Maxstar 210 Series Quick ®

Maxstar 210 Series Quick ®
Issued July 2015 • Index No. DC/32.1
Maxstar 210 Series
®
Quick
Specs
Industrial Applications
Processes
Precision Fabrication
Petro Chemical
Aerospace
Food/Beverage Industry
Dairy
Shipboard
DC TIG (GTAW)
Pulsed TIG (GTAW-P)
except STR model
Stick (SMAW)
TIG/Stick Welding
Power Source
Input Power 120 – 480 V, 1-Phase or 3-Phase Power
Amperage Range 1 – 210 A (DC)
Rated Output 210 A at 18 V, 60% Duty Cycle
Net Weight STR: 36 lb. (16.3 kg)
Base/DX: 38 lb. (17.2 kg)
DC TIG Features
Pulse. Pulsing can increase
puddle agitation, arc stability
and travel speeds while reducing
heat input and distortion. Base
and DX models only. DX models
provide extended ranges.
Exceptionally smooth and
precise arc for welding exotic
materials.
DC Stick Features
Maxstar 210 DX
Maxstar 210
Maxstar 210 STR
Update and expand. Front panel memory card data
port provides the ability to easily update software and
expand product features. See memory cards on page 7.
Visit MillerWelds.com/TIGSoftware for the latest software
updates and expansions.
Pro-Set™ eliminates the guesswork when setting weld
parameters. Use Pro-Set when you want the speed,
convenience and confidence of preset controls.
Simply select the feature and adjust until Pro-Set
appears on the display.
Sleep timer conserves electricity. This programmable
feature will power down the machine if it sits idle for a
specified time.
Allows for any input voltage
hookup (120 – 480 V)
with no manual linking,
providing convenience in any job setting. Ideal solution
for dirty or unreliable power.
Blue Lightning™ high-frequency (HF) arc starter for
non-contact arc initiation. Provides more consistent
arc starts and greater reliability compared to traditional
HF arc starters. Base and DX models only.
Meter calibration allows digital meters to be
calibrated for certification.
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 contaminants pulled though
the machine.
Dual schedule allows operators
to switch welding parameters
for specific electrodes without
readjusting the machine, minimizing downtime and enhancing
quality. STR model only.
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.
Hot Start™ adaptive control
provides positive arc starts
without sticking. Base and DX
models only.
Stick-Stuck detects if the
electrode is stuck to the part
and turns the welding output
off to safely and easily remove
the electrode. Menu selectable.
Power source is warranted for 3 years, parts and labor.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
An ITW Welding Company
1635 West Spencer Street
P.O. Box 1079
Appleton, WI 54912-1079 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
MillerWelds.com
Specifications (Subject to change without notice.)
Welding
Mode
Input
Power
Welding
Amperage
Range
TIG
(GTAW)
208–480 V
1– 210 A
Stick
(SMAW)
Rated Output
Phase
Amps Input at Rated Load Output, 50/60 Hz
120 V 208 V 240 V 400 V 480 V KVA KW
210 A at 18.4 V,
60% duty cycle
3-phase
—
14
12
7
6
5.2 4.9
1-phase
—
24
20
12
10
4.9 4.9
120 V
1– 210 A
125 A at 15 V,
60% duty cycle
1-phase
22
—
—
—
—
2.6 2.6
208–480 V
5– 210 A
160 A at 26.4 V,
60% duty cycle
3-phase
—
15
13
8
6
5.5 5.2
1-phase
—
26
22
13
11
5.3 5.3
90 A at 23.6 V,
60% duty cycle
1-phase
23
—
—
—
—
2.8 2.8
120 V
5–100 A
Max. OpenCircuit
Voltage
80 VDC
(11 VDC*)
Dimensions
Net
Weight
H: 13.6 in.
(346 mm)
W: 8.6 in.
(219 mm)
D: 19.5 in.
(495 mm)
STR:
36 lb.
(16.3 kg)
Base/DX:
38 lb.
(17.2 kg)
*Low OCV sense voltage for Stick and Lift-Arc ™ TIG.
IP23 rating — This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless sheltered.
Operating temperature range is 14 to 104° F (-10 to 40° C). Storage temperature range is -22 to 149° F (-30 to 65° C). Portions of the preceding text are contained in
EN 60974-1: “Welding power sources for arc welding equipment.”
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
All CE models conform to the applicable parts of the IEC 60974 series of standards.
Performance Data
TIG (GTAW)
Duty Cycle
Stick (SMAW)
Duty Cycle
208–480 V
210 A, 60%
175 A, 100%
210 A, 30%
160 A, 60%
125 A, 100%
120 V
150 A, 40%
125 A, 60%
100 A, 100%
100 A, 40%
90 A, 60%
75 A, 100%
Input Power
DC TIG Material Thickness Range
STR:
0.025 –1/4 in. (0.06 – 6.4 mm)
Base/DX:
0.002 –1/4 in. (0.05 – 6.4 mm)
Stick Electrode
Maximum Diameter
Generator
Requirement
6010: 3/16 in. (4.8 mm)
7018: 5/32 in. (4.0 mm)
7024: 5/32 in. (4.0 mm)
9 kW
TIG Upgrade Chart
Why Upgrade?
Amperage Range
Upgrade Benefits
10 – 210 A
1 – 210 A
1 – 210 A
Base and DX models offer wider range and
improved low-amperage performance.
Lift-Arc™ Only
Lift-Arc™ or
Blue Lightning™ HF
Lift-Arc™ or
Blue Lightning™ HF
Base and DX models provide the ability of
non-contact arc starting.
Internal Shielding
Gas Valve
No
Yes
Yes
Base and DX models control flow of shielding
gas for TIG welding.
Pulser
No
Easy pulse with Pro-Set™,
Off – 250 PPS
Full featured with Pro-Set™,
Off – 500 PPS
Higher speed pulse provides better arc control
and faster travel speeds.
Sequencer
No
No
Yes
Arc Starting
2
Maxstar 210 STR UPGRADE Maxstar 210 UPGRADE Maxstar 210 DX
Improves repeatability on similar parts.
Maxstar 210 STR Control Panel
®
7
1
8
2
9
3
4
10
5
11
12
6
13
1. Standby Switch
7. Memory Card Port
2. Voltmeter Display
8. Activity Indicator
3. Ammeter Display
9. Encoder Control
4. Output Contactor “On” Indicator
10. Menu Button
5. DC TIG (Lift-Arc Schedule 1) Process Menu Parameters
Amperage
10 – 210 A
11. DC TIG (Lift-Arc Schedule 2) Process Menu Parameters
Amperage
10 – 210 A
6. DC Stick (Schedule 1) Process Menu Parameters
Amperage
10 – 210 A
DIG
Off – 100%
12. DC Stick (Schedule 2) Process Menu Parameters
Amperage
10 – 210 A
DIG
Off –100%
13. Process Selector
User Menu (Hold Menu button three seconds.)
Tech Menu (Hold Menu button five seconds.)
DC TIG (Lift-Arc)
1. Remote Trigger = OUTPUT ON/STD
1. Arc Time
DC Stick (Schedule 1 and 2)
1. Remote Trigger = OUTPUT ON/STD
0.0 – 9999 hours
0.0 – 59 minutes
0 – 999,999 cycles
Resettable
2. Error Log = Error event recorder
3. Sleep Timer = 1/5/10/15/30/45MIN/1HR
4. Stick Stuc = OFF/ON
5. OCV = LOW/NORM
6. Machine Reset
7. Software Number
8. Serial Number
3
Maxstar 210 Control Panel
®
7
1
8
2
9
3
4
10
5
11
12
6
13
1. Standby Switch
2. Voltmeter Display
3. Ammeter Display
4. Output Contactor “On” Indicator
5. DC TIG (HF Start) Process Menu Parameters
Amperage
1 – 210 A**
Pulse*
Off – 250 PPS
Postflow
Auto/Off – 50 seconds
6. DC Stick (Schedule 1) Process Menu Parameters
Amperage
5 – 210 A
DIG*
Off – 100%
7. Memory Card Port
8. Activity Indicator
9. Encoder Control
10. Menu Button
11. DC TIG (Lift-Arc) Process Menu Parameters
Amperage
1 – 210 A**
Pulse*
Off – 250 PPS
Postflow
Auto/Off – 50 seconds
12. DC Stick (Schedule 2) Process Menu Parameters
Amperage
5 – 210 A
DIG*
Off –100%
13. Process Selector
*Pro-Set parameter selectable. **Amperage range is tungsten size dependent.
User Menu (Hold Menu button three seconds.)
Tech Menu (Hold Menu button five seconds.)
DC TIG (HF Start)
1. Tungsten Size = .020 –1/8 in. or .05 – 3.2 mm
2. Remote Trigger = STD/HOLD/OUTPUT ON
1. Arc Time
DC TIG (Lift-Arc)
1. Tungsten Size = .020 –1/8 in. or .05 – 3.2 mm
2. Remote Trigger = STD/HOLD/OUTPUT ON
DC Stick (Schedule 1 and 2)
1. Hot Start = ON/OFF
2. Remote Trigger = OUTPUT ON/STD
4
0.0 – 9999 hours
0.0 – 59 minutes
0 – 999,999 cycles
Resettable
2. Error Log = Error event recorder
3. Sleep Timer = 1/5/10/15/30/45MIN/1HR
4. Stick Stuc = OFF/ON
5. OCV = LOW/NORM
6. Machine Reset
7. Software Number
8. Serial Number
Maxstar 210 DX Control Panel
®
1
7
8
2
9
3
10
4
11
5
6
12
1. Standby Switch
7. Memory Card Port
2. Voltmeter Display
8. Activity Indicator
3. Ammeter Display
9. Encoder Control
4. Process/
Arc Starting
TIG: HF Impulse, Lift-Arc
STICK : Adaptive Hot Start
5. Output Control
Standard Remote,
2T Trigger Hold,
Output ON
6. Pulser Control
Pulses per Second* DC : 0.1 – 500 PPS
Peak Time*
5 – 95%
Background Amps* 5 – 95%
10. Amperage Button
TIG
1– 210 A**
Stick
5– 210 A
11. Gas/DIG
Preflow
Postflow
DIG*
0.0 – 25.0 seconds
Auto/Off – 50 seconds
Off –100%
12. Sequencer Control
Initial Amps
1– 210 A**
Initial Slope
0.0 – 25.0 seconds
Weld Time
0.0 – 999 seconds
Final Slope
0.0 – 25.0 seconds
Final Amps
1– 210 A**
*Pro-Set parameter selectable. **Amperage range is tungsten size dependent.
User Menu (Press Gas and Amperage buttons.)
Tech Menu (Hold Gas and Amperage buttons three seconds.)
1. Tungsten Size = .020 –1/8 in./GEN or .05 – 3.2 mm
2. Remote Trigger = 2T/3T/4T/4TL/4TLE
3. Stick Hot Start = ON/OFF
1. Arc Time
0.0 – 9999 hours
0.0 – 59 minutes
0 – 999,999 cycles
Resettable
2. Error Log = Error event recorder
3. Sleep Timer = 1/5/10/15/30/45MIN/1HR
4. Stick Stuc = OFF/ON
5. OCV = LOW/NORM
6. Weld Timers = OFF/ON
7. Locks = OFF/1– 4
8. Meter Display
9. External Pulse Control = OFF/ON
10. Machine Reset
11. Software Number
12. Serial Number
5
Maxstar 210 Models/Packages
®
Build an Air-Cooled Package
Select desired stock number for each step.
#907 683
Maxstar 210 shown.
Step #1 • Select Maxstar
Select One
Maxstar 210 STR
Maxstar 210
Maxstar 210 DX
#301 311
Contractor Kit shown.
Step #2 • Select Cable Set/TIG Torch/Regulator OR Contractor Kit
For Maxstar 210 STR Only — Select All (Cable Set/TIG Torch/Regulator)
No. 2 Stick Cable Set
#195 196
Weldcraft A-150V (WP-17) TIG Torch
#WP-17V-25-2
Flow Gauge Argon Regulator
#31-50-580
#907 682
#907 683
#907 684
For Maxstar 210 OR 210 DX — Select One
Foot Control Contractor Kit
Fingertip Control Contractor Kit
Maxstar comes with adjustable shoulder strap, 8-ft. power cord (no plug)
and two 50-mm Dinse-style connectors.
#301 309
#301 311
See page 7 for descriptions and kit contents.
Build a Water-Cooled Package
Select desired stock number for each step.
#907 683 Maxstar
210 shown with
#301 318 Small
Runner Cart and
Coolant System.
#300 429 remote shown.
Step #1 • Select Maxstar/Cart/Coolant System
Select One
Maxstar 210
Maxstar 210 DX
Select One
2-Wheel Trolley Cart
Small Runner Cart
Select All (Coolmate/Bracket/Coolant)
Coolmate™ 1.3
Mounting Bracket
(required for mounting to Coolmate 1.3)
Low-Conductivity Coolant
(must be ordered in quantities of 4)
#907 683
#907 684
#300 971
#301 318
Step #2 • Select Remote Control
Select One
Wireless Foot (recommended)
RFCS-14 HD Foot
RCC-14 E/W Fingertip
RCCS-14 N/S Fingertip
RMS-14 Pushbutton
RMLS-14 Momentary/Maintained
RHC-14 Hand
Wireless Hand
#300 429
#194 744
#151 086
#043 688
#187 208
#129 337
#242 211 020
#300 430
Step #3 • Select Torch Kit
Select One
W-250 (WP-20) Kit
(recommended)
W-280 (WP-280) Kit
#300 972
#301 312
#043 810
Maxstar comes with adjustable shoulder strap, 8-ft. power
cord (no plug) and two 50-mm Dinse-style connectors.
6
#300 185 kit shown.
See page 7 for remote descriptions.
See page 7 for kit contents.
#300 185
#300 990
Genuine Miller Accessories
®
2-Wheel Trolley Cart
#300 971
Easy-to-maneuver two-wheel
cart features single-cylinder
rack, chain for cylinder, cable
holders, torch holder, storage
area, and filler rod storage area.
Works with Dynasty/Maxstar
210 and 280 with Coolmate 1.3
cooler. Straps also included for mounting
Dynasty®/Maxstar® 200 with Coolmate 1 cooler.
Small Runner™ Cart
#301 318
Designed for Dynasty/Maxstar
210 and 280 with Coolmate 1.3
cooler. Cart features singlecylinder rack, foot pedal holder,
two cable/torch holders, and
two TIG filler rod holders.
TIG Torches, Kits and Connectors
Remote Controls and Switches
Contractor Kits
#301 309 150 A RFCS-14 HD Foot Pedal Kit
#301 311 150 A RCCS-14 Fingertip Kit
All-in-one TIG/Stick welding kit comes with either
a RFCS-14 HD foot control or RCCS-14 fingertip
control, Weldcraft™ A-150 TIG torch, 200-amp
Stick electrode holder and 300-amp work clamp
with 15-foot (4.6 m) cables, flow gauge regulator
with 12-foot (3.7 m) gas hose, gas hose coupler,
AK2C torch accessory kit and TIG torch connector.
Wireless Remote Foot Control #300 429
For remote current and contactor control. Receiver
plugs directly into the 14-pin receptacle of Miller
machine. 90-foot (27.4 m) operating range.
RCC-14 Remote Contactor and Current Control
#151 086
East/west rotary-motion fingertip control attaches
to TIG torch using two hook-and-loop fasteners.
Includes 26.5-foot (8 m) cord and 14-pin plug.
Coolmate 1.3
#300 972 120 VAC
1.3-gallon cooler designed to
cool torches up to 280 amps.
Weldcraft™ A-150 (WP-17)
150-Amp Air-Cooled TIG Torches
One-Piece Cable
#WP-17-12-R (12 ft.)
#WP-17-25-R (25 ft.)
Note: Requires #301 312 Mounting
Bracket to mount to Maxstar 210.
Note: A-150 (WP-17) one-piece torches require
#195 378 connector.
Performance TIG Gloves
#263 345 X-Small (Women’s)
#263 346 Small (Women’s)
#263 347 Medium
#263 348 Large
#263 349 X-Large
Completely unlined, goat grain
leather with triple-padded palm.
Two-Piece Cable and Valve
#WP-17V-12-2 (12 ft.)
#WP-17V-25-2 (25 ft.)
™
No. 2 Stick Cable Set #195 196
Consists of 15-foot electrode cable with holder and
work cable with clamp. 200 A, 100% duty cycle.
Memory Cards
Memory Card Expansion
#301 151 14-Pin Automation Expansion
Provides the ability to access common automation
functions through the 14-pin connection.
#301 152 14-Pin Modbus® Expansion
Provides the ability to access basic and advanced
functions through the 14-pin connection.
Memory Card (Blank) #301 080
A blank, commercially available memory card used
for transferring software updates and expandable
features from your computer to the machine.
RFCS-14 HD Foot Control #194 744
Maximum flexibility is accomplished with a
reconfigurable cord that can exit the front, back
or either side of the pedal. Foot pedal provides
remote current and contactor control. Includes
20-foot (6 m) cord and 14-pin plug.
RCCS-14 Remote Contactor and Current Control
#043 688
North/south rotary-motion fingertip control
attaches to TIG torch using two hook-and-loop
fasteners. Includes 26.5-foot (8 m) cord and
14-pin plug.
RMS-14 On/Off Control #187 208
Momentary-contact switch for contactor
control. Rubber-covered pushbutton dome
switch ideal for repetitive on-off applications.
Includes 26.5-foot (8 m) cord and 14-pin plug.
RMLS-14 Switch #129 337
Momentary- and maintained-contact rocker
switch for contactor control. Push forward for
maintained contact and backward for momentary
contact. Includes 26.5-foot (8 m) cord and
14-pin plug.
Weldcraft™ A-200 (WP-26)
200-Amp Air-Cooled TIG Torches
One-Piece Cable
#WP-26-12-R (12 ft.)
#WP-26-25-R (25 ft.)
Note: A-200 (WP-26) one-piece torches require
#195 379 connector.
Two-Piece Cable and Valve
#WP-26V-12-2 (12 ft.)
#WP-26V-25-2 (25 ft.)
Air-Cooled TIG Torch Connectors
#195 378* All air-cooled torches (except A-200)
#195 379 A-200 (WP-26)
50-mm Dinse-style for one-piece air-cooled torch.
*A-80 (WP-24) torches require 24-5 connector.
Water-Cooled Torch Kits
#300 185 W-250 (WP-20) (recommended)
#300 990 W-280 (WP-280)
Kit comes with Weldcraft™ 25-foot (7.6 m) TIG
torch with Dinse-style connector, torch cable
cover, work clamp with 15-foot (4.6 m) cable,
flowmeter regulator with gas hose and torch
accessory kit (1/16-, 3/32- and 1/8-inch 2% ceriated
tungsten, nozzles, collets and collet bodies).
RHC-14 Hand Control #242 211 020
Miniature hand control for remote current and
contactor control. Dimensions: 4 x 4 x 3.25 inches
(102 x 102 x 83 mm). Includes 20-foot (6 m)
cord and 14-pin plug.
Wireless Remote Hand Control
#300 430
For remote current and contactor
control. Receiver plugs directly
into the 14-pin receptacle of Miller
machine. 300-foot (91.4 m) operating range.
Educational Materials
To order, please call Miller Literature at 866-931-9732
or visit MillerWelds.com/resources/tools.
Gas Tungsten Arc Welding (TIG) Publication
#250 833
Setup DVD #251 116
Video topics include tungsten selection, setup
menus, DC pulse, sequencer, balance and
frequency settings.
7
Tungsten
Tungsten
Amp Range
2% Ceriated (AC/DC)
2% Lanthanated (AC/DC)
1/16 in. (1.6 mm)
70 –150 A
WC116X7
WL2116X7
3/32 in. (2.4 mm)
140 – 250 A
WC332X7
WL2332X7
1/8 in. (3.2 mm)
225 – 400 A
WC018X7
WL2018X7
5/32 in. (4.0 mm)
300 – 500 A
WC532X7
WL2532X7
Ordering Information
Equipment and Options
Stock No.
Description
Maxstar® 210 STR
Maxstar® 210
Maxstar® 210 DX
#907 682
#907 683
#907 684
Auto-Line™ 120 – 480 VAC, 50/60 Hz, CSA. 8-ft. power cord
Auto-Line™ 120 – 480 VAC, 50/60 Hz, CSA. 8-ft. power cord
Auto-Line™ 120 – 480 VAC, 50/60 Hz, CSA. 8-ft. power cord
Accessories
2-Wheel Trolley Cart
Small Runner™ Cart
Coolmate™ 1.3
Maxstar Mounting Bracket
TIG Coolant (Must be ordered in quantities of 4)
#300 971
#301 318
#300 972
#301 312
#043 810
See page 7
See page 7
120 VAC, 60 Hz, CSA. Requires coolant
Required for mounting the Maxstar 210 to the Coolmate 1.3
1-gallon plastic bottle. Protects against freezing to
-37° Fahrenheit (-38° C) or boiling to 227° Fahrenheit (108° C)
See page 7
See page 7
See page 7
TIG Gloves
No. 2 Stick Cable Set
Memory Cards
TIG Torches, Kits and Connectors
Air-Cooled Contractor Kits
Weldcraft™ A-150 (WP-17) TIG Torch
Weldcraft™ A-200 (WP-26) TIG Torch
Air-Cooled TIG Torch Connectors
Water-Cooled Torch Kits
#195 196
#301 309
#301 311
#WP-17-12-R
#WP-17-25-R
#WP-17V-12-2
#WP-17V-25-2
#WP-26-12-R
#WP-26-25-R
#WP-26V-12-2
#WP-26V-25-2
#195 378
#195 379
#300 185
#300 990
Tungsten
Remote Controls
Wireless Remote Foot Control
RFCS-14 HD
RCC-14
RCCS-14
RMS-14
RMLS-14
RHC-14
Wireless Remote Hand Control
#300 429
#194 744
#151 086
#043 688
#187 208
#129 337
#242 211 020
#300 430
Educational Materials
Gas Tungsten Arc Welding (TIG) Publication
Setup DVD
#250 833
#251 116
Date:
Distributed by:
© 2015 Miller Electric Mfg. Co.
Qty.
Foot pedal
Fingertip
12-ft. (3.7 m) 1-piece cable. Requires #195 378 connector
25-ft. (7.6 m) 1-piece cable. Requires #195 378 connector
12-ft. (3.7 m) 2-piece cable and valve
25-ft. (3.7 m) 2-piece cable and valve
12-ft. (3.7 m) 1-piece cable. Requires #195 379 connector
25-ft. (7.6 m) 1-piece cable. Requires #195 379 connector
12-ft. (3.7 m) 2-piece cable and valve
25-ft. (7.6 m) 2-piece cable and valve
Connects all air-cooled Weldcraft™ torches (except A-200) to
Dinse-style connector. A-80 (WP-24) torches require 24-5 connector
Connects Weldcraft™ A-200 (WP-26) torch to Dinse-style connector
W-250 (WP-20) (recommended for Maxstar 210)
W-280 (WP-280)
See above
Foot control with wireless 90-ft. (27.4 m) operating range
Heavy-duty foot control
Side-to-side (east/west) fingertip control
North/south fingertip control
Momentary rubber dome switch
Momentary/maintained rocker switch
Hand control
Hand control with wireless 300-ft. (91.4 m) operating range
Total Quoted Price:
Price
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