Miller Electric Maxstar 200 Parts Manual, Serial Number Chart, and Wiring Diagram

Page 46

SECTION 11 − PARTS LIST

2734

401 400402

614

.Hardware is common and not available unless listed.

615

600 Figure 11-1. Main Assembly

803 107-E

OM-2233 Page 40

Image 46

Contents Processes OM-2233 203 409QDescription From Miller to You Table of Contents − Parts List Standards DirectivesDecstat6/05 Page Arc Welding Hazards Symbol UsageMarks a special safety message Electric Shock can killFlying Metal can injure eyes ARC Rays can burn eyes and skinWelding can cause fire or explosion Buildup of GAS can injure or killCalifornia Proposition 65 Warnings EMF Information Principal Safety StandardsAbout Pacemakers LES Fumées ET LES GAZ peuvent être dangereux UNE Décharge Électrique peut entraîner la mortIndique un message de sécurité particulier DES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer unIncendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures graves’EMPLOI Excessif peut SUR Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser 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 Models60 s Weee Label For Products Sold Within The EUFalling equipment can cause injury and damage to unit Symbols And Definitions Manufacturer’s Rating Label− Installation Specifications5 V a C In p u t Volt-Ampere CurvesTh e r In p u t V o lt a g e s Overheating Duty Cycle And OverheatingMinutes Welding MinutesSection Dimensions And WeightSelecting a Location Location And AirflowWeld Output Terminals And Selecting Cable Sizes Remote 14 Receptacle InformationTurn off power before mak- ing connections Input Voltage Electrical Service GuideStick Dcep Direct Current Electrode Positive Connections Input Amperes At Rated OutputFor Three-Phase Operation Connecting Input PowerConnecting Three-Phase Input Power = GND/PE Earth GroundConnecting Single-Phase Input Power Controls − OperationNon CE Units For CE Units Lift-Arc Start Lift-ArcStart ProcedureProcess Control ApplicationDIG Control Stick Start Procedure − Scratch Start TechniqueAmperage Control MinBlowing Out Inside Of Unit − Maintenance and TroubleshootingRoutine Maintenance MonthsOutput LED High Temperature LED Troubleshooting Help AidsHelp 8 Display Shield weld zone from drafts TroubleshootingTrouble Remedy 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 TorchTungsten Without Filler Rod Torch Movement During WeldingPositioning Torch Tungsten For Various Weld Joints Tungsten With Filler RodWeld current starts when electrode touches work- piece Stick Welding Procedure− Stick Welding Smaw Guidelines Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique Positioning Electrode Holder Poor Weld Bead CharacteristicsGood Weld Bead Characteristics 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingTee Joint Butt JointsLap Joint 16 in 30 1.6 mm Tack WeldsWeld Test Troubleshooting − PorosityTroubleshooting − Excessive Spatter Possible Causes Corrective ActionsTroubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion 2734 401 400402 614 − Parts List615 600 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 Your distributor also gives ServiceSupport For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co 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.

One of the standout features of the Maxstar 200 STR is its inverter technology, which allows for efficient energy use and a lightweight, portable design. Weighing in at just 51 pounds, it is easy to transport, making it perfect for fieldwork or remote projects. The unit operates on both 120V and 240V input power, providing versatility for different environments and applications. This adaptability ensures that welders can work effectively in various settings, whether in a shop or on a construction site.

Another significant characteristic of the Maxstar 200 STR is its precise arc control. The machine offers adjustable AC frequency, allowing users to fine-tune the arc characteristics for different materials and thicknesses. This level of control is particularly beneficial when working with aluminum, as it helps reduce heat input and minimize warping. The Maxstar also features a pulsing function, which can enhance the weld pool control and improve penetration, making it easier to achieve clean and consistent welds.

The Maxstar 200 STR boasts a robust duty cycle of 60% at 200A, ensuring that it can handle demanding jobs without overheating. Additionally, the unit is equipped with an advanced cooling system, which helps maintain optimal performance during extended use. Safety features, including overload protection and an enclosed design that reduces the risk of contamination, further enhance the machine's reliability.

Moreover, the Maxstar 200 STR supports a range of accessories, including a remote foot control, which allows for added flexibility during TIG welding operations. This feature is particularly useful for precise control over the welding current, enabling welders to make adjustments on the fly without having to stop and manually change settings.

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.