Miller Maxstar 161 S Owner's Manual
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Miller Maxstar 161 S Owner's Manual

Arc welding power source with auto-line
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R
Maxstar 161 S, STL, and STH
OM-275099A
2016−10
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
With Auto-Linet
File: TIG (GTAW)

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  • Page 1 OM-275099A 2016−10 Processes Stick (SMAW) Welding TIG (GTAW) Welding Description Arc Welding Power Source Maxstar 161 S, STL, and STH With Auto-Linet For product information, File: TIG (GTAW) Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it 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 superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 10 − HIGH FREQUENCY ............10-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Tenir les bouteilles éloignées des circuits de soudage ou autres LE BRUIT peut endommager l’ouïe. circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. Le bruit des processus et des équipements peut affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec D Porter des protections approuvées pour les une bouteille.

  • Page 12: Proposition Californienne 65 Avertissements

    RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de FRÉQUENCE (H.F.) risque provoquer des interférences. provoquer des interférences. D L’énergie électromagnétique risque D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et l’équipement commandé...

  • Page 13: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves.

  • Page 14: Miscellaneous Symbols And Definitions

    A complete Parts List is available at www.MillerWelds.com Do not remove or paint over (cover) the label. Safe20 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.

  • Page 15: Section 4 − Specifications

    A complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number is located on the bottom, and rating information is located on the back of the machine. Use the rating labels to determine input power requirements and/or rated output.

  • Page 16: Environmental Specifications

    A complete Parts List is available at www.MillerWelds.com 4-4. Environmental Specifications A. IP Rating IP Rating IP23 This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered.

  • Page 17: Static Characteristics

    A complete Parts List is available at www.MillerWelds.com 4-5. Duty Cycle And Overheating For Maxstar 161STL And STH Models Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, output stops, the Overtemperature Light comes On, Over Temp is displayed, and the Stick And TIG 240 V...

  • Page 18: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Selecting a Location Do not move or operate unit where it could tip. Movement Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 19: Electrical Service Guide

    A complete Parts List is available at www.MillerWelds.com 5-2. Electrical Service Guide The Auto-Linet circuitry in this unit automatically adapts the power source to the primary voltage being applied. Check input voltage available at site. This unit can be connected to any input power between 120−240 VAC without removing the cover to relink the power source. Actual input voltage should not exceed ±...

  • Page 20: Connecting 120 Vac Input Power

    A complete Parts List is available at www.MillerWelds.com 5-4. Connecting 120 VAC Input Power Do not move or operate unit where it could tip. Installation must meet all National and Local Codes − have only qualified persons make this installation. Do not use power cord to lift or carry welding power source.
  • Page 21 A complete Parts List is available at www.MillerWelds.com Notes OM-275099 Page 17...

  • Page 22: Connecting 1-Phase Input Power For 240 Vac

    A complete Parts List is available at www.MillerWelds.com 5-5. Connecting 1-Phase Input Power For 240 VAC =GND/PE Earth Ground 240 VAC, 1 Tools Needed: 803766-C / Ref. 805577-A OM-275099 Page 18...
  • Page 23 A complete Parts List is available at www.MillerWelds.com 5-5. Connecting 1-Phase Input Power For 240 VAC (Continued) Green Or Green/Yellow Grounding Over-Current Protection Installation must meet all National Conductor and Local Codes − have only Select type and size of over-current protection using Section...

  • Page 24: Shoulder And Handle Strap Installation

    A complete Parts List is available at www.MillerWelds.com 5-6. Shoulder And Handle Strap Installation Strap Buckle Assembly A. Shoulder Strap Installation Strap Detail A Cam Buckle If necessary, before attaching shoulder/handle strap to power source, assemble strap/buckle as shown. Detail A is Critical! Insert strap through cam buckle As Shown Installing And Securing Shoul-...
  • Page 25 A complete Parts List is available at www.MillerWelds.com B. Handle Strap Installation Installing And Securing Handle Portion Of Strap. Install shoulder portion of strap, see Section 5-6A, before in- stalling handle strap. Front Metal Loop Handle Strap W/ Hook/Loop Fasteners Hook And Loop Type Fastener Rear Metal Loop...

  • Page 26: Section 6 − Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATION 6-1. Front Panel Controls And Gas Connection Ref. 803375-A / 273310-A Represents a particle message that flashes, dis- plays the remainder of the message, and then re- Represents a message that displays, scrolls peats.

  • Page 27: Process Selection (Sth Model Only)

    A complete Parts List is available at www.MillerWelds.com 6-3. Process Selection (STH Model Only) Process Selector Button Use control to select required welding process. Press Button un- til light (LED) for desired process is illuminated. TIG Impulse Start When selected, an impulse HF arc starting method is activated (see Section 6-5).

  • Page 28: Lift-Arc And Tig Impulse Start Procedures

    A complete Parts List is available at www.MillerWelds.com 6-5. Lift-Arc And TIG Impulse Start Procedures Lift-Arc Start TIG Electrode Workpiece Touch tungsten electrode to work- piece, hold for 1-2 seconds, slowly lift electrode, and an arc forms. Open-circuit voltage maybe present before electrode touches workpiece.

  • Page 29: Accessing Control Panel Menu: Lift-Arc Tig (Sth And Stl Models Only)

    A complete Parts List is available at www.MillerWelds.com 6-7. Accessing Control Panel Menu: Lift-Arc TIG (STH And STL Models Only) Menu Button While in the Lift-Arc process, press and hold Menu button for approxim- ately two seconds to access Ma- chine Configuration menus.

  • Page 30: Accessing Control Panel Menu: Stick

    A complete Parts List is available at www.MillerWelds.com 6-8. Accessing Control Panel Menu: Stick Menu Button While in the Stick process, press and hold Menu button for approxim- ately two seconds to access Ma- chine Configuration menus. Use Menu button to cycle through pa- rameters that can be set.

  • Page 31: Section 7 − Advanced Menu Functions

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − ADVANCED MENU FUNCTIONS 7-1. Accessing Tech Menu For Maxstar 161 Models Menu Button Press and hold Menu button for ap- proximately four seconds to scroll past User Menu to Tech Menu. Use Menu button to cycle through para- meters that can be set.

  • Page 32: Section 8 − Maintenance And Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. Δ = Repair n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent Every Months...

  • Page 33: Troubleshooting

    A complete Parts List is available at www.MillerWelds.com 8-3. Troubleshooting Trouble Remedy No weld output; unit completely Place line disconnect switch in On position (see Sections 5-4 or 5-5). inoperative. Check and replace line fuse(s), if necessary (see Sections 5-4 or 5-5). Check for proper input power connections (see Sections 5-4 or 5-5).
  • Page 34 A complete Parts List is available at www.MillerWelds.com Trouble Remedy Error message [See O.M. ERROR Contact a Factory Authorized Service Agent. 1.4.3] is displayed. Error message [See O.M. ERROR Contact a Factory Authorized Service Agent. 1.3.4] is displayed. Notes OM-275099 Page 30...

  • Page 35: Section 9 − Electrical Diagram

    SECTION 9 − ELECTRICAL DIAGRAM 275094-A Figure 9-1. Circuit Diagram For Welding Power Source OM-275099 Page 31...

  • Page 36: Section 10 − High Frequency

    SECTION 10 − HIGH FREQUENCY 10-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. high_freq 5/10 − S-0693 10-2. Installation Showing Possible Sources Of HF Interference Weld Zone 11, 12 50 ft...

  • Page 37: Recommended Installation To Reduce Hf Interference

    10-3. Recommended Installation To Reduce HF Interference Weld Zone 50 ft (15 m) 50 ft (15 m) Ground all metal ob- jects and all wiring in welding zone using #12 AWG wire. Ground workpiece if required by Nonmetal codes. Building Best Practices Followed Metal Building Ref.

  • Page 38: Section 11 − Selecting And Preparing A Tungsten For Dc Or Ac Welding With Inverter Machines

    SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2013-10 Whenever possible and practical, use DC weld output instead of AC weld output. 11-1. Selecting Tungsten Electrode ( Wear Clean Gloves To Prevent Contamination Of Tungsten Not all tungsten electrode manufacturers use the same colors to identify tungsten type.

  • Page 39: Section 12 − Stick Welding (Smaw) Guidelines

    SECTION 12 − STICK WELDING (SMAW) GUIDELINES 12-1. Electrode and Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG...
  • Page 40 A complete Parts List is available at www.MillerWelds.com Notes OM-275099 Page 36...
  • Page 41 A complete Parts List is available at www.MillerWelds.com Notes OM-275099 Page 37...
  • Page 42 A complete Parts List is available at www.MillerWelds.com Notes OM-275099 Page 38...
  • Page 43 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 44 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

This manual is also suitable for:

Maxstar 161 stlMaxstar 161 sth

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