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OM-206 141 754F
October 1999
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
152 Model
175 Model
Maxstar 152 And 175
Visit our website at
www.MillerWelds.com
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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. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. 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 li
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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 Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – SPECIFICATIONS Unless otherwise noted, the 175 model is shown throughout this manual. NOTE 2-1. Specifications Maximum Rated Welding Amperage Amperes Input at Overall Model Open-Circuit KVA KW Weight Output Range Rated Load Output Dimensions Voltage DC Length: 16-1/2 in (419 mm) 230 Volts AC; 50/60 Hz; 120 A @ 6.2 3.7 31 lb Width: 9-1/2 in 25 Volts DC, 152 1–150 95 Single-Phase (14 kg) 0.12* 0.01* (241 mm) 100% Duty Cycle 27.1 (0.5)* Height: 8 in (203 mm) Length: 16-1/2 in (419 mm)
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2-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- 100% Duty Cycle At 120 Amperes For 152 utes that unit can weld at rated load Models; 140 Amperes For 175 Models without overheating. Exceeding duty cycle can damage unit and void warranty. Continuous Welding A. 152 Model B. 175 Model Overheating 0 15 minutes When overheated, thermostat Let fan run for Start welding. opens, output stops, and cooling 15 minutes. fan keeps running. rduty1 5/95 – SB-121 591-B / SB-144 507-B / ST-1
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SECTION 3 – INSTALLATION 3-1. Selecting A Location 1 10 in (254 mm) Open Space On Right Side And Rear Of Unit For Good Airflow 2 Lifting Handle 2 Use handle to move unit. 1 3 Rating Label Rear Locate unit near correct input power supply. Right 3 Ref. SA-145 666-C 3-2. Selecting And Preparing Weld Output Cables 1 Weld Output Cable Determine total cable length in weld circuit and maximum welding am- 3 peres. Use Section 3-3 to select 4 proper cable size. OR Use shortest cables possible. Do not use
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3-4. Connecting To Weld Output Receptacles 1 Positive (+) Weld Output Receptacle 2 Negative (–) Weld Output Receptacle 3 Connector 1 For Electrode Positive (DCEP), connect work cable connector to negative (–) receptacle and elec- trode holder cable connector to positive (+) receptacle. For Electrode Negative (DCEN), reverse cable connections. Align keyway, insert connector, and turn clockwise. 2 3 Ref. SC-140 373 / Ref. ST-152 126 3-5. Remote 14 Receptacle Information And Connections 1 Remote 14
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3-6. Remote 14 Socket Information Socket* Socket Information REMOTE 14 A +15 volts dc. OUTPUT (CONTACTOR) B Contact closure to A completes +15 volts dc contactor control circuit. C Output command reference; 0 to +10 volts dc depending on setting of Amperage Adjustment control R4. D Remote control circuit common. AMPERAGE/ A/V VOLTAGE E Input command signal (potentiometer wiper or 0 to +10 volts dc). K Chassis common *The remaining sockets are not used. 3-7. Connecting Input Power To 152 Models H
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3-9. Connecting Input Power To 175 Models Have only qualified persons make this installation. 1 Line Disconnect Device Of Proper Rating 2 Input Conductors 7 3 Grounding Conductor 3 Select size and length using Sec- tion 3-10. Conductor rating must comply with national, state, and local electrical codes. Strip 3/8 in (10 mm) insulation off conductors. 4 4 Strain Relief Connector Remove wrapper and insert con- ductors. 6 5 Input Terminal Block 2 6 Line Terminals 5 7 Welding Power Source Ground Ter
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SECTION 4 – OPERATION 4-1. Controls 1 Amperage Adjustment Control 2 Amperage Control Switch 3 Output (Contactor) Switch 4 Lift-Arc Switch 5 Weld Process Switch 6 Power Switch 34 5 6 7 Pilot Light 2 1 7 ST-152 127-A 4-2. Output (Contactor) Switch 1 Output (Contactor) Switch Use switch to select way of control- ling output. For front panel control, place switch in On position. For remote control, place switch in 1 Remote 14 position (see Section 3-5). Weld output receptacles are energized when swi
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4-3. Amperage Controls 1 Amperage Adjustment Control Use control to select weld amper- age. Amperage may be adjusted while welding. 2 Amperage Control Switch Use switch to select way of control- 1 ling amperage adjustment. 2 For front panel control, place switch in Panel position. For remote control, place switch in Remote 14 position (see Section 3-5). See Example below. 3 Remote Foot Control 4 Remote Hand Dial 5 Fingertip Control 5 EXAMPLE Of Combination Remote Amperage Control 4 3 Unit Minimu
