Maxstar 400and800 - MillerWelds

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Issued April 2017 Index No. DC/24.5Maxstar 400 and 800 QuickSpecsIndustrial ApplicationsProcessesPrecision metal fabricationTube millsPipe and tube fabricationTool and dieExotic material fabricationPressure vessel fabricationTIG (GTAW)Pulsed TIG (GTAW-P)Stick (SMAW)Air carbon arc (CAC-A)400: 1/4 in. maximum800: 3/8 in. maximumTIG/Stick WeldingPower SourceInput Power 208–575 V, 3- or 1-phase powerAmperage Range 400: 3–400 A800: 5–800 ARated Output400: 300 A at 32 V, 60% duty cycle800: 600 A at 44 V, 60% duty cycleNet Weight400: 134 lb. (61 kg)800: 198 lb. (90 kg)Lift-Arc provides DC arc initiationwithout the use of high frequency.Allows for any input voltage hookup(208–575 V) with no manuallinking, providing convenience inany job setting. Ideal solution fordirty or unreliable power.Blue Lightning high-frequency(HF) arc starter for non-contactarc initiation. Provides moreconsistent arc starts and greaterreliability compared to traditionalHF arc starters.Meter calibration allowsdigital meters to be calibratedfor certification.DC TIG FeaturesCooler Power Supply (CPS)is an integrated 120-voltdedicated-use receptacle forthe Coolmate 3.5.Exceptionally smoothand precise arc for weldingexotic materials.Pulse. Pulsing can increasepuddle agitation, arc stabilityand travel speeds whilereducing heat input anddistortion. These modelsprovide extended ranges.Cooler-On-Demand featureoperates the auxiliary coolingsystem only when needed,reducing noise, energy use,and airborne contaminantspulled through the cooler.Wind Tunnel Technology protects internal electricalcomponents from airbornecontaminants, extendingthe product life.Fan-On-Demand power sourcecooling system operates onlywhen needed, reducing noise,energy use and the amount ofcontaminants pulled though themachine.DC Stick FeaturesMaxstar 400machine onlyMaxstar 400 Wireless CompleteProgram memory features nine independent programmemories that maintain/save your parameters.Auto-postflow adjusts the length of postflow time basedon the amperage setting, shielding your tungsten andeliminating the need to set the postflow time.DIG control allows the arccharacteristics to be changedfor specific applications andelectrodes. Lower the DIGsetting for smooth runningelectrodes like E7018 andincrease the DIG setting forstiffer, more penetratingelectrodes like E6010.Hot Start adaptive controlprovides positive arc startswithout sticking.Power source is warranted for three years, parts and labor.Miller Electric Mfg. Co.Equipment Sales US and Canada MillerWelds.comAn ITW Welding Company1635 West Spencer StreetP.O. Box 1079Appleton, WI 54912-1079 USAPhone: 866-931-9730FAX: 800-637-2315International Phone: 920-735-4554International FAX: 920-735-4125

Specifications (Subject to change without nge3-phase3– 400 A1-phaseMaxstar8003-phase1-phase3– 400 A5 – 800 A5 – 800 ARatedOutputAmps Input at Rated Load Output, 50/60 Hz208 V 230 V 400 V 460 V 575 V KVA KW250 A at 30 V,100% duty cycle2724141299.49.1300 A at 32 V,60% duty cycle33301715121211.6200 A at 28 V,100% duty cycle36331815127.46.9250 A at 30 V,60% duty cycle4843242016109.2500 A at 40 V,100% duty cycle68613430242423600 A at 44 V,60% duty cycle90804539313231400 A at 36 V,100% duty cycle89804438301917500 A at 40 V,60% duty cycle1261126153412624Certified by Canadian Standards Association to both the Canadian and U.S. Standards.Max.Open-CircuitVoltageDimensions75 VDCH: 24.75 in. (629 mm)(10 –15 VDC*) W: 13.75 in. (349 mm)D: 22 in. (559 mm)with TIGRunner H: 43.125 in. (1,095 mm)W: 23.125 in. (587 mm)D: 43.75 in. (1,111 mm)H: 34.5 in. (876 mm)75 VDC(10 –15 VDC*) W: 13.75 in. (349 mm)D: 22 in. (559 mm)NetWeight134 lb.(61 kg)withTIGRunner 251 lb.(114 kg)198 lb.(90 kg)All CE models conform to the applicable parts of the IEC 60974 series of standards.*Indicates sense-voltage for Lift-Arc TIG and Low OCV stick.Performance DataModelInputPowerTIG (GTAW)Duty CycleStick (SMAW)Duty CycleDC TIG MaterialThickness RangeStick ElectrodeMaximum DiameterCarbon Arc Gouging(CAC-A) MaximumGeneratorRequirementMaxstar 4003-phase400 A, 20%300 A, 60%250 A, 100%400 A, 20%300 A, 60%250 A, 100%.012 – 5/8 in.(0.3 –15.9 mm)6010: 1/4 in. (6.4 mm)7018: 1/4 in. (6.4 mm)7024: 1/4 in. (6.4 mm)1/4 in. (6.4 mm)20 kVA1-phase300 A, 20%250 A, 60%200 A, 100%300 A, 20%250 A, 60%200 A, 100%3-phase800 A, 20%600 A, 60%500 A, 100%800 A, 20%600 A, 60%500 A, 100%.020 –1 in.(0.5 – 25.4 mm)6010: 1/4 in. (6.4 mm)7018: 1/4 in. (6.4 mm)7024: 1/4 in. (6.4 mm)3/8 in. (9.5 mm)45 kVA1-phase500 A, 60%400 A, 100%500 A, 60%400 A, 100%Maxstar 8002

Maxstar 400 and 800 Control Panel 89432101115671312Control Panel Parameter Values1. Memory Switch18 Combinations(9 DC TIG)(9 DC stick)2. Memory Display9. Activity Indicator10. Encoder Control11. Amperage Button3. Voltmeter Display4. Ammeter Display5. Process/Arc StartingTIG: HF impulse, Lift-ArcSTICK : Adaptive Hot Start6. Output ControlStandard remote,2T trigger hold,Output on7. Pulser ControlPulses per Second*Peak Time*Background Amps*8. Memory Card PortDC : 0.1– 5,000 PPS5 – 95%5 – 95%12. Gas/DIGPreflowPostflowDIG*Off–25.0 secondsAuto/Off–50 secondsOff–100%13. Sequencer ControlInitial Amps3–400 A/5– 800 AInitial TimeOff–25.0 secondsInitial SlopeOff–50.0 secondsWeld TimeOff–999 secondsFinal SlopeOff–50.0 secondsFinal Amps3–400 A/5– 800 AFinal TimeOff–25.0 seconds*Pro-Set parameter selectable.User Menu (Press Gas and Amperage buttons.)1. Tungsten Size 400 .020 – 3/16 in./ GEN or 0.5 – 4.8 mm800 .040 –1/4 in. /GEN or 1.0 – 6.4 mm2. Remote Trigger 2T / 3T / 4T / 4TL / 4TE/4Tm3. Stick Hot Start ON / OFFTech Menu (Hold Gas and Amperage buttons five seconds.)1. Arc Time0.0–9,999 hours0.0–59 minutes0–999,999 cyclesResettable2. Error Log Error event recorder3. Stick Stuc OFF/ON4. OCV LOW/NORM5. Weld Timers OFF/ON6. Cooler Power AUTO/ON/OFF7. Locks OFF/1–48. Meter Display9. External Pulse Control OFF/ON10. Machine Reset11. Software Number12. Serial NumberAddress 1–24713. Slave (with Modbus automation expansion)Baudrate 9600/19.2KParity EVEN/ODD/NONE3

Pulsed TIG ControlsHigh-Speed DC Pulsed TIG Controls PPS Pulses per second (Hz): DC 0.1 – 5,000 PPS % ON – % Peak Time: 5 – 95% (Controls the amount of time during each pulse cycle at the PEAK amperage.) Background Amps: 5 – 99% (Sets the low-pulse amperage value as a % of the Peak Amps.)Conventional Pulsed TIGPeak AmpsPeak Time %Background Amps(% of Peak)Typically from 1 to 10 PPS. Provides a heating andcooling effect on the weld puddle and can reducedistortion by lowering the average amperage. Thisheating and cooling effect also produces a distinctripple pattern in the weld bead. The relationshipbetween pulse frequency and travel speeddetermines the distance between the ripples. Slowpulsing can also be coordinated with filler metaladdition and can increase overall control of theweld puddle.Pulse CycleHigh-Speed Pulsed TIGPeak Time %Peak AmpsPulsing the weld current at high speeds — betweena high Peak and a low Background amperage —can also constrict and focus the arc. This resultsin maximum arc stability, increased penetrationand increased travel speeds (Common Range:100 – 500 PPS).Background Amps(% of Peak)Pulse Cycle4In excess of 40 PPS, Pulsed TIG becomes moreaudible than visible — causing increased puddleagitation for a better as-welded microstructure.The Arc-Sharpening effects of high speed pulsingare expanded to new dimensions. The ability topulse at 5,000 PPS further enhances arc stabilityand concentration potential — which is extremelybeneficial to automation where maximum travelspeeds are required.

Maxstar 400 and 800 Models/Packages Machines and PreconfiguredWater-Cooled PackagesOrder machine only or use a single stock number toorder a complete preconfigured system.907716 and907718models shown.Machine OnlyMaxstar 400 (CSA)Maxstar 400 (CE)907716907716002Maxstar 800 (CSA)Maxstar 800 (CE)907718907718002Comes with: 8 ft. power cord (no plug) (400 model) Two 50 mm Dinse-style connectors (400 model) Two thread-lock connectors (800 model) One thread-lock water-cooled connector(800 model)Build aWater-CooledPackageSelect desiredstock numberfor each step.907716001package shown.951693package shown.TIGRunner Package (Machine/Cart/Cooler)Complete Package (Machine/Cart/Cooler/Torch Kit/Remote)Maxstar 400 (CSA)Maxstar 400 (CSA) w/Foot ControlMaxstar 400 (CSA) w/Wireless Foot Control907716001Comes with: 8 ft. power cord (no plug) (400 model) Runner cart 300244 Coolmate 3.5 300245Comes with: 8 ft. power cord (no plug) (400 model) Runner cart 300244 Coolmate 3.5 300245 4 gallons of coolant 043810 W-375 torch kit 301268 Remote control 194744 (foot) orRemote control 300429 (wireless foot)907716001Maxstar 400TIGRunner shownwith four bottlesof 043810Low-ConductivityCoolant.194744 remote shown.Step #1 Select Maxstar TIGRunner and CoolantMaxstar 400 TIGRunnerMaxstar 800(add 300244 cart and 300245 Coolmateto create Maxstar 800 TIGRunner)&Low-Conductivity Coolant(must be ordered in quantities of four)951692951693907716001907718043810301268 kit shown.Step #2 Select Remote ControlWireless FootRFCS-14 HD FootRCC-14 E/W FingertipRCCS-14 N/S FingertipRMS-14 PushbuttonRMLS-14 Momentary/MaintainedRHC-14 HandWireless 00430Step #3 Select Torch KitW-250 Kit300185W-280 Kit300990W-375 Kit301268(recommended for 400 model)W-400 (WP-18SC) Kit300186(recommended for 800 model)5

Genuine Miller Accessories Water-Cooled Torch KitsW-280 Torch Kit 300990Weldcraft W-280 25-foot (7.6 m) TIG torchwith Dinse-style connectorTorch cable coverWork clamp with 15-foot (4.6 m)1/0 cable and Dinse-style connectorFlowmeter regulatorGas hose (regulator to machine)AK4C torch accessory kit includes nozzles,collets, collet bodies and 2% ceriated tungstenelectrodes (1/16, 3/32 and 1/8 inch)Water-Cooled TIG Torch Connector 195377For Dynasty and Maxstar 400.50 mm Dinse-style with water return line. Foruse with all Weldcraft water-cooled torches.W-375 Torch Kit 301268Recommended for Maxstar 400Weldcraft W-375 25-foot (7.6 m) TIG torchwith Dinse-style connectorTorch cable coverWork clamp with 15-foot (4.6 m) 1/0 cableand Dinse-style connectorFlowmeter regulatorGas hose (regulator to machine)AK4C torch accessory kit includes nozzles,collets, collet bodies and 2% ceriated tungstenelectrodes (1/16, 3/32 and 1/8 inch)W-400 (WP-18SC) Torch Kit 300186Recommended for Maxstar 800Weldcraft W-400 (WP-18SC) 25-foot (7.6 m)TIG torch with thread-lock connectorTorch cable coverWork clamp with 12-foot (3.7 m)4/0 cable with thread-lock connectorFlowmeter regulatorGas hose (regulator to machine)AK18C torch accessory kit includes nozzles,collets, collet bodies and 2% ceriated tungstenelectrodes (3/32, 1/8 and 5/32 inch)Runner Cart300244Designed toaccommodateDynasty orMaxstar400or 800 powersources anda Coolmate 3.5Cooler. Cartfeatures singlecylinder rack,foot pedal holder,three cable/torchholders, and two TIG electrode filler holders.Low-ConductivityTIG Coolant043810Sold in multiples offour in one-gallonrecyclable plasticbottles. Millercoolants contains abase of ethyleneglycol and deionized water to protect againstfreezing to -37 Fahrenheit (-38 C) or boiling to227 Fahrenheit (108 C).Water-Cooled TIG Torch Connector 225028For Dynasty and Maxstar 800.50 mm thread-lock with water return line. Foruse with all Weldcraft water-cooled torches.Coolmate 3.5 300245Designed to integrate with the Dynasty andMaxstar 400 and 800 power sources. For usewith water-cooled torches rated up to 600 amps.3.5-gallon capacity.6Automation Interface Connection Kit278161 FieldProvides control of power source weldingparameters through a 28-pin receptacle.The 28-pin receptacle replaces the standard14-pin receptacle and requires a PLC controllerto operate the power source. Ideal forautomated equipment integration.Weld Current Sensor 300179 FieldDetects when work clamp is not connectedand prevents expensive damage to disconnectdevices and input power cord and wiring.

Genuine Miller Accessories (Continued) Remote Controls and SwitchesWireless RemoteFoot Control300429For remote currentand contactorcontrol. Receiverplugs directlyinto the 14-pinreceptacle of Miller machine. 90-foot (27.4 m)operating range.Wireless Remote HandControl 300430For remote currentand contactor control.Receiver plugs directly intothe 14-pin receptacle ofMiller machine. 300-foot(91.4 m) operating range.RCCS-14 Remote Contactor andCurrent Control 043688North/south rotary-motion fingertip controlattaches to TIG torch using two hook-and-loopfasteners. Great for applications that require afiner amperage control. Includes 26.5-foot (8 m)cord and 14-pin plug.RCC-14 Remote Contactor and Current Control151086East/west rotary-motion fingertip controlattaches to TIG torch using two hook-and-loopfasteners. Great for production or contractorsthat need quick ramp-up. Includes 26.5-foot (8 m)cord and 14-pin plug.RFCS-14 HD FootControl 194744Maximum flexibility isaccomplished with areconfigurable cordthat can exit the front,back or either side ofthe pedal. Foot pedal provides remote currentand contactor control. Includes 20-foot(6 m) cord and 14-pin plug.RHC-14 Hand Control242211020Miniature hand controlfor remote current andcontactor control.Dimensions: 4 x 4 x 3.25inches (102 x 102 x 83 mm).Includes 20-foot (6 m) cord and 14-pin plug.RMLS-14 Switch 129337Momentary- and maintained-contact rockerswitch for contactor control. Push forward formaintained contact and backward for momentarycontact. Includes 26.5-foot (8 m) cord and14-pin plug.RMS-14 On/Off Control 187208Momentary-contact switch for contactor control.Rubber-covered pushbutton dome switch idealfor repetitive on-off applications. Includes26.5-foot (8 m) cord and 14-pin plug.Extension Cables for 14-PinRemote Controls242208025 25 ft. (7.6 m)242208050 50 ft. (15.2 m)242208080 80 ft. (24.4 m)Performance TIG Gloves263345 X-Small263346 Small263347 Medium263348 Large263349 X-LargeCompletely unlined, goat grainleather with triple-padded palm.Performance TIG/MultitaskGloves263352 Small263353 Medium263354 Large263355 X-LargeGoat grain leather with dualpadded palm and wool back.Memory CardsMemory Card Expansion301151 14-pin automation expansionProvides the ability to access common automationfunctions through the 14-pin connection.301152 14-pin Modbus expansionProvides the ability to access basic and advancedfunctions through the 14-pin connection.Memory Card (Blank) 301080A blank, commercially available memory cardused for transferring software updates andexpandable features from your computerto the machine.Free software updates and feature expansions canbe downloaded at MillerWelds.com/tigsoftware.Educational MaterialsTo order, please call Miller Literature at 866-931-9732or visit MillerWelds.com/resources/tools.Gas Tungsten Arc Welding (TIG) Publication250833TungstenTungstenAmp Range2% Ceriated (AC/DC)2% Lanthanated (AC/DC)1/16 in. (1.6 mm)70 –150 AWC116X7WL2116X73/32 in. (2.4 mm)140 – 250 AWC332X7WL2332X71/8 in. (3.2 mm)225 – 400 AWC018X7WL2018X75/32 in. (4.0 mm)300 – 500 AWC532X7WL2532X77

Ordering InformationEquipment and OptionsStock No.DescriptionMaxstar 400907716Auto-Line 208 – 575 V, 50/60 Hz, CSA. 8 ft. power cordMaxstar 400 International907716002Auto-Line 380 – 575 V, 50/60 Hz, CE. 8 ft. power cordMaxstar 400 TIGRunner 907716001Auto-Line 208 – 575 V, 50/60 Hz, CSA. 8 ft. power cord. Requires coolantMaxstar 400 Wireless Complete951693Auto-Line 208 – 575 V, 50/60 Hz, CSA. 8 ft. power cordMaxstar 400 Complete951692Auto-Line 208 – 575 V, 50/60 Hz, CSA. 8 ft. power cordMaxstar 800907718Auto-Line 208 – 575 V, 50/60 Hz, CSAMaxstar 800 International907718002Auto-Line 380 – 575 V, 50/60 Hz, CEWater-Cooled Torch Kits300990301268300186W-280W-375 (recommended for Maxstar 400)W-400 (WP-18SC) (recommended for Maxstar 800)Water-Cooled TIG Torch Connectors195377225028Connects Weldcraft water-cooled torches to Dinse-style connectorConnects Weldcraft water-cooled torches to Maxstar 800(thread-lock connector included with 800 models) Qty. TIG Torches, Kits and ConnectorsTungstenSee page 7Remote ControlsWireless Remote Foot Control300429Foot control with wireless 90 ft. (27.4 m) operating rangeWireless Remote Hand Control300430Hand control with wireless 300 ft. (91.4 m) operating rangeRCCS-14043688North/south fingertip controlRCC-14151086East/west fingertip controlRFCS-14 HD194744Heavy-duty foot controlRHC-14242211020Hand controlRMLS-14129337Momentary/maintained rocker switchRMS-14187208Momentary rubber dome switchExtension CablesSee page 7AccessoriesRunner Cart300244Coolmate 3.5300245120 V, 50/60 Hz, CE. Requires coolantTIG Coolant(Must be ordered in quantities of four)0438101-gallon plastic bottle. Protects against freezing to -37 Fahrenheit (-38 C)or boiling to 227 Fahrenheit (108 C)Automation Interface Kit278161Field installation required. Provides 28-pin automation connectionsWeld Current Sensor300179Field installation required. Detects when work clamp is not connectedDinse-Style Connector 50 mm (1 male)042418Used to connect weld cable to Dinse terminal machineThread-Lock Connectors (2 male)225029Used to connect weld cable to Dynasty 800 or Maxstar 800Dinse-Style Connector 50 mm(1 male, 1 female)042419Used to extend weld cablesDinse/Tweco Adapter042465Male Dinse to female TwecoDinse/Cam-Lok Adapter042466Male Dinse to female Cam-LokMemory Cards30115130115230108014-Pin automation expansion14-Pin Modbus expansionBlankGas Tungsten Arc Welding (TIG) Publication250833TIG Welding GlovesDate:Distributed by: 2017 Miller Electric Mfg. Co.See page 6See page 7Total Quoted Price:Price

100% duty cycle 300 A at 32 V, 60% duty cycle 200 A at 28 V, 100% duty cycle 250 A at 30 V, 60% duty cycle 500 A at 40 V, 100% duty cycle 600 A at 44 V, 60% duty cycle 400 A at 36 V, 100% duty cycle 500 A at 40 V, 60% duty cycle Welding Amperage Range 3–400 A 3–400 A 5–800 A 5–800 A Model

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