Miller Electric Comprehensive Miller Maxstar 200 Manual for Troubleshooting and Wiring Diagrams

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6-3. Troubleshooting Help Aids

1

2

.All directions are in reference to the

front of the unit. All circuitry referred to is located inside the unit.

1Output LED

2High Temperature LED

The Output LED turns on when power is turned on. The LED is also used to indicate several machine malfunctions. When one of the malfunctions listed below occurs, the LED will first turn off for 1.5 seconds, and then it will begin to blink. The number of blinks corresponds to a Help message re- lating to that malfunction. After the LED blinks the appropriate number of times, the LED will again turn off for 1.5 seconds, and the sequence will start again.

The malfunctions that correspond to Help 2, 3, 4, 5, and 9 are thermal related. The High Temperature LED turns on along with the blinking Output LED.

A malfunction relating to Help 0 will cause the the Output LED to turn off and stay off, but the High Temperature LED turns on and

stays on.

Help 0 Display

Indicates a short in the thermal protection circuitry located on the bottom heat sink. Contact a Factory Authorized 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.

Help 3 Display

Indicates the bottom heat sink has over- heated. The unit has shut down to allow the

fan to cool it (see Section 4-3). Operation will continue when the unit has cooled.

Help 4 Display

Indicates an open in the thermal protection circuitry located on the top heat sink. Con- tact a Factory Authorized Service Agent if this happens.

Help 5 Display

Indicates the top heat sink has overheated. The unit has shut down to allow the fan to cool it (see Section 4-3). Operation will con- tinue when the unit has cooled.

Help 8 Display

Indicates a malfunction in the secondary power circuit of the unit. There is a high open circuit condition. Contact a Factory Authorized Service Agent if this happens.

Help 9 Display

Indicates a short in the thermal protection circuitry located on the top heat sink. Con- tact a factory Authorized Service Agent if this happens.

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Contents Description OM-2233 203 409QProcesses From Miller to You Table of Contents − Parts List Decstat6/05 DirectivesStandards Page Symbol Usage Marks a special safety messageArc Welding Hazards Electric Shock can killARC Rays can burn eyes and skin Welding can cause fire or explosionFlying Metal can injure eyes Buildup of GAS can injure or killCalifornia Proposition 65 Warnings About Pacemakers Principal Safety StandardsEMF Information Indique un message de sécurité particulier UNE Décharge Électrique peut entraîner la mortLES Fumées ET LES GAZ peuvent être dangereux LE Soudage peut provoquer un Incendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures gravesRisque D’INCENDIE OU D’EXPLO LA Chute DE L’APPAREIL peut blesser’EMPLOI Excessif peut SUR DES Organes Mobiles peuvent provoquer des blessuresPrincipales normes de sécurité En ce qui concerne les stimulateurs cardiaquesElectric shock from welding electrode or wiring can kill − Definitions CE ModelsFalling equipment can cause injury and damage to unit Weee Label For Products Sold Within The EU60 s Symbols And Definitions Manufacturer’s Rating Label− Installation SpecificationsTh e r In p u t V o lt a g e s Volt-Ampere Curves5 V a C In p u t Duty Cycle And Overheating Minutes WeldingOverheating MinutesDimensions And Weight Selecting a LocationSection Location And AirflowWeld Output Terminals And Selecting Cable Sizes Remote 14 Receptacle InformationTurn off power before mak- ing connections Electrical Service Guide Stick Dcep Direct Current Electrode Positive ConnectionsInput Voltage Input Amperes At Rated OutputConnecting Input Power Connecting Three-Phase Input PowerFor Three-Phase Operation = GND/PE Earth GroundConnecting Single-Phase Input Power Non CE Units − OperationControls For CE Units Lift-ArcStart Procedure Process ControlLift-Arc Start ApplicationStick Start Procedure − Scratch Start Technique Amperage ControlDIG Control Min− Maintenance and Troubleshooting Routine MaintenanceBlowing Out Inside Of Unit MonthsHelp 8 Display Troubleshooting Help AidsOutput LED High Temperature LED Troubleshooting Trouble RemedyShield weld zone from drafts Check and tighten all gas fittings see Section− Electrical Diagrams Circuit DiagramAmperage Range Gas Type Polarity Up to− Guidelines for Gtaw TIG Welding Positioning The TorchTorch Movement During Welding Positioning Torch Tungsten For Various Weld JointsTungsten Without Filler Rod Tungsten With Filler Rod− Stick Welding Smaw Guidelines Stick Welding ProcedureWeld current starts when electrode touches work- piece Striking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead 615 600 − Parts List2734 401 400402 614 PC2 Panel, Front w/Components -1Item 602 400 601 603 605Panel, Rear w/Components Magnetics Assembly w/Components 1Item Windtunnel w/Components Windtunnel w/Components -1Item604 604 600 601 602Base Assembly Support ServiceYour distributor also gives To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s

Maxstar 200 STR specifications

The Miller Electric Maxstar 200 STR is a versatile and compact welding power source designed for a range of applications, making it an ideal choice for both professional welders and hobbyists. Known for its reliability and exceptional performance, the Maxstar 200 STR is capable of delivering high-quality results in various welding processes, including Stick (SMAW) and TIG (GTAW) welding.

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In summary, the Miller Electric Maxstar 200 STR stands out in the welding industry for its combination of portability, advanced technology, and high performance. With its inverter design, precise arc control, and robust duty cycle, it is an ideal solution for professionals seeking efficiency and quality in their welding projects, whether they are working on industrial applications or artistic endeavors.