Page 2 - To locate your nearest; Thank you; From Miller to You
Miller Electric manufactures a full lineof welders and welding-related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearest distributor or service agency call...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1...
Page 9 - SECTION 2; CONSIGNES DE SÉCURITÉ
OM-275099 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2020 − 02_fre 7 Pour écarter les risques de blessure pour vous − même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Symboles utilis...
Page 12 - -4. Proposition californienne 65 Avertissements
OM-275099 Page 8 LIRE LES INSTRUCTIONS. Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’instal- lation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. N’utiliser que les pièces de rechange rec...
Page 13 - SECTION 3; -1. Additional Safety Symbols And Definitions
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 9 SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012 − 05 Wear dry insulating gl...
Page 14 - -2. Miscellaneous Symbols And Definitions; Hz
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 10 Do not weld on drums or any closed containers. Safe16 2017 − 04 Do not remove or paint over (cover) the label. Safe20 2017 − 04 Do not discard product (where applicable) with general waste.Reuse or recycle Waste Electrical a...
Page 15 - SECTION 4; -1. Serial Number And Rating Label Location; -3. Information About Default Weld Parameters And Settings
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 11 SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number is located on the bottom, and rating information is located on the back of the machine. Use the rating labels to determine input power...
Page 16 - -7. Duty Cycle And Overheating For Maxstar 161S Models
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 12 4-5. Dimensions And Weight Weight 13 lb (8.9 kg) Dimensions L = 13.5 in. (342.9 mm), W = 5.6 in. (142.2 mm), H = 10.3 in. (261.6 mm) 4-6. Environmental Specifications A. IP Rating IP Rating IP23 This equipment is designed fo...
Page 17 - -7. Duty Cycle And Overheating For Maxstar 161STL And STH Models
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 13 4-7. Duty Cycle And Overheating For Maxstar 161STL And STH Models Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.If unit overheats, output stops, the Overtemperature Light comes...
Page 18 - SECTION 5; Notes
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 14 SECTION 5 − INSTALLATION ! Do not move or operate unit where it could 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 5...
Page 24 - -6. Shoulder And Handle Strap Installation; A. Shoulder Strap Installation; B. Handle Strap Installation
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 20 5-6. Shoulder And Handle Strap Installation Strap Buckle Assembly 1 Strap 2 Cam Buckle If necessary, before attaching shoulder/handle strap to power source, assemble strap/buckle as shown. A. Shoulder Strap Installation Inse...
Page 25 - SECTION 6; -1. Front Panel Controls And Gas Connection
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 21 SECTION 6 − OPERATION Represents a particle message that flashes,displays the remainder of the message, and then repeats. 1 Ready Light (LED) Light comes on approximately two seconds af- ter power switch is placed in On (I) ...
Page 27 - USER; REMOTE STD; OFF
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 23 6-5. Lift-Arc And TIG Impulse Start Procedures Lift-Arc Start 1 TIG Electrode 2 Workpiece Touch tungsten electrode to work- piece, hold for 1-2 seconds , slowly lift electrode, and an arc forms.Open-circuit voltage maybe pre...
Page 28 - REMOTE HOLD
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 24 6-7. Accessing Control Panel Menu: Lift-Arc TIG (STH And STL Models Only) 1 Menu Button While in the Lift-Arc process, press and hold Menu button for approxim- ately two seconds to access Ma- chine Configuration menus. Use M...
Page 29 - SECTION 7; -1. Accessing Tech Menu For Maxstar 161 Models; FACTORY RESET; TECH
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 25 SECTION 7 − ADVANCED MENU FUNCTIONS 7-1. Accessing Tech Menu For Maxstar 161 Models 1 Menu Button Press and hold Menu button for approximately four seconds to scroll past User Menu to Tech Menu. Use Menu button to cycle thro...
Page 30 - RELEASE TRIGGER
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 26 SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Maintain more often during severe conditions. ! Disconnect power before maintaining. = Check = Change = Clean Δ = Repair = Replace * To be done by Factory ...
Page 32 - SECTION 9
A complete Parts List is available at www.MillerWelds.com OM-275099 Page 28 SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram For Welding Power Source 288195-A
Page 34 - 0-3. Recommended Installation To Reduce HF Interference; Best Practices Followed
OM-275099 Page 30 10-3. Recommended Installation To Reduce HF Interference 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) Ground metal machine case (clean paint from around hole in case, and use case screw), work output terminal, line discon- nect device, input s...
Page 36 - 2-1. Electrode And Amperage Selection Chart
OM − 275099 Page 32 SECTION 12 − STICK WELDING (SMAW) GUIDELINES 12-1. Electrode And Amperage Selection Chart Ref. S-087985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 ...
Page 39 - (Equipment with a serial number preface of NA or newer); Call
Effective January 1, 2020 (Equipment with a serial number preface of NA or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electri...
Page 40 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service; Register your product at
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2020 Miller Electric Mfg. LLC 2020 − 01 Miller Electric Mfg. LLC An Illinois Tool Works Company1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 Internatio...