SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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YWarning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

YMarks a special safety message.

.Means “Note”; not safety related.

1-2. Arc Welding Hazards

YThe symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.

YOnly qualified persons should install, operate, maintain, and repair this unit.

YDuring operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

DDo not touch live electrical parts.

DWear dry, hole-free insulating gloves and body protection.

DInsulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

DDo not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

DUse AC output ONLY if required for the welding process.

DIf AC output is required, use remote output control if present on unit.

DAdditional safety precautions are required when any of the follow- ing electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; 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 equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!

DDisconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

DProperly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

DAlways 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.

DWhen making input connections, attach proper grounding conduc- tor first − double-check connections.

DFrequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

DTurn off all equipment when not in use.

DDo not use worn, damaged, undersized, or poorly spliced cables.

DDo not drape cables over your body.

DIf earth grounding of the workpiece is required, ground it directly with a separate cable.

DDo not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

DDo not touch electrode holders connected to two welding ma- chines at the same time since double open-circuit voltage will be present.

DUse only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

DWear a safety harness if working above floor level.

DKeep all panels and covers securely in place.

DClamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

DInsulate work clamp when not connected to workpiece to prevent contact with any metal object.

DDo not connect more than one electrode or work cable to any single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter-type welding power sources after removal of input power.

DTurn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

DKeep your head out of the fumes. Do not breathe the fumes.

DIf inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.

DIf ventilation is poor, wear an approved air-supplied respirator.

DRead and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

DWork in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch- person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breath- ing air is safe.

DDo not weld in locations near degreasing, cleaning, or spraying op- erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

DDo not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

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Miller Electric Maxstar 200 STR Symbol Usage, Arc Welding Hazards, Electric Shock can kill, Marks a special safety message

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.