Maxstar 200 Series - Categories On Sutton

Maxstar 200 Series - Categories On Sutton
Maxstar 200 Series
Issued Jan. 2010 • Index No. DC/32.0
®
Quick
Specs
TIG/Stick Welding
Power Source
Industrial Applications
Processes
Input Power
Precision Fabrication
Petro/Chemical
Aerospace
Food/Beverage Industry
Dairy
Shipboard
TIG (GTAW)
Pulsed TIG (GTAW-P)
Stick (SMAW)
Air Carbon Arc (CAC-A)
5/32 in maximum
Amperage Range
Rated Output
Weight
115 – 460 V, 3- or 1-Phase Power
1– 200 A
200 A at 28 V, 20% Duty Cycle
37 lb (16.8 kg)
The Power of Blue .
®
Allows for any
input voltage
hookup (115–460 V) with no manual
linking, providing convenience in any job
setting. Ideal solution for dirty or
unreliable power.
Fan-On-Demand™ power source cooling
system operates only when needed,
reducing noise, energy use and the
amount of contaminates pulled through
the machine.
NEW! Complete Packages —
See page 5 for more information.
DC TIG Features
Exceptionally smooth and precise
arc for welding exotic materials.
Stick Features (DC)
Tailored arc control (DIG) allows
the arc characteristic to be changed
for specific applications and
electrodes. Smooth running 7018 or
stiffer, more penetrating 6010.
Maxstar 200 DX
Fingertip Complete
Package
Hot Start™ adaptive control provides
positive arc starts without sticking.
Maxstar 200 SD
Lift-Arc™ starting provides x-ray clean
welds without the use of high frequency.
Blue Lightning™ — High Frequency Arc
Starter for non-contact arc initiation.
More consistent arc starts compared to
traditional HF arc starters.
Greater reliability and no maintenance on
solid state components. Preset parameters
for tungsten sizes from .020 – 1/8 inch
provide optimized starting for applications
from thick to micro thin material. For
unique applications, custom settings are
programmable.
Power source is warranted for 3 years, parts and labor.
Original main power rectifier parts are warranted for 5 years.
Water cooler is warranted for 1 year, parts and labor.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
Welding
Mode
Welding
Amperage
Range
TIG
(GTAW)
DC 1–150 A
(115 VAC)
(Subject to change without notice.)
Max.
OpenCircuit
Voltage
Input
Power
Rated
Output
Amps Input at Rated Load Output, 50/60 Hz,
115 V 230 V 400 V 460 V KVA
KW
75 VDC
3-Phase
175 A at 17 V,
60% Duty Cycle
—
—
10.5
0.16*
6.0
0.24*
5.2
0.25*
4.2
0.06*
4.0
0.03*
1-Phase
175 A at 17 V,
60% Duty Cycle
—
—
17.4
0.23*
—
—
—
—
4.0
0.05*
4.0
0.02*
150 A at 16 V,
70% Duty Cycle
29.7
0.42*
—
—
—
—
—
—
3.4
0.05*
3.4
0.03*
125 A at 15 V,
100% Duty Cycle
23.0
0.42*
—
—
—
—
—
—
2.6
0.05*
2.6
0.03*
3-Phase
150 A at 26 V,
60% Duty Cycle
—
—
13.1
0.16*
7.4
0.24*
6.4
0.25*
5.2
0.06*
5.0
0.03*
1-Phase
150 A at 26 V,
60% Duty Cycle
—
—
21.7
0.23*
—
—
—
—
5.0
0.05*
5.0
0.02*
125 A at 25 V,
50% Duty Cycle
34.1
0.42*
—
—
—
—
—
—
4.0
0.05*
3.8
0.03*
90 A at 24 V,
100% Duty Cycle
25.0
0.42*
—
—
—
—
—
—
4.0
0.05*
3.8
0.03*
9 –14 VDC**
DC 1–200 A
(200–460 VAC)
Stick
(SMAW)
DC 1–90 A
(115 VAC)
75 VDC
9 –14 VDC**
DC 1–200 A
(200–460 VAC)
*Indicates idle draw. **Sense voltage for Stick and Lift-Arc TIG.
CSA approval.
All CE models conform to the applicable parts of the IEC 60974 series of standards.
Performance Data
DUTY CYCLE
110–120 V INPUT VOLTAGE
%
40%
70%
100%
2
TIG
150 A
150 A
125 A
STICK
125 A
110 A
90 A
200–460 V INPUT VOLTAGE
%
30%
40%
60%
100%
TIG
200 A
200 A
175 A
150 A
STICK
200 A
175 A
150 A
125 A
Dimensions
Net Weight
H: 13-1/2 in
(343 mm)
W:7-1/2 in
(191 mm)
D: 17-1/2 in
(445 mm)
37 lb
(16.8 kg)
Contractor
Kit
with
69 lb
(31.3 kg)
TIGRunner®
H: 46-1/4 in
(1,175 mm)
W: 23-1/2 in
(597 mm)
D: 22-1/4 in
(565 mm)
with
with
TIGRunner®
129 lb
(58.5 kg)
Control Panel
Maxstar 200 SD
Maxstar 200 DX/LX
5
1
2
5
1
2
6
3
4
7
6
3
7
8
9
4
Control Panel Parameter Values
1. Ammeter Display
2. Voltmeter Display
3. Process/
TIG: HF Impulse, Lift Arc
Arc Starting
STICK: Adaptive Hot Start
4. Output Control
Standard Remote,
2T Trigger Hold,
Output ON
5. Encoder Control
6. Amperage Control
7. Adjust Postflow 0.0 – 50 Seconds
DIG
0 – 100%
Advanced features on the Maxstar LX and DX:
8. Sequencer Control
Initial Amps
1–200 A
Initial Slope
0.0 – 25.0 Seconds
Final Slope
0.0– 25.0 Seconds
Final Amps
1–200 A
9. Pulser Control
Pulses per Second DC: 0.1– 500 PPS
Peak Time
5 – 95%
Background Amps 5 – 95%
Additional Setup Parameter Values
Preprogrammed Starts
.040 – 1/8 in Tungsten
Programmable Starts
Amperage
5 – 200 A
Time
1– 200 Milliseconds
Ramp Time
0– 250 Milliseconds
Minimum Amperage 1– 20 A
Additional Triggers 3T, 4T, Mini Logic,
4T Momentary
Spot/Timer
0.1– 25.0 Seconds
OCV
Low OCV, Normal OCV
Stick Stuck Check On/Off
Available in Three Models:
SD — Provides the basic features that are required for most TIG or Stick welding applications.
Lockouts
Four levels
Arc Timer
0.0– 9999 Hours
and 0 –59 Min
Cycle Counter
0– 999,999 Cycles
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.
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.
LX Additional Features:
Initial start time
Weld cycle time
Final current time
0.0 – 25.0 Seconds
0.0 – 999 Seconds
0.0 – 25.0 Seconds
10-Pin Remote Connection Features:
• Weld cycle start/stop
• Gas start/stop
• Final slope output signal
• Pulse output signal
• Valid arc output signal
3
Pulse TIG Controls
High Speed DC TIG-Pulse Controls
• PPS Pulses per second (Hz): DC = 0.1 – 500 PPS
• % ON – % Peak Time: 5 - 95% (Controls the amount of time during each pulse cycle at the PEAK amperage.)
• Background Amps: 5 – 99% (Sets the low-pulse amperage value as a % of the Peak Amps.)
CONVENTIONAL PULSED TIG
Peak
Amps
Peak Time %
Background
Amps
(% of Peak)
Peak
Amps
Peak Time %
Background
Amps
(% of Peak)
Pulse Cycle
Typically from 1 to 10 PPS. Provides a heating and cooling effect
on the weld puddle and can reduce distortion by lowering the
average amperage. This heating and cooling effect also produces a
distinct ripple pattern in the weld bead. The relationship between
pulse frequency and travel speed determines the distance between
the ripples. Slow pulsing can also be coordinated with filler metal
addition and can increase overall control of the weld puddle.
4
HIGH SPEED PULSED TIG
Pulse Cycle
In excess of 40 PPS, Pulsed TIG becomes more audible than visible —
causing increased puddle agitation for a better as-welded microstructure.
Pulsing the weld current at high speeds — between a high Peak and a
low Background amperage — can also constrict and focus the arc.
This results in maximum arc stability, increased penetration and
increased travel speeds (Common Range: 100 – 500 PPS).
Packages
Maxstar 200 Power Sources
®
Maxstar® 200 SD #903 701 (CSA)
Maxstar® 200 DX #903 701-01-1 (CSA)
Maxstar® 200 DX #907 354 (CE ROHS)
Maxstar® 200 LX #903 701-01-2 (CSA)
Includes:
Adjustable shoulder strap
10 ft (3 m) primary power cord
(2) international (Dinse 50) connectors
(1) air-cooled TIG torch adapter
(#195 378). SD and DX models only
(1) 14-pin and 10-pin receptacle with
mating plug. LX model only
Note: See page 6 for recommended Contractor Torch Kit
Maxstar 200 DX Contractor Kit Packages (Air Cooled)
®
Maxstar 200 DX Foot Pedal Contractor
Package #951 172 (CSA)
Maxstar 200 DX Fingertip Contractor
Package #951 173 (CSA)
Packages include:
Maxstar® 200 DX (#903 701-01-1)
Adjustable shoulder strap
10 ft (3 m) primary power cord
(2) international (Dinse 50) connectors
Protective carrying case
RFCS-14 HD foot pedal (#194 744) or
RCCS-14 fingertip control (#043 688)
Weldcraft® 25 ft (7.6 m) WP17 TIG torch
with adapter
Smith® flow gauge regulator with 12 ft
(3.7 m) gas hose
AK2C accessory kit
.040", 1/16" and 3/32" cerium tungsten
Collets and cups
200 amp, 15 ft (4.6 m) Stick electrode
holder
Work clamp with 15 ft (4.6 m) #4 cable
(1) air-cooled TIG torch adapter
(#195 378)
TIGRunner Package (Water Cooled)
®
Maxstar® 200 DX TIGRunner®
#903 701-02-2 (CSA)
Completely assembled.
Package includes:
Maxstar® 200 DX (#903 701-01-1)
Coolmate™ 1, 120 VAC (#300 360)
(2) international (Dinse 50) connectors
1 gallon of pre-mixed, low conductivity
Coolant (#043 810)
2-Wheel Trolley Cart (#300 480) with
the following features: easy-to-maneuver
single-cylinder cart with cable and torch
holders. Easy to release and remove
welder from cart for even more portability.
Convenient tray for consumable storage
and filler rod holders.
Notes: TIG Torch Adapter must be ordered separately.
See page 6 for recommended 250 A Water-Cooled
Torch Kit (#300 185)
The Coolmate 1 requires a separate source for
electricity. The Maxstar 200 does not contain
auxiliary power.
Complete Packages (Water Cooled)
Maxstar® 200 DX Foot Pedal Complete
#951 137 (CSA)
Maxstar 200 DX
Foot Pedal
Complete Package
Maxstar® 200 DX Fingertip Complete
#951 138 (CSA)
Completely assembled.
Package includes:
Maxstar® 200 DX TIGRunner®
(#903 701-01-1)
Coolmate™ 1, 120 VAC (#300 360)
(2) international (Dinse 50) connectors
1 gallon of pre-mixed, low conductivity
Coolant (#043 810)
2-Wheel Trolley Cart (#300 480) with
the following features: easy-to-maneuver
single-cylinder cart with cable and torch
holders. Easy to release and remove
welder from cart for even more portability.
Convenient tray for consumable storage
and filler rod holders.
RFCS-14 HD foot pedal (#194 744) or
RCCS-14 fingertip control (#043 688)
250 A Water-Cooled Torch Kit and
Accessories (#300 185) See pg. 6 for
more details.
Note: The Coolmate 1 requires a separate source for
electricity. The Maxstar 200 does not contain
auxiliary power.
5
Genuine Miller Accessories
Running Gear
Coolmate™ 1
#300 360 120 VAC 60 Hz CSA
#300 360-00-1 120 VAC 60 Hz CE
#300 459 240 VAC 50/60 Hz CSA
#300 459-00-1 240 VAC 50/60 Hz CE
1-gallon water cooler designed for 200 amp
portable welders. Features include:
Fin-and-Tube heat exchanger, back-lit
power switch, external filter, polyethylene
tank and coolant level sight gauge.
2-Wheel Trolley Cart #300 480
Easy-to-maneuver two-wheel cart features
single-cylinder rack, chain for cylinder,
straps (quick and easy to detach and carry
machine), cable holders, torch holder,
storage area, and filler rod storage area.
Works with Dynasty® or Maxstar® 200 and
Coolmate™ 1.
Contact you local distributor for filler material
holders.
Universal Carrying Cart and Cylinder Rack
#042 934
Holds power source, and gas cylinder up
to 56 in (142.2 cm) high measuring
6 to 9 in (15.2 to 22.8 cm) in diameter.
6
250 A Water-Cooled Torch Kit #300 185
25 ft (7.6 m) Weldcraft® WP20 torch
Torch cable cover
AK4C torch accessory kit includes
shielding cups, collets, collet bodies
and 2% cerium tungsten electrodes
(1/16, 3/32 and 1/8 in)
Smith® regulator/flowmeter HM2051A-580
12 ft (3.7 m) rubber gas hose (regulator
to machine)
Water-cooled Dinse torch adapter
15 ft (4.6 m) 1/0 weld lead with clamp
(work or ground lead) and Dinse connector
TIG Coolant
#043 810
Sold in
multiples of 4.
Pre-mixed lowconductivity
Miller coolant
contains
ethylene glycol
and deionized water to protect from freezing
and boiling -37˚ to 227˚F (-38˚ to 108˚C).
1-gallon plastic recyclable bottles.
Water-Cooled Dinse #195 377
Used to adapt WP20, WP18, and CS310 to
dinse-style connector. Order from Miller
Parts.
#195 054
kit shown.
Contractor Kits
#195 054 Foot Pedal Kit
#195 055 Fingertip Kit
RFCS-14HD foot or RCCS-14 fingertip
control, protective carrying case, 150 Amp
WP17 25 ft (7.6 m) TIG Torch with
adapter, Smith® flow gauge regulator and
12 ft (3.7 m) gas hose, AK2C Accessory
Kit (.040, 1/16, and 3/32 in cerium tungsten,
collets and cups), Stick electrode holder,
200 Amp, 15 ft (4.6 m) #4 cable, and work
clamp with 15 ft (4.6 m) #4 AWG cable.
200 Amp AirCooled Torch
#WP2612RM (12 ft)
#WP2625RM (25 ft)
Torch body gas
valve models are
available
Note: Adapter #195 379 required for WP26.
Order from Miller Parts.
Air-Cooled Torch Adapters
#195 378 WP17, WP9, WP50, WP23
#195 379 WP26
Order from Miller Parts.
TIG Welding Gloves
#227 813 Small
#227 815 Large
#227 814 Medium #227 816 X-Large
Made from soft grain goatskin. Sewn with
Kevlar® thread. Order from Miller Parts.
Genuine Miller Accessories (continued)
Tungsten
Remote Controls and Switches
Tungsten is 7 in length and available in pkgs of 10.
Order from Miller Parts.
2% Ceriated (orange) for AC/DC applications
#WC040X7 .040 in, 10– 80 A
#WC116X7 1/16 in, 70– 150 A
#WC332X7 3/32 in, 140– 250 A
#WC018X7 1/8 in, 225– 400 A
#WC532X7 5/32 in, 300– 500 A
1.5% Lanthanum (gold) for AC/DC applications
#WL040X7 .040 in, 10– 80 A
#WL116X7 1/16 in, 70– 150 A
#WL332X7 3/32 in, 140– 250 A
#WL018X7 1/8 in, 225– 400 A
#WL532X7 5/32 in, 300– 500 A
Educational Material
Gas Tungsten Arc (TIG) Welding Book
#170 555
To order, distributors can call the Miller Literature
Distribution Center at 1-920-735-4356, or
FAX 1-920-735-4011.
Ron Covell TIG Welding Basics DVD
To order go to MillerWelds.com
RCCS-14 Remote Contactor and
Current Control #043 688 14-pin plug
North/south rotary-motion fingertip control
fastens to TIG torch using two Velcro®
straps. Includes 26.5 ft (8 m) control cord.
RFCS-14 HD Foot Control #194 744
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.
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 83 mm). Includes
20 ft (6 m) cord and 14-pin plug.
RMLS-14 Switch #129 337
Momentary- and 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
Momentary-contact switch for contactor
control. Rubber-covered pushbutton dome
switch ideal for repetitive on-off
applications. Includes 26.5 ft (8 m) cord
and 14-pin plug.
Extension Cords for 14-Pin Remote Controls
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (23 m)
Multi-Operator Rack
4-Pack Rack (empty) #195 051
Appropriate fuses required.
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.
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).
Power Source
Rack
Capacity
Input Power to Rack
Generator kW
(Required)
Rack Fuse Size
(3 per Power Source Required)*
Maxstar 200
4
230 V @ 74 A
20 kW
30 A (#199 795)
460 V @ 36 A
20 kW
15 A (#220 514)
4-Pack Rack Running Gear #195 114
Large 5-inch diameter wheels enable the
rack to be moved over grating and
driveway gravel.
Dimensions
Net Weight
H: 59-3/8 in (1508 mm)
W: 43 in (1092 mm)
D: 34-3/8 in (873 mm)
Rack only
239 lb (108 kg)
with Power Sources
387 lb (176 kg)
*Rack comes with 25 A fuses. Order appropriate fuses for primary voltage
7
Ordering Information
Equipment and Options
Stock No.
Description
Maxstar 200 SD
#903 701
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 10 ft primary cord
Maxstar® 200 DX
#903 701-01-1
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 10 ft primary cord
Maxstar® 200 DX International
#907 354
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CE ROHS. 10 ft primary cord.
Maxstar® 200 LX
#903 701-01-2
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 10 ft primary cord
Maxstar® 200 DX Foot Pedal Contractor Kit
#951 172
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 10 ft primary cord
Maxstar® 200 DX Fingertip Contractor Kit
#951 173
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 10 ft primary cord
Maxstar® 200 DX TIGRunner ®
#903 701-02-2
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 10 ft primary cord.
(Torch kit and accessories sold separately.)
Maxstar® 200 DX Foot Pedal Complete
#951 137
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 10 ft primary cord
Maxstar® 200 DX Fingertip Complete
#951 138
Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 10 ft primary cord
Weldcraft® 250 A Water-Cooled Torch Kit
#300 185
See page 6
Contractor Kit Foot Pedal (Air-Cooled)
#195 054
See page 7
Contractor Kit Fingertip (Air-Cooled)
#195 055
See page 7
RCCS-14
#043 688
North/south fingertip control
RFCS-14 HD
#194 744
Heavy-duty foot control
RHC-14
#129 340
Hand control
RMLS-14
#129 337
Momentary/maintained rocker switch
RMS-14
#187 208
Momentary rubber dome switch
Extension Cords
#122 973
#122 974
#122 975
25 ft (7.6 m)
50 ft (15.2 m)
75 ft (22.9 m)
4-Pack Rack (empty)
#195 051
Order power source and fuses separately
4-Pack Rack Running Gear
#195 114
(4) 5-in diameter wheels and brackets
Fuses
#199 795
#220 514
230 V, 30 A Individual fuse. 12 required for 4 Pack
460 V, 15 A Individual fuse. 12 required for 4 Pack
2-Wheel Trolley Cart
#300 480
See page 6
Universal Carrying Cart and Cylinder Rack
#042 934
See page 6
Coolmate™ 1
#300 360
#300 360-00-1
#300 459
#300 459-00-1
120 VAC, 60 Hz, CSA. Requires coolant
120 VAC, 60 Hz, CE. Requires coolant
240 VAC, 50/60 Hz, CSA. Requires coolant
240 VAC, 50/60 Hz, CE. Requires coolant
TIG Coolant
#043 810
Sold in multiples of 4. 1-gallon plastic bottles
Gas Tungsten Arc (TIG) Welding Book
#170 555
Order at MillerWelds.com/resources/tools/
Water-Cooled Dinse
Order from Miller Parts
#195 377
Used to connect water-cooled torch to Dinse terminal machine.
For WP20, WP18 and SC310 (adapter included in Complete Package)
Air-Cooled Dinse
Order from Miller Parts
#195 378
#195 379
Used to connect WP17, WP9 and WP23 torch to Dinse terminal machine
Used to connect WP26 torch to Dinse terminal machine
Dinse Connector 50 mm (1 male)
#042 418
Used to connect weld lead to Dinse terminal machine
Dinse Connector 50 mm (1 male, 1 female)
#042 419
Used to extend weld cables
Tweco® Terminal Adapter
#042 465
Male Dinse to female Tweco
Cam-Lok Terminal Adapter
#042 466
Male Dinse to female Cam-Lok
®
Qty.
Air-Cooled Systems
Water-Cooled Systems
TIG Torch Kits
Remote Controls
Accessories
Order at MillerWelds.com/resources/tools/
Ron Covell TIG Welding Basics DVD
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Price
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