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Miller Electric Maxstar 200 STR, Owner'S Manual

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Miller Electric Maxstar 200 STR Owner'S Manual Download Page 41

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

TRAVEL SPEED

Slow

Normal

Fast

10

°

 - 

30

°

Drag

Too Short

Normal

Too Long

Spatter

Angle Too Small

Angle Too Large

Correct Angle

10-9. Electrode Movement During Welding

Normally, a single stringer bead is satisfactory for most narrow groove weld joints;

however, for wide groove weld joints or bridging across gaps, a weave bead or

multiple stringer beads work better.

NOTE

S-0054-A

1

Stringer Bead 

−

 Steady

Movement Along Seam

2

Weave Bead 

−

 Side to Side

Movement Along Seam

3

Weave Patterns

Use weave patterns to cover a wide

area in one pass of the electrode.

Do not let weave width  exceed

2-1/2 times diameter of electrode.

1

2

3

Summary of Contents for Maxstar 200 STR

Page 1: ...website at www MillerWelds com Processes Description TIG GTAW Welding Stick SMAW Welding OM 2233 203 409Q 2007 04 115 230 400 460 Volt Models W Autoline Arc Welding Power Source Maxstar 200 STR And Non CE Models ...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operatio...

Page 3: ...ion 15 4 5 Weld Output Terminals And Selecting Cable Sizes 16 4 6 Remote 14 Receptacle Information 16 4 7 TIG Lift Arc DCEN Direct Current Electrode Negative Connections 17 4 8 Stick DCEP Direct Current Electrode Positive Connections 18 4 9 Electrical Service Guide 18 4 10 Connecting Input Power 19 SECTION 5 OPERATION 20 5 1 Controls 20 5 2 Process Control 22 5 3 Lift ArcE Start Procedure 22 5 4 S...

Page 4: ... 8 Conditions That Affect Weld Bead Shape 36 10 9 Electrode Movement During Welding 36 10 10 Butt Joints 37 10 11 Lap Joint 37 10 12 Tee Joint 37 10 13 Weld Test 38 10 14 Troubleshooting Porosity 38 10 15 Troubleshooting Excessive Spatter 38 10 16 Troubleshooting Incomplete Fusion 39 10 17 Troubleshooting Lack Of Penetration 39 10 18 Troubleshooting Excessive Penetration 39 10 19 Troubleshooting B...

Page 5: ...oduct Maxstar 200 STR conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Electromagnetic Capability Directives 89 336 92 31 EEC Standards Safety Requirements for Arc Welding Equipment part 1 EN 60974 1 1990 Arc Welding Equipment Part 1 Welding Power Sources IEC 974 1 December 1996 Draft revi...

Page 6: ...Notes ...

Page 7: ... 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach ...

Page 8: ...any combustibles such as a butane lighter or matches from your person before doing any welding Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag Wear approved safety glasses with side shields...

Page 9: ...ters and communicationsequipment Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high freq...

Page 10: ...Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 6 EMF Information Considerations About Welding And The E...

Page 11: ... alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l opérateur et les normes nationales provinciales et locales Toujours vérifier la terre du cordon d alimentation Vérifier et s assurer que le fil de terre du cordon d alimentation est bien raccordé à la borne de terre du s...

Page 12: ...ustible de ses poches telles qu un allumeur au butane ou des allumettes Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et prévoir un détecteur d incendie et un ex tincteur à proximité DES PARTICULES VOLANTES peuvent blesser les yeux Le soudage l écaillement le passage de la pièce à la brosse en fil de fer et le meulage génèrent des étincelles et des particules ...

Page 13: ...érences avec les équipe ments de radio navigation et de communica tion les services de sécurité et les ordinateurs Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l instal lation L utilisateurest tenu de faire corriger rapidement par un électri cien qualifié les interférences résultant de l installation Si le FCC signale des inter...

Page 14: ...art 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux régionaux le téléphone de la région 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques Le courant de soudage pendant son passage dans les ...

Page 15: ... Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and inj...

Page 16: ...it 8 Always wear long sleeves and button your collar when servicing unit 9 After taking proper precautions as shown connect power to unit S 185 836 60 s V V V 1 2 3 4 5 6 7 8 9 S 179 309 A 60 1 Warning Watch Out There are possible hazards as shown by the symbols 2 Falling equipment can cause injury and damage to unit 3 Always lift and support unit using both handles Keep angle of lifting device le...

Page 17: ...1 115V U 1 115V 3 4 Symbols And Definitions A Amperes High Temperature Gas Tungsten Arc Welding GTAW Shielded Metal Arc Welding SMAW V Volts Voltage Input 3 Phase Static Frequency Converter Transformer Rectifier Percent Arc Force DIG Remote Lift Arc Start GTAW Protective Earth Ground Alternating Current I2 Rated Welding Current S Seconds On Off Positive Negative X Duty Cycle Direct Current Line Co...

Page 18: ...TIG Process 175 A 17 VDC 60 Duty Cycle 1 200 80 9 14 17 4 0 23 8 5 25 4 0 0 05 4 0 0 02 Single Phase Stick Process 125 A 25 VDC 50 Duty Cycle 1 200 80 9 14 34 1 0 42 4 0 0 05 3 8 0 03 Single Phase TIG Process 150 A 16 VDC 70 Duty Cycle 1 200 80 9 14 29 7 0 42 3 4 0 05 3 4 0 03 Single Phase Stick Process 100 A 24 VDC 80 Duty Cycle 1 200 80 9 14 28 1 0 42 3 2 0 05 3 2 0 03 Single Phase TIG Process 1...

Page 19: ...set tings fall between curves shown 1 1 5 V A C In p u t 0 20 40 60 80 100 120 140 0 50 100 150 200 250 Amperes Vo lts O th e r In p u t V o lta g e s 0 20 40 60 80 100 120 140 0 50 100 150 200 250 Amperes Volts Amperage setting must be reduced to obtain currents less than highlighted data point Stick Max TIG Max Stick TIG Min DIG Max Stick Max TIG Max DIG Max Stick TIG Min ...

Page 20: ...r unit to cool Reduce amper age or duty cycle before welding Exceeding duty cycle can damage unit and void warranty 150 A 60 Duty Cycle For Stick Process Other Voltages 6 Minutes Welding 4 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes 175 A 60 Duty Cycle For TIG Process Other Voltages 90 A 100 Duty Cycle For 115 Volt Single Phase Stick Process 125 A 100 Duty Cycle For 115 Vo...

Page 21: ...ower supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Location And Airflow 3 1 18 in 460 mm 18 in 460 mm 802 886 A 2 17 1 4 in 438 mm 13 3 8 in 333 mm 7 9 16 in 192 mm Dimensions And Weight 34 7 lb 15 7 kg without power cord 37 3 lb 16 9 kg with power cord ...

Page 22: ...30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 Output Receptacles This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm2 for metric use Select weld cable size for pulsing application at peak amperage value S 00...

Page 23: ...erminal Connect TIG torch to negative weld output terminal 3 Gas Cylinder 4 Cylinder Valve Open valve slightly so gas flow blows dirt from valve Close valve 5 Regulator Flowmeter 6 Flow Adjust Typical flow rate is 15 cubic feet per hour 7 1 liters per minute Connect torch gas hose to regula tor flowmeter 7 Gas Valve Valve controls gas preflow and postflow Open valve on torch just before welding To...

Page 24: ...5 25 15 8 8 Normal Operating 3 35 30 20 10 10 Min Input Conductor Size In AWG 4 10 12 14 14 14 Max Recommended Input Conductor Length In Feet Meters 57 17 79 24 102 31 308 94 407 124 Min Grounding Conductor Size In AWG 4 10 12 14 14 14 Reference 2005 National Electrical Code NEC 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the re...

Page 25: ...thout removing cover to relink the power source For Three Phase Operation 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Green Or Green Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors L1 L2 And L3 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect ...

Page 26: ...link the power source 1 Black And White Input Conductor L1 And L2 2 Red Input Conductor 3 Green Or Green Yellow Grounding Conductor 4 Insulation Sleeving 5 Electrical Tape Insulate and isolate red conductor as shown 6 Input Power Cord 7 Disconnect Device switch shown in the OFF position 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green yellow groundin...

Page 27: ...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 Temperature Shutdown Light See Section 4 3 5 Power On Troubleshooting Help Aids Light See Section 6 3 6 Power Switch Use switch to turn unit and indicator light On Off 3 5 ...

Page 28: ...dicates 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 Temperature Shutdown Light See Section 4 3 5 Power On Troubleshooting Help Aids Light See Section 6 3 6 Power Switch Use switch to turn unit and indicator light On Off 1 2 4 3 5 ...

Page 29: ... as follows 1 TIG Electrode 2 Workpiece Turn gas on Touch tungsten elec trode to workpiece at weld start point Hold electrode to work piece for 1 2 seconds and slowly lift electrode Arc is formed when electrode is lifted Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output...

Page 30: ...ctrode touches workpiece For models with stock numbers 907 036 and 907 037 normal open circuit voltage is not present before electrode touches work piece only a low sensing voltage is present between electrode and workpiece 1 2 3 5 5 Amperage Control 1 A Amperage Control Rotate knob clockwise to increase amperage Min 200 amps 1 Min CE Model 1 Min 5 6 DIG Control 1 DIG Control Control increases SMA...

Page 31: ...Clean and tighten weld terminals Replace Damaged Gas Hose 3 Months Repair Or Replace Cracked Cables And Cords 6 Months Blow out inside During heavy service clean monthly Do not remove case when blowing out inside of unit see Section 6 2 6 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 802 886 A...

Page 32: ...ized Service Agent if this happens Help 1 Display Indicates a malfunction in the primary pow er circuit caused by an overcurrent condi tion in the primary IGBT switching circuit Contact a Factory Authorized Service Agent if this happens Help 2 Display Indicates an open in the thermal protection circuitry located on the bottom heat sink Contact a Factory Authorized Service Agent if this happens Hel...

Page 33: ... 3 and 6 3 Erratic or improper weld output Use proper size and type of weld cable see Section 4 5 Clean and tighten all weld connections see Section 4 5 Fan not operating Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor Wandering arc Use proper size tungsten see Section 8 Use properly prepared tungsten see Section 8 Reduce gas flow rate see ...

Page 34: ...OM 2233 Page 28 SECTION 7 ELECTRICAL DIAGRAMS Figure 7 1 Circuit Diagram 202 314 B ...

Page 35: ...m American Welding Society AWS and electrode manufacturers 8 2 Preparing Tungsten Electrode For DC Electrode Negative DCEN Welding Or AC Welding With Inverter Machines 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 infor mation Consider usi...

Page 36: ... flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten according to Section 8 Guidelines The inside diameter of the gas cup should be at least three times the tungsten diameter to provide ade quate shielding gas coverage For example if...

Page 37: ...h to front of pool Repeat process 75 75 Welding direction Form pool Tilt torch Add filler metal Move torch to front of pool Repeat process Remove rod Welding direction 15 9 3 Positioning Torch Tungsten For Various Weld Joints ST 162 003 S 0792 75 70 90 20 20 10 15 75 20 40 30 15 75 90 15 Butt Weld And Stringer Bead T Joint Lap Joint Corner Joint ...

Page 38: ...is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 10 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp cracklin...

Page 39: ...LLET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER 10 3 Striking an Arc Scratch Start Technique S 0049 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out elec...

Page 40: ... 10 6 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 10 7 Good Weld Bead Characteristics S 0052 B 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Meta...

Page 41: ...Correct Angle 10 9 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better NOTE S 0054 A 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wi...

Page 42: ... 3 4 10 11 Lap Joint S 0063 S 0064 1 Electrode 2 Single LayerFillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum strength 30 Or Less Single Layer Fillet Weld Multi Layer Fillet Weld 30 Or Less 1 1 2 3 10 12 Tee Joint S 0060 S 0058 A S 0061 1 El...

Page 43: ...e Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 10 15 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high ...

Page 44: ...d dirt from work surface before welding 10 17 Troubleshooting Lack Of Penetration 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 puddl...

Page 45: ...allel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 10 21 Troubleshooting Distortion Distortion contraction of weld met al during welding that forces base metal to move Base metal moves in the direction of the weld bead Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in ...

Page 46: ...e 40 SECTION 11 PARTS LIST Figure 11 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 ...

Page 47: ...bel Warning Electric Shock Exploding Parts CE Models 1 30 208998 Label Rating Card Code 122 Serial Stock Number 1 32 182826 Label Warning Electric Shock Power Cord 1 33 207310 Core Toroidal CE Models Only 1 34 215002 Clip Support PC Mtg 2 400 PC2 200851 Circuit Card Assy Power Interconnect 1 400 PC2 230162 Circuit Card Assy Power Interconnect CE ROHS 1 401 PC1 206129 Circuit Card Assy Inverter Con...

Page 48: ...10 200659 Lead List Small 1 11 185712 Insulator Bulkhead Front 2 12 185713 Insulator Bulkhead Rear 2 13 185714 Washer Tooth 20MM ID X 32MM OD 2 14 185717 Nut M20 X 1 5 1 0625 Hex 19 H Locking 2 15 185718 O Ring 0 989 ID X 0 070 Wall 2 16 186228 O Ring 0 739 ID X 0 070 Wall 2 17 202326 Recpt w leads and plug 14 pin 1 400 PC3 217272 Circuit Card Assy Front Panel Interface W Program 1 400 PC3 213922 ...

Page 49: ...Lower 1 3 195646 Panel Rear Upper 1 4 201155 Bushing Strain Relief 450 709 Id X1 068 Mtg Hole 1 5 207253 Plug Gas Fitting 1 600 198245 Nut Conduit 750 Npt Pld 1 388 Od X 150 Thk 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Mo...

Page 50: ... 3 Quantity Description Part No Dia Mkgs Item No 1 195649 Panel Plenum 1 3 FM1 230808 Fan Muffin 24vdc 4200 RPM 140 CFM 4 125 MTG HOLES 1 6 CR1 198549 Relay Encl 24vdc Spst 35a 300vac 4pin Flange Mtg 1 8 189790 Inductor Output 1 9 L2 210599 Coil Inductor 9t 1 10 L3 206020 Coil Inductor 14t 1 11 T1 212268 Xfmr HF Litz Litz w Boost 1 12 109056 Core Ferrite E 2 164 Lg X 1 094 High X 826 Wide 2 13 196...

Page 51: ...slt Brs Pln 4 605 229323 Nut 010 32 31hex 13h Stl Pld Sem Cone Wshr 38d 4 611 136343 Screw K50x 20 Pan Hd phl Stl Pld Pt Thread Forming 2 613 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 2 614 010381 Connector Rectifier 1 617 170647 Bushing Snap in nyl 1 312 ID X 1 500 Mtg Hole 2 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement P...

Page 52: ...2 6 209949 Heat Sink Module 1 7 199497 Heat Sink Secondary Assembly 1 8 L1 189787 Choke Input 1 10 C9 151328 Capacitor Polyp Met Film 0047Uf 1000 Vdc W T CE Models Only 1 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High CE Models Only 4 602 154408 Bushing Snap in Nyl 562 Id X 875 Mtg Hole Cent 1 When ordering a component originally displaying a precautionary label the label should also be ord...

Page 53: ...k Ohm 25 Deg C 18 in Lead 1 5 R2 C6 206021 Resistor Capacitor 1 6 R1 C5 199138 Resistor Capacitor 1 7 SR1 199952 Diode Power Module 50 Amp 600V 1 600 207451 Screw 008 32 x 50 Pan Hd Phl Stl Pld 2 601 231214 Screw 008 32 x 1 00 Pan Hd phl Stl Pld 1 602 207451 Screw 008 32 x 50 Pan Hd Phl Stl Pld Sems 1 604 207450 Screw 004 40 x 37 Pan Hd torx Stl Pld Cone Sems 4 606 229331 Screw M 6 1 0 x 16 Pan Hd...

Page 54: ...bly Figure 11 1 Item 5 Quantity Description Part No Dia Mkgs Item No 1 195644 Base 1 2 019663 Mount Nprn 15 16odx3 8rec 3 16x3 8 4 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor ...

Page 55: ...Induction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exceptio...

Page 56: ...d retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering...

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