Miller Maxstar 150 S Owner's Manual
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Miller Maxstar 150 S Owner's Manual

Arc welding power source with auto-line ce and non-ce models
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www.MillerWelds.com
Maxstar 150 S, STL, And STH
R
CE And Non-CE Models
OM-2242
208 580AA
2011−05
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-2242 208 580AA 2011−05 Processes Stick (SMAW) Welding TIG (GTAW) Welding Description Arc Welding Power Source Maxstar 150 S, STL, And STH With Auto-Linet CE And Non-CE Models File: TIG (GTAW) Visit our website at 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: Declaration Of Conformity

    DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
  • Page 5 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−01 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 8 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 oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • Page 9: 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 10: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 11: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Warning Label Definitions A. Warning! Watch Out! There are possible Breathing welding fumes can be hazardous fire extinguisher nearby, and have a to your health. watchperson ready to use it. hazards as shown by the symbols. 3.3 Do not weld on drums or any closed 2.1 Keep your head out of the fumes.

  • Page 12: Symbols And Definitions

    2-2. Symbols And Definitions Suitable For Areas Shielded Metal Arc Amperes Voltage Input Of Increased Welding (SMAW) Shock Hazard Increase/Decrease Single Phase Static Frequency Volts Of Quantity Converter-Transformer-Rectifier Output Negative Positive Hertz Gas Input High Temperature Direct Current Line Connection Conventional Load Percent Duty Cycle...

  • Page 13: Section 3 − Specifications And Installation

    SECTION 3 − SPECIFICATIONS AND INSTALLATION 3-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 14: Specifications

    3-3. Specifications Amperes In- Rated Peak Input Power Welding KVA @ put At Rated Rated Welding Starting Single-Phase IP Rating Amperage OCV DC Load Output, Duty Voltage (Up) Output Range (Uo) Cycle 50/60Hz, Single-Phase 115 Volts Stick 70A @ 22.8 Volts DC, 20 −...

  • Page 15: Volt-Ampere Curves

    3-5. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. 115 VAC Input 230 VAC Input TIG/Stick Max TIG/Stick Max TIG Min TIG Min Stick Min Stick Min Amperes...

  • Page 16: Electrical Service Guide For 230 Vac

    3-7. Electrical Service Guide For 230 VAC 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 120−230 VAC without removing the cover to relink the power source. Actual input voltage should not exceed ...

  • Page 17: Selecting A Location, And Connecting Input Power

    3-9. Selecting A Location, And Connecting Input Power Welding Power Source Shoulder Strap Use strap to lift unit. Do not move or operate unit where it could tip. Installation must meet all National and Local Codes − have only qualified persons make this...

  • Page 18: Connecting 1-Phase Input Power For 230 Vac

    3-10. Connecting 1-Phase Input Power For 230 VAC Installation must meet National and Local Codes − have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. Always connect green or green/ yellow conductor supply grounding terminal first, and never...

  • Page 19: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Front Panel Controls And Gas Connection Ref. 803 375-A / 233 167-A Ready Light (LED) Amperage Adjustment Control Power Switch This control adjusts welding amperage. Place switch in On (I) or Off (0) position as Light comes on approximately two seconds af- needed.

  • Page 20: Process Selection (Sth Model Only)

    4-3. Process Selection (STH Model Only) =Light Off =Light On =Light Flashing Process Selector Switch Pad Use control to select required welding process. Press switch pad until light (LED) for desired process is illuminated. TIG Impulse Start When selected, an impulse HF arc starting method is activated (see Section 4-4).
  • Page 21 Notes OM-2242 Page 15...

  • Page 22: Set-Up Procedure For The Tig Process And Restoring Factory Default Settings (Sth Model Only)

    4-5. Set-Up Procedure For The TIG Process And Restoring Factory Default Settings (STH Model Only) Set-Up Procedure Power Switch Process Switch Pad Ready Light High Temp Light TIG HF Light TIG Pulse Light TIG Lift-Arc Light Stick Light To enter Set-Up Mode, turn power On while pressing and holding the Process switch pad for approximately 5 seconds, until the Ready (3) and High Temp (4) lights flash alternately.
  • Page 23 Light Flashing = Active Feature Lights Indicate Which Selection Is Active Light On = Selected Option Of Feature 1 Or 2 Press & Hold To Scroll Between Features . Release At Desired Feature. Feature 1 Feature 2 Trigger Method Pulse Frequency (PPS) Press and release switch Press and release switch pad to pad to see active Trigger Method.

  • Page 24: Section 5 − Maintenance And Troubleshooting

    SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. n = Check Z = Change ~ = Clean = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months ~ Weld Terminals...

  • Page 25: Troubleshooting

    5-3. Troubleshooting Trouble Remedy No weld output; unit completely inop- Place line disconnect switch in On position. erative; ready light (LED) Off. Check and replace line fuse(s), if necessary, or reset circuit breaker. Be sure power cord is plugged in and that receptacle is receiving input power. No weld output;...

  • Page 26: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM 219 466-H Figure 6-1. Circuit Diagram For CE And Non CE Model Welding Power Source OM-2242 Page 20...
  • Page 27 Notes OM-2242 Page 21...

  • Page 28: Section 7 − Parts List For S Models

    SECTION 7 − PARTS LIST FOR S MODELS Hardware is common and not available unless listed. 803 475-H Figure 7-1. Parts View OM-2242 Page 22...
  • Page 29 Item Dia. Part Mkgs. Description Quantity ..230 210 Kit, pcb assy (windtunnel w/cmpnts) ........

  • Page 30: Section 8 − Parts List For Stl Models

    SECTION 8 − PARTS LIST FOR STL MODELS Hardware is common and not available unless listed. 803 474-J Figure 8-1. Parts View OM-2242 Page 24...
  • Page 31 Item Dia. Part Mkgs. Description Quantity ..230 210 Kit, pcb assy (windtunnel w/cmpnts) ........

  • Page 32: Section 9 − Parts List For Sth Models

    SECTION 9 − PARTS LIST FOR STH MODELS Hardware is common and not available unless listed. 803 447-K Figure 9-1. Parts View OM-2242 Page 26...
  • Page 33 Item Dia. Part Mkgs. Description Quantity ... . . 208 701 Insulator w/label ........... . .
  • Page 34 Notes...
  • Page 35 Notes...
  • Page 36 Notes...
  • Page 37 Effective January 1, 2011 (Equipment with a serial number preface of MB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...

  • Page 38: Options And Accessories

    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 2011 Miller Electric Mfg. Co. 2011−01...

This manual is also suitable for:

Maxstar stlMaxstar sthMaxstar 150 stl

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