Maxstar 300 SD, DX And LX
OM-2222189 533AB2006 05ProcessesTIG (GTAW) WeldingStick (SMAW) WeldingDescription230/460 Volt Models W/Auto-LinkR400 Volts ModelsArc Welding Power SourceMaxstar 300 SD,DX And LXRAnd Non-CE ModelsFile: TIG (GTAW)Visit our website atwww.MillerWelds.com
From Miller to YouThank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you don’t have time to doit any other way.That’s why when Niels Miller first started building arc welders in 1929,he made sure his products offered long-lasting value and superiorquality. Like you, his customers couldn’t afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.Today, the people that build and sell Miller products continue thetradition. They’re just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.This Owner’s Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.We’ve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,there’s a Troubleshooting section that willhelp you figure out what the problem is. TheMiller is the first welding parts list will then help you to decide theequipment manufacturer in exact part you may need to fix the problem.the U.S.A. to be registered tothe ISO 9001:2000 Quality Warranty and service information for yourSystem Standard.particular model are also provided.Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.Mil Thank 4/05Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.
TABLE OF CONTENTSSECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4SECTION 2 CONSIGNES DE SÉCURITÉ LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 72-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8SECTION 3 DEFINITIONS (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-2. Manufacturer’s Rating Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154-5. 115 Volts AC Duplex Receptacle, Supplementary Protector (Optional) And Power Switch . . . . . . . . . 164-6. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164-7. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174-8. Remote Program Select Inputs (Optional For DX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184-9. Automation Connection (LX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194-10. Typical Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194-11. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-12. TIG HF Impulse/ Lift-Arc DCEN (Direct Current Electrode Negative) Connections . . . . . . . . . . . . . . . 204-13. Stick DCEP (Direct Current Electrode Positive) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-14. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214-15. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224-16. Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23SECTION 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245-2. Encoder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255-3. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255-4. Ammeter And Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255-5. Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265-6. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265-7. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275-8. Pulser Control (DX And LX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285-9. Sequencer Controls (DX, LX And All CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295-10. Adjust Controls (Preflow/Post Flow/DIG/Purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305-11. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) (All Models) . . . . . . . . . . . . . . . . . 315-12. Memory (Program Storage Locations 1-4) (DX And LX Models If Available) . . . . . . . . . . . . . . . . . . . . . 315-13. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A Preflow Control OnThe Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325-14. Factory Parameter Defaults And Range And Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335-15. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TABLE OF CONTENTSSECTION 6 ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Programmable TIG Start Parameters (Polarity, Amperage And Time) . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Arc Timer/Counter Display (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5. Setting Unit To Display PPP While Pulse Welding (DX And LX Models Only) . . . . . . . . . . . . . . . . . . . .6-6. Stick Open-Circuit Voltage (OCV) Selection (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 7 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 8 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 10 GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . .10-2. Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 11 SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING . . .11-1. Typical DC - GTAW 16 Gauge Stainless Steel Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3. Lift-ArcE And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 12 STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . . . . . . . . . .12-2. Electrode and Amperage Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-3. Stick Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-4. Striking an Arc Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-5. Striking an Arc Tapping Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6. Positioning Electrode Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-8. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-11. Butt Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-12. Lap Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13. Tee Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-14. Weld Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 13 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OPTIONS AND 4555656565757585960616262636464646565656767676872
Declaration of Conformity ForEuropean Community (CE) ProductsNOTEThis information is provided for units with CE certification (see rating label on unit.)Manufacturer:European Contact:Miller Electric Mg. Co.1635 W. Spencer St.Appleton, WI 54914 USAPhone: (920) 734-9821Mr. Danilo Fedolfi,Managing DirectorMILLER Europe S.r.l.Via Privata Iseo 6/E20098 San GiulianoMilanese, ItalyPhone: 39(02)98290-1Fax: 39(02)98290203European Contact Signature:Declares that the product:Maxstar R 300 SD, DX, LXconforms to the following Directives and Standards:DirectivesLow Voltage Directive: 73/23/EECMachinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EECElectromagnetic Capability Directives: 89/336, 92/31/EECStandardsSafety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1(December 1996 Draft revision)Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989Insulation coordination for equipment within low-voltage systems:Part 1: Principles, requirements and tests: IEC 664-1: 1992Electromagnetic compatibility (EMC) Product standard for arc welding equipment:EN50199: August 1995dec con1 Ref 6/05
Notes
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom 3/05Y Warning: Protect yourself and others from injury — read and follow these precautions.1-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.Y Marks a special safety message. Means “Note”; not safety related.This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.1-2. Arc Welding HazardsY The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-5. Read and follow allSafety Standards.Y Only qualified persons should install, operate, maintain, andrepair this unit.DDDDDDY During operation, keep everybody, especially children, away.ELECTRIC SHOCK can kill.Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded 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 matsor covers big enough to prevent any physical contact with the workor ground.D Do not use AC output in damp areas, if movement is confined, or ifthere 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 onunit.D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic 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 welderis recommended. And, do not work alone!D Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).D Properly install and ground this equipment according to itsOwner’s Manual and national, state, and local codes.D Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.D When making input connections, attach proper grounding conductor first double-check connections.D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.DDDDDDTurn off all equipment when not in use.Do not use worn, damaged, undersized, or poorly spliced cables.Do not drape cables over your body.If earth grounding of the workpiece is required, ground it directlywith a separate cable.Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will bepresent.Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.Wear a safety harness if working above floor level.Keep all panels and covers securely in place.Clamp work cable with good metal-to-metal contact to workpieceor worktable as near the weld as practical.Insulate work clamp when not connected to workpiece to preventcontact with any metal object.Do not connect more than one electrode or work cable to anysingle weld output terminal.SIGNIFICANT DC VOLTAGE exists in inverter-typewelding power sources after removal of inputpower.D Turn Off inverter, disconnect input power, and discharge inputcapacitors according to instructions in Maintenance Sectionbefore touching any parts.FUMES AND GASES can be hazardous.Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.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 thearc to remove welding fumes and gases.D If ventilation is poor, wear an approved air-supplied respirator.D Read and understand the Material Safety Data Sheets (MSDSs)and the manufacturer’s instructions for metals, consumables,coatings, cleaners, and degreasers.D Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air andlower 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 operations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.OM-2222 Page 1
ARC RAYS can burn eyes and skin.Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching(see ANSI Z49.1 and Z87.1 listed in Safety Standards).D Wear approved safety glasses with side shields under yourhelmet.D Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.WELDING can cause fire or explosion.Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires andburns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.D Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis 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 caneasily 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 cancause fire on the hidden side.D Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).D Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock, sparks, and firehazards.D Do not use welder to thaw frozen pipes.D Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.D Wear oil-free protective garments such as leather gloves, heavyshirt, 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 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51Bfor hot work and have a fire watcher and extinguisher nearby.FLYING METAL can injure eyes.D Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.D Wear approved safety glasses with sideshields even under your welding helmet.OM-2222 Page 2BUILDUP OF GAS can injure or kill.D Shut off shielding gas supply when not in use.D Always ventilate confined spaces or useapproved air-supplied respirator.HOT PARTS can cause severe burns.D Do not touch hot parts bare handed.D Allow cooling period before working on gun ortorch.D To handle hot parts, use proper tools and/orwear heavy, insulated welding gloves andclothing to prevent burns.MAGNETIC FIELDS can affect pacemakers.D Pacemaker wearers keep away.D Wearers should consult their doctor beforegoing near arc welding, gouging, or spotwelding operations.NOISE can damage hearing.Noise from some processes or equipment candamage hearing.D Wear approved ear protection if noise level ishigh.CYLINDERS can explode if damaged.Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.D Install cylinders in an upright position by securing to a stationarysupport 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 shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them andassociated parts in good condition.D Turn face away from valve outlet when opening cylinder valve.D Keep protective cap in place over valve except when cylinder is inuse or connected for use.D Use the right equipment, correct procedures, and sufficient number 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.
1-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.MOVING PARTS can cause injury.D Do not install or place unit on, over, or nearcombustible surfaces.D Do not install unit near flammables.D Do not overload building wiring be sure power supply system isproperly sized, rated, and protected to handle this unit.D Keep away from moving parts such as fans.D Keep all doors, panels, covers, and guardsclosed and securely in place.D Have only qualified persons remove doors,panels, covers, or guards for maintenance asnecessary.D Reinstall doors, panels, covers, or guardswhen maintenance is finished and before reconnecting input power.FALLING UNIT can cause injury.D Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.D Use equipment of adequate capacity to lift andsupport unit.D If using lift forks to move unit, be sure forks arelong enough to extend beyond opposite side ofunit.READ INSTRUCTIONS.D Read Owner’s Manual before using or servicing unit.D Use only genuine Miller/Hobart replacementparts.H.F. RADIATION can cause interference.OVERUSE can cause OVERHEATINGD Allow cooling period; follow rated duty cycle.D Reduce current or reduce duty cycle beforestarting to weld again.D Do not block or filter airflow to unit.DDSTATIC (ESD) can damage PC boards.D Put on grounded wrist strap BEFORE handlingboards or parts.D Use proper static-proof bags and boxes tostore, move, or ship PC boards.DDD High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.D Have only qualified persons familiar withelectronic equipment perform this installation.The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.If notified by the FCC about interference, stop using theequipment at once.Have the installation regularly checked and maintained.Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.ARC WELDING can cause interference.MOVING PARTS can cause injury.D Keep away from moving parts.D Keep away from pinch points such as driverolls.DWELDING WIRE can cause injury.D Do not press gun trigger until instructed to doso.D Do not point gun toward any part of the body,other people, or any metal
Low Voltage Directive: 73/23/EEC Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Electromagnetic Capability Directives: 89/336, 92/31/EEC Standards Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990 Arc Welding Equipment Part 1: Welding
Maxstar 210 STR 907682 Maxstar 210 907683 Maxstar 210 DX 907684 Maxstar comes with adjustable shoulder strap, 8 ft. power cord (no plug) and two 50 mm Dinse-style connectors. See page 7 for descriptions and kit contents. Maxstar 210 Models/Packages 907683 Maxstar 210 shown. Step #1 † Select Maxstar Build an Air-Cooled Package
Maxstar 300 SD Maxstar 300 SD (CE) Maxstar 300 DX/LX Maxstar 300 DX/LX (CE) For Single-Voltage Units Rated Output at 60% Duty Cycle 250 A at 30 VDC Max. Open-Circuit Voltage 95 VDC Welding Amperage Range 5–300 A Amps Input at Rated Output, 50 Hz 400 V KVA KW 16.9 11.7 8.6 Net Weight Without Aux. Power: 85 lb (39 kg) With Aux. Power: 100 lb .
Maxstar 280 Maxstar 280 DX Miller Electric Mfg. Co. An ITW Company 1635 West Spencer Street P.O. Box 1079 Appleton, WI 54912-1079 USA . (208–575 V) with no manual linking, . Syncrowave 250 Maxstar 280 Maxstar 280 DX Maxstar 280 Benefits
Maxstar 300 SD Maxstar 300 DX The Maxstar 300 Series combines advanced inverter technology with a high-end TIG power source to offer you superior arc performance. The Maxstar’s front panel interfac
de 250 A, enfriada por agua recomendada (#300 185). La Coolmate 1 requiere una fuente separada de electricidad. La Maxstar 200 no suministra potencia auxiliar. Conjuntos de Juegos de Contratista para Maxstar 200 DX (Enfriado por Aire) Maxstar 200 DX Juegos de Contratista #951 172 (C
rod storage area. Works with Dynasty or Maxstar 200 and Coolmate 1. Contact your local distributor for filler material holders. Universal Carrying Cart and Cylinder Rack #042 934 Holds power source, and gas cylinder up to 56 in (142.2 cm) high measuring 6 to 9 in (15.2 to 22.
The Maxstar 280 has a lower bottom end and can weld thinner metals. Weld longer at higher amperages. At 200 A the Maxstar 280 can weld continuously. Blue Lightning arc starting is tailored for each tungsten size to produce perfect starts. Precise adjustments can be made with all-digita
purchase any miller welding machine and receive a free 50 gift card to the miller online company . #907553 maxstar 280 dx 3809 #907538002 maxstar 280 tigrunner w/cps 4669 #907539001 maxstar . 225 ampac/30
