Miller Electric Maxstar 150 STL User manual

Processes
Lift-Arc™TIG (GTAW)
Stick (SMAW)
Input Power
1-Phase Power
Amperage Range 115 VAC: 5 – 150 A (DC TIG)
20 – 100 A (DC Stick)
230 VAC: 5 – 150 A (DC TIG)
20 – 150 A (DC Stick)
Max. Open-Circuit Voltage 90
Weight 13.7 lb (6.2 kg)
Light Industrial Applications
Process Piping
Dairy Industry
Food/Beverage Industry
Restaurant/Kitchen Repair
Experimental Aircraft
Shipboard Installation/Repair
Maintenance Repair
Maxstar®150 STL TIG/Stick Welding
Power Source
Issued February 2008 • Index No. DC/27.1
The Power of Blue® .
Portable in the shop or at the job
site — at 13.7 lb the shoulder strap
allows the end user to easily move
from location to location.
Full function remote control for
precise amperage control for critical
welds on thin materials (6-pin fingertip
or foot control available.) Fan-On-Demand™power source
cooling system operates only when
needed, reducing noise, energy use
and the amount of contaminants
pulled through the machine.
Inverter-based, DC power source has
a simple-to-use operator interface
providing only the necessary
controls in a compact machine.
Lift-Arc™start provides TIG arc starting
without the use of high frequency.
Thermal overload protection with
indicator light helps prevent machine
damage if the duty cycle is exceeded
or airflow is blocked.
Single amperage range allows
operator to accurately set amperage
on both 115 or 230 V primary power.
Quick
Specs
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
International Headquarters
Phone: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]
Power source is warranted for 3 years, parts and labor.
Original main power rectifiers are warranted for 5 years.
Adaptive Hot Start™for Stick arc
starts automatically increases the
output amperage at the start of a
weld should the start require it.
Prevents the electrode from
sticking and creating an inclusion.
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
the need for add-on voltage reducers.
Built-in gas solenoid eliminates the
need for bulky torch with a gas valve.
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.
Miller’s exclusive
multi-voltage plug
(MVP™) allows
connection to 115
or 230 V receptacles
without tools —
choose the plug that fits the receptacle
and connect it to the power cord.
TIG/Stick Package (#907 135-01-7) comes complete with:
Maxstar 150 STL
10 ft (3 m) MVP™power cord
MVP™plugs 5-15P (115 V, 15 A) and 6-50P (230 V, 50 A)
X-CASE™provides protection in transport and storage
Remote fingertip control
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
Best in class Stick arc character-
istics for those demanding jobs.
Power Factor Corrected (PFC) for
optimum performance especially
on 115 V — reduces nuisance
breaker tripping.
Improved!
New Case and
MVP Plugs!

2
3
2
4
5
1
7
8
9
6
1. Amperage Adjustment Control
2. Remote TIG Selector Light
3. TIG Selector Light
4. Stick Selector Light
5. Process Selector Touch Pad
6. Positive Weld Output Receptacle
7. Ready Light
8. Overtemperature Light
9. Negative Weld Output Receptacle
with Flow Thru
Control Panel
Performance Data
Specifications (Subject to change without notice.)
*Sense voltage for Stick and Lift-Arc TIG.
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
VOLT/AMP CURVES
AMPS
VOLTS
0
20
40
60
80
100
0 50 100 150 200
115 V TIG/Stick Max
230 V TIG/Stick Max
TIG Min
Stick Min
DUTY CYCLE CHART
10 20 40 60 80 100
% DUTY CYCLE
OUTPUT AMPERES
0
50
100
150
200
250
Stick (230 V)
Stick (115 V 20 A)
TIG/Stick (115 V 15 A)
TIG (115 V 20 A & 230 V)
Input Power
115 VAC Stick 15 A
115 VAC TIG 15 A
115 VAC Stick 20 A
115 VAC TIG 20 A
230 VAC Stick
230 VAC TIG
Rated Welding Output
70 A at 22.8 VDC, 100% Duty Cycle
100 A at 14.0 VDC, 100% Duty Cycle
70 A at 22.8 VDC, 100% Duty Cycle
100 A at 24.0 VDC, 35% Duty Cycle
100 A at 14.0 VDC, 100% Duty Cycle
150 A at 16.0 VDC, 30% Duty Cycle
100 A at 24.0 VDC, 100% Duty Cycle
150 A at 26.0 VDC, 30% Duty Cycle
100 A at 14.0 VDC, 100% Duty Cycle
150 A at 16.0 VDC, 30% Duty Cycle
Welding
Amperage
Range
20 –70 A
5–100 A
20–100 A
5–150 A
20–150 A
5–150 A
Max. Open-
Circuit Voltage
90, 12–16 V*
90, 12–16 V*
90, 12–16 V*
90, 12–16 V*
90, 12–16 V*
90, 12–16 V*
Weight
13.7 lb
(6.2 kg)
Amps Input at
Rated Output, 50/60 Hz
17.4
18.4
17.4
26.4
18.4
28.0
13.1
21.6
8.3
14.2
KVA at
Duty Cycle
2.0
2.1
2.0
3.0
2.1
3.4
3.0
4.9
2.0
3.2
KW
1.9
2.1
1.9
3.0
2.1
3.1
2.8
4.7
1.9
3.1
Dimensions
H: 9 in
(229 mm)
W: 5-1/2 in
(140 mm)
D: 13-1/4 in
(337 mm)

3
Maxstar®150 STL Packages
Packages
Standard Package #907 135
Package includes:
Maxstar 150 STL
10 ft (3 m) MVP™power cord
MVP™plugs 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) MVP™power cord
MVP™plugs 5-15P (115 V, 15 A) and 6-50P (230 V, 50 A)
X-CASE™— provides 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 Pak™with Accessories #907 135-01-5
Travel Pak™with 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) MVP™power cord
MVP™plugs 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 Pak™with Remote Control, Accessories and Hand Tools #907 135-01-3
Package includes:
Maxstar 150 STL
Remote fingertip control (#195 184)
10 ft (3 m) MVP™power cord
MVP™plugs 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

Litho in USA
Distributed by:
Ordering Information
Power Source and Options Stock No. Description Qty. Price
Maxstar®150 STL Standard Package #907 135 Maxstar 150 STL with electrode holder, work clamp, and MVP cord and plugs
Maxstar®STL TIG/Stick Package #907 135-01-6 Includes #907 135 PLUS X-CASE™, TIG torch, gas regulator with hose, and
AK-2C accessory kit
#907 135-01-7 Includes #907 135-01-6 PLUS remote fingertip control
Maxstar®150 STL Travel Pak™#907 135-01-5 Includes #907 135 PLUS Travel Pak™case, TIG torch, gas regulator with hose,
and AK-2C accessory kit
#907 135-01-4 Includes #907 135-01-5 PLUS remote fingertip control
#907 135-01-3 Includes #907 135-01-4 PLUS side cutter, file, brushes, and flashlight
Accessories
X-CASE™(only) #300 184 Carrying case for Maxstar 150 STL
Travel Pak™Case (only) #300 249 Softside travel case with wheels, telescoping handle and carrying straps
RCCS-6M #195 184 13.25 ft (4 m) remote fingertip control
#195 503 26.5 ft (8 m), remote fingertip control
RMS-6M #195 269 26.5 ft (8 m) remote on/off control
RFCS-6M #195 183 13.25 ft (4 m) remote foot control
#195 504 20 ft (6 m) remote foot control
Weldcraft TIG Torch See Accessories section above
International-Style Flow Thru Adapter #195 234 25 mm adapter for TIG torch connection
Adapter Cord, Full KVA #300 158 Adapts engine drive 120/240 V plug to Maxstar 240 V plug
MVP™Adapter Plugs See Accessories section above
Date: Total Quoted Price:
X-CASE™#300 184
Sturdy case provides
ultimate protection for
transport and storage.
Also features
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).
Travel Pak™Case
#300 249
If you are already using
the Maxstar 150 and
want the portability and
convenience to take
everything you need — purchase the bag
and customize with your own tools.
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.
Remote Controls
RCCS-6M (6-pin plug)
#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.
RFCS-6M (6-pin plug)
#195 183 13.25 ft (4 m) cord
#195 504 20 ft (6 m) cord
Foot pedal current/contactor
control. Includes cord and plug.
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.
TIG (GTAW) Torch Packages
The Weldcraft line
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.
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
MVP™Adapter Plugs
Order from Miller Service Parts.
#219 258 For Power Cable 6-50P
(230 V/50 A). Included with machine.
#219 261 For Power Cable 5-15P
(115 V/15 A). Included with machine.
#219 259 For Power Cable 5-20P
(115 V/20 A). Optional.
Genuine Miller Accessories
Female
Receptacle