Miller Maxstar 161 S Owner'S Manual Download Page 1

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Processes

Description

TIG (GTAW) Welding

Stick (SMAW) Welding

OM-275099A

2016−10

Arc Welding Power Source

Maxstar 161 S, STL, and STH

With Auto-Line

File: TIG (GTAW)

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

Summary of Contents for Maxstar 161 S

Page 1: ...TIG GTAW Welding Stick SMAW Welding OM 275099A 2016 10 Arc Welding Power Source Maxstar 161 S STL and STH With Auto Linet File TIG GTAW For product information Owner s Manual translations and more vis...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...Environmental Specifications 12 4 5 Duty Cycle And Overheating For Maxstar 161S Models 12 4 6 Static Characteristics 13 4 7 Remote 6 Receptacle Information STL And STH Models Only 13 SECTION 5 INSTALL...

Page 4: ...rence 33 SECTION 11 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES 34 11 1 Selecting Tungsten Electrode Wear Clean Gloves To Prevent Contamination Of Tungsten 34 11 2 P...

Page 5: ...uch as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a...

Page 6: ...perly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards Do not weld where the atmosphere can contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work...

Page 7: ...can injure Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintenanc...

Page 8: ...PA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of...

Page 9: ...ues lectriques dans un environnement humideou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch...

Page 10: ...es et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage v rifier e...

Page 11: ...appareil Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e P...

Page 12: ...trical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA...

Page 13: ...ect yourself from electric shock by insulating yourself from work and ground Safe3 2012 05 Disconnect input plug or power before working on machine Safe5 2012 05 Keep your head out of the fumes Safe6...

Page 14: ...ome trained and read the instructions before working on the machine or welding Safe40 2012 05 3 2 Miscellaneous Symbols And Definitions A Amperage V Voltage Hz Hertz Output Gas Input Increase Decreas...

Page 15: ...At Rated Load Output 50 60Hz Single Phase KVA Duty Cycle KW 120 Volts Stick 15A 90A 23 6 Volts DC 30 Duty Cycle 20 90A 48V 12 16 15 KV 23 16 2 78 2 76 75A 23 Volts DC 60 Duty Cycle 18 82 2 26 2 22 60...

Page 16: ...l as radiated disturbances This equipment complies with IEC 61000 3 12 ce emc 4 2011 09 C Temperature Specifications Operating Temperature Range Storage Transportation Temperature Range 40 to 104 F 40...

Page 17: ...ics The static output characteristics of the welding power source can be described as drooping during the SMAW and GTAW processes Static characteristics are also affected by control settings including...

Page 18: ...tip 5 1 Selecting a Location loc_small 2015 04 Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 1 Shoulder Strap Use strap to l...

Page 19: ...otected by time delay fuses or circuit breaker is required See Section 5 4 Input Amperes A At Rated Output 14 31 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay Fuses 2 15 Normal Operatin...

Page 20: ...0 or 240 VAC NOTICE Do Not modify the power cord The power cord plugs will work with standard NE MA receptacles Use only the power cords supplied with this unit Modifying the power cord s and or plugs...

Page 21: ...A complete Parts List is available at www MillerWelds com OM 275099 Page 17 Notes...

Page 22: ...ts List is available at www MillerWelds com OM 275099 Page 18 5 5 Connecting 1 Phase Input Power For 240 VAC 803766 C Ref 805577 A 4 3 L1 L2 1 GND PE Earth Ground 2 1 5 6 7 Tools Needed L1 L2 240 VAC...

Page 23: ...E MA receptacles Use only the power cords supplied with this unit Modifying the power cord s and or plugs or using cords not in tended for use with this product will void war ranty 1 Black And White I...

Page 24: ...ling And Securing Shoul der Portion Of Strap To Welding Power Source 1 Shoulder Handle Strap Route strap as shown 2 Bezel Front And Rear 3 Pin 4 Cam Buckle Lever Route and secure shoulder strap as fol...

Page 25: ...etal Loop 2 Handle Strap W Hook Loop Fasteners 3 Hook And Loop Type Fastener 4 Rear Metal Loop Route and secure handle strap as follows Route handle strap through front metal loop until both hook sec...

Page 26: ...Off position as needed 8 Parameter Display 9 Gas Fitting Fittings have 5 8 18 right hand threads 3 8 19 BSPP on CE units 10 Cylinder Valve Open valve slightly so gas flow blows dirt from valve Close v...

Page 27: ...When selected Adaptive Hot Start Stick Stuck and DIG circuitry are energized 5 Stick 6010 SMAW When selected Adaptive Hot Start Stick Stuck and DIG circuitry are energized Parameters are opti mized t...

Page 28: ...to cycle through parameters that can be set 2 Parameter Display 3 Encoder Rotate Encoder to adjust parame ter setting 3 1 2 USER REMOTE STD OFF PPS Trigger Mode Selection REMOTE STD Remote Standard Ty...

Page 29: ...etting 3 1 2 USER REMOTE STD OFF PPS Trigger Mode Selection REMOTE STD Remote Standard Typically used with a remote foot or hand control REMOTE STD requires a maintained contact closure to enable weld...

Page 30: ...mal Norm and Low Low open circuit voltage Low reduces open circuit voltage between 12 and 16 volts 1 Menu Button While in the Stick process press and hold Menu button for approxim ately two seconds to...

Page 31: ...RC TCY OFF STUC FACTORY RESET SOFTWARE NUMBER ARC TCY Arc Timer Monitors hours minutes and cycles of valid arc on To view rotate encoder To reset rotate encoder until RESET YES is displayed Press Menu...

Page 32: ...t Over Temperature Errors w OVER TEMPERATURE Over temperature condition in the primary inverter circuitry has occurred Error will clear after the temperature has reached ac ceptable levels Or over tem...

Page 33: ...rection of arc Reduce gas flow rate see Section 6 1 Properly prepare tungsten see Section 11 2 Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from draf...

Page 34: ...www MillerWelds com OM 275099 Page 30 Trouble Remedy Error message See O M ERROR 1 4 3 is displayed Contact a Factory Authorized Service Agent Error message See O M ERROR 1 3 4 is displayed Contact a...

Page 35: ...OM 275099 Page 31 SECTION 9 ELECTRICAL DIAGRAM Figure 9 1 Circuit Diagram For Welding Power Source 275094 A...

Page 36: ...es of Direct High Frequency Radiation 1 High Frequency Source welding power source with built in HF or separate HF unit 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table Sources of Conductio...

Page 37: ...it every 50 ft 15 m 6 Water Pipes and Fixtures Ground water pipes every 50 ft 15 m 7 External Power or Telephone Lines Locate high frequency source at least 50 ft 15 m away from power and phone lines...

Page 38: ...11 to 35 CFH cubic feet per hour Figures listed are a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers 11 2 Preparing Tungsten Electrode For...

Page 39: ...150 200 250 300 350 400 450 ELECTRODE DC AC POSITION PENETRATION USAGE MIN PREP ROUGH HIGH SPATTER GENERAL SMOOTH EASY FAST LOW HYDROGEN STRONG SMOOTH EASY FASTER CAST IRON STAINLESS DEEP DEEP LOW ME...

Page 40: ...A complete Parts List is available at www MillerWelds com OM 275099 Page 36 Notes...

Page 41: ...A complete Parts List is available at www MillerWelds com OM 275099 Page 37 Notes...

Page 42: ...A complete Parts List is available at www MillerWelds com OM 275099 Page 38 Notes...

Page 43: ...ns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components suc...

Page 44: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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