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Weird problems with DX 300, Low power, no HF start


Tue, 22 Nov 2022 07:51:24 GMT
Ever since I used my Dynasty for Stick welding, it has acted kind of weird... when welding in AC (aluminum), it doesn't always start in HF mode. Welding 1/8" aluminum in lift arc works OKI recently got a job to weld 1/4" aluminum, so I've been trying to dial it in, but again, really weird. Specifically:Weak power... not enough amps to form a puddle on 1/4" alum, even at 300 amps.HF start won't work at all.Lift arc only works sometimes, and when it doesn't work, it's because it's kind of stuck in post gas flow (after welding has stopped, and after post flow ends, and then the arc is attempted, nothing happens and the post flow light is lit).When a good arc is started, there is no pedal control.When the machine is turned on, the left panel reads, 19.6, and the right panel reads 597When welding, the left panel reads volts, and the right panel always reads 500Settings are:Water cooled torchRed tungsten (3/32", tried gold too)#5 cup with gas lens20 CFH Argonpre flow .8post flow 4.0set to HF modefrequency 60AC balance 75%Amps 290remote enabledKind of seems like a bad remote pedal, but what is up the 500 reading on the amps panel?Are there some settings I'm missing?Thanks!Last edited by Acidrain; 04-29-2012 at 01:13 AM.Hobart BetaMig 250Miller Dynasty 200DX
Reply:Also...I just checked to see if I was locked out of perameter changes by pressing memory 3 & 4 while turning on machine. Shows L-0 for no lockout.Hobart BetaMig 250Miller Dynasty 200DX
Reply:If you're not getting any error codes (sounds like you're not), then the first thing I'd try is a "system reboot".  Should be covered in your owners manual.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:I've been looking for a reboot or factory settings proceedure, but can't find anything for this particular model: http://www.millerwelds.com/om/o358b_mil.pdf Anybody link me to a hidden menu?Hobart BetaMig 250Miller Dynasty 200DX
Reply:Acidrain,You're right, I couldn't find the "reset instructions" for the 300DX.For the Dynasty 200DX, to reset the unit to Factory Default Settings, you turn the machine on, then press the Process, Output, and Adjust switch pads before the software version clears the meters, and hold the switch pads until the software version clears the meters.These instructions can be found on page 37 of the Dynasty 200DX Owners Manual.You may also want to PM Cruizer.  I'm sure he has a Service Manual that goes into more detail.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Thanks, I'll PM him.Going to try an experiment... use remote pinout A & B with a switch and try using the 4T start method. The more I think about it, the more it seams like a bad remote.Hobart BetaMig 250Miller Dynasty 200DX
Reply:Hmmm... that didn't change anything, so it's deffininely not the remote pedal.Hobart BetaMig 250Miller Dynasty 200DX
Reply:I called Miller today and talked to a tech... nice guy.First, there is no reset for this machine. Second, he confirmed my worst fears... it sounds like it needs to be diagnosed and repair by an inverter tech. Yikes, the LWS guys in my area are idiots. Last time I ordered some Ti rod, they actually looked me in the eye and asked, "what's that for"? Here's your sign.The good news is Miller knew of a top quality tech in my area, so I called him.Got my machine pried out of the welding cart and loaded up for service. I'll post results when I have them.Hobart BetaMig 250Miller Dynasty 200DX
Reply:Good luck,If you were closer to VA, I've got a "Top Notch" service facility that takes care of my needs.  One of Miller's "higher rated" techs.As well as I remember, the Dynasty 300 DX went thru three major revisions when it was in production.  According to the owner's manual you linked, think your's is the later version which was the most reliable (according to my tech).  Hope it's nothing serious.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Your repair tech will thank you for removing the welder from the cart.You would not believe how many welders I get, that have frames welded around the welder.AND to the welder.That has to be cut off, before the cover can be removed. Then the owner complains about the trouble shooting and repair time.
Reply:
Weird problems with DX 300, Low power, no HF start
Originally Posted by ccawgc
Weird problems with DX 300, Low power, no HF start
Your repair tech will thank you for removing the welder from the cart.You would not believe how many welders I get, that have frames welded around the welder.AND to the welder.That has to be cut off, before the cover can be removed. Then the owner complains about the trouble shooting and repair time.
Reply:Here's the rsults of the diagnosis:They found two open buss resistors on PC-2. Replaced those and ran a operational/load test... same results.They recommend replacement of the PC-1 control board, PC-8 clamp board, and pc-7 HF board.Estimate for the work is $3,467 including local sales tax. Yikes!
Weird problems with DX 300, Low power, no HF start
I can find the parts (genuine, new Miller parts) on line for less than $2K.I'm not inept. I understand the dangers of capacitors, etc).It would be a big gamble, but what do you guys think? Is this something I can do myself?As a side note, to finish the jobs I had in the door, I rented a 200 DX. I must say, I'm very impressed with the power. I didn't expect to weld 1/4" aluminum with a welder that only weighs 45 lbs.My LWS has a brand new, two year warranty 200 DX for $3200.So My options are: buy a new 200DX, or fix my old 300DX (buying a new 350DX is not an option).Opinions?Hobart BetaMig 250Miller Dynasty 200DX
Reply:
Weird problems with DX 300, Low power, no HF start
Originally Posted by Acidrain
Weird problems with DX 300, Low power, no HF start
Here's the rsults of the diagnosis:They found two open buss resistors on PC-2. Replaced those and ran a operational/load test... same results.They recommend replacement of the PC-1 control board, PC-8 clamp board, and pc-7 HF board.Estimate for the work is $3,467 including local sales tax. Yikes!
Weird problems with DX 300, Low power, no HF start
I can find the parts (genuine, new Miller parts) on line for less than $2K.I'm not inept. I understand the dangers of capacitors, etc).It would be a big gamble, but what do you guys think? Is this something I can do myself?As a side note, to finish the jobs I had in the door, I rented a 200 DX. I must say, I'm very impressed with the power. I didn't expect to weld 1/4" aluminum with a welder that only weighs 45 lbs.My LWS has a brand new, two year warranty 200 DX for $3200.So My options are: buy a new 200DX, or fix my old 300DX (buying a new 350DX is not an option).Opinions?
Reply:Acidrain,That sucks.  Think I'd have to get another opinion from a second service facility (or maybe Cruizer or ccawgc will respond).Frankly, that sounds like a lot of labor to replace those boards.While I love my Dynasty 200, it can't hold a candle to my buddy's Dynasty 300 DX as far as amps/duty cycle for welding aluminum.  As crab fisherman indicated the new Dynasty 280 DX is due out soon.  The prelim specs look very good.  Has a slightly higher rating (in one phase power) than the Dynasty 300.Keep us posted about what you decide.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Wow, I think I may have just been slipped a bigger mess than I can handle.I have been looking for a tig welder and thought i was getting one hell of a deal on this auction....http://www.ebay.com/itm/ws/eBayISAPI...EOIBSA:US:3160but as you can see the poster left out all the details that he was kind enough to post here. He also didnt mention that the lift arc only works sometimes.Awesome..... I am going to have a pile of junk sitting at home when I get back from this deployment.
Reply:When spending that amount on an older machine. Keep this in mind.You only get a 90 day warranty Miller warranty on the parts IF they are installed by a miller authorized shop. No warranty if self installed. A new machine will have a three year warranty.These inverters are near impossible to trouble shoot with out hands on testing.
Reply:If you found this thread and actually read it, you would see that the foot pedal control was eliminated as a problem.If you read the listing, I was completely honest in my description.It is being sold as "non working, for parts or repair".The fact is, it welds fine by scratch starting, the foot pedal works fine, and the frequency controls work.The only things it doesn't do is HF start (including lift arc), and it welds at low amperage (I'm guessing 120amps).The pictures of it welding were taken right before being listed (they are date stamped). It starts and welds everytime. How is this being deceitful?Sounds like buyers remorse to me. You never asked me any questions. Why not? I always ask questions when bidding on ebay.How the do you think you're getting a "hell of a deal" on a welder that is listed as needing repairs? It's a gamble. You buy this machine for $1075, you buy $2000 worth of parts, or better yet, pay a guy to repair the boards (they will warrant their work), and you have a 300 DX for less than $3500.Last used 300 DX I saw sold for over $4500.Am I missing something?Hobart BetaMig 250Miller Dynasty 200DX
Reply:I just got off the phone with ebay. If you guys are following along, here's what is going on...Some ebay user name sdc0163420 (probably somebody from here) found my ebay listing, and felt that I did not accurately describe my listing (didn't bother reading through this entire thread or my PMs from experts).sdc0163420 contacted my buyer, and warned them that the welder needed a lot of work (duh, that's what I said).The buyer backed out of the deal. I'm not too upset about that... whatever.However, I did report sdc0163420 to ebay for breaking the rules.sdc0163420 has a rating of 15 with 100% positive, while I only have a rating of 423 with 100% positive. I guess he feels he needs to save the world from criminals like me.Yes more people looking out for us is what we need... must be a democrat.sdc0163420, take care of your own ****. If you have the balls to respond, I'll post up your ebay message to me, and I'll show you where you're wrong.Hobart BetaMig 250Miller Dynasty 200DX
Reply:Hello, I a looking at buying a miller 300dx which powers on but does not get enough voltage to weld. Do you know if this is repairable and if so which pc board may be the issue? The serial is lf31...... Thanks.
Reply:
Weird problems with DX 300, Low power, no HF start
Originally Posted by Fred4321
Weird problems with DX 300, Low power, no HF start
Hello, I a looking at buying a miller 300dx which powers on but does not get enough voltage to weld. Do you know if this is repairable and if so which pc board may be the issue? The serial is lf31...... Thanks.

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