Miller Maxstar 300 DX Owner's Manual
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Miller Maxstar 300 DX Owner's Manual

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Maxstar 300 SD,
DX And LX
OM-2222
February 2003
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
230/460 Volt Models W/AutolinkR
400 Volts Models
Arc Welding Power Source
R
And Non-CE Models
189 533U

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  • Page 1 OM-2222 189 533U February 2003 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description 230/460 Volt Models W/AutolinkR 400 Volts Models Arc Welding Power Source Maxstar 300 SD, DX And LX And Non-CE Models Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
  • Page 3 TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 5 – MAINTENANCE AND TROUBLESHOOTING ....... . . 5-1.
  • Page 5 Declaration of Conformity For European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit.) Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Maxstar...
  • Page 7 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_7/02 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 Y Marks a special safety message.
  • Page 8 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 9 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 10 1-4. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800–463–6727 or in Toronto 416–747–4044, website: www.csa–in- (phone: 305-443-9353, website: www.aws.org). ternational.org).
  • Page 11 SECTION 1 – CONSIGNES DE SÉCURITÉ – À LIRE AVANT UTILISATION som _nd_fre 7/02 1-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie «...
  • Page 12 LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et D Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation.
  • Page 13 1-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. D Ne pas placer l’appareil sur une surface inflam- D Se tenir à l’écart des organes mobiles comme les mable, ni au–dessus ou à...
  • Page 14 1-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463–6727 ou à Toronto : (416) 747–4044, site Web : www.csa–interna- (téléphone : (305) 443–9353, site Web : www.aws.org).
  • Page 15 SECTION 2 – DEFINITIONS (CE Models Only) 2-1. Warning Label Definitions Warning! Watch Out! There are possible Breathing welding fumes can be 3.3 Do not weld on drums or any closed hazards as shown by the symbols. hazardous to your health. containers.
  • Page 16 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors.
  • Page 17 2-2. Manufacturer’s Rating Labels For label location see Section 3-4. Manufacture’s Rating Label For Non-CE Models Ref. ST-189 529-C Manufacture’s Rating Label For CE Models ST-188 153-A OM-2222 Page 11...
  • Page 18 2-3. Symbols And Definitions Gas Tungsten Arc Shielded Metal Arc Amperes Panel–Local Welding (GTAW) Welding (SMAW) 3 Phase Static Frequency Volts Input Converter-Transformer-Rectifier Output Circuit Breaker Remote Lift-Arc (GTAW) Protective Earth Postflow Timer Preflow Timer Seconds (Ground) Positive Negative Alternating Rated Welding Gas Input Gas Output...
  • Page 19 SECTION 3 – INSTALLATION 3-1. Specifications A. For Multivoltage Units Amperes Input At Welding Max. Input Rated Output at Rated Output, 60Hz Dimensions Dimensions Amperage Amperage Open-Circuit Open-Circuit Power 60% Duty Cycle Weight Range Voltage 82 lb Three- 250 A @ 30 VDC, 25.4 16.2 12.8...
  • Page 20 3-3. Duty Cycle And Overheating Duty Cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops, a Help message is displayed (see Section 5-3), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.
  • Page 21 3-4. Selecting A Location Lifting Handles Use handles to lift unit. Hand Cart Dimensions And Weight Use cart or similar device to move 82 lb (37 kg) – 100 lb (45 kg) w/aux power 24 in unit. (610 mm) Rating Label Use rating label to determine input power needs.
  • Page 22 3-5. 115 Volts AC Duplex Receptacle, Circuit breaker (Optional) And Power Switch AC Duplex Receptacle 115 V 10 A for 230/460 volt models. 115 V 7 A for 400 volt models. Circuit Breaker CB1 CB1 protects duplex receptacle from overload. Press button to reset breaker.
  • Page 23 3-7. Remote 14 Receptacle Information Socket* Socket Information Contactor control 24 volts dc. 24 VOLTS DC 24 VOLTS DC C L N OUTPUT Contact closure to A completes 24 volts dc CONTACTOR contactor control circuit and enables output. Output to remote control; 0 to +10 volts dc output to remote control.
  • Page 24 3-8. Remote Program Select Inputs (Optional For DX Models) 10-Pin Receptacle RC2 Pin Designations 0 = No Connection / 1 = Connected To Ground (Pin G) X= Do Not Care Function No Remote Control Stick EP Of Current Program Program 1 Stick EP Program 2 Stick EP Program 3 Stick EP Program 4 Stick EP...
  • Page 25 3-9. Automation Connection (LX Models) Socket Socket Information For 10-Pin Receptacle RC2 Start/Stop Output Disable Chassis ground Final slope – collector Final slope – emitter Pulse lockout – collector Pulse lockout – emitter ST-802 137-A ST-802 137-A Valid arc – collector Valid arc –...
  • Page 26 3-10. Gas Connections Gas Fitting Fittings have 5/8-18 right-hand threads. Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. Regulator/Flowmeter Flow Adjust Typical flow rate is 15 cfh (cubic feet per hour). Connect customer supplied gas hose between regulator/flowmeter and gas fitting on rear of unit.
  • Page 27 3-12. Stick DCEP (Direct Current Electrode Positive) Connections Y Turn off power before mak- ing connections. Negative (–) Weld Output Terminal Connect work lead to negative weld output terminal. Positive (+) Weld Output Terminal Connect electrode holder to posi- tive weld output terminal. Remote 14 Receptacle If desired, connect remote control to Remote 14 receptacle (see Sec-...
  • Page 28 3-14. Connecting Input Power Y Disconnect and lockout/tag- out input power before con- necting input conductors from unit. Y Have only qualified persons make this installation. Check input voltage available at site. Line Disconnect Device Input And Grounding Conductors See Section 3-13. Green Or Green/Yellow For three-phase opera-...
  • Page 29 Notes OM-2222 Page 23...
  • Page 30 SECTION 4 – OPERATION 4-1. Controls ST-198 719 / ST-801 866 Rear Panel Process Controls Adjust Controls For all front panel switch pad controls: press switch pad to turn on light and en- See Section 4-7. See Section 4-11. able normal function. Output Controls Amperage And Spot Time Control NOTE: Green on nameplate indicates a TIG...
  • Page 31 4-2. Encoder Control Encoder Control Use control in conjunction with ap- plicable front panel function switch pad to set values for that function. 4-3. Amperage Control A (Amperage Control) Encoder Control Ammeter See Section 4-16 for Amperage control range. Press Amperage switch pad, and turn Encoder control to set weld amperage.
  • Page 32 4-5. Voltmeter Volt Meter Displays output or open circuit volt- age. If output is off, the voltmeter will display a series of three dashes (-––). Open circuit voltage is dis- played if power is on and output is available. 4-6. Polarity Control (Dynastyt Models Only) Polarity Control Press switch pad until desired LED is illuminated.
  • Page 33 4-7. Process Control Process Control Press switch pad until desired pro- cess LED is illuminated: TIG HF Impulse - When selected, a pulsed HF (non-contact) (see Section 9-3) arc starting method is activated. This method can be used with either AC or DC TIG welding. Make connections according to Section 3-11.
  • Page 34 4-9. Pulser Control (DX And LX Models) Pulser Control Pulsing is available only while using the TIG process, it cannot be se- lected if the Stick process (see Sec- tion 4-7) is active. Controls can be ad- justed while welding. Press switch pad to enable pulser.
  • Page 35 4-10. Sequencer Controls (DX, LX And All CE Models) Sequencer Control Sequencing is available only while using the TIG process, but is dis- abled if a remote foot or finger cur- rent control is connected to the Re- mote receptacle while in the RMT STD mode.
  • Page 36 4-11. Adjust Controls (Preflow/Post Flow/DIG) Adjust Press switch pad until desired func- tion LED is illuminated. Encoder Control Ammeter Turn encoder (see Section 4-2) to set appropriate value for active Ad- just parameter. Value selected is shown on the ammeter (see Sec- tion 4-4).
  • Page 37 4-12. AC Waveshape (Dynasty Models Only) AC Waveshape Encoder Control Ammeter Turn encoder (see Section 4-2) to set appropriate value for active AC Waveshape parameter. Value se- lected is shown on the ammeter (see Section 4-4). See Section 4-16 for all AC Wave- shape parameter ranges.
  • Page 38 4-14. Memory (Program Storage Locations 1-4) (DX And LX Models If Available) Memory (Program Storage 1-4) Switch Pad Polarity Switch Pad Process Switch Pad To create, change, or recall a welding parameters program, proceed as follows: First, press Memory switch pad until the desired program storage loca- tion (1-4) LED is illuminated Second, press Polarity switch pad...
  • Page 39 4-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A Preflow Control On The Front Panel SEL 0.2 Rear Panel Process Control Pad Upon power up as described, the TIG Im- Encoder Control pulse, Postflow, DIG, and meter S LED’s Adjust Control Pad Turn encoder to select from 0 to 25 seconds...
  • Page 40 4-16. Factory Parameter Defaults And Range And Resolution Parameter Default Range And Resolution MEMORY 1–4 *POLARITY AC / DC PROCESS TIG HF Impulse TIG HF Impulse / TIG Lift / Stick OUTPUT RMT STD RMT STD / RMT 2T / ON **RMT 2T RMT 2T can be reconfigured for: 2T / 4T / Mini Logic / 4T Momentary / Spot (see Section 4-19C)
  • Page 41 **Impulse HF Start parameters for each program (1-4) MAXSTAR: Amperage 30 A 5 – 200 Amps Time 3 mS 1 – 200 Milliseconds *DYNASTY: Polarity EP / EN Amperage 30 A 5 – 200 Amps Time 3 mS 1 – 200 Milliseconds Polarity EP / EN Amperage...
  • Page 42 4-18. Advanced Functions Accessing Programmable TIG Start Polarity, Amperage, And Time Modes (All Models) Rear Panel NOTE: The welding cycle can be execut- pads until software version clears the Press the Process switch pad to select meters and [SEL] [EP] or [SEL] [EN] appears. ed while in programmable start mode.
  • Page 43 Changing Programmable TIG Start Polarity (Dynasty Models Only) [EP] is displayed on meters, and can be Amperage Switch Pad To adjust TIG Start Polarity proceed as follows: adjusted (see Section 4-16) by turning the Encoder control. Encoder Control Press Amperage switch pad. Switch pad LED turns on, and meter % LED turns on.
  • Page 44 D. Changing Programmable Start Time (All Models) Amperage Switch Pad To adjust Programmable Start Time pro- displayed on the amps meter, and can be ceed as follows: adjusted by turning the Encoder control Encoder Control (see Section 4-16). Press Amperage switch pad, and meter Amps Meter S LED turns on.
  • Page 45 4-19. Output Control And Trigger Functions A. Remote (Standard) Torch Trigger Operation Current (A) Main Amps Initial Slope Final Slope Initial Amps Final Amps Postflow Preflow P & H Foot Or Finger Maintained Switch Foot Or Finger Remote Control Remote Control P&H = Push trigger and hold R = Release trigger.
  • Page 46 C. Reconfiguring RMT 2T HOLD For 2T, Spot, 4T, 4T Momentary, Or Mini Logic Control Rear Panel For RMT STD (Remote Standard), RMT To access the RMT 2T HOLD reconfi- Meter Displays 2T Hold (Remote 2T Hold), and On trig- guration screen, turn power switch on, Meter displays for the different functions ger operation, see Section 4-19A, B,...
  • Page 47 (See Section 4-19B for operation) Spot (See Section 4-19G for operation) (DX, LX and CE Models) (See Section 4-19D for operation) Mini Logic (DX, LX and CE Models) (See Section 4-19E for operation) 4T Momentary (DX, LX and CE Models) (See Section 4-19F for operation) OM-2222 Page 41...
  • Page 48 D. 4T Specific Trigger Method (DX, LX And All CE Models) 4T (Specific Trigger Operation) Sequencer is required to reconfi- gure for 4T. Select 4T according to Section 4-19C. Torch trigger operation is as shown. While in 4T mode, there is a func- tion available during the main se- quence that allows the operator to toggle between weld current and...
  • Page 49 E. Mini Logic Operation (DX, LX And All CE Models) Mini Logic Meter Display Select Mini Logic according to Sec- tion 4-19C. Torch trigger operation is as shown. While in mini logic, there is a func- tion available during initial slope Mini Logic and the main sequence that allows the operator to toggle between ini-...
  • Page 50 F. 4T Momentary Operation (DX, LX And All CE Models) 4T Momentary Meter Display Select 4T Momentary according to Section 4-19C. 4T Momentary torch trigger op- eration is as shown. NOTE: When a remote device is connected to the welding power source, only trigger input is func- tional.
  • Page 51 G. Spot Control Operation (All Models) Spot Function Meter Display Select Spot function according to Section 4-19C. NOTE: While in Spot Control, Se- quencer settings will be ignored and will not be programmable. NOTE: When a remote device is connected to the welding power Spot source, only trigger input is func- tional.
  • Page 52 H. On Trigger Operation Voltage (V) 2 Sec Current (A) Stick Touch Stick Lift Stick Electrode Electrode Current (A) Lift Main Amperage Initial Slope Initial Amperage Touch Current Touch Tungsten Lift Tungsten Lift Tungsten Slightly OM-2222 Page 46...
  • Page 53 4-20. Arc Timer/Counter Display (All Models) 123 456 Rear Panel Output And Amperage Controls Arc Timer Display Arc Counter Upon power up as described above, the After 5 seconds, the meter A LED turns Power Switch meter S LED will turn on, and arc time will on, and the arc counter will be displayed be displayed for 5 seconds as [000 000 ] to for the next 5 seconds as [000 000 ] to [999...
  • Page 54 4-21. Lockout Functions A. Accessing Lockout Capability L - - L L1 or 2,3,4 Rear Panel See Section 4-1 for explanation of controls referred to in all of Toggle Amperage (A) switch pad to light the meter S LED. You may Section 4-21.
  • Page 55 B. LockOut Levels Level 1 NOTE: Before activating lockout levels, be sure that all procedures and parameters are established. Parameter adjustment is limited while lockout levels are active. Level 1 NOTE: Remote amperage control is not available in level 1. TIG Output Selection If either the TIG HF Impulse or TIG Lift Arc process (see Section 4-8)
  • Page 56 B. Lock Out Levels (Continued) Level 3 Level 3 NOTE: Remote amperage control is not available in level 3. Includes all the functions of levels 1 Use Encoder Control To and 2 plus the following: Adjust Amperage +/– 10% Of Preset Value. +/–...

  • Page 57: Section 5 - Maintenance And Troubleshooting

    SECTION 5 – MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. Maintain more often during severe conditions. 3 Months Replace Clean and tighten Replace Damaged unreadable weld terminals. Gas Hose labels. 3 Months Repair Or Replace Cracked Cables And Cords 6 Months Y Do not remove case when...

  • Page 58: Voltmeter/Ammeter Help Displays

    5-3. Voltmeter/Ammeter Help Displays HE.L HE.L HE.L HE.L HE.L HE.L HE.L HE.L HE.L HE.L HE.L HE.L HE.L Help 4 Display display is shown. Can also be displayed if All directions are in reference to the the board power supply is being shorted. Indicates an open in the thermal protection front of the unit.

  • Page 59: Troubleshooting

    5-4. Troubleshooting Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 3-14). inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-14). Check for proper input power connections (see Section 3-14). No weld output;...

  • Page 60: Section 6 - Electrical Diagrams

    SECTION 6 – ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram OM-2222 Page 54...
  • Page 61 200 325-E OM-2222 Page 55...

  • Page 62: Section 7 - High Frequency

    SECTION 7 – HIGH FREQUENCY 7-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG – helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Work high_freq 12/96 – S-0693 7-2. Incorrect Installation Weld Zone 11, 12 50 ft (15 m) Sources of Direct High-Frequency...

  • Page 63: Correct Installation

    7-3. Correct Installation Weld Zone 50 ft (15 m) 50 ft (15 m) Ground all metal ob- jects and all wiring in welding zone using #12 AWG wire. Ground workpiece if required by codes. Nonmetal Building Metal Building Ref. S-0695 / Ref. S-0695 High-Frequency Source (welding Conduit Joint Bonding and Grounding Metal Building Requirements...

  • Page 64: Section 8 - Selecting And Preparing

    SECTION 8 – 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. 8-1. Selecting Tungsten Electrode ♦...

  • Page 65: Preparing Tungsten For Dc Electrode Negative (Dcen) Welding

    8-3. 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 66: Section 9 - Guidelines For Tig Welding (Gtaw)

    SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW) 9-1. Typical DC - GTAW 16 Gauge Stainless Steel Set-Up Ammeter Encoder 198 719 This symbol indicates which functions should be active for stainless steel. • Turn power on (switch located on rear panel) •...

  • Page 67: Positioning The Torch

    9-2. Positioning The Torch Y 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 an approved respirator. Read MSDS for safety information. Consider using cerium or lanthanum based tungsten instead of thoriated.

  • Page 68: Lift-Arce And Hf Tig Start Procedures

    9-3. Lift-Arc And HF TIG Start Procedures Lift-Arc Start When Lift-Arct button light is On, start arc as follows: TIG Electrode 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 control.

  • Page 69: Torch Movement During Welding

    9-4. 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 70: Positioning Torch Tungsten For Various Weld Joints

    9-5. Positioning Torch Tungsten For Various Weld Joints ° Butt Weld And Stringer Bead ° ° ° “T” Joint ° ° ° ° Lap Joint ° ° ° ° Corner Joint ° ° ST-162 003 / S-0792 OM-2222 Page 64...

  • Page 71: Section 10 - Stick Welding (Smaw) Guidelines

    SECTION 10 – STICK WELDING (SMAW) GUIDELINES 10-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) Front Panel Correct front panel display for basic Stick DCEP welding. For all front panel switch pad controls: press switch pad to turn on light and enable function.

  • Page 72: 10-2.Electrode And Amperage Selection Chart

    10-2. 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 73: 10-3.Stick Welding Procedure

    10-3. Stick Welding Procedure Y Weld current starts when electrode touches work- piece. Y 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. Workpiece Make sure workpiece is clean be- fore welding.

  • Page 74: 10-6.Positioning Electrode Holder

    10-6. 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 10-7. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding...

  • Page 75: 10-9.Conditions That Affect Weld Bead Shape

    10-9. 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 76: 10-11.Butt Joints

    10-11. Butt Joints Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. Single V-Groove Weld °...

  • Page 77: 10-14.Weld Test

    10-14. 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 10-15. Troubleshooting – Porosity Porosity –...

  • Page 78: 10-17.Troubleshooting - Incomplete Fusion

    10-17. 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 79: 10-20.Troubleshooting - Burn Through

    10-20. 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. 10-21. Troubleshooting – Waviness Of Bead Waviness Of Bead –...

  • Page 80: Section 11 - Parts List

    SECTION 11 – PARTS LIST Hardware is common and not available unless listed. Figure 11-1. Main Assembly ST-802 005-H OM-2222 Page 74...
  • Page 81 Quantity Model Item Dia. Part 230/460 400 CE Mkgs. Description Figure 11-1. Main Assembly ....206 108 HANDLE, rubberized carrying .......
  • Page 82 Quantity Model Item Dia. Part 230/460 400 CE Mkgs. Description Figure 11-1. Main Assembly (Continued) ... 191 181 CONNECTOR & SOCKETS 10-pin (LX Models) ....
  • Page 83 Hardware is common and not available unless listed. ST-802 006-D Figure 11-2. Windtunnels w/Components Quantity Model Item Dia. Part 230/460 400 CE Mkgs. Description Figure 11-2. Windtunnels w/Components (Figure 11-1 Item 39) ..
  • Page 84 Quantity Model Item Dia. Part 230/460 400 CE Mkgs. Description Figure 11-2. Windtunnels w/Components (Figure 11-1 Item 39) (Continued) ....025 248 STAND-OFF, insul .250-20 x 1.250 lg .
  • Page 85 Effective January 1, 2002 (Equipment with a serial number preface of “LC” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...

  • Page 86: Options And Accessories

    Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

This manual is also suitable for:

Maxstar 300 sdMaxstar 300 lx

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