Miller MAXSTAR 210 DX (RED D ARC) Owners manual

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OM-273 734B

2015−12

Processes

TIG (GTAW) Welding

Stick (SMAW) Welding

Descriptio n

120−480 Volt Models W/AutolineR

Arc Welding Power Source

Maxstar 210 DX

Visit our website at

www.MillerWelds.com

File: TIG (GTAW)

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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................

1-1. Symbol Usage 1.......................................................................

1-2. Arc Welding Hazards 1.................................................................

1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................

1-4. California Proposition 65 Warnings 4......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4.....................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISA TION 5...........................

2-1. Symboles utilisés 5.....................................................................

2-2. Dangers relatifs au soudage à l’arc 5......................................................

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7.....

2-4. Proposition californienne 65 Avertissements 8..............................................

2-5. Principales normes de sécurité 8.........................................................

2-6. Informations relatives aux CEM 8.........................................................

SECTION 3 − DEFINITIONS 9..................................................................

3-1. Additional Safety Symbols And Definitions 9................................................

3-2. Miscellaneous Symbols And Definitions 12..................................................

SECTION 4 − SPECIFICATIONS 13..............................................................

4-1. Serial Number And Rating Label Location 13................................................

4-2. Specifications 13........................................................................

4-3. Duty Cycle And Overheating 15...........................................................

4-4. Static Characteristics 16.................................................................

4-5. Environmental Specifications 16...........................................................

SECTION 5 − INSTALLATION 16................................................................

5-1. Selecting a Location 16..................................................................

5-2. Dimensions, Weights, And Mounting Options 17.............................................

5-3. Selecting Cable Sizes* 17................................................................

5-4. Connections 18.........................................................................

5-5. Electrical Service Guide 19...............................................................

5-6. Connecting Three-Phase Input Power 20...................................................

5-7. Connecting Single-Phase Input Power 22...................................................

5-8. Remote 14 Receptacle Information 23......................................................

5-9. Simple Automation Application 23..........................................................

5-10. Software Updates 24....................................................................

SECTION 6 − MAXSTAR 210 DX OPERATION 26..................................................

6-1. Maxstar 210 DX Controls 26..............................................................

6-2. Accessing Control Panel Menu 28.........................................................

6-3. Accessing User Setup Menu 30...........................................................

6-4. Selecting General (GEN) Tungsten To Change Programmable TIG Starting Parameters 31.........

SECTION 7 − ADVANCED MENU FUNCTIONS 32.................................................

7-1. Accessing Tech Menu For Maxstar 210DX Models 32.........................................

7-2. Sequencer And Weld Timer For DX Model 34................................................

7-3. Output Control And Trigger Functions For DX Models 35......................................

7-4. Lockout Functions 38....................................................................

7-5. Lockout Levels Defined 38...............................................................

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TABLE OF CONTENTS

SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 39.......................................

8-1. Routine Maintenance 39.................................................................

8-2. Blowing Out Inside of Unit 39.............................................................

8-3. Voltmeter/Ammeter Display Messages 40...................................................

8-4. Troubleshooting Table 41.................................................................

SECTION 9 − ELECTRICAL DIAGRAMS 42.......................................................

SECTION 10 − HIGH FREQUENCY 43...........................................................

10-1. Welding Processes Requiring High Frequency 43............................................

10-2. Installation Showing Possible Sources Of HF Interference 43...................................

10-3. Recommended Installation To Reduce HF Interference 44.....................................

SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER

MACHINES 45................................................................................

11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) 45......

11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines 45...................................................

SECTION 12 − TIG PROCEDURES 46...........................................................

12-1. Lift-Arc And HF TIG Start Procedures 46....................................................

12-2. Pulser Control 47.......................................................................

SECTION 13 − STICK WELDING (SMAW) GUIDELINES 48.........................................

COMPLETE PARTS LIST − A vailable at www.MillerWelds.com WARRANTY

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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

s s

Protect yourself and others from injury — read, follow , and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2015−09

DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

NOTICE − Indicates statements not related to personal injury .

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shock or severe burns. The electrode and work circuit i electrically live whenever the output is on. The inpu power circuit and machine internal circuits are also live when power is on. In semiautomatic or automati wire welding, the wire, wire reel, drive roll housing and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperl grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on

unit.

D Additional safety precautions are required when any of the follow-

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, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING P ARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or repaired cables. D Do not drape cables over your body. D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in use.

D Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed. D Allow cooling period before working on

equipment.

D To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

OM-273 734 Page 1

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FUMES AND GASES can be hazardous.

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Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.

D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

D Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D Wear body protection made from durable, flame−resistant mate-

rial (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

WELDING can cause fire or explosion.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut o f f compressed gas supply when not in use. D Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EM can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implante

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their docto

and the device manufacturer before going near arc welding, spo welding, gouging, plasma arc cutting, or induction heating operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D Wear approved ear protection if noise lev-

el is high.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly of f from the welding arc. The flying sparks, hot

burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not 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 welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).

D Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards.

D Do not use welder to thaw frozen pipes.

OM-273 734 Page 2

workpiece, and hot equipment can cause fires and

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully .

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder − explosion will result. D Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient n u m -

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

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1-3. Additional Symbols For Installation, Operation, And Maintenance

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FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to 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 guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

MOVING PARTS can injure.

D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual c a r efully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

D Use only genuine replacement parts from the manufacturer. D Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and local codes.

H.F. RADIATION can cause interference.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face. D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts. D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading welding wire.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jum

start vehicles unless it has a battery chargin feature designed for this purpose.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained. 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 cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according t o this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

OM-273 734 Page 3

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1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

1-5. Principal Safety Standards

Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for W elding and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for W elding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFP A Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use.

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFP A Standard 51B, from National Fire Protection Association,

Quincy, M A 0 2 2 6 9 ( p h o n e : 1 - 8 0 0 - 3 4 4 - 3 555, websi t e : w w w.nfpa.org). OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P .O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a cable cover.

2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

OM-273 734 Page 4

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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire.

2-1 . Symboles utilisés

fre_som_2015−09

DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

AVIS − Indique des déclarations pas en relation avec des blessures personnelles.

2-2 . Dangers relatifs au soudage à l’arc

Les symboles représentés ci-dessous sont utilisés dans ce manuel pour a ttirer l’attention et i dentifier les d angers possibles. E n présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matièr e de sécuri té indiquées c i-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort.

Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l ’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties m étalliques en contact avec le fil sont sous tension électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger.

D Ne pas toucher aux pièces électriques sous tension. D Porter des gants isolants et des vêtements de protection secs et

sans trous.

D S’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec la pièce à cou p e r o u l e s o l .

D Ne pas se servir de source électrique à courant électrique dans les

zones humides, dans les endroits confinés ou là où on risque de tomber.

D Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

D Si l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.

D D’autres consignes de sécurité sont nécessaires dans les condi-

tions suivantes : risques électriques dans un environnement humide o u s i l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante (à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !

. Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger.

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-

stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

D Installez, mettez à la terre et utilisez correctement cet équipement

conformément à son Manuel d’Utilisation et aux réglementations nationales, gouvernementales et locales.

D Toujours vérifier la terre du cordon d’alimentation. Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

D En effectuant les raccordements d’entrée, fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

D Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques chaudes.

D Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −, le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps. D Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

D Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide doublée.

D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol. D S’assurer que tous les panneaux et couvercles sont correctement

en place.

D Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

D Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

D Ne pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé.

D Utiliser une protection différentielle lors de l’utilisation d’un équi-

pement auxiliaire dans des endroits humides ou mouillés.

Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée.

D Arrêter les convertisseurs, débrancher le courant électrique et

décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces.

OM-273 734 Page 5

Page 10

LES PIÈCES CHAUDES peuvent

ère

r la

ls ut nt

à s f-

provoquer des brûlures.

D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant

de travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leu inhalation peut être dangereux pour votre santé.

D Eloigner votre tête des fumées. Ne pas respirer les fumées. D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Pour déterminer la bonne ventilation, il est recommandé de procéder à un prélèvement pour la composition et la quantité de fumées et de gaz auxquels est exposé le personnel.

D Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les cons ommables, les p roduit s d e r efroidis s ement, l es dégraisseurs, les flux et les métaux.

D Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.

D Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

D Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respirateur à alimentation d’air. Les revêtements e t tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

LES RAYONS DE L’ARC peuven provoquer des brûlures dans les yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage gén

infrarouges) susceptibles de provoquer des brûlures dans les yeux et su peau. Des étincelles sont projetées pendant le soudage.

D Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

D Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

D Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

des ray ons vis i bles et i nvisibles i ntenses ( ult raviolets

LE SOUDAGE peut provoquer un incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés te que des réservoirs, tambours ou des conduites pe provoquer leur éclatement. Des étincelles peuve

être projetées de l’arc de soudure. La projection d’étincelles, des

pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un sur-

OM-273 734 Page 6

chauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

D Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

D Ne pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

D Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures.

D Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

D Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déc l e n c h e r u n i n c e n d i e d e l ’ a u t r e c ô t é .

D Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 et AWS A6.0 (voir les Normes de Sécurité).

D Ne pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par exemple).

D Brancher l e c â b l e d e m a s s e sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.

D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

D En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode o u couper le fil à la pointe de contact.

D Porter un équipement de protection pour le corps fait d’un matériau

D Avant de souder , retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

D Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.

DES PIECES DE METAL ou DE SALETES peuvent provoquer de blessures dans les yeux.

D Le soudage, l’écaillement, le passage de l a pièce la brosse en fil de fer, et le meulage génèrent des étincelles et de particules métalliques volantes. Pendant la période de re roidissement des soudures, elles risquent de projeter du laitier.

D Porter des lunettes de sécurité avec écrans latéraux ou un écra

facial.

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.

D Fermer l’alimentation du gaz comprimé en cas

de non utilisation.

D Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateur d’adduction d’air homologué.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux.

D Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à distance.

D Les porteurs d’implants médicaux doivent consulter leur médecin

et le fabricant du dispositif avant de s’approcher de la zone où se

Page 11

déroule du soudage à l’arc, du soudage par points, du gougeage,

de la découpe plasma ou une opération de chauffage par induction.

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

D Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent explose si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille es

les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.

endommagée, elle peut exploser. Du fait que

D Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

D Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

D Ne jamais placer une torche de soudage sur une bouteille à gaz. D Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

D Ne jamais souder une bouteille pressurisée − risque d’explosion. D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors de l’ouverture de la vanne.

D Le couvercle du détendeur doit toujours être en place, sauf lorsque

la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

D Utiliser les équipements corrects, les bonnes procédures et su ffi-

samment de personnes pour soulever et déplacer les bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de l a C GA (Compressed Gas Association) mentionné dans les principales normes de sécurité.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenanc

Risque D’INCENDIE OU D’EXPLOSION .

D Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

D Ne pas installer l’appareil à proximité de pro-

D Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.

duits inflammables.

LA CHUTE DE L’ÉQUIPEMENT 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 autre accessoire.

D Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

D En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

D Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

D Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

D Ne pas obstruer les passages d’air du poste.

avant de poursuivre le soudage.

LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures.

D Porter u n écran facial pour protéger le visage et

les yeux.

la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.

D Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

D Affûter l’électrode au tungstène uniquement à

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent causer des blessures.

D Ne pas s’approcher des organes mobiles.

D Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.

L’EXPLOSION DE LA BATTER peut provoquer des blessures.

D Ne pas utiliser l’appareil de soudage pour

charger des batteries ou faire démarrer de véhicules à l’aide de câbles de démarrage sauf si l’appareil dispose d’une fonctionnalit de charge de batterie destinée à cet usage.

Les PIÈCES MOBILES peuvent causer des blessures.

D S’abstenir d e toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.

D Lorsque cela est nécessaire pour des travaux d’entretien et de dé-

pannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié.

D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section.

OM-273 734 Page 7

Page 12

D N’utiliser que les pièces de rechange recommandées par le

constructeur.

D Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie, ainsi que les codes municipaux.

LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences.

D Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipements d e r a d i o−navigation et de communication, les services de sécurité et les ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées avec

des équipements électroniques de faire fonctionner l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appareil. D Effectuer régulièrement le contrôle et l’entretien de l’installation. D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles.

D Veiller à ce que tout l’équipement de la zone de soudage soit com- D Pour réduire la possibilité d’interférence, maintenir les câbles de

D Veiller à souder à une distance de 100 mètres de tout équipement D Veiller à ce que ce poste de soudage soit posé et mis à la terre D En cas d’interférences après avoir pris les mesures précédentes,

2-4 . Proposition californienne 65 Avertissements

LE SOUDAGE À L’ARC risque de provoquer des interférences.

D L’énergie électromagnétique risque de

provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

patible électromagnétiquement. soudage aussi courts que possible, les grouper, et les poser aussi

bas que possible (ex. par terre). électronique sensible. conformément à ce mode d’emploi. il incombe à l’utilisateur de prendre des mesures supplémentaires

telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’É tat de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants)

2-5. Principales normes de sécurité

Safe Practices for the Preparation of Containers and Piping for W elding and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for W elding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFP A Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060

2-6. Informations relatives aux CEM

Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après

utilisation.

Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFP A Standard 51B, from National Fire Protection Association,

Quincy, M A 0 2 2 6 9 ( p h o n e : 1 - 8 0 0 - 3 4 4 - 3 555, websi t e : w w w.nfpa.org). OSHA, Occupational Safety and Health Standards for General Indus-

Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant issu d’un soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations de chauffage par induction) crée un champ électromagnétique (CEM) autour d u circuit de soudage. Les champs électromagnétiques produits peuvent causer interférence à certains implants médicaux, p. ex. les stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: Limiter par exemple tout accès aux passants ou procéder à une évaluation des risques individuels pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

OM-273 734 Page 8

câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauf fage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.

Page 13

. A complete Parts List is available at www.MillerWelds.com

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

. Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Protect yourself from electric shock by insulating yourself from work and ground.

Safe1 2012−05

Safe2 2012−05

Disconnect input plug or power before working on machine.

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Use ventilating fan to remove fumes.

Keep flammables away from welding. Do not weld near flammables.

Safe3 2012−05

Safe5 2012−05

Safe6 2012−05

Safe8 2012−05

Safe10 2012−05

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Do not weld on drums or any closed containers.

OM-273 734 Page 9

Safe12 2012−05

Safe14 2012−05

Safe16 2012−05

Page 14

. A complete Parts List is available at www.MillerWelds.com

Do not remove or paint over (cover) the label.

When power is applied failed parts can explode or cause other parts to explode.

Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.

Always wear long sleeves and button your collar when servicing unit.

Safe20 2012−05

Safe26 2012−05

Safe27 2012−05

Safe28 2012−05

After taking proper 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 2012−05

Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection

facility. Contact your local recycling office or your local distributor for further information.

Safe37 2012−05

Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.

Safe38 2012−05

OM-273 734 Page 10

>60s

Become trained and read the instructions before working on the machine or welding.

Safe40 2012−05

Hazardous voltage remains on input capacitors after power is turned

off. Do not touch fully charged capacitors. Always wait 60 seconds after power is turned off before working on unit, OR check input capacitor voltage, and be sure it is near 0 before touching any parts.

Safe42 2012−05

Page 15

. A complete Parts List is available at www.MillerWelds.com

Notes

=<60°

Always lift and support unit using both handles. Keep angle of lifting device less than 60 degrees.

Use a proper cart to move unit.

Safe44 2012−05

Welding current creates an electric and magnetic field (EMF) around the welding circuit and welding equipment.

Safe72 2012−06

OM-273 734 Page 11

Page 16

. A complete Parts List is available at www.MillerWelds.com

3-2. Miscellaneous Symbols And Definitions

Amperage

Panel−Local

Gas Tungsten Arc

Welding (GT AW)

Shielded Metal

Arc Welding

(SMAW)

Volts

Voltage Input

3 Phase Static

Frequency

Converter-Transfo

rmer-Rectifier

Voltage Output

Circuit Breaker

Remote

Lift-Arc Start

(GTAW)

Protective Earth

(Ground)

Postflow Timer

Preflow Timer

1max

1eff

Pulse Background

Alternating

Current

Gas Input

Gas Output

Rated Welding

Current

Duty Cycle

Direct Current

Line Connection

Conventional Load Voltage

Primary Voltage

Degree Of

Protection

Rated Maximum

Supply Current

Maximum

Effective Supply

Current

Rated No Load

Voltage (OCV)

Amperage

Initial Amperage

Hertz

Recall From

Memory

Arc Force (DIG)

HF Impulse

Starting (GTA W)

Final Slope

Final Amperage

Pulse Percent

On Time

Initial Slope

Contactor Control

(Stick)

Pulser On-Off

TIG Weld Amps

And Peak Amps

While Pulsing

Pulse Frequency

Background Amps

Process

OM-273 734 Page 12

Seconds

Off

Positive

Negative

Increase/

Decrease Of

Quantity

Normal Trigger

Operation

(GTAW)

Two-Step Trigger

Operation

(GTAW)

Four-Step Trigger

Operation

(GTAW)

Percent

Pulser

Sequence

Output

Adjust

Suitable For

Areas Of

Increased Shock

Hazard

Page 17

. A complete Parts List is available at www.MillerWelds.com

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for the power source is located on the top of the machine. Use the rating labels to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Specifications

. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-5, 5-6 and 5-7 for information on

connecting input power.

Welding Amperage

Range

1-210* 80 8-15*** 15KV** 23

*Welding range for Stick process is 5-210 amperes. For TIG, the amperage range is tungsten diameter dependent (see Section 6-3). ** Arc starting device is designed for manual guided operations. *** Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected.

Max Open Circuit

Voltage (Uo)

Low Open-Circuit

Voltage (Uo)

Rated Peak Striking

Voltage (Up)

IP Rating

Process

STICK

TIG

Output Ratings

Current

(A)

210 28.4 30%

160 26.4 60%

125 25 100%

210 18.4 60%

175 17 100%

V oltage (V)

Duty

Cycle

Current Draw (A)

At Rated Input Voltage (V)

Input Power

Phase 208V 240V 400V 480V kW kVA

1 36 30 18 15 7.3 7.4 3 21 18 10 9 7.1 7.4 1 26 22 13 11 5.3 5.3 3 15 13 8 6 5.2 5.5 1 19 16 10 8 3.9 4.0 3 11 10 6 5 3.9 4.1 1 24 20 12 10 4.9 4.9 3 14 12 7 6 4.9 5.2 1 19 17 10 8 4.0 4.0 3 12 10 6 5 4.0 4.2

OM-273 734 Page 13

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. A complete Parts List is available at www.MillerWelds.com

Notes

4-2. Specifications (Continued)

Power Draw (W)

Idle OCV 0 77.5

Idle w/ Output

Off

Standby

Output Ratings

Process

STICK

TIG

Current

(A)

100 24 40% 1 25 3.0 3.0

90 23.6 60% 1 23 2.8 2.8

75 23 100% 1 19 2.3 2.3 150 16 40% 1 27 3.3 3.3 125 15 60% 1 22 2.6 2.6 100 14 100% 1 17 2.0 2.0

V oltage (V)

Duty

Cycle

1 83 83 91 96 3 93 96 101 111 1 23 25 32 35 3 29 29 43 42 1 9 11 19 25 3 13 14 28 39

Current Draw (A)

At Rated Input Voltage (V)

Input Power

Phase 120V kW kVA

Power Draw (W)

Idle w/ Output

Idle OCV 0 77.5 1 85

Off

Standby 1 8

1 24

OM-273 734 Page 14

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. A complete Parts List is available at www.MillerWelds.com

4-3. Duty Cycle And Overheating

Duty Cycle is percentage of 10 mi n utes that unit can weld at rated load without overheating.

If unit overheats, output stops, a Help message is displayed (see Section 8-3), 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 damage machine or torch and void warranty.

TIG ( 208V Input)

200

STICK ( 208V Input)

150

TIG (120V Input)

STICK (120V Input)

100

Output Amperes

10 20 30 40 50 60 70 80 90 100

% Duty Cycle

Overheating

Minutes

A or V

Reduce Duty Cycle

247 219-B

OM-273 734 Page 15

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. A complete Parts List is available at www.MillerWelds.com

4-4. Static Characteristics

The static (output) characteristics of the welding power source can be described as drooping during the SMAW and GTAW processes. Static characteristics are also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors. Contact the factory for specific information on the static characteristics of the welding power source.

4-5. Environmental Specifications

A. IP Rating

IP Rating Operating Temperature Range Storage Temperature Range

IP23

This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered.

14 to 104 °F (-10 to 40°C)

B. Information On Electromagnetic Compatibility (EMC)

! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−

voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

This equipment 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 Z It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the system impedance complies with the impedance restrictions.

at the point of common coupling is less than 52 mW (or the short−circuit power Ssc is greater than 3.1 MVA).

max

-4 to 131 °F (-20 to 55°C)

IP23 2014−06

ce-emc 1 2014-07

SECTION 5 − INSTALLATION

5-1. Selecting a Location

Movement, Location, and Airflow

18 in. (460 mm)

! Do not move or operate unit where it could tip.

! Special installation may be

required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 2 0 .

1 Carry Strap Use strap to carry power source

only . D o not use to lift power source when attached to cart/cooler.

2 Line Disconnect Device Locate unit near correct input

power supply.

OM-273 734 Page 16

805 497-A / 805 503-B

loc_dynasty 2015-04

Page 21

. A complete Parts List is available at www.MillerWelds.com

5-2. Dimensions, Weights, And Mounting Options

Dimensions

B 8-5/8 in. (219 mm)

13-5/8 in. (346 mm)

C 19-1/2 in. (495 mm)

Weight

Ref. 805 497-A

38 lb (17.2 Kg)

5-3. Selecting Cable Sizes*

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld 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 Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding

100 ft (30 m) or Less****

Welding Amperes***

100 4 (20) 4 (20) 4 (20) 3 (30) 150 3 (30) 3 (30) 2 (35) 1 (50)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 250 2 (35) 1 (50) 1/0 (60) 2/0 (70)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm2 for metric use

*** Select weld cable size for pulsing application at peak amperage value. ****For distances longer than 100 ft (30 m) and up to 200 ft (60 m), use direct current (DC) output only. For distances longer than those shown

in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).

10 − 60% Duty Cycle

AWG (mm2)

60 − 100% Duty Cycle

AWG (mm2)

150 ft

(45 m)

10 − 100% Duty Cycle

AWG (mm2)

Ref. S-0007-L 2015−02 (TIG)

200 ft

(60 m)

OM-273 734 Page 17

Page 22

5-4. Connections

Front Panel

. A complete Parts List is available at www.MillerWelds.com

Rear Panel

! Turn off power before con-

necting to weld output terminals.

! Do not use w orn, dam aged,

undersized, or repaired cables.

Connections

1 Remote Control Receptacle

(See Section 5-8) 2 Gas Out To Torch Connection Requires an 11/16 in. W rench. 3 Main Power Switch Use switch to energize/de-ener-

gize machine. 4 Gas In Connection Fitting has 5/8-18 in. right hand

threads, and usually requires an 11/16 in. Wrench. Maximum psi is

125. 5 Work Lead Connection For

TIG Welding. Stick Electrode

Holder Connection For Stick

Welding 6 TIG Torch Connection For

TIG Welding / Work Lead

Connection For Stick Welding

Tools Needed:

Ref.805 496-A

OM-273 734 Page 18

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. A complete Parts List is available at www.MillerWelds.com

Elec Serv 2015−05

Elec Serv 2014−01

5-5. Electrical Service Guide

A. Electrical Service Guide For Three-Phase Operation

Failure to f o llow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.

. Actual input voltage should not fall below 108 volts AC or rise above 528 volts AC. If actual input voltage is outside this range, unit may not operate

according to specifications.

Three-Phase

Input Voltage (V) Rated Maximum Supply Current I Maximum Effective Supply Current I Max Recommended Standard Fuse Rating In Amperes

(A) 20.5 17.7 10.4 8.7

1max

(A) 11 10 6 5

1eff

Time Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In AWG

208 240 400 480

25 20 10 10 30 25 15 15 14 14 14 14

Max Recommended Input Conductor Length In Feet (Meters) 58 (18) 78 (24) 221 (67) 319 (97) Min Grounding Conductor Size In AWG

14 14 14 14

Reference: 2014 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248.

3 “Normal O perating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16). 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)

630.12.

. Actual input voltage should not fall below 108 volts AC or rise above 528 volts AC. If actual input voltage is outside this range, unit may not operate

according to specifications.

Single-Phase

Input Voltage (V) Rated Maximum Supply Current I Maximum Effective Supply Current I Max Recommended Standard Fuse Rating In Amperes

(A) 27.4 35.8 29.9 17.6 14.6

1max

(A) 17.3 20 17 10 8

1eff

Time Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

120 208 240 400 480

30 40 35 20 15 40 50 45 25 20 12 12 12 14 14 33

(10)

(13)

(18)

111

(34)

160 (49)

12 12 12 14 14

3 “Normal O perating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16). 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.

OM-273 734 Page 19

Page 24

. A complete Parts List is available at www.MillerWelds.com

5-6. Connecting Three-Phase Input Power

= GND/PE Earth Ground

L2 L3

Tools Needed:

OM-273 734 Page 20

input2 2012−05 − 803 766-C / Ref. 805 496-A

Page 25

. A complete Parts List is available at www.MillerWelds.com

5-6. Connecting Three-Phase Input Power (Continued)

Notes

! Installation must meet all National and

Local Codes − have only qualified persons make this installation.

! Disconnect and lockout/tagout input

power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.

! Always connect green or green/yel-

low conductor to supply grounding terminal first, and never to a line terminal.

NOTICE − The Auto-Line circuitry in this unit automatically adapts the power source to the

primary voltage being applied. Check input voltage available at site. This unit can be connected to any input power between 120−480 VAC without removing cover to relink the power source.

See rating label on unit and check input voltage available at site.

For Three-Phase Operation

1 Input Power Cord. 2 Disconnect Device (switch shown in

the OFF position)

3 Green Or Green/Y ellow Grounding

Conductor

4 Disconnect Device Grounding Terminal

5 Input Conductors (L1, L2 And L3) 6 Disconnect Device Line Terminals Connect green or green/yellow grounding

conductor to disconnect device grounding terminal first.

Connect input conductors L1, L2, and L3 to disconnect device line terminals.

7 Overcurrent Protection Select type and size of overcurrent protection

using Section 5-5 (fused disconnect switch shown).

Close and secure door on disconnect device. Follow established lockout/tagout procedures to put unit in service.

input2 2012−05

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at the beginning of this manual.

OM-273 734 Page 21

Page 26

. A complete Parts List is available at www.MillerWelds.com

5-7. Connecting Single-Phase Input Power

=GND/PE Earth Ground

! Installation must meet all National

and Local Codes − have only qualified persons make this installation.

! Disconnect and lockout/tagout in-

put power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.

! Always connect green or green/

yellow conductor to supply grounding t e r m i nal first, and never to a line terminal.

NOTICE − The Auto-Line circuitry in this unit automatically adapts the power source to the primary voltage being applied. Check input voltage available at site. This unit can be connected to any input power between 120−480 VAC without removing cover to relink the power source.

See rating label on unit and check input voltage available at site.

1 Black And White Input Conductor

(L1 And L2) 2 Red Input Conductor 3 Green Or Green/Y ellow Grounding

Conductor 4 Insulation Sleeving 5 Electrical Tape Insulate and isolate red conductor as

shown. 6 Input Po w e r C o r d . 7 Disconnect Device (switch shown in

the OFF position) 8 Disconnect Device Grounding

Terminal 9 Disconnect Device Line Terminals Connect green or green/yellow grounding

conductor t o disconnect device grounding terminal first.

Connect input conductors L1 and L2 to disconnect device line terminals.

10 Overcurrent Protection Select type and size of overcurrent

protection using Section 5-5 (fused disconnect switch shown).

Close and secure door on disconnect device. Follow established lockout/tagout procedures to put unit in service.

Tools Needed:

OM-273 734 Page 22

input1 2012−05 − 803 766-C / Ref. 805 496-A

Page 27

. A complete Parts List is available at www.MillerWelds.com

5-8. Remote 14 Receptacle Information

Socket Socket Information

15 VOLTS DC

OUTPUT CONTACTOR

REMOTE

OUTPUT

CONTROL

Output

Signals

805 497-A

A Contactor control +15 volts DC, referenced to G.

B Contact closure to A completes 15 volts DC

contactor control circuit and enables output.

C Output to remote control; +10 volts DC output to

remote control.

D Remote control circuit common. E 0 to +10 volts DC input command signal from

remote control. *Reconfigurable as input for Output Enable (Weld Stop) − used to remotely stop the weld outside the normal welding cycle. Connection to the D socket must be maintained at all times. If the connection is broken, output stops, and Auto Stop is dis-

played. F Current feedback; +1 volt DC per 100 amperes. H Voltage feedback; +1 volt DC per 10 volts output. I* Valid arc indication closed to socket G with valid

arc. Electrical specifications: open collector tran-

sistor (see Section 5-9 for connection example).

J* Arc length control lockout closed to socket G dur-

ing Initial and Final Amperage and Slope, and dur-

ing the background time of a <=10 Hz pulse wave-

form. Electrical specifications: open collector tran-

sistor (see Section 5-9 for connection example).

COMMON

CHASSIS

Serial

G Return for all output signals: F, H, I, J and A.

K Chassis

L** Modbus Common (RS485 Common)

Communication Bus

Sockets G and K are electrically isloated from each other.

M** Modbus D1 (RS485 B+) N** Modbus D0 (RS485 A-)

. If a remote hand control, like the RHC-14, is connected to the Remote 14 receptacle, some current value above min. must be set on the remote

control before the Panel or Remote contactor is turned on. Failure to do so will cause current to be controlled by the panel control, and the remote hand control will not function. *Available with optional Automation Expansion memory card.. **Available with optional Modbus Expansion memory card. Modbus serial communication provides access to all front panel parameters and machine functionality. See Owner’s Manual 265415 for a list of Modbus registers. Modbus expansion also includes functionality of Automation Expansion.

5-9. Simple Automation Application

Pin I, J: Collector

Coil resistance plus R

CR1

should be chosen to limit current to 75 mA

User supplied

power up to 27 volts DC peak

−

CR1

To User Equipment

Pin G: Emitter

OM-273 734 Page 23

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. A complete Parts List is available at www.MillerWelds.com

C. How To Download Software Updates

5-10. Software Updates

A. Reasons For Downloads Of Software Updates

• To get the latest feature and software improvements with future software updates.

• For all circuit board replacements, a software update is required to ensure proper unit operation.

• A software 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 to download software updates.

The SD logo is a registered trademark of SD-3C LLC.

1. On your web browser, go to http://www.millerwelds.com/products/tig/tigsoftware.php

2. Select System Installation Instructions (PDF) and follow the instructions.

OM-273 734 Page 24

Page 29

D. Software Installation

Notes

. A complete Parts List is available at www.MillerWelds.com

. Software updates may reset

machine back to default values.

Card Requirements: Full size memory card required. 1 Memory Card Port

2 Indicator LED Insert card containing new soft-

ware into port while machine is on, (but not while welding). Inserting card while welding will interrupt the welding 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 remove card while LED is blinking green.

After successfully reading from or writing to the card, the LED switches from blinking to continuous green, and the meters illuminate. The machine is now ready for use.

Troubleshooting:

Indicator LED is blinking red: Error updating software, or software is not compatible. Try removing and inserting card.

Indicator LED is continuous red: Cannot read card. Card might be bad.

Ref. 805 496-A

OM-273 734 Page 25

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. A complete Parts List is available at www.MillerWelds.com

SECTION 6 − MAXSTAR 210 DX OPERATION

6-1. Maxstar 210 DX Controls

. For all front panel switch pad controls:

press switch pad to turn on light and enable function.

. Green on nameplate indicates a TIG

function, Gray indicates a Stick function.

1 Standby Button Use to turn machine on and off for daily oper-

ation.

OM-273 734 Page 26

2 Encoder Control Use encoder control in conjunction with ap-

plicable front panel function 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 within the machine. Indicator is lit while card is being accessed.

4 Volt Meter Displays actual voltage when voltage is

present a t the weld output terminals. It is also used to display parameter descriptions while in the menu.

247 216-C

5 Ammeter Displays actual amperage while welding and

preset amperage while idle. It is also used to display parameter selection options while i n the menu.

6 Amperage Control Use this control in conjunction with the en-

coder to set the weld amperage or peak a m perage if the Pulser is active.

Page 31

Notes

. A complete Parts List is available at www.MillerWelds.com

229895

MATERIAL THICKNESS GAUG

OM-273 734 Page 27

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. A complete Parts List is available at www.MillerWelds.com

6-2. Accessing Control Panel Menu

150A

1 Amperage Button 2 Parameter Display 3 Setting Display 4 Encoder Rotate Encoder to adjust paramet-

er setting. The Amperage Control controls the

welding amperage output, and limits the maximum output of a remote amperage device.

150A

Process Selection:

TIG HF Impulse − is a non-contact arc starting method for TIG welding (see Section 12-1). TIG Lift-Arc − Is a contact arc starting method for TIG welding (see Section 12-1). Stick − Select for DC Stick (SMAW) welding. Electrode polarity is determined by the welding

cable connections. Trigger Mode Selection: (See Section for 7-3 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 with a remote potentiometer, or it can be set at the control panel.

[RMT] 2T [HOLD] Remote control required. Allows the operator to weld without holding the trigger closed. To

start the weld, operator presses and releases trigger. To stop the weld, the operator again presses and releases the trigger . In this mode, only the output contactor is controlled by the remote control. Amperage must be set on the control panel. (see Section 7-3).

[OUT] [ON] Output on. (Lift only)

247 216-C

! Weld output terminals are energized at all times when displays read [OUT] [ON].

No remote control or trigger required. Amperage can be controlled at the control panel or with a remote potentiometer. Blue output on LED illuminates to indicate output is on.

OM-273 734 Page 28

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. A complete Parts List is available at www.MillerWelds.com

. *PRO−SET provides PROfessionally developed SETtings for the weld process. PRO−SET flashes

one time and reveals the professional setting for the parameter.

Pulse Control

Pulsing is available while in the TIG process. Controls can be adjusted while welding.

Reduces heat input to minimize distortion and i n crease travel speed. Range is 01. to 500 (pulses per second).

Press switch pad to enable pulser. [PPS]* Pulses Per Second: Range is 0.1 to 500. [PK T]* Peak Amperage Time: Range is 5 to 95%. [BK A]* Background Amperage Time: Range is

5 to 95% of peak amperage value.

. See Section 12-2 for additional Pulser in-

formation, or visit http:/www.millerwelds.com/resources/improving−your−skills/

Sequencer Control

The welding output can be programmed to specific amperages and durations for repetitive applications. Sequencer is only available in the TIG process. Sequencer is disabled if a remote control with variable amperage is connected to the machine.

[INTL] Initial Amperage: Range is min to 210 amps.

[ISLP] Initial Slope Time: Range is OFF to 25T (seconds).

[FSLP] Final Slope Time: Range is OFF to 25T (seconds).

[FNL] Final Amperage: Range is min to 210 amps.

(See Sections 7-1 and 7-2 for setting weld time.)

Gas/DIG Control

[PRE] Preflow Time: Controls length of time gas flows prior to arc start. Range is OFF to 50T (seconds). [POST] Post Flow Time: Increasing setting increases length of time gas

flows after welding stops. Range is OFF to 50T (seconds). AUTO calculates the time based on the maximum amperage of each welding cycle. The minimum time is eight seconds. Auto equals maximum amperage divided by 10.

[DIG]* Arc Force Control: Controls the amount of additional amperage at

low voltage (short arc length) conditions. Adjust the force of the arc for different joint configurations and electrodes. Range is OFF to 100%. PRO-Set values available for both 6010 and 7018 ele c t r o d e s .

PK T

INTL ISLP

FSLP

FNL

PRE

POST

DIG

100PPS 40% 25%BK A

20A

OFF OFF

10A

0.2T

AUTO

30%

OM-273 734 Page 29

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. A complete Parts List is available at www.MillerWelds.com

6-3. Accessing User Setup Menu

USER

1 Amperage Button 2 Gas/Dig Button 3 Parameter Display 4 Setting Display 5 Encoder

To access the User functions, press and hold the Amperage (A) and the Gas/DIG controls until USER MENU is displayed. To scroll through the user menu functions, press and release the Gas/DIG control.

Rotate Encoder to adjust parameter setting.

. Parameter automatically re-

turns to amperage setting 15 seconds after Encoder is inactive.

To exit user menu, press and release Amperage and Gas/DIG controls at the same time, or turn power off.

RMT

HOTS

3/32TUNG

247 216-C

Tungsten Diameter Selection:

Each tungsten size has preset starting parameters specific to that diameter for optimized starting. Range is 0.020−1/8 in. or

0.5−3.2 mm. To manually set starting parameters, see Section 6-4.

Output Trigger Mode Functions:

See Section 7-3 to reconfigure RMT functions.

Arc Starting Mode Selection:

[HOTS] [ON] Provides additional amperage while striking the electrode to pre-

vent the electrode from sticking. [HOTS] [OFF] No additional starting amperage to assist in starting the elec-

trode.

OM-273 734 Page 30

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. A complete Parts List is available at www.MillerWelds.com

6-4. Selecting General (GEN) Tungsten To Change Programmable TIG Starting Parameters

1 Encoder Control

2 Parameter Display 3 Amperage Button Once inside the machine set up

menu, tungsten parameter values can be manually changed by pressing the Amperage switch pad to step through each adjustable parameter. Turn encoder to change the value.

GENTUNG

Current (A)

Parameter

• Start Output Polarity (POL)

• Start Amperage (STRT)

• Start Time (TIME)

• Start Slope (SSLP)

• Preset Minimum Amper-

age (PMIN)

Available Parameter Settings

Start Amperage

Start Time

Start Slope Time

Preset Amperage Minimum

Default

• EN (Electrode Negative)

• 25 A

• 120 ms

• 100 ms

• 10 A

247 216-C

Range

• EP / EN

• 5−200 A

• 0−250 ms

• 1−25 A

OM-273 734 Page 31

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. A complete Parts List is available at www.MillerWelds.com

SECTION 7 − ADVANCED MENU FUNCTIONS

7-1. Accessing Tech Menu For Maxstar 210DX Models

TECH

1 Amperage Button 2 Gas/Dig Button Press and hold Amperage and

Gas/Dig buttons for approximately two seconds to scroll past User Menu to Tech Menu. Use Gas/Dig button t o cycle through parameters that can be set.

3 Parameter Display 4 Setting Display 5 Encoder Rotate Encoder to adjust paramet-

er setting. To exit tech menu, press Amperage

and Gas/DIG controls at the same time.

ARC

STUC

WELD

T/CY

LOGERR

OFFSLEP

OFF

NORMOCV

TMRS

OFF

LOCK EXPC

SOFT SERL

OFF

RSETMACH

WARE

NUM

247 216-C

OM-273 734 Page 32

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. A complete Parts List is available at www.MillerWelds.com

[ARC] [T/CY] Arc Timer: Monitors hours, minutes, and cycles of valid arc on. To view these different elements, rotate encoder. To reset, rotate encoder until [RESET] [YES] is displayed. Press Menu button to display [RESET] [Done]. Displays turn to [000] [000].

[ERR] [LOG] Error Log: Use to view last eight logged error events. Each event may list multiple Error Codes. See Section 8-4.

[SLEP] Sleep Timer: Turns power off after the machine exceeds the programmed idle time without operation. Press the Standby button

to turn power on. To set or change time, rotate encoder 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. Turns weld output off to aid in freeing the electrode. To turn on, rotate encoder. Not recommended for air carbon arc or large diameter electrodes.

[OCV] Open Circuit Voltage: Allows user to select between Normal (NORM) and Low open circuit voltage. Low reduces open circuit voltage to between 8 and 12 volts. To select, turn encoder.

[WELD] [TMRS] Weld Timers: [ON] enable and [OFF] disable the feature. See Section 7-2 for information on setting weld timers. Weld Timers work with or without Sequencer feature.

[LOCK]: Limits user control and adjustability of machine. See Section 7-4 For instructions and operation. [EXPC] External Pulse Control Commands: Turn on when it is desired to control machine from an external source. When command is

on, a command voltage of 0− 10 volts DC equals off − 210 amps.

[MACH] [RESET] Machine Reset:: Resets all machine values back to factory defaults. To reset, turn encoder to [RESET] [YES]. Then press Amperage button. [RESET] [DONE] will be displayed when the reset is complete and factory defaults have been restored.

[SOFT] [WARE] Software Number: Software number and revision will be displayed. [SERL] [NUM] Serial Number: If serial number displayed does not match serial number of machine, see Section 8-4.

OM-273 734 Page 33

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. A complete Parts List is available at www.MillerWelds.com

7-2. Sequencer And Weld Timer For DX Model

INTL

INTL ISLP

FSLP

FNL

20A

OFF OFF OFF

10A

OFFFNL OFFWELD

Sequencer Control With Weld Timers ON

This function is available while using the TIG process, but is disabled if a remote foot or fingertip control is connected while in the RMT STD mode. When active, the sequencer controls the following parameters of the weld cycle:

Initial Amperage

Range is 2−210 amps AC,1−210 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

Final Time*

Range is OFF to 25.0T (seconds)

. When a remote switch is connected to the

welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source.

*enabled features with weld timer On (see Section 7-1).

Weld Timer

With Weld Timer enabled, press Amperage (A) button, and turn encoder to set weld time. Range is Off or 0.1−99.9 and 100−999 (sec) (see Section 7-1).

OM-273 734 Page 34

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. A complete Parts List is available at www.MillerWelds.com

A. Remote (Standard), 2T, And 4TE Torch Trigger Operation

7-3. Output Control And Trigger Functions For DX Models

Current (A)

Main Amps

Time

Standard

Remote 2T

Initial Slope

Initial Amps

Preflow

P & H

P&H = Push trigger and hold

R = Release trigger.

Final Slope

Final Amps

Maintained Switch

. When a foot or finger remote current control is connected to the welding power source, initial amps, initial

slope, final slope and final amps are controlled by the remote control, not by the welding power source.

P&R

P&R = Push trigger and release.

P&R

. If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.

Postflow

Foot Or Finger Remote Control

Remote 4TE

P/R

P/R = Push and release trigger; Push and releasing during final slope will break the arc and go to postflow

P/R P/R

P/R

. For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends. . When a remote switch is connected to the welding power source, use the remote switch to control the weld cycle.

Amperage is controlled by the welding power source.

Application:

Use 4T Momentary trigger method when the functions of a remote current control are desired, but only a remote on/off control is available.

OM-273 734 Page 35

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. A complete Parts List is available at www.MillerWelds.com

B. 3T Specific Trigger Method

Current (A)

Remote Trigger Operation

A B CD

Preflow

* Arc can be extinguished at any time by pressing and releasing both initial and final switches, or by lifting the torch and breaking the arc.

1 3T (Specific Trigger Operation) Sequencer is required to reconfigure for 3T.

3T requires a specific type of remote control with two independent momentarycontact switches. One will be designated

initial switch, and it must be connected between Remote 14 receptacle pins A and B. The second will be designated as the final switch, and it must be connected between Remote 14 receptacle pins D and E.

2 Encoder Control To select 3T, turn Encoder control.

Definitions: Initial slope rate is the rate of amperage

change determined by the initial amperage, initial slope time, and main amperage.

Final slope rate is the rate of amperage change determined by the main amperage, final slope time, and final amperage.

Initial Amps/Initial Slope Main Amps Final Slope /Final Amps Postflow

Operation: A. Press and release initial switch within 3/4

second to start shielding gas flow. To stop the preflow sequence before preflow time elapses (25 seconds), press and release final switch. The preflow timer will reset and the weld sequence can be started again.

. If an initial switch closure is not made

again b e f o r e p r e f l o w t i m e 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 switch to start arc at initial

amps. Holding switch will change amperage at initial slope rate (release switch to weld at desired amperage level).

C. When main amperage level is reached,

initial switch can be released.

D. Press and hold the final switch to de-

crease amperage at final slope rate (release switch to weld at desired amperage level).

E. When final amperage has been reached,

the arc extinguishes and shielding gas flows for the time set on the Postflow control.

Application:

With the use of two remote switches instead of potentiometers, 3T gives the operator the ability to infinitely increase, decrease, or pause and hold amperage within the range determined by the initial, main, and final amperages.

OM-273 734 Page 36

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. A complete Parts List is available at www.MillerWelds.com

C. 4T And 4TL Specific Trigger Method

Current (A)

Initial Slope

Initial Amps

Preflow

P/H R

P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds

4T Torch Trigger Operation

Main Amps

P/R

Final Slope

Final Amps

P/H R

Postflow

4T Application:

Use 4T trigger method when the functions of a remote current control are desired, but only a remote on/off control is available.

4T allows the operator to toggle between weld current and final current.

. When a remote switch is con-

nected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source.

4TL Application:

The ability to change current levels without either initial slope or final slope, gives the operator the opportunity to adjust filler metal without breaking the arc.

4TL (mini logic) 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 switch is con-

nected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source.

4TL Torch Trigger Operation

Current (A)

Initial Slope

Initial Amps

Preflow

P/H R P/R P/R P/R

P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds * = Arc can be extinguished at final slope rate at any time by pushing and holding trigger

Main Amps

P/R P/R P/H

Final Slope

Postflow

OM-273 734 Page 37

Page 42

7-4. Lockout Functions

LOCK

CODE

. A complete Parts List is available at www.MillerWelds.com

OFF

247 216-C

See Section 7-1 for information on how to access Lockout Functions.

There are four (1−4) different lockout levels. Each successive level allows the operator more flexibility.

. Before activating lockout levels, be

sure that all procedures and parameters are established. Parameter adjustment is limited while lockout levels are active.

To turn On lockout feature, proceed as follows:

1 Encoder Control 2 Amperage (A) Control Press Amperage (A) control to toggle

between the lock off and code off displays. Toggle control until [CODE] [OFF] is displayed

Turn encoder to select a lockout code number. Select a number between 1 and

999. The number will appear on the amperage, right, display.

. Remember (write down) this code

number, as you will need this number to turn this feature off, or make changes to your settings.

Toggle Amperage 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 7-1.

To turn Off lockout feature, proceed as follows:

Toggle Amperage control until Code is displayed. Use encoder control to enter the same code number that was used to turn on the lockout feature. Press the Amperage control. The amperage meter display will turn to [OFF]. Lockout is now off. Exit Advanced Functions according to Section 7-1.

7-5. Lockout Levels Defined

Minimum Adjustability Degree Of Adjustability Maximum Adjustability

Lock Level 1 Lock Level 2 Lock Level 3 Lock Level 4

Adjustable Locked Adjustable Locked Adjustable Locked Adjustable Locked

Panel Amps Panel Amps Panel Amps +/- 10% Remote Amps

(min−panel)

Panel Amps +/- 10%

Process Process Process Process

Output Output Output Output

Pulser Pulser Pulser (on/off only) Pulser (on/off only)

Sequencer Sequencer Sequencer Sequencer

Gas/DIG Gas/DIG Gas/DIG Gas/DIG

Waveshape Waveshape Waveshape Waveshape

OM-273 734 Page 38

Page 43

. A complete Parts List is available at www.MillerWelds.com

SECTION 8 − MAINTENANCE AND TROUBLESHOOTING

8-1. Routine Maintenance

! Disconnect power before maintaining.

. Maintain more often during severe conditions.

n = Check Z = Change ~ = Clean Δ = Repair l = Replace

* To be done by Factory Authorized Service Agent

Every 3 Months

nl Labels n l Gas Hoses

Every 3 Months

nΔ lCables And Cords

Every 6 Months

! Do not remove case when blowing out inside of unit

~:During heavy service, clean monthly.

8-2. 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.

805 497-A

OM-273 734 Page 39

Page 44

. A complete Parts List is available at www.MillerWelds.com

8-3. Voltmeter/Ammeter Display Messages

Release Trigger

RELE

ASE

TRIG GER

Un Short Output

UN S

HORT

OUTP UT

Latching Errors:

CHEK INPT

WELD CABL

SEE O.M.

Not Valid

}

Latching Errors:

NOT VALD

Over Temperature Error

OVER TEMP

Lock Level

LOCK LEV1

Software Not Valid

SOFT

WARE

. All directions are in reference to the

front of the unit. All circuitry referred to is located inside the unit.

1 [RELE] [ASE] / [TRIG] [GER] Remote 14 receptacle contactor control

(Pins A−B) must be opened before proceeding.

2 [UN S] [HORT] / [OUTP] [UT] Short on weld output connections must be

removed before proceeding. See Section 8-4 if display shows after weld output connections have been verified as not having a short.

3 [OVER] [TEMP] Over temperature condition has occurred.

Error will clear after temperatures reach acceptable levels.

NOT VALD

4 Latching Errors: When one of the following errors occurs,

the Standby LED flashes. To clear error, press Standby button or turn off power. See Section 8-4 if error does not clear or happens frequently.

[CHEK] [INPT] Check Input High or low voltage has been sensed. Have

a qualified person check input voltage. [WELD] [CABL] Weld Cable An error relate to the weld cables has been

sensed. Straighten out or shorten weld cables.

[SEE] [O.M.] See Owner’s Manual: See Section 8-4.

5 [NOT] [VALD]

Message is displayed when attempting an incompatible setup; i.e., pressing AC Waveshape while in DC.

6 [LOCK] [LEV1], 2, 3, 4

Is displayed when attempting adjustments that are incompatible with the active selected lock level.

7 [SOFT] [WARE] [NOT] [V ALD]

A software compatibility error has been detected. A software update is required (see Section 5- 10 Software Updates). See Section 8-4 if display shows after a software update is performed.

OM-273 734 Page 40

Page 45

. A complete Parts List is available at www.MillerWelds.com

8-4. Troubleshooting Table

Trouble Remedy

No weld output; unit completely inoperative.

Place line disconnect switch in On position (see Section 5-6 or 5-7).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-6 or 5-7). Check for proper input power connections (see Section 5-6 or 5-7).

No weld output; meter display On. If using remote control, be sure correct process is enabled to provide output control at Remote 14

Erratic or improper weld output. Use proper size and type of weld cable (see Section 5-3).

Fan not operating. Check for and remove anything blocking fan movement.

Wandering arc.

Tungsten electrode oxidizing and not re maining bright after conclusion of weld

receptacle (see Section 5-8 as applicable). Input voltage outside acceptable range of variation (see Section 5-5). Check, repair, or replace remote control. Unit overheated. Allow unit to cool with fan On (see Section 4-3).

Clean and tighten all weld connections (see Section 8-1).

Have Factory Authorized Service Agent check fan motor. Use proper size tungsten (see Section 11).

Use properly prepared tungsten (see Section 11).

Reduce gas flow rate.

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings (see Section 8-1).

Water in torch. Refer to torch manual.

Blank Display.

Error message [ERR] [LOG] is displayed.

Latching Errors see Section 8-3. Contact a Factory Authorized Service Agent if error does not clear or happens frequently. Error message [SEE] [O.M.] is dis-

played.

Tech Menu (See Section 7) [SERL][NUM] is selected, and serial number displayed does not match serial number o f machine.

Error message [UN S] [HORT] / [OUTP] [UT] is displayed.

Error message [SOFT] [WARE] [NOT] [VALD] is displayed.

Verify Power to machine. A software update may be required (see Section 5-10, Software Updates). Contact factory if display re-

mains blank after a software update is performed.

Contact a Factory Authorized Service Agent for an explanation of the error code.

Contact a Factory Authorized Service Agent.

Contact a Factory Authorized Service Agent if display shows after weld output connections have been verified as not having a short.

Contact a Factory Authorized Service Agent if display shows after a software update is performed.

OM-273 734 Page 41

Page 46

SECTION 9 − ELECTRICAL DIAGRAMS

OM-273 734 Page 42

255 981-F

Figure 9-1. Circuit Diagram For Maxstar 210

Page 47

SECTION 10 − HIGH FREQUENCY

10-1. Welding Processes Requiring High Frequency

Work

TIG

10-2. Installation Showing Possible Sources Of HF Interference

Weld Zone

11, 12

50 ft

(15 m)

1 High-Frequency Voltage TIG − helps arc jump air gap

between torch and workpiece and/ or stabilize the arc.

high_freq 5/10 − S-0693

4 5 6

Best Practices

Not Followed

Sources 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 of High Frequency

7 Input Power Cable 8 Line Disconnect Device 9 Input Supply Wiring

Sources of Reradiation of High Frequency

10 Ungrounded Metal Objects 11 Lighting 12 Wiring 13 Water Pipes and Fixtures 14 External Phone and Power Lines

S-0694

OM-273 734 Page 43

Page 48

10-3. Recommended Installation To Reduce HF Interference

Ground all metal objects and all wiring in welding zone using #12 AWG wire.

Nonmetal

Building

50 ft

(15 m)

Weld Zone

Ground workpiece if required by codes.

50 ft

(15 m)

Best Practices Followed

1 High-Frequency Source (welding

power source with built-in HF or separate HF unit)

Ground metal machine case (clean paint from around hole in case, and use case screw), work output terminal, line disconnect device, input supply, and worktable.

2 Center Point of Welding Zone Midpoint between high-frequency source

and welding torch. 3 Welding Zone A circle 50 ft (15 m) from center point in all

directions. 4 Weld Output Cables Keep cables short and close together.

Metal Building

5 Conduit Joint Bonding and Grounding Electrically join (bond) all conduit sections

using copper straps or braided wire. Ground 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 lines. 8 Grounding Rod Consult the National Electrical Code for

specifications.

Ref. S-0695 / Ref. S-0695

Metal Building Requirements

9 Metal Building Panel Bonding

Methods

Bolt or weld building panels together , install copper straps or braided wire across seams, and ground frame.

10 Windows and Doorways Cover all windows and doorways with

grounded copper screen of not more than 1/4 in (6.4 mm) mesh.

11 Overhead Door Track Ground the track.

OM-273 734 Page 44

Page 49

SECTION 11 − SELECTING AND PREPARING A TUNGSTEN

11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

FOR DC OR AC WELDING WITH INVERTER MACHINES

gtaw_Inverter_2013-10

Whenever possible and practical, use DC weld output instead of AC weld output.

11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten)

. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference

the product packaging to identify the tungsten you are using.

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter (DCEN) − Argon

Direct Current Electrode Negative

(For Use With Mild Or Stainless Steel)

2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens

.010 in. (.25 mm) Up to 25 Up to 20 .020 in. (.50 mm) 15-40 15-35

.040 in. (1 mm) 25-85 20-80 1/16 in. (1.6 mm) 50-160 50-150 3/32 in. (2.4 mm) 130-250 135-235

1/8 in. (3.2 mm) 250-400 225-360

5/32 in. (4.0 mm) 400-500 300-450

3/16 in (4.8 mm) 500-750 400-500

1/4 in. (6.4 mm) 750-1000 600-800

Balance Control @ 65% Electrode Negative

♦Typical argon shielding gas flow rates are 11 to 35 CFH (cubic feet per hour).

Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.

AC − Argon

(For Use With Aluminum)

Or AC Welding With Inverter Machines

Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. W ear proper face, hand, and body protection. Keep flammables away.

Radial Grinding

Causes Wandering Arc

Wrong Tungsten

Preparation

Ideal Tungsten Preparation − Stable Arc

2-1/2 Times

Electrode Diameter

1 Grinding Wheel Grind end of tungsten on fine grit, hard

abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality.

2 Tungsten Electrode A 2% ceriated tungsten is recommended. 3 Flat Diameter of this flat determines amperage

capacity. 4 Straight Ground Grind lengthwise, not radial.

OM-273 734 Page 45

Page 50

SECTION 12 − TIG PROCEDURES

. For additional resources on welding, visit http://www.millerwelds.com/resources/improving−your−skills

12-1. Lift-Arc And HF TIG Start Procedures

Lift-Arc Start Method

“Touch”

Do NOT Strike Like A Match!

1 − 2

Seconds

gtaw_Inverter_2011-06

Lift-Arc Start

When Lift-Arct button light is On, start arc as follows:

1 TIG Electrode 2 Workpiece Touch tungsten electrode to work-

piece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control. Hold

electrode t o workpiece for 1-2 seconds, and slowly lift electrode. Arc is

formed when electrode is lifted. Normal open-circuit voltage is not

present before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece. The solid-state output contactor does not energize until after electrode is touching workpiece. This allows electrode to touch workpiece without overheating, sticking, or getting contaminated.

Application:

Lift-Arc is used for the DCEN or AC GTAW process when HF Start method is not permitted, or to replace the scratch method.

HF Start

When H F Start button light is On, start arc as follows:

High frequency turns on to help start arc when output is enabled. High frequency turns off when arc is started, and turns on whenever arc is broken to help restart arc.

Application:

HF start is used for the DCEN GTAW process when a non-contact arc starting method is required.

OM-273 734 Page 46

Page 51

12-2. Pulser Control

Percent (%) Peak Time

Control Setting

Peak 50%/Background 50%

Balanced 50%

More Time At

Peak Amperage

More Time At

Background

Amperage

(80%)

(20%)

Peak Amp

Pulsed Output Waveforms

PPS

Bkg Amp

1 Pulser Control Pulsing is available while using the TIG process. Con-

trols can be adjusted while welding.

Press switch pad to enable pulser. ON - When illuminated, this LED indicates the pulser is

on. Press switch pad until desired parameter LED is illumi-

nated. To turn Pulser off, press and release switch pad until the

On LED turns off. 2 Encoder Control (Set Value) 3 Ammeter (Displays Value) See Section 6-2 for Pulser parameter ranges. PPS - Pulse frequency or pulses per second, is the num-

ber of pulse cycles per second. Pulse frequency helps reduce heat input, part warpage, and helps weld bead cosmetics. Th e higher the PPS setting, the smoother the ripple effect, the narrower the weld bead, and the more cooling you get. By setting PPS on the lower end, the pulse is slower, and the weld bead wider. This slow pulsing helps agitate the weld puddle to help release gas trapped i n the weldment, and help reduce porosity (very useful in aluminum welding). Some beginners use a slower pulse rate (2-4 pps) to help them with their timing on adding filler material. An experienced welder may have the PPS setting much higher, depending on their personal preferences, and on what they are trying to accomplish.

PEAK t - (PEAK t) is the percentage of time in each cycle, spent at peak amperage (main amperage). Peak amperage is set with the Amperage control (see Section 6-1). If one pulse per second is being used, and peak 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 increases heat input into the part. A good starting point for peak time is about 50-60%. To find a good ratio, you will have to experiment a bit, but the idea is to decrease heat input into the part, and increase the cosmetics of the weld.

BKGND A - (Background amps) is set as a percentage of the peak amps setting. If peak amps is set at 200, and background amps at 50%, your background amps is 100 amps when the machine pulses on the background side of the cycle. The lower background amperage helps reduce heat input. Increasing or decreasing background amps increases or decreases the overall average amperage, which helps determine how fluid your puddle is on the background side of the pulse cycle. Overall, you want your puddle to shrink to about one-half the size, but still remain fluid. To start with, set background amps at about 20-30% for stainless/carbon steel, or at about 35-50% for aluminum alloys.

4 Pulsed Output Waveforms Example shows affect changing the Peak Time control

has on the pulsed output waveform.

Application:

Pulsing refers to the alternating raising and lowering of the weld output at a specific rate. The raised portions of the weld output are controlled in width, height, and frequency, forming pulses of weld output. These pulses and the lower amperage level between them (called the background amperage) alternately heat and cool the molten weld puddle. The combined effect gives the operator better control of penetration, bead width, crowning, undercutting, and heat input. Controls can be adjusted while welding.

Pulsing can also be used for filler material addition technique training.

. Function is enabled, when LED is lit

OM-273 734 Page 47

Page 52

SECTION 13 − STICK WELDING (SMAW) GUIDELINES

13-1. Electrode and Amperage Selection Chart

ELECTRODE

6010

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

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

RANGE

AMPERAGE

100

150

200

250

300

350

400

450

ELECTRODE

6010

6011

6013 7014

7018

7024

NI-CL

308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY) EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

EP EP

EP,EN EP,EN

EP,EN

EP EP

DC*

POSITION

ALL ALL ALL

ALL ALL

FLAT

HORIZ

FILLET

ALL ALL

PENETRATION

DEEP

MIN. PREP, ROUGH

DEEP

LOW MED

MED

LOW LOW

LOW

USAGE

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON STAINLESS

Ref. S-087 985-A

. For additional resources on welding, visit http://www.millerwelds.com/resources/improving−your−skills

OM-273 734 Page 48

Page 53

Page 54

Page 55

Warranty

Effective January 1, 2015

(Equipment with a serial number preface of MF or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions below, warrants to its original retail purchaser that new equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped from factory. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, manufacturer will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Manufacturer must be notified in writing within thirty (30) days of such defect or failure, at which time manufacturer will provide instructions on the warranty claim procedures to be followed. If notification is submitted as an online warranty claim, the claim must include a detailed description of the fault and the troubleshooting steps taken to identify failed components and the cause of their failure.

Manufacturer shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed twelve months after the equipment is shipped to the distributor.

1. 5 Years Parts — 3 Years Labor * Original Main Power Rectifiers Only to Include SCRs,

Diodes, and Discrete Rectifier Modules

2. 3 Years — Parts and Labor * Auto-Darkening Helmet Lenses (Except Classic

Series) (No Labor)

* Engine Driven Welder/Generators

(NOTE: Engines are Warranted Separately by the Engine Manufacturer.)

* Inverter Power Sources (Unless Otherwise Stated) * Plasma Arc Cutting Power Sources * Process Controllers * Semi-Automatic and Automatic Wire Feeders * Transformer/Rectifier Power Sources

3. 2 Years — Parts and Labor * Auto-Darkening Helmet Lenses − Classic Series Only

(No Labor)

* Fume Extractors − Capture 5, Filtair 400 and Industrial

Collector Series

4. 1 Year — Parts and Labor Unless Specified * Automatic Motion Devices * CoolBelt and CoolBand Blower Unit (No Labor) * Desiccant Air Dryer System * External Monitoring Equipment and Sensors

* Field Options

(NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

* RFCS Foot Controls (Except RFCS-RJ45) * Fume Extractors − Filtair 130, MWX and SWX Series * HF Units * ICE/XT Plasma Cutting Torches (No Labor) * Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted Separately by the M a n u f a c t u r e r.)

* LiveArc Welding Performance Management System * Load Banks * Motor-Driven Guns (except Spoolmate Spoolguns) * PAPR Blower Unit (No Labor) * Positioners and Controllers * Racks * Running Gear/Trailers * Spot Welders * Subarc Wire Drive Assemblies * Water Coolant Systems * TIG Torches (No Labor) * Wireless Remote Foot/Hand Controls and Receivers * Work Stations/Weld Tables (No Labor)

guarantees or warranties expressed or implied.

5. 6 Months — Parts * Batteries * Bernard Guns (No Labor) * Tregaskiss Guns (No Labor)

6. 90 Days — Parts * Accessory (Kits) * Canvas Covers * Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls * M-Guns * MIG Guns and Subarc (SAW) Torches * Remote Controls and RFCS-RJ45 * Replacement Parts (No labor) * Roughneck Guns * Spoolmate Spoolguns

Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.)

2. Items furnished by manufacturer, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than manufacturer, or equipment that has 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 operation outside of the specifications for the equipment.

MANUFACTURER’S PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at manufacturer’s option: (1) repair; or (2) replacement; or, where authorized in writing by manufacturer in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Manufacturer’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at an authorized service facility as determined by manufacturer. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MANUFACTURER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MANUFACTURER IS EXCLUDED AND D I S C L A I M E D B Y M A N U FACTURER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

brand_warr 2015-01

Page 56

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Contact the Delivering Carrier for:

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.

ORIGINAL INSTRUCTIONS − PRINTED IN USA 2015-01

File a claim for loss or damage during shipment.

Miller MAXSTAR 210 DX (RED D ARC) Owners manual

Specifications and Main Features

Frequently Asked Questions

User Manual