TM-357A, Dynasty DX

Transcription

TM-357A, Dynasty DX

TM-357A
June 1999
Eff. w/Serial Number KH384382
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source

Dynasty DX
With Auto-Link
Visit our website at
www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Weld Output Terminals and Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. 115 Volts AC Duplex Receptacle (Optional), Power Switch Location, and Circuit
Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
4
5
6
6
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. AC/Balance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Meter Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Output Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Sequence Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Lift-Arc and HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
10
10
10
11
11
7
7
8
SECTION 4 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
SECTION 5 – PRE-POWER CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Input Rectifier SR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Tank Capacitor C1 and Input Capacitors C3, C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Output Diodes D1, D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. IGBT Modules PM1, PM2, PM3, PM4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Diodes D1, D2, D3, D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Contactors W1, W2 (230/460 V Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
14
14
15
15
16
18
19
SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Troubleshooting Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Waveforms for Sections 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Control Board PC1 Testing Information (Use with Section 6-5) . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Display Board PC3 Testing Information (Use with Section 6-7) . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Display Board PC3 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Interconnecting Board PC2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. High-Frequency Board PC7 Testing Information (Use with Section 6-10) . . . . . . . . . . . . . . . .
6-10.High-Frequency Board PC7 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11.Clamp Board PC8 Testing Information (Use with Section 6-12) . . . . . . . . . . . . . . . . . . . . . . . .
6-12.Clamp Board PC8 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13.Secondary IGBT Board PC6 Testing Information (Use with Section 6-14) . . . . . . . . . . . . . . . .
6-14.Secondary IGBT Board PC6 Test Point Values With Contactor Off . . . . . . . . . . . . . . . . . . . . .
20
20
22
24
26
27
29
30
31
32
33
34
35
36
37
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Blowing Out Inside of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
38
38
39
40
SECTION 8 – HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
41
41
42
SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
SECTION 10 – PARTS LIST For KH384382 Thru KJ150395 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
SECTION 11 – PARTS LIST For KJ150396 And Following . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
TM-357-A
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
OM-357D 4/98, safety_stm 5/97
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Servicing Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard.
Y Only qualified persons should service, test, maintain, and repair this unit.
Y During servicing, keep everybody, especially children, away.
FLYING METAL can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
HOT PARTS can cause severe burns.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit.
D
Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.
D
Do not leave live unit unattended.
D
If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D
When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
D
Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D
D Do not touch hot parts bare handed.
D Allow cooling period before working on welding
gun or torch.
EXPLODING PARTS can cause injury.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
D Always wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
D Turn Off welding power source and wire feeder
or stop engine before making or changing meter lead connections.
D Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.
D Read instructions for test equipment.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any parts.
FALLING UNIT can cause injury.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
FIRE OR EXPLOSION hazard.
D Do not place unit on, over, or near combustible
surfaces.
D Do not service unit near flammables.
Dynasty DX
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
TM-357 Page 1
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
OVERUSE
HEATING.
can
cause
OVER-
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
READ INSTRUCTIONS.
D Use MILLER Testing Booklet (Part No. 150
853) when servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine MILLER replacement parts.
1-3. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
TM-357 Page 2
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
Dynasty DX
SECTION 2 – INSTALLATION
2-1. Specifications
Input Power
Rated Welding Output
Amperage
Range
Maximum
Open-Circuit
Voltage DC
250 A @ 30 Volts AC, 40%
Duty Cycle
Three Phase
200 A @ 28 Volts DC, 40%
Duty Cycle
5–300
90
250 A @ 30 Volts AC, 40%
Duty Cycle
Single Phase
5–300
90
200 A @ 28 Volts DC, 40%
Duty Cycle
Amperes Input at Rated Load Output 60 Hz
230 V
460 V
KVA
KW
26.3
*.27
17.9
*.15
14.2
*.09
10.5
*.04
20.5
*.27
13.4
*.15
8.4
*.09
7.6
*.04
62.6
*.33
32.2
*.18
14.8
*.10
10.4
*.07
44
*.33
25.8
*.18
11.9
*.1
8.1
*.07
*While idling
2-2. Duty Cycle and Overheating
Duty Cycle is 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 7-4), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
250 A @ 40% Duty Cycle For AC
200 A @ 40% Duty Cycle For DC
4 Minutes Welding
6 Minutes Resting
Overheating
0
A or V
15
Minutes
OR
Reduce Duty Cycle
sduty1 5/95 / SA-185 794
Dynasty DX
TM-357 Page 3
2-3. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
SA-185 793 / SA-186 294
TM-357 Page 4
Dynasty DX
2-4. Selecting a Location
24 in
(610 mm)
Dimensions And Weight
90 lb (40.7 kg)
17 in
(432 mm)
12-1/2 in
(318 mm)
Movement
1
1
Y Do not move or operate unit
where it could tip.
Lifting Handles
Use handles to lift unit.
2
Hand Cart
Use cart or similar device to move
unit.
1
3
2
Rating Label
Use rating label to determine input
power needs.
4
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
4
18 in
(460 mm)
3
18 in
(460 mm)
Dynasty DX
loc_2 3/96 - ST-801 708-A
TM-357 Page 5
2-5. Weld Output Terminals and Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
Weld Output
Terminals
Electrode
Work
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 – 60%
Duty
Cycle
60 – 100%
Duty Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
10 – 100% Duty Cycle
*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. Contact your
distributor for the mm2 equivalent weld cable sizes.
NOTE: For proper installation of gas hose, the use of a quick connect torch (such as Weldcraft QWP-17 or QWP-20), is recommened.
S-0007E
2-6. Remote 14 Receptacle Information
Socket*
ST-801 708-A
Socket Information
A
Contactor control, 24 volts dc.
B
Contact closure to A completes 24 volts dc
contactor control circuit, and enables output.
C
Output to remote control; 0 to +10 volts dc output
to remote control.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control.
M
Not used.
F
Current feedback; +1 volt dc per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt dc per 10 output
receptacle volts.
GND
K
Chassis common.
24 VOLTS DC
A
B
K
J
I
H
C L N
D M
G
E F
REMOTE
OUTPUT
CONTROL
A/V
*The remaining sockets are not used.
TM-357 Page 6
Dynasty DX
2-7. 115 Volts AC Duplex Receptacle (Optional), Power Switch Location, and Circuit
Breaker CB1
1
2
1
3
115 V 10 A AC Receptacle
Circuit Breaker CB1
CB1 protects the 115 volts ac duplex receptacle from overload.
2
Press button to reset breaker.
3
Power On/Off Switch
ST-801 866-A
2-8. Electrical Service Guide
NOTE
Actual input voltage cannot exceed ± 15% of indicated required input voltage. If
actual input voltage is outside of this range, no output is available.
Three-Phase
Input Voltage
Single-Phase
230
460
230
460
AC
26.5
17.9
62.6
32.2
DC
20.5
13.4
44
25.8
Max Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes
50
25
100
50
Min Input Conductor Size In AWG/Kcmil
10
14
8
10
104 (32)
165 (50)
90 (27)
241 (74)
10
14
8
10
Input Amperes At Rated Output
Max Recommended Input Conductor Length In Feet
(Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC).
Dynasty DX
S-0092J
TM-357 Page 7
2-9. Connecting Input Power
Check input voltage available at
site.
Tools Needed:
1
3/8 in
3/8 in
2
Input And Grounding
Conductors
Line Disconnect Device
See Section 2-8.
For single-phase operation:
3
3
1
4
5
6
Black And White Input
Conductor
Red Input Conductor
Insulation Sleeving
Electrical Tape
Insulate and isolate red conductor
as shown.
Y Always connect green wire
to supply grounding terminal, never to a line terminal.
For three-phase operation:
2
Connect black, white, and red wires
(L1, L2, L3) to line terminals.
2
Y Always connect green wire
to supply grounding terminal, never to a line terminal.
L1
L2
L1
L3
L2
Green
Green
1
1
Y Always connect grounding
conductor first.
= GND/PE
1
3
4
Green
1
6
5
input_2 3/96 - ST-801 709-A
TM-357 Page 8
Dynasty DX
SECTION 3 – OPERATION
3-1. Controls
1
2
3
4
5
6
13
12
7
8
11
10
14
9
Ref. ST-187 198
1 AC Frequency Control
Range is 20 to 250 hertz. For most applications, increasing frequency improves arc
stability.
2 Balance/DIG Control
Control functions as a balance control for
GTAW (TIG) process, and in the DIG mode
for SMAW (STICK) process, depending on
position of Process control.
Use ammeter to preset amperage. Meter displays weld amperage output of unit when
welding.
Selecting any GTAW (TIG) position enables
the gas valve, which is disabled when SMAW
(Stick) position is selected.
5
10 Sequence Control
Balance Mode:
See Section 3-2.
DIG Mode:
When set lower, short-circuit amperage at
low arc voltage is the same as normal
welding amperage.
When set higher, short-circuit amperage is
increased at low arc voltage to help with arc
starting and making overhead or vertical
welds, as well as to reduce sticking while
welding.
3 Voltmeter (see Section 3-3)
Voltmeter displays voltage (to the nearest 0.1
V) at the weld output terminals, but not necessarily the welding arc due to cable resistance, poor connections, etc.
4 Ammeter (see Section 3-3)
Dynasty DX
Amperage Adjustment Control
Turn control clockwise to increase amperage
from 5 to 300 amps.
See Section 3-5.
6
See Section 3-4.
Use control to select a starting amperage
that is different from the weld amperage.
7
12 Start t (Amperage Time) Control
Output Control Switch
Amperage Control Switch
For front panel control, place switch in Panel
position.
For remote control, make connections to
remote 14 receptacle, and place switch in
Remote 14 position.
8
Trigger Hold
To start weld, press and release gun trigger
within three seconds after an arc has been
struck. To end weld, press and release gun
trigger. If gun trigger is not released within 3
seconds, unit switches to standard trigger
control operation.
9
Process Control
Use control to select either of the GTAW
(TIG) welding process and polarity, or the
SMAW (Stick) welding process.
11 Start A (Amperage) Control
Use control to select length of time in
seconds that amperage remains at start
amperage before changing to weld
amperage.
For example, to select start amperage of 300
A for 3 seconds and weld amperage of 200
A: Set Start A amperage control to 300 A, set
Start t time control to 3 seconds, and set front
panel or remote amperage control to 200 A.
13 Crater Control
Control sets length of time in seconds to
taper weld output from weld amperage
setting to 0 A .
14 Postflow Control
Control sets length of time in seconds gas
flows after the welding stops.
TM-357 Page 9
3-2. AC/Balance Control
Balance Control:
Control changes the ac output
square wave.
Balance Control Waveform Examples
Max Penetration
At 20 Hz
1% Electrode
Positive
99% Electrode
Negative
100
Max Penetration
At 250 Hz
10% Electrode
Positive
90% Electrode
Negative
100
Max Cleaning At
All Hz
50% Electrode
Positive
50% Electrode
Negative
0
Adjust
setting
for
penetration or more
action.
È
È
È
È
È
ÈÈÈÈ
ÈÈÈÈ
ÈÈÈ
ÈÈÈÈ
ÈÈÈÈÈÈ
ÈÈ
È
ÈÈ
È ÈÈ
ÈÈ
ÈÈÈ
ÈÈÈ
ÈÈÈ
ÈÈÈ
ÈÈÈÈÈÈ
ÈÈÈ
ÈÈÈ
ÈÈ
ÈÈÈ
ÈÈÈ
ÈÈ
ÈÈ
ÈÈ
ÈÈ
ÈÈ ÈÈ
ÈÈ
deeper
cleaning
3-3. Meter Function
Mode
Meter Reading At Idle
V
80.0
On
85
V
A
24.5
85
Actual Volts (OCV)
Preset Amps
Actual Volts
Actual Amps
V
A
V
A
7.0
Lift On
Meter Reading While Welding
A
85
10.3
85
Actual Volts
Preset Amps
Actual Volts
Actual Amps
V
A
V
A
Blank
Preset Amps
Actual Volts
Actual Amps
V
A
V
A
Blank
Preset Amps
Actual Volts
Actual Amps
V
A
V
A
Blank
Preset Amps
85
HF Remote
85
Lift Remote
85
Remote
10.3
85
10.3
85
24.5
85
Actual Volts
Actual Amps
3-4. Output Switch Settings
Output Switch Setting
Process
Output On/Off Control
On
SMAW (Stick)
Electrode Hot
Lift On
GTAW (TIG) With Lift-Arc Start – See Section
3-6
Electrode Hot
HF Remote
GTAW (TIG) With HF Start – See Section 3-6
At Remote 14
Lift Remote
GTAW (TIG)
At Remote 14
Remote
SMAW (Stick)
At Remote 14
TM-357 Page 10
Dynasty DX
3-5. Sequence Control
Control Position
Allows These Controls To Be Functional
For The Following Processes
SMAW (Stick)/GTAW (TIG)
Stick
Off
Postflow t – 0-50 Seconds
TIG
Start t (Time) – 0-15 Seconds
Start A (Amperage0 – 0-300 Amps
Stick/TIG
Postflow – 0-50 Seconds
TIG
Crater
Crater t – 0-15 Seconds
Postflow t – 0-50 Seconds
TIG
Start/Crater
Start t (Time) – 0-15 Seconds
Start A (Amperage) – 0-300 Amps
Crater t – 0-15 Seconds
Postflow – 0-50 Seconds
TIG
Start
3-6. Lift-Arc and HF TIG Start Procedures
With Output Switch in Lift On
position, start arc as follows:
1
2
1
“Touch”
1–2
Seconds
2
TIG Electrode
Workpiece
Touch tungsten electrode to workpiece at weld start point, hold
electrode to workpiece for 1-2
seconds, and slowly lift electrode.
An arc will form when electrode is
lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
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 without overheating, sticking, or getting
contaminated.
With Output Switch in HF Remote
position, start arc as follows:
Do NOT Strike Like A Match!
High frequency turns on to help
start arc when contactor is energized. High frequency turns off
when arc is started, and turns on
whenever arc is broken to help
restart arc.
Ref. ST-156 279
Dynasty DX
TM-357 Page 11
SECTION 4 – THEORY OF OPERATION
1
13
Power Switch S1
Provides on/off control of welding
power source.
2
Input Rectifier SR1
Changes the ac line input power to
full-wave rectified dc.
3
Control Transformer T2
Supplies power to control board
PC1, interconnecting board PC2,
Remote 14 receptacle RC1, and
HF board PC7.
4
1
Three-Phase
Line Input
Power
2
10
Circuit Breaker CB1
17
Auto-Link
Contacts
W2, W2A
Circuit Breaker CB2
16
Control
Transformer T2
115 Volt AC Receptacle
Remote 14 Receptacle RC1
115
VAC
Connects remote amperage or
voltage, and contactor controls.
8
24
VAC
16
IGBT Board
PC4
18
VAC
CenterTapped
IGBT Power
Module PM2
IGBT Board
PC5
Gating
Signals
220
VAC
Gating
Signals
Control Board PC1
460 V Input Contactor W1
4♦
6♦
Controls weld output by changing
gate pulses (frequency of pulses) to
IGBT power modules PM1 and
PM2 after comparing current feedback to reference level set by R5 on
PC3.
9
17
IGBT Power
Module PM1
W1
3
Connects auxiliary equipment to
welding power source.
7
Interconnecting
Board PC2
220
VAC
Prior to Serial No. KJ037293, provides overload protection for 24
volts ac portion of Remote 14
receptacle RC1.
6
Inductors
L1, L3, L4
15
SCR/
Integrated
Rectifier SR1
Power
Switch
S1
Provides overload protection for
optional 115 volt ac receptacle.
5
14
Input
Capacitors
C3, C4
Circuit
Breaker
CB1
115 Volts AC
Receptacle
Provides automatic linking for different input voltages. W2 sets power circuit for correct input voltage.
W2A sets T2 primary.
Control Board PC1
7
Connects the 220 volts ac secondary voltage from T2 to interconnecting board PC2 to balance voltage
on input capacitors C3 and C4.
10 230 V Auto-Link Contactor
W2
8
9
10
5
Circuit
Breaker
CB2
Remote 14
Receptacle
RC1
460 V Input
Contactor W1
230 V
Auto-Link
Contactor W2
11
Fan Motor
FM
Ribbon
Cable
11 Fan Motor FM
Provides cooling of internal components.
12 Display Board PC3 (See
Section 3-1)
Consists of voltmeter V, ammeter
A, Amperage Adjustment control
R5, Amperage Control switch S1,
AC Frequency control R81, Balance/Dig control R82, Start Time
control R83, Start Amperage control R85, Crater Time control R84,
Postflow Time control R86, Sequence Control switch S4, Process
Select switch S3, Output Select
switch S2, and Trigger Hold switch
S5.
TM-357 Page 12
Display Board PC3
12
AC
Frequency
Control R81
Balance/Dig
Control R82
Voltmeter
V
Ammeter
A
Start Time
Control
R83
Crater Time
Control R84
Process
Control
Switch S3
Output
Control
Switch S2
Sequence
Control
Switch S4
Start
Amperage
Control R85
Postflow
Control R86
Amperage
Adjustment
Control R5
Amperage
Control
Switch S1
Trigger
Hold Switch
S5
Dynasty DX
13 Input Capacitors C3, C4
Filter the dc output voltage of SR1.
14 Inductors L1, L3, L4
L1 limits peak current in SR1, C3,
and C4. L3 and L4 limit voltage and
current in IGBT’s during turn-on
and turn-off.
18
Current
Transformer
CT1
19
20
Output
Diodes
D1, D2
Main
Transformer
T1
15 Interconnecting Board PC2
Provides electrical connections for
SR1, T1, C3, C4, L1, L3, L4, and
IGBT’s. Precharge and bleeder
resistors are mounted on PC2.
21
16 IGBT Boards PC4, PC5
Stabilizer
Z1
T1 Primary
Current
Feedback
Provide interconnection of gate
pulses from PC1 to PM1 and PM2.
17 IGBT Power Modules PM1,
PM2
22
Current
Feedback
Hall
Device
HD1
Use very fast on/off switching action to effectively turn the dc into ac.
18 Current Transformer CT1
23
24
Clamp Board
PC8
Provides current feedback to PC1
from the primary of T1 for control
circuit timing and to limit primary
current.
IGBT Switching Modules
PM3, PM4
19 Main Transformer T1
Energizes by on/off switching action of PM1 and PM2, and supplies
power to weld output circuit.
20 Output Diodes D1, D2
Rectify output of T1.
26
21 Stabilizer Z1
25
HF
Coupling Coil
T3
Smooths out welding current.
HF Board
PC7
Work
Weld Output
Receptacle
Provides weld or secondary current
feedback signal to PC1.
23 IGBT Switching Modules PM3
And PM4
27
27
22 Hall Device HD1
Electrode
Weld Output
Receptacle
Use very fast on/off switching action to effectively turn the dc into ac
output; also control AC balance.
24 Clamp Board PC8
Clamps voltage spikes created by
AC switching to protect switching
IGBT’s PM3 and PM4.
Work
Electrode
Voltage Feedback
25 HF Board PC7
Creates the high-frequency (HF)
energy to start the arc.
Voltage Feedback
26 HF Coupling Coil T3
Couples HF energy created on PC7
to weld output circuit.
27 Electrode And Work Weld
Output Receptacles
AC Or DC Control Circuits
3φ Power
Provide weld output and allow
changing of output polarity.
Weld Current Circuit
♦
Dynasty DX
Optional
TM-357 Page 13
SECTION 5 – PRE-POWER CHECKLIST
5-1. Checking Unit Before Applying Power
. See Section 6-2 for test points and values and Section
10 for parts location.
Y Discharge input capacitors according to Section 7-5 and be sure voltage is near zero before touching any parts.
Y Before troubleshooting or applying power to unit, complete following checks to avoid causing further damage.
Y Although control board PC1 and hall device HD1 are briefly checked in this procedure, more complete tests may be needed later for
these parts. This check is simply to get a basic okay to power up unit.
5-2. Input Rectifier SR1
Y Read and follow safety
information in Section 5-1
before proceeding.
. Resistance values are based
on in-circuit measurements.
1
2
3
Power Switch S1
4
Negative (–)
A. Disconnect plug PLG13
from receptacle RC1 on interconnecting board PC2.
–
AC (L1)
SCR (–)
B. Connect red clip to positive
(+) terminal.
T
Gate
+
G
AC (L2)
C. Connect black clip to SCR
(–) terminal.
S
Positive (+)
Visually inspect SR1 for
damage.
Check 6 diodes (diode test).
Check from each ac terminal
to the positive (+) terminal and
from each ac terminal to the
negative (–) terminal.
Check precharge SCR (ohms
position). Connect negative
lead to SCR (–) terminal and
positive lead to positive (+)
terminal. Resistance should
be 200 ohms ±10%. Connect
a jumper between positive (+)
and gate terminals.
Resistance should be
approximately 35 ohms.
If results are in doubt, use an
IGBT tester (MILLER Part No.
043 553) to test the SCR
portion of SR1 as follows:
AC (L3)
R2
R
Input Rectifier SR1
5
D. Connect yellow clip to gate
terminal.
If SR1 is defective, check the
three poles of power switch
S1 (switch off = OL, switch on
= 0 ohms).
ST-801 550 / Ref. SD-183 484
TM-357 Page 14
Dynasty DX
5-3. Tank Capacitor C1 and Input Capacitors C3, C4
before proceeding.
. This is not a conclusive test.
For best results use a capacitor
tester to check capacitance.
. If either C3 or C4 is shorted, remove interconnecting board
PC2 and check IGBT’s PM1
and PM2.
1
Input Capacitors C3, C4
Check C1, C3, and C4 for a
short (ohms position).
Tank Capacitor C1
ST-801 550
5-4. Output Diodes D1, D2
before proceeding.
1
Test diodes individually
according to the Diode Testing
Procedure in the MILLER
Testing Booklet (Part No. 150
853).
Weld Output
Receptacles
Diodes D1, D2
Ref. SD-183 484 / ST-802 037
Dynasty DX
TM-357 Page 15
5-5. IGBT Modules PM1, PM2, PM3, PM4
Best Test For PM1 And PM2 (Use MILLER
IGBT tester #043553)
Y Read and follow safety information in
Section 5-1 before proceeding.
. It is not necessary to remove interconnect-
ing board PC2 to test the IGBT’s unless input capacitor C3 or C4 is shorted.
1
Control Board PC1
Disconnect gate lead plug PLG5 from
receptacle RC5 on control board PC1.
Test PM1 as follows:
2
Connect red tester lead to C1, black tester
lead to E1, and yellow tester lead to gate
(PLG5–pin 10). Next, connect red lead to
C2, black lead to E2, and yellow tester
lead to gate (PLG5–pin 7).
3
Connect red tester lead to C1, black lead
to E1, and yellow lead to gate (PLG5– pin
6). Next, connect red lead to C2, black
lead to E2, and yellow lead to gate
(PLG5–pin 9).
Connect PLG5 to RC5.
If IGBT’s 1 or 2 are defective, check D1, D2, D3,
and D4 on PC2 (see Section 5-6). Also check
W1 and W2 in 230/460 volt models (see Section
5-7).
Receptacle
RC5
5
Y Read and follow safety information in
Section 5-1 before
proceeding.
1
Alternate Test For PM1 And PM2 (Use standard digital meter set to ohms position)
6
PLG5
10
Proceed to top of next page to test PM3 and
PM4.
Tab Lock
. It is not necessary to remove interconnect-
Bottom View
2
3
Disconnect gate lead plug PLG5 from
receptacle RC5 on control board PC1.
For PM1 and PM2, measure between C1
and E1, and then between C2 and E2 (a
high resistance means device is okay,
zero ohms means device is shorted)
For PM1, check for 100K ohms resistance
(+/– 10%) between the following:
6
1
12
ing board PC2 to test the IGBT’s unless input capacitor C3 or C4 is shorted.
E1 and PLG5–pin 10
E2 and PLG5–pin 7
4
For PM2, check for 100K ohms resistance
(+/– 10%) between the following:
E1 and PLG5–pin 6
E2 and PLG5–pin 9
Terminal
C1
Connect PLG5 to–RC5.
Terminal
If IGBT’s 1 or 2 are defective, check D1, D2, D3,
E2
and D4 on PC2 (see Section 5-6). Also check
W1 and W2 in 230/460 volt models (see Section
5-7).
Terminal
Proceed to bottom of next page to test PM3 and C2/E1
PM4.
Rear Of Unit
IGBT Module PM1 Or PM2
ST-802 275 / Ref. SD-183 484 / SA-188 731-A
TM-357 Page 16
Dynasty DX
Best Test For PM3 And PM4 (Use
MILLER IGBT tester #043553)
(Continued)
before proceeding.
1
2
Control Board PC1
Visually inspect PM3 and
PM4 for damage.
Disconnect gate lead plug
PLG7 from receptacle RC7 on
control board PC1.
. Make sure meter probes make
good electrical contact. Black
paint on bolts may act as an insulator.
3
Receptacle
RC7
7
1
PLG7
12
4
6
Connect red tester lead to C1,
black tester lead to E1, and
yellow tester lead to gate
(PLG7–pin 12). Next, connect
red lead to C2, black lead to
E2, and yellow tester lead to
gate (PLG7–pin 3).
Tab Lock
Bottom View
Connect red tester lead to C1,
black lead to E1, and yellow
lead to gate (PLG7– pin 6).
Next, connect red lead to C2,
black lead to E2, and yellow
lead to gate (PLG7– pin 9).
Alternate Test For PM3 And PM4
(Use standard digital meter set to
ohms position) (Continued)
before proceeding.
1
2
Visually inspect PM3 and
PM4 for damage.
Disconnect gate lead plug
PLG7 from receptacle RC7 on
control board PC1.
. Make sure meter probes make
good electrical contact. Black
paint on bolts may act as an insulator.
Front Of Unit
3
4
Terminal
C2/E1
Terminal
C2/E1
Terminal
E2
Terminal
E2
Terminal
C1
Terminal
C1
For PM3 and PM4, measure
between C1 and E1, and then
between C2 and E2 (a high
resistance means device is
okay, zero ohms means
device is shorted)
For PM3, check for 100K
ohms resistance (+/– 10%)
between the following:
E1 and PLG7–pin 12
E2 and PLG7–pin 3
5
For PM4, check for 100K
ohms resistance (+/– 10%)
between the following:
E1 and PLG7–pin 6
E2 and PLG7–pin 9
ST-802 037 / ST-802 408 / SA-188 731-A
Dynasty DX
TM-357 Page 17
5-6. Diodes D1, D2, D3, D4
before proceeding.
1
2
Diode
D3
Diode
D1
Check D1 and D2 on PC2 for
2000 ohms ±10% in 230/460
volt models or 400 ohms
±10% in 460/575 volt models
(ohms position).
Check D3 and D4 on PC2
(diode test).
Diode
D4
Diode
D2
Interconnecting Board PC2
ST-801 550 / SC-183 621-A
TM-357 Page 18
Dynasty DX
5-7. Contactors W1, W2 (230/460 V Models Only)
before proceeding.
1
Normally-Open
Contacts Of 460 V
Input Contactor W1
Check normally-open
contacts of W1 and W2 to be
sure contacts are not stuck
shut (ohms position).
Normally-Open
Contacts Of 230 V
Auto-Link Contactor W2
ST-801 550 / SC-183 621-A
Dynasty DX
TM-357 Page 19
SECTION 6 – TROUBLESHOOTING
6-1. Troubleshooting Table
. See Section 6-2 for test points and values and Section 10 for parts location.
. Use MILLER Testing Booklet (Part No. 150 853)
when servicing this unit.
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 2-9).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 2-9).
Check for proper input power connections (see Section 2-9).
Check continuity of Power switch S1, and replace if necessary.
Check control transformer T2 for signs of winding failure. Check continuity across windings, and
check for proper connections. Check secondary voltages. Replace T2 if necessary.
No weld output; meter display On.
If using remote control, be sure Amperage Control Switch S2 is in the Remote 14 position.
Unit overheated and HELP 3 or HELP 5 screen is displayed. Allow unit to cool with fan On (see Section 2-2).
Check, repair, or replace remote control.
For 230/460 volt models, check coil voltage and connections of contactors W1 and W2. Check
continuity of coils and condition of contacts. Replace W1 and W2 if necessary.
For 460/575 volt models, check coil voltage and connections of contactor CR1. Check continuity of
coil and condition of contacts. Replace CR1 if necessary.
Check input and output voltages of hall device HD1 (see Section 6-2). Replace HD1 if necessary.
Check output diodes D1 and D2, and replace if necessary (see Section 5-4).
Check input integrated rectifier SR1, and replace if necessary (see Section 5-2).
Check IGBT modules PM1, PM2, PM3, and PM4, and replace if necessary (see Section 5-1).
Check control board PC1 and connections, and replace if necessary (see Section 6-4).
Low weld output with no control.
Check position of Amperage Control Switch S2 (see Section 3-1).
Check display board PC3 and connections, and replace if necessary (see Section 6-6).
Maximum weld output with no control.
Limited output and low open-circuit
voltage.
Check incoming power for correct voltage (see Section 2-8). Replace line fuse(s), if necessary, or
reset circuit breaker (see Section 2-9).
Check for proper input and output connections.
If using remote amperage control, check position of Amperage Control R5.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 2-5).
Clean and tighten all weld connections.
TM-357 Page 20
Dynasty DX
Trouble
Remedy
Check for proper input and output connections.
Replace electrode.
Check resistance and connections of remote amperage control potentiometer, and replace if
necessary.
Prior to Serial No. KJ037293, no 24
volts ac output at Remote 14 receptacle RC1.
Reset circuit breaker CB2 if necessary (see Section 7-3).
Check receptacle wiring and connections.
No 115 volts ac output at optional duplex receptacle.
Reset circuit breaker CB1 if necessary (see Section 2-7).
Check receptacle(s) wiring and connections.
Fan motor does not run after approximately four minutes of operation at
rated load.
Check and clear blocked fan blade
Check thermistors RT1 and RT2 on display board PC3 (see Section 6-6).
Check fan motor FM, and replace if necessary.
Wandering arc; poor control of arc
direction.
Use proper size tungsten.
Use properly prepared tungsten.
Reduce gas flow rate.
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Water in torch. Refer to torch manual.
Dynasty DX
TM-357 Page 21
6-2. Troubleshooting Circuit Diagram
. No calibration available for voltmeter V or ammeter A.
Y Discharge input capacitors according to Section 7-5, and be
sure voltage is near zero before touching any parts.
Test Equipment Needed:
R1
See Section 6-8 for
PC2 information
V8
V9
V10
R3
R2
R4
V2
V1
See Section
5-5 for PC5
information
V7
V3
V5 V6
V4
V11
V12
R7
R8
See Section
5-5 for PC4
information
460 V Input
Contactor W1
230 V
Auto-Link
Contactor W2
V13
See Section 4
for RC1
information
See Section 6-6
for RT1, RT2
information
See Section
6-4 for
PC1 data
See Section 6-6
for PC3 data
TM-357 Page 22
Dynasty DX
Resistance Values
a)
b)
Tolerance – ±10% unless specified
Turn Off unit and disconnect input power
before checking resistance
R1 thru R6
Less than 1 ohm
R7, R8
7.5 ohms
Voltage Readings
a) Tolerance
specified
–
±10%
unless
b) Reference – to circuit common
(lead 42) unless noted
c) Wiring Diagram – see Section 9
See Section 6-11 for
PC8 information
See Section 6-9
for PC7 information
V18
V1, V2
230 volts ac
V3
24 volts ac
V4
115 volts ac
V5, V6
18 volts ac
V7
220 volts ac
V8
325 volts dc with 230 volts ac
input power, 650 volts dc with
460 volts ac input power
V9, V10
325 volts dc
V11*
0 volts dc with 230 volts ac
input power, 3.8 volts dc with
V12*
3.8 volts dc with 230 volts ac
input power, 0 volts dc with
V13
28 volts dc when fan FM is
running
V14
+1 volt dc per 100 amperes
of weld output
V15
–15 volts dc
V16
+15 volts dc
V17
87 volts dc open-circuit
voltage
V18
325 volts dc
* Pulsed dc values – measurements will
vary.
R10
R5
R9
V17, A, B, C, D
See Section 6-3
for waveforms
A, B, C, D
R6
V14 V15
V16
See Section 6-13
for PC6 information
SD-189 922
Dynasty DX
TM-357 Page 23
6-3. Waveforms for Sections 6-2
10 µs 50 V
gnd
2.5 ms 20 V
gnd
A. DC Open-Circuit Voltage (86.7 VDC)
B. AC Maximum Cleaning, 30 Volts AC, 250
Amperes, 140 Hertz (Resistive Load)
2.5 µs 20V
2.5 ms 20 V
gnd
gnd
C. AC Maximum Penetration, 30 Volts AC,
250 Amperes, 140 Hertz (Resistive Load)
D. DC, 28 Volts DC, 200 Amperes, (Resistive Load)
TM-357 Page 24
Dynasty DX
Notes
Dynasty DX
TM-357 Page 25
6-4. Control Board PC1 Testing Information (Use with Section 6-5)
Y Discharge input capacitors
according to Section 7-5,
and be sure voltage is near
zero before touching any
parts.
7
4
Be sure plugs are secure before
testing. See Section 6-5 for specific
values during testing.
1
6
3
1
2
3
4
5
6
7
8
9
10
11
12
Control Board PC1
Receptacle RC1
Receptacle RC2
Receptacle RC3
Receptacle RC4
Receptacle RC5
Receptacle RC6
Receptacle RC7
Receptacle RC8
Receptacle RC9
Receptacle RC10
Receptacle RC11
9
12
8
11
10
5
2
ST-802 035 / SC-188 731-A
TM-357 Page 26
Dynasty DX
6-5. Control Board PC1 Test Point Values
a) Tolerance – ±10% unless specified
PC1 Voltage Readings
Receptacle
Pin
RC1
1
+24 volts dc output
2
+15 volts dc under load with the Process Switch S6 in either DC (+) position, 0 volts dc with S6 in
either DC (–) position. For either AC position of S6, 0 to +15 volts dc under load depending on settings of Balance and AC Freq. Controls.
3
+24 volts dc output
4
+1 volt dc input per 10 volts dc of weld output
5
–24 volts dc output
6
+15 volts dc input when HELP 1 screen is displayed, 0 volts dc with normal conditions
7
–24 volts dc output
8
0 to +10 volts dc input from min to max of Balance/Dig control R2
9
Circuit common
10
Circuit common
11
–24 volts dc input with fan motor FM off, –10 volts dc with fan motor FM on
12
Zero (0) volts dc input during normal operation, +15 volts dc input when HELP 8 screen is displayed
13
+15 volts dc input with Mode switch S3 in lift arc position
14
+15 volts dc input during normal operation, 0 volts dc input when HELP 6 screen is displayed
15
+15 volts dc input with Process switch S3 in Stick position, 0 volts dc input with S3 in Tig position
16
17
+15 volts dc input with output on, 0 volts dc input with output off
18
+15 volts dc input with Mode switch S3 in droop (stick) position, 0 volts dc input with S3 in GTAW
position
19
+15 volts dc input with High Frequency on, 0 volts dc input with High Frequency off.
20
+1 volt dc output per 100 amperes of weld output
21
–24 volts dc input with gas valve GS1 deenergized, –10 volts dc input with GS1 energized.
22
0 to +10 volts dc input from min to max of Amperage Adjustment control R8
23
Not used
24
Not used
1
–15 volts dc
2
18 volts ac input with respect to pin RC2-6
3
18 volts ac input with respect to pin RC2-6
4
Circuit common
5
+1 volt dc input per 100 amperes of weld output
6
Center tap for 18 volts ac secondary windings of control transformer T2
7
+15 volts dc
8
Circuit common
9
Circuit common for RC2-10
10
–24 volts dc with respect to pin RC2-9 with gas valve GS1 energized
RC2
Dynasty DX
Value
TM-357 Page 27
Receptacle
Pin
RC3
RC4
Do not measure – high voltage present.
1
+28 volts dc output with respect to pin RC4-2 when fan motor FM is running
2
–28 volts dc output (Return circuit for FM) with respect to pin RC4-1
RC5
Make no connections – damage to test equipment or components can occur.
RC6
RC7
RC8
RC9
RC10
TM-357 Page 28
Value
Test without contactor energized and without any load.
1
Arc voltage
2
Arc voltage
3
–15 volts dc with respect to pin RC7-4
4
Circuit common for pin RC7-3
5
6
7
–7.5 volts dc with respect to pin RC7-8 with Output Switch S7 in Lift Arc On position
8
+7.5 volts dc with respect to pin RC7-7 with Output Switch S7 in Lift Arc On position
9
+15 volts dc with respect to pin RC7-10
10
11
12
1
0 volts dc with 230 volts ac input power, 3.8 volts dc with 460 volts ac input power with respect to pin
RC8-5 (contactor W1 coil)
2
3.8 volts dc with 230 volts ac input power, 0 volts dc with 460 volts ac input power with respect to pin
RC8-6 (contactor W2 coil)
3
Reference for pins RC8-4 and RC8-8
4
0 volts dc during precharge, +27 volts dc after precharge with respect to pin RC8-3
5
Reference with respect to pin RC8-1 (contactor W1 coil)
6
Reference with respect to pin RC8-2 (contactor W2 coil)
7
Not used
8
0 volts dc after precharge, + 0.6 volts dc at power-up with respect to pin RC8-3
1
750 Hz waveform with respect to pin RC9-3 (High Frequency gate pulses to HF board PC7)
2
Not used
3
Circuit common for pin RC9-1 (High Frequency gate pulses to HF board PC7)
1
+15 volts dc with contactor energized, 0 volts dc at clamp shutdown
2
Not used
3
Not used
4
Circuit common
Dynasty DX
6-6. Display Board PC3 Testing Information (Use with Section 6-7)
Y Discharge input capacitors according to Section 7-5, and be sure voltage is near zero before touching any
parts.
Be sure plugs are secure before testing. See
Section 6-7 for specific values during testing.
1 Display Board PC3
2 Receptacle RC1
3 Receptacle RC2
9
4
. No calibration available for voltmeter V
Receptacle RC4
Connection point for thermistor RT1.
5
8
9
10
11
12
13
Receptacle RC5
Connection point for thermistor RT2.
6
Voltmeter V
7
Ammeter A
or ammeter A.
Amperage Adjustment Control R8
Balance/Dig Control R2
Process Switch S3
Output Switch S2
Amps Switch S1
Start/Crater Switch S4
7
6
2
8
1
12
4
13
10
11
5
3
RC3
ST- 802 035 / SC-189 538
Dynasty DX
TM-357 Page 29
6-7. Display Board PC3 Test Point Values
Receptacle
Pin
RC1
1
+24 volts dc input
2
+15 volts dc under load with the Process Switch S6 in either DC (+) position;.0 volts dc with S6 in
either DC (–) position. For either AC position of S6, 0 to +15 volts dc under load depending on settings of Balance and AC Freq. Controls.
3
+24 volts dc input
4
+1 volt dc input per 10 volts dc of weld output
5
–24 volts dc input
6
+15 volts dc input when HELP 1 screen is displayed, 0 volts dc with normal conditions
7
–24 volts dc input
8
0 to +10 volts dc output from min to max of Balance/Dig control R44
9
Circuit common
10
Circuit common
11
–24 volts dc output with fan motor FM off, –10 volts dc with fan motor FM on
12
Zero (0) volts dc input during normal operation, +15 volts dc input when HELP 8 screen is displayed
13
+15 volts dc output with Mode switch S3 in lift arc position
14
15
+15 volts dc output with Process switch S3 in Stick position, 0 volts dc input with S3 in Tig position
16
17
+15 volts dc output with output on, 0 volts dc input with output off
18
+15 volts dc with Mode switch S3 in droop (stick) position, 0 volts dc input with S3 in GMAW or
GTAW position
19
+15 volts dc output with High Frequency on, 0 volts dc input with High Frequency off.
20
+1 volt dc input per 100 amperes of weld output
21
–24 volts dc output with gas valve GS1 deenergized, –10 volts dc input with GS1 energized.
22
0 to +10 volts dc output from min to max of Amperage Adjustment control R2
23
Not used
24
Not used
1
0 to +10 volts dc output from min to max of Amperage Adjustment Control R2
2
Circuit common
3
Reference common
4
Not used
5
+1 volt dc output per 10 volts dc of weld output
6
+1 volt dc output per 100 amperes of actual or preset amperage output
7
0 to +10 volts dc input from min to max of Remote Amperage Adjustment Control
8
24 volts dc input, contactor
RC2
Value
RC4
1, 2
Approximately 33 k ohms at 68°F (20°C) with thermistors plugged in
RC5
1, 2
Approximately 33 k ohms at 68°F (20°C) with thermistors plugged in
TM-357 Page 30
Dynasty DX
6-8. Interconnecting Board PC2 Testing Information
parts.
. Be sure to use torque values in-
dicated on PC2 when servicing. Use component-to-heat
sink torque value of 26 in-lb
when servicing SR1 and
IGBT’s PM1 and PM2.
. No test point values provided
for this PC board.
1
2
3
4
1
Receptacle RC1
Receptacle RC2
Receptacle RC3
4
3
2
ST-802 035 / Ref. SC-183 621-A
Dynasty DX
TM-357 Page 31
6-9. High-Frequency Board PC7 Testing Information (Use with Section 6-10)
parts.
testing. See Section 6-10 for
specific values during testing.
1
2
3
4
5
6
1
High-Frequency Board PC7
Receptacle RC1
Receptacle RC2
Receptacle RC3
Receptacle RC4
Spark Gap—Set At 0.010 in
(0.254 mm)
4
3
5
2
6
ST-802 035 / SC-186 808-B
TM-357 Page 32
Dynasty DX
6-10. High-Frequency Board PC7 Test Point Values
Receptacle
Pin
RC1
1
220 volts ac with respect to pin RC1-5
2
3
325 volts dc with respect to pin RC1-8
4
5
6
7
8
1
740 Hz pulse waveform with respect to pin RC2-2
2
740 Hz pulse waveform with respect to pin RC2-1
3
Reference common
4
Not used
RC2
RC3
1
RC4
1
Dynasty DX
Value
TM-357 Page 33
6-11. Clamp Board PC8 Testing Information (Use with Section 6-12)
parts.
1
2
3
Clamp Board PC8
Receptacle RC1
Receptacle RC2
1
3
2
ST-802 035 / SC-182 189-B
TM-357 Page 34
Dynasty DX
6-12. Clamp Board PC8 Test Point Values
Receptacle
Pin
RC1
1
Common
2
Clamp voltage with respect to pin RC1-3
3
Clamp voltage with respect to pin RC1-2
4
+15 volts dc with contactor energized, 0 volts dc with contactor deenergized
5
6
1
2
3
4
RC2
Dynasty DX
Value
TM-357 Page 35
6-13. Secondary IGBT Board PC6 Testing Information (Use with Section 6-14)
parts.
1
2
Secondary IGBT Board PC6
Receptacle RC1
1
2
ST-802 037 / SC-182 193-A
TM-357 Page 36
Dynasty DX
6-14. Secondary IGBT Board PC6 Test Point Values With Contactor Off
Receptacle
Pin
RC1
Dynasty DX
Value
Test without contactor energized and without any load.
1
2
3
4
Clamp voltage signal to board PC6
5
Clamp voltage signal to board PC6
6
7
8
9
10
TM-357 Page 37
SECTION 7 – MAINTENANCE
7-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Replace
unreadable
labels.
Clean and
tighten weld
terminals.
Replace damaged
gas hose.
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.
ST-801 708-A
7-3. Overload Protection
1
Circuit Breaker CB1
CB1 is part of the factory auxiliary
power option and protects the optional 115 volts ac duplex receptacle from overload.
2
1
2
Circuit Breaker CB2
Prior to Serial No. KJ037293, CB2
protects the 24 volts ac portion of
Remote 14 receptacle RC1 from
overload.
Press button to reset either circuit
breaker.
ST-801 866
TM-357 Page 38
Dynasty DX
7-4. Voltmeter/Ammeter Help Displays
V
A
1
HE.L
P–0
V
A
2
HE.L
P–1
V
A
HE.L
P–2
V
A
HE.L
P–3
V
A
HE.L
P–4
V
A
A
HE.L
P–7
V
A
HE.L
P–8
V
A
HE.L
P–9
V
A
HE.L P–10
V
A
12
HE.L
P–5
. All directions are
in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
Help 0 Display
Indicates a short in the thermal protection
circuitry located on the left side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
Help 1 Display
Indicates a malfunction in the primary power circuit. Contact a Factory Authorized
Service Agent if this display is shown.
Help 2 Display
Indicates an open in the thermal protection
circuitry located on the left side of the unit.
Help 3 Display
Indicates the left side of the unit has overheated. The unit has shut down to allow the
Dynasty DX
V
11
6
4
P–6
10
5
3
HE.L
9
4
2
A
8
3
1
V
7
fan to cool it (see Section 2-2). Operation
will continue when the unit has cooled.
5 Help 4 Display
Indicates an open in the thermal protection
circuitry located on the right side of the unit.
6 Help 5 Display
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 2-2). Operation
will continue when the unit has cooled.
7 Help 6 Display
Indicates that the input voltage is too low
and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (±15%). Have an
electrician check the input voltage if this display is shown.
8 Help 7 Display
Indicates that the input voltage is too high
and the unit has automatically shut down.
HE.L P–12
Operation will continue when the voltage is
within the operating range (±15%). Have an
electrician check the input voltage if this display is shown.
9
Help 8 Display
Indicates a malfunction in the secondary
power circuit of the unit. Contact a Factory
Authorized Service Agent if this display is
shown.
10 Help 9 Display
Indicates a short in the thermal protection
circuitry located on the right side of the unit.
11 Help 10 Display
Indicates gun trigger is depressed. Release
trigger to continue.
12 Help 12 Display
Indicates an improper set-up. Check front
panel.
TM-357 Page 39
7-5. Measuring Input Capacitor Voltage
Y Significant DC voltage can
remain on capacitors after
unit is Off. Always check capacitors as shown to be sure
they have discharged before
working on unit.
Turn Off welding power source and
disconnect input power.
Remove case.
1
Input Capacitor C3
2
Input Capacitor C4
3
Voltmeter
Check input capacitors as shown.
Measure the dc voltage across the
positive (+) and negative (–)
terminals until voltage drops to near
0 (zero) volts.
Proceed with job inside unit.
Reinstall case when finished.
1
3
3
2
Tools Needed:
5/16 in
ST-802 035
TM-357 Page 40
Dynasty DX
SECTION 8 – HIGH FREQUENCY
8-1. 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
8-2. Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
5
6
Sources of Conduction of High
Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High
Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
Dynasty DX
TM-357 Page 41
8-3. Correct Installation
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece
if required
by codes.
9
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
TM-357 Page 42
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground
conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Metal Building Requirements
9
Metal Building Panel Bonding Methods
Bolt or weld building panels together, install
copper straps or braided wire across seams,
and ground frame.
Ground water pipes every 50 ft (15 m).
10 Windows and Doorways
7
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
11 Overhead Door Track
Ground the track.
Dynasty DX
SECTION 9 – ELECTRICAL DIAGRAMS
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model
Dynasty DX (With Auto-Link)
Serial Or Style Number
Circuit Diagram
Wiring Diagram
KH384382 thru KJ037292
SD-183 036-C
SD-183 037-A♦♦
KJ037293 and following
SD-189 922
SD-183 037-B
KH384382 thru KH518627
SD-182 179♦♦
KH518628 thru KJ037292
SD-186 803♦♦
KJ037293 and following
SD-188 732-A
Circuit Board PC2 (Interconnecting Board)
KH384382 and following
SD-183 623
Circuit Board PC3 (Front Board)
SD-189 540
Circuit Board PC4,5 (IGBT Single
Board)
KH384382 thru KH518629
SD-173 599♦♦
SD-188 015
Circuit Board PC6 (IGBT Double
Board)
SD-182 195
Circuit Board PC7 (HF Board)
KH384382 thru KH517736
SD-182 187♦♦
SD-186 810
SD-182 191-A
Circuit Board PC1 (Control
Board)
Circuit Board PC8 (Clamp Board)
♦ Optional
♦♦ Not included in this manual
Dynasty DX
TM-357 Page 43
Figure 9-1. Circuit Diagram For Dynasty DX Effective With Serial No. KH384382 Thru KJ037292
TM-357 Page 44
Dynasty DX
SD-183 036-C
Dynasty DX
TM-357 Page 45
Figure 9-2. Circuit Diagram For Dynasty DX Effective With Serial No. KJ037293 And Following
TM-357 Page 46
Dynasty DX
SD-189 922
Dynasty DX
TM-357 Page 47
Figure 9-3. Wiring Diagram For Dynasty DX Effective With Serial No. KJ037293 And Following
TM-357 Page 48
Dynasty DX
SD-183 037-B
Dynasty DX
TM-357 Page 49
Figure 9-4. Circuit Diagram For Main Control Board PC1
Effective With Serial No. KJ037293 And Following (Part 1 Of 3)
TM-357 Page 50
Dynasty DX
SD-183 732-A
Dynasty DX
TM-357 Page 51
TM-357 Page 52
Dynasty DX
SD-183 732-A
Dynasty DX
TM-357 Page 53
TM-357 Page 54
Dynasty DX
SD-183 732-A
Dynasty DX
TM-357 Page 55
SD-183 623
Figure 9-7. Circuit Diagram For Interconnecting Board PC2
Effective With Serial No. KH384382 And Following
TM-357 Page 56
Dynasty DX
Notes
Dynasty DX
TM-357 Page 57
Figure 9-8. Circuit Diagram For Front Board PC3
Effective With Serial No. KH384382 And Following (Part 1 Of 2)
TM-357 Page 58
Dynasty DX
SD-189 540
Dynasty DX
TM-357 Page 59
Figure 9-9. Circuit Diagram For Front Board PC3
Effective With Serial No. KH384382 And Following (Part 2 Of 2)
TM-357 Page 60
Dynasty DX
SD-189 540
Dynasty DX
TM-357 Page 61
SD-188 015
Figure 9-10. Circuit Diagram For IGBT Single Board PC4, PC5
TM-357 Page 62
Dynasty DX
SD-182 195
Figure 9-11. Circuit Diagram For IGBT Double Board PC6
Dynasty DX
TM-357 Page 63
SD-186 810
Figure 9-12. Circuit Diagram For HF Board PC7 Effective With Serial No. KH517737 And Following
TM-357 Page 64
Dynasty DX
SD-182 191-A
Figure 9-13. Circuit Diagram For Clamp Board PC8 Effective With Serial No. KH384382 And Following
Dynasty DX
TM-357 Page 65
Notes
TM-357 Page 66
Dynasty DX
TM-357A
June 1999
Processes
TIG (GTAW) Welding
Description

Dynasty DX
Eff w/ KH384382 Thru KJ150395
For OM-357 (188 291) Revisions A thru D
With Auto-Link
www.MillerWelds.com
20
SECTION 10 – PARTS LIST For KH384382 Thru KJ150395
21
. Hardware is common and
PC2
31
PC1
PC8
39
39
1
20
37
38
40
36
41
2
35
3
34
33
Fig 10-2 – 42
32
4
5
6
7
30–PC3
8
9
10
29
11
28
27
12
13
14
15
16
26
17
25
18
24
23
19
22
not available unless listed.
Figure 10-1. Main Assembly
TM-357 Page 68
ST-801 870-A
Dynasty DX
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . . 126 416
. . . 2 . . . . . . . . . . . . . . . 126 415
. . . 3 . . . . . . . . . . . . . . . 138 442
. . . 4 . . . . . . . . . . . . . . +175 148
. . . . . . . . . . . . . . . . . . . . . 175 256
. . . 5 . . . . . . . . . . . . . . . 134 327
. . . 6 . . . . . PC8 . . . . . 182 188
. . . . . . . . . PLG21 . . . . 115 094
. . . . . . . . . PLG22 . . . . 115 093
. . . 7 . . . . . . . . . . . . . . . 183 613
. . . 8 . . . . . . . . . . . . . . . 182 498
. . . 9 . . . . . PC1 . . . . . 186 800
..
..
..
..
..
..
..
..
..
..
..
..
. . . 9 . . . . . PC1 . . . . . 188 730 . .
. . . 9 . . . . . PC1 . . . . . 191 395 . .
. . . . . . . . . . PLG2 . . . . 115 091 . .
. . . . . . . . . . PLG3 . . . . 115 092 . .
. . . . . . . . . . PLG4 . . . . 131 054 . .
. . . . . . . . . . PLG5 . . . . 115 091 . .
. . . . . . . . . . PLG7 . . . . 130 203 . .
. . . . . . . . . . PLG8 . . . . 115 092 . .
. . . . . . . . . . PLG9 . . . . 131 204 . .
. . . . . . . . . PLG10 . . . . 115 094 . .
. . . 10 . . . . . . . . . . . . . ♦187 461 . .
. . . 11 . . . . . T2 . . . . . . 182 846 . .
. . . 11 . . . . . T2 . . . . . . 187 574 . .
. . . 11 . . . . . T2 . . . . ♦174 981 . .
. . . 11 . . . . . T2 . . . . ♦187 757 . .
. . . . . . . . . . RC10 . . . . 166 679 . .
. . . . . . . . PLG1010 . . . 166 680 . .
. . . 12 . . . . . GS1 . . . . . 133 873 . .
. . . 13 . . . . . . . . . . . . . ♦189 033 . .
. . . 14 . . . . . CB1 . . . ♦083 432 . .
. . . 15 . . . . . CB2 . . . . . 083 432 . .
. . . 16 . . . . . . . . . . . . . . . 605 227 . .
. . . 17 . . . . . . . . . . . . . . . 182 205 . .
. . . 18 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . ♦175 282 . .
. . . 20 . . . . . . . . . . . . . . . 175 138 . .
. . . 21 . . . . . . . . . . . . . . . 182 561 . .
. . . 22 . . . . . . . . . . . . . . . 175 213 . .
. . . 23 . . . . . . . . . . . . . . . 182 445 . .
. . . 24 . . . . . . . . . . . . . . . 176 226 . .
. . . 25 . . . . . S1 . . . . . . 128 756 . .
. . . 26 . . . . . PC2 . . . . . 185 090 . .
. . . . . . . . . . . . . . . . . . . . . 176 879 . .
. . . . . . . . . PLG13 . . . . 131 204 . .
. . . . . . . . . PLG14 . . . . 115 094 . .
. . . . . . . . . . . . . . . . . . . . . 179 626 . .
. . . 27 . . . . . . . . . . . . . . +175 132 . .
. . . . . . . . . . . . . . . . . . . . . 126 026 . .
. . . 28 . . . . . . . . . . . . . . . 173 693 . .
. . . 29 . . . . . . . . . . . . . . . 176 736 . .
. . . 30 . . . . . PC3 . . . . . 189 900 . .
. . . 30 . . . . . PC3 . . . . . 189 537 . .
Dynasty DX
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, caution falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, side RH & LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSEMBLY, clamp (Eff w/KH384382 and on) . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, PC card clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg PC card clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSEMBLY, control
(Eff w/KH384382 thru KJ003564) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Eff w/KJ003565 thru KJ150395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Eff w/KJ150396 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg aux transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER, control (Prior to KJ003565) . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER, control (Eff w/KJ003565 and on) . . . . . . . . . . . . . . . .
TRANSFORMER, control (Prior to KJ003565) . . . . . . . . . . . . . . . . . . . . .
TRANSFORMER, control (Eff w/KJ003565 and on) . . . . . . . . . . . . . . . .
VALVE, 24VDC 2way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, str dx grd 2P 3W 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, 1P 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, 1P 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, .750-14 knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATE, identification rear (order by model & serial number) . . . . . . . . . .
COVER, receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOX, louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE, pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, strain relief .472/.787 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, stl locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, tgl 3PST 40A 600VAC (Power Switch) . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD, replacement kit (Eff w/KH384382 and on) . . . . . . . . . .
SCREW, M5–.8–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, mtg foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD, front panel (Eff w/KH384382 thru KJ037292)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD, front panel (Eff w/KJ037293 thru KJ150395)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
18
1
1
1
1
1
4
4
1
1
TM-357 Page 69
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly (Continued)
. . . 30 . . . . . PC3 . . . . . 191 396 . . CIRCUIT CARD, front panel (Eff w/KJ150396 and on)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . DD1-6 . . . . 186 914 . . . . LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . R5 . . . . . . 176 537 . . . . POTENTIOMETER, CP 1/T 2W 10K . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . R81-86 . . . . 182 771 . . . . POTENTIOMETER, CP 1/T .5W 10K . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . R84 . . . . . 183 316 . . . . POTENTIOMETER, CP 1/T .5W 2.5meg . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . SW1 . . . . . 173 551 . . . . SWITCH, rotary 2posn 1P 6A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . SW5 . . . . . 125 939 . . . . SWITCH, tgl DPDT .5VA 28VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG11 . . . . 115 092 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG17 . . . . 131 054 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG18 . . . . 131 054 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . FM . . . . . 175 084 . . . . MOTOR, fan 24VDC 3000RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 135 635 . . . . CONNECTOR & SOCKETS, fan motor . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . . 191 571 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . . 187 198 . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . .
. . . 34 . . . . . RC1 . . . . . 181 186 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . . 174 992 . . KNOB, pointer .840dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . . 185 703 . . RECEPTACLE, twist lock assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . . 175 855 . . DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . . . 187 235 . . RECEPTACLE, female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . C7,8 . . . . . 138 115 . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . . . . 183 332 . . KNOB, pointer .570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . . . 174 991 . . KNOB, pointer 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . . . . . . Fig 10-2 . . WINDTUNNELS w/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
6
1
5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
1
1
2
6
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Optional
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.
TM-357 Page 70
Dynasty DX
3
1
4
9
2
8
5
6
10
7
14
11
12
13
33
32
31
PC6
15
30
16
29
28
26
27-PC7
17
25
18
24
19
23
20
22
21
ST-801 871-A
Figure 10-2. Windtunnels w/Components
Dynasty DX
TM-357 Page 71
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-2. Windtunnels w/Components (Fig 10-1 Item 42)
. . . 1 . . . C11,12 . . . . 185 424
. . . 2 . . . . C9,10 . . . . 164 812
. . . 3 . . . . . HD1 . . . . . 182 918
. . . 4 . . . . . . . . . . . . . . +182 206
. . . . . . . . . . . . . . . . . . . . . 153 718
. . . . . . . . . . . . . . . . . . . . . 126 026
. . . 5 . . . R1,C5,6 . . . 175 194
. . . 6 . . . . D1,2 . . . . . 185 775
. . . 7 . . . . . . . . . . . . . . . 182 208
. . . 8 . . . . . T3 . . . . . . 182 667
. . . 9 . . . . . . . . . . . . . . . 183 073
. . . 10 . . . . . . . . . . . . . . . 182 499
. . . 11 . . . . . . . . . . . . . . . 182 806
. . . 12 . . . . C3,4 . . . . . 174 980
. . . 13 . . . W1,2,2A . . . 175 082
. . . . . . . . . . . . . . . . . . . . . 173 763
. . . 14 . . . . . T1 . . . . . . 183 014
. . . 15 . . . . . L2 . . . . . . 183 009
. . . 16 . . . . . L1 . . . . . . 187 522
. . . 17 . . . . . C1 . . . . . . 186 549
. . . 18 . . . . . . . . . . . . . . . 025 248
. . . 19 . . . . . CT1 . . . . . 175 199
. . . 20 . . . . . . . . . . . . . . . 177 547
. . . 21 . . . . . . . . . . . . . . . 175 140
. . . 22 . . . . . . . . . . . . . . . 181 197
. . . 23 . . . . . L3,4 . . . . . 175 482
. . . 24 . . . . . . . . . . . . . . . 109 056
. . . 25 . . . . . . . . . . . . . . +187 460
. . . 26 . . . . . . . . . . . . . . . 141 690
. . . 27 . . . . . PC7 . . . . . 186 807
. . . . . . . . . . . . . . . . . . . . . 188 109
. . . 27 . . . . . PC7 . . . . . 191 397
. . . . . . . . . . . F1 . . . . . . 012 633
. . . . . . . . . . . . . . . . . . . . . 188 109
. . . . . . . . . PLG19 . . . . 115 092
. . . . . . . . . PLG20 . . . . 131 054
. . . 28 . . . . . SR1 . . . . . 179 629
. . . 29 . PM1,2/PC4,5 . 179 628
. . . . . . . . . . RT1,2 . . . . 173 632
. . . 30 . . . . . . . . . . . . . . . 173 631
. . . 31 . PM3,4/PC6 . . 185 776
. . . . . . . . . PLG23 . . . . 115 091
. . . 32 . . . . . . . . . . . . . . . 182 641
. . . 33 . . . . . . . . . . . . . . . 182 642
. . CAPACITOR, filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, polyp met film 1MF 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSDUCER, current 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, PC card HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENCLOSURE, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg contactor/capacitor/PC board . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, elctlt 2700uf 420VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACTOR, def prp 40A 7P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, No. 10-32 x 1.418 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STABILIZER, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, polyp .27uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, insul .250-20 x 1.250 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, snap-in CT-mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GASKET, DI-DT rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COIL, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, scr No. 8/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, HF (Eff w/KH384382 thru KJ150395) . . . . . . . . . . . . . .
. . . . POINT, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, HF (Eff w/KJ150396 and on) . . . . . . . . . . . . . . . . . . . . .
. . . . FUSE, mintr 1A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . POINT, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT, transistor IGBT module (Eff w/KH384382 and on) . . . . . . . . . . . . . .
. . THERMISTOR, NTC 30K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT, IGBT (Eff w/KH384382 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, diode IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
2
2
1
4
1
2
1
1
2
1
1
1
1
2
1
1
1
1
1
TM-357 Page 72
Dynasty DX
TM-357A
June 1999
Processes
TIG (GTAW) Welding
Description

Dynasty DX
Eff w/ KJ150396 And Following
For OM-357 (188 291) Revision E
With Auto-Link
www.MillerWelds.com
22
21
20
SECTION 11 – PARTS LIST For KJ150396 And Following
19
31
PC1
PC8
39
39
1
20
37
38
40
36
41
2
35
3
34
33
32
FIG. 11–2 – 42
4
5
6
7
30–PC3
8
9
10
29
11
28
27
PC2
12
13
14
16
26
17
25
18
24
23
Figure 11-1.Main Assembly
TM-357 Page 74
ST-801 870-B
Dynasty DX
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . . 126 416 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . 126 415 . . CLAMP, saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . . 138 442 . . LABEL, caution falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . +175 148 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 175 256 . . INSULATOR, side RH & LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . PC8 . . . . . 182 188 . . CIRCUIT CARD ASSEMBLY, clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG21 . . . . 115 094 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . . . 183 613 . . INSULATOR, PC card clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . . 182 498 . . BRACKET, mtg PC card clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . PC1 . . . . . 191 395 . . CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG2 . . . . 115 091 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . ♦187 461 . . BRACKET, mtg aux transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . T2 . . . . . . 187 574 . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . T2 . . . . ♦187 757 . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC10 . . . . 166 679 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . GS1 . . . . . 133 873 . . VALVE, 24VDC 2way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . ♦189 033 . . RECEPTACLE, str dx grd 2P 3W 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . CB1 . . . ♦083 432 . . CIRCUIT BREAKER, 1P 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . . 605 227 . . NUT, .750-14 knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . . 182 205 . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, identification rear (order by model & serial number) . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . ♦175 282 . . COVER, receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . . 175 138 . . BOX, louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . . 182 561 . . CABLE, pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . . 175 213 . . BUSHING, strain relief .472/.787 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . . 182 445 . . NUT, stl locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . . 176 226 . . INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . S1 . . . . . . 128 756 . . SWITCH, tgl 3PST 40A 600VAC (Power Switch) . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . PC2 . . . . . 185 090 . . CIRCUIT CARD, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 176 879 . . SCREW, M5–.8–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 179 626 . . BUS BAR, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . +175 132 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 126 026 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . . 173 693 . . FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . . 176 736 . . SCREW, mtg foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . PC3 . . . . . 191 396 . . CIRCUIT CARD, front panel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . DD1-6 . . . . 186 914 . . . . LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . R5 . . . . . . 176 537 . . . . POTENTIOMETER, CP 1/T 2W 10K . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . R81-86 . . . . 182 771 . . . . POTENTIOMETER, CP 1/T .5W 10K . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . R84 . . . . . 183 316 . . . . POTENTIOMETER, CP 1/T .5W 2.5meg . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . SW5 . . . . . 125 939 . . . . SWITCH, tgl DPDT .5VA 28VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG17, 18 . . 131 054 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dynasty DX
2
2
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
18
1
1
1
1
1
4
4
1
6
1
5
1
1
1
1
1
1
1
2
TM-357 Page 75
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 31 . . . . . FM . . . . . 175 084 . .
. . . . . . . . . . . . . . . . . . . . . 135 635 . .
. . . 32 . . . . . . . . . . . . . . . 191 571 . .
. . . 33 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . RC1 . . . . . 188 186 . .
. . . . . . . . . . . . . . . . . . . ♦191 302 . .
. . . 35 . . . . . . . . . . . . . . . 174 992 . .
. . . 36 . . . . . . . . . . . . . . . 185 703 . .
. . . 37 . . . . . . . . . . . . . . . 175 855 . .
. . . 38 . . . . . . . . . . . . . . . 187 235 . .
. . . 39 . . . . C7,8 . . . . . 186 543 . .
. . . 40 . . . . . . . . . . . . . . . 183 332 . .
. . . 41 . . . . . . . . . . . . . . . 174 991 . .
. . . 42 . . . . . . . . . . . . . . . Fig 11-2 . .
MOTOR, fan 24VDC 3000RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . .
CONNECTOR & SOCKETS, 10-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB, pointer .840dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, twist lock assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB, pointer .570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB, pointer 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDTUNNELS w/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
4
2
1
1
2
6
1
1
♦Optional
3
1
4
9
2
8
5
6
10
7
14
11
12
13
33
32
31
15
30
16
29
27
28
26
17
25
18
24
19
23
20
22
21
ST-801 871-A
Figure 11-2.Windtunnels w/Components
TM-357 Page 76
Dynasty DX
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Windtunnels w/Components (Fig 11-1 Item 42)
. . . 1 . . . C11,12 . . . . 185 424 . . CAPACITOR, filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . C9,10 . . . . 164 812 . . CAPACITOR, polyp met film 1MF 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . HD1 . . . . . 182 918 . . TRANSDUCER, current 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . +182 206 . . WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 153 718 . . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 126 026 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . R1,C5,6 . . . 175 194 . . RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . D1,2 . . . . . 185 775 . . KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 182 208 . . HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . T3 . . . . . . 182 667 . . TRANSFORMER, coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 183 073 . . INSULATOR, PC card HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 182 499 . . ENCLOSURE, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 182 806 . . BRACKET, mtg contactor/capacitor/PC board . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . C3,4 . . . . . 174 980 . . CAPACITOR, elctlt 2700uf 420VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . W1,2,2A . . . 175 082 . . CONTACTOR, def prp 40A 7P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 173 763 . . STAND-OFF, No. 10-32 x 1.418 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . T1 . . . . . . 183 014 . . TRANSFORMER, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . L2 . . . . . . 183 009 . . STABILIZER, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . L1 . . . . . . 187 522 . . INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . C1 . . . . . . 186 549 . . CAPACITOR, polyp .27uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 025 248 . . STAND-OFF, insul .250-20 x 1.250 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . CT1 . . . . . 175 199 . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . 177 547 . . BUSHING, snap-in CT-mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 175 140 . . BRACKET, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . 181 197 . . GASKET, DI-DT rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . L3,4 . . . . . 175 482 . . COIL, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . . . 109 056 . . CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . . +187 460 . . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 141 690 . . GROMMET, scr No. 8/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 27 . . . . . PC7 . . . . . 191 397 . . CIRCUIT CARD, HF (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F1 . . . . . . 012 633 . . . . FUSE, mintr gl 1A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 188 109 . . . . POINT, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG19 . . . . 115 092 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . SR1 . . . . . 179 629 . . KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . PM1,2/PC4,5 . 179 628 . . KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RT1,2 . . . . 173 632 . . THERMISTOR, NTC 30K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 30 . . . . . . . . . . . . . . . 173 631 . . HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . PM3,4/PC6 . . 185 776 . . KIT, IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . 182 641 . . BUS BAR, diode IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . 182 642 . . BUS BAR, IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Dynasty DX
TM-357 Page 77
Call
1-800-4-AMILLER
for your local
Miller distributor.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
Phone: 920-735-4505
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1625-525556
FAX: 44 (0) 1625-537553
PRINTED IN USA
 1998 Miller Electric Mfg. Co.

TM-357A, Dynasty DX

Transcription

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