Miller Electric Maxstar 152 Owner'S Manual Download Page 22 | Manualshive

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OM-206 Page 18

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

Turn Off all power before maintaining.

3 Months

OR

Blow Out

Or

Vacuum

Inside

Replace

Unreadable

Labels

6 Months

Tape Or

Replace
Cracked

Cables

ST-145 666-C

Clean

And

Tighten Weld

Connections

3 Months

14-Pin Cord

Gas

Hose

Torch Cable

Replace
Cracked

Parts

See

Section

8

3-2

– –

3-4

– –

During Heavy Service,

Clean Monthly

5-1.

Routine Maintenance

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Summary of Contents for Maxstar 152

Page 1: ...Processes Description TIG GTAW Welding Arc Welding Power Source OM 206 141 754F October 1999 Stick SMAW Welding 152 Model 175 Model Maxstar 152 And 175 R Visit our website at www MillerWelds com...

Page 2: ...alue established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself agains...

Page 3: ...3 7 Connecting Input Power To 152 Models 13 3 8 Electrical Service Guide For 152 Ampere Models 13 3 9 Connecting Input Power To 175 Models 14 3 10 Electrical Service Guide For 175 Ampere Models 14 SEC...

Page 4: ......

Page 5: ...connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power cord for damage or...

Page 6: ...lding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane light...

Page 7: ...intained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause...

Page 8: ...a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to ele...

Page 9: ...e de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre D En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri...

Page 10: ...des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer tou...

Page 11: ...vrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences D Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de...

Page 12: ...hamps magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels...

Page 13: ...1 0 5 6 2 0 12 3 7 0 01 31 lb 14 kg Length 16 1 2 in 419 mm Width 9 1 2 in 241 mm Height 8 in 203 mm 175 140 A 25 6 Volts DC 100 Duty Cycle 1 175 95 460 Volts AC 50 60 Hz Three Phase 7 4 1 0 5 9 0 4 3...

Page 14: ...eld at rated load without overheating Y Exceeding duty cycle can damage unit and void warranty 0 15 minutes When overheated thermostat opens output stops and cooling fan keeps running Let fan run for...

Page 15: ...lder Install according to manufacturer s instructions 4 Work Clamp Install onto work cable 5 Dinse Type Connector Install onto weld cable 10 ft 3 m Total Cable Length In Weld Circuit 20 ft 6 m 10 ft 3...

Page 16: ...erse cable connections Align keyway insert connector and turn clockwise Ref SC 140 373 Ref ST 152 126 1 2 3 3 4 Connecting To Weld Output Receptacles sb7 1 5 94 ST 801 174 Ref S 0004 A S 0750 Ref ST 1...

Page 17: ...stall and connect input conduc tors and grounding conductor in conduit or equivalent between wall receptacle and deenergized line disconnect device Connect grounding conductor first then line input co...

Page 18: ...uctor and input conductors in conduit or equivalent to deener gized line disconnect device Connect grounding conductor first then line input conductors Be sure grounding conductor goes to an earth gro...

Page 19: ...6 Power Switch 7 Pilot Light 1 2 3 4 5 6 7 4 1 Controls 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...

Page 20: ...on see Section 3 5 See Example below 3 Remote Foot Control 4 Remote Hand Dial 5 Fingertip Control 3 Set Switches Adjust Remote Control Set Control EXAMPLE Of Combination Remote Amperage Control Contro...

Page 21: ...wly lift electrode An arc will form when electrode is lifted Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between electr...

Page 22: ...onths OR Blow Out Or Vacuum Inside Replace Unreadable Labels 6 Months Tape Or Replace Cracked Cables ST 145 666 C Clean And Tighten Weld Connections 3 Months 14 Pin Cord Gas Hose Torch Cable Replace C...

Page 23: ...pacitor s Measure the dc voltage across the positive and negative terminals until voltage drops to near 0 zero volts Proceed with job inside unit Reinstall wrapper when finished 1 2 3 Tools Needed 5 1...

Page 24: ...if open or reset circuit breaker see Sec tions 3 7 or 3 9 Check for proper input and output connections see Sections 3 2 3 4 and 3 7 or 3 9 Erratic or improper weld output Tighten all welding cable co...

Page 25: ...OM 206 Page 21 Notes...

Page 26: ...OM 206 Page 22 SECTION 6 ELECTRICAL DIAGRAMS SC 166 403 Figure 6 1 Circuit Diagram For 152 Model...

Page 27: ...OM 206 Page 23 SC 170 697 Figure 6 2 Circuit Diagram For 175 Model...

Page 28: ...210 100 180 5 32 360 450 40 55 200 275 160 240 3 16 450 720 55 80 250 350 190 300 1 4 720 950 80 125 325 450 250 400 2 Thorium Alloyed Tungsten Red Band 010 Up to 25 Up to 20 Up to 15 020 15 40 15 35...

Page 29: ...1 1 1 2 Times 2 Electrode Diameter 7 3 Preparing Tungsten For DC Electrode Negative DCEN Welding Ref S 0161 Ref S 0162 1 Tungsten Electrode 2 Tapered End Grind end of tungsten on fine grit hard abras...

Page 30: ...Select and prepare tungsten according to Sections 7 1 and 7 2 or 7 3 Tungsten extension is the distance the tungsten extends out gas cup of torch Arc length is the distance from the tungsten to the wo...

Page 31: ...OM 206 Page 27 8 3 Positioning Torch Tungsten For Various Weld Joints ST 162 003 S 0792 70 70 90 20 20 10 20 70 40 30 20 70 90 20 Butt Weld And Stringer Bead T Joint Lap Joint Corner Joint...

Page 32: ...OM 206 Page 28 SECTION 9 PARTS LIST Figure 9 1 Main Assembly 175 Model Illustrated ST 145 668 J Hardware is common and not available unless listed 18 Is Supplied with 152 Model only...

Page 33: ...type 50 70 series 2 2 129 527 CONN twlk insul male dinse type 50 series 2 2 16 145 743 LUG univ w scr 600V 2 14 wire 1 17 010 916 CONNECTOR clamp cable 750 1 1 18 120 484 CORD SET 250V 6 50P 12ga 3 c...

Page 34: ...1 098 BUS BAR output 1 1 51 134 756 LABEL warning electric shock can kill 1 52 C12 135 286 CAPACITOR 1 1 53 C13 135 289 CAPACITOR 1 1 54 C14 141 524 LEAD ASSEMBLY elect 1 1 54 C15 141 525 LEAD ASSEMBL...

Page 35: ...or 1 1 7 151 484 HEAT SINK pwr module 1 7 141 423 HEAT SINK pwr module 1 8 Q1 4 149 207 KIT transistor mosfet 4 4 9 D5 149 215 KIT diode fast recovery 1 10 TP2 032 810 THERMOSTAT NC 1 1 11 SR1 149 218...

Page 36: ...19 140 622 HEAT SINK diode module 1 20 R9 098 324 RESISTOR WW fxd 25W 5 ohm 1 20 R5 098 324 RESISTOR WW fxd 25W 5 ohm 1 21 D1 2 151 431 KIT diode ultra fast recovery 1 1 22 C9 10 098 325 CAPACITOR pol...

Page 37: ...Notes...

Page 38: ......

Page 39: ...ting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as...

Page 40: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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