Miller Maxstar 200 SD Owner's Manual
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Miller Maxstar 200 SD Owner's Manual

Arc welding power source
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Maxstar 200 SD, DX, And LX
(Including Optional Cart And Cooler)
CE And Non-CE Models
OM-2226
189783AL
2010−04
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
115/230/400/460 Volt Models W/AutolineR
Arc Welding Power Source

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Do you have a question about the Maxstar 200 SD and is the answer not in the manual?

Questions and answers

Daniel Gaarcia
March 17, 2025

not getting 120 v output on miller Maxstar 200

0
1 comments:
Mr. Anderson
March 17, 2025

The Miller Maxstar 200 SD is not producing output because the operator interface is not functioning. The LCD screen does not display volts or amps, and a control relay on the PC2 power interconnect board is clicking. This suggests a possible issue with the power interconnect board, control circuit, or internal connections. Further troubleshooting of the power supply and control board is needed to determine the exact cause.

This answer is automatically generated

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Summary of Contents for Miller Maxstar 200 SD

  • Page 1 OM-2226 189783AL 2010−04 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description 115/230/400/460 Volt Models W/AutolineR Arc Welding Power Source Maxstar 200 SD, DX, And LX (Including Optional Cart And Cooler) 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 6 − ADVANCED FUNCTIONS ............6-1.

  • Page 5: Declaration Of Conformity

    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-2226 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 Panel−Local Welding (GTAW) Welding (SMAW) 3 Phase Static Frequency Volts Voltage Input Converter-Transformer-Rectifier Lift-Arc Start Voltage Output Circuit Breaker Remote (GTAW) Protective Earth Postflow Timer Preflow Timer Seconds (Ground) Positive Negative Alternating...

  • 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, Max. Welding 50/60Hz Open-Cir- Rated Peak Strik- Input Power Rated Output Amperage cuit Voltage ing Voltage (Up) Range (U0) 150 A @ 26 ∇ Three-Phase VDC, 13.1 1 − 200 -− 60% Duty 0.16* 0.24* 0.25*...

  • 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, a Help message is displayed (see Section 7-3), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, 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

    ( ) = mm for metric use ***Select weld cable size for pulsing application at peak amperage value. For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart) OM-2226 Page 19...

  • Page 26: Remote 14 Receptacle Information

    4-8. Remote 14 Receptacle Information Socket* Socket Information Contactor control +15 volts DC. 15 VOLTS DC C L N OUTPUT Contact closure to A completes 15 volts DC CONTACTOR contactor control circuit and enables output. Output to remote control; 0 to +10 volts DC output to remote control.

  • Page 27: Automation 10-Pin Connection (Lx Models)

    4-9. Automation 10-Pin Connection (LX Models) Socket Socket Information For 10-Pin Receptacle RC2 Start/Stop Output enable Chassis ground Final slope − collector Final slope − emitter Pulse lockout − collector Pulse lockout − emitter Ref. ST-802 458 Valid arc − collector Valid arc −...

  • Page 28: Gas Connections

    4-11. Gas Connections Gas Fitting Fittings have 5/8-18 right-hand threads (3/8-19 BSPP on CE units). Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. Regulator/Flowmeter Flow Adjust Typical flow rate is 15 cubic feet per hour (7.1 liters per minute).

  • Page 29: Stick Dcep (Direct Current Electrode Positive) Connections

    4-13. 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. Remote 14 Receptacle If desired, connect remote control to Remote 14 receptacle (see Sec-...

  • Page 30: Tigrunner Connections

    4-14. TIGRunner Connections Cart and cooler are optional equip- ment. Gas Cylinder Chains Secure gas cylinder to cart with chains. Connect gas hose to welding power source (see Section 4-11). Connect work lead and torch to welding power source (see Section 4-12).

  • Page 31: Electrical Service Guide

    4-15. Electrical Service Guide Actual input voltage should not fall below 103 volts AC or rise above 506 volts AC. If actual input voltage is outside this range, unit may not operate according to specifications. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

  • Page 32: Connecting Input Power

    4-16. 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 33 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 34: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls See Section 5-4. Adjust Controls For all front panel switch pad controls: press Voltmeter See Section 5-11. switch pad to turn on light and enable function. See Section 5-5. Power Switch Process Controls Use switch to turn unit On/Off. Green on nameplate indicates a TIG func- See Section 5-6.

  • Page 35: Encoder Control

    5-2. Encoder Control Encoder Control Use control in conjunction with ap- plicable front panel function switch pad to set values for that function. 5-3. Amperage Control A (Amperage Control) Encoder Control Ammeter See Section 5-13 for Amperage control range. Press Amperage switch pad and turn Encoder control to set weld amperage.

  • Page 36: Voltmeter

    5-5. Voltmeter Volt Meter Displays output or open circuit volt- age. If output is off, the voltmeter will display a series of three dashes (-−−). Open circuit voltage is dis- played if power is on and output is available. 5-6. Process Control Process Control Press switch pad until desired pro- cess LED is illuminated:...

  • Page 37: Lift-Arce And Hf Tig Start Procedures

    5-7. Lift-Arc™ And HF TIG Start Procedures Lift-Arc Start When Lift-Arct button light is On, start arc as follows: TIG Electrode Lift-Arc Start Method Workpiece Touch tungsten electrode to workpiece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control.

  • Page 38: Output Control

    5-8. Output Control Output Control controlled at the remote control, not at trigger input is functional (see Section the welding power source. 6-3B). Press switch pad until desired parameter LED is illuminated. If On/Off only type trigger is used, it This switch function can be reconfi- must be a maintained switch.

  • Page 39: Pulser Control (Dx And Lx Models)

    5-9. Pulser Control (DX And LX Models) Pulser Control Pulsing is available only while using the TIG process, it cannot be se- lected if the Stick process (see Sec- tion 5-6) is active. Controls can be ad- justed while welding. Press switch pad to enable pulser.

  • Page 40: Sequencer Controls (Dx Models Only)

    5-10. Sequencer Controls (DX Models Only) Sequencer Control Sequencing is available only while using the TIG process, but is dis- abled if a remote foot or finger cur- rent control is connected to the Re- mote receptacle while in the RMT STD mode.

  • Page 41: Adjust Controls (Preflow/Post Flow/Dig/Purge)

    5-11. Adjust Controls (Preflow/Post Flow/DIG/Purge) Adjust Press switch pad until desired function LED is illuminated. Encoder Control Ammeter Turn encoder (see Section 5-2) to set ap- propriate value for active Adjust parame- ter. Value selected is shown on the am- meter (see Section 5-4).

  • Page 42: Spot Time Control (Reconfigured Rmt 2T Hold Output Selection)

    5-12. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) Spot Time Meter Display Select Spot function according to Section 6-3G. Amperage Switch Pad Encoder Control Set spot parameters as follows: Press Amperage switch pad once (meter A LED turns on) and turn En- coder to set spot amperage.

  • Page 43: Resetting Unit To Factory Default Settings (All Models)

    ADJUST *PREFLOW 0.2 S 0.0 − 25.0 Seconds POST FLOW 10.0 S 0.0 − 50.0 Seconds @ 0.2 Second Resolution 0 − 100 Percent MAXSTAR: *Tungsten .094 GEN, .020, .040, .062, .094, .125 ***Amperage 1 − 200 Amps ***Time 1 − 200 Milliseconds ***Start Slope Time 0 −...

  • Page 44: Arc Timer/Counter Display

    5-15. Arc Timer/Counter Display Rear Panel Output And Amperage Controls Arc Timer Display Arc Counter Upon power up as described above, the After 5 seconds, the meter A LED turns on, Power Switch meter S LED will turn on, and arc time will and the arc counter will be displayed for the To display the arc timer/counter, turn power be displayed for 5 seconds as [000 000 ] to...

  • Page 45: Section 6 − Advanced Functions

    SECTION 6 − ADVANCED FUNCTIONS 6-1. Accessing Advanced Functions Amperage Switch Pad starts for different tungstens. is turned off in an attempt to save the rod for reuse. Adjust • Output Remote Hold And Trigger Func- • Lockout Functions (see Section 6-7) − Encoder Control tions (see Section 6-3) −...

  • Page 46: Programmable Tig Start Parameters

    6-2. Programmable TIG Start Parameters Tungsten Selection Current (A) Preset Amperage Minimum Start Time Start Slope Time Amperage Switch Pad Preset TIG Start Parameters perage, Start Time, Start Slope Time, and Preset Amperage Minimum. If it is neces- Use Encoder control to select a tungsten Encoder Control sary or desired to manually set the TIG size from the following: .020, .040, .062...
  • Page 47 Selecting GEN Encoder Control Amps Meter Amperage Switch Pad If [GEn] is selected and displayed on the amps meter, the TIG starting parameters for a .094 tungsten are the default: Start Amperage = 60 A, Start Time = 1 ms, Start Slope Time = 40 ms, Preset Minimum Amps = 3 A.
  • Page 48 Changing Programmable TIG Start Amperage Current (A) Start Amperage Amperage Switch Pad To adjust TIG Start Amperage proceed as the amps meter, and can be adjusted (see follows: Section 5-13) by turning the Encoder con- trol. Encoder Control Press Amperage switch pad. Switch pad LED turns on, and meter A LED turns on.
  • Page 49 Changing Start Slope Time Current (A) Start Slope Time Amperage Switch Pad To adjust Start Slope Time proceed as fol- seconds on the amps meter, and can be ad- lows: justed (see Section 5-13) by turning the Encoder control. Encoder Control Press Amperage switch pad.

  • Page 50: Output Control And Trigger Functions

    6-3. Output Control And Trigger Functions A. Remote (Standard) Torch Trigger Operation Current (A) Main Amps Initial Slope Final Slope Initial Amps Final Amps Postflow Preflow P & H Maintained Switch Foot Or Finger Remote Control P&H = Push trigger and hold R = Release trigger.
  • Page 51 3T Specific Trigger Method = 3T Current (A) Remote Trigger Operation Preflow Initial Amps /Initial Slope Main Amps Final Slope /Final Amps Postflow * Arc can be extinguished at any time by pressing and releasing both initial and final switches, or by lifting the torch and breaking the arc. 3T (Specific Trigger Operation) Operation: C.
  • Page 52 D. 4T Specific Trigger Method 4T (Specific Trigger Operation) Encoder Control To select 4T, turn Encoder control. Torch trigger operation is as shown. 4T allows the operator to toggle between weld current and final current. When a remote switch is connected to the welding power source, use the remote switch to control the weld cycle.
  • Page 53 F. 4T Momentary Operation 4T Momentary Meter Display Encoder Control To select 4T Momentary, turn Encoder control. 4T Momentary torch trigger operation is as shown. When a remote switch is connected to the welding pow- er source, use the remote switch to control the weld cycle.
  • Page 54 G. Spot Control Operation Spot Function Meter Display While in Spot Control, Se- quencer settings will be ig- nored and will not be program- mable. When a remote switch is con- nected to the welding power source, use the remote switch to control the weld cycle.
  • Page 55 H. On Trigger Operation Voltage (V) 2 Sec Current (A) Stick Touch Stick Lift Stick Electrode Electrode Current (A) Lift Main Amperage Initial Slope Initial Amperage Touch Current Touch Tungsten Lift Tungsten Lift Tungsten Slightly OM-2226 Page 49...

  • Page 56: Setting Preflow Time

    6-4. Setting Preflow Time Encoder Control Turn encoder to select from 0 to 25 seconds of preflow. The value selected is displayed on the am- meter. Application: Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting.

  • Page 57: Lockout Functions

    6-7. Lockout Functions A. Accessing Lockout Capability Toggle Select Lockout Level 1, 2, 3, or 4 Toggle Select Code Number 1 to 999 See Section 5 for explanation of controls referred to in all of thru [999]. IMPORTANT: remember this code number, as you will Section 6-7.
  • Page 58 B. Lockout Levels Levels 1, 2, And 3 Use Encoder Control To Adjust Amperage ±10% Of Preset Value. Indicates which functions are available for the corresponding lockout level. Level 4 C L N ited by lock level 1, [LOCK][LEV1] is dis- limits of the machine.

  • Page 59: Setting Unit To Display Ppp While Pulse Welding (Dx Models Only)

    6-8. Setting Unit To Display PPP While Pulse Welding (DX Models Only) Encoder Control PPP Meter Display Turn Encoder to change between standard [PPP] meter display. When the [PPP] meter display feature is active while pulse weld- ing, the [PPP] will be displayed on the right meter display, and the Meter Hold feature is disabled.

  • Page 60: Section 7 − Maintenance And Troubleshooting

    SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. A. Welding Power Source n = Check Z = Change ~ = Clean Δ = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months nl Labels...

  • Page 61: Blowing Out Inside Of Unit

    7-2. Blowing Out Inside Of Unit Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. ST-802 451 OM-2226 Page 55...

  • Page 62: Voltmeter/Ammeter Help Displays

    7-3. Voltmeter/Ammeter Help Displays Help 3 Display Help 9 Display All directions are in reference to the Indicates a short in the thermal protection front of the unit. All circuitry referred to Indicates the bottom heat sink has over- is located inside the unit. circuitry located on the top heat sink.

  • Page 63: Troubleshooting

    7-4. Troubleshooting Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Section 4-16). inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-16). Check for proper input power connections (see Section 4-16). No weld output;...
  • Page 64 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-2226 Page 58...

  • Page 65: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram 237 566-B OM-2226 Page 59...

  • Page 66: Section 9 − High Frequency (Hf)

    SECTION 9 − HIGH FREQUENCY (HF) 9-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Work 9-2. Correct Installation Weld Zone 50 ft 50 ft (15 m) (15 m) Ground All...

  • Page 67: Section 10 − Setup Guides For (Gtaw) Tig Welding

    SECTION 10 − SETUP GUIDES FOR (GTAW) TIG WELDING 10-1. DC - GTAW 16 Gauge Stainless Steel Set-Up Ammeter Encoder 207 690-A This symbol indicates which functions should be active for stainless steel. • Turn power on (switch located on rear panel) •...

  • Page 68: Section 11 − Selecting And Preparing A Tungsten For Dc Or Ac Welding With Inverter Machines

    SECTION 11 − 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. 11-1. Selecting Tungsten Electrode ( Wear Clean gloves To Prevent Contamination Of Tungsten ♦...

  • Page 69: Section 12 − Guidelines For Tig Welding (Gtaw)

    SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW) 12-1. 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 70: Torch Movement During Welding

    12-2. 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 71: Section 13 − Setup Guide For (Smaw) Stick Welding

    SECTION 13 − SETUP GUIDE FOR (SMAW) STICK WELDING 13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) Front Panel Correct front panel display for basic Stick DCEP welding. For all front panel switch pad controls: press switch pad to turn on light and enable function.

  • Page 72: Stick Welding Procedure

    SECTION 14 − STICK WELDING (SMAW) GUIDELINES 14-1. 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 73: Electrode And Amperage Selection Chart

    14-2. 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 74: Positioning Electrode Holder

    14-4. Positioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle ° ° ° ° Groove Welds ° ° ° ° Fillet Welds S-0060 14-5. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S-0053-A...

  • Page 75: Conditions That Affect Weld Bead Shape

    14-7. 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 76: Lap Joint

    14-9. 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 77: Weld Test

    14-12. 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 14-13. Troubleshooting Porosity −...
  • Page 78 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 79 Notes OM-2226 Page 73...

  • Page 80: Section 15 − Parts List

    SECTION 15 − PARTS LIST Hardware is common and not available unless listed. 35 6 Figure 15-1. Main Assembly 803 227-G OM-2226 Page 74...
  • Page 81 Item Dia. Part Mkgs. Description Quantity Figure 15-1. Main Assembly ....Fig15-2 ..Panel, Front W/Cmpnt ......... . .
  • Page 82 244024 ..Membrane, Switch Control Maxstar 200 SD ......... .
  • Page 83 Hardware is common and not available unless listed. Ref. 199 492-C Figure 15-3.Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 15-3. Panel, Rear w/Components (Figure 15-1 Item 2) ....194242 .
  • Page 84 Hardware is common and not available unless listed. 805 153-A Figure 15-4. Magnetics Assembly w/Components Item Dia. Part Mkgs. Description Quantity Figure 15-4. Magnetics Assembly w/Components (Figure 15-1 Item 3) ....195649 .
  • Page 85 Item Dia. Part Mkgs. Description Quantity Figure 15-4. Magnetics Assembly w/Components (Figure 15-1 Item 3) (Continued) ....199538 ..Grommet, Scr No 8/10 Panel Hole .281 Sq .250 High .
  • Page 86 Hardware is common and not available unless listed. Ref. 199 494-F Figure 15-5. Windtunnel w/Components Item Dia. Part Mkgs. Description Quantity Figure 15-5. Windtunnel w/Components (Figure 15-1 Item 4) ....195645 .
  • Page 87 Hardware is common and not available unless listed. 199 497-H Figure 15-6. Heat Sink, Secondary Assembly Item Dia. Part Mkgs. Description Quantity Figure 15-6. Heat Sink, Secondary Assembly (Figure 15-5 Item 7) ....210783 .
  • Page 88 Hardware is common and not available unless listed. 199 493-B Figure 15-7. Base Assembly Item Dia. Part Mkgs. Description Quantity Figure 15-7. Base Assembly (Figure 15-1 Item 5) ....195644 .
  • Page 89 Notes OM-2226 Page 83...

  • Page 90: Section 16 − Cooler Parts List

    SECTION 16 − COOLER PARTS LIST Hardware is common and not available unless listed. 805 266-A Figure 16-1. Main Assembly OM-2226 Page 84...
  • Page 91 ..........Nameplate, Miller Coolmate 1 (Order By Model And Serial Number) ..

  • Page 92: Section 17 − Cart Parts List

    SECTION 17 − CART PARTS LIST Hardware is common and not available unless listed. Item 4 can be mounted in alternative position if desired. 805 337-B Figure 17-1. Cart Main Assembly Item Dia. Part Mkgs. Description Quantity Figure 17-1. Cart Main Assembly .
  • Page 93 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 94: Options And Accessories

    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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Maxstar 200 dxMaxstar 200 lx

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