Miller Maxstar 140 Owner's Manual
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Miller Maxstar 140 Owner's Manual

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Maxstar 140
OM-2224
191 802
February 1999
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
R
R
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  • Page 1 OM-2224 191 802 February 1999 Processes Stick (SMAW) Welding TIG (GTAW) Welding Description Arc Welding Power Source Maxstar 140 With Auto-Link Visit our website at www.Miller- Welds.com...
  • Page 2 This Owner’s Manual is designed to help you get the most out of your do – every power source from Miller is backed by Miller products. Please take time to read the Safety precautions. They will the most hassle-free war- help you protect yourself against potential hazards on the worksite. We’ve ranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des YIdentifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à D Rester à l’écart des organes mobiles comme le proximité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 P-1, de la Compressed Gas Association, 1235 Jefferson Davis High- way, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Specifications And Installation

    SECTION 2 – SPECIFICATIONS AND INSTALLATION 2-1. Specifications Amperes Input At Input Rated Power Welding Maximum Load Rated Welding Amperage Open-Circuit Single- 100% Dimensions Weight Output Output, Range Voltage DC Phase Duty 50/60Hz, Cyc. Single- Phase 80A @ 23.2 Volts DC, 100% Duty 5 –...

  • Page 14: Included With Your Unit (Stick Only)

    2-3. Included with Your Unit (Stick Only) Shoulder Strap (Carrying Strap) 13 ft (4 m) Cable With Electrode Holder and Quick-Connect Plug 10 ft (3 m) Cable With Work Clamp And Quick-Connect Plug 8 ft (2.4 m) 115 VAC Input Power Cord With 20 A Plug Some assembly is required.

  • Page 15: Duty Cycle And Overheating

    2-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops, the Overtemperature Light comes On, V AC and the cooling fan runs. Wait fif- teen minutes for unit to cool.

  • Page 16: Volt-Ampere Curves

    2-6. Volt-Ampere Curves Volt-ampere curves show mini- 115 VAC INPUT mum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. TIG and Stick Max. Stick Min. TIG Min. 230 VAC INPUT TIG and Stick Max.

  • Page 17: Selecting A Location

    2-7. Selecting A Location Welding Power Source Use shoulder strap to lift and move unit. Rating Label Label is located on side of unit. Use rating label to determine input power needs. Special installation may be required where gasoline or volatile liquids are present –...

  • Page 18: Connecting To Weld Output Receptacles

    2-9. Connecting To Weld Output Receptacles Turn Off welder before making connections. Negative (–) Weld Output Receptacle Positive (+) Weld Output Receptacle Connectors For TIG Welding (Electrode Nega- tive), connect work cable connec- tor to positive (+) receptacle and TIG Torch cable connector to neg- ative (–) receptacle.

  • Page 19: Connecting Input Power

    2-11. Connecting Input Power The welder is shipped with a 115 VAC input power cord installed. If unit is to be used on 230 VAC input power, in- tall new power cord accord- ing to Section 2-12. Input Power Cord 115 or 230 VAC Grounded Receptacle The Auto-Link circuitry in this...

  • Page 20: Installing 230 Volts Ac Input Power Cord

    2-12. Installing 230 Volts Ac Input Power Cord Tools Needed: DP-00333 Loosen strain relief clamp, and push sever- Green Ground Lead Disconnect input power plug from receptacle before installing differ- al inches of power cord into unit. Insert new power cord through strain relief, ent input power cord.

  • Page 21: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Front Panel Controls Weld output receptacles are energized when Power Switch is On and Input sup- ply power is connected and Ready Light a dual reading dial. Be sure to set it ac- check electrode recommendations.) For cording to the input voltage supplying TIG welding, connect work cable to this re- This light comes On when the Power...

  • Page 22: Lift-Arct Tig Procedure

    3-2. Lift-Arct TIG Procedure With Process Switch in the Lift-Arc TIG position, start an arc as follows: TIG Electrode Workpiece Touch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. An arc will form when electrode is 1 –...

  • Page 23: Blowing Out Inside Of Unit

    4-2. Blowing Out Inside Of Unit 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 OM-2224 Page 19...

  • Page 24: Troubleshooting

    4-3. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch for circuit powering welder in On position. erative; Ready light Off. Check and replace line fuse(s), if necessary, or reset circuit breaker. Be sure input power cord is plugged in and that receptacle is receiving input power. No weld output;...

  • Page 25: Section 5 - Electrical Diagram

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

  • Page 26: Section 6 - Stick Welding (Smaw) Guidelines

    SECTION 6 – STICK WELDING (SMAW) GUIDELINES 6-1. Stick Welding Procedure Weld current starts when electrode touches work- piece. Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.

  • Page 27: Electrode And Amperage Selection Chart

    6-2. Electrode and Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 6010 DEEP MIN. PREP, ROUGH 1/16 HIGH SPATTER 6011 DEEP 5/64 6013 EP,EN GENERAL 3/32 SMOOTH, EASY, 6013 7014 EP,EN FAST 5/32 3/16 LOW HYDROGEN, 7018 STRONG 7/32 FLAT SMOOTH, EASY,...

  • Page 28: Positioning Electrode Holder

    6-5. Positioning Electrode Holder ° ° ° ° End View of Work Angle Side View of Electrode Angle GROOVE WELDS ° ° ° ° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 6-6. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding...

  • Page 29: Conditions That Affect Weld Bead Shape

    6-8. Conditions That Affect Weld Bead Shape NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Correct Angle ° - ° Angle Too Large Angle Too Small Drag ELECTRODE ANGLE Spatter Normal Too Long Too Short...

  • Page 30: Butt Joints

    6-10. Butt Joints Tack Welds Prevent edges of joint from draw- ing together ahead of electrode by tack welding the materials in posi- tion before final weld. Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. Single V-Groove Weld °...

  • Page 31: Weld Test

    6-13. Weld Test Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in (51-76 mm) 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) S-0057-B 6-14. Troubleshooting – Porosity Porosity –...
  • Page 32 6-16. Troubleshooting – Incomplete Fusion Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
  • Page 33 6-19. Troubleshooting – Burn-Through Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 6-20. Troubleshooting – Waviness Of Bead Waviness Of Bead –...

  • Page 34: Section 7 -Selecting And Preparing Tungsten Electrode

    SECTION 7 – SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw 7/97 NOTE For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process. Wear clean gloves to prevent contamination of tungsten electrode. 7-1. Selecting Tungsten Electrode ♦...
  • Page 35 7-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Tungsten Electrode Tapered End Grind end of tungsten on fine grit, hard abrasive wheel before weld- ing. Do not use wheel for other jobs or tungsten can become contami- nated causing lower weld quality. 2-1/2 Times Electrode Diameter Stable Arc...

  • Page 36: Section 8 - Guidelines For Tig Welding (Gtaw)

    SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW) 8-1. Positioning The Torch Grinding the tungsten elec- trode produces dust and fly- ing sparks which can cause injury and start fires. Use lo- cal exhaust (forced ventila- tion) at the grinder or wear approved respirator.

  • Page 37: Torch Movement During Welding

    8-2. Torch Movement During Welding Tungsten Without Filler Rod ° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod ° ° Welding direction Form pool Tilt torch Add filler metal Remove rod Move torch to front of pool.

  • Page 38: Positioning Torch Tungsten For Various Weld Joints

    8-3. Positioning Torch Tungsten For Various Weld Joints ° Butt Weld And Stringer Bead ° ° ° “T” Joint ° ° ° ° Lap Joint ° ° ° ° Corner Joint ° ° ST-162 003 / S-0792 OM-2224 Page 34...
  • Page 39 Notes OM-2224 Page 35...

  • Page 40: Section 9 - Parts List

    SECTION 9 – PARTS LIST 11, 12 Hardware is common and not available unless listed. DP-00331 Figure 9-1. Welding Power Source Components Item Dia. Part Mkgs. Description Quantity Figure 9-1. Control Box Components ....191 633 LABEL, WARNING, general precautionary .
  • Page 41 Wrapper (case) grounding lead--always reconnect properly. Hardware is common and not available unless listed. DP-00346 Figure 9-2. Inside Left Components Item Dia. Part Mkgs. Description Quantity Figure 9-2. Inside Left Components ...
  • Page 42 Hardware is common and not available unless listed. DP-00347 Figure 9-3. Inside Right Components Item Dia. Part Mkgs. Description Quantity Figure 9-3. Inside Right Components ..PC1, PC2 . . . 194 225 CIRCUIT CARD PC1, main .
  • Page 43 Effective January 1, 1998 (Equipment with a serial number preface of “KJ” or newer) Warranty Questions? This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions Miller’s True Blue...
  • Page 44 File a claim for loss or damage during Contact the Delivering Carrier for: shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.  PRINTED IN USA 1999 Miller Electric Mfg. Co. 9/98...

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