Miller Electric Maxstar 200 STR manual Guidelines for Gtaw TIG Welding, Positioning The Torch

Page 36

SECTION 9 − GUIDELINES FOR (GTAW) TIG WELDING

gtaw 7/2006

9-1. Positioning The Torch

 

 

Y Grinding the tungsten elec-

 

 

 

trode produces dust and fly-

 

 

 

ing sparks which can cause

 

 

 

injury and start fires. Use lo-

 

 

 

cal exhaust (forced ventila-

 

3

 

tion) at the grinder or wear an

 

 

approved respirator. Read

 

 

 

 

 

 

MSDS for safety information.

 

2

 

Consider using

cerium or

 

 

lanthanum based tungsten

 

 

 

 

 

 

instead of thoriated. Tho-

 

 

 

rium dust contains low-level

 

 

4

radioactive material. Proper-

 

 

ly dispose of grinder dust in

 

 

 

an environmentally safe way.

 

 

 

Wear proper face, hand, and

 

90°

 

body protection. Keep flam-

 

 

 

mables away.

 

 

1

1

Workpiece

 

 

 

Make sure workpiece is clean

 

 

before welding.

 

 

 

2

Work Clamp

 

 

 

Place as close to the weld as

 

10−15°

possible.

 

 

3

Torch

 

 

 

 

 

4

4

Filler Rod (If Applicable)

 

 

5

Gas Cup

 

°

5

6

Tungsten Electrode

6

Select and prepare

tungsten

10−25

 

 

 

according to Section 8.

 

 

 

Guidelines:

 

5 6

The inside diameter of the gas cup should be at least three times the tungsten diameter to provide ade- quate shielding gas coverage. (For example, if tungsten is 1/16 in diameter, gas cup should be a minimum of 3/16 in diameter.

1/16 in

3/16 in Bottom View Of Gas Cup

Tungsten extension is the distance the tungsten extends out gas cup of torch.

The tungsten extension should be no greater than the inside diameter of the gas cup.

Arc length is the distance from the tungsten to the workpiece.

Ref. ST-161 892

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Contents OM-2233 203 409Q ProcessesDescription From Miller to You Table of Contents − Parts List Directives StandardsDecstat6/05 Page Symbol Usage Marks a special safety messageArc Welding Hazards Electric Shock can killARC Rays can burn eyes and skin Welding can cause fire or explosionFlying Metal can injure eyes Buildup of GAS can injure or killCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Pacemakers UNE Décharge Électrique peut entraîner la mort LES Fumées ET LES GAZ peuvent être dangereuxIndique un message de sécurité particulier LE Soudage peut provoquer un Incendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures gravesRisque D’INCENDIE OU D’EXPLO LA Chute DE L’APPAREIL peut blesser’EMPLOI Excessif peut SUR DES Organes Mobiles peuvent provoquer des blessuresPrincipales normes de sécurité En ce qui concerne les stimulateurs cardiaquesElectric shock from welding electrode or wiring can kill − Definitions CE ModelsWeee Label For Products Sold Within The EU 60 sFalling equipment can cause injury and damage to unit Symbols And Definitions Manufacturer’s Rating Label− Installation SpecificationsVolt-Ampere Curves 5 V a C In p u tTh e r In p u t V o lt a g e s Duty Cycle And Overheating Minutes WeldingOverheating MinutesDimensions And Weight Selecting a LocationSection Location And AirflowWeld Output Terminals And Selecting Cable Sizes Remote 14 Receptacle InformationTurn off power before mak- ing connections Electrical Service Guide Stick Dcep Direct Current Electrode Positive ConnectionsInput Voltage Input Amperes At Rated OutputConnecting Input Power Connecting Three-Phase Input PowerFor Three-Phase Operation = GND/PE Earth GroundConnecting Single-Phase Input Power − Operation ControlsNon CE Units For CE Units Lift-ArcStart Procedure Process ControlLift-Arc Start ApplicationStick Start Procedure − Scratch Start Technique Amperage ControlDIG Control Min− Maintenance and Troubleshooting Routine MaintenanceBlowing Out Inside Of Unit MonthsTroubleshooting Help Aids Output LED High Temperature LEDHelp 8 Display Troubleshooting Trouble RemedyShield weld zone from drafts Check and tighten all gas fittings see Section− Electrical Diagrams Circuit DiagramAmperage Range Gas Type Polarity Up to− Guidelines for Gtaw TIG Welding Positioning The TorchTorch Movement During Welding Positioning Torch Tungsten For Various Weld JointsTungsten Without Filler Rod Tungsten With Filler RodStick Welding Procedure Weld current starts when electrode touches work- piece− Stick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective ActionsTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion − Parts List 2734 401 400402 614615 600 PC2 Panel, Front w/Components -1Item 602 400 601 603 605Panel, Rear w/Components Magnetics Assembly w/Components 1Item Windtunnel w/Components Windtunnel w/Components -1Item604 604 600 601 602Base Assembly Service Your distributor also givesSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s

Maxstar 200 STR specifications

The Miller Electric Maxstar 200 STR is a versatile and compact welding power source designed for a range of applications, making it an ideal choice for both professional welders and hobbyists. Known for its reliability and exceptional performance, the Maxstar 200 STR is capable of delivering high-quality results in various welding processes, including Stick (SMAW) and TIG (GTAW) welding.

One of the standout features of the Maxstar 200 STR is its inverter technology, which allows for efficient energy use and a lightweight, portable design. Weighing in at just 51 pounds, it is easy to transport, making it perfect for fieldwork or remote projects. The unit operates on both 120V and 240V input power, providing versatility for different environments and applications. This adaptability ensures that welders can work effectively in various settings, whether in a shop or on a construction site.

Another significant characteristic of the Maxstar 200 STR is its precise arc control. The machine offers adjustable AC frequency, allowing users to fine-tune the arc characteristics for different materials and thicknesses. This level of control is particularly beneficial when working with aluminum, as it helps reduce heat input and minimize warping. The Maxstar also features a pulsing function, which can enhance the weld pool control and improve penetration, making it easier to achieve clean and consistent welds.

The Maxstar 200 STR boasts a robust duty cycle of 60% at 200A, ensuring that it can handle demanding jobs without overheating. Additionally, the unit is equipped with an advanced cooling system, which helps maintain optimal performance during extended use. Safety features, including overload protection and an enclosed design that reduces the risk of contamination, further enhance the machine's reliability.

Moreover, the Maxstar 200 STR supports a range of accessories, including a remote foot control, which allows for added flexibility during TIG welding operations. This feature is particularly useful for precise control over the welding current, enabling welders to make adjustments on the fly without having to stop and manually change settings.

In summary, the Miller Electric Maxstar 200 STR stands out in the welding industry for its combination of portability, advanced technology, and high performance. With its inverter design, precise arc control, and robust duty cycle, it is an ideal solution for professionals seeking efficiency and quality in their welding projects, whether they are working on industrial applications or artistic endeavors.
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