TM-2242Q
2012−02
Eff. w/ Serial No. LD160001M
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
Maxstar 150 S, STL, And STH
With Auto-Linet
CE And Non-CE Models
File: TIG (GTAW)
Visit our website at
www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
SECTION 2 − INFORMATION ON OLDER UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
7
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
3-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3-3. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
9
4-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
4-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
4-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
4-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
4-6. Remote 6 Receptacle Information (STL And STH Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Electrical Service Guide For 230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
4-9. Selecting A Location, And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
4-10. Connecting 1-Phase Input Power For 230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls And Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
5-2. Process Selection (STL Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
5-3. Process Selection (STH Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
5-4. Lift-Arc And TIG Impulse Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Set-Up Procedure For The TIG Process And Restoring Factory Default Settings (STH Model Only)
16
18
SECTION 6 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
SECTION 7 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
22
7-2. Tools Needed For Troubleshooting And Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
7-3. Wrapper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
7-4. DC Bus Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Mylar Insulator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
23
7-6. Pre-Power Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
7-7. Installing Mylar Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
7-8. Power Switch S1 Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
27
7-10. Waveforms For Section 7-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
7-11. Troubleshooting Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
32
8-1. Safety Precautions For Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
8-2. Arc Starter Board PC4 Removal (STH Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
8-3. Front Panel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Front Panel (Operator Interface) Circuit Board PC2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
34
8-5. Back Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
8-6. Gas Valve Removal (STH And STL Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
8-7. Power Switch S1 And Power Cord Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Magnetics Tunnel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
37
8-9. PC1/Wind Tunnel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
TABLE OF CONTENTS
SECTION 9 − ASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Installing PC1/Wind Tunnel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Installing Magnetics Tunnel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Installing Back Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Installing Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Installing Front Panel (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6. Installing Arc Starter Board PC4 ( STH Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-7. Installing Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − PARTS LIST FOR STH MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − PARTS LIST FOR STL MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − PARTS LIST FOR S MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
38
39
40
41
42
43
44
45
45
45
45
54
58
62
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
OM-2242AB - 2012−02, safety_stm 2011−10
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Servicing Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard.
Only qualified persons should test, maintain, and repair this
unit.
FLYING METAL or DIRT can injure eyes.
Wear safety glasses with side shields or face
shield during servicing.
Be careful not to short metal tools, parts, or
wires together during testing and servicing.
During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit.
Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.
Do not leave live unit unattended.
If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Troubleshooting Section before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
EXPLODING PARTS can injure.
Failed parts can explode or cause other parts to
explode when power is applied to inverters.
Always wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
Turn Off welding power source and wire feeder
or stop engine before making or changing meter lead connections.
Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.
Read instructions for test equipment.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
FIRE OR EXPLOSION hazard.
Do not place unit on, over, or near combustible
surfaces.
Do not service unit near flammables.
Maxstar 150 Series
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
TM-2242 Page 1
MOVING PARTS can injure.
Keep away from moving parts such as fans.
Keep away from pinch points such as drive
rolls.
Have only qualified persons remove doors,
panels, covers, or guards for maintenance and
troubleshooting as necessary.
Keep hands, hair, loose clothing, and tools
away from moving parts.
Reinstall doors, panels, covers, or guards
when maintenance is finished and before reconnecting input power.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away from servicing areas until consulting their doctor and the
device manufacturer.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
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.
READ INSTRUCTIONS.
Use Testing Booklet (Part No. 150 853) when
servicing this unit.
Consult the Owner’s Manual for welding safety
precautions.
Use only genuine replacement parts from the manufacturer.
Read and follow all labels and the Technical Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.
1-3. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-4. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures
in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
TM-2242 Page 2
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
Maxstar 150 Series
SECTION 2 − INFORMATION ON OLDER UNITS
Note
5-2
This manual includes operating information for current units. To obtain specific
operating information for older models, download the applicable Owner’s Manual from
www.MillerWelds.com
Process Selection For STL Models Eff W/Serial No. LD160001M
Thru LE050207M
=Light Off
1
=Light On
2
Lift Arc Start
When selected, a TIG arc starting
method in which the electrode must
come in contact with the workpiece to
initiate an arc is activated (see Section
5-4).
2
3
3
Stick (SMAW)
When selected, Adaptive Hot Start
and DIG circuitry are energized.
1
Press
5-5
Process Selector Switch Pad
Use control to select required welding
process. Press switch pad until LED
for desired process is illuminated.
Press
Set-Up Procedure
Model
Serial Number
See Section
STL
Effective w/Serial No. LD160001M Through
LD240021M
5-5A
STL
Effective w/Serial No. LD260001M Through
LE050207M
5-5B
There is no set-up procedure available for STL models with Serial No. LE050208M and following.
Maxstar 150 Series
TM-2242 Page 3
A. Set-Up Procedure For STL Models Eff W/Serial No. LD160001M Thru LD240021M
3
4
1
2
Read First!!
Set-Up Procedure
1
2
3
4
M IN
Power Switch
Process Switch Pad
Ready Light (LED)
High Temp Light (LED)
Modifiable Features:
Postflow − The time gas flows after welding stops.
M a x s ta r 1 5 0 S T L
Press and hold to scroll
to desired feature
=Light Off
Feature #1
Postflow Time
=Light On
=Light Flashing
.5 sec/10 amps
1 sec/10 amps
Or
Press &
Release
Press and release
to activate
Press &
Release
To save changes, wait 5 seconds until
feature light begins to flash before
scrolling to the next feature.
Feature #2
Trigger Method
Standard
2T
Lift Arc panel control.
Trigger Method − standard, 2T
(trigger hold), or Lift Arc panel control.
Set-Up Mode - To access
set-up mode, turn power
on while depressing the
process switch pad until
the ready and high temp
lights flash.
Release Process switch pad while
lights are flashing alternately to
enter set-up mode.
Once in set-up mode, press and
hold the process switch pad to
scroll to feature you want to
change. Follow the sequence as
shown to make changes.
After a parameter has been
changed, wait 5 seconds until the
feature light begins to flash before
scrolling to the next feature.
To save changes and exit set-up
mode, press and release torch
trigger, or turn power off and wait
until LED’s turn off, and then turn
power back on.
Restoring Factory Default Settings
Or
Or
Press and release
to activate
Press &
Release
Press &
Release
Press &
Release
To save changes, wait 5 seconds until feature light begins to flash before scrolling back
to the first feature, or to save all changes and exit set-up mode, press and release torch
trigger, or turn power off and wait until LED’s turn off, and then turn power back on.
To restore factory default settings,
press and hold process switch
pad and turn power On. Ready
and high temp lights will begin to
flash alternately. Continue holding
process switch pad for approximately 10 seconds until the lights
begin to flash synchronously. Release switch pad, as factory default settings are restored. The
lights will continue to flash until unit
is turned Off. To return to normal
welding operation, turn power On.
Factory default settings:
Preflow - 0.2 seconds
2T Trigger Hold Sequence
3. Trigger Lock Feature
2. Upslope
Main Arc Start
In 0 Seconds
1. Preflow
0.2 Seconds Preset
TM-2242 Page 4
Postflow - 1 second, or 1
sec/10amps
4. Down Slope
30 Amps, 0.75 Seconds
80 Amps, 2.0 Seconds
120 Amps, 3.0 Seconds
Final 0 Amps
Trigger Method- standard.
5. Post Flow
1 Second, or
1 Second per 10 Amps
Maxstar 150 Series
B. Set-Up Procedure For STL Models Eff W/Serial No. LD260001M Through LE050207M
2
M IN
M a x s ta r 1 5 0 S T L
3
Set-Up Procedure
4
1
2
3
4
Power Switch
Process Switch Pad
Ready Light (LED)
High Temp Light (LED)
Trigger Methods − Choose between: Standard (remote amperage and output control), which is
the factory default, or Lift Arc
Panel Control (for use without a remote control or with remote amperage but without output control).
The trigger method that was active
when the machine was last turned
off will be active when unit is
turned back on. To change trigger
method, enter set-up mode as
illustrated:
1
2
To enter Set-Up Mode, turn power On
while pressing and holding the Process
switch pad until the ready and high temp
lights flash alternately (approx 5 seconds).
=Light Off
=Light On
=Light Flashing
Standard
(Remote amperage
& output control.)
To save change and exit set-up mode,
press and release torch trigger, or turn
power off and wait until LED’s turn off,
and then turn power back on.
Or
Press and release to see
active trigger method.
Maxstar 150 Series
Lift Arc panel control
(For use without a remote control, or with
remote amperage, but
without output control)
Press and release again to
change trigger method.
TM-2242 Page 5
Notes
TM-2242 Page 6
Maxstar 150 Series
SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
A. Warning! Watch Out! There are possible
hazards as shown by the symbols.
1
Electric shock from welding electrode or
wiring can kill.
1.1 Wear dry insulating gloves. Do not touch
electrode with bare hand. Do not wear wet
or damaged gloves.
1.2 Protect yourself from electric shock by
insulating yourself from work and ground.
1.3 Disconnect input plug or power before
working on machine.
2
Breathing welding fumes can be hazardous
to your health.
2.1 Keep your head out of the fumes.
2.2 Use forced ventilation or local exhaust to
remove the fumes.
2.3 Use ventilating fan to remove fumes.
3 Welding sparks can cause explosion or
fire.
3.1 Keep flammables away from welding. Do
not weld near flammables.
3.2 Welding sparks can cause fires. Have a
A
fire extinguisher nearby, and have a
watchperson ready to use it.
3.3 Do not weld on drums or any closed
containers.
4 Arc rays can burn eyes and injure skin.
4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of filter.
Wear complete body protection.
5 Become trained and read the instructions
before working on the machine or welding.
6 Do not remove or paint over (cover) the
label.
A
A
Maxstar 150 Series
TM-2242 Page 7
3-2. Symbols And Definitions
A
V
Voltage Input
Volts
Increase/Decrease
Of Quantity
Output
Negative
Positive
Gas Input
High Temperature
Direct Current
Percent
Alternating
Current
I1eff
S
Suitable For Areas
Of Increased
Shock Hazard
Amperes
X
U0
Duty Cycle
Rated No Load
Voltage (Average)
Shielded Metal Arc
Welding (SMAW)
Single Phase Static Frequency
Converter-Transformer-Rectifier
U1
I1max
Primary Voltage
Rated Maximum
Supply Current
Hz
Hertz
Line Connection
U2
I2
Conventional Load
Voltage
Rated Welding
Current
Maximum Effective
Supply Current
Remote
Lift-Arc Start
(GTAW)
Gas Tungsten Arc
Welding (GTAW)
Process
TIG (GTAW) Pulse
HF Impulse Starting (GTAW)
On
Off
Look under unit for
label
3-3. WEEE Label (For Products Sold Within The EU)
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collection facility.
Contact your local recycling office
or your local distributor for further
information.
TM-2242 Page 8
Maxstar 150 Series
SECTION 4 − SPECIFICATIONS AND INSTALLATION
4-1. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment complies with IEC 61000-3-12.
ce-emc 4 2011-09
4-2. Serial Number And Rating Label Location
The serial number and rating information is located on the bottom of the machine. Use the rating labels to determine input power requirements and/or
rated output. CE model rating labels will also display the following symbols: CE, CCC, WEEE, and IEC 60974-1. For future reference, write serial
number in space provided on back cover of this manual.
Maxstar 150 Series
TM-2242 Page 9
4-3. Specifications
Input Power
Rated Welding
Single-Phase
Output
AC
115 Volts Stick
IP Rating
Welding
Amperage
Range
15A
70A @ 22.8 Volts DC,
100% Duty Cycle
23
20 − 70A
115 Volts TIG
15A
100A @ 14 Volts DC,
100% Duty Cycle
23
5 − 100A
115 Volts Stick
70A @ 22.8 Volts DC,
100% Duty Cycle
23
20A
115 Volts TIG
20A
230 Volts Stick
230 Volts TIG
90V
*12-16
20 − 100A
100A @ 24.0 Volts DC,
35% Duty Cycle
23
100A @ 14.0 Volts DC,
100% Duty Cycle
23
23
100A @ 24 Volts DC,
100% Duty Cycle
23
150A @ 26.0 Volts DC,
30% Duty Cycle
23
100A @ 14.0 Volts DC,
100% Duty Cycle
23
150A @ 16.0 Volts DC,
30% Duty Cycle
23
90V
*12-16
90V
5 − 150A
150A @ 16.0 Volts DC,
30% Duty Cycle
Max
OCV DC
(Uo)
*12-16
20 − 150A
90V
*12-16
90V
5 − 150A
*12-16
Starting
Voltage (Up)
Amperes Input At Rated
Load Output,
50/60Hz,
Single-Phase
KVA @
Duty
Cycle
KW
**15 KV
17.4
2.0
1.9
**15 KV
18.4
2.1
2.1
**15 KV
17.4
2.0
1.9
**15 KV
26.4
3.0
3.0
**15 KV
18.4
2.1
2.1
**15 KV
28.0
3.4
3.1
**15 KV
13.1
3.0
2.8
**15 KV
21.6
4.9
4.7
**15 KV
8.3
2.0
1.9
**15 KV
14.2
3.2
3.1
Rated Peak
Weight
13.7 lb (6.2 Kg)
Dimensions
H: 9 in. (229 mm), W: 5.5 in. (140 mm), L: 13.25 in. (337 mm)
*Sense Voltage For Stick And TIG Lift Arc
** Arc Striking Device Is Designed For Manual Guided Operations
4-4. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, output stops, the
Overtemperature Light comes On,
and the cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again.
250
OUTPUT AMPERES
200
STICK
(230V)
150
TIG (115V 20A
& 230V)
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
STICK
(115V 20A)
100
50
TIG/STICK
(115V 15A)
0
10
TM-2242 Page 10
% DUTY CYCLE
50
100
208 608-D
Maxstar 150 Series
4-5. Volt-Ampere Curves
Volt-ampere curves show minimum and maximum voltage and amperage output capabilities
of welding power source. Curves of other settings fall between curves shown.
115 VAC Input
100
80
80
Volts
TIG/Stick Max
40
60
TIG/Stick Max
Volts
60
40
TIG Min
20
0
50
TIG Min
20
Stick Min
Stick Min
0
230 VAC Input
100
100
Amperes
150
0
200
0
50
100
Amperes
150
200
208 604-B
4-6. Remote 6 Receptacle Information (STL And STH Models Only)
6
Socket
Socket Information
1
Contactor control +13.8 volts DC.
2
Contact closure to 1 completes contactor control
circuit and enables output when Lift-Arc TIG remote is selected.
3
Output to remote control; +10 volts DC output to
remote control.
4
0 to +10 volts DC input command signal from
remote control.
5
Remote control circuit common.
6
Chassis common.
15 VOLTS DC
OUTPUT
CONTACTOR
REMOTE
OUTPUT
CONTROL
CHASSIS
Maxstar 150 Series
TM-2242 Page 11
4-7. Electrical Service Guide For 230 VAC
The Auto-Line circuitry in this unit automatically adapts the power source to the primary voltage being applied. Check input voltage available
at site. This unit can be connected to any input power between 120−230 VAC without removing the cover to relink the power source.
Actual input voltage should not exceed  10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
50/60 Hz Single
Phase
Input Voltage (V)
230
Input Amperes (A) At Rated Output
13.1
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2
15
Normal Operating Fuses 3
20
Min Input Conductor Size In AWG 4
14
Max Recommended Input Conductor Length In Feet (Meters)
91
(28)
Min Grounding Conductor Size In AWG 4
14
Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
4-8.
Selecting Extension Cord (Use Shortest Cord Possible)
Conductor Size − AWG (mm2)*
Single Phase AC
Input Voltage
4 (21.2)
6 (13.3)
8 (8.4)
10 (5.3)
12 (3.3)
Maximum Allowable Cord Length in ft (m)
115
160 (49)
107 (33)
71 (22)
47 (14)
29 (9)
230
471 (144)
321 (98)
215 (66)
146 (45)
90 (27)
*Conductor size is based on maximum 3% voltage drop
TM-2242 Page 12
Maxstar 150 Series
4-9. Selecting A Location, And Connecting Input Power
1
Welding Power Source
Shoulder Strap
Use strap to lift unit.
Airflow Distance
Requirements
!
Do not move or operate
unit where it could tip.
!
Installation must meet all
National and Local Codes
− have only qualified
persons
make
this
installation.
!
Special installation may be
required where gasoline or
volatile liquids are present
− see NEC Article 511 or
CEC Section 20.
1
The Auto-Line circuitry in this
2
18 in. (460 mm)
unit automatically links the
power source to the primary
voltage being applied, either
115 or 230 VAC.
3
2
5
18 in.
(460 mm)
4
6
NOTICE − Do Not cut off power
cord connector and rewire. The
power cord connector and plugs
will work with standard NEMA receptacles. Modifying power cord,
connector, and plugs will void
product warranty.
For 115 volts AC input power, a
15 or 20 ampere individual
branch circuit protected by
time-delay fuses or circuit
breaker is required. For 230 volts
AC input power, see Section 4-7.
2
3
4
5
6
Power Cord Connector
Plug − NEMA Type 5−15P
Receptacle − NEMA Type
5−15R (Customer Supplied)
Plug − NEMA Type 6−50P
Receptacle − NEMA Type
6−50R (Customer Supplied)
Select plug for power supply
receptacle available at site.
Install plug onto power cord
adapter. As threaded collar is
tightened, push plug onto adapter until collar is completely tight.
Connect plug to receptacle.
Ref. 803 351-D
Maxstar 150 Series
TM-2242 Page 13
4-10. Connecting 1-Phase Input Power For 230 VAC
1
5
!
Installation must
meet all
National and Local Codes − have
only qualified persons make this
installation.
!
Disconnect and lockout/tagout
input power before connecting
input conductors from unit.
!
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
=GND/PE Earth Ground
See rating label on unit and check input
voltage available at site.
7
1
2
4
3
4
6
L1
L2
2
5
6
1
Black And White Input Conductor
(L1 And L2)
Green Or Green/Yellow Grounding
Conductor
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
Disconnect Device Grounding
Terminal
Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 and L2 to
disconnect device line terminals.
7
3
8
8
L1
L2
Over-Current Protection
Select type and size of over-current
protection using Section 4-7 (fused
disconnect switch shown).
Receptacle (NEMA 6-50R)
Customer Supplied
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
230 VAC, 1
Tools Needed:
803 766-B / Ref. 802 443-A
TM-2242 Page 14
Maxstar 150 Series
SECTION 5 − OPERATION
5-1. Front Panel Controls And Gas Connection
1
2
4
3
11
12
9
10
8
6
5
7
Ref. 803 375-A / 233 167-A
1
Ready Light (LED)
Light comes on approximately two seconds after power switch is placed in On (I) position if
Lift-Arc On or Stick has been selected. If TIG
Impulse is selected, ready light comes on only
after output is enabled. The light indicates that
the unit is energized and ready for welding. A
flashing light indicates unit is not ready, or that
there is a functional error.
The
fan motor
controlled.
2
is
thermostatically
High Temperature Light (LED)
Light comes on if unit overheats. Once unit has
cooled down, welding can resume. If this light
flashes, take unit to an Authorized Service
Agent.
3 Amperage Adjustment Control
This control adjusts welding amperage.
4 Process Select Switch
See Section 5-3.
5 Positive Weld Output Receptacle
For Stick welding, connect electrode cable to
this receptacle. For TIG welding, connect work
cable to this receptacle.
6 Negative Weld Output Receptacle
For Stick welding, connect work cable to this
receptacle. For TIG welding, connect torch
cable to this receptacle.
7 Remote Receptacle
For TIG Impulse or Lift-Arc TIG, output may be
adjusted from min to max of the front panel setting with a remote control.
8 Power Switch
Place switch in On (I) or Off (0) position as
needed.
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 valve.
11 Regulator/Flowmeter
12 Flow Adjust
Typical flow rate is 15 cubic feet per hour (7.1
liters per minute) at a maximum of 90 psi (621
kPa).
Connect customer supplied gas hose between
regulator/flowmeter and gas fitting .
5-2. Process Selection (STL Model Only)
1
=Light Off
=Light On
2
Lift Arc Start
When selected, a TIG arc starting
method in which the electrode must
come in contact with the workpiece to
initiate an arc is activated (see Section
5-4).
4
2
3
3
Stick (SMAW)
When selected, Adaptive Hot Start
and DIG circuitry are energized.
1
Press
Maxstar 150 Series
Process Selector Switch Pad
Use control to select required welding
process. Press switch pad until LED
for desired process is illuminated.
Press
Press
4
Lift Arc Start (Remote)
A TIG starting method in which the
electrode must come in contact with
the work and a closure from pin 1 to pin
2 on the remote receptacle (see Section 4-6) is required to initiate an arc.
TM-2242 Page 15
5-3. Process Selection (STH Model Only)
=Light Off
=Light On
=Light Flashing
1
3
2
4
2
5
3
1
Press & Release
Press & Release
Press & Release
TIG Impulse Start
When selected, an impulse HF arc
starting method is activated (see
Section 5-4).
6
Press & Release
Process Selector Switch Pad
Use control to select required
welding process. Press switch pad
until light (LED) for desired process
is illuminated.
Press & Release
TIG Pulse With TIG Impulse
Start
When selected, the TIG pulse
welding process with impulse HF
start is activated.
Pulsing is the alternating raising
and lowering of the weld output at
a specific rate. To change pulse
frequency, see Section 5-5.
4
TIG Pulse With Lift-Arc
Start
When selected, the TIG pulse
welding process with Lift-Arc start
is activated (see Section 5-4).
5
Lift-Arc Start
When selected, a TIG arc starting
method in which the electrode
must come in contact with the
workpiece to initiate an arc is activated (see Section 5-4).
6
Stick (SMAW)
When selected, Adaptive Hot Start
and DIG circuitry are energized.
5-4. Lift-Arc And TIG Impulse Start Procedures
Lift-Arc Start
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece, hold for 1-2 seconds, slowly
lift electrode, and an arc forms.
Open-circuit voltage maybe present
before electrode touches workpiece.
1
2
“Touch”
TIG Impulse
1−2
Seconds
Pictorials show Lift-Arc start method − do not
Do NOT Strike Like A Match!
High frequency starts arc when output
is enabled without making contact with
the workpiece. High frequency turns
off when arc is started.
use this method for TIG Impulse starts.
TM-2242 Page 16
Maxstar 150 Series
Notes
For additional welding information and resources, visit:
www.MillerWelds.com/resources/improving-your skills
Maxstar 150 Series
TM-2242 Page 17
5-5. Set-Up Procedure For The TIG Process And Restoring Factory Default Settings
(STH Model Only)
Set-Up Procedure
3
4
5
6
1
2
3
4
5
6
7
8
Power Switch
Process Switch Pad
Ready Light
High Temp Light
TIG HF Light
TIG Pulse Light
TIG Lift-Arc Light
Stick Light
7
8
2
1
2
To enter Set-Up Mode, turn power On while
pressing and holding the Process switch pad
for approximately 5 seconds, until the Ready
(3) and High Temp (4) lights flash alternately.
Selectable Features:
Feature 1 − Selectable Trigger Method (Three to choose from):
 Standard trigger − Typically used with a remote amperage control device. Standard trigger provides non-contact start in DC Impulse TIG mode. It also enables Lift-Arc start, with a remote control, in Lift- Arc mode.
 Lift-Arc Panel Control − Allows Lift-Arc start without using a
remote control device. Lift-Arc is used when HF starts are not permitted, or to replace scratch starts.
 2T Trigger Hold − In the HF mode, used with a push button control
device as an on-off switch. In the Lift-Arc mode, using the Lift-Arc
method (see Section 5-4), push and release torch trigger to start
weld. Push and release torch trigger to end weld current and start
Auto Crater. Auto Crater ramps weld current down at a fixed rate
to end the weld cycle.
To change trigger method, enter set-up mode as described above
and illustrated on the next page.
TM-2242 Page 18
Feature 2 − Pulse Frequency: Choose from the following four intervals: .5 PPS, 1 PPS, 2.5 PPS, or 60 PPS.
To change pulse frequency, enter set-up mode as described above
and illustrated on the next page.
Restoring Factory Default Settings
To restore factory default settings, press and hold process switch
pad and turn power On. Ready and high temp lights will begin to flash
alternately. Continue holding process switch pad for approximately
10 seconds until the lights begin to flash simultaneously. Release
switch pad, as factory default settings are restored. The lights will
continue to flash until unit is turned Off. To return to normal welding
operation, turn power On.
Factory default settings:
Trigger Methods for Models with Stock No. 907 136-014 only:
TIG Impulse-standard; Lift-Arc-standard
Trigger Methods: TIG Impulse-Standard; Lift-Arc−On
Pulse Frequency - 2.5 PPS
Maxstar 150 Series
Lights Indicate Which Selection Is Active
Light Flashing = Active Feature
Light On = Selected Option Of Feature 1 Or 2
Press & Hold To Scroll Between Features .
Release At Desired Feature.
Feature 1
Trigger Method
Feature 2
Pulse Frequency (PPS)
Press and release switch
pad to see active Trigger Method.
Continue to press and release switch
pad to change Trigger Method.
Press and release switch pad to
see active Pulse Frequency. Continue to press and release switch
pad to change Pulse Frequency.
If no action is taken within 5 seconds, the
If no action is taken within 5 seconds,the light
light for Feature 1 begins to flash, and
lastTrigger Method selected remains active.
for Feature 2 begins to flash, and lastPulse
Frequency selected remains active.
Lift Arc panel
control
2.5 PPS
2T Trigger Hold
60 PPS
.5 PPS
Standard
To save changes and exit
set-up mode, press and
release torch trigger, or
turn power off and wait
until lights turn off, and
then turn power back on.
Maxstar 150 Series
1 PPS
TM-2242 Page 19
SECTION 6 − THEORY OF OPERATION
1
Power Switch S1
Provides on/off control of welding
power source.
2
Single-Phase
Line Input
Power
1
Power
Switch
S1
5
Gas Valve
GS1
6
Input Inductor
L1
3
Fan Motor
FM1
Main Control Board PC1
4
Main Control Board PC1
Provides electrical connections for
S1, GS1, FM1, PC2, L1 and T1. Input capacitors, precharge relay and
resistor, bleed resistors, various filter and snubber components, input
current transducer, inverter primary
current transformer, and switchmode power supplies for control
power are mounted on PC1.
3
2
Fan Motor FM
Provides cooling of internal components.
4
Front Assy
Board PC2,
PC3
Front Panel Assy Boards
PC2, PC3
Controls output of machine, and
displays error message.
Output Voltage Feedback
5
7
Gas Valve GS1
Provides shielding gas to the arc
while TIG welding with STH and
STL models only.
Main Transformer T1
6
Input Inductor L1
Required to boost input bus voltage.
7
Main Transformer T1
Driven by IGBT’s on PC1. Supplies
power to weld output circuit.
8
Output Voltage Feedback
Output Inductor L2
Filters or smooths the DC output or
welding current.
10
9
Positive
Weld Output
Receptacle
Arc Starter
Board
PC4
9
8
Output
Inductor
L2
Arc Starter Board PC4
Produces high voltage pulses used
for TIG Impulse starts on STH models only.
10 Positive And Negative Weld
Output Receptacles
Provide weld output and allow
changing of output polarity.
+
10
Negative
Weld Output
Receptacle
_
TM-2242 Page 20
Maxstar 150 Series
Notes
Maxstar 150 Series
TM-2242 Page 21
PRE-POWER CHECKS
SECTION 7 − TROUBLESHOOTING
7-1. Checking Unit Before Applying Power
See Section 7-6 for test points and values and appropriate Parts Section for parts location.
Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit.
See the Miller Extranet for service memos that may aid in the
repair of this product.
!
Turn off power, and disconnect input power plug from receptacle before working on unit.
!
Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are off before removing wrapper.
!
Check DC bus voltage according to Section 7-4 after removing wrapper.
!
Before troubleshooting or applying power to unit, complete the following checks to avoid causing further damage.
7-2. Tools Needed For Troubleshooting And Servicing
13 mm, 13/16 in
Torx 25
7-3. Wrapper Removal
1
2
!
Read and follow safety information in Section 7-1 before
proceeding.
1
2
Wrapper
Torx 25 Screws (Fine Thread)
Remove Torx screws and slide wrapper off.
803 967-A
TM-2242 Page 22
Maxstar 150 Series
PRE-POWER CHECKS
7-4. DC Bus Voltage Check
1
2
!
Read and follow safety information in Section 7-1 before
proceeding.
!
Check DC bus voltage before
servicing. Set multimeter to
read voltage. Check voltage between TP5 pins 1 and 5. Voltage
should read 5 volts DC or less.
1
2
TP5 Pin 5
TP5 Pin 1
7-5. Mylar Insulator Removal
1
2
3
Ref. 803 966-A
!
Read and follow safety information
in Section 7-1 before proceeding.
1
Mylar Insulator
2
Rivet
Maxstar 150 Series
Remove plastic rivet from insulator by pulling out head of rivet. Retain both pieces of
rivet.
3
Positive (+) Weld Output Terminal
Remove Torx screw from inside weld output terminal.
Remove insulator by pulling up and out.
Pulling the front and back panels out slightly, may make removal easier.
TM-2242 Page 23
PRE-POWER CHECKS
7-6. Pre-Power Check
!
Read and follow safety information in Section 7-1 before proceeding.
For Windtunnel assembly circuit board PC1, part numbers 212866, 216351,
224531, And 239384.
19
17
16
18
15
14
20
9
1 2
3
4
5
10
7
6
13
12
804 039-A
Test Points 1 Through 20
For Windtunnel assembly circuit board PC1, part number 231321.
18
19
17
16
15
9
20
1 2
3
7
6
4
5
12
10
13
Test Points 1 Through 20
805 140-A
TM-2242 Page 24
Maxstar 150 Series
PRE-POWER CHECKS
If any of the measurements in Steps 1 thru 8 do not read correctly, replace PC1 (see Section 8).
1. Input diode test - Set multimeter for diode test, and look for a diode drop (.200 to .600 volts) across the following test points:
Positive Meter Lead
Negative Meter Lead
Test Point 2
Test Point 1
Test Point 3
Test Point 2
Test Point 3
Test Point 4
Test Point 4
Test Point 1
2. Main IGBT test - Set multimeter for diode test, and look for a diode drop (.200 to .600 volts) across the following test points:
Positive Meter Lead
Negative Meter Lead
Test Point 3
Test Point 6
Test Point 6
Test Point 7
3. Snubber IGBT test - Set multimeter for diode test, and look for an open (OL) across the following test points:
Positive Meter Lead
Negative Meter Lead
Test Point 12
Test Point 13
Test Point 13
Test Point 12
4. Boost IGBT test - Set multimeter for diode test, and look for a diode drop (.200 to .600 volts) across the following test points:
Positive Meter Lead
Negative Meter Lead
Test Point 3
Test Point 5
5. Boost Diode test - Set multimeter for diode test, and look for a diode drop (.5 to 1.2 volts) across the following test points:
Positive Meter Lead
Negative Meter Lead
Test Point 5
Test Point 7
6. Output Diode test - Set multimeter for diode test, and look for a diode drop (.250 to .600 volts) across the following test points:
Positive Meter Lead
Negative Meter Lead
Test Point 9
Test Point 10
7. Voltage Regulator test - Set multimeter for diode test, and look for a diode drop (.200 to .900 volts) across the following test points:
Positive Meter Lead
Negative Meter Lead
Test Point 15
Test Point 16
Test Point 15
Test Point 17
Test Point 15
Test Point 18
Test Point 15
Test Point 19
8A. Pre-charge resistor test - Set multimeter for ohms test, and look for a resistance of 100 ohms  20% across the following test
points for assembly numbers: 212886, 216351, and 224531.
Positive Meter Lead
Negative Meter Lead
Test Point 14
Test Point 1
8B. Pre-charge resistor test - Set multimeter for ohms test, and look for a resistance of 10 ohms  20% across the following test
points for assembly numbers: 231321 and 239384.
Maxstar 150 Series
Positive Meter Lead
Negative Meter Lead
Test Point 20
Test Point 1
TM-2242 Page 25
PRE-POWER CHECKS
7-7. Installing Mylar Insulator
3
1
PC1
Insulator
5
4
2
6
804 039-A / Ref. 803 966-A
!
1
2
3
4
5
Slide insulator between PC1 and base of
unit. Make sure left edge of insulator is between PC1 and windtunnel base. Pulling
back panel out slightly may help. The insulator is installed correctly when the hole in the
top center of the insulator lines up with the
hole in PC1.
Read and follow safety information
in Section 7-1 before proceeding.
Mylar Insulator
Windtunnel Base
Rivet
Insulator Tab
Operator Interface Board PC2
(Located On Back Of Front Panel)
Insert split piece of rivet through hole in insu-
lator and PC1. Push plunger of rivet into split
portion.
Bend insulator tab and slide it between PC1
and PC2. Pull front panel out slightly so tab
will slide past plastic snap that holds PC2 to
front panel.
6 Positive (+) Weld Output Terminal
Tighten Torx screw inside weld output terminal to 40 in-lbs (4.5 Nm).
7-8. Power Switch S1 Continuity Check
2
!
Read and follow safety information in Section 7-1 before
proceeding.
1
Black And White Power Cord
Leads
Power Switch S1
Power Cord Plug
2
3
Place S1 in the on position. Check for
continuity between the right side top
and bottom terminals of S1. Check for
continuity between the left side top
and bottom terminals of S1. If either
test fails, replace S1 (see Section
8-7).
Install black and white power cord
leads back onto bottom terminals of
S1 when finished. Polarity is not important.
3
1
803 969-B
TM-2242 Page 26
Maxstar 150 Series
Always check unit before applying power (see Sections 7-1 thru 7-8).
7-9. Troubleshooting
Trouble
No weld output; unit completely inoperative; all lights (LED’s) Off.
Remedy
Place line disconnect switch in On position.
Check and replace line fuse(s) if necessary, or reset circuit breaker.
Be sure power cord is plugged in, and that receptacle is receiving input power.
Check continuity of power switch S1 (see Section 7-8), and replace if necessary.
Check input inductor connector plug PLG3 to make sure pins are making contact (see Section 8-8 for
plug location).
Wind tunnel board PC1 is defective. Replace PC1 (see Sections 8 and 9).
Operator Interface board PC2 is defective. Replace PC2 (see Sections 8 and 9).
No weld output in Stick and Lift-Arc,
blue ready light is On all the time but
not flashing; in remote mode, blue light
is on all the time but not flashing when
contactor is on.
Check for loose weld cable(s) in weld output receptacle(s), and tighten if necessary.
Check for poor connection of work clamp to workpiece, and correct if necessary.
Low OCV, less than 10 volts DC (no load):
Check output stud holding screw, and tighten if necessary (see Section 9-4).
Check pin in lead 20 connector (plug PLG4) to make sure they are seated properly and making
good connection (see Section 8-8 for plug location).
Check for shorted output diode (see Section 7-6), and replace if necessary.
No lift voltage:
Check unit Serial Number and replace circuit board PC2 (see Sections 8 and 8). See proper
Parts List to order correct part.
No output current:
Check output stud holding screw, and tighten if necessary (see Section 9-4).
Check pin in lead 20 connector (plug PLG4) to make sure they are seated properly and making
good connection. Replace pins if necessary (see Section 8-8 for plug location).
Check plug PLG 4 to receptacle RC4 connection.
Replace Wind Tunnel circuit board PC1 (see Sections 8 and 8).
Replace Front Panel circuit board PC2 (see Sections 8 and 8).
No weld output; yellow high temperature light On.
Unit overheated causing thermal shutdown. Allow unit to cool with fan On (see Section 4-4). Reduce
duty cycle or amperage before resuming operation.
Check and correct blocked/poor airflow to unit (see Section 4-9).
No weld output; yellow high temperature light Flashing.
Turn Power Off and back On again. If light continues to flash, replace Wind Tunnel circuit board PC1
(see Sections 8 and 8).
No weld output. Blue ready light flashes Input line voltage to high or to low. Check to make sure line voltage is within 10%.
continuously, yellow high temperature
light off.
Check the following plug connections and make sure they are secure: PLG1, PLG4, PLG9, and PLG10
(see Sections 8-3 and 8-8 for plug locations).
Replace Wind Tunnel circuit board PC1 (see Sections 8 and 8).
Replace Front Panel circuit board PC2 (see Sections 8 and 8).
No weld output, blue ready light flashes Check the following transformer plug connections and make sure they are secure: PLG9, PLG10, and
when an arc is struck.
PLG11 (see Section 8-8 for plug locations).
Check input inductor connector plug PLG3, and make sure it is secure (see Section 8-8 for plug location).
Models with Serial Numbers prior to LF010173M may need update kit 220 888.
Replace Wind Tunnel circuit board PC1 (see Sections 8 and 8).
Maxstar 150 Series
TM-2242 Page 27
Always check unit before applying power (see Sections 7-1 thru 7-8).
Trouble
Remedy
No weld output. Blue ready light flashes Remote trigger left on. Turn off remote trigger, wait 5 seconds before resuming operation. If condition re3 times repeatedly, yellow high tempera- mains, replace Front Panel circuit board PC2.
ture light off.
No weld output. Blue ready light flashes Communication error between windtunnel board PC1 and front panel board PC2. Reset machine by turn4 times repeatedly, yellow high tempera- ing power off and back on again. If problem remains, replace front panel board PC2 (see Section 8-4),
ture light off.
or replace wind tunnel board PC1 (see Section 8-9).
System setup procedure not working ac- If unit does not remember the process that it was in when last shut down, replace Front Panel circuit board
cording to Section 5-5.
PC2.
Process Select button does not toggle Make sure there is no load on the output.
between indicator lights.
Replace Wind Tunnel circuit board PC1.
Erratic or improper welding arc or output.
Use proper size and type of weld cable.
Clean and tighten weld connections.
Check polarity of weld cables and reverse if necessary.
Check for poor connections to workpiece, and correct if necessary.
Check for correct weld cable polarity for your application.
Fan not operating. Fan only runs when
cooling is required.
Check for and remove anything blocking fan movement.
Check fan motor connection to receptacle RC6 on PC1, and make sure it is secure.
Check fan motor, replace fan motor is defective.
Wind tunnel board PC1 is defective. Replace PC1 (see Sections 8 and 9).
Stick welding problems: Hard starts; Check weld output connections, and tighten if necessary.
poor welding characteristics; unusual
Check polarity of weld cables and reverse if necessary.
spattering.
Use proper type and size of electrode.
TIG welding problems: Wandering arc; Use proper type and size of tungsten.
hard starts; poor welding characterisUse properly prepared tungsten.
tics; spattering problems.
Check polarity of weld cables and reverse if necessary.
TIG welding problems: Tungsten elec- Shield weld zone from drafts.
trode oxidizing and not remaining bright
Check for correct type shielding gas.
after welding.
Check and tighten gas fittings.
Check polarity of weld cables and reverse if necessary.
TM-2242 Page 28
Maxstar 150 Series
Always check unit before applying power (see Sections 7-1 thru 7-8).
7-10. Waveforms For Section 7-11
2 ms 5 V
gnd
A. DC Open-Circuit Voltage (12−16 VDC)
2 ms 10 V
gnd
gnd
1. 25 Volts DC, 150 Amperes, (Resistive Load)
B. 24 Volts DC, 100 Amperes (Resistive Load)
Test Equipment Needed:
Maxstar 150 Series
TM-2242 Page 29
Always check unit before applying power (see Sections 7-1 thru 7-8).
7-11. Troubleshooting Circuit Diagram
!
Check and make sure input capacitors are discharged according to
Section 7, and be sure voltage is near zero before touching any parts.
No calibration available for voltmeter V or ammeter A.
Test Equipment Needed:
V1, R1
TM-2242 Page 30
Maxstar 150 Series
Always check unit before applying power (see Sections 7-1 thru 7-8).
Voltage Readings
a) Tolerance
specified
−
10%
unless
b) Reference − single arrow:
reference to circuit common
(lead 42); double arrow: reference
to points indicated
c) Wiring Diagram − see Section 11
V1
+13.7 volts DC
V2
+13.6 volts DC
V3
+7.2 volts DC w/ HF on,
+13.7 volts DC w/HF off
V4
+12 - 16 volts DC (see
specifications in Section 4-3
V2
V3
V4
A, B
See Section 7-10 for
waveforms A and B
Resistance Values
a)
Tolerance − 10% unless specified
b)
Turn Off unit and disconnect input power
before checking resistance
R1
19.4 ohms
219 466-H
Maxstar 150 Series
TM-2242 Page 31
SECTION 8 − DISASSEMBLY PROCEDURE
8-1. Safety Precautions For Disassembly
!
Unplug unit before beginning disassembly procedure.
!
Check bus voltage according to Section 7-4 after removing wrapper.
Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit.
8-2. Arc Starter Board PC4 Removal (STH Models Only)
1
!
Read and follow safety information in Section 7-1 before proceeding with disassembly.
1
2
Arc Starter Circuit Board PC4
Plug PLG2
Disconnect PLG2 from receptacle on
PC4.
3
Leads 16 And 17
Disconnect leads 16 and 17 from PC4.
4
Torx 25 Screws
Remove the two screws from PC4.
Remove PC4 from unit.
5
Plastic Rivet And Mylar
Insulation
Remove plastic rivet from insulator by
pulling out head of rivet. Retain both
pieces of rivet.
2
5
3
4
TM-2242 Page 32
Maxstar 150 Series
8-3. Front Panel Assembly Removal
!
Read and follow safety information in Section 7-1 before
proceeding with disassembly.
1
Positive (+) Weld Output
Terminal
Remove Torx screw from inside weld
output terminal.
2
Back Of Negative (−) Weld
Output Terminal
S models do not have a gas valve
and hose.
1
Move hose clamp off of barbed fitting.
Use heat gun to soften gas hose before removing from weld output terminal.
Use a 13 mm wrench to remove nut
from back of weld output terminal.
3
4
8
3
Grounding Leads
Disconnect the green or green/yellow grounding leads from receptacles RC2 and RC12 located on
PC1 (on S models, disconnect one
lead from RC2 on PC1). Also, disconnect the green or green/yellow lead
from the slot in the front panel.
4
Ribbon Connector PLG1
Disconnect ribbon connector from receptacle RC1 on PC1.
5
Plug PLG4
Disconnect PLG4 from receptacle
RC4.
Prior to LK500101J PLG4 was a
Mollex connector for non-CE
models and an insulated friction
connector for CE models. Effective with LK500101J, PLG 4 is an
insulated friction connector for all
models.
6
Torx Screw
Remove screw.
7
Locking Tabs
Use screw driver or needle nose pliers to push down tabs. Slide front
panel off base.
Lead with ring terminal on back of
negative weld output terminal
may make it difficult to slide front
panel off.
2
5
8
EMI Suppressor
Found on CE models only.
7
6
Front Of Unit
Ref. 803 966-A / Ref. 803 968-A
Maxstar 150 Series
TM-2242 Page 33
8-4. Front Panel (Operator Interface) Circuit Board PC2 Removal
Perform this procedure only if
it is necessary to replace PC2.
!
Read and follow safety information in Section 7-1 before
proceeding with disassembly.
1
Plastic Nut (STH And STL
Models Only)
Remove 13/16 in. plastic nut.
2
Amperage Control Knob
Remove knob by pulling straight
away from front panel.
2
3
4
Front Panel (Operator
Interface) Circuit Board PC2
Upper Locking Tabs
Use your thumbs to press tabs up,
while using your index fingers to lift
top of board out.
5
Lower Locking Tabs
Use your thumbs to press tabs out,
while using your index fingers to lift
bottom of board out.
1
3
4
5
5
803 967-A
TM-2242 Page 34
Maxstar 150 Series
8-5. Back Panel Removal
1
3
4
2
6
7
5
Back Of Unit
Ref. 803 968-A
!
Read and follow safety information
in Section 7-1 before proceeding
with disassembly.
S models do not have a gas valve.
1 Grounding Leads
If present, disconnect the two green or
green/yellow grounding leads from receptacles RC7 and RC8 located on PC1 (on S
models, disconnect one lead from RC8 on
Maxstar 150 Series
PC1). Also, disconnect the green or green/
yellow lead from the slot in the back panel.
2 Gas Valve
3 Plug PLG5
Disconnect PLG5 from receptacle RC5 on
PC1.
4 Lead 1
Disconnect lead 1 from top of power switch
S1.
5
Supplementary Protector SP1 (Non
CE Models Only)
Disconnect lead 2 from SP1.
6
Torx Screw
Remove screw.
7
Locking Tabs
Use screw driver or needle nose pliers to
push down tabs. Slide back panel off base.
TM-2242 Page 35
8-6. Gas Valve Removal (STH And STL Models Only)
!
2
Read and follow safety information in Section 7-1 before
proceeding with disassembly.
Only perform this procedure if
gas valve is to be replaced.
1
2
3
Back Panel
Gas Valve
Locking Tabs
Push tabs outward to remove gas
valve.
3
1
803 969-B
8-7. Power Switch S1 And Power Cord Removal
3
!
4
Read and follow safety information in Section 7-1 before
proceeding with disassembly.
Only perform this procedure if
2
power switch S1 and/or the
power cord are to be replaced.
1
2
3
Back Panel
Power Switch S1
Power Cord Leads
Disconnect the power cord leads
from S1.
4
Locking Tabs
There are two sets of tabs, one on
the top of S1, and another set on the
bottom of S1. Depress tabs and
push switch out back of panel.
5
5
Torx Screws
Remove screws
6
Power Cord
Remove cord from unit.
1
6
803 969-B
TM-2242 Page 36
Maxstar 150 Series
8-8. Magnetics Tunnel Assembly Removal
2
6
3
4
5
7
!
Read and follow safety information
in Section 7-1 before proceeding
with disassembly.
1 Magnetics Tunnel Assembly
2 Plug PLG9
Disconnect PLG9 from receptacle RC9.
3 Plug PLG10
Disconnect PLG10 from receptacle RC10.
4 Plug PLG3
Disconnect PLG3 from receptacle RC3.
5 Plug PLG11
Disconnect PLG11 from receptacle RC11.
6 Plug PLG4
In non-CE models prior to LK500101J, use
a Mollex pin extractor (Miller Part No. 121
481) to remove lead 20 from PLG4.
For CE models prior to LK500101J and all
models effective with LK500101J, disconnect PLG4 from receptacle RC4.
Prior to LK500101J, PLG4 was a
Mollex connector in non-CE models
and an insulated friction connector in
CE models. Effective with LK500101J,
PLG 4 is an insulated friction connector
for all models.
Lift magnetics tunnel assembly out of base.
7
EMI Suppressor
Found on CE models only.
8-9. PC1/Wind Tunnel Assembly Removal
1
3
2
!
1
Read and follow safety information in Section 7-1 before proceeding with disassembly.
Disconnect fan motor plug from receptacle RC6 on PC1.
Fan Motor Plug
Remove mylar insulation from heat sink.
Maxstar 150 Series
2
Mylar Insulation
3
PC1/Wind Tunnel Assembly
Lift PC1/wind tunnel assembly from
base. Note orientation of fan motor for
reinstallation.
TM-2242 Page 37
SECTION 9 − ASSEMBLY PROCEDURE
9-1. Installing PC1/Wind Tunnel Assembly
2
1
Front Of Unit
3
803 968-A
1
Fan Motor
Place fan in base. Orient fan plug lead as
shown for correct airflow direction.
TM-2242 Page 38
2
Mylar Insulation
Ensure both pieces of mylar insulation are
on PC1/wind tunnel assembly.
3
Slots In Base
Place wind tunnel assembly in base, verifying tabs are in slots.
Maxstar 150 STH
9-2. Installing Magnetics Tunnel Assembly
3
9
8
4
7
6
5
1
Front Of Unit
803 968-A
2
1 Magnetics Tunnel Assembly
2 Alignment Slots In Base
Place magnetics tunnel assembly in base.
Make sure wind tunnel tabs (not shown) are
in slots in wind tunnel assembly, and alignment tabs are in slots in base.
Verify that leads are routed out of assembly as shown.
3 Plug PLG9
Connect PLG9 to receptacle RC9.
4 Plug PLG10
Connect PLG10 to receptacle RC10.
Maxstar 150 Series
5 Plug PLG11
Connect PLG11 to receptacle RC11.
6 Plug PLG3
Connect PLG3 to receptacle RC3.
7 Fan Motor Plug
Connect fan motor plug to receptacle RC6
on PC1. Make sure fan motor lead is routed
through slot in magnetics tunnel as shown.
8 Plug PLG4
Prior to LK500101J, PLG4 was a
Mollex connector in non-CE models
and an insulated friction connector in
CE models. Effective with LK500101J,
PLG 4 is an insulated friction connector
for all models.
For non-CE models prior to LK500101J, insert lead 20 from magnetics tunnel into
PLG4. Make sure the connector is locked
in the housing.
For CE models prior to LK500101J and all
models effective with LK500101J, connect
PLG4 to receptacle RC4.
9
EMI Suppressor
Found on CE models only.
TM-2242 Page 39
9-3. Installing Back Panel
1
8
7
4
3
6
11
5
9
10
CE Models Only
12
2
803 968-B
S models do not have a gas valve.
1 Power Switch S1
Make sure S1 is installed.
2 Power Cord
When replacing or installing power
cord, make sure at least 1 in. (25 mm)
of the cord’s outer insulation jacket extends inside of the back panel.
3 Power Cord Leads
Make sure power cord leads are connected
to the bottom two terminals on S1 as
shown. Polarity is not important.
TM-2242 Page 40
4 Gas Valve GS1
Make sure gas valve is installed.
5 Gas Hose
Make sure gas hose is connected to gas
valve barbed fitting and secured with hose
clamp.
6 Leads 21 And 22
Make sure leads 21 and 22 are connected
to top two terminals on gas valve as shown.
Polarity is not important.
7 Back Panel
Snap back panel onto base.
8 Lead 1
Connect lead 1, from wind tunnel assembly, to one of the top two terminals on S1.
Polarity is not important.
9
Power Cord Grounding Lead
Connect power cord green or green/yellow
grounding lead to receptacle RC8 on PC1.
10 Supplementary Protector SP1
Connect lead 2 to SP1.
11 Ground Lead With Tab
Place green or green/yellow ground lead
with tab into slot on back panel.
12 EMI Filter (CE Models Only)
Maxstar 150 STH
9-4. Installing Front Panel
2
1
2
3
STL Front Panel
Board Shown
Front Panel Board PC2
Route leads from PC2 as shown.
Grounding Lead
Front Panel
Snap PC2 into back of front panel.
4
Dust Cover
Slide dust cover over 6-pin remote receptacle.
5
Plastic Nut
Tighten 13/16 in. plastic nut on remote receptacle after dust cover has
been installed.
6
Amperage Control Knob
Slide knob onto shaft.
Snap front panel assembly onto
base.
7
1
Positive (+) Weld Output
Terminal
Tighten Torx screw inside weld output terminal to 40 in.-lbs (4.5 Nm).
Prior to LK500101J, non-CE
models have three leads.
S Models do not have
a 6-pin remote receptacle.
6
4
3
7
5
Maxstar 150 Series
803 967-A
TM-2242 Page 41
9-5. Installing Front Panel (Continued)
2
5
1
7
1
Plug PLG4
Prior to LK500101J, PLG4 was a
Mollex connector in non-CE models.
Effective with LK500101J, PLG 4 is an
insulated friction connector for all
models.
4
Connect PLG4 to receptacle RC4.
2
Ribbon Connector Plug PLG1
Connect ribbon connector to receptacle
RC1 on PC1.
3
Grounding Lead
Connect green or green/yellow grounding
lead, from lower right corner of PC2, to receptacle RC12 on PC1.
3
4
Grounding Lead (Not found On S
Models)
Connect green or green/yellow grounding
lead, from bottom of PC3, to receptacle
RC2 on PC1.
5
Ground Lead With Tab
Place green/yellow ground lead with tab
into slot on front panel.
6
Nut On Back Of Negative (−) Weld
Output Terminal
Make sure lead with ring terminal is
installed on weld output terminal. Tighten
nut and torque to 70 in-lbs (7.9 Nm).
1
Slide gas hose on and secure with hose
clamp.
6
8
7
Plug From Gas Valve Harness
Connect plug to receptacle RC5 on PC1.
8
EMI Suppressor
Found on CE models only.
9
Torx Screws (Coarse Threads)
Turn unit on its side and tighten screws.
9
803 968-A
TM-2242 Page 42
Maxstar 150 STH
9-6. Installing Arc Starter Board PC4 ( STH Models Only)
1
3
4
Slide mylar between front
panel and magnetics tunnel.
5
2
6
Insulator
Magnetics
Tunnel
1
Arc Starter Board PC4
2
Torx Screws (Coarse Thread)
Install PC4 and secure with two Torx
screws.
3
HF Primary Leads
Maxstar 150 Series
Connect HF primary leads 16 and 17 to
male friction connectors FT1 and FT2 on
PC4. Polarity is important.
4 Gas Valve Plug Harness
Connect one plug to receptacle RC1 on
PC4 and the second plug to receptacle RC5
on PC1.
5 Mylar Insulation
6 Rivet
Install mylar around negative weld output
stud and secure with rivet by inserting split
piece of rivet through hole in insulator and
magnetics tunnel. Push plunger of rivet into
split portion.
TM-2242 Page 43
9-7. Installing Wrapper
1
2
!
Before installing wrapper,
make sure mylar insulator is
correctly installed to the back
of circuit board PC1 according
to Section 7-7.
1
2
Wrapper
Torx 25 Screws (Fine Thread)
Slide wrapper on, make sure both
sides of wrapper are inserted into
slots in base before securing with two
Torx screws.
803 967-A
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
TM-2242 Page 44
Maxstar 150 STH
SECTION 10 − MAINTENANCE
10-1. Routine Maintenance
!
Disconnect power before maintaining.
Maintain more often during severe conditions.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
= Repair
= Replace
Every
3
Months
Labels
Weld Terminals
Gas Hoses
Every
3
Months

Cables And Cords
Every
6
Months
!
Do not remove case when blowing out inside of unit.
Blow out inside. Direct airflow through front and back louvers.
:During heavy service, clean monthly.
10-2. Overload Protection
1
Supplementary Protector CB1
CB1 protects unit from overload. If
CB1 opens, unit shuts down.
Reset supplementary protector.
1
803 375-A
SECTION 11 − ELECTRICAL DIAGRAM
The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model
Maxstar 150 Non CE Models
Maxstar 150 CE Models
Maxstar 150 Series
Serial Or Style Number
Circuit Diagram
LD160001M thru LH500214J
208 601-H
LH500215J thru LK500100J
208 684-G
LK500101J and following
219 466-G
LE180055M thru LH500214J
219 160-A
LH500215J and following
219 466-H
Wiring Diagram
TM-2242 Page 45
208 601-H
Figure 11-1. Circuit Diagram For Maxstar 150 Non CE Models
Eff w/Serial No. LD160001M Thru LH500214J
TM-2242 Page 46
Maxstar 150
208 684-G
Figure 11-2. Circuit Diagram For Maxstar Non CE Models Eff w/Serial No. LH500215J Thru LK500100J
Maxstar 150 Series
TM-2242 Page 47
219 160-A
Figure 11-3. Circuit Diagram For Maxstar 150 CE Models Eff w/Serial No. LE180055M Thru LH500214J
TM-2242 Page 48
Maxstar 150
219 466-H
Figure 11-4. Circuit Diagram For Maxstar 150 CE Models Eff w/Serial No. LH500215J And Following, And
Non CE Models Eff w/Serial No. LK500101J And Following
Maxstar 150 Series
TM-2242 Page 49
Table 10-1. Lead List Summary For Non CE Maxstar 150 STH Models Eff w/LH500215J Thru LK500100J
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Lead
−−−−
−−−−
−−−−
−−−−
−−−−
−−−−
−−−−A
−−−−A
−−−−A
−−−−A
−−−−A
−−−−A
Connections
PC1 (SC1) TO COVER FRONT GRD
PC1 (SC15) TO COVER BACK GRD
PC1 (SC2) TO PC1 (SC14)
PC1 (SC22) TO PC1 (RC13)
PC2 (SC2) TO PC1 (RC2)
PC2 (SC5) TO PC1 (RC2)
RC10 (1) TO PC1 (SC19)
RC10 (2) TO PC1 (SC20)
RC10 (3) TO PC1 (SC21)
RC9 (1) TO PC1 (SC18)
RC9 (2) TO PC1 (SC17)
RC9 (3) TO PC1 (SC16)
Lead
1A
2A
3A
5A
6A
13A
14A
15A
18A
18B
20A
20B
21A
22A
52
Connections
S1 (4) TO PC1 (SC12)
S1 (1) TO PC1 (SC13)
RC11(1) TO PC1 (SC9)
PLG3 (2) TO PC1 (SC11)
PLG3 (1) TO PC1 (SC10)
PLG2 (3) TO PLG5 (5)
PLG2 (2) TO PLG5 (2)
PLG2 (1) TO PLG5 (4)
PC2 (SC4) TO RC4 (2)
PC1 (SC3) TO PLG4 (2)
PC2 (SC3) TO RC4 (1)
CENTERTAP NEG. SENSE TO PLG4 (1)
GS1 TO PLG5 (3)
GS1 TO PLG5 (1)
S2 TO SP1
Table 10-2. Lead List Summary For Non CE Maxstar 150 STL Models Eff w/LH500215J Thru LK500100J
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Lead
−−−−
−−−−
−−−−
−−−−
−−−−
−−−−
−−−−A
−−−−A
−−−−A
−−−−A
−−−−A
−−−−A
Connections
PC1 (SC1) TO COVER FRONT
PC1 (SC15) TO COVER BACK
PC1 (SC2) TO PC1 (SC14)
PC1 (SC22) TO PC1 (RC13)
PC2 (SC2) TO PC1 (RC2)
PC2 (SC5) TO PC1 (RC2)
RC10 (1) TO PC1 (SC19)
RC10 (2) TO PC1 (SC20)
RC10 (3) TO PC1 (SC21)
RC9 (1) TO PC1 (SC18)
RC9 (2) TO PC1 (SC17)
RC9 (3) TO PC1 (SC16)
GRD
GRD
Lead
1A
2A
3A
5A
6A
18A
18B
20A
20B
21A
22A
52
Connections
S1 (4) TO PC1 (SC12)
S1 (1) TO PC1 (SC13)
RC11(1) TO PC1 (SC9)
PLG3 (2) TO PC1 (SC11)
PLG3 (1) TO PC1 (SC10)
PC2 (SC4) TO RC4 (2)
PC1 (SC3) TO PLG4 (2)
PC2 (SC3) TO RC4 (1)
CENTERTAP NEG. SENSE TO PLG4 (1)
GS1 TO PLG5 (3)
GS1 TO PLG5 (1)
S2 TO SP1
Table 10-3. Lead List Summary For Non CE Maxstar 150 S Models Eff w/LH500215J Thru LK500100J
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Lead
−−−−
−−−−
−−−−
−−−−
−−−−
−−−−A
−−−−A
−−−−A
−−−−A
−−−−A
−−−−A
Connections
PC1 (SC1) TO COVER FRONT
PC1 (SC15) TO COVER BACK
PC1 (SC2) TO PC1 (SC14)
PC1 (SC22) TO PC1 (RC13)
PC2 (SC2) TO PC1 (RC2)
RC10 (1) TO PC1 (SC19)
RC10 (2) TO PC1 (SC20)
RC10 (3) TO PC1 (SC21)
RC9 (1) TO PC1 (SC18)
RC9 (2) TO PC1 (SC17)
RC9 (3) TO PC1 (SC16)
TM-2242 Page 50
GRD
GRD
Lead
1A
2A
3A
5A
6A
18A
18B
20A
20B
52
Connections
S1 (4) TO PC1 (SC12)
S1 (1) TO PC1 (SC13)
RC11(1) TO PC1 (SC9)
PLG3 (2) TO PC1 (SC11)
PLG3 (1) TO PC1 (SC10)
PC2 (SC4) TO RC4 (2)
PC1 (SC3) TO PLG4 (2)
PC2 (SC3) TO RC4 (1)
CENTERTAP NEG. SENSE TO PLG4 (1)
S2 TO SP1
Maxstar 150 Series
Table 10-4. Lead List Summary For CE And Non CE Maxstar 150 STH Models Eff w/LK500101J And Following
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Lead
−−−−
−−−−
−−−−
−−−−
−−−−
−−−−
−−−−A
−−−−A
−−−−A
−−−−A
−−−−A
−−−−A
Connections
PC1 (SC1) TO COVER FRONT GRD
PC1 (SC15) TO COVER BACK GRD
PC1 (SC2) TO PC1 (SC14)
PC1 (SC22) TO PC1 (RC13)
PC2 (SC2) TO PC1 (RC2)
PC2 (SC5) TO PC1 (RC2)
RC10 (1) TO PC1 (SC19)
RC10 (2) TO PC1 (SC20)
RC10 (3) TO PC1 (SC21)
RC9 (1) TO PC1 (SC18)
RC9 (2) TO PC1 (SC17)
RC9 (3) TO PC1 (SC16)
Lead
1A
2A
3A
4A
5A
6A
13A
14A
15A
20A
20B
21A
22A
52
Connections
S1 (4) TO PC1 (SC12)
S1 (1) TO PC1 (SC13)
RC11(1) TO PC1 (SC9)
RC11(2) TO PC1 (SC8)
PLG3 (2) TO PC1 (SC11)
PLG3 (1) TO PC1 (SC10)
PLG2 (3) TO PLG5 (5)
PLG2 (2) TO PLG5 (2)
PLG2 (1) TO PLG5 (4)
PC1 (SC3) TO PLG4
CENTERTAP NEG. SENSE TO RC4
GS1 TO PLG5 (3)
GS1 TO PLG5 (1)
S1(1) TO CB1 (Non CE Models Only)
Table 10-5. Lead List Summary For Maxstar 150 STL Models Eff w/LK500101J And Following
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Lead
−−−−
−−−−
−−−−
−−−−
−−−−
−−−−
−−−−A
−−−−A
−−−−A
−−−−A
−−−−A
Connections
PC1 (SC1) TO COVER FRONT GRD
PC1 (SC15) TO COVER BACK GRD
PC1 (SC2) TO PC1 (SC14)
PC1 (SC22) TO PC1 (RC13)
PC2 (SC2) TO PC1 (RC2)
PC2 (SC5) TO PC1 (RC2)
RC10 (1) TO PC1 (SC19)
RC10 (2) TO PC1 (SC20)
RC10 (3) TO PC1 (SC21)
RC9 (1) TO PC1 (SC18)
RC9 (2) TO PC1 (SC17)
Lead
−−−−A
1A
2A
3A
5A
6A
20A
20B
21A
22A
52
Connections
RC9 (3) TO PC1 (SC16)
S1 (4) TO PC1 (SC12)
S1 (1) TO PC1 (SC13)
RC11(1) TO PC1 (SC9)
PLG3 (2) TO PC1 (SC11)
PLG3 (1) TO PC1 (SC10)
PC1 (SC3) TO PLG4
CENTERTAP NEG. SENSE TO RC4
GS1 TO PLG5 (3)
GS1 TO PLG5 (1)
S1 (1) TO CB1
Table 10-6. Lead List Summary For CE And Non CE Maxstar 150 S Models Eff w/LK500101J And Following
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Lead
−−−−
−−−−
−−−−
−−−−
−−−−
−−−−A
−−−−A
−−−−A
−−−−A
−−−−A
Connections
PC1 (SC1) TO COVER FRONT GRD
PC1 (SC15) TO COVER BACK GRD
PC1 (SC2) TO PC1 (SC14)
PC1 (SC22) TO PC1 (RC13)
PC2 (SC2) TO PC1 (RC2)
RC10 (1) TO PC1 (SC19)
RC10 (2) TO PC1 (SC20)
RC10 (3) TO PC1 (SC21)
RC9 (1) TO PC1 (SC18)
RC9 (2) TO PC1 (SC17)
Maxstar 150 Series
Lead
−−−−A
1A
2A
3A
5A
6A
20A
20B
52
Connections
RC9 (3) TO PC1 (SC16)
S1 (4) TO PC1 (SC12)
S1 (1) TO PC1 (SC13)
RC11(1) TO PC1 (SC9)
PLG3 (2) TO PC1 (SC11)
PLG3 (1) TO PC1 (SC10)
PC1 (SC3) TO PLG4
CENTERTAP NEG. SENSE TO RC4
S1 (1) TO CB1 (Non Ce Models Only)
TM-2242 Page 51
Notes
TM-2242 Page 52
Maxstar 150 Series
TM-2242Q
2012−02
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
Maxstar 150 STH
With Auto-Linet
CE And Non-CE Models
Eff w/LE030003M And Following
For OM-2242 (208 580) Revision A And Following
Visit our website at
www.MillerWelds.com
40
41
SECTION 12 − PARTS LIST FOR STH MODELS
Hardware is common and
19
20
22
24
36
23
26
30
27
2
3
28
4
29
31
32
25
10
1
33
5
8
6
34
24
8
9
35
37
10
7
11
12
17
13
24
18
2
14
15
38
16
not available unless listed.
803 447-J
Figure 12-1. Parts View For STH Models
TM-2242 Page 54
Maxstar 150 Series
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . PC1 . . 222 766 . . KIT, pcb assy (windtunnel w/cmpnts) (CE models) (includes)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LH250191M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . PC1 . . 222 765 . . KIT, pcb assy (windtunnel w/cmpnts) (includes) (Prior to LK500101JM) . . . . 1
. . . 1 . . . PC1 . . 230 210 . . Kit, pcb assy (windtunnel w/cmpnts) (CE models Eff w/LH250191M,
. . . . . . . . . . . . . . . . . . . . . . . . . . . all other models Eff w/ LK500101JM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 208 701 . . . . Insulator w/label (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 221 497 . . . . . Bumper, polyurethane .500 OD x .140 H adh backed . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 146 549 . . . . . Fastener, push-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 208 622 . . . . . Label, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 208 627 . . Label, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 219 674 . . Label, warning (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 195 666 . . Screw, 010-32x .50 torx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . 208 700 . . Wrapper w/label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 219 979 . . Wrapper w/label (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 208 569 . . Hose and clamps (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . GS1 . . 221 732 . . KIT, field gas valve update 14 vdc Max 150 STL/STH (Prior to LF010014M) 1
. . . 9 . . . GS1 . . 219 967 . . VALVE, 14vdc 2way .625−18 thd 2.2mm orf 100psi (Eff w/LF010014M) . . . . 1
. . . 9 . . . GS1 . . 219 966 . . VALVE, 14vdc 2way .375−19 bspp 2.2mm orf 100psi (CE models) . . . . . . . . . 1
. . . 10 . . . . . . . . . . 208 558 . . Term, friction .250 x .032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . 208 703 . . Panel, rear w/label (Prior to LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 233 175 . . Panel, rear w/label (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 219 982 . . Panel, rear w/label (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 208 549 . . Nameplate, rear (Prior to LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 233 170 . . Nameplate, rear (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 219 880 . . Nameplate, rear (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 208 550 . . Switch, rocker dpst 16A 250 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 208 536 . . Screw, K50 x 25 rnd washer, hd-trx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . 219 167 . . Cable, power (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 225 180 . . Cable, power (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 208 548 . . Strap, shoulder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . FM . . 208 496 . . Fan w/leads and plug 12 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 L1, L2, T1 208 702 . . Windtunnel, magnetics w/cmpnt (Prior To LK500101J) . . . . . . . . . . . . . . . . . . . 1
. . . 18 L1, L2, T1 246 642 . . Windtunnel, magnetics w/cmpnt (Eff w/LK500101J) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 L1, L2, T1 219 169 . . Windtunnel, magnetics w/cmpnt (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 208 552 . . Insulator, negative stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . . . . . . . Base w/label, order by serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 208 561 . . Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 208 596 . . Holder, electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 208 535 . . Screw, k50 x 12 rnd washer hd-trx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 25 . . . . . . . . . . 208 612 . . Receptacle, twist lock power/gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . 208 588 . . Nut, plastic 625-27.81 hex x .14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . 244 862 . . Screw, m5-.8 x 12 soc hd -torx stl pld sems piloted . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . 208 498 . . Receptacle, twist lock power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . 208 589 . . Cover, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . 174 992 . . Knob, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . . . . . . Nameplate, front (order by model and serial number) . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 208 573 . . Panel, front w/nameplate (Prior to LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 233 176 . . Panel, front w/nameplate (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 219 172 . . Panel, front w/nameplate (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 PC2, PC3 218 773 . . Circuit board, operator interface (CE models) (Prior to LH250191M) . . . . . . . 1
. . . 33 PC2, PC3 212 895 . . Circuit board, operator interface (Prior to LK500101J) . . . . . . . . . . . . . . . . . . . . 1
. . . 33 PC2, PC3 224 535 . . Circuit board, operator interface (CE models Eff w/LH250191M,
. . . . . . . . . . . . . . . . . . . . . . . . . . . all other models Eff w/LK500101J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . PC4 . . 228 593 . . Circuit board, arc starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . 208 556 . . Insualtor, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . 208 497 . . Nut, m08-1.2 13 mm hex 8.3 mm t semi cone washer . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . CB1 . . 225 844 . . Supplementary Protector (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . L3 . . 219 078 . . Core, toroidal (CE models) (Prior to LH250191M) . . . . . . . . . . . . . . . . . . . . . . . 1
Maxstar 150 Series
TM-2242 Page 55
Item
No.
Dia.
Mkgs.
Part
No.
. . . 38 . . . . T3 . . 219 076
. . . 40 . . . . . . . . . . 219 258
. . . 41 . . . . . . . . . . 219 261
. . . . . . . . . . . . . . . . 220 890
Description
Quantity
. . Core ferrite (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Adapter, power cable 6−50P (230V/50A) (Eff w/LH500215J) . . . . . . . . . . . . . . 1
. . Adapter, power cable 5−15P (115V/15A) (Eff w/LH500215J) . . . . . . . . . . . . . . 1
. . Assy, capacitor w/leads (not used in all models) (Prior to LH500215J) . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-2242 Page 56
Maxstar 150 Series
TM-2242Q
2012−02
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
Maxstar 150 STL
With Auto-Linet
CE And Non-CE Models
Eff w/LD160001M And Following
For OM-2245 (208 726) Revision A And Following
Visit our website at
www.MillerWelds.com
SECTION 13 − PARTS LIST FOR STL MODELS
37
38
Hardware is common and
20
22
23
26
30
27
2
3
28
29
4
31
32
25
10
1
33
24
5
6
35
8
8
9
34
36
10
7
11
12
17
13
24
18
14
15
16
not available unless listed.
803 474- J
Figure 13-1. Parts View For STL Models
TM-2242 Page 58
Maxstar 150 Series
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . PC1 . . 222 766 . . KIT, pcb assy (windtunnel w/cmpnts) (CE models) (includes)
. . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LH250191M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . PC1 . . 222 765 . . KIT, pcb assy (windtunnel w/cmpnts) (includes) (Prior to LK500101J) . . . . . . 1
. . . 1 . . . PC1 . . 230 210 . . KIT, pcb assy (windtunnel w/cmpnts) All Models (includes) (Eff w/LK500101J) 1
. . . 2 . . . . . . . . . . 208 701 . . . . Insulator w/label (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 221 497 . . . . . Bumper, polyurethane .500 OD x .140 H adh backed . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 146 549 . . . . . Fastener, push-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 208 622 . . . . . Label, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 208 627 . . Label, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 219 674 . . Label, warning (CE models) (Prior to LH250191M) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 195 666 . . Screw, 010-32x .50 torx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . 208 700 . . Wrapper w/label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 219 979 . . Wrapper w/label (CE models) (Prior to LH250191M) . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 208 569 . . Hose and clamps (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . GS1 . . 221 732 . . KIT, field gas valve update 14 vdc Max 150 STL/STH (Prior to LF010014m) 1
. . . 9 . . . GS1 . . 219 967 . . VALVE, 14vdc 2way .625−18 thd 2.2mm orf 100 psi (Eff w/LF010014m) . . . . 1
. . . 9 . . . GS1 . . 219 966 . . VALVE, 14vdc 2way .375−19 bspp 2.2mm orf 100psi
. . . . . . . . . . . . . . . . . . . . . . . . . . . (CE models) (Prior to LH250191M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 208 558 . . Term, friction .250 x .032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . 208 703 . . Panel, rear w/label (Prior to LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 233 175 . . Panel, rear w/label (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 219 982 . . Panel, rear w/label (CE models) (Prior to LH250191M) . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 208 549 . . Nameplate, rear (Prior to LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 233 170 . . Nameplate, rear (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 219 880 . . Nameplate, rear (CE models) (Prior to LH250191M) . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 208 550 . . Switch, rocker dpst 16A 250 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 208 536 . . Screw, K50 x 25 rnd washer, hd-trx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . 219 167 . . Cable, power (Prior to LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 225 180 . . Cable, power (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 208 548 . . Strap, shoulder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . FM . . 208 496 . . Fan w/leads and plug 12 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 L1, L2, T1 219 168 . . Windtunnel, magnetics w/cmpnt (CE models) (Prior to LH250191M) . . . . . . . 1
. . . 18 L1, L2, T1 208 538 . . Windtunnel, magnetics w/cmpnt (Prior to LK500101J) . . . . . . . . . . . . . . . . . . . . 1
. . . 18 L1, L2, T1 246 641 . . Windtunnel, magnetics w/cmpnt (Eff w/LK500101J) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . . . . . . . Base w/label, order by serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 208 561 . . Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 208 596 . . Holder, electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 208 535 . . Screw, k50 x 12 rnd washer hd-trx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 25 . . . . . . . . . . 208 612 . . Receptacle, twist lock power/gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . 208 588 . . Nut, plastic 625-27.81 hex x .14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . 244 862 . . Screw, m5-.8 x 12 soc hd -torx stl pld sems piloted . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . 208 498 . . Receptacle, twist lock power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . 208 589 . . Cover, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . 174 992 . . Knob, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . . . . . . Nameplate, front (order by model and serial number) . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 208 522 . . Panel, front w/nameplate (Prior to LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 233 177 . . Panel, front w/nameplate (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 219 171 . . Panel, front w/nameplate (CE models) (Prior to LH250191M) . . . . . . . . . . . . . 1
. . . 33 PC2, PC3 221114 . . Kit, 3 LED front panel (Prior to LE050208M ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 PC2, PC3 218 776 . . Circuit board, operator interface (CE models) (Prior to LH250191M) . . . . . . . 1
. . . 33 PC2, PC3 217 787 . . Circuit board, operator interface (Eff w/LE050208M thru LK500101J) . . . . . . 1
. . . 33 PC2, PC3 226 861 . . Circuit board, operator interface (All Models) (Eff w/LK500101J) . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . 208 556 . . Insualtor, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . 208 497 . . Nut, m08-1.2 13 mm hex 8.3 mm t semi cone washer . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . L3 . . 219 078 . . Core, toroidal (CE models) (Prior to LH250191M) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . T3 . . 219 076 . . Core ferrite (CE models) (Prior to LH250191M) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maxstar 150 Series
TM-2242 Page 59
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 36 . . . CB1 . . 225 844 . . Supplementary Protector (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . 219 258 . . Adapter, power cable 6−50P (230V/50A) (Eff w/LH500215J) . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . 219 261 . . Adapter, power cable 5−15P (115V/15A) (Eff w/LH500215J) . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
TM-2242 Page 60
Maxstar 150 Series
TM-2242Q
2012−02
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
Maxstar 150 S
With Auto-Linet
CE And Non-CE Models
Eff w/LD160001M And Following
For OM-2246 (208 727) Revision A And Following
Visit our website at
www.MillerWelds.com
SECTION 14 − PARTS LIST FOR S MODELS
35
36
Hardware is common and
18
20
21
24
2
25
3
26
4
27
28
23
8
1
29
22
5
6
31
30
34
8
7
9
10
15
11
22
16
12
13
33
14
not available unless listed.
803 475-G
Figure 14-1. Parts View For S Models
TM-2242 Page 62
Maxstar 150 Series
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . PC1 . . 222 765 . . KIT, pcb assy (windtunnel w/cmpnts) (includes) (Prior to LK500101J) . . . . . . 1
. . . 1 . . . PC1 . . 222 766 . . KIT, pcb assy (windtunnel w/cmpnts) CE (includes) (Prior to LH250191M) . . 1
. . . 1 . . . PC1 . . 230 210 . . Kit, pcb assy (windtunnel w/cmpnts) (CE models Eff w/LH250191M)
. . . . . . . . . . . . . . . . . . . . . . . . . . . (All other models Eff w/LK500101J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 208 701 . . . . Insulator w/label (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 221 497 . . . . . Bumper, polyurethane .500 OD x .140 H adh backed . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 146 549 . . . . . Fastener, push-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 208 622 . . . . . Label, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 208 627 . . Label, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 219 674 . . Label, warning (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 195 666 . . Screw, 010-32x .50 torx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . 208 700 . . Wrapper w/label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 219 979 . . Wrapper w/label (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 208 558 . . Term, friction .250 x .032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . 208 705 . . Panel, rear w/label (Prior to LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 233 178 . . Panel, rear w/label (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 219 983 . . Panel, rear w/label (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 208 674 . . Nameplate, rear (Prior to LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 233 171 . . Nameplate, rear (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 219 881 . . Nameplate, rear (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 208 550 . . Switch, rocker dpst 16A 250 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 208 536 . . Screw, K50 x 25 rnd washer, hd-trx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . 219 167 . . Cable, power (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 225 180 . . Cable, power (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 208 548 . . Strap, shoulder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . FM . . 208 496 . . Fan w/leads and plug 12 vdc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 L1, L2, T1 208 538 . . Windtunnel, magnetics w/cmpnt (Prior to LK500101J) . . . . . . . . . . . . . . . . . . . . 1
. . . 16 L1, L2, T1 246 641 . . Windtunnel, magnetics w/cmpnt (Eff w/LK500101J) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 L1, L2, T1 219 168 . . Windtunnel, magnetics w/cmpnt (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . . . . . . . Base w/label, order by serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 208 561 . . Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 208 596 . . Holder, electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 208 535 . . Screw, k50 x 12 rnd washer hd-trx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 23 . . . . . . . . . . 208 612 . . Receptacle, twist lock power/gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 244 862 . . Screw, m5-.8 x 12 soc hd -torx stl pld sems piloted . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . 208 498 . . Receptacle, twist lock power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . 174 992 . . Knob, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . . . . . . . Nameplate, front (order by model and serial number) . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . 208 525 . . Panel, front w/nameplate (Prior to LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . 233 179 . . Panel, front w/nameplate (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . 219 170 . . Panel, front w/nameplate (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . PC2 . . 212 905 . . Circuit board, operator interface (Prior to LK500101J) . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . PC2 . . 218 779 . . Circuit board, operator interface (CE models) (Prior to LH250191M) . . . . . . . 1
. . . 29 . . . PC2 . . 226 864 . . Circuit board, operator interface (CE models Eff w/LH250191M) (All other
. . . . . . . . . . . . . . . . . . . . . . . . . . . models Eff w/LK500101J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . 208 556 . . Insualtor, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . 208 497 . . Nut, m08-1.2 13 mm hex 8.3 mm t semi cone washer . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . L3 . . 219 078 . . Core, toroidal (CE models) (Prior to LH250191M) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . T3 . . 219 076 . . Core ferrite (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . CB1 . . 225 844 . . Supplementary Protector (Eff w/LH500215J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . 219 258 . . Adapter, power cable 6−50P (230V/50A) (Eff w/LH500215J) . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . 219 261 . . Adapter, power cable 5−15P (115V/15A) (Eff w/LH500215J) . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Maxstar 150 Series
TM-2242 Page 63
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA
 2012 Miller Electric Mfg. Co.