.

10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter DC − Argon − Electrode DC − Argon − Elec- AC − Argon AC − Argon −
Negative/Straight Po- trode Positive/Rev-
Balanced Wave
larity erse Polarity
2% Ceria (Orange Band), 1.5% Lan-
thanum (Gray Band), Or 2% Thorium
(Red Band) Alloy Tungstens
.010” Up to 25 * Up to 20 Up to 15
.020” 15-40 * 15-35 5-20
.040” 25-85 * 20-80 20-60
1/16” 50-160 10-20 50-150 60-120
3/32” 135-235 15-30 130-250 100-180
1/8” 250-400 25-40 225-360 160-250
5/32” 400-500 40-55 300-450 200-320
3/16” 500-750 55-80 400-500 290-390
1/4” 750-1000 80-125 600-800 340-525
Pure Tungsten
(Green Band)
.010” * * Up to 15 Up to 10
.020” * * 5-20 10-20
.040” * * 10-60 20-30
1/16” * 10-20 50-100 30-80
3/32” * 15-30 100-160 60-130
1/8” * 25-40 150-210 100-180
5/32” * 40-55 200-275 160-240
3/16” * 55-80 250-350 190-300
1/4” * 80-125 325-450 250-400
Zirconium Alloyed Tungsten (Brown
Band)
.010” * * Up to 20 Up to 15
.020” * * 15-35 5-20
.040” * * 20-80 20-60
1/16” * * 50-150 60-120
3/32” * * 130-250 100-180
1/8” * * 225-360 160-250
5/32” * * 300-450 200-320
3/16” * * 400-550 290-390
1/4” * * 600-800 340-525

♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour). *Not Recommended.

Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
OM-2250 Page 67
10-2. Preparing Tungsten Electrode For Welding
Y 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 infor-
mation. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environ-
mentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines
2-1/2 Times 1 Grinding Wheel
Radial Grinding Electrode Diameter
Causes Wandering Arc Grind end of tungsten on fine grit, hard
2 3 abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
1 contaminated causing lower weld quality.
2 Tungsten Electrode
3 Flat
Diameter of this flat determines amperage
4 capacity.
Wrong Tungsten Preparation
Ideal Tungsten Preparation − Stable Arc 4 Straight Ground
Grind lengthwise, not radial.

B. Preparing Tungsten For Conventional AC Welding 1 Tungsten Electrode

2 Balled End
1 − 1-1/2 Times Ball end of tungsten by applying AC amper-
Electrode Diameter age recommended for a given electrode
diameter (see Section 10-1). Let ball on end
1 of the tungsten take its own shape.
2

SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW)

11-1. Positioning The Torch

Y Weld current can damage electronic parts in vehicles. Discon-
nect both battery cables before welding on a vehicle. Place work
clamp as close to the weld as possible.

3 . For additional information, see your distributor for a handbook on the

Gas Tungsten Arc Welding (GTAW) process.
2 1 Workpiece
Make sure workpiece is clean before welding.
4 2 Work Clamp
Place as close to the weld as possible.
1 3 Torch
90° 4 Filler Rod (If Applicable)
5 Gas Cup
6 Tungsten Electrode
10−15° Select and prepare tungsten according to Sections 10-1 and 10-2.
4
Guidelines:
5
6 The inside diameter of the gas cup should be at least three times the
10−25°
tungsten diameter to provide adequate shielding gas coverage. (For
example, if tungsten is 1/16 in diameter, gas cup should be a minimum of
5 6 3/16 in diameter.
Tungsten extension is the distance the tungsten extends out gas cup of
torch.
The tungsten extension should be no greater than the inside diameter of
1/16 in the gas cup.
3/16 in Arc length is the distance from the tungsten to the workpiece.
Bottom View Of Gas Cup Ref. ST-161 892

OM-2250 Page 68
11-2. Torch Movement During Welding
Tungsten Without Filler Rod

Welding direction 75°

Form pool Tilt torch Move torch to front

of pool. Repeat process.

Tungsten With Filler Rod

75° 15°
Welding direction

Form pool Tilt torch Add filler metal

Remove rod Move torch to front

of pool. Repeat process.
ST-162 002-B

11-3. Positioning Torch Tungsten For Various Weld Joints

Butt Weld And Stringer Bead “T” Joint

20°
90°

70°
75°

20°
15°
10°

Lap Joint Corner Joint

20-40°

90°

75° 75°

15°
15°
30°
ST-162 003 / S-0792

OM-2250 Page 69
 SECTION 12 − PARTS LIST

. Hardware is common and

not available unless listed.

6
12
5
4 11
9 13
14 15
7 8 10
16

33
25 24
3 8 35
2
36
1 26
27 23 34
28
18
29
17
22
21
22 21 19
30 20
8
31

32
18
1

28

Dynasty 700 illustrated

804 133-A

Figure 12-1. Main Assembly

OM-2250 Page 70
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 12-1. Main Assembly

. . . 1 . . . . . . . . . . 223 785 .. LABEL, SIDE DYNASTY 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 1 . . . . . . . . . . 223 784 .. LABEL, SIDE MAXSTAR 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . 213 071 .. INSULATOR, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . +213 057 .. PANEL, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . 213 056 .. WRAPPER, TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 203 990 .. LABEL, WARNING GENERAL PRECAUTIONARY STATIC . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 213 073 .. SEAL, LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 PC18,PC8 207 157 .. CIRCUIT CARD ASSY, CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . 080 509 .. GROMMET, SCR NO 8/10 PANEL HOLE .312 SQ .375 HIGH . . . . . . . . . . . . 9
. . . 9 . . . . . . . . . . 221 708 .. BRACKET, MTG PC BOARD (DYNASTY 700 MODELS ONLY) . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 010 493 .. BUSHING, SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . +213 058 .. LIFT EYE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . T2 . . 213 059 .. XFMR, 665 115/24 18/18 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 155 436 .. LABEL, GROUND/PROTECTIVE EARTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 218 170 .. HOSE, NPRN BRD NO 1 X .250 ID X 25.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 089 120 .. CLAMP, HOSE .375 − .450 CLP DIA SLFTTNG GREEN . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . Figure 12-3 .. PANEL, REAR W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . Figure 12-5 .. HEAT SINK, PRIMARY ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . Figure 12-4 .. WINDTUNNEL, RIGHT HAND W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . PC7 . . 214 712 .. CIRCUIT CARD ASSY, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 189 786 .. CONTACT, SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 196 455 .. POINT, SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . 213 055 .. BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 213 074 .. CABLE, LEM 23 IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . HD1 . . 182 918 .. TRANSDUCER,CURRENT 400A MODULE SUPPLY V +/− 15V . . . . . . . . . 2
. . . 23 . . . . . . . Figure 12-7 .. HEAT SINK, SECONDARY − DYNASTY 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . Figure 12-8 .. HEAT SINK, SECONDARY − MAXSTAR 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . 213 248 .. LUG, UNIV W/SCREW 2/0−14 WIRE .266STD . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . PC5 . . 221 722 .. CIRCUIT CARD ASSY, AUX POWER W/PROGRAM . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . 215 402 .. PANEL, TOP WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . 057 357 .. BUSHING,SNAP−IN NYL .937 ID X 1.125 MTG HOLE . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . Figure 12-6 .. WINDTUNNEL, LEFT HAND W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 29 . . C6,C7 . 222 752 .. CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . 221 721 .. PANEL, WINDTUNNEL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . C8 . . 221 707 .. CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . Figure 12-2 .. PANEL, FRONT W/CMPNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 215 120 .. CONNECTION KIT, DINSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . PC19 . 187 264 .. CIRCUIT CARD ASSY, FILTER (CE MODELS ONLY) . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . 222 760 .. BRACKET, FILTER BOARD (CE MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . 226 878 .. BRACKET, HARNESS SUPPORT (MAXSTAR 700 MODELS ONLY) . . . . . . 1
. . . 36 . . . . . . . . . . 195 666 .. SCREW, 010−32X .50 TORX PANHD W/GNDRNG STL PLD . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2250 Page 71
 . Hardware is common and 13 14
not available unless listed.
12

11
10
9

15

6 8 16
17
19 18

20

4
3 7
2

1 804 138-A

Figure 12-2. Panel, Front w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

221 408 Figure 12-2. Panel, Front w/Components

... 1 .......... 213 053 .. PANEL, LOUVER COVER (ORDER SERIAL NO. CARD ALSO) . . . . . . . . . . 2
... 2 .......... 214 826 .. RECEPTACLE, THREAD LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 .......... 186 228 .. O−RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 4 .......... 185 712 .. INSULATOR, BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 5 .......... 202 552 .. RECEPTACLE, GAS(FEMALE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .......... 213 051 .. PANEL, FRONT TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 .......... 216 859 .. PLATE, FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .......... 213 069 .. PLATE, INDICATOR FRONT − DYNASTY 700 . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .......... 213 518 .. PLATE, INDICATOR FRONT − MAXSTAR 700 . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .......... 174 991 .. KNOB, POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . . . . 1
... 10 .......... 215 294 .. BUSHING, FLG 375−32X.511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 .......... 212 490 .. PANEL, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 .......... 213 320 .. NAMEPLATE/SWITCH MEMBRANE, DYNASTY 350/700 STH/FF . . . . . . . . 1
... 12 .......... 215 119 .. NAMEPLATE/SWITCH MEMBRANE, MAXSTAR 350/700 STH/FF . . . . . . . . 1
... 13 . . . PC6 . . 220 755 .. CIRCUIT CARD ASSY, CONTROL & INTERFACE W/PROGRAM . . . . . . . . . 1
... 14 . . . RC1 . . 213 327 .. RECEPTACLE, W/LEADS & PLUG 14PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 .......... 185 717 .. NUT, M20−1.5 1.00HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 16 .......... 178 548 .. TERMINAL, CONNECTOR FRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 .......... 185 714 .. WASHER, TOOTH 22MMID X 31.5MMOD 1.310−1MMT INTERN . . . . . . . . . 3
... 18 .......... 185 718 .. O−RING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 19 .......... 185 713 .. INSULATOR, BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 20 FMB,FMT 213 072 .. FAN, MUFFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2250 Page 72
 9
. Hardware is common and
not available unless listed. 8

7
6
5

10

11

804 139-A

Figure 12-3. Panel, Rear w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

221 409 Figure 12-3. Panel, Rear w/Components

. . . 1 . . . . . . . . . +213 054 . . PANEL, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . GS1 . . 216 607 . . VALVE, 24VDC 2WAY CUSTOM PORT 1/8 ORF W/FRICT . . . . . . . . . . . . . . . 1
. . . 3 . . . CB1 . . 183 492 . . SUPPLEMENTARY PROTECTOR, MAN RESET 1P 10A 250V FRIC . . . . . 1
. . . 4 . . . RC2 . . 189 033 . . RCPT, STR DX GND 2P3W 15A 125V (GRAY) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 115 516 . . RIVET, AL .187 DIA X .063−.125 GRIP BLK BLIND DOME . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 010 467 . . CONN, CLAMP CABLE 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 137 761 . . NUT, 750 NPT 1.31HEX .27H NYL BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 215 117 . . NAMEPLATE, IDENT REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 217 297 . . COVER, RECEPTACLE WEATHERPROOF DUPLEX RCPT . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 221 164 . . LABEL, WARNING ELECTRIC SHOCK/INPUT POWER CONNECT . . . . . . 1
. . . 11 . . . . S1 . . 221 124 . . SWITCH, TGL ASSY (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 213 060 . . . . SWITCH, TGL 3 PST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2250 Page 73
 . Hardware is common and
not available unless listed.
3
1
2
4

5
6
7

14

13

11

12

9
10

804 134-A

Figure 12-4. Wind Tunnel, Right Hand w/Components

Item Dia. Part

No. Mkgs. No. Description Quantity

213 345 Figure 12-4. Wind Tunnel, Right Hand w/Components

... 1 . . . . L1 . . 213 350 .. INDUCTOR, INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . T3 . . 213 326 .. XFMR, COUPLING (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 2 . . . . T4 . . 215140 .. XFMR, COUPLING (BOTTOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . +212 489 .. PANEL, RIGHT WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . 195 666 .. SCREW, 010−32X .50 TORX PANHD WGNDRNG STL PLD . . . . . . . . . . . . . 3
... 5 . . . . . . . . . . 216 861 .. STAND−OFF, CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 6 . . . . . . . . . . 170 647 .. BUSHING, SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . 216 860 .. GROMMET, CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 8 . . C4,C20 217 941 .. CAPACITOR, ELCTLT 1800 UF 500 VDC CAN 2.52 DIA . . . . . . . . . . . . . . . . . 2
... 9 . . . . . . . . . . 207 418 .. SCREW, K40X 20 PAN HD−PHL STL PLD PT THREAD FORMING . . . . . . . 2
... 10 . . . . C3 . . 216 700 .. CAPACITOR, POLYP MET FILM 16. UF 400 VAC 10% . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . 218 004 .. LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . . 1
... 12 . . . . . . . . . . 010 493 .. BUSHING, SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . 218 566 .. GASKET, INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . L2 . . 213 348 .. COIL, INDUCTOR (PRE−REGULATOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2250 Page 74
 1
. Hardware is common and
not available unless listed.
2

804 135-A

Figure 12-5. Heat Sink, Primary Assembly

Item Dia. Part

No. Mkgs. No. Description Quantity

219 344 Figure 12-5. Heat Sink, Primary Assembly

... 1 .......... 213 346 .. HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . RM1 . 205 751 .. MODULE, POWER RESISTOR W/PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .......... 207 451 .. SCREW, 008−32X .50 PAN HD−PHL STL PLD SEMS . . . . . . . . . . . . . . . . . . . 3
... 4 . RT1,RT3 213 353 .. THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . . 1
... 5 . MOD1,2 217 625 .. KIT, INPUT/PRE−REGULATOR AND INVERTER MODULE . . . . . . . . . . . . . . 1
... 6 . PC1,PC2 220 759 .. CIRCUIT CARD ASSY, POWER INTERCONNECT . . . . . . . . . . . . . . . . . . . . . 1
... 7 .......... 200 565 .. SCREW, M 5− .8X 35 PAN HD−PHL STL PLD SEMS . . . . . . . . . . . . . . . . . . . . 4
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2250 Page 75
 3

4
5
2

. Hardware is common and

not available unless listed.

10

11

7
9

8
804 136-B

Figure 12-6. Wind Tunnel, Left Hand w/Components

Item Dia. Part

No. Mkgs. No. Description

213 354 Figure 12-6. Wind Tunnel, Left Hand w/Components Quantity
... 1 . . . . . . . . . . 170 647 .. BUSHING, SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . . . . . 2
... 2 . . . . . . . . . . 218 004 .. LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . . 1
... 3 . . . CR1 . . 206 258 .. RELAY, ENCL 24VDC SPST 30A/240VAC 4PIN FLANGE MTG . . . . . . . . . . . 1
... 4 . . . . . . . . . . 145 217 .. SCREW, K40X 12 PAN HD−PHL STL PLD PT THREAD FORMING . . . . . . . 2
... 5 . . . . . . . . . +212 488 .. PANEL, LEFT WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . T1 . . 213 361 .. XFMR, HF LITZ/LITZ W/BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . Z4 . . 213 513 .. COIL, INDUCTOR (BOOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . Z1 . . 213 356 .. OUTPUT INDUCTOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . 010 493 .. BUSHING, SNAP−IN NYL .625 ID X .875 MTG HOLE . . . . . . . . . . . . . . . . . . . 3
... 10 . . . . . . . . . . 010 381 .. CONNECTOR, RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . 227 746 .. GASKET, INDUCTOR MOUNTING E55 FERRITE CORE . . . . . . . . . . . . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2250 Page 76
 7
. Hardware is common and
not available unless listed.

5
4

10
9

804 137-A

Figure 12-7. Heat Sink, Secondary − Dynasty 700

Item Dia. Part

No. Mkgs. No. Description Quantity

219 345 Figure 12-7. Heat Sink, Secondary − Dynasty 700

... 1 . PC3,PC4 222 753 .. CIRCUIT CARD ASSY, COMMUTATOR CONTROL . . . . . . . . . . . . . . . . . . . . . 1

... 2 .......... 213 517 .. BUS BAR, OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 .......... 216 867 .. BUS BAR, POSITIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . PM1 − 6 213 522 .. KIT, IGBT (CONSISTS OF 3 IGBT’S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 . . D1,D2 . 213 521 .. KIT, ULTRA FAST DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 6 . RT2,RT4 213 353 .. THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . . 1
... 7 .......... 213 346 .. HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . SR1 . . 201 530 .. KIT, DIODE FAST RECOVERY BRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .......... 216 868 .. BUS BAR, NEGATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . PC10 . 220987 .. CIRCUIT CARD ASSEMBLY, DIODE SNUBBER . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2250 Page 77
 . Hardware is common and
not available unless listed.

804 177-A

Figure 12-8. Heat Sink, Secondary − Maxstar 700

Item Dia. Part

No. Mkgs. No. Description Quantity

221 730 Figure 12-8. Heat Sink, Secondary − Maxstar 700

... 1 .......... 213 346 .. HEAT SINK, POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . D1, D2 213 521 .. KIT, ULTRA FAST DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . SR1 . . 201 531 .. KIT, DIODE POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . RT2, RT4 213 353 .. THERMISTOR, NTC 30K OHM @ 25 DEG C 8IN LEAD . . . . . . . . . . . . . . . . . 1
... 5 . . . PC3 . . 220 987 .. CIRCUIT CARD ASSY, DIODE SNUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 .......... 213 519 .. BUS BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2250 Page 78
 Effective January 1, 2006
(Equipment with a serial number preface of “LG” 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 * Induction Heating Coils and Blankets, Cables, and
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
* APT & SAF Model Plasma Cutting Torches
for your local material and workmanship at the time it is shipped by Miller. THIS * Remote Controls
Miller distributor. WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Accessory (Kits)
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Replacement Parts (No labor)
Within the warranty periods listed below, Miller will repair or * Spoolmate Spoolguns
Your distributor also gives replace any warranted parts or components that fail due to such * Canvas Covers
you ... defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which Miller’s True Blue® Limited Warranty shall not apply to:
Service time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings, relays
reliable response you Miller shall honor warranty claims on warranted equipment listed or parts that fail due to normal wear. (Exception:
need. Most replacement below in the event of such a failure within the warranty time brushes, slip rings, and relays are covered on Bobcat,
parts can be in your periods. All warranty time periods start on the date that the Trailblazer, and Legend models.)
hands in 24 hours. equipment was delivered to the original retail purchaser, or one 2. Items furnished by Miller, but manufactured by others, such
year after the equipment is sent to a North American distributor as engines or trade accessories. These items are covered
Support or eighteen months after the equipment is sent to an by the manufacturer’s warranty, if any.
Need fast answers to the International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
1. 5 Years Parts — 3 Years Labor Miller, or equipment that has been improperly installed,
Contact your distributor.
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
distributor and Miller is 2. 3 Years — Parts and Labor
necessary maintenance, or equipment which has been
there to help you, every * Transformer/Rectifier Power Sources used for operation outside of the specifications for the
step of the way. * Plasma Arc Cutting Power Sources equipment.
* Process Controllers MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Semi-Automatic and Automatic Wire Feeders USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated)
In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Engine Driven Welding Generators replacement; or, where authorized in writing by Miller in
(NOTE: Engines are warranted separately by the appropriate cases, (3) the reasonable cost of repair or
engine manufacturer.) replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
3. 1 Year — Parts and Labor Unless Specified depreciation based upon actual use) upon return of the goods at
* Motor Driven Guns (w/exception of Spoolmate customer’s risk and expense. Miller’s option of repair or
Spoolguns) replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
* Positioners and Controllers Miller. Therefore no compensation or reimbursement for
* Automatic Motion Devices transportation costs of any kind will be allowed.
* RFCS Foot Controls TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Induction Heating Power Sources, Coolers, and PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
Electronic REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Controls/Recorders DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Water Coolant Systems (Non-Integrated)
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* Flowgauge and Flowmeter Regulators (No Labor) OTHER LEGAL THEORY.
* HF Units ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Grids ANY IMPLIED WARRANTY, GUARANTY OR
* Spot Welders REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Load Banks OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Arc Stud Power Sources & Arc Stud Guns PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Racks OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Running Gear/Trailers MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Plasma Cutting Torches (except APT & SAF PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
Models) FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
* Field Options BY MILLER.
(NOTE: Field options are covered under True Blue® Some states in the U.S.A. do not allow limitations of how long an
for the remaining warranty period of the product they implied warranty lasts, or the exclusion of incidental, indirect,
are installed in, or for a minimum of one year — special or consequential damages, so the above limitation or
whichever is greater.) exclusion may not apply to you. This warranty provides specific
* Bernard-Branded Mig Guns (No Labor) legal rights, and other rights may be available, but may vary from
state to state.
* Weldcraft-Branded TIG Torches (No Labor)
In Canada, legislation in some provinces provides for certain
* Subarc Wire Drive Assemblies
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
5. 90 Days — Parts provides specific legal rights, and other rights may be available,
* MIG Guns/TIG Torches and Subarc (SAW) Guns but may vary from province to province.
miller_warr 2006−01
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters −
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
To locate a Distributor or Service Agency visit FAX: 44 (0) 1204-598066
www.millerwelds.com or call 1-800-4-A-Miller www.MillerWelds.com

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 © 2006 Miller Electric Mfg. Co. 2006−01