Miller Maxstar 175 User manual

Miller Maxstar 175 User manual
Maxstar 200 Series
Issued January 2011 • Index No. DC/32.0
®
Quick
Specs
TIG/Stick Welding
Power Source
Industrial Applications
Processes
Input Power
Precision Fabrication
Petro/Chemical
Aerospace
Food/Beverage Industry
Dairy
Shipboard
TIG (GTAW)
Pulsed TIG (GTAW-P)
Stick (SMAW)
Air Carbon Arc (CAC-A)
5/32 in maximum
Amperage Range
Rated Output
Weight
115 – 460 V, 3- or 1-Phase Power
1– 200 A
200 A at 28 V, 20% Duty Cycle
37 lb (16.8 kg)
The Power of Blue .
®
DC TIG Features
Exceptionally smooth and precise
arc for welding exotic materials.
Allows for any input voltage hookup
(115–460 V) with no manual linking,
providing convenience in any job
setting. Ideal solution for dirty or
unreliable power.
Stick Features (DC)
Fan-On-Demand™ power source
cooling system operates only when
needed, reducing noise, energy use
and the amount of contaminates
pulled through the machine.
Maxstar 200 SD
Maxstar 200 DX
Complete Package
with Wireless
Foot Control
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™ starting provides x-ray clean
welds without the use of high frequency.
Blue Lightning™ high-frequency arc starter
for non-contact arc initiation. Provides more
consistent arc starts and greater reliability
compared to traditional HF arc starters. Easy
to set and increases productivity.
Power source is warranted for 3 years, parts and labor.
Original main power rectifier parts are warranted for 5 years.
Water cooler is warranted for 1 year, parts and labor.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
Welding
Mode
Welding
Amperage
Range
TIG
(GTAW)
DC 1–150 A
(115 VAC)
(Subject to change without notice.)
Max.
OpenCircuit
Voltage
Input
Power
Rated
Output
Amps Input at Rated Load Output, 50/60 Hz,
115 V 230 V 400 V 460 V KVA
KW
80 VDC
3-Phase
175 A at 17 V,
60% Duty Cycle
—
—
10.5
0.16*
6.0
0.24*
5.2
0.25*
4.2
0.06*
4.0
0.03*
1-Phase
175 A at 17 V,
60% Duty Cycle
—
—
17.4
0.23*
—
—
—
—
4.0
0.05*
4.0
0.02*
150 A at 16 V,
70% Duty Cycle
29.7
0.42*
14.1
—
—
—
—
—
3.4
0.05*
3.4
0.03*
125 A at 15 V,
100% Duty Cycle
23.0
0.42*
—
—
—
—
—
—
2.6
0.05*
2.6
0.03*
3-Phase
150 A at 26 V,
60% Duty Cycle
—
—
13.1
0.16*
7.4
0.24*
6.4
0.25*
5.2
0.06*
5.0
0.03*
1-Phase
150 A at 26 V,
60% Duty Cycle
—
—
21.7
0.23*
—
—
—
—
5.0
0.05*
5.0
0.02*
125 A at 25 V,
50% Duty Cycle
34.1
0.42*
—
—
—
—
—
—
4.0
0.05*
3.8
0.03*
90 A at 24 V,
100% Duty Cycle
25.0
0.42*
—
—
—
—
—
—
4.0
0.05*
3.8
0.03*
9 –14 VDC**
DC 1–200 A
(200–460 VAC)
Stick
(SMAW)
DC 1–90 A
(115 VAC)
80 VDC
9 –14 VDC**
DC 1–200 A
(200–460 VAC)
Dimensions
Net Weight
H: 13-1/2 in
(343 mm)
W:7-1/2 in
(191 mm)
D: 17-1/2 in
(445 mm)
37 lb
(16.8 kg)
Contractor
Kit
with
69 lb
(31.3 kg)
TIGRunner®
H: 46-1/4 in
(1,175 mm)
W: 23-1/2 in
(597 mm)
D: 22-1/4 in
(565 mm)
with
with
TIGRunner®
129 lb
(58.5 kg)
*Indicates idle draw. **Sense voltage for Stick and Lift-Arc TIG.
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
DUTY CYCLE
110–120 V INPUT VOLTAGE
%
40%
70%
100%
2
TIG
150 A
150 A
125 A
STICK
125 A
110 A
90 A
200–460 V INPUT VOLTAGE
%
30%
40%
60%
100%
TIG
200 A
200 A
175 A
150 A
STICK
200 A
175 A
150 A
125 A
Control Panel
Maxstar 200 SD
Maxstar 200 DX/LX
5
1
2
5
1
2
6
3
4
7
6
3
7
8
9
4
Control Panel Parameter Values
1. Voltmeter Display
2. Ammeter Display
3. Process/
TIG: HF Impulse, Lift Arc
Arc Starting
STICK: Adaptive Hot Start
4. Output Control
Standard Remote,
2T Trigger Hold,
Output ON
5. Encoder Control
6. Amperage Control
7. Adjust Postflow 0.0 – 50 Seconds
DIG
0 – 100%
Advanced features on the Maxstar LX and DX:
8. Sequencer Control
Initial Amps
1– 200 A
Initial Slope
0.0 – 25.0 Seconds
Final Slope
0.0 – 25.0 Seconds
Final Amps
1– 200 A
9. Pulser Control
Pulses per Second DC: 0.1 – 500 PPS
Peak Time
5 – 95%
Background Amps 5 – 95%
Additional Setup Parameter Values
Preprogrammed Starts
.020 –1/8 in Tungsten
Programmable Starts
Amperage
5 – 200 A
Time
1– 200 Milliseconds
Ramp Time
0 – 250 Milliseconds
Minimum Amperage 1– 20 A
Additional Triggers 3T, 4T, Mini Logic,
4T Momentary
Spot/Timer
0.1– 25.0 Seconds
OCV
Low OCV, Normal OCV
Stick Stuck Check On/Off
Available in Three Models:
SD — Provides the basic features that are required for most TIG or Stick welding applications.
Lockouts
Four levels
Arc Timer
0.0 – 9999 Hours
and 0 – 59 Min
Cycle Counter
0 – 999,999 Cycles
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.
LX Additional Features:
Initial start time
Weld cycle time
Final current time
0.0 – 25.0 Seconds
0.0 – 999 Seconds
0.0 – 25.0 Seconds
10-Pin Remote Connection Features:
• Weld cycle start/stop
• Gas start/stop
• Final slope output signal
• Pulse output signal
• Valid arc output signal
3
Pulse TIG Controls
High Speed DC TIG-Pulse Controls
• PPS Pulses per second (Hz): DC = 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
Peak
Amps
Peak Time %
Background
Amps
(% of Peak)
Peak
Amps
Peak Time %
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.
4
HIGH SPEED PULSED TIG
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).
Packages
Maxstar 200 Power Sources
®
Maxstar® 200 SD #903 701 (CSA)
Maxstar® 200 DX #903 701-01-1 (CSA)
Maxstar® 200 DX #907 354 (CE)
Maxstar® 200 LX #903 701-01-2 (CSA)
Includes:
Adjustable shoulder strap
8 ft (2.4 m) primary power cord
(2) Dinse 50 connectors
DVD Setup Video (#251 116)
(1) air-cooled TIG torch adapter
(#195 378). SD and DX models only
(1) 14-pin and 10-pin receptacle with
mating plug. LX model only
Note: See page 6 for recommended Contractor Torch Kit.
Maxstar 200 DX Contractor Kit Packages (Air Cooled)
®
Maxstar 200 DX with Contractor Kit
#951 172 (CSA) w/Foot Control
#951 173 (CSA) w/Fingertip Control
Packages include:
Maxstar® 200 DX (#903 701-01-1)
RFCS-14 HD foot control (#194 744) or
RCCS-14 fingertip control (#043 688)
Protective carrying case for accessories
Weldcraft® 25 ft (7.6 m) WP17 TIG torch
with adapter
Smith® flow gauge regulator with
gas hose
AK2C accessory kit
.040", 1/16" and 3/32" cerium tungsten
Collets and cups
200 amp, 15 ft (4.6 m) Stick electrode
holder
Work clamp with 15 ft (4.6 m) #4 cable
(1) air-cooled TIG torch adapter
(#195 378)
TIGRunner Package (Water Cooled)
®
Maxstar® 200 DX TIGRunner®
#903 701-02-2 (CSA)
Completely assembled.
Package includes:
Maxstar® 200 DX (#903 701-01-1)
Coolmate™ 1, 120 VAC (#300 360)
1 gallon of pre-mixed, low-conductivity
coolant (#043 810)
2-Wheel Trolley Cart (#300 480) with
the following features: easy-to-maneuver
single-cylinder cart with cable and torch
holders. Easy to release and remove
welder from cart for even more portability.
Convenient tray for consumable storage
and filler rod holders.
Notes: TIG Torch Adapter must be ordered separately.
See page 6 for recommended 250 A Water-Cooled
Torch Kit (#300 185).
The Coolmate 1 requires a separate source for
electricity. The Maxstar 200 does not contain
auxiliary power.
Complete Packages (Water Cooled)
Maxstar 200 DX
Complete Package
with Foot Control
Maxstar® 200 DX Complete
#951 396 (CSA) w/Wireless Foot Control
#951 137 (CSA) w/Foot Control
#951 138 (CSA) w/Fingertip Control
Completely assembled.
Package includes:
Maxstar® 200 DX TIGRunner®
(#903 701-01-1)
Coolmate™ 1, 120 VAC (#300 360)
1 gallon of pre-mixed, low-conductivity
coolant (#043 810)
Wireless Remote Foot Control (#300 429)
or RFCS-14 HD foot control (#194 744)
or RCCS-14 fingertip control (#043 688)
2-Wheel Trolley Cart (#300 480) with
the following features: easy-to-maneuver
single-cylinder cart with cable and torch
holders. Easy to release and remove
welder from cart for even more portability.
Convenient tray for consumable storage
and filler rod holders.
250 A Water-Cooled Torch Kit and
Accessories (#300 185) See page 6 for
more details.
Note: The Coolmate 1 requires a separate source for
electricity. The Maxstar 200 does not contain
auxiliary power.
5
Genuine Miller Accessories
2-Wheel Trolley Cart
#300 480
Easy-to-maneuver
two-wheel cart features
single-cylinder rack,
chain for cylinder,
straps (quick and
easy to detach and
carry machine), cable
holders, torch holder,
storage area, and filler
rod storage area. Works with Dynasty® or
Maxstar® 200 and Coolmate™ 1.
Contact your local distributor for filler
material holders.
Universal
Carrying Cart
and Cylinder
Rack
#042 934
Holds power
source, and
gas cylinder
up to 56 in (142.2 cm) high measuring
6 to 9 in (15.2 to 22.8 cm) in diameter.
200 Amp Air-Cooled
Torch
#WP2612RM (12 ft)
#WP2625RM (25 ft)
Torch body gas valve models are available.
Note: Adapter #195 379 required for WP26.
Order from Miller Parts.
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
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
Air-Cooled Torch Adapters
#195 378 WP17, WP9, WP50, WP23
#195 379 WP26
Order from Miller Parts.
Educational Materials
Gas Tungsten Arc (TIG) Welding Book
#170 555
To order, distributors can call the Miller
Literature Distribution Center at
1-920-735-4356, or FAX 1-920-735-4011.
Ron Covell TIG Welding Basics DVD
To order go to MillerWelds.com
Water-Cooled Dinse #195 377
Used to adapt WP20, WP18, and CS310
to dinse-style connector. Order from
Miller Parts.
DVD Setup Video #251 116
Video topics include Tungsten Selection,
Setup Menus, DC Pulse, Sequencer,
Balance and Frequency Settings. (Included
with machine.)
TIG Welding Gloves
Coolmate™ 1
#300 360 120 VAC 60 Hz CSA
#300 360-00-1 120 VAC 60 Hz CE
#300 459 240 VAC 50/60 Hz CSA
#300 459-00-1 240 VAC 50/60 Hz CE
1-gallon water cooler designed for 200 A
portable welders. Features include:
Fin-and-Tube heat exchanger, back-lit
power switch, external filter, polyethylene
tank and coolant level sight gauge.
TIG Coolant
#043 810
Sold in multiples
of 4. Pre-mixed
low-conductivity
Miller coolant
contains ethylene
glycol and
deionized water to protect from freezing
and boiling -37˚ to 227˚F (-38˚ to 108˚C).
1-gallon plastic recyclable bottles.
6
Order from Miller Parts.
#195 054
kit shown.
Contractor Kits
#195 054 Foot Pedal Kit
#195 055 Fingertip Kit
RFCS-14HD foot or RCCS-14 fingertip
control, protective carrying case, 150 amp
WP17 25 ft (7.6 m) TIG torch with adapter,
Smith® flow gauge regulator and gas hose,
AK2C accessory kit (.040, 1/16, and 3/32 in
cerium tungsten, collets and cups), Stick
electrode holder, 200 amp, 15 ft (4.6 m)
#4 cable, and work clamp with 15 ft (4.6 m)
#4 AWG cable.
Industrial TIG
Welding Gloves
#249 199 Large
#249 200 X-Large
Unlined pigskin leather
palm with reinforced
palm patch.
TIG Welding Gloves
#249 178 Medium
#249 179 Large
#249 180 X-Large
Durable goatskin back
and palm with flameresistant cotton fleece
back.
TIG Welding Gloves
(Short Cuff)
#249 181 Medium
#249 182 Large
#249 183 X-Large
Durable pigskin back
and goatskin palm with
3-in cuff.
Genuine Miller Accessories (continued)
Tungsten
Tungsten is 7 in length and available in pkgs of 10.
Order from Miller Parts.
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
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 ft (27.4 m) operating range.
Wireless Remote Hand
Control #300 430
For remote current
and contactor control.
Receiver plugs directly
into the 14-pin
receptacle of Miller
machine. 300 ft (91.4 m) operating range.
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. Includes 26.5 ft (8 m) control cord.
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 #242 211 020
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.
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 Cables for 14-Pin Remote
Controls
#242 208 025 25 ft (7.6 m)
#242 208 050 50 ft (15.2 m)
#242 208 080 80 ft (24.4 m)
Multi-Operator Rack
4-Pack Rack (empty) #195 051
Appropriate fuses required.
Rugged enclosure provides a simple
means for protecting and transporting
multiple welding power sources for
construction, power plant turn-arounds,
and shipbuilding applications.
Light weight and small footprint for easy
transportation. Low weight enables the
use of elevators to move the rack.
Top cover protects machines from
falling debris.
Lifting eye simplifies transportation
using crane or overhead lifting device.
Lift truck side and end fork pockets.
One main disconnect box with fused
circuit breaker switches for each machine.
Common output ground connection
(for same polarity use only).
Power
Source
Maxstar
200
Rack
Capacity
4
Input Power
to Rack
Generator kW
(Required)
Rack Fuse Size
(3 per Power Source Required)*
230 V @ 74 A
20 kW
30 A (#199 795)
460 V @ 36 A
20 kW
15 A (#220 514)
4-Pack Rack Running Gear #195 114
Large 5-inch diameter wheels enable the
rack to be moved over grating and
driveway gravel.
Dimensions
Net Weight
H: 59-3/8 in (1508 mm)
W: 43 in (1092 mm)
D: 34-3/8 in (873 mm)
Rack only 239 lb (108 kg)
With Power Sources 387 lb (176 kg)
*Rack comes with 25 A fuses. Order appropriate fuses for primary voltage
7
Ordering Information
Equipment and Options
Stock No.
Description
Maxstar 200 SD
Maxstar® 200 DX
Maxstar® 200 DX International
Maxstar® 200 LX
#903 701
#903 701-01-1
#907 354
#903 701-01-2
Auto-Line 115 – 460 VAC, 50/60 Hz, CSA. 8 ft primary cord
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8 ft primary cord
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CE. 8 ft primary cord
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8 ft primary cord
Air-Cooled Packages
Maxstar® 200 DX Contractor Kit w/Foot Control
Maxstar® 200 DX Contractor Kit w/Fingertip Control
#951 172
#951 173
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8 ft primary cord
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8 ft primary cord
Water-Cooled Packages
Maxstar® 200 DX TIGRunner ®
#903 701-02-2
®
Qty.
™
Maxstar® 200 DX Complete
with Wireless Remote Foot Control
Maxstar® 200 DX Complete w/Foot Control
Maxstar® 200 DX Complete w/Fingertip Control
#951 396
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8 ft primary cord
(Torch kit and accessories sold separately.)
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8 ft primary cord
#951 137
#951 138
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8 ft primary cord
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8 ft primary cord
TIG Torch Kits
Weldcraft® 250 A Water-Cooled Torch Kit
Contractor Kit Foot Pedal (Air-Cooled)
Contractor Kit Fingertip (Air-Cooled)
Weldcraft® 200 A Air-Cooled Torch
#300 185
#195 054
#195 055
#WP2625RM
See page 6
See page 6
See page 6
Adapter #195 379 required. Order from Miller Parts
#300 429
#300 430
#043 688
#194 744
#242 211 020
#129 337
#187 208
#242 208 025
#242 208 050
#242 208 080
Foot control with wireless 90 ft (27.4 m) operating range
Hand control with wireless 300 ft (91.4 m) operating range
North/south fingertip control
Heavy-duty foot control
Hand control
Momentary/maintained rocker switch
Momentary rubber dome switch
25 ft (7.6 m)
50 ft (15.2 m)
80 ft (24.4 m)
#195 051
#195 114
#199 795
#220 514
#300 480
#042 934
#300 360
#300 360-00-1
#300 459
#300 459-00-1
#043 810
#170 555
Order power source and fuses separately
(4) 5-in diameter wheels and brackets
230 V, 30 A Individual fuse. 12 required for 4-Pack
460 V, 15 A Individual fuse. 12 required for 4-Pack
See page 6
See page 6
120 VAC, 60 Hz, CSA. Requires coolant
120 VAC, 60 Hz, CE. Requires coolant
240 VAC, 50/60 Hz, CSA. Requires coolant
240 VAC, 50/60 Hz, CE. Requires coolant
Sold in multiples of four in 1-gallon plastic bottles
Order at MillerWelds.com/resources/tools
Order at MillerWelds.com/resources/tools
Included with machine
Used to connect water-cooled torch to Dinse terminal machine.
For WP20, WP18 and SC310 (adapter included in Complete Package)
Used to connect WP17, WP9 and WP23 torch to Dinse terminal machine
Used to connect WP26 torch to Dinse terminal machine
Used to connect weld lead to Dinse terminal machine
Used to extend weld cables
Male Dinse to female Tweco
Male Dinse to female Cam-Lok
Remote Controls
Wireless Remote Foot Control
Wireless Remote Hand Control
RCCS-14
RFCS-14 HD
RHC-14
RMLS-14
RMS-14
Extension Cables
Accessories
4-Pack Rack (empty)
4-Pack Rack Running Gear
Fuses
2-Wheel Trolley Cart
Universal Carrying Cart and Cylinder Rack
Coolmate™ 1
TIG Coolant
Gas Tungsten Arc (TIG) Welding Book
Ron Covell TIG Welding Basics DVD
DVD Setup Video
Water-Cooled Dinse
Order from Miller Parts
Air-Cooled Dinse
Order from Miller Parts
Dinse Connector 50 mm (1 male)
Dinse Connector 50 mm (1 male, 1 female)
Tweco® Terminal Adapter
Cam-Lok Terminal Adapter
#251 116
#195 377
#195 378
#195 379
#042 418
#042 419
#042 465
#042 466
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Price
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