Miller Maxstar 140 Owner'S Manual Download Page 37 | Manualshive

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OM-2224 Page 33

8-2.

Torch Movement During Welding

ST-162 002-B

Tungsten Without Filler Rod

Tungsten With Filler Rod

Form pool

Tilt torch

Move torch to front

of pool. Repeat process.

75

°

75

°

Welding direction

Form pool

Tilt torch

Add filler metal

Move torch to front

of pool. Repeat process.

Remove rod

Welding direction

15

°

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Summary of Contents for Maxstar 140

Page 1: ...Maxstar 140 With Auto Link Processes Description R TIG GTAW Welding Stick SMAW Welding Arc Welding Power Source OM 2224 191 802 February 1999 Visit our website at www Miller Welds com R...

Page 2: ...ner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the works...

Page 3: ...uded with Your Unit TIG Stick 10 2 5 Duty Cycle And Overheating 11 2 6 Volt Ampere Curves 12 2 7 Selecting A Location 13 2 8 Typical Connection Methods 13 2 9 Connecting to Weld Output Receptacles 14...

Page 4: ......

Page 5: ...that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conductor first double check connections D Frequently inspect input power...

Page 6: ...elding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane ligh...

Page 7: ...aintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can caus...

Page 8: ...s a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to el...

Page 9: ...de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre D En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et...

Page 10: ...er des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer t...

Page 11: ...vrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences D Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de...

Page 12: ...s champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de te...

Page 13: ...light weight portable welding power source containing the latest high perfor mance electronics that supplies DC weld output for use with the Stick Electrode and TIG welding processes This unit also h...

Page 14: ...ntact your distributor 1 2 3 4 DP 00401 2 4 Included with Your Unit TIG Stick 1 Shoulder Strap Carrying Strap 2 12 ft 3 6 m Gas Hose Coupler And Inert Gas Regulator Flowmeter 3 10 ft 3 m Cable With Wo...

Page 15: ...age or voltage or duty cycle before starting to weld again Y Exceeding duty cycle can damage unit and void warranty 110 A 35 Duty Cycle 115 V Input 140 A 25 Duty Cycle 230 V Input Overheating 0 15 A o...

Page 16: ...V Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown 115 VAC INPUT 230 VAC INPUT TIG and S...

Page 17: ...latile liquids are present see NEC Article 511 or CEC Section 20 2 Airflow Distance Requirements 18 in 460 mm 18 in 460 mm ST 801 956 A DP 00333 193 623 1 Y Do not move or operate unit where it could...

Page 18: ...ectrode Positive connect work cable con nector to negative receptacle and Electrode Holder cable con nector to positive receptacle To connect to receptacle align keyway insert connector and turn clock...

Page 19: ...Receptacle The Auto Link circuitry in this unit automatically links the power source to the primary voltage being applied either 115 or 230 VAC An individual branch circuit capa ble of carrying 30 am...

Page 20: ...into unit Mark location of switch terminals where black and white leads are connected and note location of ground lead Disconnect leads from ground terminal and switch 2 Black Switch Lead 3 Rear Panel...

Page 21: ...ed down the output will come back ON Reduce the duty cycle or amper age before starting to weld again This light flashes if the input voltage primary is too low or if there is an input overcurrent fau...

Page 22: ...til after the electrode is lifted from workpiece This al lows electrode to touch workpiece without overheating sticking or getting contaminated 1 1 2 Seconds Touch Do NOT Strike Like A Match 2 Ref S 1...

Page 23: ...OM 2224 Page 19 4 2 Blowing Out Inside Of Unit Y Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown DP 00333...

Page 24: ...d type of weld cable see your Distributer Clean and tighten all weld connections Check and reverse electrode polarity check and correct poor connections to workpiece Fan not operating unit is equipped...

Page 25: ...OM 2224 Page 21 SECTION 5 ELECTRICAL DIAGRAM C 193 705 Figure 5 1 Circuit Diagram For Welding Power Source...

Page 26: ...is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode re quires less current than a large one Follow electrode manufactur er s instructions when setting weld amperage see Secti...

Page 27: ...LLET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER...

Page 28: ...6 6 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 6 7 Good Weld Bead Characteristics S...

Page 29: ...rrect Angle 6 9 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave...

Page 30: ...4 6 11 Lap Joint S 0063 S 0064 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be f...

Page 31: ...Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface befo...

Page 32: ...dirt from work surface before welding 6 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Cause...

Page 33: ...llel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 6 21 Troubleshooting Distortion Distortion contraction of weld meta...

Page 34: ...15 to 35 cfh cubic feet per hour 7 to 16 5 lpm liters per minute Not Recommended The figures listed are intended as a guide and are a composite of recommendations from American Welding Society AWS and...

Page 35: ...weld ing Do not use wheel for other jobs or tungsten can become contami nated causing lower weld quality 3 Ideal Tungsten Preparation Stable Arc 2 1 2 Times Electrode Diameter 1 2 1 Stable Arc 2 Flat...

Page 36: ...ep flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select...

Page 37: ...02 B Tungsten Without Filler Rod Tungsten With Filler Rod Form pool Tilt torch Move torch to front of pool Repeat process 75 75 Welding direction Form pool Tilt torch Add filler metal Move torch to fr...

Page 38: ...OM 2224 Page 34 8 3 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 39: ...OM 2224 Page 35 Notes...

Page 40: ...al number 1 5 V15 194 241 OVERTEMPERATURE LIGHT 1 6 194 217 BASE 1 7 194 220 SHOULDER STRAP 1 8 RC1 RC2 194 223 WELD OUTPUT RECEPTACLES 2 9 194 429 STICK TIG SWITCH 1 10 194 070 CABLE INPUT 115V 20A 1...

Page 41: ...SFORMER main 1 5 194 230 BUS BAR transformer top 1 6 R1 194 228 SHUNT 1 7 194 231 BUS BAR negative output 1 8 C1 C2 194 233 CAPACITORS output filter 1 9 194 244 BUS BAR flexible positive output 2 10 R...

Page 42: ...Item No Quantity Figure 9 3 Inside Right Components 1 PC1 PC2 194 225 CIRCUIT CARD PC1 main 1 2 194 236 FAN MOTOR BRACKET 1 Recommended Spare Parts To maintain the factory original performance of your...

Page 43: ...as been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for opera...

Page 44: ...ss City State Zip Please complete and retain with your personal records Always provide Model Name and Serial Style Number Contact your Distributor for To locate distributor nearest you call 1 800 4 A...

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