Miller 907684001 Owner'S Manual Download Page 4

Page: 4 / 92

TABLE OF CONTENTS

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8-2. Accessing Control Panel Menu: DC TIG HF And Lift Arc

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8-3. Accessing Control Panel Menu: DC Stick

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8-4. Accessing User Setup Menu: DC TIG And Lift-Arc

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8-5. Accessing User Setup Menu: DC Stick

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SECTION 9

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MAXSTAR 210 STR OPERATION

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9-1. Maxstar 210 STR Controls

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9-2. Accessing Control Panel Menu: DC TIG Lift Arc

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9-3. Accessing Control Panel Menu: DC Stick

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9-4. Accessing User Setup Menu: DC TIG Lift-Arc And DC Stick

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SECTION 10

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MAXSTAR 210 DX OPERATION

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10-1. Maxstar 210 DX Controls

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10-2. Accessing Control Panel Menu

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10-3. Accessing User Setup Menu

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SECTION 11

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ADVANCED MENU FUNCTIONS

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11-1. Accessing Tech Menu For Dynasty/Maxstar 210 Models

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11-2. Accessing Tech Menu For Dynasty/Maxstar 210DX Models

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11-3. Sequencer And Weld Timer For DX Model

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11-4. Output Control And Trigger Functions For DX Models

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11-5. Lockout Functions

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11-6. Lockout Levels Defined

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SECTION 12

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MAINTENANCE AND TROUBLESHOOTING

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12-1. Routine Maintenance

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12-2. Voltmeter/Ammeter Display Messages

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12-3. Troubleshooting Table

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12-4. Blowing Out Inside of Unit

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12-5. Coolant Maintenance

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SECTION 13

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PARTS LIST

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13-1. Recommended Spare Parts

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SECTION 14

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ELECTRICAL DIAGRAMS

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SECTION 15

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HIGH FREQUENCY

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15-1. Welding Processes Requiring High Frequency

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15-2. Installation Showing Possible Sources Of HF Interference

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15-3. Recommended Installation To Reduce HF Interference

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SECTION 16

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SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING

WITH INVERTER MACHINES

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16-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten)

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16-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines

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SECTION 17

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TIG PROCEDURES

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17-1. Lift-Arc And HF TIG Start Procedures

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17-2. Pulser Control

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17-3. General (GEN) Tungsten Programmable TIG Starting Parameters (DX Models Only)

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SECTION 18

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STICK WELDING (SMAW) ELECTRODE AND AMPERAGE SELECTION CHART

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WARRANTY
COMPLETE PARTS LIST

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Available at www.MillerWelds.com

Summary of Contents for 907684001

Page 1: ...AW Welding Description File TIG GTAW Dynasty 210 Stick SMAW Welding For product information Owner s Manual translations and more visit www MillerWelds com Maxstar 210 CE And Non CE Models Arc Welding...

Page 2: ...roducts continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to he...

Page 3: ...ault Weld Parameters And Settings 13 4 4 Specifications 13 4 5 Duty Cycle And Overheating 16 4 6 Static Characteristics 17 4 7 Environmental Specifications 17 SECTION 5 INSTALLATION 19 5 1 Selecting a...

Page 4: ...6 Lockout Levels Defined 64 SECTION 12 MAINTENANCE AND TROUBLESHOOTING 65 12 1 Routine Maintenance 65 12 2 Voltmeter Ammeter Display Messages 66 12 3 Troubleshooting Table 67 12 4 Blowing Out Inside...

Page 5: ...mission Regulations 2014 35 EU Low voltage 2014 30 EU Electromagnetic compatibility 2015 865 EU Restriction of the use of certain hazardous substances in electrical and electronic equipment 2009 125 E...

Page 6: ......

Page 7: ...tional exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required minimum distances apply Occupational exposure is below the...

Page 8: ...ional exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required minimum distances apply Occupational exposure is below the E...

Page 9: ...low ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting...

Page 10: ...ot possible tightly cover them with approved covers D Do not weld where flying sparks can strike flammable material D Protect yourself and others from flying sparks and hot metal D Be alert that weldi...

Page 11: ...o move unit be sure forks are long enough to extend beyond opposite side of unit D Keep equipment cables and cords away from moving vehicles when working from an aerial location D Follow the guideline...

Page 12: ...uments Website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protection Association Website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylin...

Page 13: ...e n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement...

Page 14: ...e La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incen dies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des...

Page 15: ...mettre l appareil en service LA CHUTE DE L QUIPEMENT peut provoquer des blessures D Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout...

Page 16: ...te Website www ansi org Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents Website www gl...

Page 17: ...aged gloves Safe2 2017 04 Protect yourself from electric shock by insulating yourself from work and ground Safe3 2017 04 Disconnect input plug or power before working on machine Safe5 2017 04 Keep you...

Page 18: ...oper precautions as shown connect power to unit Safe29 2012 05 Disconnect input plug or power before working on machine Safe30 2012 05 Do not use one handle to lift or support unit Safe31 2017 04 Do n...

Page 19: ...lly charged capacitors Always wait 60 seconds after power is turned off before working on unit AND check input ca pacitor voltage and be sure it is near 0 before touching any parts Safe42 2017 04 60 A...

Page 20: ...rent Line Connection U2 Conventional Load Voltage U1 Primary Voltage IP Degree Of Protection I1max Rated Maximum Supply Current I1eff Maximum Effective Supply Current U0 Rated No Load Voltage OCV Puls...

Page 21: ...equipment adoption or adjustment of default weld parameters and settings and ultimate quality and durability of all resultant welds Miller Electric expressly disclaims any and all implied warranties...

Page 22: ...Max Open Circuit Voltage Uo Low Open Circuit Voltage Uo Rated Peak Striking Voltage Up IP Rating 1 210 80 8 15 15KV 23 Welding range for Stick process is 5 210 amperes For TIG the amperage range is t...

Page 23: ...35 3 29 29 43 42 Standby 1 9 11 19 25 3 13 14 28 39 Process Output Ratings Current Draw A At Rated Input Voltage V Input Power Current A Voltage V Duty Cycle Phase 120V kW kVA STICK 100 24 40 1 25 3...

Page 24: ...ut stops a Help message is displayed see Section12 2 and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or voltage or duty cycle before welding NOTICE Exceeding duty cycle can...

Page 25: ...quipment complies with IEC61000 3 11 and IEC 61000 3 12 and can be connected to public low voltage systems provided that the public low voltage system impedance Zmax at the point of common coupling is...

Page 26: ...istributor for further information Critical raw materials possibly present in indicative amounts higher than 1 gram at component level Component Critical Raw Material Printed circuit boards Baryte Bis...

Page 27: ...only Do not use to lift power source when attached to cart cooler 2 Lift Handle Use lift handle to move and lift weld er cart cooler Do not use lift handle to lift unit when gas cylinder and accessori...

Page 28: ...s A 13 5 8 in 346 mm B 8 5 8 in 219 mm C 22 1 2 in 569 mm Dynasty and Maxstar CE 19 1 2 in 495 mm Maxstar non CE Weight Maxstar 38 lb 17 2 kg Maxstar CE 42 lb 18 8 kg Dynasty 47 lb 21 3 kg w CPS 50 lb...

Page 29: ...cables For example if the power source is 100 ft 30 m from the workpiece the total cable length in the weld circuit is 200 ft 2 cables x 100 ft Use the 200 ft 60 m column to determine cable size Weld...

Page 30: ...al Coolmate 1 3 Dedicated Power Supply Receptacle Dynasty Only 7 Supplementary Protector For Coolmate 1 3 Dedicated Power Supply Included with optional dedicated Coolmate 1 3 power supply recep tacle...

Page 31: ...ad to work weld output terminal 6 Water Out To Torch Connection Connect torch water supply blue hose to the coolers water out con nection 7 Water In From Torch Connection Connect torch water return re...

Page 32: ...If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements B Electrical Service Guide For Single Phase Operation Dynasty El...

Page 33: ...If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements B Electrical Service Guide For Single Phase Operation Maxstar Ele...

Page 34: ...mplete Parts List is available at www MillerWelds com OM 270536 Page 26 GND PE Earth Ground L1 2 1 L2 L3 3 3 4 5 6 7 Tools Needed 5 8 Connecting Three Phase Input Power input2 2012 05 803766 C Ref 805...

Page 35: ...n nected to any input power between 120 480 VAC without removing cover to relink the power source See rating label on unit and check input volt age available at site For Three Phase Operation 1 Input...

Page 36: ...voltage available at site This unit can be connected to any in put power between 120 480 VAC without removing cover to relink the power source See rating label on unit and check input voltage availab...

Page 37: ...wave form Electrical specifications open collector tran sistor see Section 5 11 for connection example Touch Sense Detection closed to Socket G with Modbus s Touch Sense enabled and machine not trigg...

Page 38: ...ftware update is required to ensure proper software expansion operation of all purchased feature expansions B Requirements A computer with an SD memory card port or SD memory card reader is required t...

Page 39: ...process LED indicator blinks green when machine is reading from or writing to the card and the meter displays go blank The update time may vary up to three minutes Do Not re move card while LED is bli...

Page 40: ...ion 5 12D 4 Volt Meter Displays actual rectified average voltage when voltage is present at the weld output terminals It is also used to display para meter descriptions while in the menu 5 Ammeter Dis...

Page 41: ...he maximum amperageof each welding cycle The minimum time is 8 seconds Auto maximum amperage 10 PRO SET provides PROfessionally de veloped SETtings for the weld process To use PRO SET press the menu b...

Page 42: ...The Background Am perage and Peak Amperage are not adjustable Background Amperage equals 25 of Peak amper age Peak amperage Time equals 40 POST Post Flow Control Controls the length of time gas flows...

Page 43: ...erage device In AC the user will be setting the rectified average value of the AC current AC AV will be displayed DIG Arc Force Control Controls the amount of additional amperage at low voltage short...

Page 44: ...t diameter for optimized starting Range is 0 020 in 1 8 in or 0 5 mm 3 2 mm Trigger Mode Selection RMT STD Typically used with a remote foot or hand control RMT STD requires a maintained contact closu...

Page 45: ...No additional starting amperage to assist in starting the electrode Trigger Mode Selection RMT STD Typically used with a remote foot or hand control RMT STD requires a maintained contact closure to e...

Page 46: ...A complete Parts List is available at www MillerWelds com OM 270536 Page 38 Notes...

Page 47: ...pplicable front panel func tion switch pads to change values for that function 3 Memory Card Port And Indicator This port is used to add features to the ma chine and update software to the boards with...

Page 48: ...ing Trigger Mode Selection See Section 11 4 for additional trigger function options RMT STD Typical setting for a remote foot or hand control RMT STD requires a maintained contact closure to enable we...

Page 49: ...g resources Gas DIG Control PRE Preflow Time Controls length of time gas flows prior to arc start Range is OFF 25T seconds POST Post Flow Time Increasing setting increases length of time gas flows aft...

Page 50: ...els Only ENEP SAME standard mode of operation for control ling AC amperage setting ENEP INDP for AC TIG welding allows the user to set the EP amperage independently from the EN amperage When ON the us...

Page 51: ...e and frequency To change the average amperage value press the Amperage switch pad and turn the amperage ad justment control control The changing average val ue is displayed on the ammeter Example If...

Page 52: ...within the machine Indicator is lit while card is being accessed 4 Volt Meter Displays actual voltage when voltage is present at the weld output terminals It is also used to display parameter descript...

Page 53: ...minimize distortion and increase travel speed Set PPS pulses per second The range is OFF 250 PPS The Background Amperage and Peak Amperage Time are not adjustable Background Amper age equals 25 of Pea...

Page 54: ...onal amperage at low voltage short arc length conditions Adjust the force of the arc for different joint configurations and electrodes Range is OFF 100 Features PRO Set values for both 6010 and 7018 e...

Page 55: ...ection for 11 4 for additional trigger function options RMT STD Typical setting for a remote foot or hand control RMT STD requires a maintained contact closure to enable weld output Amperage can be co...

Page 56: ...ypical setting for a remote foot or hand control RMT STD requires a maintained contact closure to enable weld output Amperage can be controlled with a remote potentiometer or it can be set at the cont...

Page 57: ...ate software to the boards within the machine Indicator is lit while card is being accessed 4 Volt Meter Displays actual voltage when voltage is present at the weld output terminals It is also used to...

Page 58: ...lay 3 Setting Display 4 Amperage Adjustment Control Rotate amperage adjustment control to adjust parameter setting Parameter automatically returns to amperage setting 15 seconds after amperage adjustm...

Page 59: ...short arc length conditions Adjust the force of the arc for different joint configurations and electrodes Range is OFF 100 Features PRO Set values for both 6010 and 7018 electrodes 110A Amperage Cont...

Page 60: ...s and hold Menu button until Menu Off is displayed 1 ON OUT MENU 2 3 4 USER Trigger Mode Selection RMT STD Typical setting for a remote foot or hand control RMT STD requires a maintained contact closu...

Page 61: ...junction with applicable front panel func tion switch pads to change values for that function 3 Memory Card Port And Indicator This port is used to add features to the ma chine and update software to...

Page 62: ...11 4 for additional trigger function options RMT STD Typical setting for a remote foot or hand control RMT STD requires a maintained contact clos ure to enable weld output Amperage can be controlled w...

Page 63: ...itive ap plications Sequencer is only available in the TIG process Sequencer is disabled if a remote con trol with variable amperage is connected to the machine INTL Initial Amperage Range is min to 2...

Page 64: ...mperage setting 15 seconds after amperage adjustment con trol is inactive To exit user menu press and release Amperage and Gas DIG controls at the same time or turn power off 1 2 3 4 USER 2T 3 32 TUNG...

Page 65: ...o set or change time rotate amperage adjustment control to desired time Timer range 1 5 10 20 30 45 minutes or one hour STUC Stick Stuck Detects if the electrode is stuck or shorted to the workpiece T...

Page 66: ...mperage and Gas Dig buttons for approximately two seconds to scroll past User Menu to Tech Menu Use Gas Dig button to cycle through parameters that can be set 3 Parameter Display 4 Setting Display 5 A...

Page 67: ...the reset is complete and factory defaults have been restored LOCK Limits user control and adjustability of machine See Section 11 5 For instructions and operation WELD TMRS Weld Timers ON enable and...

Page 68: ...amps DC Initial Time Range is OFF to 25 0T seconds Initial Slope Time Range is OFF to 50 0T seconds Final Slope Time Range is OFF to 50 0T seconds Final Amperage Range is 2 210 amps AC 1 210 amps DC F...

Page 69: ...te control not by the welding power source P R P R P R Push and release trigger If torch trigger is held more than 3 seconds operation reverts to RMT STD Remote Standard mode For first torch trigger p...

Page 70: ...tial switch closure is not made again before preflow time ends gas flow stops the timer resets and an initial switch press and release is necessary to start the weld sequence again B Press initial swi...

Page 71: ...gic allows the operator to toggle between initial slope or main amps and initial amps Final Amperage is not available Final slope always slopes to minimum amperage and ends the cycle When a remote swi...

Page 72: ...erage control until LOCK is displayed You may now select a lockout level See table below for the degree of adjustability associated with each lock level Exit Advanced Functions according to Section 11...

Page 73: ...ent Every 3 Months nl Labels n l Gas Hoses Every 3 Months n lCables And Cords Every 6 Months During heavy service clean monthly Do not remove case when blowing out inside of unit B Optional Cooler n C...

Page 74: ...s has been sensed Straighten out or shorten weld cables If carbon arc gouging adjust DIG setting to CARBon ARC See Section 6 4 Dynasty 7 2 Dynasty DX 9 3 Maxstar or 10 2 Maxstar DX SEE O M See Owner s...

Page 75: ...ly prepared tungsten see Section 16 Reduce gas flow rate Tungsten electrode oxidizing and not re maining bright after conclusion of weld Shield weld zone from drafts Increase postflow time Check and t...

Page 76: ...tion pump Fill with clean water and run for 10 minutes Drain and refill with coolant If replacing hoses use hoses compatible with ethylene gly col such as Buna N Neo prene or Hypalon Oxy acety lene ho...

Page 77: ...045 SST A 1 043810 Coolant 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use o...

Page 78: ...OM 270536 Page 70 SECTION 14 ELECTRICAL DIAGRAMS Figure 14 1 Circuit Diagram For Dynasty 210 255980 G...

Page 79: ...OM 270536 Page 71 Figure 14 2 Circuit Diagram For Maxstar 210 255981 H...

Page 80: ...of Direct High Frequency Radiation 1 High Frequency Source welding power source with built in HF or separate HF unit 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table Sources of Conduction...

Page 81: ...conduit every 50 ft 15 m 6 Water Pipes and Fixtures Ground water pipes every 50 ft 15 m 7 External Power or Telephone Lines Locate high frequency source at least 50 ft 15 m away from power and phone l...

Page 82: ...gstens 010 in 25 mm Up to 15 Up to 15 020 in 50 mm 5 20 5 20 040 in 1 mm 15 80 15 80 1 16 in 1 6 mm 70 150 70 150 3 32 in 2 4 mm 150 250 140 235 1 8 in 3 2 mm 250 400 225 325 5 32 in 4 0 mm 400 500 30...

Page 83: ...radioactive material Properly dispose of grinder dust in an environmentally safe way Wear proper face hand and body protection Keep flammables away Ideal Tungsten Preparation Stable Arc 1 Grinding Wh...

Page 84: ...s present between elec trode and workpiece The solid state output contactor does not energize until after electrode is touching work piece This allows electrode to touch workpiece without overheating...

Page 85: ...eak time is set at 50 one half second is spent at peak amperage and the other 50 or one half second is spent at the background amperage Increasing peak time increases time spent at peak amperage which...

Page 86: ...ugh each adjustable para meter Turn amperage adjustment control to change the value 1 2 Current A Start Time Start Slope Time Preset Amperage Minimum Start Amperage Available Parameter Settings 3 Para...

Page 87: ...0 6011 6013 7014 7018 7024 Ni Cl 308L 50 100 150 200 250 300 350 400 450 ELECTRODE DC AC POSITION PENETRATION USAGE MIN PREP ROUGH HIGH SPATTER GENERAL SMOOTH EASY FAST LOW HYDROGEN STRONG SMOOTH EASY...

Page 88: ...Notes...

Page 89: ...Notes...

Page 90: ...Notes...

Page 91: ...SAR Boxes and Panels TIG Torches No Labor Tregaskiss Guns No Labor Water Cooling Systems Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries...

Page 92: ...ersonal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Protective Equipmen...

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