TIG Buyer s Guide MillerWelds.com
Table Of Contents Whether you weld professionally or as a hobby, buying new or upgrading, Miller has a TIG welder to meet your needs. This buyer s guide will help you find the machine that s right for you. Why TIG? 4 Which TIG Welder is Right for You? 5 Why AC? 6 Key TIG Terms 7 DC TIG Maxstar 15 Series 8 Maxstar 2 STR and CST 28 9 Maxstar 2 SD and DX 1 Maxstar 35 and 7 11 Selection Chart 12 AC/DC TIG Diversion 165 14 Syncrowave 2 15 Dynasty 2 SD and DX 16 Syncrowave 25 DX and 35 LX 17 Dynasty 35 and 7 18 Torches and Accessories 19 3
Why TIG? Which TIG Welder is Right for You? TIG can weld a variety of metals, including steel, stainless steel, chrome-moly, titanium, aluminum, copper, brass and more. Other benefits of the TIG welding process include: No spatter, flux or slag On the fly amperage control Flexibility Welds more metal types than any other process Ability to weld thin and thick material High-quality welds and highly aesthetic weld beads What is TIG? A TIG welder maintains an electric arc between a tungsten electrode and the workpiece. The arc and molten puddle are shielded from the atmosphere by an inert gas (typically argon), thus the name TIG (Tungsten Inert Gas) or Gas Tungsten Arc Welding (GTAW). Because the electrode is not consumed in the welding process, as it is in MIG or Stick welding, filler metal is manually added as needed. To precisely control the welding current (heat input), operators use a remote foot pedal or fingertip control. While Miller offers several choices of TIG welders, finding the right one for you is as simple as answering a few questions. 1. What types of metal will you be welding? If you ll be welding all types of metal except aluminum, a DC only machine, such as Miller Maxstar welder will work for you. If you plan on welding aluminum, you ll need a TIG welder with AC output. Miller s Dynasty, Syncrowave and Diversion 165 TIG welders all have AC/DC output for welding any type of metal. 2. What thicknesses will you be welding? Your answer to this question will determine the power output you need. See the chart on pages 12/13 to determine which machine fits the thickness of materials you ll be working with. 3. Will you also Stick weld? Many Miller TIG units can also Stick weld. To find the capabilities of each unit, see the chart on pages 12/13. 4. Where are you going to weld? Consider the surroundings you plan to use your new TIG welder. What primary power is available? Are there any size restrictions you will encounter? Do you plan to move your machine often? See chart on pages 12/13 for all product details. Typical Water-Cooled TIG Setup Work Clamp Remote Control Shielding Gas Regulator/ Flowmeter Gas In Work Cable Torch Gas Out Gas Valve Adapter Block Coolant In Coolant Out Power Source Coolant System Power Cord Coolant System Power Icon and Capability Descriptions Type of weld output the unit supplies constant current. Type of weld output the unit supplies direct current, or both alternating and direct currents. Type of input power the unit can use single-phase, three-phase or both. Personal User, Light,, Heavy : The class of the machine based on such factors as output, duty cycle and intended use. TIG, Pulsed TIG, Stick, Air Carbon Arc: The process capabilities of the unit. Workpiece 4 5
Why AC? Key TIG Terms AC TIG is generally used to weld aluminum and magnesium materials. These metals instantly form oxides when exposed to air. Before the parts can be welded, the oxide must be removed. While it can be cleaned manually, the oxide will quickly form again. Alternating current aids in removing this oxide layer by cleaning the weld puddle. Feature Waveform Effect on Bead Effect on Appearance AC Balance Control Controls arc cleaning action. Adjusting the balance controls the width of the etching zone surrounding the weld. EN = Electrode Negative EP = Electrode Positive AC Frequency Control Controls the width of the arc cone. Increasing the AC Frequency provides a more focused arc with increased directional control. EN = Electrode Negative EP = Electrode Positive Amperage Amperage Amperage Amperage 51 99% EN % EN % EN % EP % EP Time (1 AC Cycle) 3 5% EN Time (1 AC Cycle) 6 Cycles per Second % EN 12 Cycles per Second % EN % EP % EP Time (1 AC Cycle) % EN % EP Time (1 AC Cycle) Reduces balling action and helps maintain point Deep, narrow penetration Increases balling action of the electrode Shallow penetration Wider bead, good penetration ideal for buildup work Narrower bead for fillet welds and automated applications Narrow bead, with no visible cleaning Bead No Visible Cleaning Wider bead and cleaning action Cleaning Wider bead and cleaning action Cleaning Narrower bead and cleaning action Cleaning AC Waveform Selectionthe shape, balance, and frequency of the waveforms will impact the weld bead s characteristics. Amps (+) ( ) Advanced Squarewave Fast transitions for responsive and dynamic arc. Time (1 AC Cycle) Amps (+) ( ) Bead Bead Bead Soft Squarewave All the benefits of advanced square, fine tuned to provide a smooth, soft arc with maximum puddle control and good wetting action. Time (1 AC Cycle) AC balance controls the amount of oxide cleaning (amperage time in Electrode Negative versus Electrode Positive) which is essential for high-quality aluminum welds. See page 6 for details. Alternating current (AC)an electrical current that reverses its direction at regular intervals. AC frequencycontrols the width of the arc cone. See page 6 for details. Auto-Line allows for any primary input voltage within a range, single- or three-phase with no manual linking, providing convenience in any job setting. Direct current (DC)flows in one direction and does not reverse its direction of flow as does alternating current. Duty cyclethe duty cycle of a welding power source is the amount of time you can weld at a given output without overheating the power source. Duty cycle is based upon a 1-minute period of time. For example, if a machine is rated at 3 amps at 6% duty cycle, it can weld at 3 amps for six minutes. For the remaining four minutes, the power source needs to idle and cool. Fan-On-Demand internal power source cooling system only works when needed, keeping internal components cleaner. High frequency (HF) arc starting provides non-contact arc starting that eliminates tungsten or material contamination. Lift-Arc provides arc starting without the use of high frequency. Line voltage compensation (LVC )maintains constant output, even if input voltage varies by +/- 1%. Pulsingswitching between a high and low amperage for additional control of heat input. Amps (+) ( ) Sine Wave Triangular Wave Square Unconventional wave provides transitions (+) the punch of the peak eliminate amperage, while reducing the need for overall heat input. Quick puddle continuous HF, formation reduces weld time while the sine ( ) limiting heat input and Time (1 AC Cycle) wave peaks Time (1 AC Cycle) reducing weld distortion, soften the arc. especially on thin materials. Four different AC waveforms to optimize the arc characteristic for your application. Amps 6 7
DC TIG Maxstar 15 Series Light DC TIG Maxstar 2 STR/CST 28 DC TIG (GTAW) Pulsed DC TIG (GTAW-P) with STH model DC Stick (SMAW) STH TIG/Stick Package with remote fingertip control and protective case shown Maxstar 15 is a DC TIG/Stick inverter designed with maximum portability in mind. Weighing only 13.7 lb, the unit can easily be carried by its shoulder strap, while its small size (9 x 5-1/2 x 13-1/4 inch) makes for easy storage, either in the shop or in its optional carrying case. All three models feature: Miller s exclusive MVP multi-voltage plug which allows connection to 115 or 23 V receptacles without tools Auto-Line power management technology LVC line voltage compensation S (Stick) model provides the most compact Stick package in the industry. STL (Stick, TIG, Lift-Arc ) model features Lift-Arc technology for arc starting without high frequency. STH (Stick, TIG, High Frequency) model features HF starting and Lift-Arc. In addition, the STH model features built-in pulsing with a selection of four preset pulse frequencies. Protective case, Weldcraft torch, fingertip remote control Weight: 13.7 lb 9 x 5-1/2 x 13-1/4 in Output: 15 A at 3% duty cycle 115 V, 23 V Steel Min..2 in (.5 mm) Steel Max. 3/16 in (4.8 mm) Maxstar 2 STR CST 28 DC Stick (SMAW) DC TIG (GTAW) Maxstar 2 STR and CST 28 have been optimized to provide excellent performance for the construction and pipe welding industries. Features: Superior Stick arc performance on all input voltages, even on the difficult-to-run electrodes like E61 Simple-to-use operator interface providing only the necessary controls in a compact machine Auto-Line power management technology (only available on Maxstar 2 STR) Adaptive Hot Start to automatically increase output amperage at start of Stick weld to prevent electrode from sticking Low OCV Stick to reduce open-circuit voltage to 9 14 VDC when power source is not in use, eliminating the need for add-on voltage reducers Optional accessories available Weldcraft torch, foot pedal or fingertip remote control Maxstar 2 STR Weight: 32 lb 13-1/2 x 7-1/2 x 17-1/2 in Stick Output: 175 A at 6% duty cycle TIG Output: 15 A at 6% duty cycle CST 28 Weight: 41 lb 13-1/2 x 7-1/2 x 18 in Stick/TIG Output: 28 A at 31.2 V, 35% duty cycle 2 A at 28 V, 1% duty cycle Maxstar 2 STR: 12 46 V CST 28: 22-23 V/46-575 V for Amps Input at Rated Load Output) Maxstar 2 STR Steel Min..4 in (.1 mm) CST 28 Steel Min..2 in (.5 mm) Maxstar 2 STR Steel Max. 1/4 in (6.4 mm) CST 28 Steel Max. 3/8 in (9.5 mm) 8 9
DC TIG Maxstar 2 SD and DX, Heavy DC TIG Maxstar 35 and 7 Heavy DC TIG (GTAW) Pulsed DC TIG (GTAW-P) with DX model DC Stick (SMAW) Maxstar 2s are designed to work either alone or as part of a complete water-cooled package. Their exceptionally smooth and precise arc allows for welding on common and exotic metals from 1/4 inch all the way down to.4 inch. Both models include all features of Maxstar 2 STR plus: Blue Lightning high frequency arc starting technology. Preset parameters for tungsten sizes from.2- to 1/8-inch eliminate operator guesswork. Lift-Arc technology Auto-Line power management technology SD model provides the basic features required for most DC TIG or Stick welding applications. DX model features fully adjustable Pulsed DC TIG as well as process sequence programming. Optional water-cooled Complete Packages include 2-wheel cart, Coolmate 1 cooler, Weldcraft torch and foot pedal or fingertip control. Wheel the complete package around the shop or for more portability, detach the 37-lb welder and take it anywhere (requires air-cooled torch). Weight: 37 lb 13-1/2 x 7-1/2 x 17-1/2 in Output: 175 A at 6% duty cycle 12 46 V for Amps Input at Rated Load Output) DX shown with optional water-cooled Complete Package Running gear, Coolmate cooler, Weldcraft torch, foot pedal or fingertip remote control Steel Min..4 in (.1 mm) Steel Max. 1/4 in (6.4 mm) Maxstar 35 Maxstar 7 Maxstar 35 and 7 are designed for heavy industrial use. The Maxstar 35 can weld up to 5/8-inch steel, while the 7 can weld up to 1-inch steel. Both models feature: Lift-Arc technology High frequency arc starting Program memory that can store up to 9 program memories to store parameters Auto-Line power management technology Fan-On-Demand Optional water-cooled Complete Package for 35 model includes Runner cart, Coolmate 3.5 cooler, Weldcraft torch and foot pedal or fingertip control. Maxstar 35 Weight: 135 lb 24-3/4 x 13-3/4 x 22 in Output: 25 A at 1% duty cycle (3-phase) Maxstar 7 Weight: 198 lb 34-1/2 x 13-3/4 x 22 in Output: 5 A at 1% duty cycle (3-phase) 28 575 V DC TIG (GTAW) Pulsed DC TIG (GTAW-P) DC Stick (SMAW) Runner cart, Coolmate cooler, Weldcraft torch, foot pedal or fingertip remote control Maxstar 35/7 Steel Min..2 in (.5 mm) Maxstar 35 Steel Max. 5/8 in (15.9 mm) Maxstar 7 Steel Max. 1 in (25.4 mm) 1 11
Selection Chart Power Source Welding Performance Maxstar 15 DC only (All metals except aluminum) Maxstar 2 Maxstar 35 Maxstar 7 Diversion 165 Syncrowave 2 Dynasty 2 AC/DC (All weldable metals) Syncrowave 25 DX Syncrowave 35 LX Dynasty 35 Dynasty 7 Output Min. Max. (Amps) 5 15 A 1 2 A 5 35 A 5 7 A 1 165 A 5 2 A 5 2 A (AC) 1 2 A (DC) 3 31 A 3 4 A 5 35 A 5 7 A DC TIG Material Thickness Min. Max. (Mild Steel, Stainless Steel, and Exotic Metals).2.4.2 5/8".2 1".25.2.4.12 1/2".12 5/8".2 5/8".2 1" AC TIG Material Thickness Min. Max. (Aluminum and Magnesium).3.2.2.15 3/8".15 1/2".2 5/8".2 1" Stick Max. Electrode Diameter E61 611 E613 E718 E724 3/32" 7/32" Stick Process Quality E61 611 E613 E718 E724 Good* Good Good Air Carbon Arc Max. Electrode Diameter 3/8" 3/8" Features Balance Control AC Frequency Pulse Capability Generator Power Requirement STH only 5 kw DX only 5.5 kw 12 kw 32 kw 5.5 kw 12.5 kw DX only 8.5 kw Optional 22 kw 3 kw 13 kw 35 kw *For best results choose 611. 12 13
AC/DC TIG Diversion 165 Personal User Process AC/DC TIG (GTAW) Shown with optional Runner Package AC/DC TIG Syncrowave 2 Light, AC/DC TIG (GTAW) Pulsed TIG (GTAW-P) Stick (SMAW) The Diversion 165 was designed to allow easy entry into the world of TIG. Its easy-to-understand interface allows the user to simply select the material type and thickness and start welding. Haven t TIG welded before? No problem. The Diversion 165 comes with a set-up and operation DVD and TIG Welding for Dummies book to get you started. Features: Easy-to-understand interface select the material type and thickness and start welding High frequency arc starting Advanced Squarewave Light weight (5 lb) for easy portability Fan-On-Demand Comes with: TIG Welding for Dummies, written by Miller Set-up and operation DVD Blueprint project for machine cart/cylinder rack Weldcraft LS17 TIG torch with remote fingertip control Regulator and gas hose Work clamp and lead Optional accessories available Running gear/cylinder rack, foot pedal remote control Syncrowave 2 s Squarewave output with AC balance control provides adjustable penetration and cleaning action while increasing arc stability on aluminum. The Syncrowave 2 also features: Syncro Start to allow the operator to select Soft, Standard or Hot TIG High Frequency starts for optimal performance based on application AC stabilization for AC TIG welding Built-in Pulse control enhances weld bead and puddle control for improved appearance and quality Dual digital meters for quick and easy viewing 12 V receptacle for cooling system or small tools Cable management system with dual cable handles and convenient foot pedal storage Fan-On-Demand Comes with: Remote foot pedal Weldcraft WP17 torch Stick electrode holder and lead Regulator and gas hose Work clamp and lead Optional accessories available Running gear, Coolmate 1 cooler Weight: 5 lb 17 x 9-7/8 x 23-7/8 in Output: 15 A at 2% duty cycle 23 V Aluminum Min..3 in (.75 mm) Steel Min..25 in (.6 mm) Aluminum Max. 3/16 in (4.8 mm) Steel Max. 3/16 in (4.8 mm) Weight: 238 lb 3-1/8 x 21-1/8 x 21-1/2 in Output: 15 A at 4% duty cycle 28-23 V, 46 V, 575 V Aluminum Min..2 in (.5 mm) Steel Min..2 in (.5 mm) Aluminum Max. 1/4 in (6.4 mm) Steel Max. 1/4 in (6.4 mm) 14 15
AC/DC TIG Dynasty 2 SD and DX, Heavy AC/DC TIG (GTAW) Pulsed TIG (GTAW-P) with DX model Stick (SMAW) DX shown with optional water-cooled Complete Package AC/DC TIG Syncrowave 25 DX and 35 LX Heavy AC/DC TIG (GTAW) Pulsed TIG (GTAW-P) optional on 25 DX, standard on 35 LX Stick (SMAW) SD machine only Dynasty 2 provides advanced waveforms, including Advanced Squarewave, Soft Squarewave, Sine Wave and Triangular Wave (see page 6), as well as: Extended AC balance (3 99%) AC frequency (2 25 hz) Lift-Arc technology for arc starting without the use of high frequency (AC/DC) Blue Lightning high frequency arc starting technology. Preset parameters for tungsten sizes from.2- to 1/8-inch eliminate operator guesswork. Auto-Line power management technology DC TIG features: Exceptionally smooth and precise arc for welding exotic materials Built-in high-speed Pulse control enhances weld bead and puddle control for improved appearance and quality Cart, Coolmate 1 cooler, Weldcraft torch, foot pedal or fingertip remote control Weight: 45 lb 13-1/2 x 7-1/2 x 21-1/2 in Output: 15 A at 6% duty cycle 12 46 V Aluminum Min..2 in (.5 mm) Steel Min..4 in (.1 mm) Aluminum Max. 1/4 in (6.4 mm) Steel Max. 1/4 in (6.4 mm) 16 25 DX machine only Syncrowave 25 DX and 35 LX feature Squarewave output with AC balance control to provide adjustable penetration and cleaning action while increasing arc stability on aluminum. The Syncrowave 25 DX and 35 LX provide all of the features on the Syncrowave 2, plus: Built-in Pulse control (optional on the 25 DX and standard on the 35 LX) Lift-Arc technology for arc starting without the use of high frequency (DC only) High frequency arc starting and stabilization for AC TIG welding Last procedure recall which recalls the last procedure setup when switching polarity LVC line voltage compensation Syncrowave 25 DX Weight: 378 lb 36-1/4 x 22-1/2 x 25 in Output: 25 A at 4% duty cycle Syncrowave 35 LX Weight: 496 lb 36-1/4 x 22-1/2 x 25 in Output: 35 A at 4% duty cycle 2 V, 23 V, 46 V, 575 V 17 35 LX shown with optional water-cooled Complete Package Running gear, Coolmate cooler, Weldcraft torch, foot pedal or fingertip remote control Syncrowave 25 DX/35 LX Aluminum Min..15 in (.4 mm) Steel Min..12 in (.3 mm) Syncrowave 25 DX Aluminum Max. 3/8 in (9.5 mm) Steel Max. 1/2 in (12.7 mm) Syncrowave 35 LX Aluminum Max. 1/2 in (12.7 mm) Steel Max. 5/8 in (15.9 mm)
AC/DC TIG Dynasty 35 and 7 Torches and Accessories Heavy AC/DC TIG (GTAW) Pulsed TIG (GTAW-P) Stick (SMAW) 35 machine only Dynasty 35 and 7 provide advanced waveforms, including Advanced Squarewave, Soft Squarewave, Sine Wave and Triangular Wave (see page 6), as well as: Independent amplitude/amperage control to allow EP and EN amperages to be set independently, precisely controlling heat input to the work and electrode Extended AC balance (3 99%) AC frequency (2 4 hz) DC TIG features: Exceptionally smooth and precise arc for welding exotic materials High-speed DC TIG Pulse control capable of pulsing 5 pulses per second for arc stability, reduced heat input increased travel speeds Dynasty 35 Weight: 135 lb 24-3/4 x 13-3/4 x 22 in Output: 25 A at 1% duty cycle (3-phase) Dynasty 7 Weight: 198 lb 34-1/2 x 13-3/4 x 22 in Output: 5 A at 1% duty cycle (3-phase) 28 575 V Dynasty 35/7 Aluminum Min..2 in (.5 mm) Steel Min..2 in (.5 mm) Dynasty 35 Aluminum Max. 5/8 in (15.9 mm) Steel Max. 5/8 in (15.9 mm) Dynasty 7 Aluminum Max. 1 in (25.4 mm) Steel Max. 1 in (25.4 mm) 18 7 shown with optional water-cooled Complete Package Runner cart, Coolmate cooler, Weldcraft torch, foot pedal or fingertip remote control Weldcraft torches Miller recommends Weldcraft brand TIG torchesevery Weldcraft torch is specifically engineered and assembled with the finest materials. Both air- and water-cooled torches are available. See Weldcraft.com for more information. Foot pedal and fingertip control Remote control capabilities usually include output and current control. The foot pedal control operates like a gas pedal in a car; the more it is pressed, the more current that flows. Another type which delivers more mobility is the fingertip control that mounts on the torch. Coolmate coolers Miller offers Coolmate coolers for water-cooled TIG torches. See MillerWelds.com for more information. Running gear Miller offers running gear for the larger or water-cooled systems, to allow them to be easily wheeled around the shop. Other accessories available: Protective covers Remote foot pedals and fingertip controls Torch accessory kits Contractor kits Complete packages include: Running gear Coolmate cooler Coolant Weldcraft torch Torch accessory kit Gas regulator and more 19
See Miller s TIG Resources at MillerWelds.com/TIG Improve your TIG Skills View TIG Articles Join Discussion Forums Welding Discussions Motorsports Welding Projects Get Project Plans Share in Discussion Forums View Idea Gallery For detailed specification sheets or to locate your nearest Miller distributor, call: 1-8-4-A-MILLER (1-8-426-4553) MillerWelds.com 28 Miller Electric Mfg Co.