MILLER MAXSTAR 150 S (01) PDF Document

The MILLER MAXSTAR 150 S supports the following welding processes:

• Stick (SMAW) Welding

• TIG (GTAW) Welding

To prevent electric shock while using the MILLER MAXSTAR 150 S, follow these precautions:

• 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 large 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 the unit.

• Disconnect input power before installing or servicing this equipment.

• Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

• Always verify the supply ground. Check that the input power cord ground wire is properly connected to the ground terminal in the disconnect box or that the cord plug is connected to a properly grounded receptacle outlet.

• When making input connections, attach the proper grounding conductor first and double-check connections.

• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

• Frequently inspect the input power cord for damage or bare wiring. Replace the cord immediately if damaged.

• Turn off all equipment when not in use.

• Do not use worn, damaged, undersized, or poorly spliced cables.

• Do not drape cables over your body.

• If earth grounding of the workpiece is required, ground it directly with a separate cable.

• Do not touch an 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.

• Keep all panels and covers securely in place.

• Clamp the work cable with good metal-to-metal contact to the workpiece or worktable as near the weld as practical.

• Insulate the work clamp when not connected to the workpiece to prevent contact with any metal object.

• Turn Off the inverter, disconnect input power, and discharge input capacitors according to instructions in the Maintenance Section before touching any parts, as significant DC voltage exists even after removing input power.

The specifications for the MILLER MAXSTAR 150 S models are as follows:

Duty Cycle is the percentage of 10 minutes that the unit can weld at a rated load without overheating. If the unit overheats, the output stops, the Overtemperature Light comes On, and the cooling fan runs. Wait fifteen minutes for the unit to cool. You should reduce the amperage or duty cycle before starting to weld again. Exceeding the duty cycle can damage the unit and void the warranty.

The Auto-Line circuitry automatically adapts the power source to the primary voltage being applied between 120-230 VAC. For a dedicated 230 VAC branch circuit, the recommendations are:

Use the shortest extension cord possible. The maximum allowable cord length based on conductor size is as follows:

*Conductor size is based on a maximum 3% voltage drop.

1. Select a location with proper airflow, maintaining a distance of at least 18 inches (460 mm) around the unit.

2. Do not move or operate the unit where it could tip.

3. The Auto-Line circuitry in the unit automatically links the power source to the primary voltage being applied (115 or 230 VAC).

4. Do not cut off the power cord connector. Modifying the power cord, connector, and plugs will void the product warranty.

5. For 115 volts AC input power, a 15 or 20 ampere individual branch circuit protected by time-delay fuses or a circuit breaker is required.

6. Select the appropriate plug for the power supply receptacle available at your site (NEMA Type 5-15P for 115V or NEMA Type 6-50P for 230V).

7. Install the selected plug onto the power cord adapter. As the threaded collar is tightened, push the plug onto the adapter until the collar is completely tight.

8. Connect the plug to the receptacle.

• 1. Ready Light (LED): Comes on about two seconds after the power switch is turned On, indicating the unit is energized and ready. A flashing light indicates a functional error or that the unit is not ready.

• 2. High Temperature Light (LED): Lights up if the unit overheats. Welding can resume after the unit cools down. If it flashes, the unit requires service.

• 3. Amperage Adjustment Control: Adjusts the welding amperage.

• 4. Process Select Switch: Used to select the welding process.

• 5. Positive Weld Output Receptacle: Connect the electrode cable here for Stick welding. Connect the work cable here for TIG welding.

• 6. Negative Weld Output Receptacle: Connect the work cable here for Stick welding. Connect the torch cable here for TIG welding.

• 7. Remote Receptacle: Allows for remote adjustment of output for TIG Impulse or Lift-Arc TIG.

• 8. Power Switch: Turns the unit On (I) or Off (O).

• 9. Gas Fitting: Connection for the shielding gas hose.

• 10. Cylinder Valve: Open slightly to blow dirt from the valve before connecting the regulator.

• 11. Regulator/Flowmeter: Controls gas pressure and flow.

• 12. Flow Adjust: A typical flow rate is 15 cubic feet per hour (7.1 liters per minute).

1. Use the Process Selector Switch Pad to select the required welding process.

2. Press the switch pad until the LED for the desired process is illuminated.

The available processes are:

• Lift Arc™ Start: A TIG arc starting method where the electrode must contact the workpiece to initiate an arc.

• Stick (SMAW): When selected, Adaptive Hot Start and DIG circuitry are energized.

• Lift Arc™ Start (Remote): A TIG starting method requiring electrode contact with the work and a closure signal from the remote receptacle to initiate an arc.

1. Use the Process Selector Switch Pad to select the required welding process.

2. Press the switch pad until the light (LED) for the desired process is illuminated.

The available processes are:

• TIG Impulse Start: An impulse HF arc starting method.

• TIG Pulse With TIG Impulse Start: TIG pulse welding process with impulse HF start.

• TIG Pulse With Lift-Arc™ Start: TIG pulse welding process with Lift-Arc start.

• Lift-Arc™ Start: A TIG arc starting method where the electrode contacts the workpiece to initiate an arc.

• Stick (SMAW): When selected, Adaptive Hot Start and DIG circuitry are energized.

Lift-Arc Start

1. Touch the tungsten electrode to the workpiece.

2. Hold for 1-2 seconds.

3. Slowly lift the electrode, and an arc will form.

Note: Open-circuit voltage may be present before the electrode touches the workpiece. Do NOT strike the electrode like a match.

TIG Impulse

High frequency starts the arc when output is enabled without making contact with the workpiece. The high frequency turns off once the arc is started. This method should not be used with the Lift-Arc start procedure.

To enter Set-Up Mode, turn the power On while pressing and holding the Process switch pad for approximately 5 seconds. You will know you are in Set-Up Mode when the Ready (3) and High Temp (4) lights flash alternately.

Once in Set-Up Mode, you can change the following features:

• Feature 1 – Selectable Trigger Method: Standard trigger, Lift-Arc Panel Control, or 2T Trigger Hold.

• Feature 2 – Pulse Frequency: Choose from 0.5 PPS, 1 PPS, 2.5 PPS, or 60 PPS.

To navigate and change settings:

1. Press and hold the switch pad to scroll between Feature 1 (Trigger Method) and Feature 2 (Pulse Frequency). Release at the desired feature.

2. Press and release the switch pad to cycle through the options for the selected feature. The lit LED indicates the active option.

3. To save changes and exit set-up mode, press and release the torch trigger, or turn the power off, wait for the lights to turn off, and then turn the power back on.

1. Press and hold the process switch pad and turn the power On.

2. The Ready and High Temp lights will begin to flash alternately.

3. Continue holding the process switch pad for approximately 10 seconds until the lights begin to flash simultaneously.

4. Release the switch pad. The factory default settings are now restored. The lights will continue to flash until the unit is turned Off.

5. To return to normal welding operation, turn the power On.

The factory default settings are:

• Trigger Methods: TIG Impulse-Standard; Lift-Arc-On

• Pulse Frequency: 2.5 PPS

Always disconnect power before performing maintenance. Maintenance should be performed more often during severe conditions.

Every 3 Months:

• Check Labels

• Check Gas Hoses

• Check Weld Terminals

• Check Cables And Cords

Every 6 Months:

• Blow out the inside of the unit. Direct airflow through the front and back louvers. Do not remove the case when blowing out the inside of the unit.

Note: During heavy service, clean monthly.

The MILLER MAXSTAR 150 S is equipped with a supplementary protector, CB1, which protects the unit from overload. If CB1 opens due to an overload condition, the unit will shut down. To restore operation, you must reset the supplementary protector.