Miller Maxstar 152 User Manual

cover 8/92 – SA-145 666-B PRINTED IN USA
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
Give this manual to the operator.
For help, call your distributor
or: MILLER ELECTRIC Mfg. Co., P.O. Box
1079, Appleton, WI 54912 414-734-9821
OWNER’S
MANUAL
June 1993 Form: OM-206C
Effective With Serial No. KD375312
CC/DC Welding Power Source
For GTAW And SMAW Welding
120 A At 25 V Or 140 A At 25.6 V, 100% Duty Cycle
152 Model: Single-Phase; 175 Model: Three-Phase Input Power
Thermostat Protection Against Overheating
Touch Start For GTAW Welding
14-Pin Remote Control Receptacle
Maxstar 152 And 175

Miller Maxstar 152 Specifications

General

Output Range	5-150 A
TIG Lift Arc	Yes
Stick Electrode Size	Up to 1/8 in (3.2 mm)
Input Hz	50 / 60 Hz
Duty Cycle	20%
Process	TIG and Stick
Input Phase	Single Phase

Summary

Introduction and Safety Information

Welcome and Company Information

Welcome message, company history, and commitment to quality from Miller Electric.

EMF Information and Safety Guidance

Information on welding fields and safety procedures to minimize exposure risks.

General Safety Information

Explanation of safety alert symbols, signal words, and hazard statements for safe operation.

Specifications

Welding Power Source Specifications

Detailed specifications for the welding power source, including output and input parameters.

Volt-Ampere Curves and Duty Cycle

Charts illustrating welding output capabilities and operational duty cycles for performance analysis.

Installation Procedures

Process Connections and Cable Management

Diagrams for process connections, selecting location, moving unit, and preparing cables.

Receptacle and Input Power Connections

Connecting weld output receptacles, remote interface, and input power.

Operation and Controls

Control Panel, Safety Gear, and Work Clamp

Overview of controls, safety equipment, and work clamp connection.

Output, Amperage, and Arc Start

Using output controls, amperage adjustments, and initiating the welding arc.

Process Selection and Meter Usage

Selecting weld process, power switch, and using the optional amperage/voltage meter.

Maintenance and Troubleshooting

Routine Maintenance and Overload Protection

Routine maintenance schedule, overload protection, and capacitor voltage checks.

Troubleshooting Common Issues

Solutions for common problems encountered during welding operations.

Electrical Diagrams

Circuit Diagrams for 152 and 175 Models

Detailed electrical schematics for both 152 and 175 models.

Wiring Diagrams for 152 and 175 Models

Wiring diagrams showing component connections for both 152 and 175 models.

Tungsten Electrodes

Selecting Tungsten Electrode Size

Guidance on choosing the correct tungsten electrode diameter and type for various processes.

Preparing Tungsten Electrode

Instructions on properly grinding and preparing tungsten electrodes for optimal arc performance.

Parts List

Main Assembly Parts (175 Model)

Lists and diagrams of main assembly components for the 175 model.

Module, Power & Diode Parts (175 Model)

Lists and diagrams of power and diode module components for the 175 model.

Options and Accessories

Meter, Cart, and Control Options

Details on optional meters, carts, remote controls, and pulsed GTAW controls.

Torch Kits and Connectors

Information on TIG torch kits, connector kits, and international adapters.

Warranty Information

Limited Warranty Terms and Exclusions

Details of Miller's limited warranty policy, coverage, and exclusions.

Owner Responsibilities and Claims

Requirements for owners regarding maintenance, usage, and warranty claim procedures.

Owner's Record and Service

Service Contact and Distributor Information

Contact details for service, distributors, and how to locate authorized service agencies.