Miller Maxstar 200 DX Owner'S Manual Download Page 1

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Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

OM-2226

189783AL

2010

−

115/230/400/460 Volt Models W/Autoline

Arc Welding Power Source

Maxstar 200 SD, DX, And LX

(Including Optional Cart And Cooler)

CE And Non-CE Models

Summary of Contents for Maxstar 200 DX

Page 1: ...com Processes Description TIG GTAW Welding Stick SMAW Welding OM 2226 189783AL 2010 04 115 230 400 460 Volt Models W AutolineR Arc Welding Power Source Maxstar 200 SD DX And LX R Including Optional C...

Page 2: ...inue 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 t...

Page 3: ...s 15 4 4 Volt Ampere Curves 16 4 5 Duty Cycle And Overheating 17 4 6 Selecting A Location 18 4 7 Weld Output Terminals And Selecting Cable Sizes 19 4 8 Remote 14 Receptacle Information 20 4 9 Automati...

Page 4: ...0 9 2 Correct Installation 60 SECTION 10 SETUP GUIDES FOR GTAW TIG WELDING 61 10 1 DC GTAW 16 Gauge Stainless Steel Set Up 61 SECTION 11 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH IN...

Page 5: ...tic Compatibility Standards S IEC 60974 1 2005 Arc welding equipment Part 1 Welding power sources S IEC 60974 3 2007 Arc welding equipment Part 3 Arc striking and stabilizing devices S IEC 60974 10 20...

Page 6: ...Notes...

Page 7: ...s when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equ...

Page 8: ...ess they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to th...

Page 9: ...anels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers...

Page 10: ...eb site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www...

Page 11: ...source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivantes...

Page 12: ...laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer...

Page 13: ...t rieur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comp...

Page 14: ...tan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences D L nergie lectromagn tique risque de provoquer de...

Page 15: ...r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov App...

Page 16: ...OM 2226 Page 10...

Page 17: ...se 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 f...

Page 18: ...t 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...

Page 19: ...ional Load Voltage U1 Primary Voltage IP Degree Of Protection I1max Rated Maximum Supply Current I1eff Maximum Effective Supply Current U0 Rated No Load Voltage Average Pulse Background Amperage Initi...

Page 20: ...t such as torches liquid cooling systems and arc striking and stabilizing devices as part of the welding circuit may not be a major contributor to the EMF See the Owner s Manuals for all components of...

Page 21: ...1 200 80 9 14 15 KV 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 15 KV 34 1 0 42 4 0 0 05 3 8 0 03 Single Phase TIG Process 150 A 16 VDC 70 Du...

Page 22: ...set tings fall between curves shown Amperage setting must be reduced to obtain currents less than highlighted data point 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...

Page 23: ...een minutes for unit to cool Reduce amperage or voltage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty 150 A 60 Duty Cycle For Stick Process Other Voltages...

Page 24: ...ial installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Location And Airflow 1 18 in 460 mm 18 in 460 mm 802 451 17 1 4 in 438 mm 13 3 8 i...

Page 25: ...damaged under sized or poorly spliced cables 100 ft 30 m Or Less 150 ft 45 m 200 ft 60 m Welding Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle Output Receptacles 100 4 20 4 20 4 20 3 3...

Page 26: ...it common E 0 to 10 volts DC input command signal from remote control A V AMPERAGE VOLTAGE F Current feedback 1 volt DC per 100 amperes H Voltage feedback 1 volt DC per 10 volts output GND G 15 volts...

Page 27: ...at the end of the weld even if B to D closure is opened C Closure to D must be maintained at all times If the closure between pins C and D is broken an output disable occurs Postflow begins to time ou...

Page 28: ...unit Tools Needed 3 2 4 1 11 16 1 1 8 in 21 mm 4 12 TIG HF Impulse Lift Arc DCEN Direct Current Electrode Negative Connections Ref ST 802 471 Turn off power before mak ing connections 1 Negative Weld...

Page 29: ...r before mak ing connections 1 Negative Weld Output Terminal Connect work lead to negative weld output terminal 2 Positive Weld Output Terminal Connect electrode holder to posi tive weld output termin...

Page 30: ...is recom mended Recommended fuse or circuit breaker size is 15 amperes For 230 volt models an individual branch circuit capable of carrying 10 amperes and protected by fuses or circuit breakers is re...

Page 31: ...8 8 Normal Operating Fuses 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 Condu...

Page 32: ...out 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...

Page 33: ...nk 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 condu...

Page 34: ...function switch pads to change values for that function See Section 5 2 2 Ammeter And Parameter Display See Section 5 4 3 Voltmeter See Section 5 5 4 Process Controls See Section 5 6 5 Output Controls...

Page 35: ...ge Press Amperage switch pad and turn Encoder control to set weld amperage Weld amperage setting is also peak amperage when Pulser function is active see Section 5 9 2 3 1 5 4 Ammeter And Parameter Di...

Page 36: ...lected a pulsed HF non contact see Section 5 7 arc starting method is activated This method can be used with either AC or DC TIG welding Make connections according to Section 4 12 TIG Lift Arct When s...

Page 37: ...e and workpiece The solid state output contactor does not energize until after electrode is touching work piece This allows electrode to touch workpiece without overheating sticking or getting contami...

Page 38: ...f only type trigger is used it must be a maintained switch All Se quencer functions become active and must be set by the operator RMT 2T HOLD Application Use Remote Trigger Hold 2T when long extended...

Page 39: ...perage which cools the weld puddle and af fects overall heat input Background Amps is set as a percentage of peak amperage 4 Pulsed Output Waveforms Example shows affect changing the Peak Time control...

Page 40: ...hile GTAW welding to assist in preheat ing cold material prior to depositing filler material or to ensure a soft start INITIAL t Initial Time LX Models Only Press control again and turn Encoder to sel...

Page 41: ...tungsten and weld and to prevent contamination of tungsten and weld Increase postflow time if tungsten or weld are dark in ap pearance DIG If the Stick process is active see Section5 6 use control to...

Page 42: ...ter Default Range And Resolution PROCESS Stick OCV TIG HF Impulse Low OCV TIG HF Impulse TIG Lift Stick Low OCV Normal OCV Stick Stuck Check ScI On ScI On Sc0 Off OUTPUT RMT 2T1 RMT STD 2T RMT STD RMT...

Page 43: ...e Section 6 Parameter used with the automation option LX models only Parameter adjust using Tungsten GEN only 5 14 Resetting Unit To Factory Default Settings All Models 1 Process Switch Pad 2 Output S...

Page 44: ...lay Upon power up as described above the meter S LED will turn on and arc time will be displayed for 5 seconds as 000 000 to 999 999 The first four numbers indicate hours and the last two numbers indi...

Page 45: ...for 3T 4T Momentary or Mini Logic PreflowTime see Section 6 4 Sets the gas flow time before TIG arc starts Stick OCV Selection see Section 6 5 Allows you to select either low or normal OCV open circui...

Page 46: ...1 16 in 094 3 32 in or 125 1 8 in 094 is the default When one of the listed tungsten sizes is selected the following TIG starting parameters are preset Am perage Start Time Start Slope Time and Prese...

Page 47: ...Amperage 60 A Start Time 1 ms Start Slope Time 40 ms Preset Minimum Amps 3 A These parameters can be manually changed by pressing the Amperage switch pad to step through each adjustable paramet er To...

Page 48: ...3 by turning the Encoder con trol To change Start Time proceed to Section D 2 StA 20 3 Current A Start Amperage 1 D Changing Programmable Start Time 1 Amperage Switch Pad 2 Encoder Control 3 Amps Mete...

Page 49: ...ge Minimum proceed to Section F 2 StS 20 3 Current A Start Slope Time 1 F Changing Preset Amperage Minimum 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust Preset Amperage Minimum pro ce...

Page 50: ...se trigger When a foot or finger remote current control is connected to the welding power source initial amps initial slope final slope and final amps are controlled by the remote control not by the w...

Page 51: ...arted again If an initial switch closure is not made again before preflow time ends gas flow stops the timer resets and an initial switch press and release is necessary to start the weld sequence agai...

Page 52: ...peration rt 4tL Mini Logic 1 1 Mini Logic Meter Display 2 Encoder Control To select Mini Logic turn Encoder control Torch trigger operation is as shown Mini logic allows the operator to toggle between...

Page 53: ...by the welding power source Application Use 4T Momentary trigger method when the functions of a remote current control are desired but only a remote on off control is available rt 4tE 4T Momentary Ma...

Page 54: ...uencer settings will be ig nored and will not be program mable When a remote switch is con nected to the welding power source use the remote switch to control the weld cycle Am perage is controlled by...

Page 55: ...Trigger Operation Voltage V Current A Current A Touch Stick Lift Stick Touch Current Initial Amperage Initial Slope Main Amperage Touch Tungsten Lift Tungsten Slightly Lift Tungsten Electrode Electrod...

Page 56: ...pen circuit voltage for hard to start Stick electrodes or if required for your particular application oc 1 LO 2 6 6 Stick Stuck Check Selection 1 Encoder Control 2 Ammeter Parameters Select Display Tu...

Page 57: ...ckout code number The code number will appear on the amp meter Select any number from 1 thru 999 IMPORTANT remember this code number as you will need it to turn the lockout feature off Toggle Amperage...

Page 58: ...is played as a reminder Level 3 Remote amperage control is not avail able in level 3 Includes all the functions of levels 1 and 2 plus the following 10 adjustment of preset TIG or Stick Weld Amps Sele...

Page 59: ...disabled The PPP meter display feature will not effect the normal amper age display or Meter Hold capabil ities when in a non pulse welding mode 2 PLS 1 PPP 6 9 External Pulse Control 1 Encoder Contr...

Page 60: ...es Every 3 Months n lCables And Cords Every 6 Months Durning heavy service clean monthly Do not remove case when blowing out inside of unit see Section 7 2 B Optional Cooler n Check Z Change Clean Rep...

Page 61: ...OM 2226 Page 55 7 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 ST 802 451...

Page 62: ...shown 5 Help 5 Display Indicates the top heat sink has overheated The unit has shut down to allow the fan to cool it see Section 4 5 Operation will con tinue when the unit has cooled 6 Help 8 Display...

Page 63: ...eck repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 4 5 Erratic or improper weld output Use proper size and type of weld cable see Section 4 7 Clean and tig...

Page 64: ...OM 2226 Page 58 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual...

Page 65: ...OM 2226 Page 59 SECTION 8 ELECTRICAL DIAGRAMS Figure 8 1 Circuit Diagram 237 566 B...

Page 66: ...onduit sections using copper straps or braided wire Ground conduit every 50 ft 15 m 5 Water Pipes And Fixtures Ground water pipes every 50 ft 15 m 6 External Power Or Telephone Lines Locate HF source...

Page 67: ...pad until Post Flow LED is lit Turn Encoder control to set 8 seconds of Post Flow time Press Amperage A switch pad until LED is lit Turn Encoder control to set desired amperage 50 80 amps The ammeter...

Page 68: ...mendations from American Welding Society AWS and electrode manufacturers 11 2 Preparing Tungsten Electrode For DC Electrode Negative DCEN Welding Or AC Welding With Inverter Machines Grinding the tung...

Page 69: ...entally safe way Wear proper face hand and body protection Keep 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 F...

Page 70: ...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 12 3 Positioning Torch Tungste...

Page 71: ...Direct Current Electrode Positive ST 207 690 A 1 Front Panel Correct front panel display for basic Stick DCEP welding For all front panel switch pad controls press switch pad to turn on light and enab...

Page 72: ...s clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode re quires less current than a large one Follow electrode manufactur er s instructions when setting weld amperage see Section...

Page 73: ...L ALL ALL FLAT HORIZ FILLET 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 A...

Page 74: ...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 14 6 Good Weld Bead Characteristics S 0052 B 1 Fine Spat...

Page 75: ...base metal 14 8 Electrode Movement During Welding S 0054 A Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across ga...

Page 76: ...5 mm 30 2 1 1 16 in 1 6 mm 3 4 14 10 Lap Joint S 0063 S 0064 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fill...

Page 77: ...rm near weld bead Possible Causes Corrective Actions Amperage too high for electrode Decrease amperage or select larger electrode Arc length too long or voltage too high Reduce arc length or voltage I...

Page 78: ...and or maintain steady travel speed Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Sel...

Page 79: ...OM 2226 Page 73 Notes...

Page 80: ...4 SECTION 15 PARTS LIST Figure 15 1 Main Assembly 803 227 G Hardware is common and not available unless listed 1 17 614 15 3 600 14 402 400 401 16 38 18 19 11 28 25 28 12 615 8 13 35 6 10 2 37 30 4 9...

Page 81: ...hock Exploding Parts Non CE Models 1 30 185836 Label Warning Electric Shock Exploding Parts CE Models 1 33 215002 Clip Support PC Mtg 2 35 C10 213912 Capacitor Polye Film 1 UF 1000 VDC w Terms CE Mode...

Page 82: ...Type 50 70 Series Wsl 2 9 193649 Ftg Gas Barbed 1 4 TBG 5 8 18 Female Non CE Models 1 9 193650 Ftg Gas Barbed 1 4 TBG 3 8 19 BSPP Male CE Models 1 11 185712 Insulator Bulkhead Front 2 12 185713 Insul...

Page 83: ...tg Gas Barbed 1 4 TBG 3 8 19 BSPP Male CE Models 1 6 RC2 199882 Receptacle W Leads 4 Plug 10 pin LX Models 1 146 212 Conn Circ Ms Met 10Pin Sz 18 Plug Cable Solder Mates With RC2 LX Models 1 200 544 C...

Page 84: ...o 1 X 250 Id X 12 250 2 6 CR1 198549 Relay Encl 24vdc Spst 35a 300vac 4pin Flange Mtg 1 7 112863 Ftg Hose Brs Barbed M 1 4 Tbg X 5 8 18 Sae Flare 1 8 Z1 189790 Inductor Output 1 9 L2 210599 Coil induc...

Page 85: ...l 937 Id X 1 125 Mtg Hole 2 609 137761 Nut 750NPT 1 31Hex 27h Nyl Blk 1 611 231179 Screw K50 x 20 Pan Hd phl Stl Pld Pt Thread Forming 2 614 010381 Connector Rectifier 1 617 170647 Bushing Snap in Nyl...

Page 86: ...tor 2 6 209949 Heat Sink Primary 1 7 199497 Heat Sink Secondary Assembly 1 8 L1 189787 Choke Input 1 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High CE Models 4 10 C9 151328 Capacitor Polyp Met...

Page 87: ...98028 Transducer Current 100a Module Supply V 15v 1 4 RT1 211124 Thermistor Ntc 30k 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...

Page 88: ...gure 15 1 Item 5 Quantity Description Part No Dia Mkgs Item No 1 195644 Base 1 2 239388 Bumper RBR 875 OD x 188 ID x 39 High Recessed 4 To maintain the factory original performance of your equipment u...

Page 89: ...OM 2226 Page 83 Notes...

Page 90: ...e 84 SECTION 16 COOLER PARTS LIST Hardware is common and not available unless listed 805 266 A 1 2 3 4 5 6 7 9 8 13 10 11 13 12 14 7 16 15 6 7 15 19 18 22 23 24 25 19 27 26 21 20 17 28 Figure 16 1 Mai...

Page 91: ...1 Damper Fluid Pulsation 1 17 MOT 235457 Pump Assy Coolant 115V 1 17 MOT 235501 Pump Assy Coolant 230V 1 18 PLG1 192457 Cable Power 11 Ft 7 In 16ga 3c 115V 1 18 PLG1 192458 Cable Power 11 Ft 7 In 16ga...

Page 92: ...d torx W Gndrng Stl Pld 7 8 235515 Tray Cooler 1 9 602250 Washer Flat 812 ID x 1 469 OD x 134t Stl Pld Ansi 750 4 10 163463 Wheel Rbr Tire 10 000 OD X 2 000 Wide X 750 Bore 2 11 121614 Ring Rtng Ext 7...

Page 93: ...bles No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Cont...

Page 94: ...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 Equip...

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