June 1993 Form: OM-206C

Effective With Serial No. KD375312

OWNER’S
MANUAL

Maxstar 152 And 175

CC/DC Welding Power Source
For GTAW And SMAW Welding

120 A At 25 V Or 140 A At 25.6 V, 100% Duty Cycle

152 Model: Single-Phase; 175 Model: Three-Phase Input Power
Thermostat Protection Against Overheating

Touch Start For GTAW Welding

14-Pin Remote Control Receptacle

Read and follow these instructions and all Give this manual to the operator.
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit. For help, call your distributor

Call your distributor if you do not understand or: MILLER ELECTRIC Mfg. Co., P.O. Box
the directions. 1079, Appleton, WI 54912 414-734-9821
cover 8/92 – SA-145 666-B PRINTED IN USA
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 Working as hard as you do
– every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
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
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard. particular model are also provided.

Miller offers a Technical

Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
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 orindividual catalog 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.
 EMF INFORMATION
Considerations About Welding And The Effects Of Low Frequency Electric And
NOTE Magnetic Fields
The following is a quotation from the General Conclusions Section of To reduce magnetic fields in the workplace, use the following
the U.S. Congress, Office of Technology Assessment, Biological procedures:
Effects of Power Frequency Electric & Magnetic Fields –
1. Keep cables close together by twisting or taping them.
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very large 2. Arrange cables to one side and away from the operator.
volume of scientific findings based on experiments at the cellular
3. Do not coil or drape cables around the body.
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and 4. Keep welding power source and cables as far away as practical.
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific 5. Connect work clamp to workpiece as close to the weld as
possible.
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet About Pacemakers:
allow us to draw definite conclusions about questions of possible risk The above procedures are among those also normally
or to offer clear science-based advice on strategies to minimize or recommended for pacemaker wearers. Consult your doctor for
avoid potential risks.” complete information. mod10.1 4/93

TABLE OF CONTENTS

SECTION 1 – SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 2 – SPECIFICATIONS
2-1. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2-2. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 3 – INSTALLATION
3-1. Typical Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-2. Selecting A Location And Moving Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-3. Selecting And Preparing Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-4. Connecting To Weld Output Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-5. Remote 14 Receptacle Information And Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-6. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-3. Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-4. Changing Amperage/Voltage Meter Hold Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 6 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 7 – TUNGSTEN ELECTRODE

7-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7-2. Preparing Tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SECTION 8 – PARTS LIST

Figure 8-1. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 8-2. Module, Power & Diode (175 Model Illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OM-206C – 6/93
 SECTION 1 – SAFETY INFORMATION
mod1.1 2/93

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.

1 Safety Alert Symbol

2 Signal Word
1 2 2
WARNING means possible death
or serious injury can happen.
WARNING 3 CAUTION CAUTION means possible minor
ELECTRIC SHOCK can kill. MOVING PARTS can injure. injury or equipment damage can
• Do not touch live electrical parts. • Keep away from moving parts. happen.
• Disconnect input power before 4 • Keep all panels and covers closed 3 Statement Of Hazard And
installing or servicing. when operating.
Result
4 Safety Instructions To Avoid
5 Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
WARNING READ SAFETY BLOCKS at start of Read safety blocks for each sym-
6 Section 3-1 before proceeding.
bol shown.
7 NOTE

7 NOTE Turn Off switch when using high frequency. Special instructions for best oper-
ation – not related to safety.

Figure 1-1. Safety Information

SECTION 2 – SPECIFICATIONS

NOTE Unless otherwise noted, the 175 model is shown throughout this manual.

Table 2-1. Welding Power Source

Specification Description

Type Of Output Constant Current (CC), Direct Current (DC)

Welding Process Gas Tungsten Arc (GTAW), Shielded Metal Arc (SMAW) Welding

Options See Rear Cover

152 Models 175 Models

Rated Weld Output 120 Amperes, 25 Volts DC At 100% Duty Cycle 140 Amperes, 26.5 Volts DC At 100% Duty Cycle
(See Section 2-2) (See Section 2-2)

Type Of Input Power 230 Volts AC; 50/60 Hz; Single Phase 460 Volts AC; 50/60 Hz; Three-Phase

Input Amperes At Rated Output 25 A 12.5 A

KVA/KW Used At Rated Output 5.85 kVA/3.8 kW 9.56 kVA/5.26 kW

Amperage Range 1-150 A 1-175 A

Max. Open-Circuit Voltage 95 Volts DC 95 Volts DC

Overall Dimensions Length: 16-1/2 in (419 mm); Width: 9-1/2 in (241 Length: 16-1/2 in (419 mm); Width: 9-1/2 in (241
mm); Height: 8 in (203 mm) mm); Height: 10 in (254 mm)

Weight Net: 31 lb (14 kg); Ship: 36 lb (16 kg) Net: 39 lb (18 kg); Ship: 42 lb (19 kg)

OM-206 Page 1
2-1. Volt-Ampere Curves

The volt-ampere curves show the

minimum and maximum voltage
and amperage output capabilities
of the welding power source.
Curves of other settings fall be-
tween the curves shown.
A. 152 Model B. 175 Model

ssb1.1 10/91 – SB-151 604 / SB-143 476-B

Figure 2-1. Volt-Ampere Curves

2-2. Duty Cycle

CAUTION
EXCEEDING DUTY CYCLE RATINGS will damage unit.
• Do not exceed indicated duty cycles. warn7.1 2/92

Duty cycle is how long the unit can

operate within a ten minute period
without causing overheating or
damage.
This unit is rated at 100% duty
cycle allowing continuous opera-
A. 152 Model B. 175 Model tion at rated load.

sb1.1 2/92 – SB-121 591-B / SB-144 507-B

Figure 2-2. Duty Cycle Chart

OM-206 Page 2
 SECTION 3 – INSTALLATION
3-1. Typical Process Connections
SMAW

Welding
Power Source Work

Remote Control

14 Pin GTAW

Welding
Power Source HF Unit
Work

GTAW Scratch Start

Pulse Control Pulsed GTAW
14 Pin Or
GTAW
Welding
Power Source Work

Figure 3-1. Typical Process Connections

3-2. Selecting A Location And Moving Welding Power Source

WARNING
ELECTRIC SHOCK can kill. FUMES can be hazardous; LACK OF
• Do not touch live electrical parts. FRESH AIR AND PROPER
• Disconnect input power conductors from VENTILATION can be harmful.
deenergized supply line BEFORE moving welding • Do not breathe welding fumes.
power source. • Place unit only where there is a good fresh air
FIRE OR EXPLOSION can result from supply and proper ventilation.
placing unit on, over, or near
combustible surfaces. FALLING EQUIPMENT can cause
• Do not locate unit on, over, or near combustible serious personal injury and equipment
surfaces. damage.
• Do not install unit near flammables. • Use handle to lift unit.
BLOCKED AIRFLOW causes • Have person of adequate physical strength lift unit.
overheating and possible damage to • Move unit with hand cart or similar device.
unit.
• Do not block or filter airflow.
Warranty is void if any type of filter is used. swarn11.1* 2/92

1 10 in (254 mm) Open Space

1 2 On Right Side And Rear Of
Unit For Good Airflow
Rear
2 Lifting Handle
Use handle to move unit.
3 Rating Label
Locate unit near correct input pow-
Right er supply.
3

Ref. SA-145 666-B

Figure 3-2. Location And Movement Of Welding Power Source

OM-206 Page 3
3-3. Selecting And Preparing Weld Output Cables

1 Weld Output Cable

3 Determine total cable length in

4 weld circuit and maximum welding
amperes. Use Table 3-1 to select
OR proper cable size.
Use shortest cables possible.
Do not use damaged cables.
2 Terminal Lug
Use lugs of proper amperage
2 capacity and hole size for connect-
ing to work clamp or electrode
1 holder.
3 Insulated Electrode Holder
10 ft (3 m) 4 GTAW Torch
For Example, Install according to manufacturer’s
Total Cable instructions.
6 Length In Weld
5 Circuit = 20 ft (6 m) 5 Work Clamp
Install onto work cable.
10 ft (3 m) 6 Dinse-Type Connector
Tools Needed:
Install onto weld cable as shown in
Figure 3-4.
sb6.2* 11/92 – S-0656

Figure 3-3. Selecting And Preparing Weld Output Cables

Table 3-1. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding

150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Welding 10 To 60% 60 Thru 100%
10 Thru 100% Duty Cycle
Amperes Duty Cycle Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of not more than 300 circular mils per ampere. S-0007-C

3 1 Weld Output Cable

1
2 Handle
2
3 Sleeve
Slide handle onto cable; strip cable
and install sleeve.
1 in
4 Connector Body
(26 mm)
5 Setscrew

5 Insert cable with sleeve fully into

connector body, tighten setscrew,
4 and slide handle over connector.
If job requires cable larger than 3/0
3 AWG, use 2 ft (610 mm) or shorter
piece of 3/0 AWG cable for Dinse-
Type connector installation. Con-
nect other end of short cable to the
4/0 or larger weld cable.

Tools Needed:

ST-156 496

Figure 3-4. Dinse-Type Connector Assembly

OM-206 Page 4
3-4. Connecting To Weld Output Receptacles

WARNING
ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical equipment.
• Do not touch live electrical parts.
• Turn Off welding power source before making any weld output connections.
• Do not change position of welding cable connectors while welding.
• Be sure connectors are secure in receptacles before welding. swarn12.2 2/93

1 Positive (+) Weld Output

1 Receptacle
4
2 Negative (–) Weld Output
Receptacle
3 Connector
For Electrode Positive (DCEP),
connect work cable connector to
negative (–) receptacle and elec-
trode holder cable connector to
positive (+) receptacle.
For Electrode Negative (DCEN),
2 reverse cable connections.
Align keyway, insert connector,
and turn clockwise.
4 Remote 14 Receptacle (see
3 Section 3-5).

Ref. SC-140 373 / Ref. ST-152 126

Figure 3-5. Connecting To Weld Output Receptacles

3-5. Remote 14 Receptacle Information And Connections

1 2 1 Remote 14 Receptacle RC7
2 Keyway
3 Plug
A J
K I 4 Threaded Collar
B
To connect to this receptacle, align
C L N H
keyway, insert plug, and tighten
D M G threaded collar.
E F

Socket Information:
Remote Contactor
A +15 volts dc
B Contact closure to pin A completes +15 volts dc con-
tactor control circuit.
Remote Amperage/Voltage Control
C Command reference; +10 volts dc.

Rear Panel 4 D Control circuit common.

E Input command signal (potentiometer wiper or 0 to
3
+10 volts dc).
K Chassis common.
The remaining sockets are not used.

sb7.1* 8/92 – Ref. SC-140 373 / Ref. S-0004-A / S-0750

Figure 3-6. Remote 14 Connections

OM-206 Page 5
3-6. Connecting Input Power

WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off welding power source, and disconnect input power before inspecting or installing.
• Have only qualified persons install unit.
• Installation must meet National Electrical Code and all other codes. swarn3.1 2/93

A. Connecting Input Power To 152 Models

1 230 VAC Cord/Plug

2 230 VAC Grounded
1
Receptacle
An individual branch circuit capa-
ble of carrying 25 amperes, and
including overcurrent protection
2 such as fuses or circuit breaker is
required. Recommended standard
fuse or circuit breaker rating is 40
amperes.
Connect input power plug to proper
230 VAC receptacle.

ST-156 250

Figure 3-7. Input Power Connections

B. Connecting Input Power To 175 Models

Table 3-2. Electrical Service Requirements For 175 Ampere Models*

Input Voltage 460

Input Amperes At Rated Output 12

Recommended Standard Fuse Or Circuit Breaker Rating In Amperes1 20

Input Conductor Size In AWG/Kcmil2 14

Max Input Conductor Length In Feet (Meters)3 326 (99)

Grounding Conductor Size In AWG/Kcmil4 14

* These values are calculated from the 1990 edition of the National Electrical Code (NEC).
1 Recommended fuse or circuit breaker size is that closest to 150% of rated input amperage of the welding power
source. Article 630-12(a) of NEC allows fuse or circuit breaker sizing up to 200% of rated input amperage.
2 Input conductor size is for insulated copper wire with 75°C rating with not more than three single current-carrying
conductors in a cable or raceway (Table 310-16 of NEC).
3 Maximum length is to prevent more than a 3% voltage drop between service entrance and input terminals of the
welding power source (Articles 210-19(a) and 215-2(b) of NEC).
4 The grounding conductor shall be colored or identified as specified in the NEC. Grounding conductor size for
copper wire is not required to be larger than input conductor (Article 250-95 of NEC). S-0092-F
OM-206 Page 6
 Have only qualified persons make
this installation.
Remove wrapper.
7 3 1 Line Disconnect Device Of
Proper Rating
2 Input Conductors
3 Grounding Conductor
Select size and length using
4 Table 3-2. Conductor rating must
comply with national, state, and lo-
cal electrical codes.
Strip 3/8 in (10 mm) insulation off
all conductors.
6
2 4 Strain Relief Connector
5 Insert conductors through strain
relief.
5 Input Terminal Block
6 Line Terminals
7 Ground Terminal
Insert grounding conductor into
grounding terminal and tighten
screw.
Insert each input conductor into
proper screw terminal L1, L2, or L3
on terminal block and tighten
screws.
Install and connect grounding
conductor and input conductors in
conduit or equivalent to deener-
gized line disconnect device.
Be sure grounding conductor goes
to an earth ground.
Reinstall wrapper.
8 Overcurrent Protection
Select type and size using
Table 3-2. Install into deenergized
line disconnect device (fused
disconnect switch shown)

Tools Needed:

5/16 in

ssb2.4* 3/93 – ST-145 667-B / SA-145 666-B

Figure 3-8. Input Power Connections

OM-206 Page 7
 SECTION 4 – OPERATION

WARNING
ELECTRIC SHOCK can kill. ARC RAYS can burn eyes and skin;
• Always wear dry insulating gloves. NOISE can damage hearing.
• Insulate yourself from work and ground. • Wear welding helmet with correct shade of filter.
• Do not touch live electrical parts. • Wear correct eye, ear, and body protection.
• Keep all panels and covers securely in place.
MOVING PARTS can cause injury.
FUMES AND GASES can be hazardous
to your health. • Keep away from moving parts.
• Keep your head out of the fumes. • Keep all doors, panels, covers, and guards closed
and securely in place.
• Ventilate area, or use breathing device.
• Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used. MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
WELDING can cause fire or explosion. • Pacemaker wearers keep away.
• Do not weld near flammable material.
• Wearers should consult their doctor before going
• Watch for fire; keep extinguisher nearby. near arc welding, gouging, or spot welding opera-
• Do not locate unit over combustible surfaces. tions.
• Do not weld on closed containers.
See Safety Precautions at beginning of manual for ba-
• Allow work and equipment to cool before handling. sic welding safety information. swarn6.1 10/91

3 4 5 6 1 Amperage Adjustment
2 Control
2 Amperage Control Switch
1 3 Output (Contactor) Switch
7
4 Touch Start Switch
5 Weld Process Switch
6 Power Switch
7 Pilot Light
8 8 Optional Amperage/Voltage
Meter And Switch

ST-152 127

Figure 4-1. Controls

1 2 3 1 Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet
Wear dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct
shade of filter (see ANSI Z49.1).
sb3.1 10/91

Figure 4-2. Safety Equipment

1 Work Clamp
1
Tools Needed: Connect work clamp to a clean,
paint-free location on workpiece,
as close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
sb4.1 2/93

Figure 4-3. Work Clamp

OM-206 Page 8
 WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Do not touch weld output receptacles when contactor is energized.
• Do not touch electrode and work clamp at the same time. swarn7.1* 10/91

1 Output (Contactor) Switch

Use switch to select way of control-
ling output.
For front panel control, place
switch in On position.
1 For remote control, place switch in
Remote 14 position (see Section
3-5).

Weld output receptacles are energized

when switch is On and Power is On.

Figure 4-4. Output (Contactor) Switch

1 Amperage Adjustment Control

Use control to select weld amper-
age. Amperage may be adjusted
while welding.
2 Amperage Control Switch
Use switch to select way of control-
ling amperage adjustment.
For front panel control, place switch
in the Panel position.
For remote control, place switch in
Remote 14 position (see Section
3-5).
2
3 Remote Foot Control
1 4 Remote Hand Dial
5 Remote Fingertip Control
See Example below.
5

EXAMPLE Of Combination Remote Amperage Control

3
Unit
Minimum

Control
Setting
(80 A)

Set Switches Set Control Adjust Remote Control

ST-159 059 / Ref. SC-140 372-C / S-0769

Figure 4-5. Amperage Controls

OM-206 Page 9
 1 Weld Process Switch
Use switch to select type of weld
output current. Use GTAW position
for Gas Tungsten Arc Welding.
1 Use SMAW position for Shielded
Metal Arc Welding.
Switch position determines the op-
eration of the Touch Start switch
(see Figure 4-7).

Figure 4-6. Weld Process Switch

NOTE Touch Start switch must be in Off position when using a High-Frequency unit with
this welding power source, or when using the SMAW welding process.

1 Touch Start Switch

Use switch to select touch start On
or Off.
With touch start On, start an arc in
2 3 GTAW welding as follows:
2 GTAW Electrode
3 Workpiece
Touch tungsten electrode to work-
piece at weld start point, hold elec-
1–2
“Touch” Seconds trode to workpiece for 1-2 sec-
1 onds, and slowly lift electrode. An
arc will form when electrode is
lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present be-
tween electrode and workpiece.
The solid-state output contactor
does not energize until after tung-
sten electrode is touching work-
piece. This allows electrode to
Do NOT Strike Like A Match! touch workpiece without overheat-
ing, sticking, or getting contami-
nated. Ref. S-156 279

Figure 4-7. Touch Start Switch

1 Power Switch
Use switch to turn unit and pilot
2 light On and Off.
2 Pilot Light

Figure 4-8. Power Switch And Pilot Light

OM-206 Page 10
 1 Amperage/Voltage Meter
Meter displays amperage or volt-
age output.
1 2 Meter Switch
Use switch to select amperage (A)
or voltage (V) display.
2 In Volts position, the meter dis-
plays the voltage at the weld output
receptacles. In Amperage posi-
tion, the meter displays the welding
current during welding, and the
preset amperage when welding is
not taking place.
The meter displays the actual val-
ue for 15 seconds after welding
stops (see Section 5-4).

Figure 4-9. Optional Amperage/Voltage Meter And Switch

Install & Install & Connect Select Insert Put On

Connect High-Frequency Tungsten (See Tungsten Personal Safety Set Controls
Equipment Unit Section 7) Into Torch Equipment

Turn On Turn On Turn On

Shielding Gas High-Frequency Welding Power Begin Welding
Unit Source
ssb8.1 12/92

Figure 4-10. Sequence Of Gas Tungsten Arc Welding (GTAW)

Install & Install & Connect Install & Connect Select Insert Put On
Connect Pulser Control High-Frequency Tungsten (See Tungsten Personal Safety
Equipment Unit Unit Section 7) Into Torch Equipment

Turn On Turn On Pulser Turn On

Set Controls Shielding Gas And High- Welding Power Begin Welding
Frequency Unit Source

Figure 4-11. Sequence Of Gas Tungsten Arc Welding - Pulsed (GTAW-P)

Install & Select Put On Insert Turn On

Connect Electrode Personal Safety Set Controls Electrode Welding Power
Equipment Equipment Into Holder Source

Begin Welding

ssb7.1 9/92

Figure 4-12. Sequence Of Shielded Metal Arc Welding (SMAW)

OM-206 Page 11
 SECTION 5 – MAINTENANCE & TROUBLESHOOTING

WARNING
ELECTRIC SHOCK can kill; MOVING PARTS can cause injury.
SIGNIFICANT DC VOLTAGE exists after • Keep away from moving parts.
removal of input power.
• Do not touch live electrical parts.
• Turn Off welding power source, disconnect input
power, wait 60 seconds, measure voltage on input STATIC ELECTRICITY can damage parts
capacitors according to Section 5-3, and wait for on circuit boards.
voltage to drop to zero before touching any parts. • Put on grounded wrist strap BEFORE handling
boards or parts.
HOT PARTS can cause severe burns.
• Allow cooling period before maintaining or
servicing.
Maintenance to be performed only by qualified
persons.
swarn8.1* 2/93

5-1. Routine Maintenance

3 Months Turn Off all power before maintaining. 3 Months

Tape Or
Replace
Cracked
Cables
3-3

Clean
Replace And
See Unreadable Tighten
Section Labels Weld
8 3-4 Connections

Replace 6 Months
Cracked
Parts
14-Pin Cord Blow Out
OR Or
Vacuum
–– Inside

Gas
–– Hose Torch Cable
ST-145 666-B

Figure 5-1. Maintenance Schedule

5-2. Overload Protection

Thermostats TP1 and TP2 protect the unit from damage due to overheating. If the unit gets too hot, TP1 and/or TP2
open and weld output stops. The pilot light stays on, and the fan keeps running to cool the transformer. Wait several
minutes before trying to weld.

OM-206 Page 12
5-3. Measuring Input Capacitor Voltage

WARNING READ SAFETY BLOCKS at start of

Section 5 before proceeding.

Significant DC voltage can remain on capacitors after unit Turn Off welding power source and
is Off. Always check capacitors as shown to be sure they disconnect input power.
have discharged before working on unit. Remove wrapper.
1 Input Capacitor C1 (Both
Models)
2 Input Capacitor C2 (175
3 Models Only)
3 Voltmeter
Check input capacitor(s).
Measure the dc voltage across the
positive (+) and negative (–) termi-
nals every 30 seconds until voltage
drops to 0 (zero) volts.
Proceed with job inside unit.
Reinstall wrapper when finished.

1
2

Tools Needed:
5/16 in
ST-153 136-A

Figure 5-2. Measuring Input Capacitor Voltage

5-4. Changing Amperage/Voltage Meter Hold Function

WARNING READ SAFETY BLOCKS at start of

Section 5 before proceeding.

The Amperage/Voltage meter is

able to hold the displayed weld out-
put value for 15 seconds after
welding stops. This procedure al-
2 lows the hold function to be turned
On or Off.
1

ON
If the hold function is not used, the
OFF
2

displayed value leaves when weld-

1 Hold Not Used ing stops.
Turn Off welding power source,
disconnect input power, and check
3
1

OFF voltage on input capacitors ac-

cording to Section 5-3 before pro-
ON
2

ceeding.
Hold Used 1 A/V Meter Board PC3
4
2 DIP Switch S2
3 Toggle 1
4 Toggle 2
Tools Needed:
Set toggles in desired position. Re-
install wrapper. ST-158 741

Figure 5-3. Changing Amperage/Voltage Meter Hold Function

OM-206 Page 13
5-5. Troubleshooting

WARNING
ELECTRIC SHOCK can kill. MOVING PARTS can cause injury.
SIGNIFICANT DC VOLTAGE exists after • Keep away from moving parts.
removal of input power.
• Do not touch live electrical parts.
• Turn Off welding power source, disconnect input
power, wait 60 seconds, measure voltage on input STATIC ELECTRICITY can damage parts
capacitors according to Section 5-3, and wait for on circuit boards.
voltage to drop to zero before touching any parts. • Put on grounded wrist strap BEFORE handling
boards or parts.
HOT PARTS can cause severe burns. • Use proper static-proof bags and boxes.
• Allow cooling period before servicing.
Troubleshooting to be performed only by qualified
persons.
swarn9.1* 2/93

Table 5-1. Welding Trouble

Trouble Remedy Section
No weld output; unit completely inop- Be sure Power switch is On. Figure 4-8
erative.
Secure power cord plug in receptacle (152 model). 3-6A
Be sure line disconnect switch is On (175 model). 3-6B
Check line fuse(s) and replace if necessary. Reset circuit 3-6
breakers.
Check for proper input power connections. 3-6

No weld output; fan motor running and Check position of Output (Contactor) switch. Figure 4-4
pilot light on.
Thermostats TP1 and/or TP2 open (overheating). Allow fan to 5-2
run; thermostat(s) closes when unit has cooled.

Low weld output with no control. Check position of Amperage Control switch. Figure 4-5
Have Factory Authorized Service Station/Service Distributor ––
check control board PC1.

Limited output and low open-circuit Check incoming power for correct voltage. Replace line fuse if 3-6
voltage. open or reset circuit breaker.
Check for proper input and output connections. 3-3, 3-4, 3-6

Erratic or improper weld output. Tighten all welding cable connections. 3-3, 3-4
Check for proper size and type of cable. 3-3
Check for proper input and output connections. 3-3, 3-4, 3-6
Replace electrode. 7-1, 7-2

Arc not forming when using Touch Check electrode and workpiece, clean as needed to allow good ––
Start. contact.

Fan motor does not run. Check and clear blocked fan blade; be sure blade is secure on ––
shaft.
Have Factory Authorized Service Station/Service Distributor ––
check fan motor.

OM-206 Page 14
 Trouble Remedy Section
Wandering arc; poor control of arc di- Reduce gas flow rate. ––
rection.
Select proper size tungsten. 7-1
Properly prepare tungsten. 7-2

Tungsten electrode oxidizing and not Shield weld zone from drafts. ––
remaining bright after conclusion of
weld.
Increase postflow time. ––
Check and tighten all gas fittings. ––
Water in torch. Refer to torch Owner’s Manual for part(s) requir- ––
ing replacement, and repair torch as necessary.

OM-206 Page 15
OM-206 Page 16
SECTION 6 – ELECTRICAL DIAGRAMS

SC-158 547-A

Figure 6-1. Circuit Diagram For 152 Model

 SC-153 157

OM-206 Page 17
Figure 6-2. Circuit Diagram For 175 Model
 Figure 6-3. Wiring Diagram For 152 Model
OM-206 Page 18
 SD-158 546-A

OM-206 Page 19
 Figure 6-4. Wiring Diagram For 175 Model
OM-206 Page 20
 SD-153 153-A

OM-206 Page 21
 SECTION 7 – TUNGSTEN ELECTRODE
mod2.1 3/93

NOTE For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.
Wear clean gloves to prevent contamination of tungsten electrode.

7-1. Selecting Tungsten Electrode

Table 7-1. Tungsten Size

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter DC – Argon – Electrode DC – Argon – Electrode AC – Argon – Using AC – Argon – Balanced
Negative/Straight Polarity Positive/Reverse Polarity High Frequency Wave Using High Freq.
Pure Tungsten
(Green Band)
.010” Up to 15 * Up to 15 Up to 10
.020” 5-20 * 5-20 10-20
.040” 15-80 * 10-60 20-30
1/16” 70-150 10-20 50-100 30-80
3/32” 125-225 15-30 100-160 60-130
1/8” 225-360 25-40 150-210 100-180
5/32” 360-450 40-55 200-275 160-240
3/16” 450-720 55-80 250-350 190-300
1/4” 720-950 80-125 325-450 250-400
2% Thorium Alloyed
Tungsten (Red Band)
.010” Up to 25 * Up to 20 Up to 15
.020” 15-40 * 15-35 5-20
.040” 25-85 * 20-80 20-60
1/16” 50-160 10-20 50-150 60-120
3/32” 135-235 15-30 130-250 100-180
1/8” 250-400 25-40 225-360 160-250
5/32” 400-500 40-55 300-450 200-320
3/16” 500-750 55-80 400-500 290-390
1/4” 750-1000 80-125 600-800 340-525
Zirconium Alloyed Tung-
sten (Brown Band)
.010” * * Up to 20 Up to 15
.020” * * 15-35 5-20
.040” * * 20-80 20-60
1/16” * * 50-150 60-120
3/32” * * 130-250 100-180
1/8” * * 225-360 160-250
5/32” * * 300-450 200-320
3/16” * * 400-550 290-390
1/4” * * 600-800 340-525

♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers. S-0009

OM-206 Page 22
7-2. Preparing Tungsten

1 Tungsten Electrode
1 2 Balled End
Ball end of tungsten before welding
by applying either an ac amperage
slightly higher than what is recom-
1-1/2 Times mended for a given electrode diam-
Electrode Diameter
eter (see Table 7-1), or a dc elec-
trode positive amperage.

2
Ref. S-0161

Figure 7-1. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding

CAUTION
FLYING SPARKS AND HOT METAL can cause injury and start fires.
• Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
• Keep flammables away.
warn2.1 9/91

1 Tungsten Electrode
1 2
2 Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld-
ing. Do not use wheel for other jobs
or tungsten can become contami-
nated causing lower weld quality.

2-1/2 Times
Electrode Diameter
Ref. S-0161

1 1 Stable Arc
2 Flat
2
Diameter of this flat determines am-
perage capacity.
3 Grinding Wheel
3
4 Straight Ground

4
Ideal Tungsten Preparation – Stable Arc Ref. S-0162

1 1 Arc Wander
2 Point
2 3 Grinding Wheel
4 Radial Ground

Wrong Tungsten Preparation – Wandering Arc Ref. S-0162

Figure 7-2. Preparing Tungsten For DC Electrode Negative (DCEN) Welding

OM-206 Page 23
 1
28 29
2
27
Fig 8-2
3
26
25

OM-206 Page 24
4 5 6 7
8
9 24

10 23

11

12 22

13
51 52 21
53 9
14 20
50 54
55
15
16 19
17 18 10
49

48
12

15
47
SECTION 8 – PARTS LIST

30

46
44 31
45 32
34
43
42 35

41 40 39 38 37 36 33 6

ST-145 668-E

Figure 8-1. Main Assembly (175 Model Illustrated)

 Quantity
Item Dia. Part Model
No. Mkgs. No. Description 152 175

Figure 8-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . . . 126 416 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1

. . . 2 . . . . . . . . . . . . . . . . 126 415 . . CLAMP, saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 3 . . . . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 4 . . . . . . . . . . . . . . . +151 755 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . +140 620 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . PC1 . . . . . 156 858 . . CIRCUIT CARD, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . PLG1,2 . . . 131 052 . . HOUSING RECEPTACLE & SOCKETS, (consisting of) . . . . . 2 . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . 16 . . . . 16
. . . . . . . . . . . PLG3 . . . . 131 056 . . HOUSING RECEPTACLE & SOCKETS, (consisting of) . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . 14
. . . . . . . . . . . PLG5 . . ++130 203 . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . 12
. . . . . . . . . . . PLG8 . +++115 092 . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 8
. . . 6 . . . . . . . . . . . . . . . . 141 690 . . GROMMET, scr No. 8/10 panel hole .281sq .197 high . . . . . . 6 . . . . 6
. . . 7 . . . . . . . . . . . . . . . . 140 627 . . INSULATION, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 8 . . . . . . . . . . . . . . . . 151 280 . . BRACKET, mtg PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . +141 520 . . BRACKET, mtg PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . C1 . . . . . 151 281 . . CAPACITOR, elctlt 1600uf 400VDC . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . C1,2 . . . . . 124 696 . . CAPACITOR, elctlt 1700uf 400VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . . . 006 426 . . CLAMP, capacitor 2.000dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 2
. . . 11 . . . . . . . . . . . . . . . . 153 178 . . LABEL, warning exploding parts etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . . 136 190 . . NUT, speed U type 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 4
. . . 13 . . . . . . . . . . . . . . . . 133 405 . . NUT, speed 10-24 flat type rectangular . . . . . . . . . . . . . . . . . . . 1 . . . . 2
. . . 14 . . . . . . . . . . . . . . . . 130 215 . . PLATE, output rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . . 140 373 . . PLATE, output rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . Neg,Pos . . . 129 525 . . RECEPTACLE, twlk insul fem (Dinse type) 50/70 series . . . . 2 . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 042 418 . . CONNECTOR KIT, Dinse male 50 series . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 16 . . . . . . . . . . . . . . . . 145 743 . . LUG, univ w/scr 600V 2-14 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . . . 111 443 . . BUSHING, strain relief .240/.510 ID x .875mtg hole . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 120 484 . . CORD SET, 250V 6-50P 12ga 3/c 8ft . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . . 010 916 . . CONNECTOR, clamp cable .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . TE1 . . . . . 147 386 . . BLOCK, term 70A 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . . 147 255 . . BRACKET, mtg terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . . 119 757 . . BAR, support heat sink bottom . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 21 . . . . . . . . . . . . . . . . 126 372 . . STRIP, polyest gl lam .187 x .250 x .625 . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 22 . . . . . . . . . . . . . . . . 140 626 . . STRIP, polyest gl lam .187 x .500 x 2.250 . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 23 . . . . . . . . . . . . . . . +128 803 . . BAR, support heat sink top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 24 . . . . . . CT1 . . . . . 150 925 . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . Fig 8-2 . . MODULE, power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 26 . . . . . . . . . . . . . . . . . Fig 8-2 . . MODULE, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 27 . . . . . . . . . . . . . . . . 141 515 . . STRIP, polyest gl lam .187 x .500 x .812 . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 28 . . . . . . . . . . . . . . . . 126 026 . . LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 29 . . . . . . . . . . . . . . . . 119 943 . . STRIP, polyest gl lam .187 x .500 x 6.500 . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . . 140 380 . . STRIP, polyest gl lam .187 x .500 x 8.687 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . Z1 . . . . . . 130 794 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . Z1 . . . . . . 131 866 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . 019 663 . . MOUNT, nprn 15/16 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4
. . . 32 . . . . . . HD1 . . . . . 156 149 . . TRANSDUCER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . HD1 . . . . . 124 684 . . TRANSDUCER, current 300A module supply . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . PLG10 . . . . 130 204 . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 114 066 . . . . CONNECTOR, rect skt 20-14ga . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3
. . . 33 . . . . . . . T1 . . . . . . 151 585 . . TRANSFORMER, pwr main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . T1 . . . . . . 141 669 . . TRANSFORMER, pwr main 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . R2 . . . . . 139 203 . . RESISTOR, WW fxd 30W 8K ohm . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . R2,3 . . . . . 139 203 . . RESISTOR, WW fxd 30W 8K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . R1 . . . . . 136 076 . . RESISTOR, WW fxd 30W 200 ohm . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 36 . . . . . . . . . . . . . . . . 141 422 . . INSULATOR, flat pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
OM-206 Page 25
 Quantity
Item Dia. Part Model
No. Mkgs. No. Description 152 175

Figure 8-1. Main Assembly (Continued)

. . . 37 . . . . . . . S1 . . . . . 090 328 . . SWITCH, tgl DPST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . PLG11 . . . . 115 094 . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . RC11 . . . . 115 090 . . HOUSING PLUG & PINS, (consisting of) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 114 656 . . . . CONNECTOR, rect pin 24-18ga . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . 047 838 . . BLANK, snap-in nyl 1.000mtg hole . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . S1 . . . . . 091 441 . . SWITCH, tgl 3PST 40A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . . 148 297 . . NUT, speed U type 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 39 . . . . . . . . . . . . . . . . 146 684 . . INSULATOR, switch pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . CR1 . . . . . 106 462 . . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . 1 . . . . 1
. . . 42 . . . . . . PL1 . . . . . 135 199 . . LIGHT, ind red lens 28V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 43 . . . . . . S2-5 . . . . . 120 376 . . SWITCH, rocker SPDT 4A 250VAC . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4
. . . 44 . . . . . . . . . . . . . . . ♦042 880 . . METER KIT A & V DC, (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . ♦042 613 . . METER KIT A & V DC, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . . . 133 644 . . . . FRAME, snap-in switch rocker panel mtg . . . . . . . . . . . . . . . 1 . . . . 1
. . . 46 . . . . . . PC3 . . . . . 157 587 . . . . CIRCUIT CARD, meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . PLG9 . . . . 089 222 . . . . CONNECTOR, plug 11posn . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 136 339 . . COVER, opening meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 47 . . . . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 48 . . . . . . R4 . . . . . 073 562 . . POTENTIOMETER, C sltd sft 1/T 2W 10K ohm . . . . . . . . . . . 1 . . . . 1
. . . 49 . . . . . . . . . . . . . . . . 151 533 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . . . 146 333 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . . . 134 756 . . LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . C12 . . . . . 135 286 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 52 . . . . . . C13 . . . . . 135 289 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 53 . . . . . . C14 . . . . . 141 524 . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 53 . . . . . . C15 . . . . . 141 525 . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 53 . . . . . . C16 . . . . . 141 522 . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 53 . . . . . . C17 . . . . . 141 523 . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 54 . . . . . . RC7 . . . . . 143 976 . . RECEPTACLE w/SOCKETS, (consisting of) . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 079 534 . . . . CONNECTOR, circ skt push-in 14-18ga . . . . . . . . . . . . . . . . 14 . . . . 14
. . . . . . . . . . . . . . . . . . . . . . 134 734 . . CONNECTOR, circ 14 pin plug Amp 213571-2
. . . . . . . . . . . . . . . . . . . . . . 134 731 . . CONNECTOR, circ pin push-in 14-18ga Amp 213603-1
. . . . . . . . . . . . . . . . . . . . . . 079 739 . . CONNECTOR, circ clamp str rlf .703 max cable OD
Amp 206322-2 (or)
. . . . . . . . . . . . . . . . . . . . . . 143 922 . . CONNECTOR, circ clamp str rlf .453 max cable OD
Amp 206070-3
. . . 55 . . . . . . . . . . . . . . . . 151 535 . . CASE SECTION, bottom/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . . . 140 621 . . CASE SECTION, bottom/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 161 098 . . BUS BAR, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
++Included with Interconnecting Circuit Card PC2.
+++Part of 042 880 and 042 613 Meter Kit Options.
♦OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-206 Page 26
 Quantity
Model
Item Dia. Part
No. Mkgs. No. Description 152 175

Figure 8-2. Module, Power & Diode (Fig 8-1 Item 25 & 26)

. . . 1 . . . . . . C11 . . . . . 093 085 . . CAPACITOR, polye MF .0047uf 1000V . . . . . . . . . . . . . . . . . . . 1 . . . . 1

. . . 2 . . . . . VR1-3 . . . . 090 304 . . VARISTOR, 220 joule 730VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . . . . . . . . . . . . . . . 158 540 . . MODULE, pwr (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . 141 668 . . MODULE, pwr (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . 156 247 . . . . BLADE, fan 6 in 4wg 30deg .252 bore CCW . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . 155 426 . . . . KIT, fan blade (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . . 134 209 . . . . . . NUT, speed push-on-type .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . 000 366 . . . . RING, retainer E .250 shaft grv x .025thk . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . FM . . . . . 156 246 . . . . MOTOR, fan 120/230V 2600RPM w/36V sec (consisting of) 1
. . . . . . . . . . . . RC6 . . . . . 135 409 . . . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 114 656 . . . . . . . CONNECTOR, rect pin 24-18ga Molex 39-00-0040 . . . 8
. . . 7 . . . . . . FM . . . . . 141 518 . . . . MOTOR, fan 230/460V 2600RPM w/36V sec . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . 146 238 . . . . BRACKET, mtg fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 9 . . . . . . . . . . . . . . . +151 484 . . . . HEAT SINK, pwr module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 153 178 . . . . LABEL, warning exploding parts etc . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . 141 423 . . . . HEAT SINK, pwr module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . Q1-4 . . . . 149 207 . . . . KIT, transistor mosfet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4
. . . 11 . . . . . . D5 . . . . . 149 215 . . . . KIT, diode fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . TP2 . . . . . 032 810 . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 13 . . . . . . SR1 . . . . . 149 218 . . . . KIT, rectifier integ 100A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . SR1 . . . . . 149 217 . . . . KIT, rectifier integ 100A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . PC2 . . . . . 151 284 . . . . CIRCUIT CARD, interconnecting . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . PC2 . . . . . 141 662 . . . . CIRCUIT CARD, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 010 913 . . . . WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . 601 835 . . . . NUT, brs hex 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

23

22

17
21
20 5
19
4
18
16
6
15 7
8

9
10
11 3

12
13
14
ST-145 796-A

Figure 8-2. Module, Power & Diode (175 Model Illustrated)

OM-206 Page 27
 Quantity
Model
Item Dia. Part
No. Mkgs. No. Description 152 175

Figure 8-2. Module, Power & Diode (Fig 8-1 Item 25 & 26)
(Continued)

. . . . . . . . . . . PLG6 . . . . 115 092 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . 1

...................... 113 746 . . . . CONNECTOR, rect skt 24-18 ga Molex 39-00-0038 . . . . . . 8
...................... 010 193 . . WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . 4 . . . . 2
...................... 601 835 . . NUT, brs hex 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 2
. . . 15 . . . . . . VR4 . . . . . 004 113 . . VARISTOR, 40 joule 390VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 16 . . . . . . R10 . . . . . 030 839 . . RESISTOR, WW fxd 5W 220 ohm . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 17 . . . . . . DM1 . . . . . 151 479 . . MODULE, diode (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . DM1 . . . . . 140 492 . . MODULE, diode (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . D5,6 . . . . . 151 229 . . . . KIT, diode ultra fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 19 . . . . . . . . . . . . . . . . 151 470 . . . . HEAT SINK, diode module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . . 140 622 . . . . HEAT SINK, diode module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . R9 . . . . . 098 324 . . . . RESISTOR, WW fxd 25W 5 ohm . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . R5 . . . . . 098 324 . . . . RESISTOR, WW fxd 25W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . D1,2 . . . . . 151 431 . . . . KIT, diode ultra fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 22 . . . . . C9,10 . . . . 098 325 . . . . CAPACITOR, polyp film .027uf 630V . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 23 . . . . . . TP1 . . . . . 129 552 . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-206 Page 28
OPTIONS AND ACCESSORIES
BACKLIT LCD METER KIT Fastens to TIG torch handle. (Will accept Dinse or other International
(#042 613 Factory) For 175 Includes 28 ft. (8.5 m) cord and connectors.)
(#042 880 Factory) For 152 plug. Maxstar power sources are
(#042 614 Field) For all models AMTV REMOTE CONTACTOR equipped with International–style
A presettable, lighted digital AND CURRENT CONTROL connectors for secondary
display meter. Meter displays (#152 608) connections. (Power source is
preset amperage, weld amperage, Fastens to TIG torch handle using shipped with two 50 mm male
or weld voltage. velcro strips. International–style plugs for use
UNIVERSAL LARGE with #1 or #2 AWG size cable.)
CYLINDER CART PC–300 PULSED GTAW INTERNATIONAL–STYLE
(#042 934) (DC TIG) CONTROL CONNECTOR KIT
Maxstar can mount on this cart (#042 297) (#042 418) 50 mm
along with argon cylinder. Will The PC–300 provides two Required if male plugs shipped
accommodate 6 to 9 in. (152 to internally switchable scales. with power source must be
228 mm) diameter, and 24 to 56 in. An inverter power source can replaced or if additional plugs are
(610 to 1422 mm) high. utilize the 0.5 to 20 needed.
UNIVERSAL RUNNING pulses–per–second scale or the 10 Kit includes one International–style
GEAR/CYLINDER RACK to 300 pulses–per–second scale. male plug, which attaches to the
(#042 454) The PC–300 can be used with work and/or weld cables and plugs
Height: 17–1/4 in. (438 mm) welding power sources with or into the International–style
Length: 29–1/2 in. (749 mm) without built–in high–frequency, or receptacles on the power source.
Width: 14–1/4 in. (362 mm) with external high–frequency units. Accepts #1 or #2 AWG size cable.
Accepts “R” size gas cylinders.
Front panel controls provide: EXTENSION KIT FOR
Shipped disassembled.
• Peak Amperage Adjustment INTERNATIONAL–STYLE
CARRYING CART • Background Amperage CABLE CONNECTORS
(#056 301) Adjustment (#042 419) 50 mm
Height: 34 in. (864 mm) • Pulses–Per–Second Adjustment Used to adapt or extend weld
Width: 30 in. (762 mm) • Percent On–Time Adjustment and/or work cables.
Depth: 17 in. (432 mm) • Amperage Remote/Panel Kit includes one male
Maxstar and Intellitig units fit nicely • Output Contactor On/Off International–style plug and one
on this cart. • Pulser On/Off in–line female International–style
EXTENSION CORDS • Power On/Off receptacle.
For 14–Pin Remote Controls A remote control receptacle is also Accepts #1 or #2 AWG size cable.
(#122 972) 10 ft. (3 m) included for use with a remote
(#122 973) 25 ft. (7.6 m) INTERNATIONAL/TWECO 
hand or foot control.
(#122 974) 50 ft. (15.2 m) ADAPTER
An 8 ft. (2.4 m) interconnecting (#042 465)
(#122 975) 75 ft. (22.9 m)
cord and 115 VAC power cord are A one–piece adapter which has an
RFC-14 FOOT CONTROL provided (115 VAC power is International–style male plug (to
(#129 339) required). power source) on one end and a
Heavy–duty foot current and female Tweco receptacle (for weld
contactor control. MILLER EXPERT PROGRAM cable connection) on the other
20 ft. (6 m) cord and 14–pin plug. (#042 849) Maxstar 152 end.
(#042 850) Maxstar 175
RFC-E FOOT CONTROL The Miller Expert Program is an INTERNATIONAL/CAM–LOK
(#042 856) easy–to–use computerized ADAPTER
Lightweight, com–pact foot control. software program to systematically (#042 466)
15 ft. (4.6 m) cord and 14–pin guide you through the repair of A one–piece adapter which has an
plug. your equipment. Refer to Literature International–style male plug (to
Index No. AV/6.0. power source) on one end and a
RCC-14 REMOTE CONTACTOR
female Cam–Lok receptacle (for
AND CURRENT CONTROL INTERNATIONAL-STYLE weld cable connection) on the
(#151 086) CONNECTORS other end.

3/93
OPTIONS AND ACCESSORIES
INTERNATIONAL TIG TORCH 80 AMP AIR–COOLED MODELS sizes (.040 in., 1/16 in., 3/32 in.) of
CONNECTOR KIT (#116 091) MT–24–12–1
(#135 492) 80 Amp Torch (#116 092) MT–24–25–1 collets, collet bodies, cups, and 2%
(#135 493) 150 Amp Torch Note: International Connector Kit thoriated tungsten
(#135 494) 200 Amp Torch* (#135 492) must be used with the 80 Amp • Regulator/flowmeter (HRF–2425)
(#135 495) 250/350 Amp
TIG torches listed.
• Work cable with clamp (clamp
Water–Cooled Torch rated for 350 Amps), 12–1/2 ft.
KIT FOR MT–24 SERIES
For direct connection of one–piece (3.8 m) or 25 ft. (7.6 m) lengths to
AIR–COOLED MODELS
torches to power sources with match TIG torch length
(#142 413) 12–1/2 ft. (3.8 m)
International–style connectors. length 200 AMP AIR–COOLED
Note: Two–piece torches do not require (#142 414) 25 ft. (7.6 m) length MODELS
this connector kit. They can use one of Kit includes: (#116 123) MT–26–12–1
the two International–style connectors • Hose and hardware hook–up kit (#116 124) MT–26–25–1
supplied with the power source.
*May not be compatible with competitive
(THK–2) (#116 127) MT–26V–12–1*
brand torches. • Consumable accessory kit
(#116 128) MT–26V–25–1*
(TAK–4) - three sizes (.040 in., Note: International Connector Kit
TOTAL TIG INSTALLATION 1/16 in., 3/32 in.) of collets, collet (#135 494) must be used with the 200
KIT bodies, cups, and 2% thoriated Amp TIG torches listed.
For Total TIG system, select tungsten
one each of the following items: • Regulator/flowmeter (HRF–2425) KIT FOR MT–26 SERIES
• Welding power source • Work cable with clamp (clamp AIR–COOLED TIG TORCH
• TIGtorch (recommended torches rated for 350 Amps), 12–1/2 ft. (#129 588) 12–1/2 ft. (3.8 m)
listed below) (3.8 m) or 25 ft. (7.6 m) lengths to length
• TIG kit (see kits listed below) match TIG torch length (#129 587) 25 ft. (7.6 m) length
• Remote control (optional) Kit includes:
• Snap Start (optional) 150 AMP AIR–COOLED • Hose and hardware hook–up kit
MODELS (THK–2)
TIG TORCHES AND (#116 107) MT–17–12–1 • Consumable accessory kit
CONNECTING KITS (#116 108) MT–17–25–1 (TAK–3) - one backcap and three
For hand–held, manual (#116 111) MT–17V–12–1* sizes (1/16 in., 3/32 in., 1/8 in.) of
applications. collets, collet bodies, cups, and 2%
(#116 112) MT–17V–25–1*
For complete information on all Note: International Connector Kit
thoriated tungsten
Miller TIG torches and (#135 493) must be used with the 150 • Regulator/flowmeter (HRF–2425)
accessories, see Literature Index Amp TIG torches listed. • Work cable with clamp (clamp
No. TG/1.0. rated for 350 Amps), 12–1/2 ft.
KIT FOR MT–17 SERIES (3.8 m), or 25 ft. (7.6 m) lengths to
Explanation of Model AIR–COOLED TIG TORCH match TIG torch length
Description (#129 590) 12–1/2 ft. (3.8 m)
length *Torches with manual gas valves
MT = Miller torch are recommended for use with
XX = Model number of torch (#129 589) 25 ft. (7.6 m) length
Kit includes: “Touch Start”. When the
V = Gas valve in torch handle* Maxstar is used with an
12 = 12–1/2 ft. (3.8 m) cable • Hose and hardware hook–up kit
(THK–2) optional Snap Start or
25 = 25 ft. (7.6 m) cable Intellitig, torches with gas
1 = One–piece, high–flex cable • Consumable accessory kit
(TAK–1) - one backcap and three valves are not recommended.

3/93
 Effective January 1, 2001
(Equipment with a serial number preface of “LB” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.

Call LIMITED WARRANTY – Subject to the terms and conditions * APT, ZIPCUT & PLAZCUT Model Plasma Cutting
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches
1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold
* Remote Controls
for your local after the effective date of this limited warranty is free of defects
* Accessory Kits
in material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Replacement Parts (No labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to
you ... Miller’s True Blue Limited Warranty shall not apply to:
such defects in material or workmanship. Miller must be
Service notified in writing within thirty (30) days of such defect or 1. Consumable components; such as contact tips,
failure, at which time Miller will provide instructions on the cutting nozzles, contactors, brushes, slip rings,
You always get the fast, warranty claim procedures to be followed.
reliable response you relays or parts that fail due to normal wear.
need. Most replacement Miller shall honor warranty claims on warranted equipment
2. Items furnished by Miller, but manufactured by others,
parts can be in your listed below in the event of such a failure within the warranty
such as engines or trade accessories. These items are
time periods. All warranty time periods start on the date that
hands in 24 hours. the equipment was delivered to the original retail purchaser, or
covered by the manufacturer’s warranty, if any.
Support one year after the equipment is sent to a North American 3. Equipment that has been modified by any party other
Need fast answers to the distributor or eighteen months after the equipment is sent to an than Miller, or equipment that has been improperly
International distributor. installed, improperly operated or misused based upon
tough welding questions?
Contact your distributor. 1. 5 Years Parts – 3 Years Labor industry standards, or equipment which has not had
The expertise of the reasonable and necessary maintenance, or equipment
* Original main power rectifiers which has been used for operation outside of the
distributor and Miller is specifications for the equipment.
* Inverters (input and output rectifiers only)
there to help you, every
step of the way. 2. 3 Years — Parts and Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Transformer/Rectifier Power Sources PERSONS TRAINED AND EXPERIENCED IN THE USE
* Plasma Arc Cutting Power Sources AND MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Inverter Power Supplies exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Intellitig appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
3. 1 Year — Parts and Labor replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
* Motor Driven Guns (w/exception of Spoolmate transportation costs of any kind will be allowed.
Spoolguns)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Process Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Positioners and Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources ANY OTHER LEGAL THEORY.
* Water Coolant Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
* HF Units AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Maxstar 140 OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
* Spot Welders OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Load Banks OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* Miller Cyclomatic Equipment MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
* Running Gear/Trailers EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
* Plasma Cutting Torches (except APT & SAF DISCLAIMED BY MILLER.
Models) Some states in the U.S.A. do not allow limitations of how long
* Field Options an implied warranty lasts, or the exclusion of incidental,
(NOTE: Field options are covered under True indirect, special or consequential damages, so the above
Blue for the remaining warranty period of the limitation or exclusion may not apply to you. This warranty
product they are installed in, or for a minimum of provides specific legal rights, and other rights may be
one year — whichever is greater.) available, but may vary from state to state.

4. 6 Months — Batteries In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,
5. 90 Days — Parts and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
* MIG Guns/TIG Torches Warranty provides specific legal rights, and other rights may
* Induction Heating Coils and Blankets be available, but may vary from province to province.

miller_warr 10/01
 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
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate 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
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters–USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters –
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com

Contact the Delivering Carrier for: 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.

PRINTED IN USA  2002 Miller Electric Mfg. Co. 1/02