Maxstar TIG/Stick Welding

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1 00 Series Issued March 00 Index No. DC/ Maxstar TIG/Stick Welding Power Source Quick Specs Heavy Industrial Applications Petro/Chem Fabrication Aerospace Food/Beverage Industry Mechanical Contractors Pressure Vessel Manufacturing Shipboard Installation/Repair Automation Processes TIG (GTAW) Welding Pulsed TIG (GTAW-P) Welding with DX and LX Models Stick (SMAW) Welding Input Power Requires - or 1-Phase Power Amperage Range 00 A Rated Output 0 A at 0 VDC, 0% Duty Cycle (-Phase) 00 A at 8 VDC, 0% Duty Cycle (1-Phase) Weight Without Auxiliary Power: 8 lb (9 kg) With Auxiliary Power: 100 lb ( kg) The Power of Blue. Inverter-based, DC power source has state-of-the-art operator interface allowing the user extra set-up capabilities in a compact machine. Features more precise control of output parameters than traditional knobs and switches. Programmable HF start parameters allows the operator to independently set HF starting conditions based upon process and memory selection. HF start only provides non-contact arc starting that eliminates tungsten or material contamination. Available in Three Models: SD: Provides the basic features that are required for most DC TIG or Stick welding applications. DX: When the job demands greater control the DX provides pulse on/off, pulse frequency, peak % time, background amperage, initial amperage, initial slope time, final slope time and final amperage control. LX: Automation made simple. With the Automation Interface Connector, the integrator can quickly interface to the output disable, weld start/stop, gas start/stop inputs; valid arc, pulse lock out, and end of weld sequence outputs. Maxstar 00 SD Maxstar 00 LX Maxstar 00 DX Shown with Deluxe Carrying Cart and Cylinder Rack, Coolmate and RFCS-1 HD Foot Control. Superior arc performance with DC TIG/Stick welding performance, even on the difficult to run electrodes like E010. Lift-Arc start TIG arc starting without the use of high frequency. Auto-Link provides flexibility to the operator. Connectable to 0 V or 0 V, 1- or -phase power without having to remove the covers and relink the power source. Power source is warranted for years, parts and labor. Original main power rectified parts are warranted for years. Miller Electric Mfg. Co. An Illinois Tool Works Company 1 West Spencer Street Appleton, WI 91 USA International Headquarters Phone: USA FAX: Canadian FAX: International FAX: Web Site

2 Specifications (Subject to change without notice.) For Multivoltage Units Input Power Three- Phase Single- Phase Rated Output at 0% Duty Cycle 0 A at 0 VDC 00 A at 8 VDC For Single-Voltage Units Welding Amperage Range 00 A Max. Open- Circuit Voltage 9 VDC Amps Input at Rated Output, 0 Hz 0 V 0 V KVA KW Dimensions H: 1 in ( mm) W: 1-1/ in (18 mm) D: in (10 mm) Net Weight Without Aux. Power: 8 lb (9 kg) With Aux. Power: 100 lb ( kg) Rated Output at 0% Duty Cycle 0 A at 0 VDC Welding Amperage Range 00 A Max. Open- Circuit Voltage 9 VDC Amps Input at Rated Output, 0 Hz 00 V KVA KW Dimensions H: 1 in ( mm) W: 1-1/ in (18 mm) D: in (10 mm) Net Weight Without Aux. Power: 8 lb (9 kg) With Aux. Power: 100 lb ( kg) Certified by Canadian Standards Association to both Canadian and U.S. Standards. Conforms to European standards. Control Panel Maxstar 00 SD Maxstar 00 DX/LX Voltmeter. Ammeter. Process Control. Output Control. Encoder Control. Amperage Control. Adjust Control 8. Sequencer Control 9. Pulser Controls 1 Maxstar 00 SD (CE) 1 Maxstar 00 DX/LX (CE) Control Panel Parameter Values A. Preflow (s) 0.0 B. Initial Time (s) 0.0 (LX only) C. Initial Amperage (A) 00 D. Initial Slope Time (s) 0.0 E. Weld Amperage (A) 00 F. Pulse Frequency (Hz) G. Background Amperage (%) H. Peak Percent Time (%) 9 I. Final Slope Time (s) 0.0 J. Final Amperage (A) 00 K. Final Time (s) 0.0 (LX only) L. Postflow Time (s) M. Dig (%) 0 100

3 Performance Data WELDING AMPS DUTY CYCLE CHART -PHASE 1-PHASE VOLTS STICK MAX TIG MAX TIG MIN DIG MAX VOLT/AMP CURVES % DUTY CYCLE 0 0 STICK MIN AMPS Included Accessories Non-CE SD/DX Models Include: (1) DA180L torch adapter () International-style connectors /0 Non-CE LX Model Includes: (1) DA180L torch adapter () International-style connectors /0 (1) 1-pin amphenol with clamp (1) 10-pin amphenol with clamp CE SD/DX Models Include: () International-style connectors /0 (1) 1-pin amphenol with clamp (1) /8 in - 18 gas fitting CE LX Model Includes: () International-style connectors /0 (1) 1-pin amphenol with clamp (1) 10-pin amphenol with clamp (1) /8 in - 18 gas fitting

4 Genuine Miller Accessories Remote Controls RFCS-1 HD Foot Control #19 after serial number JK1. This new design increases stability with a larger base and durability with a heavier cord. Maximum flexibility is accomplished with a reconfigurable cord that can exit the front, back or either side of the pedal. Foot pedal provides remote current and contactor control. Includes 0 ft ( m) cord and 1-pin plug. RCCS-1 Remote Contactor and Current Control # pin plug after serial number JK1. North/south rotary-motion fingertip control fastens to TIG torch using two Velcro straps. Great for applications that require a finer amperage control. Includes. ft (8 m) control cord. RCC-1 Remote Contactor and Current Control # pin plug after serial number JK1. Side-to-side rotary-motion fingertip control fastens to TIG torch using two Velcro straps. Great for production or contractors that need quick ramp-up. Includes. ft (8 m) control cord. RMLS-1 Switch #19 after serial number JK1. Momentaryand maintained-contact rocker switch for contactor control. Push forward for maintained contact and backward for momentary contact. Includes. ft (8 m) cord and 1-pin plug. RMS-1 On/Off Control #18 08 after serial number JK1. Momentarycontact switch for contactor control. Rubber-covered pushbutton dome switch ideal for repetitive on-off applications. Includes. ft (8 m) cord and 1-pin plug. RFCS-1 Foot Control #0 after serial number JK1. Foot pedal provides remote current and contactor control. Includes 0 ft ( m) cord and 1-pin plug.

5 Genuine Miller Accessories (Continued) Carts and Racks Educational Resources Gas Tungsten Arc (TIG) Welding Book #10 To order, call the Miller Literature Distribution Center at , or FAX A comprehensive, 8-page text on all aspects of the TIG process. Deluxe Carrying Cart and Cylinder Rack #0 8 Accommodates inverter power source, cooler, and one gas cylinder. Includes bottom drawer for miscellaneous items. Universal Carrying Cart and Cylinder Rack #0 9 Accommodates power source, plus one gas cylinder up to in (1. cm) high measuring to 9 in (1. to.8 cm) in diameter. Also provides storage for auxiliary items such as electrodes, helmets, gloves, etc. Can also be used with XMT, Dynasty Series, Maxstar Series, and Millermatic 10 power sources. Running Gear/Cylinder Rack #0 Has adjustable handles and is slanted for convenient access to power source front panel controls. Carries two 10 lb (. kg) gas cylinders, or one gas cylinder and one Coolmate V coolant system for TIG (GTAW) welding. Can be used with the Dynasty, Maxstar, Invision or XMT inverter power supplies. Also accommodates Radiator, Watermate, or Coolmate coolant systems. Inverter Rack #0 -Rack 0/0 V The XMT 0 Rack conveniently houses multiple power sources for multiple welders. This is an ideal system for onsite applications including construction and ship building. TIG Fundamentals Welding CD #19 To order, please call , or FAX , or log on to our Web site. An interactive CD designed for anyone who s looking to better understand the TIG process. TIG (GTAW) Torches Weldcraft TIG Torches The Weldcraft line of TIG torches complements the most popular TIG power source line available today. The Weldcraft torch line includes both air-cooled and water-cooled models. Available with genuine Weldcraft parts. TIG (GTAW) Torch Adapters DA-91F #19 0 Used to adapt a 1-piece 1 or 10 amp air-cooled torch to an International-style connector. DA-180L # Used to adapt a 0 or 0 amp watercooled torch to an International-style connector. DA-R #19 Used to adapt a 1-piece 00 amp air-cooled torch to an International-style connector.

6 Genuine Miller Accessories (Continued) Coolant Systems For more information, see the Miller Coolant Systems literature sheet, Index No. AY/.. Coolmate # VAC # VAC, CE # VAC # VAC, CE For use with water-cooled torches rated up to 00 amps. Unique paddle-wheel indicator, external filter and easy-fill spout. Coolmate V # VAC # VAC, CE For use with water-cooled torches rated up to 00 amps. Vertical design conveniently mounts to Miller cylinder rack in place of one cylinder. Coolmate # VAC # VAC, CE For use with water-cooled torches rated up to 00 amps. Tough molded polyethylene case with carrying handle. Coolmate Low-Conductivity Coolant #0 810 Sold in multiples of four in 1-gallon recyclable plastic bottles. Primarily used in TIG (high-frequency) applications, but can also be used in MIG systems where aluminum is not in the water path. Miller coolants contain a base of ethylene glycol and deionized water to protect against freezing to - F (-8 C) or boiling to F (108 C). Also contains a compound that resists algae growth. Coolmate V Coolmate Aluminum-Protecting Coolant #0 809 Sold in multiples of four in 1-gallon recyclable plastic bottles. Primarily used in MIG products, such as the water-cooled XR, which has an aluminum drive housing, or in any system where high frequency is not used. Miller coolants contain a base of ethylene glycol and deionized water to protect against freezing to - F (-8 C) or boiling to F (108 C). Also contains a compound that resists algae growth. International-Style Connectors (Will accept Dinse or other International connectors.) Note: All Maxstar power sources are equipped with International-style connectors for secondary connections. (Power source is shipped with two 0-mm male International-style plugs for use with #1 or # AWG size cable.) International-Style Connector Kit # mm Accepts #1 or # AWG cable size. Required if male plugs shipped with power source must be replaced, if additional plugs are needed. Kit includes one International-style male plug which attaches to the work and/or weld cables and plugs into the Internationalstyle receptacles on the power source. Extension Kit for International-Style Cable Connectors # mm Accepts #1 or # AWG size cable. Used to adapt or extend weld and/or work cables. Kit includes one male International-style plug and one in-line female International-style receptacle. International/Tweco Adapter #0 A one-piece adapter which has an International-style male plug (to power source) on one end and a female Tweco receptacle (for weld cable connection) on other end. International/Cam-Lok Adapter #0 A one-piece adapter which has an International-style male plug (to power source) on one end and a Cam-Lok receptacle (for weld cable connection) on other end.

7 Typical Installations TIG (GTAW) Basic Equipment Remote Control TIG Torch Shielding Gas Cylinder Work Stick (SMAW) Basic Equipment Stick Electrode Work

8 Ordering Information Equipment and Options Stock No. Description Qty. Price Power Source Maxstar 00 SD #90 8 Basic controls, 0/0 VAC, 0/0 Hz #90 88 Basic controls, 00 VAC, 0/0 Hz, CE # Basic controls w/11 V auxiliary power, 0/0 VAC, 0/0 Hz Maxstar 00 DX # Full feature controls, 0/0 VAC, 0/0 Hz # Full feature controls w/11 V auxiliary power, 0/0 VAC, 0/0 Hz # Full feature controls w/11 V auxiliary power, 00 VAC, 0/0 Hz, CE Maxstar 00 LX # Full feature controls w/11 V auxiliary power & required automation connections # Full feature controls w/11 V aux. power & required automation connections, CE TIG Accessories Weldcraft TIG Torches WP0RM 0 A, ft (. m) water-cooled w/nylon-braided rubber hoses CS10RM 10 A, ft (. m) water-cooled w/nylon-braided rubber hoses (w/cable cover) TIG Torch Adapters #19 0 DA-91F # DA-180L #19 DA-R Consumables, Tungsten Distributor see Parts Guide Gas Cylinder, Gas Hose and Fittings Stick Accessories Stick Electrodes Remote Controls RFCS-1 HD #19 Heavy-duty foot control RFCS-1 #0 Foot control RCCS-1 #0 88 North/south fingertip control RCC-1 #11 08 Side-to-side fingertip control RMLS-1 #19 Momentary/maintained rocker control RMS-1 #18 08 Momentary rubber dome switch Carts and Racks Deluxe Carrying Cart and Cylinder Rack #0 8 Universal Carrying Cart and Cylinder Rack #0 9 Running Gear/Cylinder Rack #0 Inverter Rack #0 Educational Resources Gas Tungsten (TIG) Welding Book #10 TIG Fundamentals Welding CD #19 Coolant Systems Coolmate # VAC # VAC, CE # VAC # VAC, CE Coolmate V # VAC # VAC, CE Coolmate # VAC # VAC, CE Aluminum-Protecting Coolant #0 809 Low-Conductivity Coolant #0 810 Cooling System Hoses International-Style Connectors International-Style Connector Kit # mm Extension Kit for International-Style # mm International/Tweco Adapter #0 A one-piece adapter with International-style male plug International/Cam-Lok Adapter #0 A one-piece adapter with International-style male plug Date: Total Quoted Price: Distributed by: Litho in USA

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