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Miller Electric Maxstar 200 STR manual Table of Contents

Models: Maxstar 200 STR

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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING		1
1-1.	Symbol Usage	1
1-2.	Arc Welding Hazards	1
1-3.	Additional Symbols For Installation, Operation, And Maintenance	3
1-4.	California Proposition 65 Warnings	3
1-5.	Principal Safety Standards	4
1-6.	EMF Information	4
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION		5
2-1.	Signification des symboles	5
2-2.	Dangers relatifs au soudage à l’arc	5
2-3.	Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil	7
2-4.	Principales normes de sécurité	8
2-5.	Information sur les champs électromagnétiques	8
SECTION 3 − DEFINITIONS (CE Models)		9
3-1.	Warning Label Definitions	9
3-2.	Manufacturer’s Rating Label	11
3-3.	Symbols And Definitions	11
SECTION 4 − INSTALLATION		12
4-1.	Specifications	12
4-2.	Volt-Ampere Curves	13
4-3. Duty Cycle And Overheating		14
4-4.	Selecting A Location	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. Stick Start Procedure − Scratch Start Technique		23
5-5.	Amperage Control	23
5-6.	DIG Control	23
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING		24
6-1.	Routine Maintenance	24
6-2.	Blowing Out Inside Of Unit	24
6-3.	Troubleshooting Help Aids	25
6-4.	Troubleshooting	26
SECTION 7 − ELECTRICAL DIAGRAMS		27
SECTION 8 − SELECTING AND PREPARING
TUNGSTEN ELECTRODE		28
8-1.	Selecting Tungsten Electrode	28
8-2.	Safety Information About Tungsten	28
8-3.	Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding	29
SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW)		30
9-1.	Positioning The Torch	30
9-2.	Torch Movement During Welding	31
9-3.	Positioning Torch Tungsten For Various Weld Joints	32

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Miller Electric Maxstar 200 STR manual Table of Contents

Contents

OM-2233 203 409Q ProcessesDescription From Miller to You Table of Contents − Parts List Directives StandardsDecstat6/05 Page Electric Shock can kill Symbol UsageMarks a special safety message Arc Welding HazardsBuildup of GAS can injure or kill ARC Rays can burn eyes and skinWelding can cause fire or explosion Flying Metal can injure eyesCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Pacemakers UNE Décharge Électrique peut entraîner la mort LES Fumées ET LES GAZ peuvent être dangereuxIndique un message de sécurité particulier DES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer unIncendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser ’EMPLOI Excessif peut SUREn ce qui concerne les stimulateurs cardiaques Principales normes de sécurité− Definitions CE Models Electric shock from welding electrode or wiring can killWeee Label For Products Sold Within The EU 60 sFalling equipment can cause injury and damage to unit Manufacturer’s Rating Label Symbols And DefinitionsSpecifications − InstallationVolt-Ampere Curves 5 V a C In p u tTh e r In p u t V o lt a g e s Minutes Duty Cycle And OverheatingMinutes Welding OverheatingLocation And Airflow Dimensions And WeightSelecting a Location SectionRemote 14 Receptacle Information Weld Output Terminals And Selecting Cable SizesTurn off power before mak- ing connections Input Amperes At Rated Output Electrical Service GuideStick Dcep Direct Current Electrode Positive Connections Input Voltage= GND/PE Earth Ground Connecting Input PowerConnecting Three-Phase Input Power For Three-Phase OperationConnecting Single-Phase Input Power − Operation ControlsNon CE Units For CE Units Application Lift-ArcStart ProcedureProcess Control Lift-Arc StartMin Stick Start Procedure − Scratch Start TechniqueAmperage Control DIG ControlMonths − Maintenance and TroubleshootingRoutine Maintenance Blowing Out Inside Of UnitTroubleshooting Help Aids Output LED High Temperature LEDHelp 8 Display Check and tighten all gas fittings see Section TroubleshootingTrouble Remedy Shield weld zone from draftsCircuit Diagram − Electrical DiagramsUp to Amperage Range Gas Type PolarityPositioning The Torch − Guidelines for Gtaw TIG WeldingTungsten With Filler Rod Torch Movement During WeldingPositioning Torch Tungsten For Various Weld Joints Tungsten Without Filler RodStick Welding Procedure Weld current starts when electrode touches work- piece− Stick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode HolderElectrode Movement During Welding Conditions That Affect Weld Bead Shape16 in 30 1.6 mm Tack Welds Butt JointsLap Joint Tee JointPossible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld TestTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion − Parts List 2734 401 400402 614615 600 PC2 602 400 601 603 605 Panel, Front w/Components -1ItemPanel, Rear w/Components Magnetics Assembly w/Components 1Item Windtunnel w/Components -1Item Windtunnel w/Components604 600 601 602 604Base Assembly Service Your distributor also givesSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact