Miller Maxstar 200 LX User manual

Miller Maxstar 200 LX User manual
Maxstar 200 Series
Issued March 2001 • Index No. DC/32
®
Quick
Specs
TIG/Stick Welding
Power Source
Heavy Industrial Applications
Processes
Input Power
Petro/Chem Fabrication
Aerospace
Food/Beverage Industry
Mechanical Contractors
Shipboard Installation/Repair
Dairy Industry
TIG (GTAW)
Pulsed TIG (GTAW-P)
with DX and LX Models
Stick (SMAW)
Amperage Range
Requires 3- or 1-Phase Power
1 – 200 A
Max. Open-Circuit Voltage
Weight
80
37 lb (16.8 kg)
The Power of Blue .
®
Auto-Line™ provides state-of-theart flexibility to the end user. The
Auto-Line circuitry automatically
connects to 120 – 460 VAC, singleor three-phase power without
removing the covers to relink the
power source. No longer is there a
concern if you have the correct
machine for shop or the job site.
HF arc starting provides non-contact arc starting
that eliminates tungsten or material contamination.
Lift-Arc™ start provides TIG arc starting without
the use of high frequency.
New!
Portable in the shop or at the job site
— at 37 lb the Maxstar 200 is easily
moved from location to location.
Inverter-based, DC power source
has state-of-the-art operator
interface allowing the user extra
set-up capabilities in a compact
machine. Features more precise
control of output parameters than
traditional knobs and switches.
Superior TIG/Stick arc performance
on all input voltages. Even on the
difficult to run electrodes like E6010.
Maxstar 200 DX
Maxstar 200 SD
Maxstar 200 LX
Available in Three Models:
SD — Provides the basic features that are required for most TIG or Stick welding applications.
DX — When the job demands greater control the DX provides pulse on/off, pulse frequency, peak % time,
background amperage, initial amperage, initial slope time, final slope time and final amperage control.
Programmable HF start parameters
allows the independently set
HF starting conditions based upon
process and memory selection.
LX — Automation made simple. With the Automation Interface Connector, the integrator can quickly
interface to the output disable, weld start/stop, gas start/stop inputs; valid arc, pulse lock out, and
end of weld sequence outputs.
Power source is warranted for 3 years, parts and labor.
Original main power rectified parts are warranted for 5 years.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
(Subject to change without notice.)
Max.
OpenCircuit
Voltage
Welding
Mode
Input
Power
Rated
Output
Welding
Amperage
Range
TIG
(GTAW)
3-Phase
175 A at 17 V,
60% Duty Cycle
120 VAC,
1–110 A
1-Phase
175 A at 17 V,
60% Duty Cycle
200 –460 VAC,
1–200 A
Stick
(SMAW)
Amps Input at Rated Load Output, 50/60 Hz,
120 V 200 V 230 V 400 V 440 V 460 V
KVA
—
—
12.1 10.5 6.0
0.16* 0.16* 0.24*
5.3
0.24*
5.2
0.25*
4.2
4.0
0.06* 0.03*
—
—
19.9 17.4 —
0.25* 0.23* —
—
—
—
—
4.0
4.0
0.05* 0.02*
150 A at 16 V,
70% Duty Cycle
29.7 17.1 14.1 —
0.42* 0.25* 0.23* —
—
—
—
—
3.4
3.4
0.05* 0.03*
110 A at 15 V,
100% Duty Cycle
20.0 —
0.42* —
—
—
—
—
2.0
2.0
0.05* 0.03*
80 VDC
—
—
—
—
KW
—
—
14.7 13.1 7.4
0.16* 0.16* 0.24*
6.6
0.24*
6.4
0.25*
5.2
5.0
0.06* 0.03*
—
—
24.9 21.7 —
0.25* 0.23* —
—
—
—
—
5.0
5.0
0.05* 0.02*
125 A at 25 V,
50% Duty Cycle
34.1 19.6 17.2 —
0.42* 0.25* 0.23* —
—
—
—
—
4.0
3.8
0.05* 0.03*
90 A at 24 V,
100% Duty Cycle
25.0 —
0.42* —
—
—
—
—
4.0
3.8
0.05* 0.03*
80 VDC
3-Phase
150 A at 26 V,
60% Duty Cycle
120 VAC,
1–90 A
1-Phase
150 A at 26 V,
60% Duty Cycle
200 –460 VAC,
1–200 A
—
—
—
—
Dimensions
H: 13-1/2 in
(343 mm)
W: 7-1/2 in
(191 mm)
D: 17-1/2 in
(445 mm)
Net
Weight
37 lb
(16.8 kg)
*Indicates idle draw.
CSA approval.
Models with CE specifications are available and manufactured according to the Standards IEC-974-1 and EN-60974-1.
Control Panel
Maxstar 200 DX/LX
Maxstar 200 SD
5
1
2
5
1
2
6
1. Voltmeter
2. Ammeter
3. Process Control
4. Output Control
5. Encoder Control
6. Amperage Control
7. Adjust Control
8. Sequencer Controls
9. Pulser Controls
3
4
7
6
3
4
Maxstar 200 DX/LX (CE)
Maxstar 200 SD (CE)
5
1
7
8
9
5
1
2
2
6
6
3
4
7
8
3
4
7
8
9
Control Panel Parameter Values
A.
B.
C.
D.
E.
2
Preflow (s)
Initial Time (s)
Initial Amperage (A)
Initial Slope Time (s)
Weld Amperage (A)
0.0 – 25
0.0 – 25 (LX only)
1 – 200
0.0 – 25
1 – 200
F.
G.
H.
I.
J.
Pulse Frequency (Hz)
Background Amperage (%)
Peak Percent Time (%)
Final Slope Time (s)
Final Amperage (A)
0.1 – 500
0 – 100
5 – 95
0.0 – 25
1 – 200
K. Final Time (s)
L. Postflow Time (s)
M. Dig (%)
0.0 – 25 (LX only)
0 – 0.50
0 – 100
Performance Data
140
200
STICK
VOLTS
100
STICK
(115 V INPUT)
0
10
STICK MAX.
100
TIG MAX.
150
50
120
STICK MAX.
100
60
40
40
100
60
STICK/
TIG MIN.
20
DIG MAX.
0
DIG MAX.
0
0
% DUTY CYCLE
80
40
STICK/
TIG MIN.
20
30
TIG MAX.
80
VOLTS
TIG (115 V INPUT)
140
120
TIG
OUTPUT AMPERES
OTHER INPUT VOLTAGES
115 VAC INPUT
MAXSTAR 200 DUTY CYCLE CHART
250
50
100
150
200
250
AMPERES
0
50
100
150
200
250
AMPERES
Included Accessories
Non-CE SD/DX Models Include:
(2) International-style connectors 35/50
Non-CE LX Model Includes:
(2) International-style connectors 35/50
(1) 14-pin amphenol with clamp
(1) 10-pin amphenol with clamp
CE SD/DX Models Include:
(2) International-style connectors 35/50
(1) 14-pin amphenol with clamp
(1) 5/8 in - 18 gas fitting
CE LX Model Includes:
(2) International-style connectors 35/50
(1) 14-pin amphenol with clamp
(1) 10-pin amphenol with clamp
(1) 5/8 in - 18 gas fitting
Genuine Miller Accessories
Remote Controls
RFCS-14 HD Foot
Control #194 744
For all Miller solidstate power sources
after serial number
JK674521. This new
design increases stability with a larger base
and durability with a heavier cord. Maximum
flexibility is accomplished with a reconfigurable
cord that can exit the front, back or either
side of the pedal. Foot pedal provides
remote current and contactor control.
Includes 20 ft (6 m) cord and 14-pin plug.
RFCS-14 Foot
Control #043 554
For all Miller solidstate power sources
after serial number
JK674521. Foot pedal
provides remote current and contactor control.
Includes 20 ft (6 m) cord and 14-pin plug.
RCCS-14 Remote
Contactor and
Current Control
#043 688
For all Miller solid-state power sources
after serial number JK674521. North/south
rotary-motion fingertip control fastens to
TIG torch using two Velcro® straps. Great
for applications that require a finer amperage
control. Includes 26.5 ft (8 m) control cord
and 14-pin plug.
RCC-14 Remote
Contactor and
Current Control
#151 086
For all Miller solid-state power sources
after serial number JK674521. Side-to-side
rotary-motion fingertip control fastens to
TIG torch using two Velcro® straps. Great for
production or contractors that need quick
ramp-up. Includes 26.5 ft (8 m) control cord
and 14-pin plug.
RMLS-14 Switch #129 337
For all Miller solid-state power sources
after serial number JK674521. Momentaryand maintained-contact rocker switch
for contactor control. Push forward for
maintained contact and backward for
momentary contact. Includes 26.5 ft
(8 m) cord and 14-pin plug.
RMS-14 On/Off Control #187 208
For all Miller solid-state power sources
after serial number JK674521. Momentarycontact switch for contactor control. Rubbercovered pushbutton dome switch ideal for
repetitive on-off applications. Includes 26.5 ft
(8 m) cord and 14-pin plug.
Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15 m)
#122 975 75 ft (23 m)
For 14-pin remote controls. 25, 50 or 75 ft
(7.6, 15.2 or 22.8 m) cords. 14-pin plug to
a 14-pin socket.
TIG (GTAW) Torches
Diamondback™ TIG Torches
The NEW Diamondback line of ergonomically
designed TIG torches from Miller Electric
complements the most popular TIG power
source line available today. The Diamondback
torch line includes both air-cooled and
water-cooled models. The air-cooled models
range in size from 125 to 200 A. The watercooled models include 250 and 350 A torches.
All models are standard with a rigid head.
See Diamondback TIG Torch Selector Guide.
TIG (GTAW) Torch Adapters
DA-917F #194 720
Used to adapt a 1-piece 125 or 150 amp
air-cooled torch to an International-style
connector.
DA-1820L #190 219
Used to adapt a 250 or 350 amp water-cooled
torch to an International-style connector.
DA-26R #194 724
Used to adapt a 1-piece 200 amp air-cooled
torch to an International-style connector.
3
International-Style Connectors
Note: All Maxstar power sources are equipped with
International-style connectors for secondary connections.
(Power source is shipped with two 50-mm male
International-style plugs for use with #1 or #2 AWG
size cable.)
International-Style Connector Kit
#042 418 50 mm
Accepts #1 or #2 AWG cable size. Required
if male plugs shipped with power source must
be replaced or if additional plugs are needed.
Kit includes one International-style male
plug which attaches to the work and/or
weld cables and plugs into the Internationalstyle receptacles on the power source.
(Will accept Dinse™ or other international connectors.)
Extension Kit for International-Style
Cable Connectors #042 419 50 mm
Accepts #1 or #2 AWG size cable. Used to
adapt or extend weld and/or work cables.
Kit includes one male International-style
plug and one in-line female Internationalstyle receptacle.
International/Tweco®
Adapter #042 465
A one-piece adapter
which has an
International-style male
plug (to power source) on one end and a
female Tweco receptacle (for weld cable
connection) on other end.
International/Cam-Lok
Adapter #042 466
A one-piece adapter
which has an
International-style
male plug (to power source) on one end
and a Cam-Lok receptacle (for weld cable
connection) on other end.
Ordering Information
Power Source and Options
Stock No.
Description
Maxstar® 200 SD
#903 701
#903 768
#903 701-01-1
#903 768-01-1
#903 701-01-2
#903 768-02-1
Basic controls for TIG/Stick, 120 – 460 VAC
Basic controls for TIG/Stick, 120 – 460 VAC with CE
Full-feature controls for TIG/Stick, 120 – 460 VAC
Full-feature controls for TIG/Stick, 120 – 460 VAC with CE
Full-feature controls with the required automation connections, 120 – 460 VAC
Full-feature controls with the required automation connections, 120 – 460 VAC with CE
#194 720
#190 219
#194 724
DA-917F
DA-1820L
DA-26R
See Diamondback TIG Torch Selector Guide
See Parts Guide
#194 744
#043 554
#043 688
#151 086
#129 337
#187 208
Heavy-duty foot control
Foot control
North/south fingertip control
Side-to-side fingertip control
Momentary/maintained rocker control
Momentary rubber dome switch
See page 3
115 VAC
115 VAC with CE
230 VAC
230 VAC with CE
115 VAC
115 VAC, 50/60 Hz with CE
115 VAC
115 VAC with CE
Aluminum-Protecting Coolant
Low-Conductivity Coolant
#043 007
#043 007-01-2
#043 008
#043 008-01-2
#043 009
#043 009-01-2
#042 288
#042 288-01-5
#043 809
#043 810
International-Style Connectors
International-Style Connector Kit
Extension Kit for International-Style
International/Tweco® Adapter
International/Cam-Lok Adapter
#042 418
#042 419
#042 465
#042 466
50 mm
50 mm
A one-piece adapter with International-style male plug
A one-piece adapter with International-style male plug
Maxstar® 200 DX
Maxstar® 200 LX
TIG Accessories
TIG Torch Adapters
Diamondback™ TIG Torches
Consumables/Tungsten
Gas Cylinder/Hose and Fittings
Remote Controls
RFCS-14 HD
RFCS-14
RCCS-14
RCC-14
RMLS-14
RMS-14
Extension Cords
Coolant Systems
Coolmate™ 3
Coolmate™ V3
Coolmate™ 4
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Qty.
Price
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