Miller Maxstar 200 LX- Manuals

OM-2226 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This gr...

OM-2226 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system isproperly sized,...

OM-2226 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. »Cette procédure présente des risques identifiés par lessymboles adjacents aux directives. Y Identifie un message de sécurité ...

OM-2226 Page 9 SECTION 3 − DEFINITIONS (CE Models) 3-1. Warning Label Definitions Warning! Watch Out! There are possiblehazards as shown by the symbols. 1 Electric shock from welding electrodeor wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Donot wear wet or...

OM-2226 Page 11 3-2. Manufacturer ’s Rating Label 195 646-B . See Section 4-4 forlocation. . Use rating label to de-termine input powerrequirements. 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 3...

OM-2226 Page 12 3-3. Symbols And Definitions A Amperes Panel−Local Gas Tungsten Arc Welding (GTAW) Shielded Metal Arc Welding (SMAW) V Volts Voltage Input 3 Phase Static Frequency Converter-Transformer-Rectifier Voltage Output Circuit Breaker Remote Lift-Arc Start (GTAW) Protective Earth (Ground) Po...

OM-2226 Page 13 SECTION 4 − INSTALLATION 4-1. Specifications Input Power Rated Output Welding Amperage Max. Open-Circuit Amperes Input At Rated Output, 50/60Hz KVA KW Input Power Rated Output Amperage Range Open-Circuit Voltage 115 230 400 460 KVA KW Three-Phase Stick Process 150 A @ 26 VDC, 60% Dut...

OM-2226 Page 15 4-3. Duty Cycle And Overheating ST-189 770-A Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. If unit overheats, output stops, aHelp message is displayed (seeSection 7-3), and cooling fan runs.Wait fifteen minutes for unit to cool.Reduce am...

OM-2226 Page 16 4-4. Selecting A Location 1 Identification Plate 2 Rating Label 3 Line Disconnect Device Locate unit near correct inputpower supply. Y Special installation may berequired where gasoline orvolatile liquids are present −see NEC Article 511 or CECSection 20. Location And Airflow 3 1 18 ...

OM-2226 Page 17 4-5. Weld Output Terminals And Selecting Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding Y Turn off power beforeconnecting to weld out-put terminals. 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...

OM-2226 Page 19 4-8. Gas Connections ST-802 452 1 Gas Fitting Fittings have 5/8-18 right-handthreads (3/8-19 BSPP on CE units). 2 Cylinder Valve Open valve slightly so gas flowblows dirt from valve. Close valve. 3 Regulator/Flowmeter 4 Flow Adjust Typical flow rate is 15 cubic feet perhour (7.1 lite...

OM-2226 Page 21 4-12. Connecting Input Power 2/04 - Ref. 802 136-A Y Installation must meet all Nationaland Local Codes − have only quali-fied persons make this installation. Y Disconnect and lockout/tagout in-put power before connecting inputconductors from unit. Y Always connect green or green/yel...

OM-2226 Page 24 SECTION 5 − OPERATION ST-207 690-A / ST-802 452 1 2 3 4 5 6 7 8 9 10 . For all front panel switch pad controls: pressswitch pad to turn on light and enablefunction. NOTE: Green on nameplate indicates a TIGfunction, Gray indicates a Stick function.1 Encoder Control Use encoder control...

OM-2226 Page 26 5-5. Voltmeter 1 Volt Meter Displays output or open circuit volt-age. If output is off, the voltmeter willdisplay a series of three dashes(-−−). Open circuit voltage is dis-played if power is on and output isavailable. 1 5-6. Polarity Control (Dynasty t Models Only) 1 Polarity Contro...

OM-2226 Page 27 5-7. Process Control 1 Process Control Press switch pad until desired pro-cess LED is illuminated: TIG HF Impulse - When selected,a pulsed HF (non-contact) (seeSection 11-3) arc starting method isactivated. This method can be usedwith either AC or DC TIG welding.Make connections acco...

OM-2226 Page 31 5-12. AC Waveshape (Dynasty Models Only) 1 AC Waveshape 2 Encoder Control 3 Ammeter Turn encoder (see Section 5-2) toset appropriate value for active ACWaveshape parameter. Value se-lected is shown on the ammeter(see Section 5-4). See Section 5-16 for all AC Wave-shape parameter rang...

OM-2226 Page 33 5-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A Preflow Control On The Front Panel 1 And SEL 0.2 4 2 1 Process Control Pad 2 Adjust Control Pad 3 Power Switch To adjust preflow, turn power switch on, andthen press the Process and Adjust switchpads ...

OM-2226 Page 34 5-16. Factory Parameter Defaults And Range And Resolution Parameter Default Range And Resolution MEMORY 1 1−4 PROCESS ** Stick OCV TIG HF Impulse Low OCV TIG HF Impulse / TIG Lift / Stick Low OCV / Normal OCV OUTPUT **RMT 2T RMT STD 2T RMT STD / RMT 2T / ON RMT 2T can be reconfigured...

OM-2226 Page 36 SECTION 6 − ADVANCED FUNCTIONS 6-1. Programable TIG Start Parameters A. Accessing Programmable TIG Start Parameters NOTE: The welding cycle can be execut-ed while in programmable start mode.Before accessing programmable TIGStart Polarity, Amperage, and Timemodes, be sure that all pro...

OM-2226 Page 37 B. Changing Programmable TIG Start Polarity (Dynasty Models Only) 2 SEL E− 3 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust TIG Start Polarity proceed asfollows: Press Amperage switch pad. Switch padLED turns on, and meter % LED turns on.The current Start Polarity, (S...

OM-2226 Page 39 6-2. Output Control And Trigger Functions A. Remote (Standard) Torch Trigger Operation Current (A) Preflow Initial Amps Initial Slope Final Slope Postflow Main Amps Final Amps R R P & H Maintained Switch Foot Or FingerRemote Control P&H = Push trigger and hold R = Release tri...

OM-2226 Page 40 C. Reconfiguring RMT 2T HOLD For 2T, 3T, Spot, 4T, 4T Momentary, Or Mini Logic Control 1 4 H−2 SEL 2 And Rear Panel 3 V Or Or Or For RMT STD (Remote Standard), RMT2T Hold (Remote 2T Hold), and On trig-ger operation, see Section 6-2A, B, andH. 1 Process Switch Pad 2 Output Switch Pad ...

OM-2226 Page 48 6-3. Arc Timer/Counter Display 1 Output And Amperage Controls 2 Power Switch To display the arc timer/counter, turn pow-er switch on, and then press the Amper-age Control and Output switch pads be-fore the software version clears the me-ters, and hold the switch pads until soft-ware ...

OM-2226 Page 49 6-4. Lockout Functions A. Accessing Lockout Capability 1 L−0 L − − 4 6 000 or 2,3,4 2 5 L−0 L L1 000 And Rear Panel 3 V Or See Section 5-1 for explanation of controls referred to in all ofSection 6-4. There are four (1−4) different lockout levels. Each successive levelallows the oper...

OM-2226 Page 52 6-5. Setting Unit To Display PPP While Pulse Welding (DX And LX Models Only) 1 Output Switch Pad 2 Pulser Switch Pad 3 Power Switch To access the PPP while welding dis-play, turn power switch on, and thenpress the Output and Pulser switchpads before the software version clears the me...

OM-2226 Page 53 6-6. Stick Open-Circuit Voltage (OCV) Selection (All Models) 1 Process Switch Pad 2 Adjust Switch Pad 3 Amperage Switch Pad 4 Power Switch To access the Stick OCV selection,turn power switch on and then pressthe Process, Adjust and Amperageswitch pads before the software ver- sion cl...

OM-2226 Page 54 SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replaceunreadablelabels. Clean and tightenweld terminals. Replace DamagedGas Hose 3 Months Repair Or ReplaceCracked Cab...

OM-2226 Page 55 7-3. Voltmeter/Ammeter Help Displays . All directions are in reference to thefront of the unit. All circuitry referred tois located inside the unit. 0 Help 0 Display Indicates a short in the thermal protectioncircuitry located on the bottom heat sink.Contact a Factory Authorized Serv...

OM-2226 Page 56 7-4. Troubleshooting Trouble Remedy No weld output; unit completelyinoperative. Place line disconnect switch in On position (see Section 4-12). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-12). Check for proper input power connections (see Sec...

OM-2226 Page 57 SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram SC-189 769-E

OM-2226 Page 61 SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW) 207 690-A This symbol indicates which functions should be active for stainless steel. • Turn power on (switch located on rear panel) • Press Process switch pad until TIG HF Impulse LED is lit • Press Output switch pad until RMT STD LED i...

OM-2226 Page 63 11-3. Lift-Arc  And HF TIG Start Procedures Lift-Arc Start When Lift-Arc t button light is On, start arc as follows: 1 TIG Electrode 2 Workpiece Touch tungsten electrode to work-piece at weld start point, enable out-put and shielding gas with torch trig-ger, foot control, or hand co...

OM-2226 Page 65 11-5. Positioning Torch Tungsten For Various Weld Joints ST-162 003 / S-0792 70 ° 70 ° 90 ° 20 ° 20 ° 10 ° 20 ° 70 ° 40 ° 30 ° 20 ° 70 ° 90 ° 20 ° Butt Weld And Stringer Bead “T” Joint Lap Joint Corner Joint

OM-2226 Page 66 SECTION 12 − STICK WELDING (SMAW) GUIDELINES 12-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) ST-207 690-A 1 Front Panel Correct front panel display for basicStick DCEP welding. . For all front panel switch padcontrols: press switch pad toturn on light and...

OM-2226 Page 67 12-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/323/167/32 1/4 1/165/643/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/163/32 1/8 5/32 6010 & 6011 6013 7014 7018 7024 Ni-Cl 308L 50 100...

OM-2226 Page 70 12-9. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, andthickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRAVEL SPEED Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Small A...

OM-2226 Page 72 12-14. Weld Test S-0057-B 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown.A good weld bends over but doesnot break. 2 To 3 in 1/4 in 3 2 1 2 To 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 12-15. Troubleshooting − Porosity Porosity − small cavities or holes resulting f...

OM-2226 Page 74 12-20. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resultingin holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady trave...

OM-2226 Page 76 SECTION 13 − PARTS LIST Figure 13-1. Main Assembly 803 227-C . Hardware is common andnot available unless listed. GROUND STUD DETAIL 1 3 14 11 12 8 10 2 13 600 614 401 400 402 6 4 9 5 19 18 16 17 32 7 403 615 30 31 29 25 28 15 33

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PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters−USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...