June 1993 Form: OM-206C Effective With Serial No. KD375312 OWNER’S MANUAL Maxstar 152 And 175 CC/DC Welding Power Source For GTAW And SMAW Welding 120 A At 25 V Or 140 A At 25.6 V, 100% Duty Cycle 152 Model: Single-Phase; 175 Model: Three-Phase Input Power Thermostat Protection Against Overheating Touch Start For GTAW Welding 14-Pin Remote Control Receptacle Read and follow these instructions and all safety blocks carefully. Give this manual to the operator.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
EMF INFORMATION NOTE Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields – Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May 1989): “. . .
SECTION 1 – SAFETY INFORMATION mod1.1 2/93 Read all safety messages throughout this manual. Obey all safety messages to avoid injury. Learn the meaning of WARNING and CAUTION. 1 2 2 WARNING ELECTRIC SHOCK can kill. MOVING PARTS can injure. • Do not touch live electrical parts. • Disconnect input power before • Keep away from moving parts. • Keep all panels and covers closed 4 installing or servicing. Safety Alert Symbol 2 Signal Word WARNING means possible death or serious injury can happen.
2-1. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. A. 152 Model B. 175 Model ssb1.1 10/91 – SB-151 604 / SB-143 476-B Figure 2-1. Volt-Ampere Curves 2-2. Duty Cycle CAUTION EXCEEDING DUTY CYCLE RATINGS will damage unit. • Do not exceed indicated duty cycles. warn7.
SECTION 3 – INSTALLATION 3-1. Typical Process Connections SMAW Welding Power Source Work Remote Control GTAW 14 Pin Welding Power Source HF Unit Work Scratch Start Pulsed GTAW Or GTAW GTAW Pulse Control 14 Pin Welding Power Source Work Figure 3-1. Typical Process Connections 3-2. Selecting A Location And Moving Welding Power Source WARNING ELECTRIC SHOCK can kill. • • Do not touch live electrical parts.
3-3. Selecting And Preparing Weld Output Cables 1 3 Weld Output Cable Determine total cable length in weld circuit and maximum welding amperes. Use Table 3-1 to select proper cable size. 4 OR Use shortest cables possible. Do not use damaged cables. 2 Terminal Lug Use lugs of proper amperage capacity and hole size for connecting to work clamp or electrode holder.
3-4. Connecting To Weld Output Receptacles WARNING ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical equipment. • • • • Do not touch live electrical parts. Turn Off welding power source before making any weld output connections. Do not change position of welding cable connectors while welding. Be sure connectors are secure in receptacles before welding. 1 swarn12.
3-6. Connecting Input Power WARNING ELECTRIC SHOCK can kill. • • • • Do not touch live electrical parts. Turn Off welding power source, and disconnect input power before inspecting or installing. Have only qualified persons install unit. Installation must meet National Electrical Code and all other codes. swarn3.1 2/93 A.
Have only qualified persons make this installation. Remove wrapper. 7 1 3 4 Line Disconnect Device Of Proper Rating 2 Input Conductors 3 Grounding Conductor Select size and length using Table 3-2. Conductor rating must comply with national, state, and local electrical codes. Strip 3/8 in (10 mm) insulation off all conductors. 6 2 5 4 Strain Relief Connector Insert conductors through strain relief.
SECTION 4 – OPERATION WARNING ELECTRIC SHOCK can kill. • • • • ARC RAYS can burn eyes and skin; NOISE can damage hearing. Always wear dry insulating gloves. Insulate yourself from work and ground. Do not touch live electrical parts. Keep all panels and covers securely in place. • • MOVING PARTS can cause injury. FUMES AND GASES can be hazardous to your health. • • • • • Keep your head out of the fumes. Ventilate area, or use breathing device.
WARNING ELECTRIC SHOCK can kill. • • • Do not touch live electrical parts. Do not touch weld output receptacles when contactor is energized. Do not touch electrode and work clamp at the same time. swarn7.1* 10/91 1 Output (Contactor) Switch Use switch to select way of controlling output. For front panel control, place switch in On position. 1 For remote control, place switch in Remote 14 position (see Section 3-5). Weld output receptacles are energized when switch is On and Power is On. Figure 4-4.
1 Weld Process Switch Use switch to select type of weld output current. Use GTAW position for Gas Tungsten Arc Welding. Use SMAW position for Shielded Metal Arc Welding. 1 Switch position determines the operation of the Touch Start switch (see Figure 4-7). Figure 4-6. Weld Process Switch NOTE Touch Start switch must be in Off position when using a High-Frequency unit with this welding power source, or when using the SMAW welding process.
1 Amperage/Voltage Meter Meter displays amperage or voltage output. 2 1 Meter Switch Use switch to select amperage (A) or voltage (V) display. In Volts position, the meter displays the voltage at the weld output receptacles. In Amperage position, the meter displays the welding current during welding, and the preset amperage when welding is not taking place. 2 The meter displays the actual value for 15 seconds after welding stops (see Section 5-4). Figure 4-9.
SECTION 5 – MAINTENANCE & TROUBLESHOOTING WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE exists after removal of input power. • • • Keep away from moving parts. Do not touch live electrical parts. Turn Off welding power source, disconnect input power, wait 60 seconds, measure voltage on input capacitors according to Section 5-3, and wait for voltage to drop to zero before touching any parts. HOT PARTS can cause severe burns. • MOVING PARTS can cause injury.
5-3. Measuring Input Capacitor Voltage READ SAFETY BLOCKS at start of Section 5 before proceeding. WARNING Turn Off welding power source and disconnect input power. Remove wrapper. 1 Input Capacitor C1 (Both Models) 2 Input Capacitor C2 (175 Models Only) 3 Voltmeter Check input capacitor(s). Measure the dc voltage across the positive (+) and negative (–) terminals every 30 seconds until voltage drops to 0 (zero) volts. Proceed with job inside unit. Reinstall wrapper when finished.
5-5. Troubleshooting WARNING ELECTRIC SHOCK can kill. SIGNIFICANT DC VOLTAGE exists after removal of input power. • • MOVING PARTS can cause injury. • Do not touch live electrical parts. Turn Off welding power source, disconnect input power, wait 60 seconds, measure voltage on input capacitors according to Section 5-3, and wait for voltage to drop to zero before touching any parts. STATIC ELECTRICITY can damage parts on circuit boards. • • HOT PARTS can cause severe burns.
Trouble Wandering arc; poor control of arc direction. Tungsten electrode oxidizing and not remaining bright after conclusion of weld. Remedy Section Reduce gas flow rate. –– Select proper size tungsten. 7-1 Properly prepare tungsten. 7-2 Shield weld zone from drafts. –– Increase postflow time. –– Check and tighten all gas fittings. –– Water in torch. Refer to torch Owner’s Manual for part(s) requiring replacement, and repair torch as necessary.
Figure 6-1.
OM-206 Page 17 Figure 6-2.
Figure 6-3.
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Figure 6-4.
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SECTION 7 – TUNGSTEN ELECTRODE mod2.1 3/93 NOTE For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process. Wear clean gloves to prevent contamination of tungsten electrode. 7-1. Selecting Tungsten Electrode Table 7-1. Tungsten Size Amperage Range - Gas Type♦ - Polarity DC – Argon – Electrode Negative/Straight Polarity DC – Argon – Electrode Positive/Reverse Polarity AC – Argon – Using High Frequency AC – Argon – Balanced Wave Using High Freq. .
7-2. Preparing Tungsten 1 1 Tungsten Electrode 2 Balled End Ball end of tungsten before welding by applying either an ac amperage slightly higher than what is recommended for a given electrode diameter (see Table 7-1), or a dc electrode positive amperage. 1-1/2 Times Electrode Diameter 2 Ref. S-0161 Figure 7-1. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding CAUTION FLYING SPARKS AND HOT METAL can cause injury and start fires.
OM-206 Page 24 44 45 46 47 1 48 43 49 2 42 3 41 50 4 15 53 40 39 52 55 38 54 37 6 7 8 36 35 34 12 11 10 9 16 15 14 13 17 33 Figure 8-1.
Item No. Dia. Mkgs. Part No. Description Quantity Model 152 175 Figure 8-1. Main Assembly . . . 1 . . . . . . . . . . . . . . . . 126 416 . . . 2 . . . . . . . . . . . . . . . . 126 415 . . . 3 . . . . . . . . . . . . . . . . 134 327 . . . 4 . . . . . . . . . . . . . . . +151 755 . . . 4 . . . . . . . . . . . . . . . +140 620 . . . 5 . . . . . . PC1 . . . . . 156 858 . . . . . . . . . . PLG1,2 . . . 131 052 . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . . . . . . . PLG3 . . . . 131 056 .
Item No. Dia. Mkgs. Part No. Description Quantity Model 152 175 Figure 8-1. Main Assembly (Continued) . . . 37 . . . . . . . S1 . . . . . 090 328 . . SWITCH, tgl DPST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG11 . . . . 115 094 . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . RC11 .
Quantity Item No. Dia. Mkgs. Part No. Model Description 152 175 Figure 8-2. Module, Power & Diode (Fig 8-1 Item 25 & 26) . . . 1 . . . . . . C11 . . . . . 093 085 . . . 2 . . . . . VR1-3 . . . . 090 304 . . . 3 . . . . . . . . . . . . . . . . 158 540 . . . 3 . . . . . . . . . . . . . . . . 141 668 . . . 4 . . . . . . . . . . . . . . . . 156 247 . . . 4 . . . . . . . . . . . . . . . . 155 426 . . . 5 . . . . . . . . . . . . . . . . 134 209 . . . 6 . . . . . . . . . . . . . . . . 000 366 . . . 7 . . . .
Quantity Item No. Dia. Mkgs. Part No. Model Description 152 175 Figure 8-2. Module, Power & Diode (Fig 8-1 Item 25 & 26) (Continued) . . . . . . . . . . . PLG6 . . . . ...................... ...................... ...................... . . . 15 . . . . . . VR4 . . . . . . . . 16 . . . . . . R10 . . . . . . . . 17 . . . . . . DM1 . . . . . . . . 17 . . . . . . DM1 . . . . . . . . 18 . . . . . . D5,6 . . . . . . . . 19 . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . . . . . . 20 .
OPTIONS AND ACCESSORIES BACKLIT LCD METER KIT (#042 613 Factory) For 175 (#042 880 Factory) For 152 (#042 614 Field) For all models A presettable, lighted digital display meter. Meter displays preset amperage, weld amperage, or weld voltage. UNIVERSAL LARGE CYLINDER CART (#042 934) Maxstar can mount on this cart along with argon cylinder. Will accommodate 6 to 9 in. (152 to 228 mm) diameter, and 24 to 56 in. (610 to 1422 mm) high. UNIVERSAL RUNNING GEAR/CYLINDER RACK (#042 454) Height: 17–1/4 in.
OPTIONS AND ACCESSORIES INTERNATIONAL TIG TORCH CONNECTOR KIT (#135 492) 80 Amp Torch (#135 493) 150 Amp Torch (#135 494) 200 Amp Torch* (#135 495) 250/350 Amp Water–Cooled Torch For direct connection of one–piece torches to power sources with International–style connectors. Note: Two–piece torches do not require this connector kit. They can use one of the two International–style connectors supplied with the power source. *May not be compatible with competitive brand torches.
Effective January 1, 2001 (Equipment with a serial number preface of “LB” 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.
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.
