Miller Electric Maxstar 200 STR User manual

Miller Electric Maxstar 200 STR User manual
Maxstar 200 STR
Issued September 2003 • Index No. DC/29.5
®
Quick
Specs
Stick/TIG Welding
Power Source
Industrial Applications
Processes
Input Power
Petro/Chem Fabrication
Mechanical Contractors
Shipboard Installation
Mining
Process Piping
MRO
Stick (SMAW) Lift Stick
TIG (GTAW) Lift-Arc
Amperage Range
Requires 1- or 3-Phase Power
5 – 200 A
Max. Open-Circuit Voltage
Weight
80
32 lb (14.5 kg)
The Power of Blue .
®
Includes two International-style
connectors 35/50.
Easy installation — Auto-Line™
provides state-of-the-art flexibility
to the end user. The Auto-Line
circuitry automatically connects
to 120 – 460 VAC, single- or
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.
Superior Stick arc performance
on all input voltages. Even on the
difficult-to-run electrodes like E6010.
Lift-Arc™ start provides TIG arc starting without the use of high frequency.
Portable in the shop or at the job
site — at 32 lb the Maxstar 200 STR
easily moves from location to location.
NEW! Low OCV Stick is a simple
design that reduces the opencircuit voltage to 13 volts when
the welding power source is not
in use. This circuit design is now
built into the Maxstar 200 STR
eliminating the need for add-on
voltage reducers.
Inverter-based, DC power source has
a simple-to-use operator interface
providing only the necessary
controls in a compact machine.
DIG control allows the arc characteristics to be changed for specific
applications and electrodes. Lower
the DIG setting for smooth running
electrodes like E7018 and increase
the DIG setting for stiffer, more
penetrating electrodes like E6010.
Adaptive Hot Start™ for Stick arc
starts automatically increases the
output amperage at the start of a
weld should the start require it.
Prevents the electrode from sticking
and creating an inclusion.
Remote amperage control provided
through 14-pin receptacle on front
of the machine. This permits use
of standard remote amperage
control devices.
Optional 4-pack racks are available
for multiple operator applications.
These are commonly used in
construction and shipyard applications.
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.)
Welding
Mode
Input
Power
Rated
Output
Welding
Amperage
Range
Stick
(SMAW)
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
TIG
(GTAW)
Max.
OpenCircuit
Voltage
—
80 VDC,
9–14 VDC** —
Amps Input at Rated Load Output, 50/60 Hz,
120 V 200 V 230 V 400 V 440 V 460 V KVA
14.7 13.1 7.4
6.6
6.4
5.2
5.0
0.16* 0.16* 0.24* 0.24* 0.25* 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*
3-Phase
175 A at 17 V,
60% Duty Cycle
120 VAC,
1 –140 A
1-Phase
175 A at 17 V,
60% Duty Cycle
200 – 460 VAC,
1 –200 A
—
—
KW
—
—
—
—
—
—
12.1 10.5 6.0
5.3
5.2
4.2
4.0
0.16* 0.16* 0.24* 0.24* 0.25* 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
—
—
—
—
Dimensions
H: 13-1/2 in
(343 mm)
W: 7-1/2 in
(191 mm)
D: 17-1/2 in
(445 mm)
Net
Weight
32 lb
(14.5 kg)
*Indicates idle draw. **Sense voltage for Stick and Lift-Arc TIG.
CSA applied for.
Models with CE specifications are available and manufactured according to the Standards IEC-974-1 and EN-60974-1.
Control Panel
Maxstar 200 STR
Maxstar 200 STR (CE)
1
2
1
2
4
5
3
4
5
3
1. Output Light
2. Overtemp Light
3. Weld Process Selector Switch
4. Amperage Adjustment Control
5. Dig Adjustment Control
Control Panel Parameter Values
A. Amperage (A)
2
5 – 200
B. Dig Control (%)
1 – 100
Performance Data
140
200
STICK
VOLTS
100
0
10
STICK MAX.
100
TIG MAX.
150
50
120
STICK MAX.
100
STICK
(115 V INPUT)
60
40
40
60
STICK/
TIG MIN.
20
DIG MAX.
0
100
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
DUTY CYCLE CHART
250
DIG MAX.
0
0
50
100
% DUTY CYCLE
150
200
250
0
50
100
150
200
250
AMPERES
AMPERES
Genuine Miller Accessories
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-26R #194 724
Used to adapt a 1-piece 200 amp air-cooled
torch to an International-style connector.
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.
DA-1820L #190 219
Used to adapt a 250 or 350 amp water-cooled
torch to an International-style connector.
Remote Controls
RCC-14 Remote
Contactor and
Current Control
#151 086 14-pin plug
Side-to-side rotary-motion fingertip control
fastens to TIG torch using two Velcro®
straps. Includes 28 ft (8.5 m) control cord.
Great for production or contractors that
need quick ramp-up.
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.
RCCS-14 Remote
Contactor and
Current Control
#043 688
Up-and-down rotary-motion fingertip
control fastens to TIG torch using two
Velcro® straps. Includes 28 ft (8.5 m)
control cord. Great for applications that
require a finer amperage control.
RFCS-14 HD Foot
Control #194 744
New design with larger,
more stable base and
heavier cord that can
exit front, back or sides of pedal. Provides
remote current and contactor control and
includes 20 ft (6 m) cord and 14-pin plug.
RHC-14 Hand Control
#129 340
Miniature hand control for
remote current and contactor
control. Dimensions: 4 x 4
x 3-1/4 in (102 x 102 x 82 mm). Includes
20 ft (6 m) cord and 14-pin plug.
(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/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.
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.
3
CST (Maxstar ) Rack
™
®
Rugged enclosure provides a simple means
for protecting and transporting multiple
welding power sources for construction,
power plant turn-arounds, and shipbuilding
applications.
Light weight and small footprint for easy
transportation. Low weight enables the use of
elevators to move the rack.
CST Rack Specifications
Top cover protects machines from falling debris.
Lifting eye simplifies transportation using
crane or overhead lifting device.
Lift truck side and end fork pockets.
One main disconnect box with fused circuit
breaker switches for each machine.
Common output ground connection
(for same polarity use only).
(Subject to change without notice.)
Power Source
Used
Input Power to Rack
Maxstar 200
STR
230 – 460 V, 60 Hz,
Three-Phase
Rack
Capacity
4
Dimensions
Net Weight
H: 59-3/8 in (1508 mm)
W: 43 in (1092 mm)
D: 34-3/8 in (873 mm)
298 lb
(135 kg)
Ordering Information
Power Source and Options
Stock No.
Description
Maxstar 200 STR
#907 036
#907 037
120 – 460 VAC, 50/60 Hz
120 – 460 VAC, 50/60 Hz, CE
CST™ (Maxstar) Rack
#195 051
#907 079
Empty Rack
With four Maxstar 200 STRs for 230–460 V
#194 720
#194 724
#190 219
DA-917F
DA-26R
DA-1820L
®
Qty.
TIG Accessories
Diamondback™ TIG Torches
TIG Torch Adapters
See Diamondback TIG Torch Selector Guide
Consumables/Tungsten
See Parts Guide
Gas Cylinder/Hose and Fittings
Remote Controls
RCC-14
#151 086
Remote current side-to-side rotary control
RCCS-14
#043 688
Remote current up and down rotary control
RFCS-14 HD
#194 744
Remote current foot pedal control
RHC-14
#129 340
Remote current hand control
International-Style Connector Kit
#042 418
50 mm
Extension Kit for International-Style
#042 419
50 mm
International/Tweco® Adapter
#042 465
A one-piece adapter with International-style male plug
International/Cam-Lok Adapter
#042 466
A one-piece adapter with International-style male plug
International-Style Connectors
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Price
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