Issued May 2014 • Index No. DC/32.

Maxstar 200 Series ® TIG/Stick Welding

Power Source

Industrial Applications Processes Input Power 115 – 460 V, 3- or 1-Phase Power

Quick Precision Fabrication TIG (GTAW)
Amperage Range 1– 200 A
Petro/Chemical Pulsed TIG (GTAW-P)
Specs Aerospace Stick (SMAW) Rated Output 200 A at 28 V, 20% Duty Cycle
Food/Beverage Industry Air Carbon Arc (CAC-A)
Dairy 5/32-inch maximum Net Weight 37 lb. (16.8 kg)
Shipboard

DC TIG Features
Exceptionally smooth and precise
Allows for any input voltage hookup arc for welding exotic materials.
(115–460 V) with no manual linking,
providing convenience in any job setting.
Ideal solution for dirty or unreliable power.
DC Stick Features
DIG control allows the arc charac-
teristics to be changed for specific
Fan-On-Demand™ power source cooling applications and electrodes. Lower
system operates only when needed, the DIG setting for smooth running
reducing noise, energy use and the electrodes like E7018 and increase
amount of contaminants pulled through the DIG setting for stiffer, more
the machine. penetrating electrodes like E6010.
Maxstar 200 DX
Complete Package Hot Start™ adaptive control provides
with Wireless positive arc starts without sticking.
Maxstar 200 SD Foot Control

Lift-Arc™ start provides DC arc initiation

without the use of high frequency.

Blue Lightning™ high-frequency (HF) arc

starter for non-contact arc initiation.
Provides more consistent arc starts and
greater reliability compared to traditional
HF arc starters.

Power source is warranted for 3 years, parts and labor.

Coolant system is warranted for 1 year, parts and labor.

Miller Electric Mfg. Co. Equipment Sales US and Canada MillerWelds.com

An ITW Company Phone: 866-931-9730
1635 West Spencer Street FAX: 800-637-2315
P.O. Box 1079 International Phone: 920-735-4554
Appleton, WI 54912-1079 USA International FAX: 920-735-4125
 Specifications (Subject to change without notice.)
Max.
Welding Open-
Welding Amperage Circuit Input Rated Amps Input at Rated Load Output, 50/60 Hz,
Mode Range Voltage Power Output 115 V 230 V 400 V 460 V KVA KW Dimensions Net Weight
TIG DC 1–150 A 80 VDC 3-Phase 175 A at 17 V, — 10.5 6.0 5.2 4.2 4.0 H: 13.5 in. 37 lb.
(GTAW) (115 VAC) 9 –14 VDC** 60% Duty Cycle — 0.16* 0.24* 0.25* 0.06* 0.03* (343 mm) (16.8 kg)
DC 1–200 A 1-Phase 175 A at 17 V, — 17.4 — — 4.0 4.0 W: 7.5 in.
(191 mm) with
(200–460 VAC) 60% Duty Cycle — 0.23* — — 0.05* 0.02*
D: 17.5 in. Contractor
150 A at 16 V, 29.7 14.1 — — 3.4 3.4 (445 mm) Kit
70% Duty Cycle 0.42* — — — 0.05* 0.03* 69 lb.
125 A at 15 V, 23.0 — — — 2.6 2.6 with (31.3 kg)
100% Duty Cycle 0.42* — — — 0.05* 0.03* TIGRunner®
H: 46.25 in. with
Stick DC 1–90 A 80 VDC 3-Phase 150 A at 26 V, — 13.1 7.4 6.4 5.2 5.0 (1175 mm) TIGRunner®
(SMAW) (115 VAC) 9 –14 VDC** 60% Duty Cycle — 0.16* 0.24* 0.25* 0.06* 0.03* W: 23.5 in. 129 lb.
DC 1–200 A 1-Phase 150 A at 26 V, — 21.7 — — 5.0 5.0 (597 mm) (58.5 kg)
(200–460 VAC) 60% Duty Cycle — 0.23* — — 0.05* 0.02* D: 22.25 in.
125 A at 25 V, 34.1 — — — 4.0 3.8 (565 mm)
50% Duty Cycle 0.42* — — — 0.05* 0.03*
90 A at 24 V, 25.0 — — — 4.0 3.8
100% Duty Cycle 0.42* — — — 0.05* 0.03*
*Indicates idle draw. **Sense voltage for Stick and Lift-Arc TIG.
Certified by Canadian Standards Association to both the Canadian and U.S. Standards. All CE models conform to the applicable parts of the IEC 60974 series of standards.

Performance Data
DUTY CYCLE
110–120 V INPUT VOLTAGE 200–460 V INPUT VOLTAGE
% TIG STICK % TIG STICK
40% 150 A 125 A 30% 200 A 200 A
70% 150 A 110 A 40% 200 A 175 A
100% 125 A 90 A 60% 175 A 150 A
100% 150 A 125 A

2
 Control Panel
Maxstar 200 SD Maxstar 200 DX/LX

1 5 1 5

2 2
6 6

3 7 3 7
4 8
4 9

Control Panel Parameter Values

1. Voltmeter Display Advanced Features on the Maxstar LX and DX: Additional Setup Parameter Values
2. Ammeter Display 8. Sequencer Control Preprogrammed Starts
3. Process/ TIG: HF Impulse, Lift Arc Initial Amps 1– 200 A .020 –1/8 in. tungsten
Arc Starting STICK: Adaptive Hot Start Initial Slope 0.0 – 25.0 seconds
Programmable Starts
Final Slope 0.0 – 25.0 seconds
4. Output Control Standard Remote, Amperage 5 – 200 A
Final Amps 1– 200 A
2T Trigger Hold, Time 1– 200 milliseconds
Output ON 9. Pulser Control Ramp Time 0 – 250 milliseconds
Pulses per Second 0.1 – 500 PPS Minimum Amperage 1– 20 A
5. Encoder Control Peak Time 5 – 95% Additional Triggers 3T, 4T, Mini Logic,
6. Amperage Control Background Amps 5 – 95% 4T Momentary
7. Adjust Postflow 0.0 – 50 seconds
Spot/Timer 0.1– 25.0 seconds
DIG 0 – 100%
OCV Low OCV, Normal OCV
Stick Stuck Check On/Off
Lockouts Four levels
Arc Timer 0.0 – 9999 hours
and 0 – 59 minutes
Available in Three Models:
Cycle Counter 0 – 999,999 cycles
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.
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 0.0 – 25.0 seconds
Weld cycle time 0.0 – 999 seconds
Final current time 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
 Pulsed TIG Controls
High-Speed DC Pulsed TIG 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 High-Speed Pulsed TIG

Peak Time % Peak Time %

Peak Peak
Amps Amps

Background Background
Amps Amps
(% of Peak) (% of Peak)
Pulse Cycle Pulse Cycle

Typically from 1 to 10 PPS. Provides a heating and cooling effect In excess of 40 PPS, Pulsed TIG becomes more audible than visible —
on the weld puddle and can reduce distortion by lowering the causing increased puddle agitation for a better as-welded microstructure.
average amperage. This heating and cooling effect also produces a Pulsing the weld current at high speeds — between a high Peak and a
distinct ripple pattern in the weld bead. The relationship between low Background amperage — can also constrict and focus the arc.
pulse frequency and travel speed determines the distance between This results in maximum arc stability, increased penetration and
the ripples. Slow pulsing can also be coordinated with filler metal increased travel speeds (Common Range: 100 – 500 PPS).
addition and can increase overall control of the weld puddle.

4
Packages
Maxstar 200 Power Sources
®

Maxstar 200 SD #903 701 (CSA) Two Dinse 50-mm connectors

Maxstar 200 DX #903 701 011 (CSA) DVD Setup Video (#251 116)
Maxstar 200 DX #907 354 (CE) One air-cooled TIG torch connector
Maxstar 200 LX #903 701 012 (CSA) (#195 378). SD and DX models only
One 14-pin and 10-pin receptacle with
Includes:
mating plug. LX model only
Adjustable shoulder strap Note: See page 6 for recommended Contractor Torch Kit.
8-ft. (2.4 m) primary power cord

Maxstar 200 DX Contractor Kit Packages (Air Cooled)

®

Maxstar 200 DX with Contractor Kit Work clamp with 15-ft. (4.6 m) #4 cable
#951 172 (CSA) w/Foot Control Flow gauge regulator with gas hose
#951 173 (CSA) w/Fingertip Control AK2C accessory kit with short back cap,
Packages include: nozzles, collets, collet bodies, and
Maxstar 200 DX (#903 701 011) 2% ceriated tungsten electrodes
RFCS-14 HD foot control (#194 744) or (.040, 1/16, and 3/32 in.)
Fingertip contractor kit shown. RCCS-14 fingertip control (#043 688) One air-cooled TIG torch connector
Weldcraft® A-150 (WP-17) 25-ft. (7.6 m) (#195 378)
TIG torch Protective carrying case for accessories
200-amp Stick electrode holder with
15-ft. (4.6 m) #4 cable

TIGRunner Package (Water Cooled)

®

Maxstar 200 DX TIGRunner 2-Wheel Trolley Cart (#300 480) with

#903 701 022 (CSA) the following features: easy-to-maneuver
Completely assembled. single-cylinder cart with cable and torch
holders. Easy to release and remove
Package includes: welder from cart for even more portability.
Maxstar 200 DX (#903 701 011) Convenient tray for consumable storage
Coolmate™ 1, 115 VAC (#300 360) and filler rod holders.
One gallon of pre-mixed, low-conductivity
Notes: TIG Torch Connector must be ordered
coolant (#043 810) separately. See page 6 for recommended
W-250 (WP-20) 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 Complete 2-Wheel Trolley Cart (#300 480) with
#951 396 (CSA) w/Wireless Foot Control the following features: easy-to-maneuver
#951 137 (CSA) w/Foot Control single-cylinder cart with cable and torch
Maxstar 200 DX #951 138 (CSA) w/Fingertip Control holders. Easy to release and remove
Complete Package
Completely assembled. welder from cart for even more portability.
with Foot Control Convenient tray for consumable storage
Package includes: and filler rod holders.
Maxstar 200 DX TIGRunner W-250 (WP-20) Torch Kit (#300 185).
(#903 701 011) See page 6 for more details.
Coolmate™ 1, 115 VAC (#300 360)
Note: The Coolmate 1 requires a separate source for
One gallon of pre-mixed, low-conductivity electricity. The Maxstar 200 does not contain
coolant (#043 810) auxiliary power.
Wireless Remote Foot Control (#300 429)
or RFCS-14 HD foot control (#194 744)
or RCCS-14 fingertip control (#043 688)

5
 Genuine Miller Accessories ®

2-Wheel Trolley Cart Remote Controls and Switches

#300 480
Wireless Remote Foot
Easy-to-maneuver
Control #300 429
two-wheel cart features
For remote current and con-
single-cylinder rack,
tactor control. Receiver plugs
chain for cylinder,
directly into the 14-pin receptacle of Miller
straps (quick and machine. 90-foot (27.4 m) operating range.
W-250 (WP-20) Torch Kit #300 185
easy to detach and
Weldcraft® W-250 (WP-20) 25-foot Wireless Remote Hand
carry machine), cable
(7.6 m) TIG torch with Dinse connector Control #300 430
holders, torch holder,
Torch cable cover For remote current and
storage area, and filler
Work clamp with 15-foot (4.6 m) contactor control. Receiver
rod storage area. Works with Dynasty® or
1/0 cable and Dinse connector plugs directly into the 14-pin
Maxstar® 200 and Coolmate™ 1.
Miller | Smith flowmeter regulator receptacle of Miller machine. 300-foot
Contact your local distributor for filler
material holders.
Gas hose (regulator to machine) (91.4 m) operating range.
AK4C torch accessory kit includes
Universal nozzles, collets, collet bodies and RCCS-14 Remote Contactor and Current
Carrying Cart 2% ceriated tungsten electrodes Control #043 688
and Cylinder North/south rotary-motion fingertip control
(1/16, 3/32 and 1/8 inch)
Rack fastens to TIG torch using two Velcro®
#042 934 Water-Cooled TIG straps. Includes 26.5-foot (8 m) cord and
Holds power Torch Connector 14-pin plug.
source, and #195 377
RCC-14 Remote Contactor and Current
gas cylinder 50-mm Dinse with water return line. Control #151 086
up to 56 inches (142.2 cm) high measuring For use with all Weldcraft® water-cooled East/west rotary-motion fingertip control
6 to 9 inches (15.2 to 22.8 cm) in diameter. torches. fastens to TIG torch using two Velcro®
straps. Includes 26.5-foot (8 m) cord and
#195 054 14-pin plug.
kit shown.
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
Contractor Kits provides remote current and contactor
Coolmate™ 1 #300 360 #195 054 150 A RFCS-14 HD Foot Pedal Kit control. Includes 20-foot (6 m) cord and
115 VAC, 60 Hz. One-gallon water cooler #195 055 150 A RCCS-14 Fingertip Kit 14-pin plug.
designed for 200 A portable welders. All-in-one TIG/Stick welding kit comes RHC-14 Hand Control #242 211 020
Features include fin-and-tube heat with either a RFCS-14 HD foot control or Miniature hand control for remote current
exchanger, back-lit power switch, external RCCS-14 fingertip control, Weldcraft® and contactor control. Dimensions: 4 x 4 x
filter, polyethylene tank and coolant level A-150 TIG torch, 200-amp Stick electrode 3.25 inches (102 x 102 x 83 mm). Includes
sight gauge. holder with 15-foot (4.6 m) cable, 300-amp 20-foot (6 m) cord and 14-pin plug.
work clamp with 15-foot (4.6 m) cable,
Low-Conductivity RMLS-14 Switch
Miller | Smith flow gauge regulator with
TIG Coolant #129 337
12-foot (3.7 m) gas hose, gas hose coupler,
#043 810 Momentary- and maintained-contact rocker
AK2C torch accessory kit, TIG torch
Sold in multiples switch for contactor control. Push forward
connector and protective carrying case.
of four in one- for maintained contact and backward for
gallon recyclable Weldcraft® A-200 momentary contact. Includes 26.5-foot
plastic bottles. (WP-26) TIG Torch (8 m) cord and 14-pin plug.
Miller coolants #WP-26-12-R (12 ft.) RMS-14 On/Off
contains a base of ethylene glycol and #WP-26-25-R (25 ft.) Control #187 208
deionized water to protect against freezing Torch body gas valve models are available. Momentary-contact switch for contactor
to -37° Fahrenheit (-38° C) or boiling to Note: A-200 (WP-26) torch requires #195 379 connector. control. Rubber-covered pushbutton dome
227° Fahrenheit (108° C). Air-Cooled TIG Torch Connectors switch ideal for repetitive on-off applications.
#195 379 A-200 (WP-26) Includes 26.5-foot (8 m) cord and 14-pin plug.
#195 378* All others Extension Cables for 14-Pin Remote Controls
50-mm Dinse-style for #242 208 025 25 ft. (7.6 m)
one-piece air-cooled torch. #242 208 050 50 ft. (15.2 m)
*A-80 (WP-24) torches require 24-5 connector. #242 208 080 80 ft. (24.4 m)

6
 Genuine Miller Accessories (Continued)
®

Educational Materials TIG Welding Gloves Premium TIG/Multitask

Gloves
To order, please call Miller Literature at 866-931-9732 Classic TIG #263 352 Small
or visit MillerWelds.com/resources/tools. Welding Gloves #263 353 Medium
Gas Tungsten Arc Welding (TIG) Publication #249 199 Large #263 354 Large
#250 833 #249 200 X-Large #263 355 X-Large
Unlined pigskin leather palm Premium goat grain leather with dual-padded
Ron Covell TIG Welding Basics DVD
with reinforced palm patch. palm and wool back.
#196 567
Premium TIG Gloves
DVD Setup Video #251 116
#263 345 X-Sm (Women’s)
Video topics include tungsten selection, setup
#263 346 Small (Women’s)
menus, DC pulse, sequencer, balance and
#263 347 Medium
frequency settings. (Included with machine.)
#263 348 Large
#263 349 X-Large
Completely unlined, premium goat grain
leather with triple-padded palm.

Tungsten
Tungsten Amp Range 2% Ceriated (AC/DC) 2% Lanthanated (AC/DC)
.040 in. (1.2 mm) 10 – 80 A WC040X7 WL2040X7
1/16 in. (1.6 mm) 70 –150 A WC116X7 WL2116X7
3/32 in. (2.4 mm) 140 – 250 A WC332X7 WL2332X7
1/8 in. (3.2 mm) 225 – 400 A WC018X7 WL2018X7
5/32 in. (4.0 mm) 300 – 500 A WC532X7 WL2532X7

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. 4-Pack Rack Running Gear #195 114
Lifting eye simplifies transportation Large 5-inch diameter wheels enable the
using crane or overhead lifting device. rack to be moved over grating and
Lift truck side and end fork pockets. driveway gravel.
One main disconnect box with fused
circuit breaker switches for each machine.
Common output ground connection
(for same polarity use only).

Power Rack Input Power Generator kW Rack Fuse Size

Source Capacity to Rack (Required) (3 per Power Source Required)* Dimensions Net Weight
Maxstar 4 230 V @ 74 A 20 kW 30 A (#199 795) H: 59.375 in. (1508 mm) Rack only 239 lb. (108 kg)
200 W: 43 in. (1092 mm) With power sources 387 lb. (176 kg)
460 V @ 36 A 20 kW 15 A (#220 514) D: 34.375 in. (873 mm)
*Rack comes with 25 A fuses. Order appropriate fuses for primary voltage.

7
 Ordering Information
Equipment and Options Stock No. Description Qty. Price
Maxstar 200 SD
® #903 701 Auto-Line 115 – 460 VAC, 50/60 Hz, CSA. 8-ft. primary cord
™

Maxstar® 200 DX #903 701 011 Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8-ft. primary cord
Maxstar® 200 DX International #907 354 Auto-Line™ 115 – 460 VAC, 50/60 Hz, CE. 8-ft. primary cord
Maxstar® 200 LX #903 701 012 Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8-ft. primary cord
Air-Cooled Packages
Maxstar® 200 DX Contractor Kit w/Foot Control #951 172 Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8-ft. primary cord
Maxstar® 200 DX Contractor Kit w/Fingertip Control #951 173 Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8-ft. primary cord
Water-Cooled Packages
Maxstar® 200 DX TIGRunner ® #903 701 022 Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8-ft. primary cord
(Torch kit and accessories sold separately)
Maxstar® 200 DX Complete #951 396 Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8-ft. primary cord
with Wireless Remote Foot Control
Maxstar® 200 DX Complete w/Foot Control #951 137 Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8-ft. primary cord
Maxstar® 200 DX Complete w/Fingertip Control #951 138 Auto-Line™ 115 – 460 VAC, 50/60 Hz, CSA. 8-ft. primary cord
TIG Torches, Kits and Connectors
W-250 (WP-20) Torch Kit #300 185
Water-Cooled TIG Torch Connector #195 377 Connects Weldcraft® water-cooled torches to Dinse connector
Air-Cooled Contractor Kits #195 054 Foot pedal
#195 055 Fingertip
Weldcraft® A-200 (WP-26) TIG Torch #WP-26-12-R 12-ft. (3.7 m) cable. Requires #195 379 connector
#WP-26-25-R 25-ft. (7.6 m) cable. Requires #195 379 connector
Air-Cooled TIG Torch Connectors #195 379 Connects Weldcraft® A-200 (WP-26) torch to Dinse connector
#195 378 Connects all air-cooled Weldcraft® torches (except A-200) to
Dinse connector. A-80 (WP-24) torches require 24-5 connector
Remote Controls
Wireless Remote Foot Control #300 429 Foot control with wireless 90-ft. (27.4 m) operating range
Wireless Remote Hand Control #300 430 Hand control with wireless 300-ft. (91.4 m) operating range
RCCS-14 #043 688 North/south fingertip control
RCC-14 #151 086 East/west fingertip control
RFCS-14 HD #194 744 Heavy-duty foot control
RHC-14 #242 211 020 Hand control
RMLS-14 #129 337 Momentary/maintained rocker switch
RMS-14 #187 208 Momentary rubber dome switch
Extension Cables #242 208 025 25 ft. (7.6 m)
#242 208 050 50 ft. (15.2 m)
#242 208 080 80 ft. (24.4 m)
Accessories
4-Pack Rack (empty) #195 051 Order power source and fuses separately
4-Pack Rack Running Gear #195 114 Four 5-in. diameter wheels and brackets
Fuses #199 795 230 V, 30 A individual fuse. 12 required for 4-Pack
#220 514 460 V, 15 A individual fuse. 12 required for 4-Pack
2-Wheel Trolley Cart #300 480
Universal Carrying Cart and Cylinder Rack #042 934
Coolmate™ 1 #300 360 115 VAC, 60 Hz. Requires coolant
TIG Coolant (Must be ordered in quantities of four) #043 810 1-gallon plastic bottle
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
Dinse/Tweco® Terminal Adapter #042 465 Male Dinse to female Tweco
Dinse/Cam-Lok Terminal Adapter #042 466 Male Dinse to female Cam-Lok
Gas Tungsten Arc Welding (TIG) Publication #250 833
Ron Covell TIG Welding Basics DVD #196 567
DVD Setup Video (included with machine) #251 116

Date: Total Quoted Price:

Distributed by:

© 2013 Miller Electric Mfg. Co.