Page 2 - From Miller to You
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual catalog sheets. To locate your nearestdistributor or service agency call 1-800-...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - Declaration of Conformity For; NOTE; Maxstar
dec_con1 _11/02 Declaration of Conformity For European Community (CE) Products This information is provided for units with CE certification (see rating label on unit.) NOTE Manufacturer’s Name: Miller Electric Mfg. Co. Manufacturer’s Address: 1635 W. Spencer StreetAppleton, WI 54914 USA Declares tha...
Page 6 - Notes
Page 7 - Symbol Usage; Arc Welding Hazards
OM-2226 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This gr...
Page 9 - Additional Symbols For Installation, Operation, And Maintenance; California Proposition 65 Warnings
OM-2226 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system isproperly sized,...
Page 11 - Signification des symboles; Dangers relatifs au soudage à l’arc
OM-2226 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. »Cette procédure présente des risques identifiés par lessymboles adjacents aux directives. Y Identifie un message de sécurité ...
Page 15 - Warning Label Definitions
OM-2226 Page 9 SECTION 3 − DEFINITIONS (CE Models) 3-1. Warning Label Definitions Warning! Watch Out! There are possiblehazards as shown by the symbols. 1 Electric shock from welding electrodeor wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Donot wear wet or...
Page 17 - Manufacturer ’s Rating Label
OM-2226 Page 11 3-2. Manufacturer ’s Rating Label 195 646-B . See Section 4-4 forlocation. . Use rating label to de-termine input powerrequirements. S S 40% 60% 100% 150 175 200 16 17 18 X 2 U I 2 EN 60974−1 1A 10V 50/60 Hz 50/60 Hz 100% 125 25 26 150 60% 40% 175 27 U 80V o 1A 20V 80V o U 35 25 17 3...
Page 18 - Symbols And Definitions; IP
OM-2226 Page 12 3-3. Symbols And Definitions A Amperes Panel−Local Gas Tungsten Arc Welding (GTAW) Shielded Metal Arc Welding (SMAW) V Volts Voltage Input 3 Phase Static Frequency Converter-Transformer-Rectifier Voltage Output Circuit Breaker Remote Lift-Arc Start (GTAW) Protective Earth (Ground) Po...
Page 19 - SECTION 4 − INSTALLATION; Specifications
OM-2226 Page 13 SECTION 4 − INSTALLATION 4-1. Specifications Input Power Rated Output Welding Amperage Max. Open-Circuit Amperes Input At Rated Output, 50/60Hz KVA KW Input Power Rated Output Amperage Range Open-Circuit Voltage 115 230 400 460 KVA KW Three-Phase Stick Process 150 A @ 26 VDC, 60% Dut...
Page 21 - Duty Cycle And Overheating
OM-2226 Page 15 4-3. Duty Cycle And Overheating ST-189 770-A Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. If unit overheats, output stops, aHelp message is displayed (seeSection 7-3), and cooling fan runs.Wait fifteen minutes for unit to cool.Reduce am...
Page 22 - Selecting A Location
OM-2226 Page 16 4-4. Selecting A Location 1 Identification Plate 2 Rating Label 3 Line Disconnect Device Locate unit near correct inputpower supply. Y Special installation may berequired where gasoline orvolatile liquids are present −see NEC Article 511 or CECSection 20. Location And Airflow 3 1 18 ...
Page 23 - Weld Output Terminals And Selecting Cable Sizes*; Remote 14 Receptacle Information
OM-2226 Page 17 4-5. Weld Output Terminals And Selecting Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding Y Turn off power beforeconnecting to weld out-put terminals. 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105...
Page 25 - Gas Connections
OM-2226 Page 19 4-8. Gas Connections ST-802 452 1 Gas Fitting Fittings have 5/8-18 right-handthreads (3/8-19 BSPP on CE units). 2 Cylinder Valve Open valve slightly so gas flowblows dirt from valve. Close valve. 3 Regulator/Flowmeter 4 Flow Adjust Typical flow rate is 15 cubic feet perhour (7.1 lite...
Page 27 - Connecting Input Power
OM-2226 Page 21 4-12. Connecting Input Power 2/04 - Ref. 802 136-A Y Installation must meet all Nationaland Local Codes − have only quali-fied persons make this installation. Y Disconnect and lockout/tagout in-put power before connecting inputconductors from unit. Y Always connect green or green/yel...
Page 30 - SECTION 5 − OPERATION; Controls
OM-2226 Page 24 SECTION 5 − OPERATION ST-207 690-A / ST-802 452 1 2 3 4 5 6 7 8 9 10 . For all front panel switch pad controls: pressswitch pad to turn on light and enablefunction. NOTE: Green on nameplate indicates a TIGfunction, Gray indicates a Stick function.1 Encoder Control Use encoder control...
Page 32 - Voltmeter; Polarity Control (Dynasty
OM-2226 Page 26 5-5. Voltmeter 1 Volt Meter Displays output or open circuit volt-age. If output is off, the voltmeter willdisplay a series of three dashes(-−−). Open circuit voltage is dis-played if power is on and output isavailable. 1 5-6. Polarity Control (Dynasty t Models Only) 1 Polarity Contro...
Page 33 - Output Control
OM-2226 Page 27 5-7. Process Control 1 Process Control Press switch pad until desired pro-cess LED is illuminated: TIG HF Impulse - When selected,a pulsed HF (non-contact) (seeSection 11-3) arc starting method isactivated. This method can be usedwith either AC or DC TIG welding.Make connections acco...
Page 37 - SPO
OM-2226 Page 31 5-12. AC Waveshape (Dynasty Models Only) 1 AC Waveshape 2 Encoder Control 3 Ammeter Turn encoder (see Section 5-2) toset appropriate value for active ACWaveshape parameter. Value se-lected is shown on the ammeter(see Section 5-4). See Section 5-16 for all AC Wave-shape parameter rang...
Page 39 - Preflow Control On The Front Panel
OM-2226 Page 33 5-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A Preflow Control On The Front Panel 1 And SEL 0.2 4 2 1 Process Control Pad 2 Adjust Control Pad 3 Power Switch To adjust preflow, turn power switch on, andthen press the Process and Adjust switchpads ...
Page 40 - -16. Factory Parameter Defaults And Range And Resolution
OM-2226 Page 34 5-16. Factory Parameter Defaults And Range And Resolution Parameter Default Range And Resolution MEMORY 1 1−4 PROCESS ** Stick OCV TIG HF Impulse Low OCV TIG HF Impulse / TIG Lift / Stick Low OCV / Normal OCV OUTPUT **RMT 2T RMT STD 2T RMT STD / RMT 2T / ON RMT 2T can be reconfigured...
Page 42 - SECTION 6 − ADVANCED FUNCTIONS; Programable TIG Start Parameters
OM-2226 Page 36 SECTION 6 − ADVANCED FUNCTIONS 6-1. Programable TIG Start Parameters A. Accessing Programmable TIG Start Parameters NOTE: The welding cycle can be execut-ed while in programmable start mode.Before accessing programmable TIGStart Polarity, Amperage, and Timemodes, be sure that all pro...
Page 43 - Changing Programmable TIG Start Polarity (Dynasty Models Only); SEL E−; Changing Programmable TIG Start Amperage (All Models)
OM-2226 Page 37 B. Changing Programmable TIG Start Polarity (Dynasty Models Only) 2 SEL E− 3 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust TIG Start Polarity proceed asfollows: Press Amperage switch pad. Switch padLED turns on, and meter % LED turns on.The current Start Polarity, (S...
Page 45 - Output Control And Trigger Functions
OM-2226 Page 39 6-2. Output Control And Trigger Functions A. Remote (Standard) Torch Trigger Operation Current (A) Preflow Initial Amps Initial Slope Final Slope Postflow Main Amps Final Amps R R P & H Maintained Switch Foot Or FingerRemote Control P&H = Push trigger and hold R = Release tri...
Page 46 - SEL
OM-2226 Page 40 C. Reconfiguring RMT 2T HOLD For 2T, 3T, Spot, 4T, 4T Momentary, Or Mini Logic Control 1 4 H−2 SEL 2 And Rear Panel 3 V Or Or Or For RMT STD (Remote Standard), RMT2T Hold (Remote 2T Hold), and On trig-ger operation, see Section 6-2A, B, andH. 1 Process Switch Pad 2 Output Switch Pad ...
Page 54 - Arc Timer/Counter Display
OM-2226 Page 48 6-3. Arc Timer/Counter Display 1 Output And Amperage Controls 2 Power Switch To display the arc timer/counter, turn pow-er switch on, and then press the Amper-age Control and Output switch pads be-fore the software version clears the me-ters, and hold the switch pads until soft-ware ...
Page 55 - Lockout Functions; or
OM-2226 Page 49 6-4. Lockout Functions A. Accessing Lockout Capability 1 L−0 L − − 4 6 000 or 2,3,4 2 5 L−0 L L1 000 And Rear Panel 3 V Or See Section 5-1 for explanation of controls referred to in all ofSection 6-4. There are four (1−4) different lockout levels. Each successive levelallows the oper...
Page 58 - sel; PPP
OM-2226 Page 52 6-5. Setting Unit To Display PPP While Pulse Welding (DX And LX Models Only) 1 Output Switch Pad 2 Pulser Switch Pad 3 Power Switch To access the PPP while welding dis-play, turn power switch on, and thenpress the Output and Pulser switchpads before the software version clears the me...
Page 59 - oc
OM-2226 Page 53 6-6. Stick Open-Circuit Voltage (OCV) Selection (All Models) 1 Process Switch Pad 2 Adjust Switch Pad 3 Amperage Switch Pad 4 Power Switch To access the Stick OCV selection,turn power switch on and then pressthe Process, Adjust and Amperageswitch pads before the software ver- sion cl...
Page 60 - SECTION 7 − MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance; Blowing Out Inside Of Unit
OM-2226 Page 54 SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replaceunreadablelabels. Clean and tightenweld terminals. Replace DamagedGas Hose 3 Months Repair Or ReplaceCracked Cab...
Page 61 - Voltmeter/Ammeter Help Displays
OM-2226 Page 55 7-3. Voltmeter/Ammeter Help Displays . All directions are in reference to thefront of the unit. All circuitry referred tois located inside the unit. 0 Help 0 Display Indicates a short in the thermal protectioncircuitry located on the bottom heat sink.Contact a Factory Authorized Serv...
Page 62 - Troubleshooting
OM-2226 Page 56 7-4. Troubleshooting Trouble Remedy No weld output; unit completelyinoperative. Place line disconnect switch in On position (see Section 4-12). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-12). Check for proper input power connections (see Sec...
Page 63 - SECTION 8 − ELECTRICAL DIAGRAMS
OM-2226 Page 57 SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram SC-189 769-E
Page 67 - SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW)
OM-2226 Page 61 SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW) 207 690-A This symbol indicates which functions should be active for stainless steel. • Turn power on (switch located on rear panel) • Press Process switch pad until TIG HF Impulse LED is lit • Press Output switch pad until RMT STD LED i...
Page 69 - And HF TIG Start Procedures
OM-2226 Page 63 11-3. Lift-Arc And HF TIG Start Procedures Lift-Arc Start When Lift-Arc t button light is On, start arc as follows: 1 TIG Electrode 2 Workpiece Touch tungsten electrode to work-piece at weld start point, enable out-put and shielding gas with torch trig-ger, foot control, or hand co...
Page 71 - 1-5. Positioning Torch Tungsten For Various Weld Joints
OM-2226 Page 65 11-5. Positioning Torch Tungsten For Various Weld Joints ST-162 003 / S-0792 70 ° 70 ° 90 ° 20 ° 20 ° 10 ° 20 ° 70 ° 40 ° 30 ° 20 ° 70 ° 90 ° 20 ° Butt Weld And Stringer Bead “T” Joint Lap Joint Corner Joint
Page 72 - SECTION 12 − STICK WELDING (SMAW) GUIDELINES
OM-2226 Page 66 SECTION 12 − STICK WELDING (SMAW) GUIDELINES 12-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) ST-207 690-A 1 Front Panel Correct front panel display for basicStick DCEP welding. . For all front panel switch padcontrols: press switch pad toturn on light and...
Page 73 - 2-2. Electrode and Amperage Selection Chart
OM-2226 Page 67 12-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/323/167/32 1/4 1/165/643/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/163/32 1/8 5/32 6010 & 6011 6013 7014 7018 7024 Ni-Cl 308L 50 100...
Page 76 - 2-9. Conditions That Affect Weld Bead Shape
OM-2226 Page 70 12-9. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, andthickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRAVEL SPEED Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Small A...
Page 78 - 2-16. Troubleshooting − Excessive Spatter
OM-2226 Page 72 12-14. Weld Test S-0057-B 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown.A good weld bends over but doesnot break. 2 To 3 in 1/4 in 3 2 1 2 To 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 12-15. Troubleshooting − Porosity Porosity − small cavities or holes resulting f...
Page 80 - 2-21. Troubleshooting − Waviness Of Bead
OM-2226 Page 74 12-20. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resultingin holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady trave...
Page 82 - SECTION 13 − PARTS LIST
OM-2226 Page 76 SECTION 13 − PARTS LIST Figure 13-1. Main Assembly 803 227-C . Hardware is common andnot available unless listed. GROUND STUD DETAIL 1 3 14 11 12 8 10 2 13 600 614 401 400 402 6 4 9 5 19 18 16 17 32 7 403 615 30 31 29 25 28 15 33
Page 93 - (Equipment with a serial number preface of “LE” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 6/04 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...
Page 94 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2004 Miller Electric Mfg. Co. 1/04 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters−USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...
