208 580H Processes Stick (SMAW) Welding ENGLISH OM-2242 January 2005 Arc Welding Power Source Maxstar 150 STH DEUTSCH ITALIANO With Auto-Linet ESPAÑOL Description FRANÇAIS TIG (GTAW) Welding And Non-CE Models Visit our website at www.MillerWelds.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
NOTE This information is provided for units with CE certification (see rating label on unit.) Miller Electric Mfg. Co. Manufacturer’s Name: Manufacturer’s Address: Declares that the product: 1635 W.
som _8/03 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 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.
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.
1-5. 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.
2-1. Warning Label Definitions A. Warning! Watch Out! There are possible hazards as shown by the symbols. 1 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. 2 Breathing welding fumes can be hazardous to your health. 2.
2-2.
ENGLISH SECTION 3 − SPECIFICATIONS AND INSTALLATION 3-1. Specifications Input Power Single-Phase Welding Amperage Range Rated Welding Output AC 70A @ 22.8 Volts DC, 100% Duty Cycle 115 Volts Stick 20 − 100A 100A @ 24.0 Volts DC, 35% Duty Cycle 100A @ 14.0 Volts DC, 100% Duty Cycle 115 Volts TIG 5 − 150A 150A @ 16.0 Volts DC, 30% Duty Cycle Max OCV DC Amperes Input At Rated Load Output, 50/60Hz, Single-Phase KVA @ Duty Cycle KW 17.4 2.0 1.9 26.4 3.0 3.0 18.4 2.1 2.1 28.0 3.4 3.
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 Install strap as shown. Use strap to lift unit. 2 4 Rating Label Label is located on bottom of unit. Use rating label to determine input power needs.
ENGLISH 3-6. Remote 6 Receptacle Information 6 Socket Socket Information 1 Contactor control +13.8 volts DC. 2 Contact closure to 1 completes contactor control circuit and enables output when Lift-Arc TIG remote is selected. 3 Output to remote control; +10 volts DC output to remote control. 4 0 to +10 volts DC input command signal from remote control. 5 Remote control circuit common. 6 Chassis common. 15 VOLTS DC OUTPUT CONTACTOR REMOTE OUTPUT CONTROL Ref.
4-2. Process Selection 1 =Light Off Process Selector Switch Pad Use control to select required welding process. Press switch pad until light (LED) for 2 desired process is illuminated. 2 =Light On =Light Flashing 3 4 TIG Impulse Start When selected, an impulse HF arc starting method is activated (see Section 4-3). 3 5 TIG Pulse With TIG Impulse Start 6 When selected, the TIG pulse welding process with impulse HF start is activated.
ENGLISH Notes OM-2242 Page 11
4-4. Set-Up Procedure For The TIG Process And Restoring Factory Default Settings Set-Up Procedure 3 4 5 6 1 2 3 4 5 6 7 8 Power Switch Process Switch Pad Ready Light High Temp Light TIG HF Light TIG Pulse Light TIG Lift-Arc Light Stick Light 7 8 2 M a x s ta r 1 5 0 S T H 1 2 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.
ENGLISH Lights Indicate Which Selection Is Active Light Flashing = Active Feature Light On = Selected Option Of Feature 1 Or 2 Press & Hold To Scroll Between Features . Release At Desired Feature. Feature 1 Trigger Method Feature 2 Pulse Frequency (PPS) Press and release switch pad to see active Trigger Method. Continue to press and release switch pad to change Trigger Method. Press and release switch pad to see active Pulse Frequency.
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 (LED) Off.
ENGLISH SECTION 6 − ELECTRICAL DIAGRAM 208 601-G Figure 6-1.
219 160-A Figure 6-2.
ENGLISH Notes OM-2242 Page 17
SECTION 7 − PARTS LIST Hardware is common and 20 22 24 36 23 26 30 27 1 2 28 3 29 31 32 25 10 4 33 5 8 6 34 24 8 35 9 10 7 11 12 17 13 24 18 19 2 14 37 15 38 16 not available unless listed.
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 4 5 5 6 7 7 8 9 9 10 11 11 12 12 13 14 15 15 16 17 18 18 19 20 22 23 24 25 26 27 28 29 30 31 31 32 32 33 33 33 34 35 36 37 38 Dia. Mkgs. Part No. Description Quantity . . . . . . . . . . 208 701 . . Insulator w/label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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 Contact 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.
