Miller Maxstar 140 STR Owner's Manual
  1. Manuals
  2. Brands
  3. Miller Manuals
  4. Welding System
  5. Maxstar 140 STR
  6. Owner's manual

Miller Maxstar 140 STR Owner's Manual

With auto-link and remote receptacle
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Visit our website at
www.MillerWelds.com
Maxstar 140 STR
OM-2224
March 2002
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
R
With Auto-Link And
Remote Receptacle
191 802E
R

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Maxstar 140 STR and is the answer not in the manual?

Questions and answers

Related Manuals for Miller Maxstar 140 STR

Summary of Contents for Miller Maxstar 140 STR

  • Page 1 OM-2224 191 802E March 2002 Processes Stick (SMAW) Welding TIG (GTAW) Welding Description Arc Welding Power Source Maxstar 140 STR With Auto-Link And Remote Receptacle Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it 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 superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Specifications And Installation

    SECTION 2 – SPECIFICATIONS AND INSTALLATION 2-1. Specifications Amperes Input At Input Rated Power Welding Maximum Rated Welding Load Out- Amperage Open-Circuit Single- 100% Dimensions Weight Output put, Range Voltage DC Phase Duty 50/60Hz, Cyc. Single- Phase 80A @ 23.2 Volts DC, 100% Duty 5 –...

  • Page 14: Included With Your Unit (Stick Only)

    2-3. Included with Your Unit (Stick Only) Shoulder Strap (Carrying Strap) 13 ft (4 m) Cable With Electrode Holder and Quick-Connect Plug 10 ft (3 m) Cable With Work Clamp And Quick-Connect Plug 6 ft (1.8 m) 115 VAC Input Power Cord With 20 A Plug Some assembly is required.

  • Page 15: Duty Cycle And Overheating

    2-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, output stops, the Overtemperature Light comes On, 230 VAC and the cooling fan runs. Wait fif- teen minutes for unit to cool.

  • Page 16: Volt-Ampere Curves

    2-6. Volt-Ampere Curves Volt-ampere curves show minimum 115 VAC INPUT and maximum voltage and amper- age output capabilities of welding power source. Curves of other set- tings fall between curves shown. TIG and Stick Max. Stick Min. TIG Min. 230 VAC INPUT TIG and Stick Max.

  • Page 17: Selecting A Location

    2-7. Selecting A Location Welding Power Source Use shoulder strap to lift and move unit. Rating Label Label is located on side of unit. Use rating label to determine input pow- er needs. Y Special installation may be required where gasoline or volatile liquids are present –...

  • Page 18: Connecting To Weld Output Receptacles

    2-9. Connecting To Weld Output Receptacles Y Turn Off welder before mak- ing connections. Negative (–) Weld Output Receptacle Positive (+) Weld Output Receptacle Connectors For TIG Welding (Electrode Nega- tive), connect work cable connector to positive (+) receptacle and TIG Torch cable connector to negative (–) receptacle.

  • Page 19: Connecting Input Power

    2-12. Connecting Input Power Y The welder is shipped with a 115 VAC 20 amp input power cord installed. If unit is to be used on 230 VAC 20 amp in- put power, install new power cord according to Section 2-12.

  • Page 20: Selecting Extension Cord

    2-13. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) 350 (106) 225 (68) 137 (42) 100 (30) 400 (122) 250 (76) 150 (46) 100 (30) 62 (19) 400 (122)

  • Page 21: Installing 230 Volts Ac Input Power Cord

    2-14. Installing 230 Volts Ac Input Power Cord Tools Needed: Ref. ST-802 385 Y Disconnect input power plug from re- Loosen strain relief clamp, and push several Green Ground Lead ceptacle before installing different inches of power cord into unit. Insert new power cord through strain relief, input power cord.

  • Page 22: Remote Receptacle Information

    2-15. Remote Receptacle Information (For Lift-ArcE TIG Only) NOTE Remote control device has complete control of amperage at all times when connected to the remote receptacle. Socket* Socket Information +10 volts DC 0 to +10 volts DC input command signal from remote control. Remote control circuit common.

  • Page 23: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Front Panel Controls Weld output receptacles are energized when Power Switch is On and Input sup- ply power is connected and Ready Light Overtemperature Light Place the switch in the desired position to suit the application. This switch is NOT a This light comes On when the Power This light comes ON when the unit over- Polarity Switch.

  • Page 24: Lift-Arct Tig Procedure

    3-2. Lift-Arct TIG Procedure With Process Switch in the Lift-Arc TIG position, start an arc as follows: TIG Electrode Workpiece Touch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. An arc will form when electrode is lifted.

  • Page 25: Blowing Out Inside Of Unit

    4-2. Blowing Out Inside Of Unit Y Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. Ref. ST-802 385-A OM-2224 Page 21...

  • Page 26: Troubleshooting

    4-3. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch for circuit powering welder in On position. erative; Ready light Off. Check and replace line fuse(s), if necessary, or reset circuit breaker. Be sure input power cord is plugged in and that receptacle is receiving input power. No weld output;...

  • Page 27: Section 5 - Electrical Diagram

    SECTION 5 – ELECTRICAL DIAGRAM 203 617-A Figure 5-1. Circuit Diagram For Welding Power Source OM-2224 Page 23...

  • Page 28: Section 6 - Stick Welding (Smaw) Guidelines

    SECTION 6 – STICK WELDING (SMAW) GUIDELINES 6-1. Stick Welding Procedure Y Weld current starts when electrode touches work- piece. Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.
  • Page 29 6-2. Electrode and Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 6010 DEEP MIN. PREP, ROUGH 1/16 HIGH SPATTER 6011 DEEP 5/64 6013 EP,EN GENERAL 3/32 SMOOTH, EASY, 6013 7014 EP,EN FAST 5/32 3/16 LOW HYDROGEN, 7018 STRONG 7/32 FLAT SMOOTH, EASY,...
  • Page 30 6-5. Positioning Electrode Holder ° ° ° ° End View of Work Angle Side View of Electrode Angle GROOVE WELDS ° ° ° ° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 6-6. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding...
  • Page 31 6-8. Conditions That Affect Weld Bead Shape NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Correct Angle ° - ° Angle Too Large Angle Too Small Drag ELECTRODE ANGLE Spatter Normal Too Long Too Short...
  • Page 32 6-10. Butt Joints Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. Single V-Groove Weld °...
  • Page 33 6-13. Weld Test Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in (51-76 mm) 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) S-0057-B 6-14. Troubleshooting – Porosity Porosity –...
  • Page 34 6-16. Troubleshooting – Incomplete Fusion Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
  • Page 35 6-19. 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. 6-20. Troubleshooting – Waviness Of Bead Waviness Of Bead –...

  • Page 36: Section 7 - Selecting And Preparing Tungsten Electrode

    SECTION 7 – SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw 7/97 NOTE For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process. Wear clean gloves to prevent contamination of tungsten electrode. 7-1. Selecting Tungsten Electrode ♦...

  • Page 37: Preparing Tungsten For Dc Electrode Negative (Dcen) Welding

    7-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Tungsten Electrode Tapered End Grind end of tungsten on fine grit, hard abrasive wheel before weld- ing. Do not use wheel for other jobs or tungsten can become contami- nated causing lower weld quality. 2-1/2 Times Electrode Diameter Stable Arc...

  • Page 38: Section 8 - Guidelines For Tig Welding (Gtaw)

    SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW) 8-1. 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- tion) at the grinder or wear an approved respirator.

  • Page 39: Torch Movement During Welding

    8-2. Torch Movement During Welding Tungsten Without Filler Rod ° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod ° ° Welding direction Form pool Tilt torch Add filler metal Remove rod Move torch to front of pool.

  • Page 40: Positioning Torch Tungsten For Various Weld Joints

    8-3. Positioning Torch Tungsten For Various Weld Joints ° Butt Weld And Stringer Bead ° ° ° “T” Joint ° ° ° ° Lap Joint ° ° ° ° Corner Joint ° ° ST-162 003 / S-0792 OM-2224 Page 36...
  • Page 41 Notes OM-2224 Page 37...

  • Page 42: Section 9 - Parts List

    SECTION 9 – PARTS LIST Hardware is common and not available unless listed. ST-802 386-C Figure 9-1. Welding Power Source Components OM-2224 Page 38...
  • Page 43 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Welding Power Source Components ....203 990 LABEL, WARNING, general precautionary ..... . .
  • Page 44 OM-2224 Page 40...
  • Page 47 Effective January 1, 2001 (Equipment with a serial number preface of “LB” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...
  • Page 48 Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

Table of Contents