115/230/400/460 Volt Models W/Autoline Maxstar 200 SD, DX .

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OM-2226189783QOctober 2003ProcessesTIG (GTAW) WeldingStick (SMAW) WeldingDescription115/230/400/460 Volt Models W/AutolineRArc Welding Power SourceRMaxstar 200 SD,DX, And LXAnd Non-CE ModelsVisit our website atwww.MillerWelds.com

From Miller to YouThank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you don’t have time to doit any other way.That’s why when Niels Miller first started building arc welders in 1929,he made sure his products offered long-lasting value and superiorquality. Like you, his customers couldn’t afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.Today, the people that build and sell Miller products continue thetradition. They’re just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.This Owner’s Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.We’ve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,there’s a Troubleshooting section that willhelp you figure out what the problem is. TheMiller is the first welding parts list will then help you to decide theequipment manufacturer in exact part you may need to fix the problem.the U.S.A. to be registered tothe ISO 9001:2000 Quality Warranty and service information for yourSystem Standard.particular model are also provided.Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.Mil Thank 7/03Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

TABLE OF CONTENTSSECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4SECTION 2 CONSIGNES DE SÉCURITÉ À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 52-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . . 72-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8SECTION 3 DEFINITIONS (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-2. Manufacturer’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12SECTION 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164-5. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174-6. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174-7. Automation 10-Pin Connection (LX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184-8. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194-9. TIG HF Impulse/ Lift-Arc DCEN (Direct Current Electrode Negative) Connections . . . . . . . . . . . . . . . 194-10. Stick DCEP (Direct Current Electrode Positive) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204-12. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21SECTION 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225-2. Encoder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235-3. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235-4. Ammeter And Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235-5. Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245-6. Polarity Control (Dynastyt Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245-7. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255-8. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255-9. Pulser Control (DX And LX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265-10. Sequencer Controls (DX, LX And All CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275-11. Adjust Controls (Preflow/Post Flow/DIG/Purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285-12. AC Waveshape (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295-13. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) (All Models) . . . . . . . . . . . . . . . . . 295-14. Memory (Program Storage Locations 1-4) (DX And LX Models If Available) . . . . . . . . . . . . . . . . . . . . . 305-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A Preflow Control OnThe Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315-16. Factory Parameter Defaults And Range And Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325-17. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33SECTION 6 ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346-1. Programable TIG Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346-2. Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6-3. Arc Timer/Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5. Setting Unit To Display PPP While Pulse Welding (DX And LX Models Only) . . . . . . . . . . . . . . . . . . . .6-6. Stick Open-Circuit Voltage (OCV) Selection (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 7 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 8 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 HIGH FREQUENCY (HF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 10 SELECTING AND PREPARINGTUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2. Safety Information About Tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . . . .SECTION 11 GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1. DC - GTAW 16 Gauge Stainless Steel Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3. Lift-ArcE And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 12 STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . . . . . . . . . .SECTION 13 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OPTIONS AND 657585859606162636372

Declaration of Conformity ForEuropean Community (CE) ProductsNOTEThis information is provided for units with CE certification (see rating label on unit.)Miller Electric Mfg. Co.Manufacturer’s Name:1635 W. Spencer StreetAppleton, WI 54914 USAManufacturer’s Address:Declares that the product:Maxstar R 200 SD, DX, LXconforms to the following Directives and Standards:DirectivesLow Voltage Directive: 73/23/EECMachinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EECElectromagnetic Capability Directives: 89/336, 92/31/EECStandardsSafety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1(December 1996 Draft revision)Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989Insulation coordination for equipment within low-voltage systems:Part 1: Principles, requirements and tests: IEC 664-1: 1992Electromagnetic compatibility (EMC) Product standard for arc welding equipment:EN50199: August 1995European Contact:Telephone:Fax:dec con1 11/02Mr. Danilo Fedolfi, Managing DirectorITW WELDING PRODUCTS ITALY S.r.l.Via Privata Iseo 6/E20098 San GiulianoMilanese, Italy39(02)98290139(02)98290 203

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom 8/031-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.Y Marks a special safety message. Means “Note”; not safety related.1-2. Arc Welding HazardsY The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-5. Read and follow allSafety Standards.D If earth grounding of the workpiece is required, ground it directlywith a separate cable.Y Only qualified persons should install, operate, maintain, andrepair this unit.D Wear a safety harness if working above floor level.D Keep all panels and covers securely in place.Y During operation, keep everybody, especially children, away.D Clamp work cable with good metal-to-metal contact to workpieceor worktable as near the weld as practical.D Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.D Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.D Insulate work clamp when not connected to workpiece to preventcontact with any metal object.ELECTRIC SHOCK can kill.Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard.D Do not connect more than one electrode or work cable to anysingle weld output terminal.SIGNIFICANT DC VOLTAGE exists after removal ofinput power on inverters.D Turn Off inverter, disconnect input power, and discharge inputcapacitors according to instructions in Maintenance Sectionbefore touching any parts.D Do not touch live electrical parts.D Wear dry, hole-free insulating gloves and body protection.D Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with the workor ground.D Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.D Use AC output ONLY if required for the welding process.D If AC output is required, use remote output control if present onunit.D Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).D Properly install and ground this equipment according to itsOwner’s Manual and national, state, and local codes.D Keep your head out of the fumes. Do not breathe the fumes.D Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.D When making input connections, attach proper grounding conductor first double-check connections.D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.D Turn off all equipment when not in use.D Do not use worn, damaged, undersized, or poorly spliced cables.D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.D Do not drape cables over your body.FUMES AND GASES can be hazardous.Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.D If inside, ventilate the area and/or use exhaust at the arc to removewelding fumes and gases.D If ventilation is poor, use an approved air-supplied respirator.D Read the Material Safety Data Sheets (MSDSs) and themanufacturer’s instructions for metals, consumables, coatings,cleaners, and degreasers.D Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breathing air is safe.D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and if necessary, while wearing anair-supplied respirator. The coatings and any metals containingthese elements can give off toxic fumes if welded.Return To Table Of ContentsOM-2226 Page 1

ARC RAYS can burn eyes and skin.BUILDUP OF GAS

Maxstar 200 SD, DX, And LX And Non-CE Models. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds .

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Three phase voltages generally available are 208 volt, 240 volt, 480 volt and 600 volt. Since there is a voltage drop between the power source and the electric motor, the single phase motors are rated either 115 volt or 230 volt. Three phase motors are rated 200 volt, 230 volt, 460 volt and 575 volt.

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Group Primary Secondary VA Sizes View Detals on Page A 220 x 440, 230 x 460, 240 x 480 110, 115, 120 50 - 5000 9 B 240 x 480 24 50 - 750 9 C 120 x 240 24 50 - 750 10 D 115 x 230 24 50 - 500 10 E 550, 575, 600 110, 115, 120 50 - 750 11 F 208/277 120 50 - 750 11 G 200/220/440, 208/230/460, 240/480 110, 115, 120 50 - 3000 12 H 230/460/57

600 x 300 350 1260 50 6 14 600 x 300 669 2409 50 21 9 600 x 300 1137 4094 50 60 6 600 x 300 1750 6300 50 142 5 400 x 400 400 1440 50 9 12 400 x 400 674 2425 50 27 8 400 x 400 1170 4212 50 80 6 400 x 400 1750 6300 50 179 4 500 x 400 360 1296 50 5 15 500 x 400 715 2574 50 19 9 500 x 400 1330 4787 50 66 6 500 x 400 1800 6480 50 122 5 600 x 400 450 1620 50 5 15 600 x 400 958 3448 50 24 9 600 x 400 .

14 CFR Part 460 . Commercial Space . Human Space Flight -Checklist . Transportation . Purpose of Checklist . Checklist Sections . Other Tools . The following checklist is for the use of an applicant proposing to conduct . 460.7, 460.11, 460.13, 460.15, 460.17 460.51, aud 460.53. 431.8 ;

Taurus 120 12 450 230 3 Meteor CSI 20 17 160 230 3 Mariner CSI 40 17 270 230 3 Sirius CSI 80 12 320 230 3 Titan CSI 100 12 410 230 3 Taurus CSI 120 12 450 230 3 Altus 50 RTS 6/17 6 17 90 230 5 Altus 50 RTS 10/17 10 17 120 230 5 Altus 50 RTS 15/17 15 17 140 230 5 Altus 50 RTS 25/17 25 17 170 230 5

Standard equipment is Viking Lid-Ease Strainer w/40 mesh. All strainers offerred in 20, 40 or 60 mesh. 1 ph 60 Hz 115 Volt 1 ph 60 Hz 230-240 Volt 3 ph 60 Hz 208-230-460 Volt 3 ph 60 Hz 575 Volt 3 ph 50 Hz 380-415 Volt Phase-Cycle-Voltage Standard Equipment Viking Heavy Duty Positive Displacement Rotary Gear or Spur Gear Pumps (2)