Miller Maxstar 200 LX Bedienungshandbuch

Visit our website atwww.MillerWelds.comProcessesDescriptionTIG (GTAW) WeldingStick (SMAW) WeldingOM-2226 189783GApril 2002115/230/400/460 Volt Models

OM-2226 Page 41-5. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flow

OM-2226 Page 5SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANTUTILISATIONsom _nd_fre 4/981-1. Signification des symbolesSignifie Mise en garde ! Soyez v

OM-2226 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles

OM-2226 Page 71-3. Dangers supplémentaires en relation avec l’installation, le fonctionnementet la maintenanceRisque D’INCENDIE OUD’EXPLOSION.D Ne pas

OM-2226 Page 81-4. Principales normes de sécuritéSafety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-ding Society, 550 N.W. Lejeune Rd,

OM-2226 Page 9SECTION 2 – DEFINITIONS (CE Models)2-1. Warning Label DefinitionsWarning! Watch Out! There are possiblehazards as shown by the symbols.1

OM-2226 Page 10Warning! Watch Out! There arepossible hazards as shown by thesymbols.1 Electric shock from wiring cankill.2 Disconnect input plug orpow

OM-2226 Page 112-2. Manufacturer’s Rating Label195 646-B. See Section 3-4 forlocation.. Use rating label to de-termine input powerrequirements.SS40% 6

OM-2226 Page 122-3. Symbols And DefinitionsAAmperes Panel–LocalGas Tungsten ArcWelding (GTAW)Shielded Metal ArcWelding (SMAW)VVolts Voltage Input3 Pha

OM-2226 Page 13SECTION 3 – INSTALLATION3-1. SpecificationsWelding Max.Amperes Input At Rated Output, 50/60HzInput Power Rated OutputAmperageRangeOpen-

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-2226 Page 14115VAC Input0204060801001201400 50 100 150 200 250AmperesStick Max.TIG Max.Stick/TIG Min.DIG Max.3-2. Volt-Ampere CurvesST- 189 767Volt

OM-2226 Page 153-3. Duty Cycle And OverheatingST-189 770-ADuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

OM-2226 Page 163-4. Selecting A Location1 Identification Plate2 Rating Label3 Line Disconnect DeviceLocate unit near correct inputpower supply.Y Speci

OM-2226 Page 173-5. Weld Output Terminals And Selecting Cable Sizes*Weld Cable Size** and Total Cable (Copper) Length in Weld CircuitNot ExceedingY Tu

OM-2226 Page 183-7. Automation 10-Pin Connection (LX Models)Socket Socket Information For 10-Pin Receptacle RC2FEDA Start/StopJGICHDB GasABC Output en

OM-2226 Page 193-8. Gas ConnectionsST-802 4521 Gas FittingFittings have 5/8-18 right-handthreads (3/8-19 BSPP on CE units).2 Cylinder ValveOpen valve

OM-2226 Page 203-10. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)ST-192 8851 Front PanelCorrect front panel display

OM-2226 Page 213-11. Stick DCEP (Direct Current Electrode Positive) ConnectionsRef. ST-802 471Y Turn off power before mak-ing connections.1 Negative (

OM-2226 Page 223-12. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)ST-192 8851 Front PanelCorrect front panel display for basi

OM-2226 Page 233-13. Electrical Service GuideActual input voltage cannot exceed ± 10% of indicated required input voltage. Ifactual input voltage is o

TABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1. . .

OM-2226 Page 24Y Disconnect and lockout/tag-out input power before con-necting input conductorsfrom unit.Y Have only qualified personsmake this instal

OM-2226 Page 25SECTION 4 – OPERATION4-1. ControlsA. Non CE Units (DX/LX Model Shown)ST-192 885 / ST-802 452123456789 10. For all front panel switch pa

OM-2226 Page 26B. For CE Units (DX/LX Model Shown)ST-192 889 / ST-802 45212345678910. For all front panel switch pad controls:press switch pad to turn

OM-2226 Page 274-2. Encoder Control1 Encoder ControlUse control in conjunction with ap-plicable front panel function switchpad to set values for that

OM-2226 Page 284-5. Lift-Arc And HF TIG Start ProceduresLift-Arc StartWhen Lift-Arct button light is On,start arc as follows:1 TIG Electrode2 Workpie

OM-2226 Page 294-6. Stick Start Procedure – Scratch Start TechniqueWith Stick selected, start arc as fol-lows:1 Electrode2 Workpiece3 ArcDrag electrod

OM-2226 Page 304-7. Output Control1CE Models OnlyCurrent (A)PreflowInitial AmpsInitial SlopeFinal SlopePostflowWeld AmpsFinal AmpsRelease ForMaintaine

OM-2226 Page 311 Output ControlPress switch pad until desired parameterLED is illuminated.RMT 2T HoldPress switch pad to activate function.Torch trigg

OM-2226 Page 324-8. Amperage Control1 A (Amperage Control)2 Encoder Control3 Parameter DisplayPress Amperage switch pad, andturn Encoder control to se

OM-2226 Page 334-9. Adjust Controls (Post Flow/DIG)1 Post Flow/DIG ControlPress switch pad until desired func-tion LED is illuminated.2 Encoder Contro

TABLE OF CONTENTSSECTION 5 – MAINTENANCE AND TROUBLESHOOTING 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintena

OM-2226 Page 341 Pulser ControlIf the Pulser is off, pressing the switch padwill enable the pulser, and place it in thePPS (Pulses Per Second) mode an

OM-2226 Page 354-11. Sequencer Controls (DX, LX And All CE Models)1 Sequencer ControlPress switch pad until desired pa-rameter LED is illuminated. Se-

OM-2226 Page 364-12. Preflow Adjust (All Models)1 Process Control Pad2 Adjust Control Pad3 Power SwitchTo adjust preflow, turn power off, pushand hold

OM-2226 Page 37CE Models OnlyRear Panel324SEL00.21 Process Control Pad2 Adjust Control Pad3 Power SwitchTo adjust preflow, turn Off power. Pushand hol

OM-2226 Page 384-13. Programmable TIG HF Impulse Start Amperage And Time ModesA. Accessing Programmable TIG Start Amperage And Time Modes (All Models)

OM-2226 Page 39CE Models OnlyNOTE: Before accessing programmableTIG HF Impulse Start Amperage and Timemodes, be sure that all procedures and pa-ramete

OM-2226 Page 40B. Setting Programmable TIG Impulse Start Amperage (All Models)NOTE: Before accessing programmableTIG HF Impulse Start Amperage mode, b

OM-2226 Page 41CE Models OnlyNOTE: Before accessing programmableTIG Impulse Start Amperage mode, besure that all procedures and parametersare establis

OM-2226 Page 42C. Setting Programmable Start Time (All Models)NOTE: Before accessing programmablestart time mode, be sure that all proceduresand param

OM-2226 Page 43CE Models OnlyNOTE: Before accessing programmablestart time mode, be sure that all proceduresand parameters are established. Especial-l

dec_con1 10/95Declaration of Conformity ForEuropean Community (CE) ProductsThis information is provided for units with CE certification (see rating la

OM-2226 Page 444-14. Reconfiguring 2T For 4T, 4T Momentary, Mini Logic Control, Or Spot (DX, LX And AllCE Models)1 Process Switch Pad2 Output Switch P

OM-2226 Page 45SEL H-2====2T (See Section 4-7Mini Logic (See Section 4-16Spot (See Section 4-175SEL H-4SEL H4LSEL SPO4T (See Section 4-15=SEL H4E4T Mo

OM-2226 Page 46Reconfiguring 2T For 4T, 4T Momentary, Mini Logic Control, Or Spot (DX, LX And All CEModels) (Continued)1 Process Switch Pad2 Output Sw

OM-2226 Page 47SEL H-2====2TMini Logic (See Section 4-16Spot (See Section 4-175SEL H-4SEL H4LSEL SPO4T (See Section 4-15=SELH4E4T Momentary(See Sectio

OM-2226 Page 484-15. 4T Specific Trigger Method (DX, LX And All CE Models)1 4T (Specific TriggerOperation)Sequencer is required to reconfi-gure for 4T

OM-2226 Page 494-16. Mini Logic Operation (DX, LX And All CE Models)1 Mini Logic Meter DisplaySequencer option required to re-configure for Mini Logic

OM-2226 Page 504-17. Spot Control Operation (All Models)1 Spot Function DisplaySelect Spot function according toSection 4-14.2 Amperage Switch Pad3 En

OM-2226 Page 514-18. 4T Momentary Operation (DX, LX And All CE Models)1 4T Momentary DisplaySelect 4T Momentary accordingto Section 4-14.If unit is eq

OM-2226 Page 524-19. Arc Timer/Counter Display (All Models)1 Output And Amperage Controls2 Power SwitchTo display the arc timer/counter, turn pow-er o

OM-2226 Page 531 Output And Amperage Controls2 Power SwitchTo display the arc timer/counter, turnpower off. Push and hold Output and Am-perage control

OM-2226 Page 544-20. Lockout FunctionsA. Accessing Lockout CapabilitySee Section 4-1 for explanation of controls referred to in all ofSection 4-20.The

OM-2226 Page 55B. Lockout LevelsLevel 1NOTE: Before activating lock outlevels, be sure that all proceduresand parameters are established.Parameter adj

OM-2226 Page 56C. Lockout Levels (Continued)Level 3+/– 10 % Amperage Adjust ControlSelect Stick Or TIGLevel 4Remote Amperage ControlLevel 3NOTE: Befo

OM-2226 Page 574-21. Resetting Unit To Factory Default Settings (All Models)1 Process Switch Pad2 Output Switch Pad3 Adjust Switch Pad4 Power SwitchTo

OM-2226 Page 584-22. Setting Unit To Display PPP While Pulse Welding1 Output Switch Pad2 Pulser Switch Pad3 Power SwitchTurn power off. Push and hold

OM-2226 Page 59CE Models Only2SEL- - -241AndRear Panel35PPP1 Output Switch Pad2 Pulser Switch Pad3 Power SwitchTurn power off. Push and hold the Out-p

OM-2226 Page 60SECTION 5 – MAINTENANCE AND TROUBLESHOOTING5-1. Routine MaintenanceY Disconnect power before maintaining.. Maintain more often during s

OM-2226 Page 615-3. Voltmeter/Ammeter Help Displays. All directions are in reference to thefront of the unit. All circuitry referred tois located insi

OM-2226 Page 625-4. TroubleshootingTrouble RemedyNo weld output; unit completelyinoperative.Place line disconnect switch in On position (see Section 3

OM-2226 Page 63SECTION 6 – ELECTRICAL DIAGRAMSFigure 6-1. Circuit DiagramSC-189 769-D

OM-2226 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_4/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-2226 Page 64SECTION 7 – HIGH FREQUENCY7-1. Welding Processes Requiring High Frequencyhigh_freq 12/96 – S-06931 High-Frequency VoltageTIG – helps a

OM-2226 Page 657-3. Correct Installation1 High-Frequency Source (weldingpower source with built-in HF orseparate HF unit)Ground metal machine case, wo

OM-2226 Page 66SECTION 8 – SELECTING AND PREPARINGTUNGSTEN ELECTRODEgtaw 7/97For additional information, see your distributor for a handbook on the Ga

OM-2226 Page 678-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) WeldingRef. S-0161 / Ref. S-01621 Tungsten Electrode2 Tapered EndGrind e

OM-2226 Page 68SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW)9-1. Positioning The TorchRef. ST-161 892Y Grinding the tungsten elec-trode produces dust

OM-2226 Page 699-2. Torch Movement During WeldingST-162 002-BTungsten Without Filler RodTungsten With Filler RodForm pool Tilt torch Move torch to fro

OM-2226 Page 709-3. Positioning Torch Tungsten For Various Weld JointsST-162 003 / S-079270°70°90°20°20°10°20°70°20-40°30°20°70°90°20°Butt Weld And St

OM-2226 Page 71SECTION 10 – STICK WELDING (SMAW) GUIDELINES10-1. Stick Welding Procedurestick 12/96 – ST-151 593Y Weld current starts whenelectrode to

OM-2226 Page 7210-2. Electrode and Amperage Selection ChartRef. S-087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/321/43/321/85/323/167/321/43

OM-2226 Page 7310-5. Positioning Electrode HolderS-006090° 90°10°-30°45°45°GROOVE WELDSFILLET WELDSEnd View of Work Angle Side View of Electrode Angle

OM-2226 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Spark

OM-2226 Page 7410-8. Conditions That Affect Weld Bead ShapeWeld bead shape is affected by electrode angle, arc length, travel speed, andthickness o

OM-2226 Page 7510-10. Butt JointsS-06621 Tack WeldsPrevent edges of joint from drawingtogether ahead of electrode by tackwelding the materials in posi

OM-2226 Page 7610-13. Weld TestS-0057-B1 Vise2 Weld Joint3 HammerStrike weld joint in direction shown.A good weld bends over but doesnot break.2 To 3

OM-2226 Page 7710-16. Troubleshooting – Incomplete FusionIncomplete Fusion – failure of weld metal to fuse completely withbase metal or a preceeding w

OM-2226 Page 7810-19. Troubleshooting – Burn-ThroughBurn-Through – weld metal melting completely through base metal resultingin holes where no metal r

OM-2226 Page 79Notes

OM-2226 Page 80SECTION 11 – PARTS LISTFigure 11-1. Main Assembly803 227. Hardware is common andnot available unless listed.131411128102 1513GROUND STU

OM-2226 Page 81QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Main Assembly1 Fig11-2 Panel, Front W/Cmpnt 1. . . . . . . . . . . . . . . . .

OM-2226 Page 82Figure 11-2. Panel, Front w/ComponentsRef. 199 491-A. Hardware is common andnot available unless listed.QuantityDescriptionPartNo.Dia.M

OM-2226 Page 83QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.11-2. Panel, Front w/Components (Figure 11-1 Item 1) (continued)601 106702 Nut, 006–32 .31he

OM-2226 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-2226 Page 84Figure 11-3.Panel, Rear w/ComponentsRef. 199 492. Hardware is common andnot available unless listed.Figure 11-3. Panel, Rear w/Componen

OM-2226 Page 85Figure 11-4. Magnetics Assembly w/ComponentsRef. 199 501. Hardware is common andnot available unless listed.Figure 11-4. Magnetics Asse

OM-2226 Page 86Figure 11-4. Magnetics Assembly w/Components(Figure 11-1 Item 3) (Continued)QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.603 057357 Bushin

OM-2226 Page 87Figure 11-5. Windtunnel w/ComponentsRef. 199 49410. Hardware is common andnot available unless listed.Figure 11-5. Windtunnel w/Compone

OM-2226 Page 88Figure 11-6. Heat Sink, Secondary Assembly199 497-B. Hardware is common andnot available unless listed.Figure 11-6. Heat Sink, Secondar

OM-2226 Page 89Figure 11-7. Base Assembly199 493. Hardware is common andnot available unless listed.Figure 11-7. Base Assembly(Figure 11-1 Item 5)Quan

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 10/01Your distributor also givesyou ...ServiceYou always get the f

PRINTED IN USA  2002 Miller Electric Mfg. Co. 1/02Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US