MILLER MAXSTAR 150 STH (01) PDF Document

The specifications for the MILLER MAXSTAR 150 STH are as follows:

*Sense Voltage For Stick And TIG Lift Arc™

**Arc Striking Device Is Designed For Manual Guided Operations

The duty cycle is the percentage of a 10-minute period that the MILLER MAXSTAR 150 STH can weld at its rated load without overheating.

If the unit overheats, the output will stop, the Overtemperature Light will illuminate, and the cooling fan will continue to run. You should wait for fifteen minutes for the unit to cool down. To prevent further overheating, reduce the amperage or duty cycle before you start welding again. Exceeding the duty cycle can cause damage to the unit.

These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the MILLER MAXSTAR 150 STH.

Use the shortest extension cord possible. The following table provides the maximum allowable cord length based on the conductor size (AWG) and input voltage for your MILLER MAXSTAR 150 STH. The conductor size is based on a maximum 3% voltage drop.

When selecting a location for your MILLER MAXSTAR 150 STH, ensure there is a minimum of 18 inches (460 mm) of clearance for airflow around the unit. Do not move or operate the unit where it could tip over.

To connect input power:

1. The MILLER MAXSTAR 150 STH features Auto-Line circuitry, which automatically links the power source to the primary voltage being applied (115 or 230 VAC).

2. Do not cut off the power cord connector to rewire it. Modifying the power cord, connector, and plugs will void the product warranty.

3. 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.

4. For 230 volts AC input power, refer to the Electrical Service Guide.

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

6. Install the selected plug onto the power cord adapter. As you tighten the threaded collar, push the plug onto the adapter until the collar is completely tight.

7. Connect the plug to the receptacle.

Installation must meet all National and Local Codes, and only qualified persons should perform this installation. Always disconnect and lockout/tagout input power before connecting input conductors from the unit.

1. See the rating label on the unit and check the input voltage available at the site.

2. Connect the green or green/yellow grounding conductor to the disconnect device grounding terminal first. Never connect it to a line terminal.

3. Connect the input conductors L1 (Black) and L2 (White) to the disconnect device line terminals.

4. Select the type and size of over-current protection (e.g., fused disconnect switch) according to the Electrical Service Guide in your manual.

5. Once connections are made, close and secure the door on the disconnect device. Remove the lockout/tagout device and place the switch in the On position.

The front panel controls of the MILLER MAXSTAR 150 STH are as follows:

1. Ready Light (LED): This light comes on about two seconds after the power switch is turned On (I) if Lift-Arc On or Stick is selected. If TIG Impulse is selected, the ready light only comes on after the output is enabled. A solid light indicates the unit is energized and ready for welding. A flashing light indicates the unit is not ready or has a functional error.

2. High Temperature Light (LED): This light illuminates if the unit overheats. Once the unit has cooled, welding can resume. If this light flashes, take the unit to an Authorized Service Agent.

3. Amperage Adjustment Control: This knob adjusts the welding amperage.

4. Process Select Switch: This allows you to choose the desired welding process.

5. Positive Weld Output Receptacle: For Stick welding, connect the electrode cable here. For TIG welding, connect the work cable here.

6. Negative Weld Output Receptacle: For Stick welding, connect the work cable here. For TIG welding, connect the torch cable here.

7. Remote Receptacle: For TIG Impulse or Lift-Arc TIG, the output can be adjusted from minimum to maximum of the front panel setting with a remote control.

8. Power Switch: Place the switch in the On (I) or Off (O) position.

9. Gas Fitting: Connect the customer-supplied gas hose between the regulator/flowmeter and this fitting.

10. Cylinder Valve: Open the valve slightly to let gas flow blow any dirt from the valve, then close it before connecting the hose.

11. Regulator/Flowmeter: Used to regulate gas pressure.

12. Flow Adjust: A typical flow rate is 15 cubic feet per hour (7.1 liters per minute) at a maximum of 90 psi (621 kPa).

To select a welding process on your MILLER MAXSTAR 150 STH, use the Process Selector Switch Pad. Press the switch pad until the light (LED) for your desired process is illuminated. The available processes are:

1. TIG Impulse Start: Activates an impulse High Frequency (HF) arc starting method.

2. TIG Pulse With TIG Impulse Start: Activates the TIG pulse welding process with an impulse HF start.

3. TIG Pulse With Lift-Arc™ Start: Activates the TIG pulse welding process with a Lift-Arc start.

4. Lift-Arc™ Start: Activates a TIG arc starting method where the electrode must contact the workpiece to initiate an arc.

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

Lift-Arc Start Procedure:

1. Touch the tungsten electrode to the workpiece.

2. Hold it in place for 1-2 seconds.

3. Slowly lift the electrode, and an arc will form. Note that open-circuit voltage may be present before the electrode touches the workpiece. Do not strike the electrode like a match.

TIG Impulse Start Procedure:

For this method, high frequency (HF) starts the arc when the output is enabled, without the electrode needing to make contact with the workpiece. The high frequency automatically turns off once the arc is started.

To enter the Set-Up Mode on your MILLER MAXSTAR 150 STH, turn the power On while simultaneously pressing and holding the Process switch pad. Continue holding for approximately 5 seconds, until the Ready (3) and High Temp (4) lights begin to flash alternately.

Once in Set-Up Mode, you can adjust two features on your MILLER MAXSTAR 150 STH:

Feature 1 – Selectable Trigger Method:

You can choose from three trigger methods:

• Standard trigger: Typically used with a remote amperage control. It provides a non-contact start in DC Impulse TIG mode and enables Lift-Arc start with a remote control in Lift-Arc mode.

• Lift-Arc Panel Control: Allows for a Lift-Arc start without using a remote control device. This is used when HF starts are not permitted or to replace scratch starts.

• 2T Trigger Hold: Used with a push-button control as an on-off switch. In HF mode, it functions as a simple on/off. In Lift-Arc mode, pushing and releasing the torch trigger starts the weld, and a second push and release ends the weld current and starts the Auto Crater function, which ramps the weld current down.

Feature 2 – Pulse Frequency:

You can choose from four pulse frequency intervals: 0.5 PPS (Pulses Per Second), 1 PPS, 2.5 PPS, or 60 PPS.

After entering Set-Up Mode on your MILLER MAXSTAR 150 STH:

1. The light for Feature 1 (Trigger Method) will be flashing. Press and release the switch pad to cycle through the available trigger methods. The selected option will have a solid light, while the active feature light continues to flash.

2. To switch to Feature 2 (Pulse Frequency), press and hold the switch pad until the light for Feature 2 begins to flash, then release.

3. Press and release the switch pad to cycle through the available pulse frequencies. The selected option will have a solid light.

4. To save your 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.

To restore the factory default settings on your MILLER MAXSTAR 150 STH, follow these steps:

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 back 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.

The MILLER MAXSTAR 150 STH 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 manually reset the supplementary protector.