Miller

Econotig

Quick

Specs

®

Light Industrial Applications

Farm

Ranch

Hobby

Processes

TIG (GTAW)

Stick (SMAW)

Input Power

1-Phase Power

Issued April 2003 • Index No. AD/1.2

Arc Welding

Power Source

Rated Output at 20% Duty Cycle

TIG: 150 A at 15 VDC, 150 A at 15 VAC

Stick: 130 A at 25 VDC, 150 A at 25 VAC

Amperage Range AC High AC Low DC

TIG: 50 –165 20–50 30–160

Stick: 35 –165 20–50 25–130

Max. Open-Circuit Voltage

78

Weight

140 lb (64 kg)

The Power of Blue .

®

Upgraded circuitry gives you finer TIG output adjustment with the remote foot or fingertip control. If you need more output while using the remote control, simply increase the setting of the front panel amperage control.

AC output for superior aluminum welding and DC output for mild and stainless steel.

Four-position polarity and range selector

switch offers two AC current ranges, DC electrode (–) for TIG, and DC electrode (+) for Stick.

Special arc starting

circuitry eliminates high- frequency starts.

Built-in arc assist starter for DC TIG.

Built-in arc assist stabilizer for AC TIG on aluminum.

Process switch automatically sets machine for TIG or Stick.

Unique “flow-through” shielding

gas TIG torch connection allows removal of torch without tools.

Complete

Package!

Just supply Argon gas, stick electrodes, filler rod, gloves and helmet and you are ready to weld!

Power source is warranted for 3 years, parts and labor.

Original main power rectified parts are warranted for 5 years.

Comes Complete With:

Power source with primary cord

(plug provided on 230 V model)

DB1712RDI TIG torch with backcap, ceramic gas cup, 3/32 in (2.4 mm) collet and collet body, and 2% thoriated tungsten

International-style quick-connect torch

12 ft (3.7 m) work cable and clamp

Stick electrode holder with 15 ft

(4.6 m) cable

RFCS-14 foot-operated remote control with 20 ft (6 m) cord

Gas regulator, flowmeter and

12-1/2 ft (3.8 m) shielding gas hose

“How-To” DVD (in English and

Spanish)

Preset automatic postflow timer protects tungsten tip, workpiece and torch.

Automatic high temperature shutdown.

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters

Phone: 920-735-4505

USA FAX: 920-735-4134

Canadian FAX: 920-735-4169

International FAX: 920-735-4125

Web Site www.MillerWelds.com

2

Specifications

(Subject to change without notice.)

Rated Output at 20% Duty Cycle

TIG: 150 A at 15 VDC

150 A at 15 VAC

Stick:130 A at 25 VDC

150 A at 25 VAC

Welding Amperage Range

AC High AC Low DC

TIG Welding Range

50 – 165 20 – 50 30 – 160

Stick Welding Range

35 – 165 20 – 50 25 – 130

Max. Open-Circuit Voltage

78

Input Amps at Rated Output

200 V 60 A

230 V 52 A

460 V 33 A

380 V 39 A

415 V 36 A

Dimensions

H: 18 in (457 mm)

W: 13 in (330 mm)

D: 25-1/2 in (648 mm)

Net Weight

140 lb (64 kg)

Process and Material Thickness Guide

Material and

Weld Output

Steel or

Stainless Steel

DCEN

Electrode Negative

Aluminum

AC

22 ga

0.033 in

0.8 mm

TIG (GTAW)

20 ga

0.036 in

0.9 mm

Difficult

Material Thickness

18 ga

0.048 in

1.2 mm

16 ga

0.06 in

1.5 mm

14 ga

0.07 in

1.8 mm

12 ga

0.1 in

2.5 mm

11 ga

0.125 in

3.2 mm

TIG (GTAW)

Recommended

10 ga

0.14 in

3.6 mm

6 ga

0.186 in

4.8 mm

2 ga

0.25 in

6.3 mm

Stick

(SMAW)

TIG

(GTAW)

—

0.25+ in

6.3+ mm

With

DCEP

Output

Not

Recommended

Control Panel

1. Range/Polarity Switch

2. Process Switch

3. Amperage Control

4. High Temp Light

5. Remote Receptacle

6. Power Switch

7. International Flow-

Through Receptacle

1

2

3

4

5

6

7

Performance Data

DUTY CYCLE CHART

200

150

100

80

60

15 20 25 30 40 50

% DUTY CYCLE

60 70 80 90 100

Genuine Miller Accessories

RCCS-14 Remote Contactor and

Current Control #043 688

North and South rotary-motion fingertip control fastens to TIG torch using two

Velcro ® straps. Includes 28 ft (8.5 m) control cord. Great for applications that require a finer amperage control.

Universal Carrying Cart and Cylinder Rack

#042 934

This cart adds convenience to the Econotig package. The power source mounts securely to the top, and a cylinder rack supports the argon cylinder. The bottom tray can hold electrode leads or welding hood, gloves, etc. Cylinder rack will accommodate 6 – 9 in

(152 – 228 mm) diameter, and 24 – 56 in

(610 –1422 mm) high cylinders. The cart also supports five standard TIG filler metal tubes and one Stick welding rod tube. Net shipping weight is 69 lbs (31 kg).

RHC-14 Hand Control #129 340

Miniature hand control for remote current and contactor control. Dimensions: 4 in

(102 mm) x 4 in (102 mm) x 3-1/4 in

(82 mm). Includes 20 ft (6 m) cord and

14-pin plug.

Replacement Torches

Note: Torches are available through your local welding distributor.

DB1712RDI

12 ft (3.7 m), 150 A air-cooled, flow thru

TIG torch

DI-917F #194 722

Flow thru connector

Torches are equipped with “quick-connect”

International-style connector. “Flow-through” shielding gas TIG torch connection allows complete removal of torch without using any tools.

RCC-14 Remote Contactor and Current

Control #151 086

Comes standard with 50 Hz units.

A fingertip control can be used instead of the supplied remote foot control. Useful when welding where a foot control cannot be used.

Side-to-side rotary-motion fingertip control fastens to TIG torch using two Velcro ® straps. Includes 28 ft (8.5 m) control cord.

Great for production or contractors that need quick ramp-up.

RFCS-14 Foot Control #043 554

Comes standard with 60 Hz units.

Foot current and contactor control.

Includes 20 ft (6 m) cord and 14-pin plug.

3

Ordering Information

Power Source

Econotig ®

Stock No.

#903 422

#903 367

#903 368

#903 423

#902 424

Accessories

Universal Carrying Cart and Cylinder Rack

RCC-14

RCCS-14

RHC-14

RFCS-14

Replacement Torches

Date:

#042 934

#151 086

#043 688

#129 340

#043 554

Description

60 Hz, 200 V

60 Hz, 230 V

60 Hz, 460 V

50 Hz, 380 V, CE

50 Hz, 415 V, CE

Fingertip control

Fingertip control

Hand control

Foot control

See pg 3

60 Hz models are certified by Canadian Standards Association to both Canadian and U.S. requirements.

50 Hz models come with RCC-14 fingertip control instead of RFCS-14 foot control, and include 25 ft (7.6 m)

TIG torch instead of 12-1/2 ft (3.8 m) model. Gas regulator not included.

Total Quoted Price:

Qty.

Price

Litho in USA

Distributed by:

Syncrowave

®

200

Quick

Specs


Light Metal Fabrication

Maintenance/Repair Operations

Light Manufacturing

Automotive Repair

Vocational Training

Hobbyist

Processes

TIG (GTAW) Welding

Stick (SMAW) Welding

Pulsed TIG (GTAW-P) Welding

The Power of Blue .

®

Squarewave output with AC balance control features adjustable penetration and cleaning action while increasing arc stability on various aluminum alloys, and helps eliminate tungsten spitting and arc rectification.

NEW! Cable management system uses dual cable hangers and foot control storage conveniently attach to the power source side panels to allow all weld cables and the remote foot control to be neatly stored, preventing torch, cable or remote damage.

NEW! Syncro Start ™ allows the operator to choose from three different starting conditions to optimize the application

(Soft/Standard/Hot).

NEW! Runner has low cylinder rack to eliminate the need for lifting when changing gas cylinders.

Fan-On-Demand ™ improves power efficiency and reduces noise and maintenance by lessening the amount of airborne contaminants pulled through the machine.

Adaptive Hot Start ™ for

Stick arc starts automatically increases the output amperage at the start of a weld should the start require it. Prevents the electrode from sticking and creating an inclusion.

NEW! Weldcraft ® WP1712SFDI50

TIG torch. 150 A, air-cooled torch features super flex (SF) braided nylon power cable for maximum flexibility.

Syncrowave

200 Runner

Issued November 2005 • Index No. AD/4.4

TIG/Stick Welding

Power Source

Input Power

Requires 1-Phase Power

Amperage Range 5 – 200 A

Rated Output 150 A at 26 V, 40% Duty Cycle

Weight

Base Model: 238 lb (108 kg)

Runner: 271 lb (123 kg)

NEW! Auto-Postflow protects the weld end zone and electrode by optimizing postflow time based on welding amperage — for adequate shielding every time without waste and no need for adjustment.

NEW! Dual digital meters with alpha-numeric displays allow for quick and easy viewing and preset values for voltage, amperage and other key variables. Allows for greater accuracy and repeatability in the welding procedure.

NEW! Built-in pulse control enhances weld bead and puddle control for improved appearance and quality — reduce burn through, coordinate the addition of filler material, and reduce the warping effects of distortion by reducing the average heat input.

NEW! 115 V auxiliary power receptacle is conveniently located on the front panel, allowing for operation of a Coolmate

™ torch coolant system or other small tools.

Arc hour/cycle counter records actual welding time and number of arc starts.

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.








Phone: 920-735-4505

USA FAX: 920-735-4134




Specifications


Input

Power

208-230 V

460 V

575 V

Rated Output at 40% Duty Cycle

150 A at 26 V

Welding

Amperage Range

5 – 200 A

Max. Open-

Circuit Voltage

80

Certified to both the Canadian and U.S. Standards for welding equipment.

Amps Input at Rated

Output, 50/60 Hz

54

27

22

KVA

12.3

12.52

12.35

KW

6.0

6.0

6.0

Dimensions

H: 30-1/8 in (765 mm)

W: 21-1/8 in (537 mm)

D: 21-1/2 in (546 mm)

Net

Weight

238 lb

(108 kg)

Control Panel

1

2

5

6

7

8

9

1. Balance/DIG Pushbutton Control

2. Process Pushbutton Control

3. Power Switch

4. Polarity Switch

5. Voltmeter and Parameter Adjust

6. Ammeter and Parameter Adjust

7. Encoder Adjustment Control

8. Main Amps Pushbutton

(Amperage Control)

9. Pulse Pushbutton Control

3

4

2

Performance Data

200

150

100

50

10


20 30 40 50 60 70 80 90 100

% DUTY CYCLE

70

60

50

40

30

20

10

0

VOLT/AMP CURVES – AC MODE

AC TIG Min

AC Stick Min

AMPERES

AC TIG Max

VOLT/AMP CURVES – DC MODE

70

60

50

40

30

20

10

0

0

DC Stick Min

(Max DIG)

DC TIG Min

50

DC TIG

Max

DC Stick Max

(Max DIG)

100 150 200 250 300 350

AMPERES


Runner ® Package

Syncrowave ® 200 Runner

#907 308-01-1 208 – 230 V, 50/60 Hz

#907 309-01-1 460/575 VAC, 50/60 Hz

Includes Syncrowave 200, No. 39 running gear, 150 amp WP1712SFDI Weldcraft torch with quick-connect, 12 ft (3.7 m) work cable with clamp and quick-connect, electrode holder with quick-connect,

RFCS-14 remote foot control with 20 ft

(6 m) cord, gas regulator and gas hose.

Primary cord is included with 208 – 230 V model only.

RMLS-14 Switch #129 337

For all Miller solid-state power sources after serial number JK674521. Momentaryand maintained-contact rocker switch for contactor control. Push forward for maintained contact and backward for momentary contact. Includes 26.5 ft (8 m) cord and 14-pin plug.

Running Gear and Covers

Remote Controls

RFCS-14 HD

Foot Control

#194 744

For all Miller solid-state power sources after serial number JK674521. This new design increases stability with a larger base and durability with a heavier cord. 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.


RMS-14 On/Off Control #187 208

For all Miller solid-state power sources after serial number JK674521. Momentarycontact switch for contactor control.

Rubber-covered pushbutton dome switch ideal for repetitive on-off applications.

Includes 26.5 ft (8 m) cord and 14-pin plug.

RHC-14 Hand Control

#129 340

Miniature hand control for remote current and contactor control.

Dimensions:

4 x 4 x 3-1/4 in (102 x 102 x 82 mm).


RCCS-14 Remote Contactor and Current

Control #043 688 14-pin plug

For all Miller solid-state power sources after serial number JK674521. North/south rotary-motion fingertip control fastens to

TIG torch using two Velcro ® straps. Great for applications that require a finer amperage control. Includes 26.5 ft (8 m) control cord.

Water Coolant Systems

For more information, see the Miller Coolant

Systems literature sheet, Index No. AY/7.2.

Coolmate ™ 3 #043 007 115 VAC

For use with water-cooled torches rated up to 500 amps. Unique paddle-wheel indicator, external filter and easy-fill spout.

Low-Conductivity Coolant #043 810

Sold in cases of four 1-gallon recyclable plastic bottles. Miller coolants contain a base of ethylene glycol and deionized water to protect against freezing to -37˚F (-38˚C) or boiling to 227˚F (108˚C). Also contains a compound that resists algae growth.

RCC-14 Remote Contactor and Current

Control #151 086 14-pin plug

For all Miller solid-state power sources after serial number JK674521. Side-to-side

(east/west) rotary-motion fingertip control fastens to TIG torch using two Velcro ® straps. Great for production or contractors that need quick ramp-up. Includes 26.5 ft

(8 m) control cord.

No. 39 Running Gear #300 009

Includes low cylinder rack, two 8 in

(203 mm) wheels and two 4 in (102 mm) casters. Two compartments have been integrated for filler materials and will accommodate one gas cylinder up to

60 in (152 cm) high measuring 9 in

(23 cm) in diameter.

Protective Cover #300 059

Heavy-duty, water- and mildew-resistant.

Protects and maintains the finish of the welder.

TIG (GTAW) Torches

Weldcraft ® TIG Torches

The Weldcraft line of TIG torches complements the most popular TIG power source line available today. The Weldcraft torch line includes both air-cooled and water-cooled models. Available with genuine Weldcraft parts.

Water-Cooled Torch #WP2025RM

Requires adapter #195 380.

Water-Cooled TIG Torch Adapter

#195 380

TIG (Gas Tungsten Arc Welding) Handbook

#170 555

To order, call the Miller Literature

Distribution Center at 1-920-751-2120, or

FAX 1-920-751-2121. A comprehensive, text on all aspects of the TIG process.

3

Package Components

Complete

Packages!

No. 39 Running Gear

Gas Regulator and Hose

Electrode

Holder with

Quick-Connect

150 A WP1712SFDI50

TIG Torch with Quick-Connect

Syncrowave

200 Runner

Power Source with 8 ft (2.4 m)

Primary Cord

(Cord included with 208 – 230 V model only)

RFCS-14 Foot

Control with

20 ft (6 m) Cord

12 ft (3.7 m) Work

Cable with Clamp and Quick-Connect

Syncrowave

200

Gas Regulator and Hose

Electrode

Holder with

Quick-Connect

150 A WP1712SFDI50

TIG Torch with Quick-Connect


Equipment and Options Stock No.

Description

Syncrowave ® 208-230 V, 50/60 Hz

#907 309 460/575 VAC, 50/60 Hz

Syncrowave ® 200 Runner #907 308-01-1 208-230 V, 50/60 Hz

#907 309-01-1 460/575 VAC, 50/60 Hz

Running Gear and Covers

No. 39 Running Gear

Protective Cover

Remote Controls

RFCS-14 HD

RCCS-14

RCC-14

RMLS-14

RMS-14

RHC-14

Coolant Systems

Coolmate ™ 3

Low-Conductivity Coolant

Coolant System Hoses

#300 009

#300 059

#194 744

#043 688

#151 086

#129 337

#187 208

#129 340

#043 007

#043 810

Heavy-duty foot control

North/south fingertip control

Side-to-side fingertip control

Momentary/maintained rocker control

Momentary rubber dome switch

Miniature hand control

115 VAC coolant system

TIG Accessories

Water-Cooled Torch

Water-Cooled TIG Torch Adapter

Air-Cooled Torch

#WP2025RM Requires adapter #195 380

#195 380

#WP1712SFM 12 ft (3.7 m) replacement torch

#WP1725SFM 25 ft (7.6 m) replacement torch

#194 722 Flow-Thru Air-Cooled TIG Torch Adapter

Consumables, Tungsten

Gas Cylinder

Stick Accessories

Stick Electrodes

Educational Resources

TIG (Gas Tungsten Arc Welding) Handbook #170 555

TIG Calculator #171 086

Date: Total Quoted Price:

Power Source with 8 ft (2.4 m)

Primary Cord

(Cord included with 208 – 230 V model only)

RFCS-14 Foot

Control with

20 ft (6 m) Cord

12 ft (3.7 m) Work

Cable with Clamp and Quick-Connect

Qty. Price

Distributed by:

Litho in USA

Dynasty

®

Issued July 2004 • Index No. AD/4.8

200 Series

TIG/Stick Welding

Power Source

Quick

Specs

Heavy Industrial Applications

Petro/Chem Fabrication

Aerospace

Food/Beverage Industry

Mechanical Contractors

Shipboard Installation/Repair

Dairy Industry

Processes

TIG (GTAW)

Pulsed TIG (GTAW-P) with DX Model

Stick (SMAW)

Input Power

Requires 3- or 1-Phase Power



80

Weight

45 lb (20.5 kg)

The Power of Blue .

®

NEW! Low OCV Stick is a simple design that reduces the open-circuit voltage to 12–16 volts when the welding power source is not in use.

This built-in circuit design eliminates the need for add-on voltage reducers.

Easy installation — Auto-Line ™ provides state-of-the-art flexibility to the end user. The

Auto-Line circuitry automatically connects to

120 – 460 VAC, single- or three-phase power without removing the covers to relink the power source. No longer is there a concern if you have the correct machine for shop or the job site.

Inverter-based, AC/DC power

source has state-of-the-art operator interface allowing the user extra set-up capabilities in a compact machine. Features more precise control of output parameters.

Advanced Squarewave arc for improved weldability on aluminum and magnesium using low power. Continuous high-frequency is NOT needed because of the advanced

Squarewave arc, and extended balance control allows you to fine-tune the duration of the electrode negative portion of the cycle from 30 to 90%. This provides precise cleaning control and prolonged tungsten life.

Programmable HF start parameters allows the operator to independently set HF starting conditions based upon process or application.

HF start for non-contact arc starting that eliminates tungsten or material contamination.

Lift-Arc ™ start for TIG arc starting without the use of high frequency.

Dynasty 200 SD Dynasty 200 DX

Superior arc performance even on difficult to run electrodes like E6010.

Available in Two Models:

SD — Provides the basic features that are required for most AC/DC TIG or Stick welding applications.

DX — When the job demands greater control the DX provides pulse on/off, pulse frequency, peak % time, background amperage, initial amperage, initial slope time, final slope time and final amperage control.

Portable in the shop or at the job site

— at 45 lb the Dynasty 200 is easily moved from location to location.

Extended Balance Control range (30–90% EN) allows precise cleaning control and prolonged tungsten life.

AC frequency control range of 20–250 Hz provides control for a focused arc, resulting in better directional control to help produce desired arc/weld bead characteristics.








Phone: 920-735-4505

USA FAX: 920-735-4134




2

Specifications


Welding

Mode

TIG

(GTAW)

Stick

(SMAW)

Welding

Amperage

Range

120 VAC

1 – 150 A

200 – 460 VAC

1 – 200 A

120 VAC

1 – 105 A

200 – 460 VAC

1 – 200 A

Max.

Open-

Circuit

Voltage

80 VDC

12 – 16**

80 VDC

12 – 16**

Input

Power

3-Phase

1-Phase

3-Phase

1-Phase

Rated

Output

200 A at 18 V,

20% Duty Cycle

150 A at 16 V,

60% Duty Cycle

150 A at 16 V,

60% Duty Cycle

140 A at 15.6 V,

40% Duty Cycle

100 A at 14 V,

100% Duty Cycle

200 A at 28 V,

20% Duty Cycle

130 A at 25.2 V,

60% Duty Cycle

130 A at 25.2 V,

60% Duty Cycle

100 A at 24 V,

60% Duty Cycle

90 A at 23.6 V,

100% Duty Cycle

Amps Input at Rated Load Output, 50/60 Hz

120 V 230 V 400 V 460 V KVA KW

—

—

13.7

8.7

6.9

5.5

5.2

0.16* 0.24* 0.25* 0.06* 0.03*

—

—

—

—

31.0

—

0.42* —

9.4

6.0

4.7

3.8

3.6

0.16* 0.24* 0.25* 0.06* 0.03*

15.8

—

0.23* —

7.9

3.6

3.6

0.25* 0.05* 0.02*

—

—

—

—

3.6

3.5

0.05* 0.03*

20.7

—

0.42* —

—

—

—

—

2.3

2.3

0.05* 0.03*

—

—

20.8

13.0

10.2

8.1

7.8

0.16* 0.24* 0.25* 0.06* 0.03*

—

—

—

—

31.3

—

0.42* —

12.3

7.6

6.0

4.8

4.6

0.16* 0.24* 0.25* 0.06* 0.03*

20.0

—

0.23* —

10.0

4.7

4.7

0.25* 0.05* 0.03*

—

—

—

—

3.6

3.6

0.05* 0.03*

27.6

—

0.42* —

—

—

—

—

3.2

3.2

0.05* 0.03*

Dimensions

H: 13-1/2 in

(343 mm)

W: 7-1/2 in

(191 mm)

D: 21-1/2 in

(546 mm)

Net

Weight

45 lb

(20.5 kg)

* While idling. **Sense voltage for Stick and Lift-Arc

™

TIG. Note: Duty cycle limitations on units with 115 V input power are due to the input power cord supplied with the unit.

Certified by Canadian Standards Association to both Canadian and U.S. Standards.

Conforms to European standards.

Control Panels

Dynasty 200 SD Dynasty 200 DX

1

2

6 1

2

6

7 7 1. Voltmeter

2. Ammeter

3. Polarity Control

4. Process Control

5. Output Control

6. Encoder Control

7. Amperage Control

8. AC Waveshape Control

9. Adjust Control

10. Sequencer Controls

11. Pulser Control

1

2

3

4

5

Dynasty 200 SD (CE)

8

9

6 1

2

3

4

5

Dynasty 200 DX (CE)

8

9

10

11

6

7 7

Control Panel Parameter Values

A. Preflow (s) 0.0 – 25

B. Initial Amperage (A) 5 – 200

C. Initial Slope Time (s) 0.0 – 25

D. Weld Amperage (A) 5 – 200

3

4

5

8

9

10

E. AC Frequency (Hz)

F. Balance Control (%EN)

20 – 250

50 – 90

G. Background Amperage (%) 0 – 100

H. Pulse Frequency (Hz) 0.1 – 500

I. Peak Percent Time (%) 5 – 95

3

4

5

J. Final Slope Time (s) 0.0 – 25

K. Final Amperage (A) 5 – 200

L. Postflow Time (s) 0.0 – 50

M. Dig (%) 0 – 100

8

9

10

11

Performance Data

115 VAC INPUT / AC OUTPUT

140

120

100

80

60

40

20

0

0

*

STICK MAX

TIG MAX

STICK/TIG MIN

50 100 150

AMPERES

200 250

115 VAC INPUT / DC OUTPUT

140

120

100

80

60

40

20

0

0

*

STICK/TIG MIN

50

STICK MAX

TIG MAX

DIG MAX

100 150

AMPERES

200 250

140

120

100

80

60

40

20

0

0

230 VAC SINGLE-PHASE INPUT / AC OUTPUT

*

STICK/TIG MIN

50

STICK MAX

TIG MAX

200 100 150

AMPERES

250

140

120

100

80

60

40

20

0

0

230 VAC SINGLE-PHASE INPUT / DC OUTPUT

*

STICK MAX

TIG MAX

STICK/TIG MIN

50

DIG MAX

200 100 150

AMPERES

250

3-PHASE VOLTAGE INPUT / AC OUTPUT

140

120

100

80

60

40

20

0

0

*

STICK MAX

TIG MAX

STICK/TIG MIN

50 100 150

AMPERES

200 250

140

120

100

80

60

40

20

0

0

3-PHASE VOLTAGE INPUT / DC OUTPUT

*

50

STICK MAX

TIG MAX

STICK/TIG MIN DIG MAX

100 150

AMPERES

*DIG setting must be reduced to obtain currents less than those shown in Volt-Ampere curves.

200 250


250

200

TIG (115 V INPUT)

150

STICK

100

STICK (115 V INPUT)

50

0

10

TIG

20 30 40 50 60 70 80 90 100

% DUTY CYCLE

3

Included Accessories

Non-CE SD/DX Models Include:

(1) DA-917F air-cooled torch adapter

(2) International-style connectors 35/50

CE SD/DX Models Include:


(1) 14-pin amphenol with clamp

(1) 3/8 in - 19 BSPP gas fitting


Equipment and Options

Power Source

Dynasty ® 200 SD

Stock No.

Dynasty ® 200 DX

Description

#907 099

#907 100

Basic controls for TIG/Stick, 120 – 460 VAC

Basic controls for TIG/Stick, 120 – 460 VAC, CE

#907 099-01-1 Full feature controls for TIG/Stick, 120 – 460 VAC

#907 100-01-1 Full feature controls for TIG/Stick, 120 – 460 VAC, CE

TIG Accessories

TIG Torch Adapters

Contractor Kits

#194 720

#190 219

#194 724

#195 055

#195 054

DA-917F

DA-1820L

DA-26R

150 A TIG/Stick with RCCS-14 fingertip control

150 A TIG/Stick with RFCS-14 HD foot control

See Diamondback TIG Torch Selector Guide

See Parts Guide

Diamondback ™ TIG Torches

Consumables, Tungsten

Gas Cylinder, Gas Hose and Fittings

Stick Accessories

Stick Electrodes

Remote Controls

RFCS-14 HD

RFCS-14

RCCS-14

RCC-14

RMLS-14

RMS-14

Educational Resources

Gas Tungsten Arc (TIG) Welding Book

TIG Fundamentals Welding CD

Coolant Systems

Coolmate ™ 3

Coolmate ™ V3

Coolmate ™ 4

#194 744

#043 554

#043 688

#151 086

#129 337

#187 208

#170 555

#196 567


Foot control





#043 007 115 VAC

#043 007-01-2 115 VAC, CE

#043 008 230 VAC

#043 008-01-2 230 VAC, CE

#043 009 115 VAC

#043 009-01-2 115 VAC, CE

#042 288 115 VAC

#042 288-01-5 115 VAC, CE

#043 810 Recommended for TIG welding and HF applications Low-Conductivity Coolant

Cooling System Hoses

International-Style Connectors

International-Style Connector Kit

Extension Kit for International-Style

International/Tweco ® Adapter

International/Cam-Lok Adapter

Additional Accessories

Machine Cover

Date:

#042 418

#042 419

#042 465

#042 466

#195 322

50 mm

50 mm

A one-piece adapter with International-style male plug


Water and mildew-resistant. Protects machine finish


Qty. Price

Distributed by:

Litho in USA

Issued March 2008 • Index No. AD/5.0

Dynasty

®

350 and 700

TIG/Stick Welding

Power Source

Quick

Specs

Industrial Applications

Precision Fabrication

Heavy Fabrication

Pipe and Tube Fabrication

Aerospace

Aluminum Ship Repair

Anodized Aluminum Fabrication

Processes

TIG (GTAW)

Pulsed TIG (GTAW-P)

Stick (SMAW)

Input Power

208 – 575 V, 3- or 1-Phase

Amperage Range

350: 5 – 350 A

700: 5 – 700 A

Rated Output 350: 300 A at 32 V, 60% Duty Cycle

700: 600 A at 44 V, 60% Duty Cycle

Weight

350: 135.5 lb (61 kg)

700: 198 lb (90 kg)

The Power of Blue .

®

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.

120 V auxiliary power receptacle for cooling system or small tools.

Wind Tunnel Technology ™ protects internal electrical components from airborne contaminants, extending the product life.

Fan-On-Demand ™ power source cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled though the machine.

TIGRunner ® packages feature a

3.5 gallon (13.2 L) cooling system. The cart is equipped with cylinder carrying capabilities, filler rod holder, foot pedal holder, torch and cable holders. A pullout drawer provides additional storage for torch consumables and tools. See page 6.

Dynasty 700

Programmable start parameters allow independent starting conditions based on process and memory selections

(amperage, time and polarity).

Dynasty 350

Program memory features

9 independent program memories that maintain/save your parameters.

High-frequency arc starter for non-contact arc initiation.

Stick Features (AC/DC)

Tailored arc control (DIG) allows the arc characteristic to be changed for specific applications and electrodes.

Smooth running 7018 or stiffer, more penetrating 6010.

Hot Start ™ adaptive control provides positive arc starts without sticking.

Lift-Arc ™ start provides AC or DC arc starting without the use of high frequency

AC frequency control adds additional stability when Stick welding in AC for smoother welds.

Auto-Postflow calculates the length of postflow time based on the amperage setting. This eliminates the need to independently set the postflow time for different amperages. This feature preserves your tungsten and prevents porosity.


Original main power rectifier parts are warranted for 5 years.

AC TIG Features

Independent Amplitude/Amperage

Control allows EP and EN amperages to be set independently to precisely control heat input to the work and electrode.

Extended AC balance (30–99%) controls the amount of oxide cleaning (amperage time in EN) which is essential for high quality welds on aluminum.

AC frequency (20–400 hz) controls the width of the arc cone and the force of the arc.

AC Waveforms

Advance Squarewave, fast freezing puddle, deep penetration and fast travel speeds.

Soft Squarewave for a soft buttery arc with maximum puddle control and good wetting action.

Sine wave for customers that like a traditional arc.

Quiet with good wetting.

Triangular wave reduces the heat input and is good on thin aluminum. Fast travel speeds.

DC TIG Features

Exceptionally smooth and precise arc for welding exotic materials.

High-Speed DC TIG Pulse Control

Pulse frequency capable of pulsing

5000 pulses per second. Pulsing adds arc stability, reduces heat input and warpage and can increase travel speeds. Other parameters include peak amperage, peak time and background amperage.






Phone: 920-735-4505

USA FAX: 920-735-4134




2

Specifications


Model

Dynasty

350

Dynasty

700

Input

Power

Three-

Phase

Single-

Phase

Three-

Phase

Single-

Phase

Welding

Amperage

Range

Max.

Open-Circuit

Voltage

5 – 350 A 75 VDC

10 –15 VDC*

5 – 350 A

5 – 700 A

5 – 700 A

75 VDC

10 –15 VDC*

75 VDC

10 –15 VDC*

75 VDC

10 –15 VDC*

Rated

Output

250 A at 30 V,

100% Duty Cycle

300 A at 32 V,

60% Duty Cycle

180 A at 27.2 V,

100% Duty Cycle

225 A at 29 V,

60% Duty Cycle

500 A at 40 V,

100% Duty Cycle

600 A at 44 V,

60% Duty Cycle

360 A at 34 V,

100% Duty Cycle

450 A at 38 V,

60% Duty Cycle


*Indicates sense-voltage for Lift-Arc TIG and Low OCV Stick.


208 V 230 V 400 V 460 V 575V KVA KW

29

35

35

47

26

32

32

43

15

18

—

—

13

16

15

21

10

13

12

17

10.3

7.4

9.9

12.7

12.1

6.8

9.8

9.1

Dimensions

H: 24-3/4 in (629 mm)

W: 13-3/4 in (349 mm)

D: 22 in (559 mm)

Net

Weight

135.5 lb

(61 kg) with TIGRunner ®

H: 45-1/8 in (1146 mm)

W: 23-1/8 in (587 mm)

D: 43-3/4 in (1111 mm) with

TIGRunner ®

308 lb

(140 kg)

75

97

82

68

88

74

39

51

—

115 104 —

34

44

37

52

27

35

30

42

27

35

17

24


26

34

16

22

H: 34-5/8 in (879 mm)

W: 13-3/4 in (349 mm)

D: 22 in (559 mm)

198 lb


H: 55-1/8 in (1400 mm)

W: 23-1/8 in (587 mm)

D: 43-3/4 in (1111 mm) with

TIGRunner ®

370 lb

(168 kg)

Control Panel

11

12

13

1 f

10

9

7. Gas/DIG Preflow 0.0 – 25.0 Seconds

Postflow Auto Postflow,

Adjust 0.0 – 50 Seconds

DIG

8. AC Waveshape

EN Amperage

EP Amperage

Balance

AC Frequency

9. Amperage Control

10. Encoder Control

11. Ammeter Display

12. Voltmeter Display

0 – 100%

5 – 350 A /5 – 700 A

5 – 350 A/5 – 700 A

30 – 99%

20– 400 Hz

2 3 4


1. Memory 36 Combinations

(9 AC TIG)

(9 AC Stick)

(9 DC TIG)

(9 DC Stick)

2. Polarity

3. Process/

Arc Starting

AC/DC

TIG: HF Impulse, Lift Arc

STICK: Adaptive Hot Start

4. Output Control Standard Remote,

2T Trigger Hold,

Output ON

5 6 7 8

5. Pulser Control

Pulses per Second DC : 0.1– 5000 PPS

Peak Time

AC : 0.1 – 500 PPS

5 – 95%

Background Amps 5 – 95%

6. Sequencer Control

Initial Amps Dynasty 350: 5 –350 A

Initial Slope

Final Slope

Final Amps

Dynasty 700: 5– 700 A

0.0 – 50.0 Seconds

0.0 – 50.0 Seconds

Dynasty 350: 5 –350 A

Dynasty 700: 5– 700 A

Additional Setup Parameter Values

Programmable Starts

Amperage

Time

5 – 200 A

1– 200 Milliseconds

Additional Triggers 3T, 4T, Mini Logic,

4T Momentary

Waveshapes Advance Squarewave,

Soft Squarewave, Sine

Wave, Triangular wave

Amplitude Lock EN EP Same,

EN EP Independent

Spot/Weld Timer 0.0 – 999 Seconds

OCV Low OCV, Normal OCV

Lockouts Four levels

Arc Timer

Cycle Counter

0.0 – 9999 Hours and 0 – 59 Min

0 – 999,999 Cycles

Performance Data


800

700

Dynasty 700, 3-Phase

600

500


400


300


200

100

0

% DUTY CYCLE

$1,600

$1,400

$1,200

$1,000

$800

$600

$400

$200

$-

ANNUAL POWER COST OF OPERATION

Annual power costs based on one 8 hour shift (40 hrs/wk).

Power cost of $0.08/kWh.

T 25% ARC ON= 2 HOURS/SHIFT

50% ARC ON= 4 HOURS/SHIFT

75% ARC ON= 6 HOURS/SHIFT

D= Dynasty T= Traditional

D

T

D

D

T

D

T

D T

D T

D T

50 100 150 200

AMPERAGE

250 300 350

TIG Upgrade Chart

Which Machine is Right for You?

Why Upgrade?

Maximum Thickness Capacity

High Frequency Arc Starting

Frequency Control

AC Output Control

AC Waveforms

Syncrowave 350

1/2 in Aluminum

Continuous HF

Fixed at 60 Hz

Soft Squarewave

UPGRADE

UPGRADE

UPGRADE

Dynasty 350

5/8 in Aluminum

Start Only

Variable 20–400 Hz

UPGRADE Advanced Squarewave Soft Squarewave

Weld Aluminum with Pointed Tungsten

Portability

Power Draw at 300 Amps

Precise Controls

496 lb

Manual Links

208/230/460 V

Single-Phase

110 A at 230 V

Single-Phase

UPGRADE

Sine Wave Triangular Wave

UPGRADE

UPGRADE

135 lb

Auto-Line™

208–575 V

Single-Phase or Three-Phase

32 A at 230 V

Three-Phase

Some Digital Controls UPGRADE All Digital Controls

Dynasty 350 Benefits

Increases aluminum thickness.

Start Only limits HF interference issues.

Higher frequencies provide better arc control and faster travel speeds.

Advanced Squarewave=Travel faster

Soft Squarewave= Maximum puddle control

Sine Wave= Traditional characteristics

Triangular Wave= Reduced heat input

Waveshaping controls maintain the point. The benefits are: reduced heat input into your part, smaller weld beads, better starting and more control of the arc.

Easier to move because of size and weight.

Auto-Line™ allows the unit to operate on any voltage. Single- or three-phase. Even generators!

Power requirement to operate is much less.

Smaller electrical service needed, smaller breaker/fuses and power cord.

Accuracy and repeatability with all digital controls.

3

4

AC Waveshape Controls

Feature

AC Balance Control

Controls arc cleaning action. Adjusting the

% EN of the AC wave controls the width of the etching zone surrounding the weld.

Note: Set the AC Balance control for adequate arc cleaning action at the sides and in front of the weld puddle. AC Balance should be fine tuned according to how heavy or thick the oxides are.

AC Frequency Control

Controls the width of the arc cone. Increasing the AC Frequency provides a more focused arc with increased directional control.

Note: Decreasing the AC Frequency softens the arc and broadens the weld puddle for a wider weld bead.

Independent AC Amperage Control

Allows the EN and EP amperage values to be set independently. Adjusts the ratio of EN to

EP amperage to precisely control heat input to the work and the electrode. EN amperage controls the level of penetration, while EP amperage dramatically effects the arc cleaning action along with the AC Balance control.

Waveform

51 – 99% EN

0

% EP

% EN

Time (1 AC Cycle)

30 – 50% EN

0

% EP

% EN

Time (1 AC Cycle)

0

60 Cycles per Second

% EP

% EN

Time (1 AC Cycle)

120 Cycles per Second

0

%

EP

%

EP

% EN % EN

Time (1 AC Cycle)

Effect on Bead

Reduces balling action and helps maintain point

Deep, narrow penetration

Increases balling action of the electrode

Shallow penetration

Wider bead, good penetration — ideal for buildup work

Narrower bead for fillet welds and automated applications

0

EP+

Time

EN –

More current in

EN than EP:

Deeper penetration and faster travel speeds

0

EP+

EN –

Time

More current

in EP than EN:

Shallower penetration

Effect on Appearance

Narrow bead, with no visible cleaning

Bead

No Visible Cleaning

Wider bead and cleaning action


Bead

Cleaning

Bead

Cleaning

Narrower bead and cleaning action

Bead

Cleaning

Narrow bead, with no visible cleaning

Bead

No Visible Cleaning


Bead

Cleaning

AC Waveshape Controls

(Continued)

AC Waveform Selection

Select from four different AC waveforms to optimize the arc characteristic for your application. Choose from:

ADVANCED SQUAREWAVE SOFT SQUAREWAVE

(+)

0

(–)

(+)

0

(–)

Time (1 AC Cycle)

SINEWAVE

Time (1 AC Cycle)

Fast transitions for responsive and dynamic arc.

Square transitions eliminate the need for continuous HF, while the sinewave peaks soften the arc.

(+)

0

(–)

(+)

0

(–)

All the benefits of advanced square, fine tuned to provide a smooth, soft arc with maximum puddle control and good wetting action.

Time (1 AC Cycle)

TRIANGULAR WAVE

Time (1 AC Cycle)

Unconventional wave provides the punch of the peak amperage, while reducing overall heat input. Quick puddle formation reduces weld time — limiting heat input and reducing weld distortion, especially on thin materials.

Pulse TIG Controls

High Speed DC TIG-Pulse Controls

• PPS Pulses per second (Hz): DC = 0.1 – 5,000 PPS / AC = 0.1 – 500 PPS

• % ON – % Peak Time: 5 - 95% (Controls the amount of time during each pulse cycle at the PEAK amperage.)

• Background Amps: 5 – 99% (Sets the low-pulse amperage value as a % of the Peak Amps.)

CONVENTIONAL PULSED TIG HIGH SPEED PULSED TIG

Peak Time % Peak Time %

Peak

Amps

Peak

Amps

Background

Amps

(% of Peak)

Pulse Cycle

Typically from 1 to 10 PPS. Provides a heating and cooling effect on the weld puddle and can reduce distortion by lowering the average amperage. This heating and cooling effect also produces a distinct ripple pattern in the weld bead. The relationship between pulse frequency and travel speed determines the distance between the ripples. Slow pulsing can also be coordinated with filler metal addition and can increase overall control of the weld puddle.

Background

Amps

(% of Peak)

Pulse Cycle

In excess of 40 PPS, Pulsed TIG becomes more audible than visible — causing increased puddle agitation for a better as-welded microstructure.

Pulsing the weld current at high speeds — between a high Peak and a low Background amperage — can also constrict and focus the arc.

This results in maximum arc stability, increased penetration and increased travel speeds (Common Range: 100 – 500 PPS).

The Arc-Sharpening effects of high speed pulsing are expanded to new dimensions. The ability to pulse at 5,000 PPS further enhances arc stability and concentration potential — which is extremely beneficial to automation where maximum travel speeds are required.

5

6

Packages and Torch Kits

Dynasty ® Power Sources

Dynasty ® 350 #907 204 (CSA)

(Auto-Line ™ 208–575 VAC)

Dynasty ® 350 #907 204-01-2 (CE)


8 ft (2.4 m) primary cord, (2) international

(Dinse 50) connectors, and CD-ROM Setup and Simulator.

Note: TIG torch adapter must be ordered separately.

Dynasty ® 700 #907 101 (CSA)


Dynasty ® 700 #907 101-01-2 (CE)


(2) thread lock weld cable connectors

(#225 029), (1) water-cooled thread lock torch adapter (#225 028) for #18 or #20 torches, and CD-ROM Setup and Simulator.

Note: Primary cord and TIG torch must be ordered separately.

TIGRunner ® Packages

Dynasty 350 TIGRunner ®

#907 204-01-1 (CSA)

Completely assembled.

Package includes:

Dynasty ® 350 (#907 204)

RFCS-14 HD foot control

Coolmate ™ 3.5 Coolant System

Cart with the following features: single cylinder rack, foot pedal holder,

(3) cable/torch holders, (2) TIG electrode filler holders and a convenient drawer for tungsten and consumable storage

Note: Torch package and coolant must be ordered separately.

Dynasty 700 TIGRunner ®

#907 101-01-1 (CSA)


Package includes:

Dynasty ® 700 (#907 101)

RFCS-14 HD foot control





TIGRunner ® Complete Packages

Dynasty 350 TIGRunner ® Complete

#951 074 (CSA)


Package includes:

Dynasty ® TIGRunner ® (#907 204-01-1)

25 ft (7.6 m) Weldcraft CS310 water-cooled torch

Torch cable cover

CS310AKC torch accessory kit includes shielding cups, collets, collet bodies, and 2% cerium tungsten electrodes

(1/16, 3/32, and 1/8 in)

Smith regulator/flowmeter HM2051A-580

12 ft (3.7 m) rubber gas hose (regulator to machine)

Water-cooled Dinse torch adapter

15 ft (4.6 m) 1/0 weld lead with clamp

(work or ground lead) and Dinse connector

4 gallons of pre-mixed low-conductivity coolant (#043 810)

Dynasty 700 TIGRunner ® Complete

#951 075 (CSA)


Package includes:

Dynasty ® 700 TIGRunner (#907 101-01-1)

25 ft (7.6 m) Weldcraft WP18SC water-cooled torch

Torch cable cover

AK18C Torch Accessory Kit includes shielding cups, collets, collet bodies and

2% cerium tungsten electrodes (3/32,

1/8 and 5/32 in)

Smith regulator/flowmeter H1954D-580


Water-cooled thread lock torch adapter


(work or ground lead)



Torch Kits

250 A Water-Cooled Torch Kit #300 185

25 ft (7.6 m) Weldcraft ® WP20 torch

Torch cable cover

AK4C torch accessory kit includes shielding cups, collets, collet bodies and 2% cerium tungsten electrodes

(1/16, 3/32 and 1/8 in)

Smith ® regulator/flowmeter HM2051A-580






Recommended for Dynasty 350

25 ft (7.6 m) Weldcraft ®

Torch cable cover

CS310 torch

CS310AKC torch accessory kit includes shielding cups, collets, collet bodies and 2% cerium tungsten electrodes

(1/16, 3/32 and 1/8 in)






Runner Cart

#300 244

Designed to accom modate the Dynasty ® or Maxstar ® 350 or

700 power sources and the Coolmate ™

3.5 Cooler. Cart features: single cylinder rack, foot pedal holder,

(3) cable/torch holders, (2) TIG electrode filler holders and a convenient drawer for tungsten and consumable storage.

Coolmate ™ 3.5

#300 245

Designed to integrate with the Dynasty ® and Maxstar ® 350 and 700 power sources. For use with water-cooled torches rated up to 600 amps. 3.5 gallon capacity.

TIG Coolant

#043 810

Sold in multiples of

4. Pre-mixed lowconductivity Miller coolant contains ethylene glycol and deionized water to protect from freezing and boiling -37˚ to 227˚F (-38˚ to 108˚C).

Coolant contains 2.4% algae growth inhibitor. 1-gallon plastic recyclable bottles.

Water-Cooled Dinse #195 377

Used to adapt WP20, WP18, and CS310 to dinse-style connector.

TIG Welding Gloves

#227 813 Small #227 815 Large

#227 814 Medium #227 816 X-Large

Made from soft grain goatskin. Sewn with

Kevlar ® thread.

Automation Interface Kit #195 516

Field Includes automation PC board, 28-pin socket receptacle with harness, 28-pin plug connector. Provides required and advanced automation controls.

Weld Current Sensor #300 179

Detects when work clamp is not connected and prevents expensive damage to disconnect devices and input power cord and wiring.

Educational Materials

To order these items, distributors can call the Miller Literature Distribution Center at

1-920-735-4356, or FAX 1-920-735-4011.

Gas Tungsten Arc (TIG) Welding Book

#170 555

CD-ROM #233 558

Simulator and setup video (included with machine).

Tungsten

Tungsten is 7 in length and available in pkgs of 10.

2% Ceriated (orange) for AC/DC applications

#WC040X7 .040 in, 10– 80 A

#WC116X7 1/16 in, 70– 150 A

#WC332X7 3/32 in, 140– 250 A

#WC018X7 1/8 in, 225– 400 A

#WC532X7 5/32 in, 300– 500 A

1.5% Lanthanum (gold) for AC/DC applications

#WL040X7 .040 in, 10– 80 A

#WL116X7 1/16 in, 70– 150 A

#WL332X7 3/32 in, 140– 250 A

#WL018X7 1/8 in, 225– 400 A

#WL532X7 5/32 in, 300– 500 A


Recommended for Dynasty 700

25 ft (7.6 m) Weldcraft ®

Torch cable cover

WP18SC torch

AK18C torch accessory kit includes shielding cups, collets, collet bodies and 2% cerium tungsten electrodes

(3/32, 1/8 and 5/32 in)

Smith ® regulator/flowmeter H1954D-580


Water-cooled thread lock torch adapters



Remote Controls and Switches

RCCS-14 Remote

Contactor and Current

Control #043 688

14-pin plug. North/south rotary-motion fingertip control fastens to TIG torch using two Velcro ® control cord.

straps. Includes 26.5 ft (8 m)

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 ft (6 m) cord and 14-pin plug.

RHC-14 Hand Control #129 340

Miniature hand control for remote current and contactor control. Dimensions: 4 x 4 x

3-1/4 in (102 x 102 x 83 mm). Includes

20 ft (6 m) cord and 14-pin plug.

RMLS-14 Switch

#129 337

Momentary- and maintained-contact rocker switch for contactor control. Push forward for maintained contact and backward for momentary contact. Includes 26.5 ft (8 m) cord and 14-pin plug.

Momentary-contact switch for contactor control. Rubber-covered pushbutton dome switch ideal for repetitive on-off applications. Includes 26.5 ft (8 m) cord and 14-pin plug.

MS-14

On/Off Control

#187 208

Extension Cords for 14-Pin Remote Controls

#122 973 25 ft (7.6 m)

#122 974 50 ft (15.2 m)

#122 975 75 ft (23 m)

7



Dynasty ® 350

Dynasty ® 350 TIGRunner ®

Dynasty ® 350 TIGRunner ® Complete

Dynasty ® 350 International

Dynasty ® 700

Dynasty ® 700 TIGRunner ®

Dynasty ® 700 TIGRunner ® Complete

Dynasty ® 700 International

TIG Torch Kits

Weldcraft ® 250 A Water-Cooled Torch Kit



Consumables and Tungsten

Gas Cylinder, Hose and Fittings

Remote Controls

RCCS-14

RFCS-14 HD

RHC-14

RMLS-14

RMS-14

Extension Cords

Stock No.

Description

#907 204 Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8 ft primary cord

#907 204-01-1 Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8 ft primary cord. Requires coolant

#951 074 Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8 ft primary cord.

#907 204-01-2 Auto-Line™ 380 – 575 VAC, 50/60 Hz, CE. 8 ft primary cord

#907 101 Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA.

#907 101-01-1 Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. Requires coolant

#951 075 Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA.

#907 101-01-2 Auto-Line™ 380 – 575 VAC, 50/60 Hz, CE.

#300 185

#300 183

#300 186

#043 688

#194 744

#129 340

#129 337

#187 208

#122 973

#122 974

#122 975

See page 7

See page 7. Recommended for Dynasty 350

See page 7. Recommended for Dynasty 700

Distributor: See Miller Parts Catalog



Hand control

Momentary/maintained rocker switch


25 ft (7.6 m)

50 ft (15.2 m)

75 ft (22.9 m)

Accessories

Runner ™ Cart

Coolmate ™ 3.5

TIG Coolant

Automation Interface Kit

Weld Current Sensor


CD-ROM

Torch Adapters

Water-Cooled Dinse

#300 244

#300 245

#043 810

#195 516

#300 179

#170 555

#233 558

#195 377

Water-Cooled Thread Lock

Cable Connectors

Dinse Connector 50 mm (1 male)

Thread Lock Connectors (2 male)

#225 028

#042 418

#225 029

Dinse Connector 50 mm (1 male, 1 female) #042 419

Tweco Terminal Adapter #042 465

Cam-Lok Terminal Adapter #042 466

Miscellaneous

Stick Electrodes

Welding and Work Cables

Welding Gloves and Helmet

Date:

See page 7

Requires coolant

Sold in multiples of 4. 1-gallon plastic bottles.

Field. Provides required automation connections

Field. Installation required.

Contact your distributor

Setup and simulator video (included with machine)

Supplied with power source and torch kits

Used to connect water-cooled torch to Dinse terminal machine.

For WP20, WP18 and CS310 (adapter included in Complete Package)

Used to connect water-cooled torch to Dynasty/Maxstar 700


Used to connect weld lead to Dinse terminal machine

Used to connect weld lead to Dynasty 700 or Maxstar 700

Used to extend weld cables

Male Dinse to female Tweco

Male Dinse to female Cam-Lok


Qty.

Price

Distributed by:

Litho in USA

Issued March 2008 • Index No. DC/24.0

Maxstar

®

350 and 700

TIG/Stick Welding

Power Source

Quick

Specs

Industrial Applications

Precision Metal Fabrication

Tube Mills

Pipe and Tube Fabrication

Tool and Die

Exotic Material Fabrication

Pressure Vessel Fabrication

Processes

TIG (GTAW)

Pulsed TIG (GTAW-P)

Stick (SMAW)

Input Power

208 – 575 V, 3- or 1-Phase

Amperage Range 350:

5 – 350 A

700:

5 – 700 A

Rated Output 350: 300 A at 32 V, 60% Duty Cycle

700:

600 A at 44 V, 60% Duty Cycle

Weight 350:

135.5 lb (61 kg)

700:

198 lb (90 kg)

The Power of Blue .

®

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.

120 V auxiliary power receptacle for cooling system or small tools.

Wind Tunnel Technology ™ protects internal electrical components from airborne contaminates, extending the product life.

Fan-On-Demand ™ power source cooling system operates only when needed, reducing noise, energy use and the amount of contaminates pulled though the machine.

TIGRunner ® Packages feature a

3.5 gallon (13.2 L) cooling system.

The cart is equipped with cylinder carrying capabilities, filler rod holder, foot pedal holder, torch and cable holders. A pullout drawer provides additional storage for torch consumables and tools. See page 5.

Programmable start parameters allow independent starting conditions based on process and memory selections (amperage and time).

Auto-Postflow calculates the length of postflow time based on the amperage setting. This eliminates the need to independently set the postflow time for different amperages.

This feature preserves your tungsten and prevents porosity.

Maxstar 350

Maxstar 700

Program memory features 9 independent program memories that maintain/save your parameters.

DC TIG Features

Exceptionally smooth and precise arc for welding exotic materials.

High-Speed DC TIG Pulse

Control — pulse frequency capable of pulsing 5000 pulses per second. Pulsing adds arc stability, reduces heat input and warpage and can increase travel speeds.

Other parameters include peak amperage, peak time and background amperage.

High-frequency arc starter for non contact arc initiation.

Lift-Arc ™ start provides arc starting without the use of high frequency.

DC Stick Features

Tailored arc control (DIG) allows the arc characteristic to be changed for specific applications and electrodes.

Smooth running 7018 or stiffer, more penetrating

6010.

Hot Start ™ adaptive control provides positive arc starts without sticking.


Original main power rectifier parts are warranted for 5 years.






Phone: 920-735-4505

USA FAX: 920-735-4134




2

Specifications


Model

Maxstar

350

Maxstar

700

Input

Power

Three-

Phase

Single-

Phase

Three-

Phase

Single-

Phase

Welding

Amperage

Range

Max.

Open-Circuit

Voltage

5 – 350 A 75 VDC

10 –15 VDC*

5 – 350 A

5 – 700 A

5 – 700 A

75 VDC

10 –15 VDC*

75 VDC

10 –15 VDC*

75 VDC

10 –15 VDC*

Rated

Output

250 A at 30 V,

100% Duty Cycle

300 A at 32 V,

60% Duty Cycle

180 A at 27.2 V,

100% Duty Cycle

225 A at 29 V,

60% Duty Cycle

500 A at 40 V,

100% Duty Cycle

600 A at 44 V,

60% Duty Cycle

360 A at 34 V,

100% Duty Cycle

450 A at 38 V,

60% Duty Cycle


208 V 230 V 400 V 460 V 575V

27

33

32

41

67

89

77

106


*Indicates sense-voltage for Lift-Arc TIG and Low OCV Stick.

24

30

16

37

60

80

70

96

14

17

—

—

35

46

—

—

12

15

14

19

30

40

35

48

9

12

11

15

24

32

28

38

KVA

9.7

12 11.5

6.4

8.6

8.2

24

32

16

22


KW

9.3

6

23

31

15

21

Dimensions

H: 24-3/4 in (629 mm)

W: 13-3/4 in (349 mm)

D: 22 in (559 mm)

Net

Weight

135.5 lb


H: 45-1/8 in (1146 mm)

W: 23-1/8 in (587 mm)

D: 43-3/4 in (1111 mm) with

TIGRunner ®

308 lb

(140 kg)

H: 34-5/8 in (879 mm)

W: 13-3/4 in (349 mm)

D: 22 in (559 mm)

198 lb

(90 kg)

Performance Data


800

700

Maxstar 700, 3-Phase

600

500


400


300


200

100

0

% DUTY CYCLE

Maxstar

®

350 and 700 Control Panel

9

10

11

1

8

7

2 3 4 5 6


1. Memory

2. Process/

Arc Starting

18 Combinations

(9 DC TIG)

(9 DC Stick)

TIG: HF Impulse, Lift Arc

STICK: Adaptive Hot Start

3. Output Control Standard Remote,

2T Trigger Hold,

Output ON

4. Pulser Control

Pulses per Second DC : 0.1– 5000 PPS

Peak Time 5 – 95%

Background Amps 5 – 95%

5. Sequencer Control

Initial Amps Maxstar 350: 5 –350 A

Initial Slope

Maxstar 700: 5– 700 A

0.0 – 50.0 Seconds

Final Slope

Final Amps

0.0 – 50.0 Seconds

Maxstar 350: 5 –350 A

Maxstar 700: 5– 700 A

6. Gas/DIG Preflow 0.0 – 25.0 Seconds

Postflow Auto Postflow,

Adjust 0.0 – 50 Seconds

DIG 0 – 100%

Additional Setup Parameter Values

Programmable Starts

Amperage 5 – 200 A

Time 1– 200 Milliseconds

Additional Triggers 3T, 4T, Mini Logic,

4T Momentary

Spot/Weld Timer 0.0 – 999 Seconds

OCV Low OCV, Normal OCV

Lockouts

Arc Timer

Four levels

0.0 – 9999 Hours and 0 – 59 Min

Cycle Counter 0 – 999,999 Cycles

7. Amperage Control

8. Encoder Control

9. Ammeter Display

10. Voltmeter Display

11. Memory Display

3

4

Pulse TIG Controls

High Speed DC TIG-Pulse Controls

• PPS Pulses per second (Hz): DC = 0.1 – 5,000 PPS

• % ON – % Peak Time: 5 - 95% (Controls the amount of time during each pulse cycle at the PEAK amperage.)

• Background Amps: 5 – 99% (Sets the low-pulse amperage value as a % of the Peak Amps.)

CONVENTIONAL PULSED TIG

Peak Amps

Background Amps

(% of Peak)

Peak Time %

Typically from 1 to 10 PPS. Provides a heating and cooling effect on the weld puddle and can reduce distortion by lowering the average amperage. This heating and cooling effect also produces a distinct ripple pattern in the weld bead. The relationship between pulse frequency and travel speed determines the distance between the ripples. Slow pulsing can also be coordinated with filler metal addition and can increase overall control of the weld puddle.

Pulse Cycle

HIGH SPEED PULSED TIG

Peak Amps

Background Amps

(% of Peak)

Pulse Cycle

Peak Time %

In excess of 40 PPS, Pulsed TIG becomes more audible than visible — causing increased puddle agitation for a better as-welded microstructure.

Pulsing the weld current at high speeds — between a high Peak and a low Background amperage — can also constrict and focus the arc. This results in maximum arc stability, increased penetration and increased travel speeds (Common Range: 100 –

500 PPS).

The Arc-Sharpening effects of high speed pulsing are expanded to new dimensions. The ability to pulse at 5,000 PPS further enhances arc stability and concentration potential — which is extremely beneficial to automation where maximum travel speeds are required.

Packages

Maxstar ® Power Sources

Maxstar ® 350 #907 334 (CSA)


Maxstar ® 350 #907 334-01-2 (CE)


8 ft (2.4 m) primary cord, (2) international

(Dinse 50) connectors, and CD-ROM Setup and Simulator.

Note: TIG torch adapter must be ordered separately.

Maxstar ® 700 #907 103 (CSA)


Maxstar ® 700 #907 104 (CE)


(2) thread lock weld cable connectors

(#225 029), (1) water-cooled thread lock torch adapter (#225 028) for #18 or #20 torches, and CD-ROM Setup and Simulator.

Note: Primary cord and TIG torch must be ordered separately.

TIGRunner ® Package

Maxstar 350 TIGRunner ®

#907 334-01-1 (CSA)


Package includes:

Maxstar ® 350 (#907 334)

RFCS-14 HD remote foot control





TIGRunner ® Complete Package

Maxstar 350 TIGRunner ®

#951 073 (CSA)

Complete


Package includes:

Maxstar ® 350 TIGRunner ® (#907 334-01-1)

25 ft (7.6 m) Weldcraft CS310 torch

Torch cable cover

CS310AKC torch accessory kit includes shielding cups, collets, collet bodies and 2% cerium tungsten electrodes

(1/16, 3/32, and 1/8 in)

Smith regulator/flowmeter HM2051A-580






5


Torch Kits


25 ft (7.6 m) Weldcraft ® WP20 torch

Torch cable cover

AK4C torch accessory kit includes shielding cups, collets, collet bodies and


3/32 and 1/8 in)







Recommended for Maxstar 350

25 ft (7.6 m) Weldcraft ® CS310 torch

Torch cable cover

CS310AKC torch accessory kit includes shielding cups, collets, collet bodies and


3/32 and 1/8 in)







Recommended for Maxstar 700

25 ft (7.6 m) Weldcraft ® WP18SC torch

Torch cable cover

AK18C torch accessory kit includes shielding cups, collets, collet bodies and


1/8 and 5/32 in)

Smith ® regulator/flowmeter H1954D-580


Water-cooled thread lock torch adapters



TIG Welding Gloves

#227 813 Small

#227 814 Medium

#227 815 Large

#227 816 X-Large

Made from soft grain goatskin. Sewn with Kevlar ® thread.

Automation Interface Kit #195 516 Field

Includes automation PC board, 28-pin socket receptacle with harness, 28-pin plug connector. Provides required and advanced automation controls.

Weld Current Sensor #300 179

Detects when work clamp is not connected and prevents expensive damage to disconnect devices and input power cord and wiring.

Educational Materials

To order these items, distributors can call the Miller Literature Distribution Center at

1-920-735-4356, or FAX 1-920-735-4011.

Gas Tungsten Arc (TIG) Welding Book

#170 555

86 pages — 8-1/2 x 11 in. A comprehensive text on all aspects of the GTAW process.

Filled with figures and tables to illustrate process technique and equipment setup.

Glossary of TIG terms also provided.

CD-ROM #233 558

Simulator and setup video (included with machine).

Tungsten

Tungsten is 7 in length and available in pkgs of 10.

2% Ceriated (orange) for AC/DC applications

#WC040X7 .040 in, 10– 80 A

#WC116X7 1/16 in, 70– 150 A

#WC332X7 3/32 in, 140– 250 A

#WC018X7 1/8 in, 225– 400 A

#WC532X7 5/32 in, 300– 500 A

1.5% Lanthanum (gold) for AC/DC applications

#WL040X7 .040 in, 10– 80 A

#WL116X7 1/16 in, 70– 150 A

#WL332X7 3/32 in, 140– 250 A

#WL018X7 1/8 in, 225– 400 A

#WL532X7 5/32 in, 300– 500 A

2% Thoriated (red) for DC applications only

#WT040X7 .040 in, 10– 80 A

#WT116X7 1/16 in, 70– 150 A

#WT332X7 3/32 in, 140– 250 A

#WT018X7 1/8 in, 225– 400 A

#WT532X7 5/32 in, 300– 500 A

Runner Cart

#300 244

Designed to accommodate the Dynasty ® or Maxstar ®

350 or 700 power sources and the Coolmate ™

3.5 Cooler.

Cart features: single cylinder rack, foot pedal holder, (3) cable/torch holders, (2)

TIG electrode filler holders and a convenient drawer for tungsten and consumable storage.

6


(continued)

Water-Cooled Dinse #195 377

Used to adapt WP20, WP18, and CS310 to dinse-style connector.

Coolmate ™ 3.5 #300 245

Designed to integrate with the Dynasty ®

Maxstar ® and

350 and 700 power sources. For use with water-cooled torches rated up to

600 amps. 3.5 gallon capacity.

TIG Coolant #043 810

Sold in multiples of 4. Pre-mixed lowconductivity Miller coolant contains ethylene glycol and deionized water to protect from freezing and boiling -37˚ to

227˚F (-38˚ to 108˚C). Coolant contains

2.4% algae growth inhibitor. 1-gallon plastic recyclable bottles.

Remote Controls and Switches

RCCS-14 Remote Contactor and

Current Control #043 688 14-pin plug

North/south rotary-motion fingertip control fastens to TIG torch using two Velcro ® straps. Great for applications that require a finer amperage control. Includes 26.5 ft

(8 m) control cord.

RHC-14 Hand Control

#129 340

Miniature hand control for remote current

3-1/4 in (102 x 102 x

83 mm). Includes 20 ft (6 m) cord and

14-pin plug.

and contactor control.

Dimensions: 4 x 4 x

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 ft (8 m) cord and 14-pin plug.

Extension Cords for 14-Pin Remote Controls

#122 973 25 ft (7.6 m)

#122 974 50 ft (15.2 m)

#122 975 75 ft (23 m)

RFCS-14 HD

Foot Control

#194 744

Maximum flexibility is accomplished with a recon figurable cord that can exit the front, back or either side of the pedal. Foot pedal provides remote current and contactor control.


RMLS-14 Switch #129 337

Momentary- and maintained-contact rocker switch for contactor control. Push forward for maintained contact and backward for momentary contact. Includes 26.5 ft (8 m) cord and 14-pin plug.

7



Maxstar ® 350

Maxstar ® 350 International

Maxstar ® 350 TIGRunner ®

Maxstar ® 350 TIGRunner ® Complete

Maxstar ® 700

Maxstar ® 700 International

TIG Torch Kits

Weldcraft ® 250 A Water-Cooled Torch Kit #300 185



Consumables and Tungsten

Gas Cylinder, Hose and Fittings

Remote Controls

RCCS-14

RFCS-14 HD

RHC-14

RMLS-14

RMS-14

Extension Cords

#043 688

#194 744

#129 340

#129 337

#187 208

#122 973

#122 974

#122 975

Accessories

Runner ™ Cart

Coolmate ™ 3.5

TIG Coolant

Automation Interface Kit

Weld Current Sensor


CD-ROM

Torch Adapters

Water-Cooled Dinse

#300 244

#300 245

#043 810

#195 516

#300 179

#170 555

#233 558

#195 377

Water-Cooled Thread Lock

Cable Connectors

Dinse Connector 50 mm (1 male)

Thread Lock Connectors (2 male)

Miscellaneous

Stick Electrodes

Welding and Work Cables

Welding Gloves and Helmet

Stock No.

#225 028

#042 418

#225 029

Dinse Connector 50 mm (1 male, 1 female) #042 419

Tweco Terminal Adapter #042 465

Cam-Lok Terminal Adapter #042 466

Description

#907 334 Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8 ft primary cord

#907 334-01-2 Auto-Line™ 380 – 575 VAC, 50/60 Hz, CE. 8 ft primary cord

#907 334-01-1 Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8 ft primary cord. Requires coolant

#951 073 Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA. 8 ft primary cord.

#907 103 Auto-Line™ 208 – 575 VAC, 50/60 Hz, CSA

#907 103-01-2 Auto-Line™ 380 – 575 VAC, 50/60 Hz, CE

See page 6

See page 6. Recommended for Maxstar 350

See page 6. Recommended for Maxstar 700

Distributor: See Miller Parts Catalog



Hand control

Momentary/maintained rocker switch


25 ft (7.6 m)

50 ft (15.2 m)

75 ft (22.9 m)

See page 6

Requires coolant

Sold in multiples of 4. 1-gallon plastic bottles.

Field. Provides required automation connections

Field. Installation required.

Contact your distributor

Simulator and setup video (included with machine)


Used to connect water-cooled torch to Dinse terminal machine.

For WP20, WP18 and CS310 (adapter included in Complete Package)

Used to connect water-cooled torch to Dynasty/Maxstar 700


Used to connect weld lead to Dinse terminal machine

Used to connect weld lead to Dynasty 700 or Maxstar 700

Used to extend weld cables

Male Dinse to female Tweco

Male Dinse to female Cam-Lok

Qty.


Price

Distributed by:

Litho in USA

Issued February 2008 • Index No. DC/27.1

Maxstar

®

150 STL

TIG/Stick Welding

Power Source

Quick

Specs


Process Piping

Dairy Industry


Restaurant/Kitchen Repair

Experimental Aircraft


Maintenance Repair

Processes

Lift-Arc ™ TIG (GTAW)

Stick (SMAW)

Input Power

1-Phase Power

Amperage Range

115 VAC: 5 – 150 A (DC TIG)

20 – 100 A (DC Stick)

230 VAC: 5 – 150 A (DC TIG)

20 – 150 A (DC Stick)

Max. Open-Circuit Voltage 90

Weight

13.7 lb (6.2 kg)

The Power of Blue .

®

Improved!

New Case and

MVP Plugs!

Auto-Line ™ provides state-of-the-art flexibility to the end user. The Auto-

Line circuitry automatically connects to 115–230 VAC, single-phase power without removing the covers to relink the power source. No longer is there a concern if you have the correct machine for the shop or job site.

Miller’s exclusive multi-voltage plug

(MVP ™ ) allows connection to 115 or 230 V receptacles without tools — choose the plug that fits the receptacle and connect it to the power cord.

Portable in the shop or at the job site — at 13.7 lb the shoulder strap allows the end user to easily move from location to location.

Lift-Arc ™ start provides TIG arc starting without the use of high frequency.

Built-in gas solenoid eliminates the need for bulky torch with a gas valve.

Full function remote control for precise amperage control for critical welds on thin materials (6-pin fingertip or foot control available.)

Thermal overload protection with

indicator light helps prevent machine damage if the duty cycle is exceeded or airflow is blocked.

TIG/Stick Package (#907 135-01-7) comes complete with:

Maxstar 150 STL

10 ft (3 m) MVP ™ power cord

MVP ™ plugs 5-15P (115 V, 15 A) and 6-50P (230 V, 50 A)

X-CASE ™ provides protection in transport and storage

Remote fingertip control

Weldcraft ® WP1712RD125 TIG torch with adapter

13 ft (4 m) Stick electrode holder with 25 mm Dinse connector

10 ft (3 m) work clamp with 25 mm Dinse connector

Smith ® regulator with gas hose

AK-2C accessory kit

Shoulder strap

Single amperage range allows operator to accurately set amperage on both 115 or 230 V primary power.

Inverter-based, DC power source has a simple-to-use operator interface providing only the necessary controls in a compact machine.

Adaptive Hot Start ™ for Stick arc

starts automatically increases the output amperage at the start of a weld should the start require it.

Prevents the electrode from sticking and creating an inclusion.

Low OCV Stick is a simple design that reduces the open-circuit voltage to 12–16 V when the welding power source is not in use.

This circuit design is now built into the Maxstar 150 STL eliminating the need for add-on voltage reducers.

Best in class Stick arc character -

istics for those demanding jobs.

Power Factor Corrected (PFC) for optimum performance especially on 115 V — reduces nuisance breaker tripping.

Fan-On-Demand ™ power source cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled through the machine.


Original main power rectifiers are warranted for 5 years.






Phone: 920-735-4505

USA FAX: 920-735-4134




3

4

1

2

Specifications


Input Power

115 VAC Stick 15 A

115 VAC TIG 15 A

115 VAC Stick 20 A

115 VAC TIG 20 A

230 VAC Stick

230 VAC TIG

Welding

Amperage

Range

20 –70 A

5 –100 A

20 –100 A

5 –150 A

20 –150 A

5 –150 A

Rated Welding Output

70 A at 22.8 VDC, 100% Duty Cycle










Amps Input at

Rated Output, 50/60 Hz

28.0

13.1

21.6

8.3

14.2

17.4

18.4

17.4

26.4

18.4

KVA at

Duty Cycle

3.4

3.0

4.9

2.0

3.2

2.0

2.1

2.0

3.0

2.1

KW

3.1

2.8

4.7

1.9

3.1

1.9

2.1

1.9

3.0

2.1

Max. Open-

Circuit Voltage

90, 12 –16 V*

90, 12 –16 V*

90, 12 –16 V*

90, 12 –16 V*

Dimensions

H: 9 in

(229 mm)

W: 5-1/2 in

(140 mm)

D: 13-1/4 in

(337 mm)

Weight

13.7 lb

(6.2 kg)

90, 12 –16 V*

90, 12 –16 V*


*Sense voltage for Stick and Lift-Arc TIG.

Control Panel

7

5

8

1. Amperage Adjustment Control

2. Remote TIG Selector Light

3. TIG Selector Light

4. Stick Selector Light

5. Process Selector Touch Pad

6. Positive Weld Output Receptacle

7. Ready Light

8. Overtemperature Light

9. Negative Weld Output Receptacle with Flow Thru

6 9

2

Performance Data


250

200

150

Stick (230 V)

Stick (115 V 20 A)

100

TIG (115 V 20 A & 230 V)

50

0

10

TIG/Stick (115 V 15 A)

20 40

% DUTY CYCLE

60 80 100

40

20

0

0

100

80

60

VOLT/AMP CURVES

230 V TIG/Stick Max

115 V TIG/Stick Max

TIG Min

Stick Min

50 100

AMPS

150 200

Maxstar ® 150 STL Packages

Packages

Standard Package #907 135

Package includes:

Maxstar 150 STL





International flow-thru adapter

Shoulder strap

TIG/Stick Package #907 135-01-6

TIG/Stick Package with Remote Fingertip Control #907 135-01-7

Package includes:

Maxstar 150 STL

Remote fingertip control (#195 184) (#907 135-01-7 Package only)



X-CASE ™ — provides protection in transport and storage





AK-2C accessory kit

Shoulder strap

Maxstar Travel Paks ™

Travel Pak ™ with Accessories #907 135-01-5

Travel Pak ™ with Remote Control and Accessories #907 135-01-4

Package includes:

Maxstar 150 STL

Remote fingertip control (#195 184) (#907 135-01-4 Package only)



Softside travel case with wheels, telescoping handle and carrying straps





AK-2C accessory kit and Stick electrode box

Shoulder strap

Travel Pak ™ with Remote Control, Accessories and Hand Tools #907 135-01-3

Package includes:

Maxstar 150 STL

Remote fingertip control (#195 184)








AK-2C accessory kit and stick electrode box

Shoulder strap

Kline 9-in side cutter, Nicholson 10-in half-round file, and Weiler SS brushes

Mini MagLite flashlight, and 1-in diameter inspection mirror

3


X-CASE ™ #300 184

Sturdy case provides ultimate protection for transport and storage.

Also features convenient top carrying handle and side recessed hand grips. Store the Maxstar 150, accessories and gear in this generous case to be ready to go at any time. Dimensions:

13 in H x 10-1/2 in W x 30-5/8 in D

(330 x 267 x 778 mm).

Travel Pak ™ Case

#300 249

If you are already using the Maxstar 150 and want the portability and convenience to take everything you need — purchase the bag and customize with your own tools.

Remote Controls

RCCS-6M (6-pin plug)

#195 184 13.25 ft (4 m) cord

#195 503 26.5 ft (8 m) cord

North/south rotary-motion fingertip current/contactor control fastens to TIG torch using two Velcro ® straps. Great for applications that require a finer amperage control. Includes cord and plug.

RFCS-6M (6-pin plug)

#195 183 13.25 ft (4 m) cord

#195 504 20 ft (6 m) cord

Foot pedal current/contactor control. Includes cord and plug.

TIG (GTAW) Torch Packages

The Weldcraft line of TIG torches complements the most popular TIG power source line available today. The Weldcraft torch line includes both air-cooled and water-cooled models. Available with genuine

Weldcraft parts.

Air-Cooled Torches

#WP1712RDI25 150 A, 12 ft (3.7 m) air-cooled torch with flow-thru adapter


MVP ™ Adapter Plugs

Order from Miller Service Parts.

#219 258 For Power Cable 6-50P

(230 V/50 A). Included with machine.

Female

Receptacle

Adapter Cord, Full KVA #300 158 Field

NEMA 14-50P to NEMA 6-50R. Adapts engine drive 120/240 V plug to Maxstar

240 V plug.

RMS-6M (6-pin plug) #195 269

Momentary-contact switch for contactor control. Rubber-covered pushbutton dome switch ideal for repetitive on-off applications. Includes 26.5 ft (8 m) cord and plug.




(115 V/20 A). Optional.


Power Source and Options

Maxstar ® 150 STL Standard Package

Maxstar ® STL TIG/Stick Package

Maxstar ® 150 STL Travel Pak ™

Stock No.

Description

#907 135 Maxstar 150 STL with electrode holder, work clamp, and MVP cord and plugs

#907 135-01-6 Includes #907 135 PLUS X-CASE ™ , TIG torch, gas regulator with hose, and

AK-2C accessory kit

#907 135-01-7 Includes #907 135-01-6 PLUS remote fingertip control

#907 135-01-5 Includes #907 135 PLUS Travel Pak ™ and AK-2C accessory kit case, TIG torch, gas regulator with hose,

#907 135-01-4 Includes #907 135-01-5 PLUS remote fingertip control

#907 135-01-3 Includes #907 135-01-4 PLUS side cutter, file, brushes, and flashlight

Qty.

Accessories

X-CASE ™ (only)

Travel Pak ™ Case (only)

RCCS-6M

RMS-6M

RFCS-6M

Weldcraft TIG Torch

International-Style Flow Thru Adapter

Adapter Cord, Full KVA


Date:

#300 184

#300 249

#195 184

#195 503

#195 269

#195 183

#195 504

#195 234

#300 158

Carrying case for Maxstar 150 STL


13.25 ft (4 m) remote fingertip control

26.5 ft (8 m), remote fingertip control

26.5 ft (8 m) remote on/off control

13.25 ft (4 m) remote foot control

20 ft (6 m) remote foot control

See Accessories section above

25 mm adapter for TIG torch connection

Adapts engine drive 120/240 V plug to Maxstar 240 V plug



Distributed by:

Price

Litho in USA

Issued February 2008 • Index No. DC/27.2

Maxstar

®

150 STH

TIG/Stick Welding

Power Source

Quick

Specs


Process Pipe

Dairy Industry


Restaurant/Kitchen Repair

Experimental Aircraft


Maintenance Repair

Processes

TIG (GTAW)

Pulsed TIG (GTAW-P)

Stick (SMAW)

Input Power

1-Phase Power

Amperage Range

115 VAC: 5 – 150 A (DC TIG)

20 – 100 A (DC Stick)

230 VAC: 5 – 150 A (DC TIG)

20 – 150 A (DC Stick)

Max. Open-Circuit Voltage 90

Weight

13.7 lb (6.2 kg)

The Power of Blue .

®

Improved!

New Case and

MVP Plugs!

Auto-Line ™ provides state-of-the-art flexibility to the end user. The Auto-

Line circuitry automatically connects to 115–230 VAC, single-phase power without removing the covers to relink the power source. No longer is there a concern if you have the correct machine for the shop or job site.

Miller’s exclusive multi-voltage plug (MVP ™ ) allows connection to 115 or 230 V receptacles without tools — choose the plug that fits the receptacle and connect it to the power cord.

Portable in the shop or at the job site — at 13.7 lb the shoulder strap allows the end user to easily move from location to location.

Built-in pulsing capabilities allow the operator to select from four fixed pulse frequencies to satisfy the application.

HF start for non-contact arc starting that eliminates tungsten or material contamination.

Selectable trigger configuration allows the operator to choose standard or 2T trigger method to meet the application.

Lift-Arc ™ start provides TIG arc starting without the use of high frequency.

Built-in gas solenoid eliminates the need for bulky torch with a gas valve.

Full function remote control for precise amperage control for critical welds on thin materials (6-pin fingertip or foot control available.)

TIG/Stick Package (#907 136-01-7) comes complete with:

Maxstar 150 STH

10 ft (3 m) MVP

MVP ™

® WP1712RD125 TIG torch with adapter




AK-2C accessory kit

Shoulder strap

™ power cord plugs 5-15P (115 V, 15 A) and 6-50P (230 V, 50 A)

X-CASE ™ provides protection in transport and storage

Remote fingertip control

Weldcraft



Thermal overload protection with

indicator light helps prevent machine damage if the duty cycle is exceeded or airflow is blocked.

Single amperage range allows operator to accurately set amperage on both 115 or 230 V primary power.

Inverter-based, DC power source has a simple-to-use operator interface providing only the necessary controls in a compact machine.

Adaptive Hot Start ™ for Stick arc

starts automatically increases the output amperage at the start of a weld should the start require it.

Prevents the electrode from sticking and creating an inclusion.

Low OCV Stick is a simple design that reduces the open-circuit voltage to 12–16 volts when the welding power source is not in use.

This circuit design is now built into the Maxstar 150 STH eliminating the need for add-on voltage reducers.

Best in class Stick arc character -

istics for those demanding jobs.

Power Factor Corrected (PFC) for optimum performance especially on 115 V — reduces nuisance breaker tripping.

Fan-On-Demand ™ power source cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled through the machine.






Phone: 920-735-4505

USA FAX: 920-735-4134




Specifications


Input Power

115 VAC Stick 15 A

115 VAC TIG 15 A

115 VAC Stick 20 A

115 VAC TIG 20 A

230 VAC Stick

230 VAC TIG

Welding

Amperage

Range

20 –70 A

5 –100 A

20 –100 A

5 –150 A

20 –150 A

5 –150 A

Rated Welding Output











Amps Input at

Rated Output, 50/60 Hz

17.4

18.4

17.4

26.4

18.4

28.0

13.1

21.6

8.3

14.2

KVA at

Duty Cycle

3.0

4.9

2.0

3.2

2.0

2.1

2.0

3.0

2.1

3.4

KW

2.8

4.7

1.9

3.1

1.9

2.1

1.9

3.0

2.1

3.1

Max. Open-

Circuit Voltage

90, 12 –16 V*

90, 12 –16 V*

90, 12 –16 V*

90, 12 –16 V*

Dimensions

H: 9 in

(229 mm)

W: 5-1/2 in

(140 mm)

D: 13-1/4 in

(337 mm)

Weight

13.7 lb

(6.2 kg)

90, 12 –16 V*

90, 12 –16 V*


*Sense voltage for Stick and Lift-Arc TIG.

6

1

4

5

2

3

Control Panel

8

9

1. TIG HF Impulse Selector Light

2. Pulsed TIG Selector Light

3. Amperage Adjustment Control

4. TIG Selector Light

5. Stick Selector Light

6. Process Selector Touch Pad

7. Positive Weld Output Receptacle

8. Ready Light

9. Overtemperature Light

10. Negative Weld Output Receptacle with Flow Thru

7 10

2

Performance Data


250

200

Stick (230 V)

150

Stick (115 V 20 A)

100

TIG (115 V 20 A & 230 V)

50

0

10

TIG/Stick (115 V 15 A)

20 40

% DUTY CYCLE

60 80 100

40

20

0

0

100

80

60

VOLT/AMP CURVES

230 V TIG/Stick Max

115 V TIG/Stick Max

TIG Min

Stick Min

50 100

AMPS

150 200

Maxstar ® 150 STH Packages

Packages

Standard Package #907 136

Package includes:

Maxstar 150 STH





International flow-thru adapter

Shoulder strap

TIG/Stick Package #907 136-01-7

Package includes:

Maxstar 150 STH




X-CASE ™ — provides protection in transport and storage





AK-2C accessory kit

Shoulder strap

Maxstar Travel Paks ™

Travel Pak ™ with Remote Control and Accessories #907 136-01-6

Package includes:

Maxstar 150 STH










Shoulder strap

Travel Pak ™ with Remote Control, Accessories and Hand Tools #907 136-01-5

Package includes:

Maxstar 150 STH










Shoulder strap

Kline 9-in side cutter, Nicholson 10-in half-round file, and Weiler SS brushes

Mini MagLite flashlight, and 1-in diameter inspection mirror

3


X-CASE ™ #300 184

Sturdy case provides ultimate protection for transport and storage.

Also features convenient top carrying handle and side recessed hand grips. Store the Maxstar 150, accessories and gear in this generous case to be ready to go at any time. Dimensions:

13 in H x 10-1/2 in W x 30-5/8 in D

(330 x 267 x 778 mm).

Travel Pak ™ Case

#300 249

If you are already using the Maxstar 150 and want the portability and convenience to take everything you need — purchase the bag and customize with your own tools.

Remote Controls

RCCS-6M (6-pin plug)

#195 184 13.25 ft (4 m) cord

#195 503 26.5 ft (8 m) cord

North/south rotary-motion fingertip current/contactor control fastens to TIG torch using two Velcro ® straps. Great for applications that require a finer amperage control. Includes cord and plug.

RFCS-6M (6-pin plug)

#195 183 13.25 ft (4 m) cord

#195 504 20 ft (6 m) cord

Foot pedal current/contactor control. Includes cord and plug.

TIG (GTAW) Torch Packages

The Weldcraft line of TIG torches complements the most popular TIG power source line available today. The Weldcraft torch line includes both air-cooled and water-cooled models. Available with genuine

Weldcraft parts.

Air-Cooled Torches




Order from Miller Service Parts.



Female

Receptacle

Adapter Cord, Full KVA #300 158 Field

NEMA 14-50P to NEMA 6-50R. Adapts engine drive 120/240 V plug to Maxstar

240 V plug.

RMS-6M (6-pin plug) #195 269

Momentary-contact switch for contactor control. Rubber-covered pushbutton dome switch ideal for repetitive on-off applications. Includes 26.5 ft (8 m) cord and plug.




(115 V/20 A). Optional.



Maxstar ® 150 STH Standard Package

Maxstar ® 150 STH TIG/Stick Package with Remote Fingertip Control

Maxstar ® 150 STH Travel Pak ™

Stock No.

Description

#907 136 Maxstar 150 STH with electrode holder, work clamp, and MVP cord and plugs

#907 136-01-7 Includes #907 136 PLUS X-CASE ™ , TIG torch, gas regulator with hose,

AK-2C accessory kit, and remote fingertip control

#907 136-01-6 Includes #907 136 PLUS Travel Pak ™ case, TIG torch, gas regulator with hose,

AK-2C accessory kit, and remote fingertip control

#907 136-01-5 Includes #907 136-01-6 PLUS side cutter, file, brushes, and flashlight

Qty.

Accessories

X-CASE ™ (only)

Travel Pak ™ Case (only)

RCCS-6M

RMS-6M

RFCS-6M

Weldcraft TIG Torch

International-Style Flow Thru Adapter

Adapter Cord, Full KVA


Date:

#300 184

#300 249

#195 184

#195 503

#195 269

#195 183

#195 504

#195 234

#300 158

Carrying case for Maxstar 150 STL


13.25 ft (4 m) remote fingertip control

26.5 ft (8 m), remote fingertip control

26.5 ft (8 m) remote on/off control

13.25 ft (4 m) remote foot control

20 ft (6 m) remote foot control


25 mm adapter for TIG torch connection

Adapts engine drive 120/240 V plug to Maxstar 240 V plug



Price

Distributed by:

Litho in USA

Issued August 2007 • Index No. DC/32.0

Maxstar

®

200 Series

TIG/Stick Welding

Power Source

Quick

Specs

Heavy Industrial Applications

Petro/Chem Fabrication

Aerospace


Mechanical Contractors


Dairy Industry

Processes

TIG (GTAW)

Pulsed TIG (GTAW-P) with DX and LX Models

Stick (SMAW)

Input Power Requires 1- or 3-Phase Power



80

Weight

37 lb (16.8 kg)

The Power of Blue ® .

HF arc starting provides non-contact arc starting that eliminates tungsten or material contamination.

Auto-Line ™ provides state-of-theart flexibility to the end user. The

Auto-Line circuitry automatically connects to 120 – 460 VAC, singleor three-phase power without removing the covers to relink the power source. No longer is there a concern if you have the correct machine for shop or the job site.

Lift-Arc ™ start provides TIG arc starting without the use of high frequency.

Inverter-based, DC power source has state-of-the-art operator

interface allowing the user extra set-up capabilities in a compact machine. Features more precise control of output parameters than traditional knobs and switches.

Programmable HF start parameters allows the independently set

HF starting conditions based upon process or application.

NEW! Low OCV Stick is a simple design that reduces the open-circuit voltage to 13 volts when the welding power source is not in use. This built-in circuit design eliminates the need for add-on voltage reducers.

Maxstar 200 DX Maxstar 200 LX Maxstar 200 SD

Available in Three Models:

SD — Provides the basic features that are required for most TIG or Stick welding applications.

DX — When the job demands greater control the DX provides pulse on/off, pulse frequency, peak % time, background amperage, initial amperage, initial slope time, final slope time and final amperage control.

LX — Automation made simple. With the Automation Interface Connector, the integrator can quickly interface to the output disable, weld start/stop, gas start/stop inputs; valid arc, pulse lock out, and end of weld sequence outputs.

Superior TIG/Stick arc performance on all input voltages. Even on the difficult to run electrodes like E6010.

Portable in the shop or at the job site — at 37 lb the Maxstar 200 is easily moved from location to location.








Phone: 920-735-4505

USA FAX: 920-735-4134




2

Specifications


Welding

Mode

TIG

(GTAW)

Stick

(SMAW)

Input

Power

3-Phase

1-Phase

3-Phase

1-Phase

Rated

Output

175 A at 17 V,

60% Duty Cycle

175 A at 17 V,

60% Duty Cycle

150 A at 16 V,

70% Duty Cycle

125 A at 15 V,

100% Duty Cycle

150 A at 26 V,

60% Duty Cycle

150 A at 26 V,

60% Duty Cycle

125 A at 25 V,

50% Duty Cycle

90 A at 24 V,

100% Duty Cycle

Welding

Amperage

Range

115 VAC,

1 –140 A

200 – 460 VAC,

1 – 200 A

115 VAC,

1 – 90 A

200 – 460 VAC,

1 – 200 A

Max.

Open-

Circuit

Voltage

75 VDC

9 –14 VDC**

75 VDC

Amps Input at Rated Load Output, 50/60 Hz,

115 V 200 V 230 V 400 V 440 V 460 V KVA KW

— 12.1

10.5

6.0

5.3

5.2

4.2

4.0

— 0.16* 0.16* 0.24* 0.24* 0.25* 0.06* 0.03*

— 19.9

17.4

— —

— 0.25* 0.23* — —

29.7

— — — —

0.42* — — — —

23.0

— — — —

0.42* — — — —

—

—

—

—

—

—

4.0

3.4

2.6

4.0

0.05* 0.02*

3.4

0.05* 0.03*

2.6

0.05* 0.03*

— 14.7

13.1

7.4

6.6

6.4

5.2

5.0

— 0.16* 0.16* 0.24* 0.24* 0.25* 0.06* 0.03*

— 24.9

21.7

— —

— 0.25* 0.23* — —

—

—

5.0

5.0

0.05* 0.02*

34.1

— — — —

0.42* — — — —

25.0

— — — —

0.42* — — — —

—

—

—

—

4.0

3.8

0.05* 0.03*

4.0

3.8

0.05* 0.03*

Dimensions

H: 13-1/2 in

(343 mm)

W: 7-1/2 in

(191 mm)

D: 17-1/2 in

(445 mm)

* Indicates idle draw. **Sense voltage for Stick and Lift-Arc TIG.

CSA approval.

Models with CE specifications are available and manufactured according to the Standards IEC-974-1 and EN-60974-1.

Net

Weight

37 lb

(16.8 kg)

Control Panel

Maxstar 200 SD Maxstar 200 DX/LX

1. Voltmeter

2. Ammeter

3. Process Control

4. Output Control

5. Encoder Control

6. Amperage Control

7. Adjust Control

8. Sequencer Controls

9. Pulser Controls

3

4

1

2

1

2

Maxstar 200 SD (CE)

5 1

2

6

7

3

4

5 1

2

6

3

4

7

8

3

4


A. Preflow (s)

B. Initial Time (s)

0.0 – 25

0.0 – 25 (LX only)

C. Initial Amperage (A) 1 – 200

D. Initial Slope Time (s) 0.0 – 25

E. Weld Amperage (A) 1 – 200

F. Pulse Frequency (Hz)

G. Background Amperage (%)

H. Peak Percent Time (%)

I. Final Slope Time (s)

J. Final Amperage (A)

0.1 – 500

0 – 100

5 – 95

0.0 – 25

1 – 200

Maxstar 200 DX (CE)

K. Final Time (s) 0.0 – 25 (LX only)

L. Postflow Time (s) 0 – 50.0

M. Dig (%) 0 – 100

5

6

7

8

9

5

6

7

8

9

Performance Data


250

TIG

200

TIG (115 V INPUT)

STICK

150

100

50

STICK

(115 V INPUT)

0

10 20 30 40 50 60 70 80 90 100

% DUTY CYCLE

OTHER INPUT VOLTAGES

60

40

20

0

140

120

100

80

STICK/

TIG MIN.

STICK MAX.

TIG MAX.

DIG MAX.

AMPERES*

*Amperage setting must be reduced to obtain currents less than highlighted data point.

115 VAC INPUT

140

120

100

80

60

STICK MAX.

TIG MAX.

40

20

0

0

STICK/

TIG MIN.

50

DIG MAX.

100 150

AMPERES*

200 250

Included Accessories

Non-CE SD/DX Models Include:


(1) DA-917F torch adapter to international-style connector (#194 720)

Non-CE LX Model Includes:




(1) 5/8 in - 18 gas fitting

CE SD/DX Models Include:



(1) 5/8 in - 18 gas fitting

(1) 3/8 in BSPP gas fitting

3



Maxstar

Maxstar

®

®

200 SD

200 DX

Stock No.

Description

#903 701

#903 768

Basic controls for TIG/Stick, 120 – 460 VAC

Basic controls for TIG/Stick, 120 – 460 VAC with CE

#903 701-01-1 Full-feature controls for TIG/Stick, 120 – 460 VAC

#903 768-01-1 Full-feature controls for TIG/Stick, 120 – 460 VAC with CE

#903 701-01-2 Full-feature controls with the required automation connections, 120 – 460 VAC Maxstar ® 200 LX

TIG Accessories

TIG Torch Adapters

Contractor Kits

#194 720

#190 219

#194 724

#195 055

#195 054

DA-917F

DA-1820L

DA-26R

150 A TIG/Stick with RCCS-14 fingertip control

150 A TIG/Stick with RFCS-14 HD foot control

See Diamondback TIG Torch Selector Guide

See Parts Guide

Diamondback ™ TIG Torches

Consumables/Tungsten

Gas Cylinder/Hose and Fittings

Remote Controls

RFCS-14 HD

RCCS-14

RCC-14

RMLS-14

RMS-14

Extension Cords

Coolant Systems

Coolmate ™ 3

#194 744

#043 688

#151 086

#129 337

#187 208






Coolmate

Coolmate

™

™

V3

4

Low-Conductivity Coolant

#043 007 115 VAC

#043 007-01-2 115 VAC with CE

#043 008 230 VAC

#043 008-01-2 230 VAC with CE

#043 009 115 VAC

#043 009-01-2 115 VAC, 50/60 Hz with CE

#042 288 115 VAC

#042 288-01-5 115 VAC with CE

#043 810

International-Style Connectors

International-Style Connector Kit #042 418

Extension Kit for International-Style #042 419

International/Tweco ® Adapter #042 465

International/Cam-Lok Adapter #042 466

Dinse, (1) male plug - 50 mm

Dinse, (1) plug and (1) receptacle - 50 mm




Qty.

Price

Litho in USA

Distributed by:

Miller | User manual | A AD1-2 Econotig.qxd

Econotig

Complete

Package!

Syncrowave

200

Dynasty

200 Series

Dynasty

350 and 700

Quick

Specs

The Power of Blue .

Specifications

(Subject to change without notice.)

Control Panel

Performance Data

TIG Upgrade Chart

Why Upgrade?

Syncrowave 350

Dynasty 350

Dynasty 350 Benefits

AC Waveshape Controls

Feature

AC Waveshape Controls

(Continued)

AC Waveform Selection

Pulse TIG Controls

High Speed DC TIG-Pulse Controls

Packages and Torch Kits

Genuine Miller Accessories

Ordering Information

Maxstar

350 and 700

Quick

Specs

The Power of Blue .

Specifications

(Subject to change without notice.)

Performance Data

Maxstar

350 and 700 Control Panel

Pulse TIG Controls

High Speed DC TIG-Pulse Controls

CONVENTIONAL PULSED TIG

Peak Amps

Background Amps

(% of Peak)

HIGH SPEED PULSED TIG

Peak Amps

Background Amps

(% of Peak)

Packages

Genuine Miller Accessories

Genuine Miller Accessories

(continued)

Ordering Information

Maxstar

150 STL

Improved!

Maxstar

150 STH

Improved!

Maxstar

200 Series

Related manuals

Miller Electric

150 S

Miller Electric

150 STL

Miller Electric

Arc Welding Power Source

Miller Electric

Syncrowave 200

Maxstar 150 STH