Miller MAXSTAR 161 STL Owners manual

OM-275099C 2017-07

Processes

Stick (SMAW) Welding

TIG (GTAW) Welding

Description

Arc Welding Power Source



Maxstar 161 S, STL, and STH

With Auto-Linet

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

File: TIG (GTAW)

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2017−06

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................

1-1. Symbol Usage 1.......................................................................

1-2. Arc Welding Hazards 1.................................................................

1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................

1-4. California Proposition 65 Warnings 4......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4.....................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5...........................

2-1. Symboles utilisés 5.....................................................................

2-2. Dangers relatifs au soudage à l’arc 5......................................................

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7.....

2-4. Proposition californienne 65 Avertissements 8..............................................

2-5. Principales normes de sécurité 8.........................................................

2-6. Informations relatives aux CEM 8.........................................................

SECTION 3 − DEFINITIONS 9..................................................................

3-1. Additional Safety Symbols And Definitions 9................................................

3-2. Miscellaneous Symbols And Definitions 10..................................................

SECTION 4 − SPECIFICATIONS 11..............................................................

4-1. Serial Number And Rating Label Location 11................................................

4-2. Specifications 11........................................................................

4-3. Dimensions And Weight 11...............................................................

4-4. Environmental Specifications 12...........................................................

4-5. Duty Cycle And Overheating For Maxstar 161S Models 12.....................................

4-6. Static Characteristics 13.................................................................

4-7. Remote 6 Receptacle Information (STL And STH Models Only) 13..............................

SECTION 5 − INSTALLATION 14................................................................

5-1. Selecting a Location 14..................................................................

5-2. Electrical Service Guide 15...............................................................

5-4. Connecting 120 VAC Input Power 16.......................................................

5-5. Connecting 1-Phase Input Power For 240 VAC 18............................................

5-6. Shoulder And Handle Strap Installation 20...................................................

SECTION 6 − OPERATION 22...................................................................

6-1. Front Panel Controls And Gas Connection 22................................................

6-2. Process Selection (STL Model Only) 22....................................................

6-3. Process Selection (STH Model Only) 23....................................................

6-4. Process Selection (S Model Only) 23.......................................................

6-5. Lift-Arc And TIG Impulse Start Procedures 24...............................................

6-6. Accessing Control Panel Menu: TIG−HF (STH Model Only) 24.................................

6-7. Accessing Control Panel Menu: Lift-Arc TIG (STH And STL Models Only) 25.....................

6-8. Accessing Control Panel Menu: Stick 26....................................................

SECTION 7 − ADVANCED MENU FUNCTIONS 27.................................................

7-1. Accessing Tech Menu For Maxstar 161 Models 27...........................................

SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 28.......................................

8-1. Routine Maintenance 28.................................................................

8-2. Meter Troubleshooting Displays 28.........................................................

8-3. Troubleshooting 29......................................................................

SECTION 9 − ELECTRICAL DIAGRAM 31........................................................

TABLE OF CONTENTS

SECTION 10 − HIGH FREQUENCY 32...........................................................

10-1. Welding Processes Requiring High Frequency 32............................................

10-2. Installation Showing Possible Sources Of HF Interference 32...................................

10-3. Recommended Installation To Reduce HF Interference 33.....................................

SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING

WITH INVERTER MACHINES 34................................................................

11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) 34......

11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines 34...................................................

SECTION 12 − STICK WELDING (SMAW) GUIDELINES 35.........................................

COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2015−09

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.

1-2. Arc Welding 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. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

 Do not touch live electrical parts.

 Wear dry, hole-free insulating gloves and body protection.
 Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

 Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

 Use AC output ONLY if required for the welding process.
 If AC output is required, use remote output control if present on

unit.

 Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

 Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

 Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

 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.

 Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

 When making input connections, attach proper grounding conduc-

tor first − double-check connections.

 Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

 Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare
wiring can kill.

 Turn off all equipment when not in use.
 Do not use worn, damaged, undersized, or repaired cables.
 Do not drape cables over your body.
 If earth grounding of the workpiece is required, ground it directly

with a separate cable.

 Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

 Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

 Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

 Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

 Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in
use.

 Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

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 Maintenance 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, insu-

lated welding gloves and clothing to prevent burns.

OM- 275099 Page 1

FUMES AND GASES can be hazardous.

)

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

 Keep your head out of the fumes. Do not breathe the fumes.
 If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.

 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

 Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch­person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath­ing air is safe.

 Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

 Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.

 Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).

 Wear approved safety glasses with side shields under your

helmet.

 Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

 Wear body protection made from durable, flame−resistant mate-

rial (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.

WELDING can cause fire or explosion.

 Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

 Wear body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.

 Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

 After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

 Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

 Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

FLYING METAL or DIRT can injure eyes.

 Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,
they can throw off slag.

 Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

 Shut off compressed gas supply when not in use.
 Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF
can affect Implanted Medical Devices.

 Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

 Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

 Wear approved ear protection if noise lev-

el is high.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot

burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.

 Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

 Do not weld where flying sparks can strike flammable material.
 Protect yourself and others from flying sparks and hot metal.
 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.
 Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

 Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).

 Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

 Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.

 Do not use welder to thaw frozen pipes.

OM-275099 Page 2

workpiece, and hot equipment can cause fires and

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.

 Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

 Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

 Keep cylinders away from any welding or other electrical circuits.
 Never drape a welding torch over a gas cylinder.
 Never allow a welding electrode to touch any cylinder.
 Never weld on a pressurized cylinder − explosion will result.
 Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them
and associated parts in good condition.

 Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

 Keep protective cap in place over valve except when cylinder is in

use or connected for use.

 Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

 Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

 Do not install or place unit on, over, or near

combustible surfaces.

 Do not install unit near flammables.

 Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

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.

 Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

 Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu­ally lifting heavy parts or equipment.

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.

MOVING PARTS can injure.

 Keep away from moving parts such as fans.
 Keep all doors, panels, covers, and guards

closed and securely in place.

 Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

 Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

 Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

 Use only genuine replacement parts from the manufacturer.
 Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and
local codes.

H.F. RADIATION can cause interference.

FLYING SPARKS can injure.

 Wear a face shield to protect eyes and face.
 Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper
face, hand, and body protection.

 Sparks can cause fires — keep flammables away.

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.

MOVING PARTS can injure.

 Keep away from moving parts.
 Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

 Do not press gun trigger until instructed to do

so.

 Do not point gun toward any part of the body,

other people, or any metal when threading
welding wire.

BATTERY EXPLOSION can injure.

 Do not use welder to charge batteries or jump

start vehicles unless it has a battery charging
feature designed for this purpose.

 High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

 The user is responsible for having a qualified electrician prompt-

ly 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.

ARC WELDING can cause interference.

 Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.

 Be sure all equipment in the welding area is

electromagnetically compatible.

 To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

 Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according to this manual.

 If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

OM- 275099 Page 3

1-4. 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.)

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).

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.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro­cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can 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 con-
duct 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.

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.

OM-275099 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

fre_som_2015−09

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.

2-2. Dangers relatifs au soudage à l’arc

Les symboles représentés ci-dessous sont utilisés dans ce ma­nuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Sec­tion 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonc­tionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimen­tation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.

 Ne pas toucher aux pièces électriques sous tension.
 Porter des gants isolants et des vêtements de protection secs et

sans trous.

 S’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.

 Ne pas se servir de source électrique à courant électrique dans les

zones humides, dans les endroits confinés ou là où on risque de
tomber.

 Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

 Si l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.

 D’autres consignes de sécurité sont nécessaires dans les condi-

tions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est re­commandée. En outre, ne pas travailler seul !

 Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

 Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-

stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor­mes de sécurité).

 Installez, mettez à la terre et utilisez correctement cet équipement

conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.

 Toujours vérifier la terre du cordon d’alimentation. Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.

 En effectuant les raccordements d’entrée, fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

 Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques
chaudes.

 Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî­ner la mort.

 L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
 Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

 Ne pas enrouler les câbles autour du corps.
 Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.

 Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

 Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou­blée.

 N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformé­ment à ce manuel.

 Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
 S’assurer que tous les panneaux et couvercles sont correctement

en place.

 Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près pos­sible de la soudure.

 Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

 Ne pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.

 Utiliser une protection différentielle lors de l’utilisation d’un équi-

pement auxiliaire dans des endroits humides ou mouillés.

Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.

 Arrêter les convertisseurs, débrancher le courant électrique et

décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.

OM-275099 Page 5

LES PIÈCES CHAUDES peuvent

e

e

a

provoquer des brûlures.

 Ne pas toucher à mains nues les parties chaudes.
 Prévoir une période de refroidissement avant

de travailler à l’équipement.

 Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.

 Eloigner votre tête des fumées. Ne pas respirer les fumées.
 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.

 Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

 Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.

 Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.

 Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for­mer des gaz hautement toxiques et irritants.

 Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génèr

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur l
peau. Des étincelles sont projetées pendant le soudage.

 Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).

 Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

 Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

 Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

des rayons visibles et invisibles intenses (ultraviolets

LE SOUDAGE peut provoquer un
incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut

être projetées de l’arc de soudure. La projection d’étincelles, des

pièces chaudes et des équipements chauds peut provoquer des incen­dies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un sur-

OM-275099 Page 6

provoquer leur éclatement. Des étincelles peuvent

chauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.

 Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.

 Ne pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

 Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

 Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.

 Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

 Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

 Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).

 Ne pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par exemple).

 Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo­quant des risques d’électrocution, d’étincelles et d’incendie.

 Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

 En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

 Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

 Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

 Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.

 Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.

DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.

 Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de ref­roidissement des soudures, elles risquent de projeter du laitier.

 Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.

 Fermer l’alimentation du gaz comprimé en cas

de non utilisation.

 Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateur d’adduction d’air homologué.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.

 Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à
distance.

 Les porteurs d’implants médicaux doivent consulter leur médecin

et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut
affecter l’ouïe.

 Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser
si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est

les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.

 Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.

 Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.

endommagée, elle peut exploser. Du fait que

 Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

 Ne jamais placer une torche de soudage sur une bouteille à gaz.
 Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

 Ne jamais souder une bouteille pressurisée − risque d’explosion.
 Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.

 Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.

 Le couvercle du détendeur doit toujours être en place, sauf lorsque

la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

 Utiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

 Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLOSION.

 Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

 Ne pas installer l’appareil à proximité de pro-

duits inflammables.

 Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.

 Utiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.

 Utiliser un équipement de levage de capacité suffisante pour lever

l’appareil.

 En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.

 Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

 Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

 Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

 Ne pas obstruer les passages d’air du poste.

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

 Porter un écran facial pour protéger le visage et

les yeux.

 Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exé­cuter dans un endroit sûr lorsque l’on porte l’équipement ho­mologué de protection du visage, des mains et du corps.

 Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

LES CHARGES ÉLECTROSTATI­QUES peuvent endommager les cir­cuits imprimés.

 Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-

placer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent
causer des blessures.

 Ne pas s’approcher des organes mobiles.
 Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

 Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

 Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.

L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.

 Ne pas utiliser l’appareil de soudage pour

charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.

Les PIÈCES MOBILES peuvent
causer des blessures.

 S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

 Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.

 Lorsque cela est nécessaire pour des travaux d’entretien et de dé-

pannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.

 Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.

LIRE LES INSTRUCTIONS.

 Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’instal­lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.

 N’utiliser que les pièces de rechange recommandées par le

constructeur.

 Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.

OM-275099 Page 7

LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de
provoquer des interférences.

 Le rayonnement haute fréquence (H.F.) peut

pements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.

 Demander seulement à des personnes qualifiées familiarisées avec

des équipements électroniques de faire fonctionner l’installation.

 L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

 Si le FCC signale des interférences, arrêter immédiatement l’appareil.
 Effectuer régulièrement le contrôle et l’entretien de l’installation.
 Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distan­ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.

provoquer des interférences avec les équi-

 Veiller à ce que tout l’équipement de la zone de soudage soit com-

 Pour réduire la possibilité d’interférence, maintenir les câbles de

 Veiller à souder à une distance de 100 mètres de tout équipement

 Veiller à ce que ce poste de soudage soit posé et mis à la terre

 En cas d’interférences après avoir pris les mesures précédentes,

2-4. Proposition californienne 65 Avertissements

LE SOUDAGE À L’ARC risque de
provoquer des interférences.

 L’énergie électromagnétique risque de

provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.

patible électromagnétiquement.

soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).

électronique sensible.

conformément à ce mode d’emploi.

il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

2-6. Informations relatives aux CEM

Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après

utilisation.

Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

OM-275099 Page 8

câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la
soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc­tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

 A complete Parts List is available at www.MillerWelds.com

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

 Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Safe1 2012−05

Safe2 2017−04

Protect yourself from electric shock by insulating yourself from work and ground.

Disconnect input plug or power before working on machine.

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Use ventilating fan to remove fumes.

Safe3 2017−04

Safe5 2017−04

Safe6 2017−04

Safe8 2012−05

Safe10 2012−05

Keep flammables away from welding. Do not weld near flammables.

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

OM-275099 Page 9

Safe12 2012−05

Safe14 2012−05

 A complete Parts List is available at www.MillerWelds.com

Do not weld on drums or any closed containers.

Safe16 2017−04

Do not remove or paint over (cover) the label.

Safe20 2017−04

Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection

facility.
Contact your local recycling office or your local distributor for further information.

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.

Safe37 2017−04

Safe38 2012−05

3-2. Miscellaneous Symbols And Definitions

A

V

Hz

Amperage

Voltage

Hertz

S

Output

Gas Input

Increase/Decreas

e Of Quantity

Percent

Become trained and read the instructions before working on the
machine or welding.

Safe40 2012−05

Negative

On/Off (Standby)

Suitable For

Areas Of

Increased Shock

Hazard

Shielded Metal

Arc Welding

(SMAW)

Positive

Single Phase

Static Frequency

Converter-Transfo

rmer-Rectifier

U

U

U

I

1max

I

1

2

0

2

Primary Voltage

Conventional
Load Voltage

Rated No Load

Voltage (Average)

Rated Maximum

Supply Current

Rated Welding

Current

Remote

Arc Striking With

Contact (LiftArc)

I

1eff

OM-275099 Page 10

Alternating

Current

Maximum

Effective Supply

Current

Menu

X

Direct Current

Line Connection

Duty Cycle

Gas Tungsten Arc

Welding (GTAW)

TIG (GTAW)

Pulse

Arc Striking

Without Contact

(HF and Impulse)

 A complete Parts List is available at www.MillerWelds.com

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number is located on the bottom, and rating information is located on the back of the machine. Use the rating labels to determine input power
requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Specifications

 This equipment will deliver rated output at an ambient air temperature up to 1045F ( 405C).

 Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-2 thru 5-5 for information on con-

necting input power.

Input Power

Single-Phase

AC

120 Volts Stick

120 Volts TIG

240 Volts Stick

Rated Welding

Output

90A @ 23.6 Volts DC,

30% Duty Cycle

75A @ 23 Volts DC, 60%

Duty Cycle

60A @ 22.4 Volts DC,

100% Duty Cycle

130A @ 15.2 Volts DC,

30% Duty Cycle

110A @ 14.4 Volts DC,

60% Duty Cycle

90A @ 13.6 Volts DC,

100% Duty Cycle

160A @ 26.4 Volts DC,

20% Duty Cycle

130A @ 25.2 Volts DC,

60% Duty Cycle

110A @ 24.4 Volts DC,

100% Duty Cycle

Welding Am-

perage

Range

20 − 90A

5 − 130A

20 − 160A

Max

OCV DC

(Uo)

48V

*12-16

48V

*12-16

48V

*12-16

Rated Peak

Starting

Voltage (Up)

**15 KV

**15 KV

**15 KV

Amperes Input

At Rated Load

Output, 50/60Hz,

Single-Phase

23.16 2.78 2.76

18.82 2.26 2.22

14.68 1.75 1.71

22.6 2.73 2.70

18.67 2.25 2.20

14.61 1.75 1.70

22.55 5.41 5.25

17.60 4.24 4.09

14.31 3.43 3.30

KVA @

Duty

Cycle

KW

160A @ 16.4 Volts DC,

20% Duty Cycle

240 Volts TIG

*Sense Voltage For Stick And TIG Lift Arc
** Arc Striking Device Is Designed For Manual Guided Operations

130A @ 15.4 Volts DC,

60% Duty Cycle

110A @ 14.4 Volts DC,

100% Duty Cycle

5 − 160A

4-3. Dimensions And Weight

Weight 13 lb (8.9 kg)

Dimensions L = 13.5 in. (342.9 mm), W = 5.6 in. (142.2 mm), H = 10.3 in. (261.6 mm)

48V

*12-16

**15 KV

15.05 3.62 3.49

11.41 2.73 2.60

9.35 2.24 2.12

OM-275099 Page 11

 A complete Parts List is available at www.MillerWelds.com

4-4. Environmental Specifications

A. IP Rating

IP Rating

IP23

This equipment is designed for outdoor use.

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.

IP23 2017−02

This equipment complies with IEC 61000-3-12.

C. Temperature Specifications

Operating Temperature Range* Storage/Transportation Temperature Range

-40 to 104 °F (-40 to 40°C)

*Output is derated at temperatures above 104°F (40°C).

-40 to 158 °F (-40 to 70°C)

4-5. Duty Cycle And Overheating For Maxstar 161S Models

250

200

150

100

Output Amperes

50

Stick 240 V

Stick 120 V

ce-emc 4 2011-09

Temp_2016-07

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,
Over Temp is displayed, and the
cooling fan runs. Wait fifteen min­utes for unit to cool. Reduce amper­age or duty cycle before starting to
weld again.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

0

10 20 30 40 50 60 70 80 90 100

OM-275099 Page 12

% Duty Cycle

 A complete Parts List is available at www.MillerWelds.com

4-5. Duty Cycle And Overheating For Maxstar 161STL And STH Models

Duty Cycle is percentage of 10 min­utes that unit can weld at rated load
without overheating.

If unit overheats, output stops, the

250

Stick And TIG 240 V

200

150

100

TIG 120 V

Output Amperes

50

0

10 20 30 40 50 60 70 80 90 100

Stick 120 V

% Duty Cycle

Overtemperature Light comes On,
Over Temp is displayed, and the
cooling fan runs. Wait fifteen min­utes for unit to cool. Reduce amper­age or duty cycle before starting to
weld again.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

4-6. Static Characteristics

The static (output) characteristics of the welding power source can be described as drooping during the SMAW and GTAW processes. Static
characteristics are also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors. Contact
the factory for specific information on the static characteristics of the welding power source.

4-7. Remote 6 Receptacle Information (STL And STH Models Only)

Socket Socket Information

6

1 Contactor control +15 volts DC.

15 VOLTS DC

OUTPUT
CONTACTOR

REMOTE

OUTPUT

CONTROL

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.

Ref. 805575-A

CHASSIS

5 Remote control circuit common.

6 Chassis common.

OM-275099 Page 13

 A complete Parts List is available at www.MillerWelds.com

SECTION 5 − INSTALLATION

5-1. Selecting a Location

Movement

! Do not move or operate unit

where it could tip.

1

Location And Airflow

18 in.

(460 mm)

Notes

2

18 in.

(460 mm)

! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.

1 Shoulder Strap
Use strap to lift unit.
2 Line Disconnect Device
Locate unit near correct input

power supply.

loc_small 2015-04

OM-275099 Page 14

 A complete Parts List is available at www.MillerWelds.com

5-2. Electrical Service Guide



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 120−240 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

1-Phase

Input Voltage (V) 120 240
Rated Maximum Supply Current I
Maximum Effective Supply Current I
Max Recommended Standard Fuse Rating In Amperes

Normal Operating Fuses

Min Input Conductor Size In AWG (mm2)
Max Recommended Input Conductor Length In Feet (Meters) 53 (16)
Min Grounding Conductor Size In AWG (mm2)

Reference: 2017 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) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than

three single current−carrying conductors in a raceway. 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.

(A)

1max

(A) 14.3

1eff

1

Time-Delay Fuses

4

2

3

4

A 15 or 20

ampere

individual

branch circuit

protected by

time-delay

fuses or circuit

breaker is

required. See

Section 5-4.

50/60 Hz
1-Phase

22.6

25
30

14 (2.5)

14 (2.5)

5-3. Selecting Extension Cord (Use Shortest Cord Possible)

Conductor Size − AWG (mm2)*

Single Phase AC

Input Voltage

120 160 (49) 107 (33) 71 (22) 47 (14) 29 (9)

240 471 (144) 321 (98) 215 (66) 146 (45) 90 (27)

*Conductor size is based on maximum 3% voltage drop

4 (21.2) 6 (13.3) 8 (8.4) 10 (5.3) 12 (3.3)

Maximum Allowable Cord Length in ft (m)

OM-275099 Page 15

 A complete Parts List is available at www.MillerWelds.com

5-4. Connecting 120 VAC Input Power

4

2

1

! 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.

! Do not use power cord to

lift or carry welding power
source.

! Special installation may be

required where gasoline or
volatile liquids are present

− see NEC Article 511 or

5

CEC Section 20.

! Remove power cord from

receptacle on the back of
the welding power source
before transporting or
storing the unit. Failure to
remove power cord may
result in damage to the
cord.

! Do not wrap cord around

welding power source or
cord may be damaged.

 The Auto-Line circuitry in this

unit automatically links the
power source to the primary

3

6

voltage being applied, either
120 or 240 VAC.

NOTICE − Do Not modify the
power cord. The power cord
plugs will work with standard NE­MA receptacles. Use only the
power cords supplied with this
unit. Modifying the power cord(s)
and/or plugs, or using cords not
intended for use with this product
will void warranty.

For 120 volts AC input power, a
15 or 20 ampere individual
branch circuit protected by
time-delay fuses or circuit
breaker is required. For 240 volts
AC input power, see Section 5-5.

1 Power Cord 120 VAC
120 VAC cord with NEMA type 5

-15P plug and SDG plug.
2 Plug - SDG
3 Plug - NEMA Type 5 - 15P
4 Receptacle - SDG
5 Receptacle - NEMA Type

5-15R

6 Receptacle - NEMA Type 6

- 20R

Connect plug (3) to receptacle (5
or 6).

OM-275099 Page 16

Ref. 803351-D

Notes

 A complete Parts List is available at www.MillerWelds.com

OM-275099 Page 17

 A complete Parts List is available at www.MillerWelds.com

5-5. Connecting 1-Phase Input Power For 240 VAC

1

L2

5

L1

L2

2

3

8

L1

=GND/PE Earth Ground

7

4

6

1

240 VAC, 1

12

10

11

9

Tools Needed:

803766-C / Ref. 805577-A

OM-275099 Page 18

 A complete Parts List is available at www.MillerWelds.com

5-5. Connecting 1-Phase Input Power For 240 VAC (Continued)

! 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.

! Do not use power cord to lift or carry

welding power source.

! Remove power cord from receptacle

on the back of the welding power
source before transporting or storing
the unit. Failure to remove power cord
may result in damage to the cord.

! Do not wrap cord around welding

power source or cord may be dam­aged.

See rating label on unit and check input volt­age available at site.

 The Auto-Line circuitry in this unit auto-

matically links the power source to the
primary voltage being applied, either 120
or 240 VAC.

NOTICE − Do Not modify the power cord. The
power cord plugs will work with standard NE­MA receptacles. Use only the power cords
supplied with this unit. Modifying the power
cord(s) and/or plugs, or using cords not in­tended for use with this product will void war­ranty.

1 Black And White Input Conductor (L1

And L2)

2 Green Or Green/Yellow Grounding

Conductor

3 Input Power Cord.

4 Disconnect Device (switch shown in the

OFF position)

5 Disconnect Device Grounding Terminal

6 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 Over-Current Protection
Select type and size of over-current

protection using Section 5-2 (fused
disconnect switch shown).

8 Receptacle (NEMA 6-50R)

Customer Supplied

Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.

9 Power Cord
240 VAC cord with NEMA type 6-50P plug

and SDG plug.
10 Plug - SDG
11 Plug - NEMA Type 6-50P
12 Receptacle - SDG

Notes

OM-275099 Page 19

 A complete Parts List is available at www.MillerWelds.com

5-6. Shoulder And Handle Strap Installation

A. Shoulder Strap Installation

2

Detail A

1

Detail A is Critical!

Insert strap through cam buckle

As Shown

Strap Buckle Assembly

1 Strap
2 Cam Buckle
If necessary, before attaching

shoulder/handle strap to power
source, assemble strap/buckle as
shown.

B. Handle Strap Installation

4

Strap
End

Installing And Securing Shoul­der Portion Of Strap To Welding
Power Source

1 Shoulder/Handle Strap
Route strap as shown.

1

2

2 Bezel (Front And Rear)
3 Pin
4 Cam Buckle Lever
Route and secure shoulder strap as

follows:

• Route looped ends of strap
through openings in bezels.

• Insert pins through strap loops.

• Pull up on straps to pull pins up in-

to bezel openings. Pull straps
firmly enough to seat pins in re­taining slots in openings.

• Press buckle lever, and slide
strap through buckle to obtain de­sired length. Release lever.

2

3

OM-275099 Page 20

Ref. 803351-D / Ref. 805576-B / Ref. 805574-B

Notes

 A complete Parts List is available at www.MillerWelds.com

Welding Tip:

Securely connect work clamp to a clean area
close to the weld joint.

OM-275099 Page 21

 A complete Parts List is available at www.MillerWelds.com

SECTION 6 − OPERATION

6-1. Front Panel Controls And Gas Connection

7

11

1012

 Represents a message that displays, scrolls

and repeats.

1 Ready Light (LED)
Light comes on approximately two seconds af-

ter 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 is thermostatically

controlled.

3

9

4

 Represents a particle message that flashes, dis-

plays the remainder of the message, and then re-

8

2 Amperage Adjustment Control
This control adjusts welding amperage.
3 Process Select Button
See Section 6-3.
4 Positive Weld Output Receptacle
For Stick welding, connect electrode cable to

this receptacle. For TIG welding, connect work
cable to this receptacle.

5 Negative Weld Output Receptacle
For Stick welding, connect work cable to this

receptacle. For TIG welding, connect torch
cable to this receptacle.

6 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

peats.

6

7 Power Switch
Place switch in On or Off position as needed.
8 Parameter Display
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 .

Ref. 803375-A / 273310-A

1

8
2

5

6-2. Process Selection (STL Model Only)

=Light On

4

1

2

1

Press

OM-275099 Page 22

=Light Off

3

1

Press

Press

1 Process Selector Button
Use control to select required welding

process. Press Button until LED for de­sired process is illuminated.

2 Lift Arc Start
When selected, a TIG arc starting meth-

od in which the electrode must come in
contact with the workpiece to initiate an
arc is activated (see Section 6-5).

3 Stick (SMAW)
When selected, Adaptive Hot Start ,Stick

Stuck, and DIG circuitry are energized.
4 Stick 6010 (SMAW)
When selected, Adaptive Hot Start ,Stick

Stuck, and DIG circuitry are energized.
Parameters are optimized to run a 6010
Stick electrode.

 A complete Parts List is available at www.MillerWelds.com

6-3. Process Selection (STH Model Only)

=Light Off =Light On

2

3

4

1

Press Press Press

1 Process Selector Button
Use control to select required

welding process. Press Button un­til light (LED) for desired process is
illuminated.

2 TIG Impulse Start
When selected, an impulse HF arc

starting method is activated (see
Section 6-5).

3 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 6-5).

4 Stick (SMAW)
When selected, Adaptive Hot

Start, Stick Stuck and DIG circuitry
are energized.

5

Press

5 Stick 6010 (SMAW)
When selected, Adaptive Hot Start

,Stick Stuck, and DIG circuitry are
energized. Parameters are opti­mized to run a 6010 Stick elec­trode.

6-4. Process Selection (S Model Only)

=Light Off

2

1

Press

=Light On

3

1

Press

1 Process Selector Button
Use control to select required welding

process. Press Button until LED for
desired process is illuminated.

2 Stick (SMAW)
When selected, Adaptive Hot Start

,Stick Stuck, and DIG circuitry are en­ergized.

3 Stick 6010 (SMAW)
When selected, Adaptive Hot Start

,Stick Stuck, and DIG circuitry are en­ergized. Parameters are optimized to
run a 6010 Stick electrode.

OM-275099 Page 23

 A complete Parts List is available at www.MillerWelds.com

6-5. Lift-Arc And TIG Impulse Start Procedures

1

“Touch”

2

1 − 2

Seconds

Do NOT Strike Like A Match!

 Pictorials show Lift-Arc start method − do not

use this method for TIG Impulse starts.

6-6. Accessing Control Panel Menu: TIG−HF (STH Model Only)

2

1

USER

3

Lift-Arc Start

1 TIG Electrode
2 Workpiece
Touch tungsten electrode to work-

piece, hold for 1-2 seconds, slowly
lift electrode, and an arc forms.

Open-circuit voltage maybe present
before electrode touches workpiece.

TIG Impulse

High frequency starts arc when output
is enabled without making contact with
the workpiece. High frequency turns
off when arc is started.

1 Menu Button
While in the High Frequency (HF)

process, press and hold Menu but­ton for approximately two seconds
to access Machine Configuration
menus. Use Menu button to cycle
through parameters that can be set.

2 Parameter Display
3 Encoder
Rotate Encoder to adjust parame-

ter setting.

REMOTE STD

PPS

OM-275099 Page 24

OFF

Trigger Mode Selection:

[REMOTE STD] Remote Standard
Typically used with a remote foot or hand control. REMOTE STD requires

a maintained contact closure to enable weld output. Amperage can be con­trolled with a remote potentiometer, or it can be set at the control panel.

[REMOTE HOLD] Remote Hold
Remote control required. Allows the operator to weld without holding the

trigger closed. To start the weld, operator presses and releases trigger. To
stop the weld, the operator again presses and releases the trigger. In this
mode, only the output contactor is controlled by the remote control. Amper­age must be set on the control panel.

[PPS] Pulse Control:

Reduces heat input to minimize distortion and increase travel speed. Set
PPS (pulse per second). The range is OFF−150 PPS. Background Am­perage and Peak Amperage are not adjustable. Background Amperage
equals 25% of Peak Amperage. Peak Amperage Time equals 40%.

 A complete Parts List is available at www.MillerWelds.com

6-7. Accessing Control Panel Menu: Lift-Arc TIG (STH And STL Models Only)

1 Menu Button
While in the Lift-Arc process, press

and hold Menu button for approxim-

2

1

USER

3

ately two seconds to access Ma­chine Configuration menus. Use
Menu button to cycle through pa­rameters that can be set.

2 Parameter Display
3 Encoder
Rotate Encoder to adjust parame-

ter setting.

REMOTE STD

PPS

OFF

Trigger Mode Selection:

[REMOTE STD] Remote Standard
Typically used with a remote foot or hand control. REMOTE STD requires

a maintained contact closure to enable weld output. Amperage can be con­trolled with a remote potentiometer, or it can be set at the control panel.

[OUTPUT ON] Output on (Lift only)

[PPS] Pulse Control: (STH Model Only)

Reduces heat input to minimize distortion and increase travel speed. Set
PPS (pulse per second). The range is OFF−150 PPS. Background Am­perage and Peak Amperage are not adjustable. Background Amperage
equals 25% of Peak Amperage. Peak Amperage Time equals 40%.

OM-275099 Page 25

 A complete Parts List is available at www.MillerWelds.com

6-8. Accessing Control Panel Menu: Stick

2

1

1 Menu Button
While in the Stick process, press

and hold Menu button for approxim­ately two seconds to access Ma­chine Configuration menus. Use
Menu button to cycle through pa­rameters that can be set.

2 Parameter Display
3 Encoder
Rotate Encoder to adjust parame-

ter setting.

USER

3

OCV

OM-275099 Page 26

NORM

[OCV] Open-Circuit Voltage:

Allows user to select between Normal [Norm] and Low [Low]
open-circuit voltage. Low reduces open-circuit voltage between 12
and 16 volts.

 A complete Parts List is available at www.MillerWelds.com

SECTION 7 − ADVANCED MENU FUNCTIONS

7-1. Accessing Tech Menu For Maxstar 161 Models

2

1

TECH

3

1 Menu Button
Press and hold Menu button for ap-

proximately four seconds to scroll
past User Menu to Tech Menu. Use
Menu button to cycle through para­meters that can be set.

2 Parameter Display
3 Encoder
Rotate Encoder to adjust paramet-

er setting.
To exit Tech Menu, press and hold

menu button approximately one
second, or turn power off.

 Settings in the Tech Menu are

global, meaning they may per­tain to all or some of the pro­cess.

ARC/TCY

STUC

OFF

FACTORY RESET

SOFTWARE NUMBER

[ARC/TCY] Arc Timer: Monitors hours, minutes, and cycles of
valid arc on. To view, rotate encoder. To reset, rotate encoder until
[RESET] [YES] is displayed. Press Menu button to display [RESET]
[Done]. Displays turn to [000] [000].

[STUC] > [OFF] Stick Stuck: Detects if the electrode is stuck or
shorted to the workpiece. Turns weld output off to aid in freeing the
electrode. To turn on, rotate encoder. Not recommended for large
diameter electrodes.

[FACTORY RESET] Machine Reset: Resets all machine values
back to factory defaults. To reset, turn encoder to [RESET] [YES].
Then press Menu button. [RESET] [DONE] will be displayed when
the reset is complete and factory defaults have been restored.

[SOFTWARE NUMBER] Software Number: Software number and
revision will be displayed.

OM-275099 Page 27

 A complete Parts List is available at www.MillerWelds.com

SECTION 8 − MAINTENANCE AND TROUBLESHOOTING

8-1. Routine Maintenance

! Disconnect power before maintaining.

 Maintain more often during severe conditions.

 = Check  = Change  = Clean Δ = Repair  = Replace

* To be done by Factory Authorized Service Agent

Every
3
Months

 Labels   Gas Hoses

Every
3
Months

Δ Cables And Cords

Every
6
Months

:During heavy service, clean monthly.

! Do not remove case when blowing out inside of unit.

8-2. Meter Troubleshooting Displays

1

 Weld Terminals

Blow out inside. Direct airflow through front and back louvers.

RELE

 All directions are in reference to the

front of the unit. All circuitry referred to
is located inside the unit.

1 Typical meter display may be in

several segments. Each segment is
shown for two seconds, and then
scrolls to the remaining segments
of the display. The message then

repeats itself.
Release Trigger Error:
w [RELEASE TRIGGER]

Remote 14 receptacle contactor control
(Pins A−B) must be opened before pro­ceeding.

w [See O.M. ERROR 7.2.3]

Serial Communication to the user interface
card board has been lost. To clear error, turn
off power. If error does not clear or happens

frequently, contact a Factory Authorized
Service Agent.

Over Temperature Errors:

OM-275099 Page 28

w [OVER TEMPERATURE]

Over temperature condition in the primary
inverter circuitry has occurred. Error will
clear after the temperature has reached ac­ceptable levels. Or, over temperature of the
weld output circuitry has occurred. Error will
clear after the temperature has reached ac­ceptable levels.

Temperature Sensor Failure:
w [See O.M. ERROR 3.4.1]

Indicates a short or open in the thermal pro­tection circuitry located in the primary in­verter circuitry of the unit. Contact a Factory
Authorized Service Agent if this display is
shown.

w [See O.M. ERROR 3.3.1]

Indicates a short or open in the thermal pro­tection circuitry located in the weld output
circuitry of the unit. Contact a Factory Au­thorized Service Agent if this display is
shown.

Latching Errors:

w [See O.M. ERROR 1.3.4]

Secondary clamp voltage too high.
Straighten out or shorten weld cables. If this
does not correct the problem, contact a
Factory Authorized Service Agent.

w [See O.M. ERROR 1.4.0]

Indicates failure of primary input circuitry.
Check input power and if error does not
clear contact a Factory Authorized Service
Agent.

w [See O.M. ERROR 1.4.3]

Input current too high. To clear error, re­move power from unit, then reconnect pow­er to unit. If this error does not clear or hap­pens frequently, contact a Factory Autho­rized Service Agent.

Not Valid Error:
w [Not Valid]

Indicates a non-allowable set-up on the
front panel.

8-3. Troubleshooting

Trouble Remedy

 A complete Parts List is available at www.MillerWelds.com

No weld output; unit completely
inoperative.

No weld output; unit on. Check, repair, or replace remote control.

Unit provides only maximum or
minimum weld output.

Erratic or improper weld output.

No control of weld output. Make sure Material Amperage control is in proper position (see Section 6-1).

Lack of high frequency; difficulty in
starting GTAW arc.

Wandering arc − poor control of
direction of arc.

Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.

Place line disconnect switch in On position (see Sections 5-4 or 5-5).

Check and replace line fuse(s), if necessary (see Sections 5-4 or 5-5).

Check for proper input power connections (see Sections 5-4 or 5-5).

Have Factory Authorized Service Agent check unit.

Make sure Material Amperage control is in proper position (see Section 6-1).
Have Factory Authorized Service Agent check unit.

Lay weld cables out straight, do not leave weld cables coiled.
Check position of Process Selector switch (see Section Figure 6-1).
Check position of Amperage control (see Section 6-1).

Be sure torch cable is not close to any grounded metal.

Check cables and torch for cracked insulation or bad connections. Repair or replace.

Reduce gas flow rate (see Section 6-1).

Properly prepare tungsten (see Section 11-2).
Shield weld zone from drafts.

Check and tighten all gas fittings.

Properly prepare tungsten (see Section 11-2).

Fan not operating. Unit equipped with Fan-On-Demand. Fans run only when necessary. Unit equipped with circuitry to

No weld output; fan does not run. Place line disconnect switch in On position (see Sections 5-4 or 5-5).

No weld output; fan on.

Fan not operating; weld output
available.

Error message [See O.M. ERROR

3.4.1] is displayed.

Error message [See O.M. ERROR

3.3.1] is displayed.

Error message [See O.M. ERROR

7.2.3] is displayed.

Error message [See O.M. ERROR

1.4.0] is displayed.

protect against overheating.

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Sections 5-4 or 5-5).

Check for proper input power connections (see Sections 5-4 or 5-5).

Check connection to remote control receptacle (see Section 4-7).

Check remote control (see remote control Owner’s Manual).

Unit overheated. Allow unit to cool (see Section 4-5).

Check for and remove anything blocking fan movement.

Have Factory Authorized Service Agent check fan motor.

Contact a Factory Authorized Service Agent.

Contact a Factory Authorized Service Agent.

Contact a Factory Authorized Service Agent.

Contact a Factory Authorized Service Agent.

OM-275099 Page 29

 A complete Parts List is available at www.MillerWelds.com

Trouble Remedy

Error message [See O.M. ERROR

1.4.3] is displayed.

Error message [See O.M. ERROR

1.3.4] is displayed.

Notes

Contact a Factory Authorized Service Agent.

Contact a Factory Authorized Service Agent.

OM-275099 Page 30

SECTION 9 − ELECTRICAL DIAGRAM

Figure 9-1. Circuit Diagram For Welding Power Source

275094-B

OM-275099 Page 31

SECTION 10 − HIGH FREQUENCY

10-1. Welding Processes Requiring High Frequency

1

1 High-Frequency Voltage
TIG − helps arc jump air gap

between torch and workpiece and/
or stabilize the arc.

TIG

10-2. Installation Showing Possible Sources Of HF Interference

Weld Zone

11, 12

50 ft

(15 m)

10

9

8

7

3

13

2

high_freq 5/10 − S-0693

14

Sources of Direct High-Frequency
Radiation

1 High-Frequency Source (welding

power source with built-in HF or

separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table

OM-275099 Page 32

1

4 5 6

Best Practices

Not Followed

Sources of Conduction of High
Frequency

7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring

Sources of Reradiation of High
Frequency

10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines

S-0694

10-3. Recommended Installation To Reduce HF Interference

6

8

Ground all metal ob­jects and all wiring in
welding zone using
#12 AWG wire.

Nonmetal

Building

3

50 ft

(15 m)

1

Weld Zone

2

4

Ground
workpiece if
required by
codes.

7

50 ft

(15 m)

5

8

Best Practices Followed

1 High-Frequency Source (welding

power source with built-in HF or
separate HF unit)

Ground metal machine case (clean paint
from around hole in case, and use case
screw), work output terminal, line discon­nect device, input supply, and worktable.

2 Center Point of Welding Zone
Midpoint between high-frequency source

and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all

directions.
4 Weld Output Cables
Keep cables short and close together.

Metal Building

8

11

10

5 Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections

using copper straps or braided wire.
Ground conduit every 50 ft (15 m).

6 Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7 External Power or Telephone Lines
Locate high-frequency source at least 50 ft

(15 m) away from power and phone lines.
8 Grounding Rod
Consult the National Electrical Code for

specifications.

9

8

Ref. S-0695 / Ref. S-0695

Metal Building Requirements

9 Metal Building Panel Bonding

Methods

Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.

10 Windows and Doorways
Cover all windows and doorways with

grounded copper screen of not more than
1/4 in (6.4 mm) mesh.

11 Overhead Door Track
Ground the track.

OM-275099 Page 33

SECTION 11 − SELECTING AND PREPARING A TUNGSTEN

FOR DC OR AC WELDING WITH INVERTER MACHINES

gtaw_Inverter_2016-10

Whenever possible and practical, use DC weld output instead of AC weld output.

11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten)

A. Select Tungsten Electrode.

 Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference

the product packaging to identify the tungsten you are using.

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter (DCEN) − Argon

Direct Current Electrode Negative

(For Use With Mild Or Stainless Steel)

2% Ceriated, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens

.010 in. (.25 mm) Up to 15 Up to 15
.020 in. (.50 mm) 5-20 5-20

.040 in. (1 mm) 15-80 15-80
1/16 in. (1.6 mm) 70-150 70-150
3/32 in. (2.4 mm) 150-250 140-235

1/8 in. (3.2 mm) 250-400 225-325
5/32 in. (4.0 mm) 400-500 300-400

3/16 in (4.8 mm) 500-750 400-500

1/4 in. (6.4 mm) 750-1000 500-630

♦Typical argon shielding gas flow rates are 10 to 25 CFH (cubic feet per hour).

Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS).

AC − Argon

Unbalanced Wave

(For Use With Aluminum)

B. Electrode Composition.

Tungsten Type Application Notes

2% Cerium
(Grey*)

1.5−2% Lanthanum
(Yellow/Blue)

2% Thorium
(Red)

Pure Tungsten
(Green)

* Color may vary depending on manufacturer, please refer to manufacturer’s guide for color designation.

Good all−around tungsten for both AC and DC welding.

Excellent low amp starts for AC and DC welding.

Commonly used for DC welding, not ideal for AC.

Not Recommended for inverters!

For best results in most applications use a sharpened cerium or lanthanum electrode for AC and DC welding.

OM-275099 Page 34

11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines

Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires.
Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety
information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust
from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an
environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

1 Grinding Wheel
Grind end of tungsten on fine grit, hard

abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.

2 Tungsten Electrode
A 2% ceriated tungsten is recommended.
3 Ideal Grind Angle Range: 15° to 30°

 30 degrees is the recommended elec-

trode grind angle.

4 Straight Ground
Grind lengthwise, not radial.

Radial Grinding

Causes Wandering Arc

Wrong Tungsten

Preparation

1-1/2 To 4 Times

Electrode Diameter

2

Ideal Tungsten Preparation − Stable Arc

4

1

3

15° to 30°

Notes

OM-275099 Page 35

SECTION 12 − STICK WELDING (SMAW) GUIDELINES

12-1. Electrode and Amperage Selection Chart

ELECTRODE

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

3/32

1/8
5/32
3/16
7/32

1/4
1/16
5/64
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
3/32

1/8
5/32

RANGE

AMPERAGE

50

100

150

200

250

300

350

400

450

ELECTRODE

6010
6011
6013

7014

7018

7024

NI-CL

308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

EP
EP

EP,EN

EP,EN

EP

EP,EN

EP
EP

DC*

AC

HORIZ*

POSITION

ALL
ALL
ALL

ALL

ALL

FLAT

ALL
ALL

PENETRATION

DEEP

MIN. PREP, ROUGH

DEEP

LOW

MED

LOW HYDROGEN,

MED

LOW

LOW
LOW

USAGE

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

Ref. S-087985-A

OM-275099 Page 36

Notes

229895

MATERIAL THICKNESS GAUGE

Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in.)
22 Gauge (.031 in.)
20 Gauge (.037 in.)

18 Gauge (.050 in.)
16 Gauge (.063 in.)
14 Gauge (.078 in.)

1/8 in. (.125 in.)

3/16 in. (.188 in.)

1/4 in. (.25 in.)

5/16 in. (.313 in.)

3/8 in. (.375 in.)

1/2 in. (.5 in.)

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

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you ...

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reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

Effective January 1, 2017

(Equipment with a serial number preface of MH or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions below,
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
retail purchaser that new Miller equipment sold after the effective date of
this limited warranty is free of defects in material and workmanship at
the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS.

Within the warranty periods listed below, Miller will repair or replace any
warranted parts or components that fail due to such defects in material
or workmanship. Miller must be notified in writing within thirty (30) days
of such defect or failure, at which time Miller will provide instructions on
the warranty claim procedures to be followed. If notification is submitted
as an online warranty claim, the claim must include a detailed
description of the fault and the troubleshooting steps taken to identify
failed components and the cause of their failure.

Miller shall honor warranty claims on warranted equipment listed below
in the event of such a failure within the warranty time periods. All
warranty time periods start on the delivery date of the equipment to the
original end-user purchaser, and not to exceed twelve months after the
equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.

1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,

Diodes, and Discrete Rectifier Modules

2. 3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic

Series) (No Labor)

* Engine Driven Welder/Generators

(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)

* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources

3. 2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only

(No Labor)

* Fume Extractors − Capture 5, Filtair 400 and Industrial

Collector Series

4. 1 Year — Parts and Labor Unless Specified
* AugmentedArc and LiveArc Welding Systems
* Automatic Motion Devices
* Bernard BTB Air-Cooled MIG Guns (No Labor)
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options

(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)

* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)

* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* TIG Torches (No Labor)
* Tregaskiss Guns (No Labor)
* Water Cooling Systems
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)

guarantees or warranties expressed or implied.

5. 6 Months — Parts
* Batteries

6. 90 Days — Parts
* Accessory (Kits)
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* M-Guns
* MIG Guns, Subarc (SAW) Torches, and External

Cladding Heads
* Remote Controls and RFCS-RJ45
* Replacement Parts (No labor)
* Spoolmate Spoolguns

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)

2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.

miller_warr 2017-01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2017 Miller Electric Mfg. Co. 2017−01

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.