Miller Maxstar 200 LX Bedienungshandbuch

Visit our website atwww.MillerWelds.comProcessesDescriptionTIG (GTAW) WeldingStick (SMAW) WeldingOM-2226 189783AL2010−04115/230/400/460 Volt Models W/

OM-2226 Page 41-4. California Proposition 65 WarningsWelding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of

OM-2226 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONfre_som_2010−037Se protéger et protéger les autres contre le risque de blessur

OM-2226 Page 6Il reste une TENSION DC NON NÉGLIGEABLE dansles sources de soudage onduleur UNE FOISl’alimentation coupée.D Arrêter les convertisseurs,

OM-2226 Page 7LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou même la mort.D Fermer l’alimentation du gaz protecteur en casde non-utilis

OM-2226 Page 8Les PIÈCES MOBILES peuventcauser des blessures.D Ne pas s’approcher des organes mobiles.D Ne pas s’approcher des points de coincementtel

OM-2226 Page 92-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents

OM-2226 Page 10

OM-2226 Page 11SECTION 3 − DEFINITIONS (CE Models)3-1. Warning Label DefinitionsWarning! Watch Out! There are possiblehazards as shown by the symbols.

OM-2226 Page 12Warning! Watch Out! There arepossible hazards as shown by thesymbols.1 Electric shock from wiring cankill.2 Disconnect input plug orpow

OM-2226 Page 133-3. Symbols And DefinitionsAAmperes Panel−LocalGas Tungsten ArcWelding (GTAW)Shielded Metal ArcWelding (SMAW)VVolts Voltage Input3 Pha

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

OM-2226 Page 14SECTION 4 − INSTALLATION4-1. Important Information Regarding CE Products (Sold Within The EU)! This equipment shall not be used by the

OM-2226 Page 154-3. SpecificationsInput Power Rated OutputWeldingAmperageRangeMax.Open-Cir-cuit Voltage(U0)Rated Peak Strik-ing Voltage (Up)Amperes I

OM-2226 Page 164-4. Volt-Ampere CurvesST- 189 767-AVolt-ampere curves show minimumand maximum voltage and amper-age output capabilities of weldingpowe

OM-2226 Page 174-5. 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 184-6. Selecting A Location1 Line Disconnect DeviceLocate unit near correct inputpower supply.! Special installation may berequired where

OM-2226 Page 194-7. Weld Output Terminals And Selecting Cable Sizes*NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined

OM-2226 Page 204-8. Remote 14 Receptacle InformationST-802 541AJBKICLNHDMGEFSocket* Socket Information15 VOLTS DCOUTPUTCONTACTORA Contactor control +1

OM-2226 Page 214-9. Automation 10-Pin Connection (LX Models)Ref. ST-802 458AJBGICFEHDSocket Socket Information For 10-Pin Receptacle RC2A Start/StopB

OM-2226 Page 224-11. 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 234-13. Stick DCEP (Direct Current Electrode Positive) ConnectionsRef. ST-802 471! Turn off power before mak-ing connections.1 Negative (

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

OM-2226 Page 244-14. TIGRunner ConnectionsCart and cooler are optional equip-ment.1 Gas Cylinder2 ChainsSecure gas cylinder to cart withchains.Connect

OM-2226 Page 254-15. Electrical Service Guide. Actual input voltage should not fall below 103 volts AC or rise above 506 volts AC. If actual input vol

OM-2226 Page 264-16. Connecting Input Power2/04 - Ref. 802 136-A! Installation must meet all Nationaland Local Codes − have only quali-fied persons ma

OM-2226 Page 27B. Connecting Single-Phase Input Power 2/04 - Ref. 802 136-A! Installation must meet all Nationaland Local Codes − have only quali-fied

OM-2226 Page 28SECTION 5 − OPERATIONST-207 690-A / ST-802 452123456789 10. For all front panel switch pad controls: pressswitch pad to turn on light a

OM-2226 Page 295-2. Encoder Control1 Encoder ControlUse control in conjunction with ap-plicable front panel function switchpad to set values for that

OM-2226 Page 305-5. Voltmeter1 Volt MeterDisplays output or open circuit volt-age. If output is off, the voltmeter willdisplay a series of three dash

OM-2226 Page 315-7. Lift-Arc™And HF TIG Start ProceduresLift-Arc StartWhen Lift-Arct button light is On, start arc asfollows:1 TIG Electrode2 Workpie

OM-2226 Page 325-8. Output Control11 Output ControlPress switch pad until desired parameterLED is illuminated.RMT STD (Remote Standard)Application: Us

OM-2226 Page 331 Pulser ControlPulsing is available only while usingthe TIG process, it cannot be se-lected if the Stick process (see Sec-tion 5-6) is

TABLE OF CONTENTSSECTION 6 − ADVANCED FUNCTIONS 39...6-1. Accessing Advanced Functions 39...

OM-2226 Page 345-10. Sequencer Controls (DX Models Only)2311 Sequencer ControlSequencing is available only whileusing the TIG process, but is dis-able

OM-2226 Page 355-11. Adjust Controls (Preflow/Post Flow/DIG/Purge)1 AdjustPress switch pad until desired functionLED is illuminated.2 Encoder Control3

OM-2226 Page 365-12. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection)SPO1.0131 Spot Time Meter DisplaySelect Spot function according toSe

OM-2226 Page 37ADJUST*PREFLOWPOST FLOWDIG0.2 S10.0 S30%0.0 − 25.0 Seconds0.0 − 50.0 Seconds @ 0.2 Second Resolution0 − 100 PercentMAXSTAR:*Tungsten***

OM-2226 Page 385-15. Arc Timer/Counter Display1 Output And Amperage Controls2 Power SwitchTo display the arc timer/counter, turn powerswitch on, and t

OM-2226 Page 39SECTION 6 − ADVANCED FUNCTIONS6-1. Accessing Advanced Functions3121 Amperage Switch Pad2 Adjust3 Encoder ControlTo access the advanced

OM-2226 Page 406-2. Programmable TIG Start ParametersA. Tungsten Selection2tun09431 Amperage Switch Pad2 Encoder Control3 Amps MeterPreset TIG Start P

OM-2226 Page 41B. Selecting GEN1 Encoder Control2 Amps Meter3 Amperage Switch PadIf [GEn] is selected and displayedon the amps meter, the TIG startin

OM-2226 Page 42C. Changing Programmable TIG Start Amperage1 Amperage Switch Pad2 Encoder Control3 Amps MeterTo adjust TIG Start Amperage proceed asfol

OM-2226 Page 43E. Changing Start Slope Time1 Amperage Switch Pad2 Encoder Control3 Amps MeterTo adjust Start Slope Time proceed as fol-lows:Press Ampe

DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street,

OM-2226 Page 446-3. Output Control And Trigger FunctionsA. Remote (Standard) Torch Trigger OperationCurrent (A)PreflowInitial AmpsInitial SlopeFinal S

OM-2226 Page 45C. 3T Specific Trigger Method1 3T (Specific Trigger Operation)Sequencer is required to reconfigure for 3T.3T requires a specific type o

OM-2226 Page 46D. 4T Specific Trigger Method1 4T (Specific Trigger Operation)2 Encoder ControlTo select 4T, turn Encoder control.Torch trigger operati

OM-2226 Page 47F. 4T Momentary Operation1 4T Momentary Meter Display2 Encoder ControlTo select 4T Momentary, turn Encoder control.4T Momentary torch t

OM-2226 Page 48G. Spot Control Operation=rtSPOSpot1Current (A)PreflowPostflowTimed Spot Weld AmpsPush & HoldTrigger1 Spot Function Meter Display.

OM-2226 Page 49H. On Trigger OperationVoltage (V)Current (A)Current (A)Touch StickLift StickTouch CurrentInitial AmperageInitial SlopeMain AmperageTou

OM-2226 Page 506-4. Setting Preflow Time1 Encoder ControlTurn encoder to select from 0 to25 seconds of preflow. The valueselected is displayed on the

OM-2226 Page 516-7. Lockout FunctionsA. Accessing Lockout Capability2oFFcod1oFFLocSee Section 5 for explanation of controls referred to in all ofSecti

OM-2226 Page 52B. Lockout Levels. Before activating lockout levels, besure that all procedures and parame-ters are established. Parameter adjust-ment

OM-2226 Page 536-8. Setting Unit To Display PPP While Pulse Welding (DX Models Only)1 Encoder Control2 PPP Meter DisplayTurn Encoder to change between

Notes

OM-2226 Page 54SECTION 7 − MAINTENANCE AND TROUBLESHOOTING7-1. Routine Maintenance. Maintain more often during severe conditions.! Disconnect power be

OM-2226 Page 557-2. Blowing Out Inside Of Unit! Do not remove case whenblowing out inside of unit.To blow out unit, direct airflowthrough front and ba

OM-2226 Page 567-3. Voltmeter/Ammeter Help Displays. All directions are in reference to thefront of the unit. All circuitry referred tois located insi

OM-2226 Page 577-4. TroubleshootingTrouble RemedyNo weld output; unit completelyinoperative.Place line disconnect switch in On position (see Section 4

OM-2226 Page 58NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

OM-2226 Page 59SECTION 8 − ELECTRICAL DIAGRAMSFigure 8-1. Circuit Diagram237 566-B

OM-2226 Page 60SECTION 9 − HIGH FREQUENCY (HF)9-1. Welding Processes Requiring High Frequency1 High-Frequency VoltageTIG − helps arc jump air gapbetw

OM-2226 Page 61SECTION 10 − SETUP GUIDES FOR (GTAW) TIG WELDING207 690-AThis symbol indicates which functions should be active for stainless steel.• T

OM-2226 Page 62SECTION 11 − SELECTING AND PREPARING A TUNGSTENFOR DC OR AC WELDING WITH INVERTER MACHINESgtaw_Inverter_2010-04Whenever possible and pr

OM-2226 Page 63SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW)12-1. Positioning The TorchRef. ST-161 892110−25°10−15°623490°453/16 in.1/16 in.65Bottom

OM-2226 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _2010−037Protect yourself and others from injury — read and follow these precautio

OM-2226 Page 6412-2. Torch Movement During WeldingST-162 002-BTungsten Without Filler RodTungsten With Filler RodForm pool Tilt torch Move torch to fr

OM-2226 Page 65SECTION 13 − SETUP GUIDE FOR (SMAW) STICK WELDING13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)ST-207 690

OM-2226 Page 66SECTION 14 − STICK WELDING (SMAW) GUIDELINES14-1. Stick Welding Procedurestick 2010−02 − 151 593! Weld current starts whenelectrode tou

OM-2226 Page 6714-2. 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 6814-4. Positioning Electrode HolderS-006090° 90°10°-30°45°45°10°-30°1 End View Of Work Angle2 Side View Of ElectrodeAngle1122Groove Weld

OM-2226 Page 6914-7. Conditions That Affect Weld Bead ShapeS-0061SlowNormal Fast10° - 30°DragToo ShortNormal Too LongSpatterAngle Too SmallAngle Too L

OM-2226 Page 7014-9. Groove (Butt) JointsS-00621 Tack WeldsPrevent edges of joint from draw-ing together ahead of electrode bytack welding the materia

OM-2226 Page 7114-12. Weld TestS-0057-B1 Vise2 Weld Joint3 HammerStrike weld joint in directionshown. A good weld bends overbut does not break.2 To 3

OM-2226 Page 72Lack of PenetrationGood PenetrationLack Of Penetration − shallow fusion between weld metal and base metal.Possible Causes Corrective Ac

OM-2226 Page 73Notes

OM-2226 Page 2Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.FUMES AND GASES can be hazardous.D Keep

OM-2226 Page 74SECTION 15 − PARTS LISTFigure 15-1. Main Assembly803 227-G. Hardware is common andnot available unless listed.1176141536001440240040116

OM-2226 Page 75QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 15-1. Main Assembly1 Fig15-2 Panel, Front W/Cmpnt 1... ... ...

OM-2226 Page 76Figure 15-2. Panel, Front w/Components. Hardware is common andnot available unless listed.805 151-C65417316044007603141312260291511168Q

OM-2226 Page 77Figure 15-3.Panel, Rear w/ComponentsRef. 199 492-C. Hardware is common andnot available unless listed.Figure 15-3. Panel, Rear w/Compon

OM-2226 Page 78Figure 15-4. Magnetics Assembly w/Components805 153-A. Hardware is common andnot available unless listed.Figure 15-4. Magnetics Assembl

OM-2226 Page 79Figure 15-4. Magnetics Assembly w/Components(Figure 15-1 Item 3) (Continued)QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.600 199538 Gromme

OM-2226 Page 80Figure 15-5. Windtunnel w/ComponentsRef. 199 494-F. Hardware is common andnot available unless listed.6218460235107Figure 15-5. Windtun

OM-2226 Page 81Figure 15-6. Heat Sink, Secondary Assembly199 497-H. Hardware is common andnot available unless listed.6007413660426066045Figure 15-6.

OM-2226 Page 82Figure 15-7. Base Assembly199 493-B. Hardware is common andnot available unless listed.Figure 15-7. Base Assembly(Figure 15-1 Item 5)Qu

OM-2226 Page 83Notes

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 84SECTION 16 − COOLER PARTS LIST. Hardware is common andnot available unless listed.805 266-A12345679813101113121471615671519182223242519

OM-2226 Page 85QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 16-1. Main Assembly1 +235416 Wrapper, ... .. ...

OM-2226 Page 86SECTION 17 − CART PARTS LIST805 337-B. Hardware is common andnot available unless listed.1374562891091112131415161717612. Item 4 can be

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2010−01Your distributor also givesyou ...ServiceYou always get the

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2010 Miller Electric Mfg. Co. 2010−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer