907709001 - Miller Maxstar 161 S Stick Welder Package with X-Case

Miller Maxstar 161 S Stick Welder Overview

The Miller Maxstar 161 S (907709001) is a compact, inverter-based Stick (SMAW) welding power source designed for maximum portability and industrial performance. Weighing only 13 lbs (5.9 kg), this machine is engineered for maintenance repair, shipboard installation, farm/ranch applications, and hobbyist projects where mobility is critical. The package includes the rugged Miller X-Case for transport and storage protection.

Power Management and Performance

Equipped with Miller's Auto-Line™ technology, the Maxstar 161 S automatically connects to 120V or 240V single-phase input power (50/60 Hz) without the need for manual linking or tools. This feature ensures flexibility in varied work environments with unreliable power. The unit features Power Factor Correction (PFC), which optimizes performance on 120V circuits and reduces nuisance breaker tripping. The machine delivers a rated output of 160 A at 20% duty cycle on 240V, and 90 A at 30% duty cycle on 120V.

Arc Control and Safety Features

The Maxstar 161 S provides superior Stick arc performance, specifically engineered to run difficult electrodes such as E6010. It incorporates Adaptive Hot Start™ technology to ensure positive arc starts without sticking. Safety is enhanced via the Stick-Stuck™ feature, which detects if an electrode is fused to the part and shuts off welding output, allowing for safe removal. Additionally, the Low OCV Stick design reduces open-circuit voltage to 12-16 V when the machine is idle, eliminating the need for add-on voltage reducers. Thermal overload protection safeguards internal components by shutting down the unit if airflow is blocked or the duty cycle is exceeded.

Operational Efficiency

The Fan-On-Demand™ cooling system operates only when necessary, minimizing noise, energy consumption, and the intake of airborne contaminants. A digital meter allows for precise presetting and monitoring of welding amperage. The unit comes complete with 6.5 ft primary cords for both voltage inputs, a 13 ft stick electrode holder, and a 10 ft work clamp, all utilizing 25 mm Dinse-style connectors for secure electrical connections.