Pulse | 280 | User manual | Pulse 280 User manual

Issued Dec. 2014 • Index No. DC/35.0
Maxstar 280 Series
®
Quick
Specs
Industrial Applications
Processes
Precision Fabrication
Petro Chemical
Aerospace
Food/Beverage Industry
Dairy
Shipboard
DC TIG (GTAW)
Pulsed TIG (GTAW-P)
Stick (SMAW)
Air Carbon Arc (CAC-A)
TIG/Stick Welding
Power Source
Input Power 208 – 575 V, 3- or 1-Phase Power
Amperage Range 1 – 280 A (DC)
Rated Output 200 A at 28 V, 60% Duty Cycle
Net Weight 47 lb. (21.3 kg)
Update and expand. Front panel
memory card data port provides
the ability to easily update software
and expand product features.
DC TIG Features
Pulse. Pulsing can increase
puddle agitation, arc stability
and travel speeds while reducing
heat input and distortion. DX
models provide extended ranges.
Visit MillerWelds.com/TIGSoftware
for the latest software updates
and expansions.
Pro-Set™ eliminates the guesswork
when setting weld parameters.
Use Pro-Set when you want the
speed, convenience and confidence
of preset controls. Simply select
the feature and adjust until Pro-Set
appears on the display.
Exceptionally smooth and
precise arc for welding exotic
materials.
DC Stick Features
Sleep timer conserves electricity.
This programmable feature will power
down the machine if it sits idle for a
specific time.
Maxstar 280
Allows for any input voltage hookup
(208 – 575 V) with no manual linking,
providing convenience in any job setting.
Ideal solution for dirty or unreliable power.
Cooler Power Supply (CPS). An
integrated 120-volt dedicated-use
receptacle to power the Coolmate™ 1.3.
The power switch on the Maxstar also
activates the receptacle to help prevent
torch failure. Available on select models,
see page 6.
Maxstar 280 DX
Dual schedule allows operators
to switch welding parameters
for specific electrodes without
readjusting the machine,
minimizing downtime and
enhancing quality. Base model
only (not DX).
Wind Tunnel Technology™ protects internal electrical
components from airborne contaminates, extending the
product life.
DIG control allows the arc
characteristics to be changed
for specific applications and
electrodes. Lower the DIG
setting for smooth running
electrodes like E7018 and
increase the DIG setting for
stiffer, more penetrating
electrodes like E6010.
Fan-On-Demand™ power source cooling system operates
only when needed, reducing noise, energy use and the
amount of contaminants pulled though the machine.
Hot Start™ adaptive control
provides positive arc starts
without sticking.
Meter calibration allows digital meters to be calibrated
for certification.
Stick-Stuck detects if the
electrode is stuck to the part
and turns the welding output
off to safely and easily remove
the electrode. Menu selectable.
Blue Lightning™ high-frequency (HF)
arc starter for non-contact arc initiation.
Provides more consistent arc starts and
greater reliability compared to traditional
HF arc starters.
Power source is warranted for 3 years, parts and labor.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
An ITW Company
1635 West Spencer Street
P.O. Box 1079
Appleton, WI 54912-1079 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
MillerWelds.com
Specifications (Subject to change without notice.)
Welding
Mode
Input
Power
Welding
Amperage
Range
TIG
(GTAW)
3-phase
1–280 A
235 A at 19.4 V,
60% duty cycle
17
15
9
7
6
6.2
6.0
1-phase
1–280 A
235 A at 19.4 V,
60% duty cycle
28
26
15
13
10
6.0
6.0
3-phase
5–280 A
200 A at 28 V,
60% duty cycle
20
18
10
9
7
7.2
7.0
1-phase
5–280 A
180 A at 27.2 V,
60% duty cycle*
30
27
15
13
10
6.2
6.2
Stick
(SMAW)
Rated Output
Max. OpenCircuit
Voltage
Amps Input at Rated Load Output, 50/60 Hz
208 V 230 V 400 V 460 V 575 V KVA KW
Dimensions
H: 13.6 in. (346 mm)
W: 8.6 in. (219 mm)
D: 22.5 in. (569 mm)
60 VDC
(11 VDC**)
Net
Weight
47 lb.
(21.3 kg)
50 lb.
(22.7 kg)
with CPS
*Refer to owner’s manual for 208 V output ratings and duty cycle. **Low OCV sense voltage for Stick and Lift-Arc ™ TIG.
IP23 rating — This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless sheltered.
Operating temperature range is 14 to 104° F (-10 to 40° C). Storage temperature range is -22 to 149° F (-30 to 65° C). Portions of the preceding text are contained in
EN 60974-1: “Welding power sources for arc welding equipment.”
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
All CE models conform to the applicable parts of the IEC 60974 series of standards.
Performance Data
Input
Power
TIG (GTAW)
Duty Cycle
Stick (SMAW)
Duty Cycle
DC TIG Material
Thickness Range
Stick Electrode
Maximum Diameter
Carbon Arc Gouging
(CAC-A) Maximum
Generator
Requirement
3-phase
280 A, 25%
235 A, 60%
200 A, 100%
280 A, 15%
200 A, 60%
160 A, 100%
.004 – 3/8 in.
6010: 1/4 in.
7018: 7/32 in.
7024: 3/16 in.
3/16 in.
12.5 kW
1-phase*
280 A, 25%
235 A, 60%
200 A, 100%
280 A, 10%
180 A, 60%
160 A, 100%
*Refer to owner’s manual for 208 V output ratings and duty cycle.
Coolmate 1.3 Cooler
™
• Maxstar® models with CPS turn Coolmate 1.3
on and off
• Power indicator light
• Fluid level sight window
• Rustproof polyethylene-molded coolant tank
and filler spout
• 1/4-HP motor is thermally protected to guard
against overheating
2
• Efficient fin and tube heat exchanger
• Factory-set pressure relief valve (55 PSI)
maintains consistent pressure during operation
• Filter and coolant filling spout are conveniently
located
• Brass-body, positive displacement rotary vane
pump provides consistent coolant flow and
pressure rating with long pump-life expectancy
Input Power
Maximum Current Draw
Maximum Cooling Capacity
Rated Cooling Capacity
Tank Capacity
Dimensions
Net Weight
115 VAC,
60 Hz
4.7 A (60 Hz)
3400 W (11,600 BTU/hr.)
3.8 qt./min. (1.7 L/min.)
1330 W (4540 BTU/hr.)
1.1 qt./min. (1 L/min.)
1.3 gal. (4.9 L)
H: 11.25 in. (286 mm)
W: 10.375 in. (264 mm)
D: 24 in. (610 mm)
43 lb.
(20 kg)
Weldcraft W-280 (WP-280) TIG Torch
™
• Two-piece torch head and exclusive Super Cool™
Technology provides additional surface area to
increase cooling efficiency and capacity
• Torch body includes an anti-rotation feature
and multi-position locking to prevent handle
movement during welding and improve
operator control
• Secure mechanical fittings and connections
minimize leakage
Cooling Method
AC Rating
DC Rating
Consumables
Electrode Range
Cable
Water-cooled
195 A, 100% duty cycle
280 A, 100% duty cycle
13N
.020–1/8 in. (0.5–3.2 mm)
Three-piece
TIG Upgrade Chart
Why Upgrade?
Thickness Capacity
Syncrowave 250 UPGRADE Maxstar 280 UPGRADE Maxstar 280 DX Maxstar 280 Benefits
.012 – 3/8 in. Steel
.004 – 3/8 in. Steel
Duty Cycle
200 A, 60%
235 A, 60%
Arc Starting
HF and Lift-Arc™
Blue Lightning™ HF and Lift-Arc™
Precision Controls
Digital and Dial %
All Digital
Precise adjustments can be made with all-digital controls
for greater quality control and repeatability.
Trial and Error
Pro-Set™ eliminates the guesswork when
setting weld parameters.
Select the feature and adjust until Pro-Set appears in
display. Pro-Set is available for Pulse and DIG parameters.
Confusion on Where
to Set the Controls?
The Maxstar 280 has a lower bottom end and can weld
thinner metals.
Weld longer at higher amperages. At 200 A the
Maxstar 280 can weld continuously.
Blue Lightning arc starting is tailored for each tungsten
size to produce perfect starts.
Pulser
Optional Field Kit
0.25 – 10 PPS
Portability
378 lb. (172 kg)
Crane or Cart
47 lb. (21.3 kg)
Carry or Cart
Manual Link, 208/230/460 V
1-Phase Only
Auto-Line™, 208 – 575 V
1-Phase or 3-Phase
Auto-Line allows the unit to operate on any voltage.
1- or 3-phase. Even generators!
77 A, 230 V, 1-Phase
21 A, 230 V, 1-Phase
13 A, 230 V, 3-Phase
Line requirement to operate is much less. Smaller
electrical service needed, smaller breaker/fuses and
power cord.
Power Flexibility
Line Draw at
200 Amps
Easy pulse with
Pro-Set, .01 – 250 PPS
Full featured with
Pro-Set, .01 – 500 PPS
Higher speed pulse provides better arc control and faster
travel speeds.
Easier to move because of size and weight. Don’t have to
wait for a crane operator.
3
Maxstar 280 Control Panel
®
7
1
8
2
9
3
4
10
5
11
12
6
13
1. Standby Switch
7. Memory Card Port
2. Voltmeter Display
8. Activity Indicator
3. Ammeter Display
9. Encoder Control
4. Output Contactor “On” Indicator
10. Menu Ranges
5. DC TIG (HF Start) Process Menu Parameters
Amperage
1– 280 A**
Pulse*
Off – 250 PPS
Postflow
Auto/Off – 50 seconds
11. DC TIG (Lift-Arc) Process Menu Parameters
Amperage
1 – 280 A**
Pulse*
Off – 250 PPS
Postflow
Auto/Off – 50 seconds
6. DC Stick (Schedule 1) Process Menu Parameters
Amperage
5 – 280 A
DIG*
Off –100%
12. DC Stick (Schedule 2) Process Menu Parameters
Amperage
5 – 280 A
DIG*
Off –100%
13. Process Selector
*Pro-Set parameter selectable. **Amperage range is tungsten size dependent.
User Menu (Hold Menu button three seconds.)
Tech Menu (Hold Menu button five seconds.)
DC TIG (HF Start)
1. Tungsten Size = .020 –1/8 in. or .05 – 3.2 mm
2. Remote Trigger = STD/HOLD/OUTPUT ON
1. Arc Time
DC TIG (Lift-Arc)
1. Tungsten Size = .020 –1/8 in. or .05 – 3.2 mm
2. Remote Trigger = STD/HOLD/OUTPUT ON
DC Stick (Schedule 1 and 2)
1. Hot Start = ON/OFF
2. Remote Trigger = OUTPUT ON/HOLD/STD
4
0.0 – 9999 hours
0.0 – 59 minutes
0 – 999,999 cycles
Resettable
2. Error Log = Error event recorder
3. Sleep Timer = 1/5/10/15/30/45MIN/1HR
4. Stick Stuc = OFF/ON
5. OCV = LOW/NORM
6. Cooler Power = AUTO/OFF (only on Maxstar models with CPS )
7. Machine Reset
8. Software Number
9. Serial Number
Maxstar 280 DX Control Panel
®
1
7
8
2
9
3
10
4
11
5
6
12
1. Standby Switch
7. Memory Card Port
2. Voltmeter Display
8. Activity Indicator
3. Ammeter Display
9. Encoder Control
4. Process/
Arc Starting
TIG: HF Impulse, Lift-Arc
STICK: Adaptive Hot Start
5. Output Control
Standard Remote,
2T Trigger Hold,
Output ON
6. Pulser Control
Pulses per Second* DC: 0.1 – 500 PPS
Peak Time*
5 – 95%
Background Amps* 5 – 95%
10. Amperage Button
11. Gas/DIG
Preflow
Postflow
DIG*
0.0 – 25.0 seconds
Auto/Off – 50 seconds
Off –100%
12. Sequencer Control
Initial Amps
1– 280 A
Initial Slope
0.0 – 25.0 seconds
Weld Time
0.0 – 999 seconds
Final Slope
0.0 – 25.0 seconds
Final Amps
1– 200 A
*Pro-Set parameter selectable.
User Menu (Press Gas and Amperage buttons.)
Tech Menu (Hold Gas and Amperage buttons five seconds.)
1. Tungsten Size = .020 –1/8 in./GEN or .05 – 3.2 mm
2. Remote Trigger = 3T/4T/4TL/4TLE
3. Stick Hot Start = ON/OFF
1. Arc Time
0.0 – 9999 hours
0.0 – 59 minutes
0 – 999,999 cycles
Resettable
2. Error Log = Error event recorder
3. Sleep Timer = 1/5/10/15/30/45MIN/1HR
4. Stick Stuc = OFF/ON
5. OCV = LOW/NORM
6. Cooler Power = AUTO/OFF (only on Maxstar models with CPS )
7. Weld Timers = OFF/ON
8. Locks = OFF/1– 4
9. Meter Display
10. External Pulse Control = OFF/ON
11. Machine Reset
12. Software Number
13. Serial Number
5
Maxstar 280 Models/Packages
®
Build an Air-Cooled Package
Select desired stock number for each step.
#907 552
Maxstar shown.
#195 055
kit shown.
Step #1 • Select Maxstar
Maxstar 280
Maxstar 280 with CPS
Maxstar 280 DX
Maxstar 280 DX with CPS
#907 552
#907 538
#907 553
#907 539
Step #2 • Select Contractor Kit
Note: For models without the Cooler Power
Supply (CPS), the Coolmate 1.3 must
be powered through an external 120-volt
facility power.
Maxstar comes with adjustable shoulder strap, 8-ft. power cord (no plug)
and two 50-mm Dinse-style connectors.
Foot Control Contractor Kit
Fingertip Control Contractor Kit
#195 054
#195 055
See page 7 for kit contents.
Build a Water-Cooled Package
Select desired stock number for each step.
#907 538 002
Maxstar 280
TIGRunner® shown
with four bottles
of #043 810
Low-Conductivity
Coolant.
#194 744 remote shown.
Step #1 • Select Maxstar TIGRunner® and Coolant
6
#300 990 kit shown.
Step #2 • Select Remote Control
Maxstar 280 (with CPS) TIGRunner
#907 538 002
Maxstar 280 DX (with CPS) TIGRunner #907 539 001
&
Low-Conductivity Coolant
#043 810
(must be ordered in quantities of 4)
Wireless Foot
RFCS-14 HD Foot
RCC-14 E/W Fingertip
RCCS-14 N/S Fingertip
RMS-14 Pushbutton
RMLS-14 Momentary/Maintained
RHC-14 Hand
Wireless Hand
Maxstar TIGRunner comes with 8-ft. power cord (no plug),
two 50-mm Dinse-style connectors, Coolmate™ 1.3 and
Small Runner™ cart.
See page 7 for remote descriptions.
#300 429
#194 744
#151 086
#043 688
#187 208
#129 337
#242 211 020
#300 430
Step #3 • Select Torch Kit
W-250 (WP-20) Kit
W-280 (WP-280) Kit
(recommended)
W-375 Kit
See page 7 for kit contents.
#300 185
#300 990
#301 268
Genuine Miller Accessories
®
Weldcraft™ A-200 (WP-26)
TIG Torch
#WP-26-12-R (12 ft.)
#WP-26-25-R (25 ft.)
200-amp air-cooled torch.
Torch body gas valve
models also available.
Small Runner™ Cart #300 988
Designed for Dynasty or
Maxstar 280 with or without a
Coolmate 1.3 cooler. Cart features
single cylinder rack, foot pedal
holder, two cable/torch holders,
and two TIG filler holders.
Note: A-200 (WP-26) torches require #195 379 connector.
Coolmate™ 1.3
#300 972 120 VAC
1.3-gallon cooler designed to
cool torches up to 280 amps.
Performance TIG Gloves
#263 345 X-Small (Women’s)
#263 346 Small (Women’s)
#263 347 Medium
#263 348 Large
#263 349 X-Large
Completely unlined, goat grain leather with
triple-padded palm.
Memory Card (Blank) #301 080
A blank, commercially available memory card used
for transferring software updates and expandable
features from your computer to the machine.
Memory Card Expansion
#301 151 14-Pin Automation Expansion
Provides the ability to access common automation
functions through the 14-pin connection.
#301 152 14-Pin Modbus® Expansion
Provides the ability to access basic and advanced
functions through the 14-pin connection.
TIG Torches, Kits and Connectors
Contractor Kits
#195 054 150 A RFCS-14 HD Foot Pedal Kit
#195 055 150 A RCCS-14 Fingertip Kit
All-in-one TIG/Stick welding kit comes with
either a RFCS-14 HD foot control or RCCS-14
fingertip control, Weldcraft™ A-150 TIG torch,
200-amp Stick electrode holder with 15-foot
(4.6 m) cable, 300-amp work clamp with
15-foot (4.6 m) cable, flow gauge regulator with
12-foot (3.7 m) gas hose, gas hose coupler,
AK2C torch accessory kit, TIG torch connector,
and protective carrying case.
Air-Cooled TIG Torch
Connectors
#195 379 A-200 (WP-26)
#195 378* All others
50-mm Dinse-style for one-piece air-cooled torch.
*A-80 (WP-24) torches require 24-5 connector.
Water-Cooled Torch Kits
#300 185 W-250 (WP-20)
#300 990 W-280 (WP-280) (recommended)
#301 268 W-375
Kit comes with Weldcraft™ 25-foot (7.6 m)
TIG torch with Dinse-style connector, torch
cable cover, work clamp with 15-foot (4.6 m)
cable, flowmeter regulator with gas hose and
torch accessory kit (1/16-, 3/32- and 1/8-inch
2% ceriated tungsten, nozzles, collets and
collet bodies).
Water-Cooled TIG Torch
Connector #195 377
50-mm Dinse-style with
water return line. For use with all Weldcraft™
water-cooled torches.
Remote Controls and Switches
Wireless Remote Foot
Control #300 429
For remote current and
contactor control. Receiver
plugs directly into the 14-pin
receptacle of Miller machine. 90-foot (27.4 m)
operating range.
RFCS-14 HD Foot Control
#194 744
Maximum flexibility is accomplished with a reconfigurable
cord that can exit the front,
back or either side of the pedal. Foot pedal
provides remote current and contactor control.
Includes 20-foot (6 m) cord and 14-pin plug.
RCC-14 Remote Contactor and
Current Control #151 086
East/west rotary-motion fingertip control
attaches to TIG torch using two hook-and-loop
fasteners. Includes 26.5-foot (8 m) control cord
and 14-pin plug.
RCCS-14 Remote Contactor and
Current Control #043 688
North/south rotary-motion fingertip control
attaches to TIG torch using two hook-and-loop
fasteners. Includes 26.5-foot (8 m) cord and
14-pin plug.
RMS-14 On/Off Control
#187 208
Momentary-contact switch for contactor
control. Rubber-covered pushbutton dome
switch ideal for repetitive on-off applications.
Includes 26.5-foot (8 m) cord and 14-pin plug.
RMLS-14 Switch #129 337
Momentary- and maintainedcontact rocker switch for contactor control.
Push forward for maintained contact and
backward for momentary contact. Includes
26.5-foot (8 m) cord and 14-pin plug.
RHC-14 Hand Control
#242 211 020
Miniature hand control for
remote current and contactor
control. Dimensions: 4 x 4 x
3.25 inches (102 x 102 x 83 mm). Includes
20-foot (6 m) cord and 14-pin plug.
Wireless Remote Hand Control
#300 430
For remote current and contactor
control. Receiver plugs directly
into the 14-pin receptacle of
Miller machine. 300-foot
(91.4 m) operating range.
Educational Materials
To order, please call Miller Literature at 866-931-9732
or visit MillerWelds.com/resources/tools.
Gas Tungsten Arc Welding (TIG) Publication
#250 833
Setup DVD #251 116
Video topics include tungsten selection, setup
menus, DC pulse, sequencer, balance and
frequency settings.
Tungsten
Tungsten
Amp Range
2% Ceriated (AC/DC)
2% Lanthanated (AC/DC)
1/16 in. (1.6 mm)
70 –150 A
WC116X7
WL2116X7
3/32 in. (2.4 mm)
140 – 250 A
WC332X7
WL2332X7
1/8 in. (3.2 mm)
225 – 400 A
WC018X7
WL2018X7
5/32 in. (4.0 mm)
300 – 500 A
WC532X7
WL2532X7
7
Ordering Information
Equipment and Options
Stock No.
Description
Qty.
Maxstar® 280
#907 552
Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8-ft. power cord
Maxstar® 280 with CPS
#907 538
Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8-ft. power cord
Maxstar® 280 DX
#907 553
Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8-ft. power cord
Maxstar® 280 DX with CPS
#907 539
Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8-ft. power cord
Maxstar® 280 (with CPS) TIGRunner®
#907 538 002
Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8-ft. power cord
(Torch kit, accessories and coolant sold separately.)
Maxstar® 280 DX (with CPS) TIGRunner®
#907 539 001
Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8-ft. power cord
(Torch kit, accessories and coolant sold separately.)
Water-Cooled Packages
Accessories
Small Runner™ Cart
#300 988
Coolmate™ 1.3
#300 972
120 VAC, 60 Hz, CSA. Requires coolant
TIG Coolant (Must be ordered in quantities of 4)
#043 810
1-gallon plastic bottle. Protects against freezing to
-37° Fahrenheit (-38° C) or boiling to 227° Fahrenheit (108° C)
TIG Gloves
See page 7
Memory Card (Blank)
#301 080
Memory Card Expansion
#301 151
#301 152
14-pin automation expansion
14-pin Modbus® expansion
Air-Cooled Contractor Kits
#195 055
#195 054
Fingertip
Foot pedal
Weldcraft™ A-150 (WP-17) TIG Torch
#WP-17-12-R
#WP-17-25-R
12-ft. (3.7 m) cable. Requires #195 378 connector
25-ft. (7.6 m) cable. Requires #195 378 connector
Weldcraft™ A-200 (WP-26) TIG Torch
#WP-26-12-R
#WP-26-25-R
12-ft. (3.7 m) cable. Requires #195 379 connector
25-ft. (7.6 m) cable. Requires #195 379 connector
Air-Cooled TIG Torch Connectors
#195 379
#195 378
Connects Weldcraft™ A-200 (WP-26) torch to Dinse-style connector
Connects all air-cooled Weldcraft™ torches (except A-200) to
Dinse-style connector. A-80 (WP-24) torches require 24-5 connector
Water-Cooled Torch Kits
#300 185
#300 990
#301 268
W-250 (WP-20)
W-280 (WP-280) (recommended for Maxstar 280)
W-375
Water-Cooled TIG Torch Connector
#195 377
Connects Weldcraft™ water-cooled torches to Dinse-style connector
TIG Torches, Kits and Connectors
Tungsten
See page 7
Remote Controls
Wireless Remote Foot Control
#300 429
Foot control with wireless 90-ft. (27.4 m) operating range
RFCS-14 HD
#194 744
Heavy-duty foot control
RCC-14
#151 086
Side-to-side (east/west) fingertip control
RCCS-14
#043 688
North/south fingertip control
RMS-14
#187 208
Momentary rubber dome switch
RMLS-14
#129 337
Momentary/maintained rocker switch
RHC-14
#242 211 020
Hand control
Wireless Remote Hand Control
#300 430
Hand control with wireless 300-ft. (91.4 m) operating range
Educational Materials
Gas Tungsten Arc Welding (TIG) Publication
#250 833
Setup DVD
#251 116
Date:
Distributed by:
© 2013 Miller Electric Mfg. Co.
Total Quoted Price:
Price

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