Manuals / Miller Electric / Power Tools / Welder

Miller Electric Maxstar 200 STR Troubleshooting − Burn-Through, Troubleshooting − Distortion

Models: Maxstar 200 STR

1 56

Download 56 pages 127 b

Page 45

10-19. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes	Corrective Actions

Excessive heat input.	Select lower amperage. Use smaller electrode.

	Increase and/or maintain steady travel speed.

10-20. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes	Corrective Actions

Unsteady hand.	Use two hands. Practice technique.

10-21. Troubleshooting − Distortion

			Distortion − contraction of weld met-
			al during welding that forces base
			metal to move.
		Base metal moves
		Base metal moves
		in the direction of
		in the direction of
		the weld bead.

Possible Causes			Corrective Actions

Excessive heat input.			Use restraint (clamp) to hold base metal in position.

			Make tack welds along joint before starting welding operation.

			Select lower amperage for electrode.

			Increase travel speed.

			Weld in small segments and allow cooling between welds.

OM-2233 Page 39

Image 45

Miller Electric Maxstar 200 STR manual Troubleshooting − Burn-Through, Troubleshooting − Waviness Of Bead

Contents

OM-2233 203 409Q ProcessesDescription From Miller to You Table of Contents − Parts List Directives StandardsDecstat6/05 Page Marks a special safety message Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion ARC Rays can burn eyes and skinFlying 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 Incendie ou une explosion LE Soudage peut provoquer unDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures gravesLA Chute DE L’APPAREIL peut blesser Risque D’INCENDIE OU D’EXPLO’EMPLOI Excessif peut SUR DES Organes Mobiles peuvent provoquer des blessuresEn ce qui concerne les stimulateurs cardiaques Principales normes de sécurité− Definitions CE Models Electric shock from welding electrode or wiring can killWeee Label For Products Sold Within The EU 60 sFalling equipment can cause injury and damage to unit Manufacturer’s Rating Label Symbols And DefinitionsSpecifications − InstallationVolt-Ampere Curves 5 V a C In p u tTh e r In p u t V o lt a g e s Minutes Welding Duty Cycle And OverheatingOverheating MinutesSelecting a Location Dimensions And WeightSection Location And AirflowRemote 14 Receptacle Information Weld Output Terminals And Selecting Cable SizesTurn off power before mak- ing connections Stick Dcep Direct Current Electrode Positive Connections Electrical Service GuideInput Voltage Input Amperes At Rated OutputConnecting Three-Phase Input Power Connecting Input PowerFor Three-Phase Operation = GND/PE Earth GroundConnecting Single-Phase Input Power − Operation ControlsNon CE Units For CE Units Process Control Lift-ArcStart ProcedureLift-Arc Start ApplicationAmperage Control Stick Start Procedure − Scratch Start TechniqueDIG Control MinRoutine Maintenance − Maintenance and TroubleshootingBlowing Out Inside Of Unit MonthsTroubleshooting Help Aids Output LED High Temperature LEDHelp 8 Display Trouble Remedy TroubleshootingShield weld zone from drafts Check and tighten all gas fittings see SectionCircuit Diagram − Electrical DiagramsUp to Amperage Range Gas Type PolarityPositioning The Torch − Guidelines for Gtaw TIG WeldingPositioning Torch Tungsten For Various Weld Joints Torch Movement During WeldingTungsten 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 Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleElectrode Movement During Welding Conditions That Affect Weld Bead ShapeLap Joint Butt JointsTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Excessive Spatter Troubleshooting − PorosityWeld 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 602 400 601 603 605 Panel, Front w/Components -1ItemPanel, Rear w/Components Magnetics Assembly w/Components 1Item Windtunnel w/Components -1Item Windtunnel w/Components604 600 601 602 604Base Assembly Service Your distributor also givesSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s