Maxstar140str (KK013519)

Maxstar 140 STR
With Auto-Link And

Remote Receptacle
R
R
Processes
Description
TIG (GTAW) Welding
Stick (SMAW) Welding
Arc Welding Power Source
TM-2224A February 2002
Eff. w/Serial Number KK013000
Visit our website at
www.MillerWelds.com
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS FOR SERVICING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Servicing Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. EMF Information 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 SPECIFICATIONS AND INSTALLATION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Description 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Included with Your Unit (Stick Only) 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Included with Your Unit (TIG / Stick) 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Duty Cycle And Overheating 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Volt-Ampere Curves 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Selecting A Location 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Typical Connection Methods 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Connecting To Weld Output Receptacles 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Connecting Remote Control To Remote Receptacle (For Lift-ArcE TIG Only) 8 . . . . . . . . . . . .
2-11. Rear Panel And Power Switch 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. Connecting Input Power 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14. Installing 230 Volts Ac Input Power Cord 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15. Remote Receptacle Information (For Lift-ArcE TIG Only) 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 OPERATION 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Front Panel Controls 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Lift-Arct TIG Procedure 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 HOW AN INVERTER WORKS 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 THEORY OF OPERATION 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 PRE-POWER CHECKLIST 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Checking Unit Before Applying Power 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Output Rectifier SR2 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Varistor 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Power Switch S1 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 EXPLANATION OF ELECTRICAL PARTS 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 TROUBLESHOOTING 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Troubleshooting 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Troubleshooting Circuit Diagram 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 MAINTENANCE 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Routine Maintenance 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Blowing Out Inside Of Unit 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Measuring Input Capacitor Voltage 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 ELECTRICAL DIAGRAM 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 STICK WELDING (SMAW) GUIDELINES 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 SELECTING AND PREPARING
TUNGSTEN ELECTRODE 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Selecting Tungsten Electrode 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2. Safety Information About Tungsten 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding 40 . . . . . . . . . . . . . . . . . . . . .
SECTION 13 GUIDELINES FOR TIG WELDING (GTAW) 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Positioning The Torch 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Torch Movement During Welding 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Positioning Torch Tungsten For Various Weld Joints 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 PARTS LIST 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
TM-2224 Page 1 Maxstar 140 STR
SECTION 1 SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
OM-2224F - 3/02, safety_stm 7/98
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
.Means Note; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Servicing Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard.
Y Only qualified persons should service, test, maintain, and re-
pair this unit.
Y During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from re-
ceptacle, or stop engine before servicing unless the procedure spe-
cifically requires an energized unit.
D Insulate yourself from ground by standing or working on dry insulat-
ing mats big enough to prevent contact with the ground.
D Do not leave live unit unattended.
D If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
D Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any parts.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
FIRE OR EXPLOSION hazard.
D Do not place unit on, over, or near combustible
surfaces.
D Do not service unit near flammables.
FLYING METAL can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on welding
gun or torch.
EXPLODING PARTS can cause injury.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
D Always wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
D Turn Off welding power source and wire feeder
or stop engine before making or changing me-
ter lead connections.
D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
D Read instructions for test equipment.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
MAGNETIC FIELDS can affect pacemak-
ers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
OVERUSE can cause OVER-
HEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
D Consult the Owners Manual for welding safety
precautions.
D Use only genuine replacement parts.
1-3. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 SPECIFICATIONS AND INSTALLATION
2-1. Specifications
Input
Power
Single-
Phase
AC
Rated Welding
Output
Welding
Amperage
Range
Maximum
Open-Circuit
Voltage DC
Amperes
Input At
Rated
Load Out-
put,
50/60Hz,
Single-
Phase
KVA
AT
100%
Duty
Cyc.
KW Dimensions Weight
115
Volts
80A @ 23.2 Volts
DC, 100% Duty
Cycle
5 110A 93V 31 3.5 2.24
H: 8 in (203 mm)
10 lb
230
Volts
100A @ 24 Volts
DC, 100% Duty
Cycle
5 140A 93V 23 5.3 2.76
W: 4-5/16 in (110 mm)
L: 12-1/4 in (311 mm)
10 lb
(4.5 kg)
2-2. Description
Ref. ST-802 385-A
1 Welding Power Source
This unit is a compact, light weight,
portable welding power source
containing the latest high perfor-
mance electronics that supplies DC
weld output for use with the Stick
Electrode and TIG welding pro-
cesses.
This unit also has a carrying strap
and quick-disconnect weld output
receptacles to aid portability and to
encourage use wherever the job
may be located. Because of its
electronic design, this unit con-
sumes only modest amounts of in-
put power and provides superb arc
characteristics. Further, it is easy
to install and simple to operate. This
welding power source is equipped
with the advanced Auto-Link cir-
cuitry which automatically adjusts
the unit to operate from the avail-
able input voltage without making
any internal changes. The circuitry
works with either 115 or 230 volts
input power.
1
2-3. Included with Your Unit (Stick Only)
1 Shoulder Strap (Carrying
Strap)
2 13 ft (4 m) Cable With
Electrode Holder and
Quick-Connect Plug
Work Clamp And
Quick-Connect Plug
4 6 ft (1.8 m) 115 VAC Input
Power Cord With 20 A Plug
.Some assembly is required.
For options and accessories,
contact your distributor.
1
2
3
4
Ref. ST-802 387-A
2-4. Included with Your Unit (TIG / Stick)
1 Shoulder Strap (Carrying
Strap)
2 12 ft (3.6 m) Gas Hose /
Coupler And Inert Gas
Regulator / Flowmeter
Work Clamp And
Quick-Connect Plug
4 12 ft (3.6 m) TIG Torch
With valve and
Quick-Connect Plug
Electrode Holder and
Quick-Connect Plug
6 6 ft (1.8 m) 115 VAC Input
Power Cord With 20 A Plug
.Some assembly is required.
For options and accessories,
contact your distributor.
1
2
3
4
ST-802 387A / ST-802 020
5
6
2-5. Duty Cycle And Overheating
193 116
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,
and the cooling fan runs. Wait fif-
teen minutes for unit to cool. Re-
duce amperage or voltage or duty
cycle before starting to weld again.
Y Exceeding duty cycle can
damage unit and void
warranty.
110 A @ 35% Duty Cycle (115 V Input)
Overheating
0
15
A or V
OR
Reduce Duty Cycle
Minutes
3-1/2 Minutes Welding 6-1/2 Minutes Resting
35% duty cycle for 115 vac
Continuous Welding
100%dutycycle
230 VAC
115 VAC
2-1/2 Minutes Welding 7-1/2 Minutes Resting
25% duty cycle for 230 vac
2-6. Volt-Ampere Curves
193 117-115V / 193 117-230V
Volt-ampere curves show minimum
and maximum voltage and amper-
age output capabilities of welding
power source. Curves of other set-
tings fall between curves shown.
115 VAC INPUT
230 VAC INPUT
TIG and Stick Max.
Stick Min.
TIG Min.
TIG and Stick Max.
Stick Min. TIG Min.
2-7. Selecting A Location
1 Welding Power Source
Use shoulder strap to lift and move
unit.
2 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
see NEC Article 511 or CEC
Section 20.
2
Airflow Distance
Requirements
18 in
(460 mm)
18 in
(460 mm)
ST-801 956-A / Ref. ST-802 385-A / 193 623-A
1
Y Do not move or operate unit
where it could tip.
ETP-1400-PDF
Y Turn Off welder before mak-
ing connections.
1 Stick Connections
2 TIG Connections
Obtain gas cylinder and proper TIG
torch from your distributor.
2
2-8. Typical Connection Methods
Typical TIG Connections
And Equipment
Typical Stick
Connections
1
Y Turn Off welder before mak-
ing connections.
1 Negative () Weld Output
Receptacle
2 Positive (+) Weld Output
Receptacle
3 Connectors
For TIG Welding (Electrode Nega-
tive), connect work cable connector
to positive (+) receptacle and TIG
Torch cable connector to negative
() receptacle.
For STICK Welding (Electrode
Positive), connect work cable con-
nector to negative () receptacle
and Electrode Holder cable con-
nector to positive (+) receptacle.
To connect to receptacle, align key-
way, insert connector, and turn
clockwise (approximately 1/2 turn).
.
Ref. ST-802 385-A
1
3
2-9. Connecting To Weld Output Receptacles
2
2-10. Connecting Remote Control To Remote Receptacle (For Lift-ArcE TIG Only)
ST-802 385-A
1 Remote Control Plug
To tighten, insert plug into recep-
tacle and turn collar clockwise 90.
.Connecting a remote control
automatically places the ma-
chine in Lift-Arc TIG regardless
of front panel setting.
1
2-11. Rear Panel And Power Switch
Ref. ST-802 385
1 Rear Panel
2 Power On/Off Switch
Rotate the Power Switch to the On
(l) or Off (0) position as needed ac-
cording to the markings on the rear
panel.
3 Input Power Cord
2
1
3
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.
1 Input Power Cord
2 115 or 230 VAC Grounded
Receptacle
.The Auto-Link circuitry in this
unit automatically links the
power source to the primary
voltage being applied, either
115 or 230 VAC.
An individual branch circuit capable
of carrying 30 amperes and pro-
tected by fuses or circuit breaker is
required. Recommended fuse or
circuit breaker size is 35 amperes.
Connect input power plug to proper
receptacle.
Ref. ST-802 385A
1
2-12. Connecting Input Power
2
1
2-13. Selecting Extension Cord (Use Shortest Cord Possible)
Conductor Size (AWG)*
Single Phase AC
Input Voltage
4 6 8 10 12 14
Input Voltage
Maximum Allowable Cord Length in ft (m)
115 160 (49) 107 (33) 71 (22) 47 (14) 29 (9) 19 (6)
230 471 (144) 321 (98) 215 (66) 146 (45) 90 (27) 59 (18)
*Conductor size is based on maximum 3% voltage drop
2-14. Installing 230 Volts Ac Input Power Cord
Y Disconnect input power plug from re-
ceptacle before installing different
input power cord.
Remove the case by removing the two top
handle screws and sliding case up and off.
Disconnect case grounding wire when re-
moving case.
1 Input Power Cord
Remove knob from Power Switch (4). Note
how knob goes onto shaft.
Remove screws holding Power Switch in
place, and pull switch out toward inside of
unit.
Loosen strain relief clamp, and push several
inches of power cord into unit.
Mark location of switch terminals where
black and white leads are connected, and
note location of ground lead. Disconnect
leads from ground terminal and switch.
2 Black Switch Lead
3 Rear Panel
4 Power Switch
Pull out power cord from rear of unit.
5 Case Grounding Lead
6 White Lead
7 Green Ground Lead
Insert new power cord through strain relief,
and push an extra inch into unit.
Connect ground lead and black and white
leads to marked locations. Double-check all
connections.
Reinstall Power Switch onto rear panel. Pull
power cord back through strain relief until
leads are properly dressed in unit. Tighten
clamp.
Reinstall case and reconnect case ground-
ing lead during assembly.
Ref. ST-802 385
5
4
6
2
1
3
7
Tools Needed:
2-15. Remote Receptacle Information (For Lift-ArcE TIG Only)
Remote control device has complete control of amperage at all times when
connected to the remote receptacle.
NOTE
Socket* Socket Information
1 N/A
2 N/A
3 +10 volts DC
4 0 to +10 volts DC input command signal from remote control.
5 Remote control circuit common.
ST-802 385-A
6 Remote enable. Closure to circuit common enables the remote
control and places the machine in Lift-Arct TIG (see Section
3-2).
*The remaining sockets are not used.
Note: Receptacle is not used to control contactor. Output is always on.
Note: Connecting a remote control automatically places the machine in Lift-Arc TIG regardless of front panel setting.
SECTION 3 OPERATION
3-1. Front Panel Controls
192 999-A
2
3
4
5
1
6
1 Ready Light
This light comes On when the Power
Switch on the rear panel is placed in the ON
(I) position. The light indicates that the unit
is energized and ready for welding opera-
tions.
.The fan motor is thermostatically
controlled and only runs when cooling
is needed.
2 Amperage Adjustment Control
This control adjusts the desired amperage
for the welding application. Use this control
to set the required value for the specific job
and electrode. The dial is calibrated in actu-
al amperes according to the input voltage
used to power the unit.
.The Amperage Adjustment Control is a
dual reading dial. Be sure to set it ac-
cording to the input voltage supplying
power to the unit.
3 Overtemperature Light
This light comes ON when the unit over-
heats. When this happens, the unit shuts
down and the fan motor runs. Once the unit
has cooled down, the output will come back
ON. Reduce the duty cycle or amperage
before starting to weld again. This light
flashes if the input voltage (primary) is too
low or if there is an input overcurrent fault.
4 Positive Weld Output Receptacle
Indicator
For STICK welding, connect the electrode
cable to this receptacle (normally uses re-
verse polarity connections, but always
check electrode recommendations.) For
TIG welding, connect work cable to this re-
ceptacle (normally uses straight polarity).
5 STICK / TIG Selector Switch
This switch provides a simple and easy
way to select the required welding process.
Place the switch in the desired position to
suit the application. This switch is NOT a
Polarity Switch. This switch activates the
Lift Arc (see Section 3-2) and Dig circuitry.
6 Negative Weld Output Receptacle
Indicator
For STICK welding, connect the work cable
to this receptacle (normally uses reverse
polarity connections, but always check
electrode recommendations.) For TIG
welding, connect torch cable to this recep-
tacle (normally uses straight polarity).
7 Remote Receptacle (For Lift-Arc TIG
Only)
Allows amperage to be controlled remotely.
Amperage may be adjusted from min to
max of unit output, regardless of where
front panel amperage control is set.
.Connecting a remote control automati-
cally places the machine in Lift-Arc TIG
regardless of front panel setting.
Weld output receptacles are
energized when Power
Switch is On and Input sup-
ply power is connected and
On.
7
3-2. Lift-Arct TIG Procedure
With Process Switch in the Lift-Arc
TIG position, start an arc as follows:
1 TIG Electrode
2 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.
Open-circuit voltage is present be-
fore tungsten electrode touches
workpiece. However, the arc will
not initiate until after the electrode is
lifted from workpiece. This allows
electrode to touch workpiece with-
out overheating, sticking, or getting
contaminated.
1
1 2
Seconds
Touch
Do NOT Strike Like A Match!
2
Ref. S-156 279
SECTION 4 HOW AN INVERTER WORKS
This welding power source uses inverter
technology. An inverter is a specific type of
power converter. Power converters change
electrical power from one form to another.
What is commonly called an inverter-type
welding power source is really three con-
verters in one. (See Figure) AC primary in-
put power is first converted to DC by the in-
put rectifier. The actual inverter section of
the power source converts DC back to AC.
And after the inverter section, the AC is con-
verted back to DC welding output power.
HOW DO INVERTERS WORK?
Instead of operating at common input power
frequency of 50 or 60 hertz (Hz), inverters
boost the frequency as much as 1000 times
that of input frequency. This allows for a
drastic reduction in the number of trans-
former coil turns, and reduced core area.
The inverter creates its own operating fre-
quency to drastically reduce the transform-
er size and to provide electrical advantages
to enhance weld performance. To do this
with electrical efficiency, the converting
must take place to raise the frequency and
ultimately provide the desired DC arc char-
acteristics.
This high operating frequency is the secret.
Because an inverter has the high operating
frequency, the duration of each cycle is
much shorter. Therefore, the amount of
power available in each cycle is drastically
reduced. With less power in each cycle, the
inverters output power can be controlled
much more precisely and also much quick-
er. The increased precision in output control
means that the best weld characteristics
can be obtained for various weld processes.
The ultra-fast, electrical circuitry response
provides smooth, clean, blast free arc initi-
ations and quick reactions to changes in the
weld puddle.
Inv 4/01
SECTION 5 THEORY OF OPERATION
1 Power Switch S1
Provides on/off control of welding
power source.
2 Fan Motor FM
Provides cooling of internal compo-
nents.
3 Main Control Board PC1
Provides electrical connections for
S1, PC1, PC10, PM1, L1 and L2. In-
put capacitors, precharge relay and
resistor, bleed resistors, various fil-
ter and snubber components, input
current transducer, inverter primary
current transformer, and switch-
mode power supplies for control
power are mounted on PC2.
4 Thermistor RT1
Protects output sink from overheat-
ing.
5 Thermistor RT2
Protects main transformer T1 from
overheating.
6 Front Assembly Board PC2
Controls output of machine, and
displays error message.
7 Main Transformer T1
Driven by MOSFETs in PM1. Sup-
plies power to weld output circuit.
8 Inductors L1 And L2
Filter switching noise from output of
T1.
9 Output Rectifier SR2
Rectifies main transformer T1 volt-
age.
10 Shunt
Monitors output current for regula-
tion.
11 Positive And Negative Weld
Output Receptacles
Provide weld output and allow
changing of output polarity.
Power
Switch
S1
Line Input
Power
1
Main Transformer
T1
Shunt
Single-Phase
Main Control Board PC1
9
O
u
t
p
u
t

C
u
r
r
e
n
t

F
e
e
d
b
a
c
k
O
u
t
p
u
t

V
o
l
t
a
g
e

F
e
e
d
b
a
c
k
Fan Motor
FM1
Inductor L1
Output Rectifier SR2
Negative
Weld Output
Receptacle
11
_
Weld Output
Receptacle
11
Positive
+
Thermistor
RT1
Thermistor
RT2
O
u
t
p
u
t

C
u
r
r
e
n
t

F
e
e
d
b
a
c
k
Inductor L1
F
i
l
t
e
r

S
i
g
n
a
l
F
i
l
t
e
r

S
i
g
n
a
l
O
u
t
p
u
t

V
o
l
t
a
g
e
F
e
e
d
b
a
c
k
3 2
4
5
7
8 8
10
Front Assy
Board PC2
6
SECTION 6 PRE-POWER CHECKLIST
6-1. Checking Unit Before Applying Power
.See Section 8-2 for test points and values and
Section 14 for parts location.
Y Discharge input capacitors according to Section 9-3 and be sure voltage is near zero before touching any parts.
Y Before troubleshooting or applying power to unit, complete following checks to avoid causing further damage.
6-2. Output Rectifier SR2
Ref. 802 931
Y Read and follow safety
information in Section 6-1
before proceeding.
1 Output Rectifier SR2
Visually inspect SR2 for discolor-
ation or signs of heat damage.
Isolate diode module for testing.
Check each diode anode to cath-
ode (diode test). Replace module if
necessary.
Forward Bias Testing
(Conducting)
= .200 to .900
Set meter for
Diode testing.
K
A
1
6-3. Varistor
before proceeding.
From component side of circuit
board, visually inspect varistor for
discoloration or signs of heat dam-
age.
1 Varistor Test Points
Check the resistance of varistor at
points indicated. Polarity is not im-
portant. Resistance should mea-
sure 650K ohms 10%. If resist-
ance is infinite, varistor was dam-
aged by an over-voltage condition.
1
Rear Of Unit
6-4. Power Switch S1
Ref 802 931
before proceeding.
1 Checking Resistance
Make sure unit is unplugged and
Power switch S1 is in the On posi-
tion. First check resistance across
terminals labeled A. Meter should
read near 0 ohms. Next, check re-
sistance across terminals labeled
B. Meter should read near 0 ohms.
Turn Power switch Off.
2 Checking Input Voltage
Plug unit in and turn Power switch
to the On position. Measure input
voltage across terminals labeled C.
Meter should read 115 or 230 VAC
depending upon input power.
Power Switch S1
A
A
B
B
1
2
C
C
SECTION 7 EXPLANATION OF ELECTRICAL PARTS
elect_parts 2/02
7-1. Safety Precautions Read Before Using This Guide
Y WARNING: ELECTRIC SHOCK can kill.
D Disconnect input power or stop engine before servicing.
D Do not touch live electrical parts.
D Do not operate machines with covers removed.
D Have only qualified persons install, use, or service equipment.
7-2. Explanation Of Electrical Parts
PART NAME FUNCTION PICTURE CIRCUIT SYMBOL
CAPACITOR A device that stores electrical energy. Large
capacitors or a bank of capacitors can be
used to smooth out the DC welding arc in a
MIG welding power source. Smaller disk
capacitors can be used for HF protection.
C1 C1
POLARIZED NON-POL.
CIRCUIT BREAKER A protection device that breaks a circuit when
current levels exceed its rating. Unlike a fuse
that needs to be replaced when blown, a
circuit breaker can be reset.
CB1
DIODE A device that allows current to flow in one
direction only. Most common use is to
change AC to DC.
D1
FUSE A protection device, usually an enclosed
piece of wire that melts and breaks the circuit
when the current exceeds the fuse rating.
F1
HALL DEVICE Produces a small DC voltage proportional to
the current it is sensing (usually welding
current). This feedback signal can be used to
regulate the welding output (line voltage
compensation). It may even be used to drive
an ammeter.
HD1
RESISTOR A device which resists the flow of electric
current. Uses include limiting the current for a
motor brake circuit in a wire feeder and for
discharging a capacitor.
FIXED
FIXED TAPPED
R1
R1
POTENTIOMETER
OR
RHEOSTAT
Both devices have a moveable brush that
makes contact along a resistor, allowing you
to easily change the resistance measured at
the brush (sometimes referred to as a wiper).
Their primary purpose is to give the operator
a way to adjust welding parameters such as
wire speed, preflow time, voltage,
inductance, etc.
VARIABLE R1
PART NAME CIRCUIT SYMBOL PICTURE FUNCTION
PILOT LIGHT A light located on the front panel which
indicates if the machine is on or off.
PL
1
FAN MOTOR This device provides cooling of the internal
parts of a welding power source.
FM
VARISTOR A protection device whose resistance is
dependent on the voltage applied to it. In
normal operation it has a high resistance;
however, a surge of voltage (voltage spike)
will cause its resistance to go way down and
absorb the spike. These devices are most
often found in rectifying circuits, where they
are used to protect the diodes.
VR1
GAS OR WATER
SOLENOID
(VALVE)
These are electromechanical devices used to
start or stop the flow of shielding gas or
water.
GS1
OR
WS1
RELAYCOIL AND
CONTACTS,
NORMALLY OPEN
AND NORMALLY
CLOSED
This is an electromechanical device whose
contacts change state (the normally open
points close and the normally closed points
open) when proper voltage is applied to the
coil. These contact points in turn may control
a fan motor, gas solenoid, contactor, etc.
Circuit diagrams (schematics) always show
the contact points in the power off state.
CR1 CR1
COIL
NRM OPEN
POINTS
NRM CLOSED
POINTS
THERMOSTAT,
NORMALLY OPEN
AND NORMALLY
CLOSED
This is a switch that closes its normally open
contacts (or opens its normally closed
contacts) when a preset temperature is
reached. When the temperature goes back
down, it will reset itself. Uses of these
devices include turning on a fan motor when
needed and shutting off the output of a
welding power source if it is overheating.
NRM OPEN NRM CLOSED
TP1 TP1
CONTACTOR A heavy duty relay. Usually used to make
and break the welding arc or primary power.
W
W
COIL
NRM OPEN
POINTS
STABILIZER/
REACTOR
When placed in a DC circuit, the inductor or
stabilizer as it is usually called, will oppose
any change in existing current. It is therefore
widely used to stabilize the welding arc.
When the inductor is placed in an AC circuit it
is referred to as a reactor where it now acts
to restrict the flow of current. A tapped
reactor is used to create current ranges for
welding.
Z1
L1
MOTOR A device that is typically used to feed wire in
a MIG welding system.
B1
SHUNT A precision low-value resistor typically used
to supply a small voltage to drive an
ammeter.
SHUNT
MOSFET A device that is used as an electronic
switch. When a signal is applied to the gate
(G), current is allowed to flow from the source
(S) to the drain (D). This device can be used
to control a relay, the speed of a motor, or
even the output of a welding machine.
D
G
AS
S
IGBT A device that is used as an electronic
switch. When a signal is applied to the gate
(G), current is allowed to flow from the emitter
(E) to the collector (C). This device is typically
used in Invertor designed welding machines
to control the welding output.
C1
G1 (B1)
E1
BRUSHES/SLIP
RINGS
Components that allow electrical connections
between stationary and rotating contacts.
SLIP
RINGS
BRUSHES
TERMINAL STRIP An insulated connection point for wires. They
are used for the ease of making multiple
connections and can be a convenient point
for making electrical checks when
troubleshooting. (Notice the jumper link
connecting terminals A and B together.)
A B C D E
1T
42 42 104 105 74
SWITCH A mechanical device that completes or
breaks the path of the current or sends it over
a different path.
SPDT SPST
DPDT DPST
SCR A Silicon Controlled Rectifier (SCR) is an
electrical device with three connections,
anode, cathode, and gate. It will allow current
to flow in only one direction and will only do
so after receiving a signal on the gate lead.
SCRs are used to change AC to DC and to
control the output to a load such as a welding
arc.
K
A
G
THERMISTOR A thermally sensitive resistor. The resistance
of a thermistor changes with a change in
temperature. Primarily used for Fan on
Demand and Thermal Shutdown circuits.
RT1
TH1
OR
TRANSFORMER A device that changes AC voltage from one
magnitude to another. Typically used to
reduce high primary voltages to lower
welding voltages.
T1
INTEGRATED
BRIDGE
RECTIFIER
An arrangement of four diodes used to
change AC to DC.
AC
AC
+
AC
AC
+
_
SPARK GAP The arrangement of two electrodes between
which a discharge of electricity will occur.
Typically used to produce high frequency
which can be used for arc starting when TIG
welding.
G
CURRENT
TRANSFORMER
A transformer that produces an AC voltage
used for measuring purposes. The primary
winding is in series with the circuit carrying
the current to be measured. Its main use in
engine-driven equipment is to activate the
Automatic Idle circuit by sensing welding
current or auxiliary power current.
CT1
OR
CT1
SECTION 8 TROUBLESHOOTING
8-1. Troubleshooting
Trouble Remedy
No weld output; unit completely inop-
erative; Ready light Off.
Place line disconnect switch for circuit powering welder in On position.
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.
Check continuity of Power switch S1 (see Sections 6-4 and , and replace if necessary.
Check resistance of varistor on circuit board PC1. Correct resistance is 650K ohms 10% (see Section
6-3).
No weld output; Ready light On; Over-
temperature light Off.
Check and secure loose weld cable(s) into receptacle(s) on welding power source.
Check and correct poor connection of work clamp to workpiece.
temperature light On.
Unit overheated causing thermal shutdown. Allow unit to cool with fan On (see Section 2-5).
Reduce duty cycle or amperage to prevent further overload conditions.
Check and correct blocked/poor airflow to and around unit or move unit clear of blockages (see Sec-
tion 2-7).
Check and clean dirty power module (see Section 9-2).
Check thermistor RT1, and replace if necessary (see Section 8-2).
Check fan motor FM, and replace if necessary (see Section 8-2).
temperature light Flashing.
Turn Power Switch Off and back On again. If light continues to flash, this condition may indicate a
fault in the power section.
Erratic or improper welding arc or
output.
Use proper size and type of weld cable (see your Distributor).
Clean and tighten all weld connections.
Check and reverse electrode polarity; check and correct poor connections to workpiece.
Fan not operating (unit is equipped with
Fan-On-Demand, so fan runs only
when needed).
Unit is cool and not warmed up enough to require fan cooling.
Check for and remove anything blocking fan movement.
Check fan motor and control circuitry.
Stick welding problems: Hard starts; Use proper type and size of electrode.
poor welding characteristics; unusual
spattering problems.
Use method shown in Section 11 to get better starts.
Make sure a remote control is not connected to the remote receptacle (see Section 2-10).
TIG welding problems: Wandering arc; Use proper type and size of tungsten.
hard starts; poor welding characteris-
tics; spattering problems.
Use properly prepared tungsten.
Trouble Remedy
TIG welding problems: Tungsten elec- Shield weld zone from drafts.
trode oxidizing and not remaining bright
after conclusion of weld.
Check shielding gas supply, and be sure it is the correct type (argon) and that the cylinder is not empty.
after conclusion of weld.
Check and tighten all gas fittings.
Check and change electrode polarity; move Changeover Switch to TIG position.
8-2. Troubleshooting Circuit Diagram
All voltage and resistance measurements
have a +10% tolerance unless specified.
9
5

V
D
C

M
a
x
1
0
K

o
h
m
s
+
1
5

V
D
C
203 617-A
1
1
5

o
r

2
3
0

V
A
C
SECTION 9 MAINTENANCE
9-1. Routine Maintenance
Y Disconnect power before maintaining.
.Maintain more often during severe conditions.
3 Months
Replace
unreadable
labels.
Clean and tighten
weld terminals. Replace Damaged
Gas Hose
3 Months
Repair Or Replace
Cracked Cables
And Cords
6 Months
Blow out inside. During
heavy service clean
monthly.
Y Do not remove case when
blowing out inside of unit
(see Section 9-2) .
9-2. 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
Y Significant DC voltage can
remain on capacitors after
unit is Off. Always check ca-
pacitors as shown to be sure
they have discharged before
working on unit.
Y Turn Off welding power
source and disconnect input
power.
Remove case.
1 Input Capacitors
2 Voltmeter
Check input capacitors as shown.
Measure the dc voltage across the
positive (+) and negative ()
terminals until voltage drops to near
0 (zero) volts.
Proceed with job inside unit.
Reinstall case when finished.
Tools Needed:
5/16 in
9-3. Measuring Input Capacitor Voltage
1
2
2
SECTION 10 ELECTRICAL DIAGRAM
.The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model Serial Or Style Number Circuit Diagram
Maxstar 140 KK013519 thru LB066290 193 705-C
Maxstar 140 STR LB066291 and following 203 617-A
193 705-C
Figure 10-1. Circuit Diagram For Maxstar 140 Prior To Serial Number LB066291
Figure 10-2. Circuit Diagram For Maxstar 140 STR Effective With Serial Number LB066291
203 617-A
SECTION 11 STICK WELDING (SMAW) GUIDELINES
11-1. Stick Welding Procedure
stick 12/96 ST-151 593
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.
1 Workpiece
Make sure workpiece is clean be-
fore welding.
2 Work Clamp
3 Electrode
A small diameter electrode requires
less current than a large one. Fol-
low electrode manufacturers
instructions when setting weld am-
perage (see Section 11-2).
4 Insulated Electrode Holder
5 Electrode Holder Position
6 Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.
7 Slag
Use a chipping hammer and wire
brush to remove slag. Remove slag
and check weld bead before mak-
ing another weld pass.
Tools Needed:
1
4
3
5
2
7
6
11-2. Electrode and Amperage Selection Chart
Ref. S-087 985-A
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
6010
&
6011
6013
7014
7018
7024
Ni-Cl
308L
5
0
1
0
0
1
5
0
2
0
0
2
5
0
3
0
0
3
5
0
4
0
0
4
5
0
E
L
E
C
T
R
O
D
E
D
C
*
A
C
P
O
S
I
T
I
O
N
P
E
N
E
T
R
A
T
I
O
N
U
S
A
G
E
MIN. PREP, ROUGH
HIGH SPATTER
GENERAL
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
SMOOTH, EASY,
FASTER
CAST IRON
STAINLESS
DEEP
DEEP
LOW
MED
LOW
LOW
LOW
LOW
ALL
ALL
ALL
ALL
ALL
FLAT
HORIZ
FILLET
ALL
ALL
EP
EP
EP,EN
EP,EN
EP
EP,EN
EP
EP
6010
6011
6013
7014
7018
7024
NI-CL
308L
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
E
L
E
C
T
R
O
D
E
A
M
P
E
R
A
G
E
R
A
N
G
E
D
I
A
M
E
T
E
R
11-3. Striking an Arc Scratch Start Technique
S-0049
1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted too
high. If electrode sticks to work-
piece, use a quick twist to free it.
1
2
3
11-4. Striking an Arc Tapping Technique
S-0050
1 Electrode
2 Workpiece
3 Arc
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
1
3
2
11-5. Positioning Electrode Holder
S-0060
90 90
10-30
45
45
GROOVE WELDS
FILLET WELDS
End View of Work Angle Side View of Electrode Angle
End View of Work Angle Side View of Electrode Angle
10-30
11-6. Poor Weld Bead Characteristics
S-0053-A
1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration
5
4 2 3
1
11-7. Good Weld Bead Characteristics
S-0052-B
1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
4 No Overlap
5 Good Penetration into Base
Metal
1
5 2 3 4
11-8. Conditions That Affect Weld Bead Shape
Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.
NOTE
S-0061
ELECTRODE ANGLE
ARC LENGTH
TRAVEL SPEED
Slow
Normal Fast
10 - 30
Drag
Too Short Normal Too Long
Spatter
Angle Too Small
Angle Too Large
Correct Angle
11-9. Electrode Movement During Welding
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads work better.
NOTE
S-0054-A
1 Stringer Bead Steady
Movement Along Seam
2 Weave Bead Side to Side
Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.
1 2
3
11-10. Butt Joints
S-0662
1 Tack Welds
Prevent edges of joint from drawing
together ahead of electrode by tack
welding the materials in position be-
fore final weld.
2 Square Groove Weld
Good for materials up to 3/16 in (5
mm) thick.
3 Single V-Groove Weld
Good for materials 3/16 3/8 in (5-9
mm) thick. Cut bevel with oxyacety-
lene or plasma cutting equipment.
Remove scale from material after
cutting. A grinder can also be used
to prepare bevels.
Create 30 degree angle of bevel on
materials in V-groove welding.
4 Double V-Groove Weld
Good for materials thicker than 3/8
in (9 mm).
30
2
1
1/16 in
(1.6 mm)
3
4
11-11. Lap Joint
S-0063 / S-0064
1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.
3 Multi-Layer Fillet Weld
Weld a second layer when a heavi-
er fillet is needed. Remove slag be-
fore making another weld pass.
Weld both sides of joint for maxi-
mum strength.
30
Or Less
Single-Layer Fillet Weld Multi-Layer Fillet Weld
30
Or Less
1 1
2 3
11-12. Tee Joint
S-0060 / S-0058-A / S-0061
1 Electrode
2 Fillet Weld
Keep arc short and move at definite
rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.
For maximum strength weld both
sides of upright section.
3 Multi-Layer Deposits
Weld a second layer when a heavi-
er fillet is needed. Use any of the
weaving patterns shown in Section
11-9. Remove slag before making
another weld pass.
45
Or Less
1
2
1
3
2
11-13. Weld Test
S-0057-B
1 Vise
2 Weld Joint
3 Hammer
Strike weld joint in direction shown.
A good weld bends over but does
not break.
2 To 3 in
1/4 in
3
2
1
2 To 3 in
3
2
1
(51-76 mm)
(6.4 mm)
(51-76 mm)
11-14. Troubleshooting Porosity
Porosity small cavities or holes resulting from gas
pockets in weld metal.
Possible Causes Corrective Actions
Arc length too long. Reduce arc length.
Damp electrode. Use dry electrode.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
11-15. Troubleshooting Excessive Spatter
Excessive Spatter scattering of molten metal particles
that cool to solid form near weld bead.
Amperage too high for electrode. Decrease amperage or select larger electrode.
Arc length too long or voltage too high. Reduce arc length or voltage.
11-16. Troubleshooting Incomplete Fusion
Incomplete Fusion failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
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.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
11-17. Troubleshooting Lack Of Penetration
Lack Of Penetration shallow fusion between weld metal and
base metal.
Lack of Penetration Good Penetration
Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique. Keep arc on leading edge of weld puddle.
Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
11-18. Troubleshooting Excessive Penetration
Good Penetration
Excessive Penetration weld metal melting through base metal and
hanging underneath weld.
Excessive Penetration
Excessive heat input. Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
11-19. Troubleshooting Burn-Through
Burn-Through weld metal melting completely through base metal resulting
in holes where no metal remains.
Excessive heat input. Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
11-20. Troubleshooting Waviness Of Bead
Waviness Of Bead weld metal that is not parallel and does not cover
joint formed by base metal.
Unsteady hand. Use two hands. Practice technique.
11-21. Troubleshooting Distortion
Distortion contraction of weld met-
al during welding that forces base
metal to move.
Base metal moves
in the direction of
the weld bead.
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.
SECTION 12 SELECTING AND PREPARING
TUNGSTEN ELECTRODE
gtaw 7/97
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.
NOTE
12-1. Selecting Tungsten Electrode
Amperage Range - Gas Type - Polarity
Electrode Diameter DC Argon Electrode Negative/Straight
Polarity
DC Argon Electrode Positive/Reverse
Polarity
2% Thorium Alloyed Tungsten (Red
Band)
.010 Up to 25 *
.020 15-40 *
.040 25-85 *
1/16 50-160 10-20
3/32 135-235 15-30
1/8 250-400 25-40
5/32 400-500 40-55
3/16 500-750 55-80
1/4 750-1000 80-125
Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour) 7 to 16.5 lpm (liters per minute).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
12-2. Safety Information About Tungsten
Ref. S-0161
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. Read
MSDS for safety information.
Consider using tungsten
containing ceria, lanthana,
or yttria instead of thoria.
Grinding dust from thoriated
electrodes contains low-lev-
el radioactive material.
Properly dispose of grinder
dust in an environmentally
safe way. Wear proper face,
hand, and body protection.
Keep flammables away.
1 Pointed Tungsten Electrode
2 Tungsten Electrode With
Balled End
2
1
12-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding
Ref. S-0161 / Ref. S-0162
1 Tungsten Electrode
2 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.
3
Ideal Tungsten Preparation Stable Arc
2-1/2 Times
Electrode Diameter
1
2
1 Stable Arc
2 Flat
Diameter of this flat determines
amperage capacity.
3 Grinding Wheel
4 Straight Ground
3
1
2
1 Arc Wander
2 Point
3 Grinding Wheel
4 Radial Ground
2
1
4
Wrong Tungsten Preparation Wandering Arc
4
SECTION 13 GUIDELINES FOR TIG WELDING (GTAW)
13-1. Positioning The Torch
Ref. ST-161 892
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. Read
MSDS for safety information.
Consider using tungsten
containing ceria, lanthana,
or yttria instead of thoria.
Grinding dust from thoriated
electrodes contains low-lev-
el radioactive material. Prop-
erly dispose of grinder dust
in an environmentally safe
way. Wear proper face, hand,
and body protection. Keep
flammables away.
1 Workpiece
Make sure workpiece is clean
before welding.
2 Work Clamp
Place as close to the weld as
possible.
3 Torch
4 Filler Rod (If Applicable)
5 Gas Cup
6 Tungsten Electrode
Select and prepare tungsten
according to Sections 12-1, and
12-2 or 12-3.
Guidelines:
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.
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.
1
1025
1015
6
2
3
4
90
4
5
3/16 in
1/16 in
6
5
Bottom View Of Gas Cup
13-2. Torch Movement During Welding
ST-162 002-B
Tungsten Without Filler Rod
Tungsten With Filler Rod
Form pool Tilt torch Move torch to front
of pool. Repeat process.
75
75
Welding direction
Form pool Tilt torch Add filler metal
Move torch to front
of pool. Repeat process.
Remove rod
Welding direction
15
13-3. Positioning Torch Tungsten For Various Weld Joints
ST-162 003 / S-0792
70
70
90
20
20
10
20
70
40
30
20
70
90
20
Butt Weld And Stringer Bead
T Joint
Lap Joint
Corner Joint
Notes
Visit our website at
www.MillerWelds.com
Processes
Description
TIG (GTAW) Welding
Stick (SMAW) Welding
TM-2224A February 2002
Eff. w/Serial Number KK013000
Maxstar 140 STR
With Auto-Link And
Remote Receptacle
R
SECTION 14 PARTS LIST
.Hardware is common and
not available unless listed.
ST-802 386-C
1
2
3
4
3
5
6
7
8
9
1
01
1
1
3
1
6
1
7
2
4
2
8
2
9
3
1
3
2
1
4
1
5
2
3
2
5
2
6
2
7
1
0

o
r

1
0
A
1
2
1
8
2
0
2
2
1
9
3
3
3
4
3
5
2
1
Figure 14-1. Welding Power Source Components
Description
Part
No.
Dia.
Mkgs.
Item
No. Quantity
Figure 14-1. Welding Power Source Components
1 203 990 LABEL, WARNING, general precautionary 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 +194 218 WRAPPER (order by serial number) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 S1 194 227 SWITCH, Input Power 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 +194 216 PANEL, REAR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 197 443 CABLE, INPUT, 115V, 20A 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 043 962 CABLE, INPUT, 230V, 20A (optional) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 190 028 LABEL, WARNING, electric shock hazard 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 FM1 194 226 FAN MOTOR ASSY 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 194 237 BRACKET, shield 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 194 235 BRACKET, transformer 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 PC1, PC2 194 225 CIRCUIT CARD ASSY, main (consisting of circuit cards PC1 and . . . . . . . . . . .
PC2, and heat sink) (Prior to LB066291) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 PC1 203 619 CIRCUIT CARD ASSY, main (consisting of circuit cards PC1 and . . . . . . . . . . . . . . . . .
heat sink (Eff w/LB066291) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10A PC2 203 621 CIRCUIT CARD ASSY, front (Eff w/LB066291) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 194 236 FAN MOTOR BRACKET 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 197 460 INSULATOR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 197 463 BUS BAR, transformer, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 Z1,Z2 194 234 TORROID, output filter 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 197 462 BUS BAR, transformer, bottom 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 T1 194 224 TRANSFORMER, main 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 RT2 197 459 THERMOSTAT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 SR2 185 940 DIODE FAST RECOVERY KIT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 197 461 CAP, rectifier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 RT1 194 219 THERMISTOR, assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 C1,C2 194 233 CAPACITORS, output filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 194 244 BUS BAR, flexible, positive output 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 194 215 PANEL, FRONT (Prior to LB066291) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 203 618 PANEL, FRONT (Eff w/LB066291) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 RC1,RC2 194 223 WELD OUTPUT RECEPTACLES 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 194 221 AMPERAGE ADJUSTMENT KNOB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 194 222 COVER, KNOB, BLUE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 192 999 NAMEPLATE (Prior to LB066291) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 203 620 NAMEPLATE (Eff w/LB066291) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 194 231 BUS BAR, negative output 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 R1 194 228 SHUNT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 194 217 BASE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 194 220 SHOULDER STRAP 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 197 457 ELECTRODE HOLDER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 197 456 WORK CABLE, w/clamp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
197 458 CONNECTOR, tw lk male (Dinse type) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 203 753 COVER (Eff w/LB066291) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
200 257 KIT, diode conversion 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
PRINTED IN USA 2002 Miller Electric Mfg. Co.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066

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