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OM-270536 Page 79

SECTION 18

−

STICK WELDING (SMAW) ELECTRODE AND

AMPERAGE SELECTION CHART

Ref. S-087985-A

3/32

1/8

5/32

3/16

7/32

1/4

1/16

5/64

3/32

1/8

5/32

3/16

7/32

1/4

3/32

1/8

5/32

3/16

7/32

1/4

3/32

1/8

5/32

3/16

7/32

1/4

3/32

1/8

5/32

3/16

7/32

1/4

3/32

1/8

5/32

3/16

3/32

1/8

5/32

6010

6011

6013

7014

7018

7024

Ni-Cl

308L

100

150

200

250

300

350

400

450

ELECTRODE

DC*

POSITION

PENETRA

TION

USAGE

MIN. PREP, ROUGH

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

DEEP
DEEP

LOW

MED

LOW

LOW
LOW

ALL
ALL
ALL

ALL

FLAT

HORIZ*

ALL
ALL

EP
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

MED

Содержание 907684001

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 88: ...Notes...

Страница 89: ...Notes...

Страница 90: ...Notes...

Страница 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...

Страница 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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