help with set up of Miller Maxstar 200

[Megadesertdiesel]

i just borrowed a miller maxstar 200 from work and want to try and weld with it. i am welding 1/8" to 3/16" mild steel. i have Argon. i also have afoot pedal, but not sure i need it.



what pressure should i run at the flowmeter?

volts?

amps?

process?

output?

positive ground?





any help would be great

 

[DValentine]

I am a welder but don't know everything. I think you need a mix of co2 and argon 75% argon 25% co2. You need to tell what size wire you are using . 035 is common. You don't need a foot peddle. MIG process is constant voltage... . that is to say you set voltage on the machine and wire speed. Your amps fluctuate. Try 22-24 volts.



HEY is this a stick machine? You threw me off with the flow meter. If it is stick you need to tell what size rod you are running? 3/32 65-80 amps, 1/8 115-130 amps. All this depends on which position you are running and thickness of material.



Dave

 

[Megadesertdiesel]

its a tig rig. i am using argon and 3/32" rod. i sure can melt the end of my tungsten, but thats all i can seem to do. too many buttons and variables for me to experiment with. i also have a Miller 175 which is a mig rig that i use the mix gas for.

 

[GHarman]

Hey Bud, you definitely need the foot pedal or hand control as a rheostat. The reason to are melting the tungsten is the amperage is set to high with no provision for adjustment. If you want to scratch start and go( this is not for beginners), you need to preset your amperage for your tungsten size, base metal joint geometry, filler rod and travel speed. Most weldors walk the cup on steel and stainless steel (pipe) where this method is used in the field. Got questions? Ask away. GregH

 

[JoeZimmerman]

Maxstar 200

I would recomend going to Miller Web site(Miller - Welding Equipment - MIG/TIG/Stick Welders & Plasma Cutting) and down load oweners manual for your exact model. I have a Maxstar 200 STR which is DC only. Other modes l have alot more adjustments. Also Miller has a Guide to GTAW(TIG) which will give you all the information you are looking for. Such as 3/16" lap joint would use a 3/32 electrode,1/8" filler rod,115-135 amps,Argon @ 20 CFH. DON'T FOR GET ELECTRONE NEGITIVE !!! Foot switch works well to control amperage.



Also get info on the tourch you have as the one I have is a air cooled and has max amps of 120 which limits me to some 3/16".



Another great site is Miller Motor Sports which will give you lots of info if you search (TIG)



Good Luck. Joe Z

 

[Bob4x4]

Hey Mike,You might want to pick up the weldors handbook I think thats the one I used years ago when i picked up my tig machine. If you think of the torch like a gas torch you will be on your way. The tungston should be ground (in the correct direction)to a sharp point for welding steel. You should have the pedal to get the best welds possible(the reason for tig in the first place).



Bob

 

[DValentine]

Greg thanks for chimin in... . I forgot to mention your name this morning as I was in a hurry. I didn't even think of TIG. HA



Mike you having any luck?

 

[Megadesertdiesel]

thanks everyone for the help. i am getting the hang of it and will post some pics later today.

 

[Steve St.Laurent]

Here's a link to Miller's TIG handbook - Miller - Education - TIG Handbook . If you look at chapter 6 ( http://www.millerwelds.com/education/TIGhandbook/pdf/TIGBook_Chpt6.pdf ) on page 52 you'll see their table for suggested settings for mild steel.

 

[GHarman]

Progress?

Megadesertdiesel, How's the TIG welding coming along? GregH

 

[evldsl]

its a tig rig. i am using argon and 3/32" rod. i sure can melt the end of my tungsten, but thats all i can seem to do. too many buttons and variables for me to experiment with. i also have a Miller 175 which is a mig rig that i use the mix gas for.

Sorry to say but if your tig welding your useing the tungston and thats the hardest steel out here so the only thing it's going to do is loose its sharpness not melt. Tungston doesnt melt and feed the weld pool only the mig or stick electrode will do that.

 

[evldsl]

i just borrowed a miller maxstar 200 from work and want to try and weld with it. i am welding 1/8" to 3/16" mild steel. i have Argon. i also have afoot pedal, but not sure i need it.



what pressure should i run at the flowmeter?

volts?

amps?

process?

output?

positive ground?





any help would be great

The job needs to be accomplished inside so the wind doesnt blow away the gas protecting the weld from oxidizing, this is a ac process that is the torch should be attached to the - and the work to the + side this will also be easer for a beginner to use, The flow meter on the work side pressure will be set at 10 psi and the volts should be set at max 85 ( I use a higher voltage around 115 incase I need more)you will control the voltage with the foot pedal. I would take a scribe and scribe a line on each side of the work piece so while you weld you can have a start - stop line and the weld will be neat instead of uneven, perhaps depending on the size of the work the lines should be 1/16 to 1/8 away from the edge on each side of the work edge. Remember tig is a pull the weld pool and then push the weld pool back and forth between the lines without stopping if possible for a good strong looking weld also keep a very sharp tungston rod the edge should look like a sharp pensil.

 

[Flinty]

When you sharpen your tungsten make sure you use a grinding wheel or disc that has not been used on anything else. I use an angle grinder with a 60 grit sanding disc and I grind the tungsten with the grain. Do not go against the grain. If you use a wheel that has been used on anything else it will contaminate your electrode. Once the tungsten is ground to a point I will then nick the point off to achieve about a 1/64th flat spot. (I won't do this if I'm welding something really thin)



Flow of current is electrode negative. Electrode positive will fry the point right off. (incidently, this is how you put the ball on the end of your electrode when welding aluminum).



Don't let the tip touch your work once the arc has been established. Your weld should be straw (yellowish) in color. If it's blue you have too much heat (turn down the initial setting or don't press on the foot pedal as much).



Make sure you have adequate post flow on your gas. When I finish a bead I'll bathe the last part in gas to keep the nice color.

 

[evldsl]

One other thing be sure you have a 10 shade minimum for your helmet the arc is very strong on the tig and it can give you a flash problem, if your eyes feel sandy and watery after welding you have flash burn and need more shade for your eyes also wear a dark shirt and dont have any reflection behind you due to flash into your helmet from the reflection behind you.

 

[Megadesertdiesel]

thanks for all of the help guys!!! i just finished my little project and now its off to bigger projects. here is a couple of pics of what i just finished.

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[Bob4x4]

An aero truss.

Bob

 

[Megadesertdiesel]

An aero truss.

Bob

yeah, less drag when doing 60+ in the dunes.