Miller Electric Maxstar 200 STR manual

Visit our website at www.MillerWelds.com Pro cesses Descrip ti on TIG (GT A W) Welding Stick (SMAW ) Welding OM -2233 203 409Q 2007 − 04 1 15/230/400/460 V olt Models W/Autoline  Arc Welding Power Source Maxstar 200 STR  And Non-CE Models[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

T ABLE OF CONTENTS SECTION 10 − STICK WELDING (SMA W) GUIDELINES 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. Stick W elding Procedure 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2. Electrode and Amperage Selec[...]

dec_stat_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W . Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r .l. Phon[...]

Notes[...]

OM-2233 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special safety m[...]

OM-2233 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin.  Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching [...]

OM-2233 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard.  Do not install or place unit on, over , or near combustible surfaces.  Do not install unit near flammables.  Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this un[...]

OM-2233 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A WS F[...]

OM-2233 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som _3/05  A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les util isés Sy mbole graphique d’av ertis s ement ! At tention ! Cette pro - cédur e c omport e d es risques pos[...]

OM-2233 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la peau.[...]

OM-2233 Page 7 2-3 . Da ngers supplémenta ires en r e lation ave c l’instal lation, le fonctionnement et l a maintenanc e Risque D’INCENDIE OU D’EXPLO- SION.  Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables.  Ne pas installer l’appareil à proximité de produits inflammables.  Ne pas surcharger[...]

OM-2233 Page 8 2-5. Princi pales nor mes de sécuri té Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W eldin[...]

OM-2233 Page 9 SECTION 3 − DEFINITIONS (CE Models) 3-1. W arning Label Definitions W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from [...]

OM-2233 Page 10 W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from wiring can kill. 2 Disconnect input plug or power before working on machine. 3 Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. 4 Always wait 60 seconds after power is turned o[...]

OM-2233 Page 1 1 3-3. Manufacturer ’ s Rating Label 195 646-B  See Section 4-4 for location.  Use rating label to de- termine input power requirements. S S 40% 60% 100% 150 175 200 16 17 18 X 2 U I 2 EN 60974 − 1 1A 10V 50/60 Hz 50/60 Hz 100% 125 25 26 150 60% 40% 175 27 U 80V o 1A 20V 80V o U 35 25 17 31 eff max II 11 IP23 1 1 f1 f2 11 1[...]

OM-2233 Page 12 SECTION 4 − INST ALLA TION 4-1. Specifications Input Power Rated Output W elding Amperage Max. Open-Circuit Amperes Input At Rated Output, 50/60Hz KV A KW I nput P ower R ate d O utput Amperage Range O pen- C ircuit V oltage 11 5 230 400 460 KV A KW Three-Phase Stick Process 150 A @ 26 VDC, 60% Duty Cycle 1 − 200 80 ∇ 9-14 ♦[...]

OM-2233 Page 13 4-2. V olt-Ampere Curves 189 767-A V olt-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. 115V AC Input 0 20 40 60 80 100 120 140 0 50 1 0 0 150 2 00 25 0 Ampe re s Vo lt s O t her I nput Vo l t ag e s 0 20 40 60 80 100 12[...]

OM-2233 Page 14 4-3. Duty Cycle And Overheating 189 770-A Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, output stops, an d cooling fan runs. Wait fifteen min- utes for unit to cool. Reduce amper- age or duty cycle before welding.  Exceeding duty cycle can damage unit and void wa[...]

OM-2233 Page 15 4-4. Selecting A Location 1 Identification Plate 2 Rating Label 3 Line Disconnect Device Locate unit near correct input power supply .  Special installation may be required where gasoline or volatile liquids are present − see NEC Article 51 1 or CEC Section 20. Location And Airflow 3 1 18 in (460 mm) 18 in (460 mm) 802 886-A 2 [...]

OM-2233 Page 16 4-5. W eld Output T erminals And Selecting Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in W eld Circuit Not Exceeding 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals  T urn off power before connecting to weld out- put terminal[...]

OM-2233 Page 17 4-7. TIG Lift-Arc DCEN (Direct Current Electrode Negative) Connections Ref. 802 888-A  T urn off power before mak- ing connections. 1 Positive (+) Weld Output T erminal Connect work lead to positive weld output terminal. 2 Negative ( − ) W eld Output T erminal Connect TIG torch to negative weld output terminal. 3 Gas Cylinder 4[...]

OM-2233 Page 18 4-8. Stick DCEP (Direct Current Electrode Positive) Connections Ref. 802 888-A  T urn off power before mak- ing connections. 1 Negative ( − ) W eld Output T erminal Connect work lead to negative weld output terminal. 2 Positive (+) Weld Output T erminal Connect electrode holder to posi- tive weld output terminal. 1 2 4-9. Elect[...]

OM-2233 Page 19 4-10. Connecting Input Power 2/04 - Ref. 802 136-A  Installation must meet all National an d 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 to supply grounding te[...]

OM-2233 Page 20 B. Connecting Single-Phase Input Power 2/04 - Ref. 802 136-A  Installation must meet all National an d 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 to supply gr[...]

OM-2233 Page 21 SECTION 5 − OPERA TION 5-1. Controls A. Non CE Units 202 323-B / 802 889 1 2 4 6 NOTE: Green on nameplate indicates a TIG function, Gray indicates a Stick function. 1 Process Controls See Section 5-2. 2 Amperage Control See Section 5-5. 3 DIG Control See Section 5-6. 4 High T emperature Shutdown Light See Section 4-3. 5 Power On/T[...]

OM-2233 Page 22 B. For CE Units 202 722-A / 802 889 6 NOTE: Green on nameplate indicates a TIG function, Gray indicates a Stick function. 1 Process Controls See Section 5-2. 2 Amperage Control See Section 5-5. 3 DIG Control See Section 5-6. 4 High T emperature Shutdown Light See Section 4-3. 5 Power On/Troubleshooting Help Aids Light See Section 6-[...]

OM-2233 Page 23 5-2. Process Control 1 Process Control Rotate knob up to select the Stick process. Rotate knob down to se- lect the TIG Lift Arc process. Stick (SMA W ) - This is a DCEP (di- rect current electrode positive) pro- cess. Make connections according to Section 4-8. TI G Lift-Arc  - This is a DCEN (di- rect current electrode negative)[...]

OM-2233 Page 24 5-4. Stick Start Procedure − Scratch Start T echnique With Stick selected, start arc as follows: 1 Electrode 2 W orkpiece 3 Arc Drag electrode across workpiece like strik- in g a match; lift electrode slightly after touch- ing work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist t[...]

OM-2233 Page 25 SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance  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.[...]

OM-2233 Page 26 6-3. T roubleshooting Help Aids  All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. 1 Output LED 2 High T emperature LED The Output LED turns on when power is turned on. The LED is also used to indicate several machine malfunctions. When one of the malfunctions listed b[...]

OM-2233 Page 27 6-4. T roubleshooting T rouble Remedy No weld output; unit completely inoperative. Place line disconnect switch in On position (see Section 4-10 ). Check and replace line fuse(s), if necessary , or reset circuit breaker (see Section 4-10 ). Check for proper input power connections (see Section 4-10 ). No weld output; Output LED on. [...]

OM-2233 Page 28 SECTION 7 − ELECTRICAL DIAGRAMS Figure 7-1. Circuit Diagram 202 314-B[...]

OM-2233 Page 29 SECTION 8 − SELECTING AND PREP ARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_7/2006  Whenever possible and practical, use DC weld output instead of AC weld output. 8-1. Selecting T ungsten Electrode ( Wear Clean gloves T o Prevent Contamination Of T ungsten ) Amperage Range - Gas T ype ♦ - Polarit[...]

Om-2233 Page 30 SECTION 9 − GUIDELINES FOR (GT A W) TIG WELDING gtaw 7/2006 9-1. Positioning The T orch Ref. ST-161 892  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 info[...]

OM-2233 Page 31 9-2. T orch Movement During Welding ST-162 002-B T ungsten Without Filler Rod T ungsten With Filler Rod Form pool Tilt torch Move torch to front of pool. Repeat process. 75 ° 75 ° W elding direction Form pool Tilt torch Add filler metal Move torch to front of pool. Repeat process. Remove rod W elding direction 15 ° 9-3. Positioni[...]

OM-2233 Page 32 SECTION 10 − STICK WELDING (SMA W) GUIDELINES 10-1. Stick Welding Procedure stick 12/96 − ST-151 593  W eld current starts when electrode touches work- piece.  W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pl ace wo rk c lam p a s close t o the weld as po[...]

OM-2233 Page 33 10-2. 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 & 601 1 6013 7014 7018 7024 Ni-Cl 308L 50 100 150 200 250 300 350 400 450 ELECTR[...]

OM-2233 Page 34 10-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End V iew of Work Angle Sid e V iew of Electrode Angle End V iew of Work Angle S ide V iew of Electrode Angle 10 ° -30 ° 10-6. Poor Weld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crate[...]

OM-2233 Page 35 10-8. 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 TRA VEL SPEED Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo Small Angle T oo Large Correct Angle 10-9. Electro[...]

OM-2233 Page 36 10-10. Butt Joints S-0662 1 T ack Welds Prevent ed ge s of j oint 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 − 3/4 in (5-19 mm) thick. Cut bevel with oxy- [...]

OM-2233 Page 37 10-13. Weld T est S-0057-B 1 V ise 2 W e ld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in 1/4 in 3 2 1 2 T o 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 10-14. T roubleshooting − Porosity Porosity − small cavities or holes resulting from gas pockets i n weld metal. Possi[...]

OM-2233 Page 38 10-16. T roubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insuf ficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in prop[...]

OM-2233 Page 39 10-19. T roubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 10-20. T roubleshooting − W avine[...]

OM-2233 Page 40 SECTION 1 1 − P ARTS LIST Figure 1 1-1. Main Assembly 803 107-E  Hardware is common and not available unless listed. 1 3 14 11 12 8 10 2 13 600 614 401 400 402 615 6 4 9 5 19 18 16 25 32 26 28 26 28 27 27 29 33 15 34[...]

OM-2233 Page 41 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly 1 Fig1 1-2 Panel, Front W/Cmpnt 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fig1 1-3 Panel, Rear W/Cmpnt 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-2233 Page 42 Figure 1 1-2. Panel, Front w/Components 202 508-E  Hardware is common and not available unless listed. 8 16 11 15 9 2 605 12 13 14 7 4 5 17 603 400 602 10 601 1 3 6 Quantity Description Part No. Dia. Mkgs. Item No. 1 1-2. Panel, Front w/Components (Figure 1 1-1 Item 1) 1 194242 Panel, Front/Rear 1 . . . . . . . . . . . . . . . . [...]

OM-2233 Page 43 Figure 1 1-3.Panel, Rear w/Components 202 397-E  Hardware is common and not available unless listed. 2 600 1 4 5 3 Figure 1 1-3. Panel, Rear w/Components (Figure 1 1-1 Item 2) Quantity Description Part No. Dia. Mkgs. Item No. 1 194242 Panel, Front/Rear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-2233 Page 44 Figure 1 1-4. Magnetics Assembly w/Components 202 398-H  Hardware is common and not available unless listed. 614 14 13 605 12 9 603 617 8 6 11 604 611 1 617 12 10 14 13 605 3 613 604 603 613 17 Figure 1 1-4. Magnetics Assembly w/Components (Figure 1 1-1 Item 3) Quantity Description Part No. Dia. Mkgs. Item No. 1 195649 Panel, Ple[...]

OM-2233 Page 45 Figure 1 1-4. Magnetics Assembly w/Components (Figure 1 1-1 Item 3) (Continued) Quantity Description Part No. Dia. Mkgs. Item No. 17 213208 Connector , Faston Male 1/4 Ring W/75deg Bend 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603 057357 Bushing, Snap − in Nyl .937 Id X 1.125 Mtg Hole 2 . . .[...]

OM-2233 Page 46 Figure 1 1-5. Windtunnel w/Components 199 494-F  Hardware is common and not available unless listed. 6 2 1 8 4 602 3 5 10 7 Figure 1 1-5. Windtunnel w/Components (Figure 1 1-1 Item 4) Quantity Description Part No. Dia. Mkgs. Item No. 1 195645 Panel, Midplain Horizontal 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-2233 Page 47 Figure 1 1-6. Heat Sink, Secondary Assembly 199 497-H  Hardware is common and not available unless listed. 600 7 602 4 1 3 601 6 604 2 606 604 5 Figure 1 1-6. Heat Sink, Secondary Assembly (Figure 1 1-5 Item 7) Quantity Description Part No. Dia. Mkgs. Item No. 1 210783 Heat Sink, Diode 1 . . . . . . . . . . . . . . . . . . . . . [...]

OM-2233 Page 48 Figure 1 1-7. Base Assembly 199 493-B  Hardware is common and not available unless listed. Figure 1 1-7. Base Assembly (Figure 1 1-1 Item 5) Quantity Description Part No. Dia. Mkgs. Item No. 1 195644 Base, 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe[...]

PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compan y 1635 West Spenc er S treet Applet on, W I 54914 US A International He adquarters − US A USA P hone: 920-735-4505 Aut o-At tended USA & C anada F A X: 920-735-4134 Int ernat ional FAX: 920-735-4125 European Headqua rters − [...]