Miller Maxstar 200 STR Owner's Manual
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Miller Maxstar 200 STR Owner's Manual

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Maxstar 200 STR
CE And Non-CE Models
OM-2233
2010−07
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
115/230/400/460 Volt Models W/AutolineR
Arc Welding Power Source
R
203 409Z

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  • Page 1 OM-2233 203 409Z 2010−07 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description 115/230/400/460 Volt Models W/AutolineR Arc Welding Power Source Maxstar 200 STR CE And Non-CE Models 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 4 TABLE OF CONTENTS SECTION 10 − STICK WELDING (SMAW) GUIDELINES ......... . . SECTION 11 −...
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
  • Page 6 Notes...

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 8 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. 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 10: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 12 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, elle peut exploser.

  • Page 14: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité...

  • Page 15: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 16 OM-2233 Page 10...

  • Page 17: Section 3 − Definitions (Ce Models)

    SECTION 3 − DEFINITIONS (CE Models) 3-1. Warning Label Definitions Warning! Watch Out! There are possible Breathing welding fumes can be 3.3 Do not weld on drums or any closed hazards as shown by the symbols. hazardous to your health. containers.

  • Page 18: Weee Label (For Products Sold Within The Eu)

    Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors.

  • Page 19: Symbols And Definitions

    3-3. Symbols And Definitions Gas Tungsten Arc Shielded Metal Arc Amperes High Temperature Welding (GTAW) Welding (SMAW) 3 Phase Static Frequency Volts Voltage Input Converter-Transformer-Rectifier Lift-Arc Start Percent Arc Force (DIG) Remote (GTAW) Protective Earth Alternating Rated Welding Seconds (Ground) Current Current Positive...

  • Page 20: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Important Information Regarding CE Products (Sold Within The EU) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 21: Specifications

    4-3. Specifications Amperes Input At Rated Output, 50/60Hz Welding Max. Input Power Rated Output Amperage Open-Circuit Range Voltage ∇ Three-Phase 150 A @ 26 VDC, 13.1 1 − 200 -− 60% Duty Cycle 0.16* 0.24* 0.25* 0.06* 0.03* Stick Process ♦...

  • Page 22: Volt-Ampere Curves

    4-4. Volt-Ampere Curves 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. 1 1 5 V A C I n p u t Stick Max TIG Max Stick/TIG Min DIG Max...

  • Page 23: Duty Cycle And Overheating

    4-5. 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, and cooling fan runs. Wait fifteen min- utes for unit to cool. Reduce amper- age or duty cycle before welding.

  • Page 24: Selecting A Location

    4-6. Selecting A Location Line Disconnect Device Locate unit near correct input power supply. Dimensions And Weight Special installation may be 34.7 lb (15.7 kg) - without power cord required where gasoline or 37.3 lb (16.9 kg) - with power cord volatile liquids are present −...

  • Page 25: Weld Output Terminals And Selecting Cable Sizes

    4-7. Weld Output Terminals And Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 26: Remote 14 Receptacle Information

    4-8. Remote 14 Receptacle Information Socket* Socket Information C L N Output to remote control; 0 to +10 volts DC output to remote control. Remote control circuit common. REMOTE OUTPUT CONTROL 0 to +10 volts DC input command signal from remote control.

  • Page 27: Stick Dcep (Direct Current Electrode Positive) Connections

    4-10. Stick DCEP (Direct Current Electrode Positive) Connections Turn off power before mak- ing connections. Negative (−) Weld Output Terminal Connect work lead to negative weld output terminal. Positive (+) Weld Output Terminal Connect electrode holder to posi- tive weld output terminal. Ref.

  • Page 28: Connecting Input Power

    4-12. Connecting Input Power A. Connecting Three-Phase Input Power Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input conductors from unit. = GND/PE Earth Ground Always connect green or green/ yellow conductor...
  • Page 29 B. Connecting Single-Phase Input Power Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Always connect green or green/ yellow conductor supply grounding terminal first, and never...

  • Page 30: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls A. Non CE Units See Section 5-5. Power On/Troubleshooting Help Aids Green on nameplate indicates a TIG Light function, Gray indicates a Stick DIG Control function. See Section 6-3. See Section 5-6. Process Controls Power Switch High Temperature Shutdown Light See Section 5-2.
  • Page 31 B. For CE Units See Section 5-5. Power On/Troubleshooting Help Aids Green on nameplate indicates a TIG Light function, Gray indicates a Stick DIG Control See Section 6-3. function. See Section 5-6. Process Controls Power Switch High Temperature Shutdown Light See Section 5-2.

  • Page 32: Process Control

    5-2. Process Control Process Control CE Model Rotate knob up to select the Stick process. Rotate knob down to se- lect the TIG Lift Arc process. Stick (SMAW) - This is a DCEP (di- rect current electrode positive) pro- cess. Make connections according to Section 4-10.

  • Page 33: Stick Start Procedure − Scratch Start Technique

    5-4. Stick Start Procedure − Scratch Start Technique With Stick selected, start arc as follows: Electrode Workpiece Drag electrode across workpiece like strik- ing a match; lift electrode slightly after touch- ing work. If arc goes out electrode was lifted to high.

  • Page 34: Section 6 − Maintenance And Troubleshooting

    SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. n = Check Z = Change ~ = Clean Δ = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months nl Labels...

  • Page 35: Troubleshooting Help Aids

    6-3. Troubleshooting Help Aids stays on. fan to cool it (see Section 4-5). Operation All directions are in reference to the will continue when the unit has cooled. front of the unit. All circuitry referred to Help 0 Display is located inside the unit. Help 4 Display Indicates a short in the thermal protection Output LED...

  • Page 36: Troubleshooting

    6-4. Troubleshooting Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 4-12). inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-12). Check for proper input power connections (see Section 4-12). No weld output;...
  • Page 37 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-2233 Page 31...

  • Page 38: Section 7 − Electrical Diagrams

    SECTION 7 − ELECTRICAL DIAGRAMS Figure 7-1. Circuit Diagram 237 568-C OM-2233 Page 32...

  • Page 39: Section 8 − Selecting And Preparing A Tungsten For Dc Or Ac Welding With Inverter Machines

    SECTION 8 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2010-04 Whenever possible and practical, use DC weld output instead of AC weld output. 8-1. Selecting Tungsten Electrode ( Wear Clean gloves To Prevent Contamination Of Tungsten ♦...

  • Page 40: Section 9 − Guidelines For Tig Welding (Gtaw)

    SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW) 9-1. Positioning The Torch Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information.

  • Page 41: Torch Movement During Welding

    9-2. 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 42 Notes OM-2233 Page 36...
  • Page 43 SECTION 10 − STICK WELDING (SMAW) GUIDELINES 10-1. Stick Welding Procedure Weld current starts when electrode touches work- piece. Equipment Needed: Tools Needed: 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 44 10-2. Electrode and Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG 3/32 FLAT SMOOTH, EASY, 7024 EP,EN HORIZ...
  • Page 45 10-4. Positioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle ° ° ° ° Groove Welds ° ° ° ° Fillet Welds S-0060 10-5. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S-0053-A...
  • Page 46 10-7. Conditions That Affect Weld Bead Shape Weld bead shape is affected electrode angle, length, travel speed, and thickness of base metal. Correct Angle ° - Angle Too Large ° Angle Too Small Electrode Angle Drag Spatter Arc Length Normal Too Long Too Short Travel Speed...
  • Page 47 10-9. Groove (Butt) Joints Tack Welds Prevent edges of joint from draw- ing together ahead of electrode by tack welding the materials in posi- tion before final weld. Square Groove Weld Good for materials up to 3/16 in. (5 mm) thick. Single V-Groove Weld Good for materials 3/16 −...
  • Page 48 10-12. 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 10-13. Troubleshooting Porosity −...
  • Page 49 Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions 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.
  • Page 50 SECTION 11 − PARTS LIST Hardware is common and not available unless listed. Figure 11-1. Main Assembly 803 107-G OM-2233 Page 44...
  • Page 51 199478 ..Label, Miller 6.000 X 2.500 Horizontal ......
  • Page 52 202323 ..Nameplate, Miller Maxstar 200STR .......
  • Page 53 Hardware is common and not available unless listed. 202 397-E Figure 11-3.Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 11-3. Panel, Rear w/Components (Figure 11-1 Item 2) ....194242 .
  • Page 54 Hardware is common and not available unless listed. 805 303-B Figure 11-4. Magnetics Assembly w/Components Item Dia. Part Mkgs. Description Quantity Figure 11-4. Magnetics Assembly w/Components (Figure 11-1 Item 3) ....195649 .
  • Page 55 Item Dia. Part Mkgs. Description Quantity Figure 11-4. Magnetics Assembly w/Components (Figure 11-1 Item 3) (Continued) ....213208 ..Connector, Faston Male 1/4 Ring W/75deg Bend .
  • Page 56 Hardware is common and not available unless listed. 199 494-F Figure 11-5. Windtunnel w/Components Item Dia. Part Mkgs. Description Quantity Figure 11-5. Windtunnel w/Components (Figure 11-1 Item 4) ....195645 .
  • Page 57 Hardware is common and not available unless listed. 199 497-H Figure 11-6. Heat Sink, Secondary Assembly Item Dia. Part Mkgs. Description Quantity Figure 11-6. Heat Sink, Secondary Assembly (Figure 11-5 Item 7) ....210783 .
  • Page 58 Hardware is common and not available unless listed. 199 493-B Figure 11-7. Base Assembly Item Dia. Part Mkgs. Description Quantity Figure 11-7. Base Assembly (Figure 11-1 Item 5) ....195644 .
  • Page 59 Effective January 1, 2010 (Equipment with a serial number preface of MA or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • Page 60 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2010 Miller Electric Mfg. Co. 2010−01...

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