Miller | LD160005 | Owner Manual | Miller MAXSTAR 150 STL User manual

Miller MAXSTAR 150 STL User manual
OM-2245
208 726A
May 2003
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
Maxstar 150 STL
With Auto-Line
Visit our website at
www.MillerWelds.com
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Installing Shoulder Strap, Selecting A Location, And Connecting Input Power . . . . . . . . . . .
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Process Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Lift-ArcE And TIG Impulse Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Set-Up Procedure And Restoring Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_7/02
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Only qualified persons should install, operate, maintain, and
repair this unit.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
During operation, keep everybody, especially children, away.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Keep your head out of the fumes. Do not breathe the fumes.
Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first – double-check connections.
Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-2245 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
OM-2245 Page 2
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-2245 Page 3
1-4. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800–463–6727 or in Toronto 416–747–4044, website: www.csa–international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212–642–4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269–9101 (phone: 617–770–3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269–9101 (phone:
617–770–3000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202–4102 (phone: 703–412–0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices––phone for Region 5, Chicago, is
312–353–2220, website: www.osha.gov).
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-2245 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 – DEFINITIONS
2-1. Warning Label Definitions
A. Warning! Watch Out! There are possible
hazards as shown by the symbols.
2
1
2.1
2.2
Electric shock from welding electrode or
wiring can kill.
1.1 Wear dry insulating gloves. Do not touch
electrode with bare hand. Do not wear
wet or damaged gloves.
1.2 Protect yourself from electric shock by
insulating yourself from work and
ground.
1.3 Disconnect input plug or power before
working on machine.
1
1.1
2
2.1
3
3.1
2.3
3
3.1
3.2
A
Breathing welding fumes can be
hazardous to your health.
Keep your head out of the fumes.
Use forced ventilation or local exhaust to
remove the fumes.
Use ventilating fan to remove fumes.
Welding sparks can cause explosion or
fire.
Keep flammables away from welding. Do
not weld near flammables.
Welding sparks can cause fires. Have a
fire extinguisher nearby, and have a
watchperson ready to use it.
1.2
1.3
2.2
2.3
3.2
4
3.3 Do not weld on drums or any closed
containers.
4 Arc rays can burn eyes and injure skin.
4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.
5
6
Become trained and read the instructions
before working on the machine or
welding.
Do not remove or paint over (cover) the
label.
4.1
5
3.3
6
S-179 310-A
2-2. Symbols And Definitions
A
V
Voltage Input
Volts
Increase/Decrease
Of Quantity
Output
Negative
Positive
Gas Input
High Temperature
Direct Current
Percent
Alternating
Current
I1eff
S
Shielded Metal Arc
Welding (SMAW)
Amperes
Maximum Effective
Supply Current
X
U0
Duty Cycle
Rated No Load
Voltage (Average)
Remote
Process
Single Phase Static Frequency
Converter-Transformer-Rectifier
U1
I1max
Primary Voltage
Rated Maximum
Supply Current
Lift-Arc Start
(GTAW)
Hz
Hertz
Line Connection
U2
I2
Conventional Load
Voltage
Rated Welding
Current
Gas Tungsten Arc
Welding (GTAW)
Suitable For Areas Of Increased Shock Hazard
OM-2245 Page 5
SECTION 3 – SPECIFICATIONS AND INSTALLATION
3-1. Specifications
Input Power
Single-Phase
AC
Welding
Amperage
Range
Rated Welding
Output
Max
OCV
DC
Amperes Input At Rated
Load Output,
50/60Hz,
Single-Phase
KVA AT
Duty
Cyc.
KW
17.4
2.0
1.9
26.4
3.0
3.0
18.4
2.1
2.1
28.0
3.4
3.1
70A @ 22.8 Volts DC,
100% Duty Cycle
115 Volts Stick
20 – 100A
100A @ 14.0 Volts DC,
100% Duty Cycle
5 – 150A
Weight
H: 9 in (229 mm)
13.7 lb
(6.2 kg)
90V
100A @ 24.0 Volts DC,
40% Duty Cycle
115 Volts TIG
Dimensions
90V
150A @ 16.0 Volts DC,
30% Duty Cycle
W: 5.5 in (140 mm)
100A @ 24 Volts DC,
100% Duty Cycle
230 Volts Stick
20 – 150A
13.1
3.0
2.8
21.6
4.9
4.7
8.3
2.0
1.9
14.2
3.2
3.1
90V
150A @ 26.0 Volts DC,
30% Duty Cycle
100A @ 14.0 Volts DC,
100% Duty Cycle
230 Volts TIG
5 – 150A
L: 13.25 in (337 mm)
90V
150A @ 16.0 Volts DC,
30% Duty Cycle
3-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
250
Output Amperes
200
If unit overheats, output stops, the
Overtemperature Light comes On,
and the cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again.
150
TIG &
Stick (230V)
100
Exceeding duty cycle can
damage unit and void
warranty.
Stick (115V)
50
0
10
100
% Duty Cycle
208 608-B
3-3. Volt-Ampere Curves
100
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of welding
power source. Curves of other settings fall between curves shown.
90
80
70
60
50
40
30
SMAW Max
20
SMAW Min
10
TIG Min
TIG Max
0
0
OM-2245 Page 6
20
40
60
80
100
120
140
160
180
200
208 604-A
3-4. Installing Shoulder Strap, Selecting A Location, And Connecting Input Power
Do not move or operate unit
where it could tip.
1
Welding Power Source
Shoulder Strap
Use strap to lift unit.
2
Rating Label
Label is located on bottom of unit.
Use rating label to determine input
power needs.
4
3
4
Input Power Cord
115 or 230 VAC Grounded
Receptacle
The Auto-Line circuitry in this
18 in
(460 mm)
Airflow Distance
Requirements
unit automatically links the
power source to the primary
voltage being applied, either
115 or 230 VAC.
3
( S E
( B
A R
C
O
D
E
)
R
I A L
N
U M
B
E R
PR OT EC T ED
BY ONE
F O L L O W IN G
18 in
(460 mm)
OR M O RE
An individual branch circuit capable
of carrying 30 amperes and protected by fuses or circuit breaker is
recommended.
Recommended
fuse or circuit breaker size is 30
amperes.
)
OF T HE
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( X ,X X X,X X X )
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2
E V ID E NC E
1
OF L A B E L
T A M P E R IN G
V OID S
W A RR A NTY
XXXXXXX X
To Rear Panel
M ill e r
E l e c t r ic
A p p le t o n ,
M fg . C o .
WI USA
M a xs ta r 1 5 0 (X X X )
(X X X X X X X X X X X X X )
1
S / N: (X X X X X X X X X X )
f1
f2
5 A / 10 V
Front Panel
X
30 %
I2
1 50
U2
16
6 0 % 1 0 0 % 30 %
6 0%
1 0 0%
12 0
100
1 50
12 0
100
1 4 .8
14
16
1 4 .8
14
1 5 0 A /2 6 V
U 1= 1 1 5 V
1
50/60H z
Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
U 1= 2 3 0 V
5 A / 20 V
U 0= 9 0 V
Connect input power plug to proper
receptacle.
1 5 0 A /1 6 V
U 1= 1 1 5 V
U 0= 9 0 V
Unit is supplied with a 115
VAC plug. For 230 VAC operation, have a qualified person obtain a proper plug that
meets all applicable codes,
and install the plug according to the manufacturer’s instructions.
U 1= 2 3 0 V
X
40%
6 0 % 1 0 0 % 3 0%
6 0%
1 0 0%
I2
10 0
85
70
1 50
12 0
10 0
U2
24
2 3.4
2 2 .8
26
2 4.8
24
I 1m a x
I 1e f f
U 1= 1 1 5 V
28
18
U 1= 2 3 0 V
23
13
Ref. 803 351-C / 208 651-B
3-5.
Selecting Extension Cord (Use Shortest Cord Possible)
Conductor Size (AWG)*
Single Phase AC
Input Voltage
4
6
8
10
12
Maximum Allowable Cord Length in ft (m)
115
160 (49)
107 (33)
71 (22)
47 (14)
29 (9)
230
471 (144)
321 (98)
215 (66)
146 (45)
90 (27)
*Conductor size is based on maximum 3% voltage drop
OM-2245 Page 7
SECTION 4 – OPERATION
4-1. Front Panel Controls
1
2
8
4
MIN
3
1
Ready Light
M a x star 1 5 0 S TL
Light comes on approximately two seconds after power switch is placed in On (I) position if
Lift-Arc or Stick has been selected. The light indicates that the unit is energized and ready for
welding. A flashing light indicates unit is not
ready, or that there is a functional error.
The
fan motor
controlled.
2
is
5
Ref. 803 375 / 208 670
7
thermostatically 4
Process Select Switch
See Section 4-2.
High Temperature Light
For Stick welding, connect work cable to this
receptacle. For TIG welding, connect torch
cable to this receptacle.
7
Light comes on if unit overheats. Once unit has 5 Positive Weld Output Receptacle
cooled down, welding can resume. If this light
flashes, take unit to an Authorized Service For Stick welding, connect electrode cable to
this receptacle. For TIG welding, connect work
Agent.
cable to this receptacle.
3 Amperage Adjustment Control
This control adjusts welding amperage.
6
6
Negative Weld Output Receptacle
Remote Receptacle
For Lift-Arc TIG, output may be adjusted from
min to max of the front panel setting with a remote control.
8
Power Switch
Place switch in On (I) or Off (0) position as
needed.
4-2. Process Selection
=Light Off
1
=Light On
Process Selector Switch Pad
Use control to select required welding
process. Press switch pad until LED
for desired process is illuminated.
2
Lift Arc Start
When selected, a TIG arc starting
method in which the electrode must
come in contact with the workpiece to
initiate an arc is activated (see Section
4-3).
2
3
3
Stick (SMAW)
When selected, Adaptive Hot Start
and DIG circuitry are energized.
1
Press
Press
4-3. Lift-Arc And TIG Impulse Start Procedures
Lift-Arc Start
1
2
“Touch”
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece, hold for 1-2 seconds, slowly
lift electrode, and an arc forms.
1–2
Seconds
Open-circuit voltage maybe present
before electrode touches workpiece.
Do NOT Strike Like A Match!
OM-2245 Page 8
4-4. Set-Up Procedure And Restoring Factory Default Settings
3
4
Read First!!
Set-Up Procedure
1
1
2
3
4
M IN
2
Power Switch
Process Switch Pad
Ready Light (LED)
High Temp Light (LED)
Modifiable Features:
Postflow – The time gas flows after welding stops.
M a x s ta r 1 5 0 S T L
Press and hold to scroll
to desired feature
=Light Off
=Light On
=Light Flashing
.5 sec/10 amps
Feature #1
Postflow Time
1 sec/10 amps
Or
Press &
Release
Press and release
to activate
Press &
Release
To save changes, wait 5 seconds until
feature light begins to flash before
scrolling to the next feature.
Lift Arc panel control (or
Maxstar 140 STR remote current control).
Feature #2
Trigger Method
Standard
2T
Trigger Method – standard, 2T
(trigger hold), or Lift Arc panel control (or Maxstar 140 STR remote
current control).
Set-Up Mode - To access
set-up mode, turn power
on while depressing the
process switch pad until
the ready and high temp
lights flash.
Release Process switch pad while
lights are flashing alternately to
enter set-up mode.
Once in set-up mode, press and
hold the process switch pad to
scroll to feature you want to
change. Follow the sequence as
shown to make changes.
After a parameter has been
changed, wait 5 seconds until the
feature light begins to flash before
scrolling to the next feature.
To save changes and exit set-up
mode, press and release torch
trigger, or turn power off and wait
until LED’s turn off, and then turn
power back on.
Restoring Factory Default Settings
Or
Or
Press and release
to activate
Press &
Release
Press &
Release
Press &
Release
To save changes, wait 5 seconds until feature light begins to flash before scrolling back
to the first feature, or to save all changes and exit set-up mode, press and release torch
trigger, or turn power off and wait until LED’s turn off, and then turn power back on.
To restore factory default settings,
press and hold process switch
pad and turn power On. Ready
and high temp lights will begin to
flash alternately. Continue holding
process switch pad for approximately 10 seconds until the lights
begin to flash synchronously. Release switch pad, as factory default settings are restored. The
lights will continue to flash until unit
is turned Off. To return to normal
welding operation, turn power On.
Factory default settings:
Postflow - 1 sec/10amps
Trigger Method- standard.
OM-2245 Page 9
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
Disconnect power before maintaining.
Maintain more often during severe conditions.
3 Months
Replace
unreadable
labels.
Replace Damaged
Gas Hoses
Repair Or Replace
Cracked Cables
And Cords
6 Months
Do not remove case when blowing out inside of unit .
Blow out inside. Direct airflow through front and back louvers.
5-2. Troubleshooting
Trouble
No weld output; unit completely inoperative; ready light Off.
No weld output; ready light On.
No weld output; high temperature light
On.
No weld output; high temperature light
Flashing.
Remedy
Place line disconnect switch in On position.
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.
Check and secure loose weld cable(s) into receptacle(s).
Check and correct poor connection of work clamp to workpiece.
Unit overheated causing thermal shutdown. Allow unit to cool with fan On (see Section 3-2).
Reduce duty cycle or amperage.
Check and correct blocked/poor airflow to unit (see Section 3-4).
Turn Power Off and back On again. If light continues to flash, check with Factory Authorized Service
Agent.
No weld output. Blue light flashes contin- Line voltage to high or to low. Line voltage must be within ±10%.
uously, yellow LED off.
Unit needs to rest. Cycle power off and back on. If problem is not corrected, contact Factory Authorized
Service Agent.
No weld output. Blue LED flashes 3 Remote trigger left on. Turn off remote trigger, wait 5 seconds, and restart operation.
times repeatedly, yellow LED off.
Erratic or improper welding arc or output.
Use proper size and type of weld cable (see your Distributor).
Clean and tighten weld connections.
Check and reverse polarity; check and correct poor connections to workpiece.
Unit not warmed up enough to require fan cooling.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor and control circuitry.
Stick welding problems: Hard starts; Use proper type and size of electrode.
poor welding characteristics; unusual
Check and reverse electrode polarity; check and correct poor connections.
spattering.
Fan not operating.
Make sure a remote control is not connected.
TIG welding problems: Wandering arc; Use proper type and size of tungsten.
hard starts; poor welding characterisUse properly prepared tungsten.
tics; spattering problems.
Check and reverse electrode polarity.
TIG welding problems: Tungsten elec- Shield weld zone from drafts.
trode oxidizing and not remaining bright Check for correct type shielding gas.
after welding.
Check and tighten gas fittings.
Check and change electrode polarity.
OM-2245 Page 10
SECTION 6 – ELECTRICAL DIAGRAM
208 601-D
208 601-A
Figure 6-1. Circuit Diagram For Welding Power Source
OM-2245 Page 11
SECTION 7 – PARTS LIST
Hardware is common and
not available unless listed.
803 474-A
OM-2242 Page 12
OM-2242 Page 13
Part number
208 701
208 610
208 622
208 625
208 627
195 666
208 700
208 569
208 664
208 558
208 703
208 549
208 550
208 536
208 687
208 548
208 496
208 538
208 552
208 545
208 651
208 561
208 596
208 535
208 699
208 588
208 591
208 698
208 589
174 992
208 544
208 522
208 711
208 556
208 497
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Nut, plastic 625-27.81 hex x .14
Screw, m5-.8 x 12 soc hd-torx
Receptacle, twist lock power
Cap, dust
Knob, pointer
Nameplate, front
Panel, front
Circuit Board, operator interface
Insulator, heat sink
Nut, m08-1.213 mm hex 8.3
mm t semi cone washer
Insulator w/label
Fastener, push-in
Label, warning
Windtunnel, heatsink w/cmpnts
Label, warning
Screw, 010-3 2x .50 torx
Case w/label
Hose and clamps (2)
Valve, gas w/fittings
Term, friction .250 x .032
Panel, rear
Nameplate, rear
Switch, power
Screw, k50 x 25 rnd wshr hd-trx
Cable, power
Strap, shoulder
Fan w/leads and plug
Windtunnel, magnetics w/cmpnt
Insulator, negative stud
Base
Label, ID-order by serial no.
Ground Cable
Holder, electrode
Screw, k50 x 12 rnd wshr hd-trx
Receptacle, twist lock power/
gas
English
Spanish
French
Italian
German
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
4
1
Qty.
Effective January 1, 2002
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 6/02
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
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.
PRINTED IN USA
 2003 Miller Electric Mfg. Co.
1/03
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