Miller Electric Welder 150 STL User Manual

Issued February 2008 • Index No. DC/27.1  
TIG/Stick Welding  
®
Power Source  
Maxstar 150 STL  
Light Industrial Applications  
Processes  
Lift-Arc TIG (GTAW)  
Stick (SMAW)  
Amperage Range 115 VAC: 5150 A (DC TIG)  
20100 A (DC Stick)  
Process Piping  
Dairy Industry  
230 VAC: 5150 A (DC TIG)  
20150 A (DC Stick)  
Quick  
Specs  
Food/Beverage Industry  
Restaurant/Kitchen Repair  
Experimental Aircraft  
Shipboard Installation/Repair  
Maintenance Repair  
Input Power  
1-Phase Power  
Max. Open-Circuit Voltage 90  
Weight 13.7 lb (6.2 kg)  
®
New Case and  
MVP Plugs!  
Improved!  
The Power of Blue.  
Single amperage range allows  
operator to accurately set amperage  
on both 115 or 230 V primary power.  
Auto-Line provides state-of-the-art  
flexibility to the end user. The Auto-  
Line circuitry automatically connects  
to 115–230 VAC, single-phase power  
without removing the covers to relink  
the power source. No longer is there  
a concern if you have the correct  
machine for the shop or job site.  
Inverter-based, DC power source has  
a simple-to-use operator interface  
providing only the necessary  
controls in a compact machine.  
Adaptive Hot Startfor Stick arc  
starts automatically increases the  
output amperage at the start of a  
weld should the start require it.  
Prevents the electrode from  
Miller’s exclusive  
multi-voltage plug  
(MVP) allows  
connection to 115  
or 230 V receptacles  
sticking and creating an inclusion.  
without tools—  
choose the plug that fits the receptacle  
and connect it to the power cord.  
Low OCV Stick is a simple design  
that reduces the open-circuit  
voltage to 12–16 V when the  
welding power source is not in use.  
This circuit design is now built into  
the Maxstar 150 STL eliminating  
Portable in the shop or at the job  
siteat 13.7 lb the shoulder strap  
allows the end user to easily move  
from location to location.  
TIG/Stick Package (#907 135-01-7) comes complete with:  
Maxstar 150 STL  
the need for add-on voltage reducers.  
10 ft (3 m) MVPpower cord  
Best in class Stick arc character-  
istics for those demanding jobs.  
MVPplugs 5-15P (115 V, 15 A) and 6-50P (230 V, 50 A)  
X-CASEprovides protection in transport and storage  
Remote fingertip control  
Lift-Arc start provides TIG arc starting  
without the use of high frequency.  
Power Factor Corrected (PFC) for  
optimum performance especially  
on 115 Vreduces nuisance  
breaker tripping.  
Built-in gas solenoid eliminates the  
need for bulky torch with a gas valve.  
Weldcraft® WP1712RD125 TIG torch with adapter  
13 ft (4 m) Stick electrode holder with 25 mm Dinse connector  
10 ft (3 m) work clamp with 25 mm Dinse connector  
Smith® regulator with gas hose  
Full function remote control for  
precise amperage control for critical  
welds on thin materials (6-pin fingertip  
or foot control available.)  
AK-2C accessory kit  
Shoulder strap  
Fan-On-Demandpower source  
cooling system operates only when  
needed, reducing noise, energy use  
and the amount of contaminants  
pulled through the machine.  
Thermal overload protection with  
indicator light helps prevent machine  
damage if the duty cycle is exceeded  
or airflow is blocked.  
Power source is warranted for 3 years, parts and labor.  
Original main power rectifiers are warranted for 5 years.  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
International Headquarters Web Site  
Phone: 920-735-4505  
USA FAX: 920-735-4134  
Canadian FAX: 920-735-4169  
International FAX: 920-735-4125  
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®
Maxstar 150 STL Packages  
Packages  
Standard Package #907 135  
Package includes:  
Maxstar 150 STL  
10 ft (3 m) MVPpower cord  
MVPplugs 5-15P (115 V, 15 A) and 6-50P (230 V, 50 A)  
13 ft (4 m) Stick electrode holder with 25 mm Dinse connector  
10 ft (3 m) work clamp with 25 mm Dinse connector  
International flow-thru adapter  
Shoulder strap  
TIG/Stick Package #907 135-01-6  
TIG/Stick Package with Remote Fingertip Control #907 135-01-7  
Package includes:  
Maxstar 150 STL  
Remote fingertip control (#195 184) (#907 135-01-7 Package only)  
10 ft (3 m) MVPpower cord  
MVPplugs 5-15P (115 V, 15 A) and 6-50P (230 V, 50 A)  
X-CASEprovides protection in transport and storage  
Weldcraft® WP1712RD125 TIG torch with adapter  
13 ft (4 m) Stick electrode holder with 25 mm Dinse connector  
10 ft (3 m) work clamp with 25 mm Dinse connector  
Smith® regulator with gas hose  
AK-2C accessory kit  
Shoulder strap  
Maxstar Travel Paks  
Travel Pakwith Accessories #907 135-01-5  
Travel Pakwith Remote Control and Accessories #907 135-01-4  
Package includes:  
Maxstar 150 STL  
Remote fingertip control (#195 184) (#907 135-01-4 Package only)  
10 ft (3 m) MVPpower cord  
MVPplugs 5-15P (115 V, 15 A) and 6-50P (230 V, 50 A)  
Softside travel case with wheels, telescoping handle and carrying straps  
Weldcraft® WP1712RD125 TIG torch with adapter  
13 ft (4 m) Stick electrode holder with 25 mm Dinse connector  
10 ft (3 m) work clamp with 25 mm Dinse connector  
Smith® regulator with gas hose  
AK-2C accessory kit and Stick electrode box  
Shoulder strap  
Travel Pakwith Remote Control, Accessories and Hand Tools #907 135-01-3  
Package includes:  
Maxstar 150 STL  
Remote fingertip control (#195 184)  
10 ft (3 m) MVPpower cord  
MVPplugs 5-15P (115 V, 15 A) and 6-50P (230 V, 50 A)  
Softside travel case with wheels, telescoping handle and carrying straps  
Weldcraft® WP1712RD125 TIG torch with adapter  
13 ft (4 m) Stick electrode holder with 25 mm Dinse connector  
10 ft (3 m) work clamp with 25 mm Dinse connector  
Smith® regulator with gas hose  
AK-2C accessory kit and stick electrode box  
Shoulder strap  
Kline 9-in side cutter, Nicholson 10-in half-round file, and Weiler SS brushes  
Mini MagLite flashlight, and 1-in diameter inspection mirror  
3
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Genuine Miller Accessories  
X-CASE#300 184  
Sturdy case provides  
Remote Controls  
TIG (GTAW) Torch Packages  
The Weldcraft line  
ultimate protection for  
of TIG torches  
complements the most popular TIG power  
source line available today. The Weldcraft  
torch line includes both air-cooled and  
water-cooled models. Available with genuine  
Weldcraft parts.  
transport and storage.  
Also features  
RCCS-6M (6-pin plug)  
convenient top carrying handle and side  
recessed hand grips. Store the Maxstar 150,  
accessories and gear in this generous case  
to be ready to go at any time. Dimensions:  
13 in H x 10-1/2 in W x 30-5/8 in D  
(330 x 267 x 778 mm).  
#195 184 13.25 ft (4 m) cord  
#195 503 26.5 ft (8 m) cord  
North/south rotary-motion fingertip  
current/contactor control fastens to TIG  
torch using two Velcro straps. Great for  
applications that require a finer amperage  
control. Includes cord and plug.  
Air-Cooled Torches  
®
#WP1712RDI25 150 A, 12 ft (3.7 m)  
air-cooled torch with flow-thru adapter  
#WP1725RDI25 150 A, 25 ft (7.6 m)  
air-cooled torch with flow-thru adapter  
Travel PakCase  
#300 249  
If you are already using  
the Maxstar 150 and  
want the portability and  
RFCS-6M (6-pin plug)  
#195 183 13.25 ft (4 m) cord  
#195 504 20 ft (6 m) cord  
MVPAdapter Plugs  
Order from Miller Service Parts.  
Foot pedal current/contactor  
convenience to take  
control. Includes cord and plug.  
everything you need — purchase the bag  
and customize with your own tools.  
#219 258 For Power Cable 6-50P  
(230 V/50 A). Included with machine.  
Female  
Receptacle  
RMS-6M (6-pin plug) #195 269  
Momentary-contact switch for contactor  
control. Rubber-covered pushbutton  
dome switch ideal for repetitive on-off  
applications. Includes 26.5 ft (8 m) cord  
and plug.  
#219 261 For Power Cable 5-15P  
(115 V/15 A). Included with machine.  
Adapter Cord, Full KVA #300 158 Field  
NEMA 14-50P to NEMA 6-50R. Adapts  
engine drive 120/240 V plug to Maxstar  
240 V plug.  
#219 259 For Power Cable 5-20P  
(115 V/20 A). Optional.  
Ordering Information  
Power Source and Options  
Stock No.  
#907 135  
#907 135-01-6  
Description  
Qty.  
Price  
Maxstar® 150 STL Standard Package  
Maxstar® STL TIG/Stick Package  
Maxstar 150 STL with electrode holder, work clamp, and MVP cord and plugs  
Includes #907 135 PLUS X-CASE, TIG torch, gas regulator with hose, and  
AK-2C accessory kit  
#907 135-01-7  
#907 135-01-5  
Includes #907 135-01-6 PLUS remote fingertip control  
Includes #907 135 PLUS Travel Pakcase, TIG torch, gas regulator with hose,  
and AK-2C accessory kit  
Maxstar® 150 STL Travel Pak™  
#907 135-01-4  
#907 135-01-3  
Includes #907 135-01-5 PLUS remote fingertip control  
Includes #907 135-01-4 PLUS side cutter, file, brushes, and flashlight  
Accessories  
X-CASE(only)  
Travel PakCase (only)  
RCCS-6M  
#300 184  
#300 249  
#195 184  
#195 503  
Carrying case for Maxstar 150 STL  
Softside travel case with wheels, telescoping handle and carrying straps  
13.25 ft (4 m) remote fingertip control  
26.5 ft (8 m), remote fingertip control  
RMS-6M  
RFCS-6M  
#195 269  
#195 183  
#195 504  
26.5 ft (8 m) remote on/off control  
13.25 ft (4 m) remote foot control  
20 ft (6 m) remote foot control  
Weldcraft TIG Torch  
See Accessories section above  
International-Style Flow Thru Adapter  
Adapter Cord, Full KVA  
MVPAdapter Plugs  
#195 234  
#300 158  
25 mm adapter for TIG torch connection  
Adapts engine drive 120/240 V plug to Maxstar 240 V plug  
See Accessories section above  
Date:  
Total Quoted Price:  
Distributed by:  
Litho in USA  
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