Manual de Pruebas O150853g

September 2005 FORM: 150 853G
Technical
Manual
TESTING BOOKLET
testing 2/04 © 2005 MILLER Electric Mfg. Co. PRINTED IN USA
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − EXPLANATION OF ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 3 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-1. Needed Test Equipment And Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 − PARTS TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-1. Diode Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-2. Integrated Rectifier (Three-Phase) Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-3. Integrated Rectifier (Single-Phase) Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-4. Style 1 Dual Diode Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-5. Style 2 Dual Diode Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-6. Straight And Reverse Polarity Diode Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-7. Hockey-Puk Diode Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-8. Stud-Mount SCR Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-9. Hockey-Puk SCR Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-10. Single SCR Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-11. NPN Power Transistor Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-12. SCR/Integrated Rectifier (Single-Phase) Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4-13. SCR/Integrated Rectifier (Three-Phase) Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-14. SCR Power Module Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-15. IGBT Power Module Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
IGBT/MOSFET Tester Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
IGBT Power Module Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
IGBT Power Module Testing Procedure (212 106) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4-16. MOSFET Power Transistor Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
IGBT/MOSFET Tester Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
MOSFET Power Transistor Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4-17. Modular Main Rectifier Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECTION 5 − TOOLS AND PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5-1. Using Tool Part Number 121 481 To Remove Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5-9. Using Tool Part Number 133 357 To Remove DIP Integrated Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 6 − TORQUE SPECIFICATIONS FOR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
WHO DO I CONTACT FOR HELP?

H CALL: H FAX: H WRITE:
Miller Customer Service 920-735-4136 Miller Electric Mfg. Co.
Department at 1635 West Spencer St.
920-735-4505 P.O. Box 1079
Appleton, WI 54912-1079 USA
Always provide Model Name and Serial or Style Number
150 853 2/04

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
safety_testing 1/00
1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this Y Marks a special safety message.
procedure! The possible hazards are shown in the adjoining symbols. . Means NOTE; not safety related.
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to
avoid the hazards.
1-2. Servicing Hazards
WARNING
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.
Only qualified persons should service, test, maintain, and repair this unit.
During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill. HOT PARTS can cause severe burns.
1. Do not touch live electrical parts. 1. Do not touch hot parts bare handed.
2. Stop engine or turn OFF power source and wire 2. Wear protective gloves and clothing when working
feeder and disconnect and lockout input power on a hot engine.
using line disconnect switch, circuit breakers, or by 3. Allow cooling period before servicing gun or torch.
removing plug from receptacle before servicing
unless the procedure specifically requires an EXPLODING PARTS can cause injury.
energized unit.
1. Failed parts can explode or cause other parts to
3. Insulate yourself from ground by standing or explode when power is applied to inverters.
working on dry insulating mats big enough to
prevent contact with the ground. 2. Always wear a face shield and long sleeves when
servicing inverters.
4. Do not leave live unit unattended.
5. When testing a live unit, use the one-hand method. ELECTRIC SHOCK HAZARD from
Do not put both hands inside unit. Keep one hand incorrect use of test equipment.
free. 1. Turn Off power source and wire feeder or stop
6. Disconnect input power conductors from engine before making or changing meter lead
deenergized supply line BEFORE moving a connections.
welding power source. 2. At least one meter lead should be a self-retaining
SIGNIFICANT DC VOLTAGE exists after spring clip such as an alligator clamp.
removal of input power on inverters. 3. Read instructions for test equipment.
7. Turn Off inverter, disconnect input power, and
discharge input capacitors according to
HIGH-FREQUENCY RADIATION can
Maintenance Section of Technical Manual or interfere with radio navigation, safety
Owner’s Manual before touching any parts. services, computers, and
communications equipment.
STATIC ELECTRICITY can damage 1. Have only qualified persons familiar with electronic
parts on circuit boards. equipment perform this installation.
1. Put on grounded wrist strap BEFORE handling 2. The user is responsible for having a qualified
boards or parts. electrician promptly correct any interference
2. Use proper static-proof bags to store, move, or ship problem resulting from the installation.
PC boards. 3. If notified by the FCC about interference, stop using
the equipment at once.
FIRE OR EXPLOSION can result from
4. Have the installation regularly checked and
placing unit on, over, or near maintained.
combustible surfaces.
5. Keep high-frequency source doors and panels
1. Do not place unit on, over, or near combustible tightly shut, keep spark gaps at correct setting, and
surfaces. use grounding and shielding to minimize the
2. Do not service unit near flammables. possibility of interference.
FLYING PIECES OF METAL or DIRT can FALLING EQUIPMENT can cause

injure eyes. serious personal injury and equipment
1. Wear safety glasses with side shields or face shield damage.
during servicing. 1. Use equipment of adequate capacity to lift unit.
2. Be careful not to short metal tools, parts, or wires 2. Use lifting eye to lift unit only, NOT running gear,
together during testing and servicing. gas cylinders, trailer, or any other accessories.
150 853 Page 1

MAGNETIC FIELDS FROM HIGH OVERUSE can cause OVERHEATED
CURRENTS can affect pacemaker EQUIPMENT.
operation. 1. Allow cooling period.
1. Pacemaker wearers keep away from servicing
2. Reduce current or reduce duty cycle before
areas until consulting your doctor.
starting to weld again.
MOVING PARTS can cause injury. 3. Follow rated duty cycle.
1. Keep away from moving parts such as fans.
READ INSTRUCTIONS.
2. Keep all doors, panels, covers, and guards closed
and securely in place. 1. Use this information along with the Technical
Manual.
MOVING PARTS can cause injury. 2. Consult the Owner’s Manual for welding safety
1. Keep away from moving parts. precautions.
2. Keep away from pinch points such as drive rolls. 3. Use only genuine MILLER replacement parts.
1-3. Engine Hazards

MOVING PARTS can cause injury. BATTERY EXPLOSION can BLIND and
1. Keep away from moving parts such as fans, belts, INJURE.
and rotors. 1. Always wear a face shield when working on a
2. Have only qualified people remove guards or battery.
covers for maintenance and troubleshooting as 2. Stop engine before disconnecting or connecting
necessary. battery cables.
3. Keep hands, hair, loose clothing, and tools away 3. Do not allow tools to cause sparks when working
from moving parts. on a battery.
4. Reinstall panels or guards and close doors when 4. Do not use welder to charge batteries or jump start
servicing is finished and before starting engine. vehicles.
5. Observe correct polarity (+ and −) on batteries.
ENGINE EXHAUST GASES can kill. BATTERY ACID can BURN SKIN.
1. Do not breathe exhaust fumes. 1. Do not tip.
2. Use in open, well-ventilated areas, or vent exhaust 2. Replace damaged battery.
outside and away from any building air intakes.
3. Flush eyes and skin immediately with water.
ENGINE FUEL can cause fire or explo- STEAM AND PRESSURIZED HOT
sion. COOLANT can burn face, eyes, and
1. Stop engine before fueling. skin.
2. Do not fuel while smoking or near sparks or flames. 1. Check coolant level when engine is cold to avoid
3. Do not overfill tank; clean up any spilled fuel. scalding.
2. If the engine is warm and checking is needed,
UNCONTROLLED TILTING OR TIPPING follow steps 3 and 4.
OF UNIT can result in personal injury 3. Wear safety glasses and gloves and put a rag over
and equipment damage. cap.
1. Do not put any body part under unit while lifting. 4. Turn cap slightly and let pressure escape slowly
before completely removing cap.
2. Use adequate blocks to support components as
needed during job.
PINCH POINTS can injure.
1. Be careful when working on stator and rotor.
1-4. EMF Information
Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause 2. Arrange cables to one side and away from the operator.
electromagnetic fields. There has been and still is some concern
about such fields. However, after examining more than 500 studies 3. Do not coil or drape cables around your body.
spanning 17 years of research, a special blue ribbon committee of the
National Research Council concluded that: “The body of evidence, 4. Keep welding power source and cables as far away from
in the committee’s judgment, has not demonstrated that exposure to operator as practical.
power-frequency electric and magnetic fields is a human-health
hazard.” However, studies are still going forth and evidence 5. Connect work clamp to workpiece as close to the weld as
continues to be examined. Until the final conclusions of the research possible.
are reached, you may wish to minimize your exposure to
electromagnetic fields when welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your
procedures: doctor, then following the above procedures is recommended.
150 853 Page 2

SECTION 2 − EXPLANATION OF ELECTRICAL PARTS
elect_parts 2/04
2-1. Safety Precautions − Read Before Using This Guide
Y WARNING: ELECTRIC SHOCK can kill.

D Disconnect input power or stop engine before servicing.
D Do not touch live electrical parts.
D Do not operate machines with covers removed.
D Have only qualified persons install, use, or service equipment.
PART NAME FUNCTION PICTURE CIRCUIT SYMBOL
BATTERY A source of DC voltage. Typically used in +

Engine Driven equipment.
BRUSHES/SLIP Components that allow electrical connections

RINGS between stationary and rotating contacts.
SLIP
RINGS
BRUSHES
CAPACITOR A device that stores electrical energy. Large POLARIZED NON-POL.

capacitors or a “bank” of capacitors can be +
used to “smooth out” the DC welding arc in a
MIG welding power source. Smaller “disk” C1 C1
capacitors can be used for HF protection.
CHASSIS The green ground wire of a primary cord is

connected to the machine frame (chassis) for
safety. Also, you may find many “HF bypass”
capacitors connected to chassis to reduce
High Frequency interference. Expect to see
this symbol used numerous times in circuit
diagrams. The picture shown here is from an
Engine Drive where several wires including
the battery are connected to the chassis.
CIRCUIT BREAKER A protection device that breaks a circuit when

current levels exceed its rating. Unlike a fuse CB1
that needs to be replaced when blown, a
circuit breaker can be reset.
CIRCUIT COMMON When many wires are connected together,

rather than showing all the “lines” and “dots”,
this symbol may appear on the circuit. Look
for other Circuit Common symbols on a
circuit diagram. For instance, say 10 symbols
are found on a circuit, this means all ten
points are electrically tied together.
150 853 Page 3

CLAMP A spring-loaded connection device. A good

example would be the “work clamp” used to
connect the weld cable from a power source
to the workpiece that will be welded.
CONTACTOR A heavy duty relay. Usually used to make

and break the welding arc or primary power. W COIL
NRM OPEN
POINTS
CURRENT A transformer that produces an AC voltage CT1

TRANSFORMER used for measuring purposes. The primary
winding is in series with the circuit carrying
the current to be measured. Its main use in OR
engine-driven equipment is to activate the
“Automatic Idle” circuit by sensing welding
current or auxiliary power current. CT1
DASHED LINE A dashed line between parts means there is

a mechanical connection between these
parts. When a dashed line boxes in parts,
this means the parts make up an option or
are combined into one part. In all cases, FM
dashed lines do not conduct electricity. The
picture shown is a combination fan motor and
transformer in one part.
DIODE A device that allows current to flow in one

direction only. Most common use is to D1
change AC to DC.
FAN MOTOR This device provides cooling of the internal

parts of a welding power source.
FM
FUSE A protection device, usually an enclosed

piece of wire that melts and breaks the circuit F1
when the current exceeds the fuse rating.
GAS OR WATER These are electromechanical devices used to

SOLENOID start or stop the flow of shielding gas or
(VALVE) water. GS1
OR
WS1
HALL DEVICE Produces a small DC voltage proportional to

the current it is sensing (usually welding HD1
current). This feedback signal can be used to
regulate the welding output (line voltage
compensation). It may even be used to drive
an ammeter.
150 853 Page 4

IGBT A device that is used as an “electronic

switch”. When a signal is applied to the gate C1
(G), current is allowed to flow from the emitter
(E) to the collector (C). This device is typically G1 (B1)
used in “Inverter” designed welding machines
to control the welding output. E1
INTEGRATED An arrangement of four diodes used to +

BRIDGE change AC to DC.
RECTIFIER AC
+
AC AC
−
AC
_
INTEGRATED IC’s often called “chips” provide a complete

CIRCUIT circuit function with inputs and outputs. A
good example would be the “Pulse Width
Modulation” chip used in many wire feeder U1
designs.
JUMPER LINK Usually, the jumper link is a piece of brass

that connects two terminals together. Dashed TE1
lines indicate possible locations for other
jumper links.
LIGHT EMITTING This device usually referred to by its initials

DIODE LED is used to tell you when a particular
D1
circuit is activated. This function is very
helpful for troubleshooting.
MAGNETIC This device usually referred to as a

AMPLIFIER “Mag-Amp” is made up of coil windings and
an iron core similar to a transformer. It
controls a large welding current by varying a
small “control current”.
MA1
METER A measuring device. A “voltmeter” is a good

example. V = voltmeter
V A = ammeter
HM = hour
meter
MOSFET A device that is used as an “electronic D

switch”. When a signal is applied to the gate
(G), current is allowed to flow from the source
(S) to the drain (D). This device can be used
G
to control a relay, the speed of a motor, or
even the output of a welding machine. AS
S
150 853 Page 5

MOTOR A device that converts electrical energy into

mechanical energy. Typically used to feed M1 = DC
wire in a MIG welding system, or pump
coolant in a recirculating liquid-cooling
system. = AC
M1
OPERATIONAL Usually referred to as an “Op-Amp”, this IC

AMPLIFIER chip is very versatile and widely used on PC
boards. A typical use might be as a +
“comparator”, comparing the command A1
_
signal to the feedback signal allowing the
welding output to be kept constant.
OPTICAL A device that uses “light” to get electrical

COUPLER separation (isolation). This eliminates noise OC1
that might be in one circuit from affecting
another circuit.
PILOT LIGHT A light located on the front panel which

1
indicates if the machine is on or off.
PL
POTENTIOMETER Both devices have a moveable brush that

OR makes contact along a resistor, allowing you
RHEOSTAT to easily change the resistance measured at R1
the brush (sometimes referred to as a wiper).
Their primary purpose is to give the operator CW = CLOCKWISE
a way to adjust welding parameters such as
wire speed, preflow time, voltage, CCW =COUNTER-
inductance, etc. CLOCKWISE
PLUG A connection device that hangs loose with

wires coming out the back of it. Please note MALE
that the plug terminals can be either male or FEMALE
female.
PLG =
PLG1 LOOSE
RECEPTACLE A connection device that is mounted or fixed.

Just like a plug, the terminals can be either MALE
male or female. FEMALE
RC =
RC1 MOUNTED
RELAY−−COIL AND This is an electromechanical device whose COIL

CONTACTS, contacts change state (the normally open
CR1
NORMALLY OPEN points close and the normally closed points
AND NORMALLY open) when proper voltage is applied to the
CLOSED coil. These contact points in turn may control CR1 CR1
a fan motor, gas solenoid, contactor, etc.
Circuit diagrams (schematics) always show NRM OPEN NRM CLOSED
the contact points in the power off state. POINTS POINTS
RESISTOR A device which resists the flow of electric FIXED R1

current. Uses include limiting the current for a
motor brake circuit in a wire feeder and for
discharging a capacitor.
FIXED TAPPED R1
150 853 Page 6

RIBBON CABLE A connection device where the wires are laid

out flat. Usually to connect circuits from one 26-CONDUCTOR
CABLE
PC board to another PC board.
RC54 RC44
SCR A Silicon Controlled Rectifier (SCR) is an

electrical device with three connections,
anode, cathode, and gate. It will allow current K
G
to flow in only one direction and will only do
so after receiving a signal on the gate lead.
SCR’s are used to change AC to DC and to
A
control the output to a load such as a welding
arc.
SHUNT A precision low-value resistor typically used

to supply a small voltage to drive an
SHUNT
ammeter.
SNUBBER A device used to absorb voltage spikes,

sometimes found connected across the
points of a relay. SN1
SPARK GAP The arrangement of two electrodes between

which a discharge of electricity will occur.
Typically used to produce “ high frequency”
which can be used for arc starting when TIG G
welding.
STABILIZER/ When placed in a DC circuit, the inductor or

REACTOR stabilizer as it is usually called, will oppose
Z1
any change in existing current. It is therefore
widely used to “stabilize” the welding arc.
When the inductor is placed in an AC circuit it
is referred to as a reactor where it now acts L1
to restrict the flow of current. A “tapped
reactor” is used to create current ranges for
welding.
SWITCH A mechanical device that completes or SPST SPDT

breaks the path of the current or sends it over
a different path.
A multi-pole switch will use dashed lines to

connect poles. DPST DPDT
SPST = Single Pole Single Throw

SPDT = Single Pole Double Throw
DPST = Double Pole Single Throw
DPDT = Double Pole Double Throw
MOMENTARY A switch that “springs back” to its original

SWITCH position. S1
LIMIT SWITCH A switch mounted in the path of a moving

object and actuated by its passage. NRM OPEN NRM
S1 CLOSED
S1
150 853 Page 7

PUSH BUTTON A switch in which a button must be NRM NRM

SWITCH depressed each time the contacts are to be OPEN CLOSED
opened or closed. PB1 PB1
ROTARY SWITCH A switch in which its shaft must be rotated to

actuate the contacts.
S1 S1
PRESSURE A change in the pressure of a gas or liquid OPENS CLOSES

SWITCH will actuate this switch. ON ON
INCREASE INCREASE
S1 S1
TEMPERATURE Typically used to protect engines, this switch OPENS CLOSES

SWITCH is actuated by heat. ON ON
INCREASE INCREASE
S1 S1
WATER FLOW A switch that is actuated by the flow of a

SWITCH liquid. Typically used to protect
“water-cooled” torches.
OPENS CLOSES
ON ON
INCREASE INCREASE
S1 S1
TERMINAL A connection point for primary power and the

ASSEMBLY jumper links that are used to match the input TE1
voltage to the machine. Usually, the terminal
assembly is marked with the letters “TE”, but
the electrical symbol looks identical to a
standard terminal strip.
TE1
TERMINAL STRIP An insulated connection point for wires. They 42 42 104 105 74
are used for the ease of making multiple 1T
connections and can be a convenient point A B C D E
for making electrical checks when
troubleshooting. (Notice the “jumper link” 104 105
connecting terminals A and B together.)
THERMISTOR A thermally sensitive resistor. There are two

types of thermistor, PTC (Positive
Temperature Coefficient) and NTC (Negative
Temperature Coefficient). A PTC thermistor’s RT1
resistance will increase as the temperature OR
goes up, where as an NTC thermistor’s TH1
resistance will decrease as the temperature
goes up. Primarily used for “Fan on Demand”
and “Thermal Shutdown” circuits.
150 853 Page 8

THERMOSTAT, This is a switch that closes its normally open

NORMALLY OPEN contacts (or opens its normally closed
AND NORMALLY contacts) when a preset temperature is TP1 TP1
CLOSED reached. When the temperature goes back
down, it will reset itself. Uses of these
devices include turning on a fan motor when NRM OPEN NRM CLOSED
needed and shutting off the output of a
welding power source if it is overheating.
TRANSISTOR Most commonly used as an electronic switch. Q1 C Q1 C

There are two basic types, PNP and NPN.
This refers to their internal design, which B B
determines current flow direction.
E E
NPN PNP
TRANSFORMER A device that changes AC voltage from one

magnitude to another. Typically used to IRON
reduce high primary voltages to lower T1 CORE
welding voltages.
FERRITE
T1 CORE
AIR
T1 CORE
TRIAC An electronic AC switch. It is turned on by a

gate signal similar to an SCR. Q1
TWISTED WIRE Wires are twisted to prevent “electrical noise”

from interfering with the circuit. A good
example is the red and white gate leads RED
going to an SCR. Typically, these wires are
twisted together to help prevent the SCR WHT
from misfiring.
VARISTOR A protection device whose resistance is

dependent on the voltage applied to it. In
normal operation it has a high resistance; VR1
however, a surge of voltage (voltage spike)
will cause its resistance to go way down and
absorb the spike. These devices are most
often found in rectifying circuits, where they
are used to protect the diodes.
WIRES WITH When lines (wires) cross on a circuit diagram

CONNECTION and there is a “black dot”, this means that the
two wires are electrically connected together.
The method of connection (bolted, friction
lugs, etc.) is not indicated with this symbol.
However, a “white dot” indicates that the
method of connection is a terminal strip. Of
course, no dot means no connection.
150 853 Page 9

SECTION 3 − INTRODUCTION
3-1. Needed Test Equipment And Description
1 Continuity Tester
1 Grainger Supply Co.
2
Part #2V544 Or Equivalent
With two D size batteries, minimum
3 volts.
2 FLUKE Digital Multimeter
(DMM) Or Equivalent
One megohm input impedance or
greater and diode test function.
3 One Insulated Jumper Lead
3 Approximately 6 to 10 in (152 to 254
mm) long.
4 IGBT/MOSFET Tester
Miller Part #043 553
Before use, install 9 volt batteries.
To check battery, connect Red and
Black leads together; test light
(LED) = On; battery okay.
5 Test Button
6 Test Light (LED)
4 5 6
Yellow
Black
Red
150 853 Page 10

SECTION 4 − PARTS TESTING PROCEDURES
4-1. Diode Testing Procedure
See Parts List for location of parts in
unit.
K A
1 Diode
Circuit Diagram Symbol Mark and disconnect one lead of
1 diode.
2 3 3 2 Cathode (K)
1
3 Anode (A)
Replace part if it fails any test.
Actual Part
2
179 630
1 3
3
2 2
1
185 775
209 464
1 2
Set meter for

Diode testing.
= .200 to .900
K
K = .OL
A
Reverse Bias Testing
(Blocking)
Forward Bias Testing
(Conducting)
Ref. 048 894-K / Ref. 803 772-A / S-0149
150 853 Page 11

4-2. Integrated Rectifier (Three-Phase) Testing Procedure
unit.
1 Integrated Rectifier (Three-
Phase)
1 Mark and disconnect leads from

1
negative (−) and positive (+) termi-
+ nals.
− AC
AC AC AC
+ AC
AC AC −
AC
− AC
+
1
Actual Part Actual Part 179 542
AC −
AC
AC
+
Circuit Diagram Symbol
1 2
Set meter for
Diode testing.
= .200 to .900
AC
AC +
= .OL
+
Forward Bias Testing Reverse Bias Testing

(Conducting) (Blocking)
3 4
AC + AC +
= .200 to .900 = .OL

150 853 Page 12

5 6
+ +
AC = .200 to .900 AC = .OL

7 8
AC AC
= .200 to .900 = .OL
− −

9 10
AC AC
= .200 to .900 = .OL
− −

11 12
AC = .200 to .900 AC = .OL
− −

S-0672 / S-0474
150 853 Page 13

4-3. Integrated Rectifier (Single-Phase) Testing Procedure
2 3 See Parts List for location of parts in
unit.
AC +
1 Integrated Rectifier (Single-
Phase)
Mark and disconnect all leads from
1 1 1 integrated rectifier.
_ AC
2 Anode (A)
− Circuit Diagram Symbol
− + AC
3 Cathode (K)
+ + Replace part if it fails any test.
1
AC AC AC −
−
AC AC AC
Actual Part Actual Part Actual Part +

AC
201 530
Set meter for

Diode testing.
1 = .200 to .900 2
AC
AC
+
= .OL
+

3 4
+ +
= .200 to .900 = .OL
AC AC

5 6
− = .200 to .900
− = .OL
AC AC

7 AC 8 AC
− = .200 to .900 − = .OL

(Conducting) (Blocking) Ref. S-0454 / S-0328-A / S-0665-A
150 853 Page 14

4-4. Style 1 Dual Diode Testing Procedure
A1 unit.
K1, K2
A2 1 Dual Diode
Mark and disconnect leads from
1
Circuit Diagram Symbol anodes (A1, A2).
2, 5 2 Cathode 1 (K1)
2 4
3 Anode 1 (A1)
3 4
4 Anode 2 (A2)
3 1 3
5 Cathode 2 (K2)
1
4 179 869
2, 5
5 204 820
Style 1
Actual Part
AC 3, 5
+ 2 AC
− 4
A1 K1 K2 A2
1
Circuit Diagram
Symbol
198 148
1 2
Set meter for

Diode testing.
= .200 to .900
K1
K1
A1
A1
= .OL

3 4
= .200 to .900 = .OL
A2 A2
K2 K2

S-0473
150 853 Page 15

4-5. Style 2 Dual Diode Testing Procedure
unit.
1 Dual Diode
Mark and disconnect leads from
1 cathode K1 and anode A2.
5
2 2 Cathode 1 (K1)
2
1 3 Anode 1 (A1)
5
A2 K1 4 Cathode 2 (K2)
5 Anode 2 (A2)
168 413 Replace part if it fails any test.
4 A1, K2
4
3 3
Jumper
Bar A1 K1
Style 2 A2 K2
Actual Part
2
3
3
1 1
A1 K1
A1
A2 K2 2, 4 K1, K2
A2
190 531
Circuit Diagram Symbol 206 987
212 037 Circuit Diagram Symbol
4
5 5
1 2
Set meter for

Diode testing.
= .200 to .900 A2
A2
K2 = .OL
K2

3 4
K1 K1
= .200 to .900 = .OL
A1 A1

S-0472
150 853 Page 16

4-6. Straight And Reverse Polarity Diode Testing Procedure
unit.
1 Straight Polarity Diode
2 Reverse Polarity Diode
4 3 3 Cathode (K)
4 Anode (A)
1 2
K A
3 4
Actual Part Actual Part Circuit Diagram Symbol
Straight Polarity Diode
1 2
Set meter for
Diode testing.
A
= .200 to .900
A
= .OL
K
K

Reverse Polarity Diode
1 2
Set meter for

Diode testing.
K
= .200 to .900
K
= .OL
A
A

Ref. S-0488
150 853 Page 17

4-7. Hockey-Puk Diode Testing Procedure
unit.
1 Hockey-Puk Diode
2 Cathode (K)
3 Anode (A)
2 4 Heat Sink
K
1 Replace part if it fails any test.
3 A
Actual Part Circuit Diagram Symbol
Clamp diode at proper pressure (see Section 6) BEFORE testing.
Set meter for

Diode testing. 4
= .200 to .900
Forward Bias Testing

(Conducting)
= .OL
Reverse Bias Testing

(Blocking)
S-0675
150 853 Page 18

4-8. Stud-Mount SCR Testing Procedure
unit.
1 Stud-Mount Silicon-Controlled
Rectifier (SCR)
2 Anode (A)
3 Cathode (K)
5 1 4 Auxiliary Cathode (Red Lead)
4 G − Not Tested
3 5 Gate (G) (White Lead)
2
K A Replace part if it fails any test.
1 2
G
K A
K A
Cathode-To-Anode Testing
(Blocking) Gate Testing
(Conducting)
Light OFF Cathode to anode OK Light OFF SCR not working properly
Light ON Cathode to anode shorted Light ON SCR is conducting
K A
Holding Current Test

(Conducting)
Light OFF Replace tester batteries

or SCR not working
properly
Light ON Light should remain ON

S-0674
150 853 Page 19

4-9. Hockey-Puk SCR Testing Procedure
unit.
1 Hockey-Puk Type Silicon-
Controlled Rectifier (SCR)
2 Cathode (K)
3 Auxiliary Cathode (Red Lead)
2 − Not Tested
3 4 Gate (G) (White Lead)
K
1 G 5 Anode (A)
4 6 Heat Sink
A
5
Clamp SCR at proper pressure (see Section 6) BEFORE testing.
1 6 2
K
K
G
A A
Cathode-To-Anode Testing Gate Testing

(Blocking) (Conducting)
K
3
G

(Conducting)

or SCR not working
properly
S-0654
150 853 Page 20

4-10. Single SCR Testing Procedure
unit.
1 Single Silicon-Controlled Rec-
tifier (SCR)
1 2 Cathode (K)
3 Gate (G) (White Lead)
3 4 Anode (A)
K Replace part if it fails any test.
2 G
4 199 988 A
Clamp SCR at proper pressure (see Section 6) BEFORE testing.
1 2 G
G
K K
A A
Cathode-To-Anode Testing Gate Testing


or SCR not working
properly

(Conducting)
150 853 Page 21

4-11. NPN Power Transistor Testing Procedure
unit.
1 NPN Power Transistor
1 transistor.
2
C 2 Collector (C)
3 Base (B)
4 Emitter (E)
B
4 E
3
Set meter for

Diode testing.
1 = .200 to .900 2
E
= .OL
E
B
B
Emitter-To-Base Testing
(Blocking)
Emitter-To-Base Testing
(Conducting)
3 4
C C
= .200 to .900 = .OL
B B
Collector-To-Base Testing Collector-To-Base Testing

5 6
C C
E = .OL E = .OL
Collector-To-Emitter Testing Collector-To-Emitter Testing

(Blocking) (Blocking)
S-0475
150 853 Page 22

Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
150 853 Page 23

4-12. SCR/Integrated Rectifier (Single-Phase) Testing Procedure
unit.
1 SCR/Integrated Rectifier
(Single-Phase)
8 Mark and disconnect all leads from
1 integrated rectifier.
1
2 AC Input 1 (AC1)
7
3 Gate 1 (G1)
7
2 4 Negative DC Output (−)
2 6
6 3 5 Positive DC Output (+)
3 5
5 6 Gate 2 (G2)
4
4 7 AC Input 2 (AC2)
8
8 Varistor − Not Tested
Actual Part Actual Part Replace part if it fails any test.
AC1 G1 G2
AC2
−
1 Set meter for

2
Diode testing.
= .200 to .900
AC1
AC1 = .OL
−
−
Diode − Forward Bias Testing Diode − Reverse Bias Testing

3 4
AC2 AC2
= .200 to .900 = .OL

− −

150 853 Page 24

5 6
+ = .200 to .900 + = .OL

− −

7 8 9
AC1 AC1 AC1

+ + +
SCR − Cathode-To-Anode Testing SCR − Gate Testing SCR − Holding Current Test
(Blocking) (Conducting) (Conducting)
Light OFF Cathode to anode OK Light OFF SCR not working properly Light OFF Replace tester batteries
or SCR not working
Light ON Cathode to anode shorted Light ON SCR is conducting properly
10 11 12
AC2 AC2 AC2
+ + +
or SCR not working
Light ON Cathode to anode shorted Light ON SCR is conducting properly
S-0676 / S-0686
150 853 Page 25

4-13. SCR/Integrated Rectifier (Three-Phase) Testing Procedure
R2 G See Parts List for location of parts in
unit.
+ 1 SCR/Integrated Rectifier
(Three-Phase)
1 Mark and disconnect leads from
R negative (−), positive (+), R2, and G
S terminals.
T 2 AC Input (R, S, T)
3
3 SCR Anode (R2)
2 4 Gate (G)
4 −
5 Positive DC Output (+)
5 6 Negative DC Output (−)
Actual Part
1 Set meter for

2
Diode testing.
= .200 to .900
R
R R2
R2
= .OL

3 4
R2 R2
S S
= .200 to .900 = .OL

5 6
R2 R2
= .200 to .900 = .OL

T T

150 853 Page 26

7 8
R R
= .200 to .900 = .OL

9 10
S S
= .200 to .900 = .OL

11 12
= .200 to .900 = .OL

T T

13 14 15
R2 R2 R2
G G
or SCR not working properly
S-0881
150 853 Page 27

4-14. SCR Power Module Testing Procedure
unit.
1 SCR Power Module
AC module.
1
2 AC Input
3 Positive DC Output (+)
2
4 Negative DC Output (−)
3 + 5 Gate 1 (G1)
6 Cathode 1 (K1)
4
7 Cathode 2 (K2)
8 Gate 2 (G2)
5 −
6
7 8 G1 K1 K2 G2
Actual Part Circuit Diagram
Symbol
AC AC
218 296 2
1 1 3
3 G1
7 8 K1
2
4 196 754
5
6 6 G2
5 K2
7
8
Actual Part Circuit Diagram Circuit Diagram
Symbol Symbol
BASE AC AC
1
1
3 218 292
3
7
8
2
2 3
197 698 6 6
5
5
Circuit Diagram Circuit Diagram

Symbol Symbol
150 853 Page 28

1 2 AC
+
K1 − K2 G1
+ K2
− +
K1
SCR − Cathode-To-Anode Testing SCR − Gate Testing

Light OFF Cathode to anode OK Light OFF SCR not working

properly
Light ON Cathode to anode
shorted Light ON SCR is conducting
+ AC
3 4
AC
G1 −
− +
K2
− +
K1
SCR − Holding Current Test SCR − Cathode-To-Anode Testing

Light OFF Replace tester batteries Light OFF Cathode to anode OK

or SCR not working
properly Light ON Cathode to anode
shorted
5 6
AC AC
− + − +
− −
G2 G2
+ +
SCR − Gate Testing SCR − Holding Current Test

(Conducting) (Conducting)
Light OFF SCR not working Light OFF Replace tester batteries
properly or SCR not working
properly
Light ON SCR is conducting
Ref. ST-129 611-A / ST-802 534 / Ref. S-0426
150 853 Page 29

4-15. IGBT Power Module Testing Procedure
unit.
1 IGBT Power Module
Check plastic case for cracks in
1 side of case or a separation of case
2 from its base plate. Replace any
damaged part.
C1
8 power module.
3 G1 (B1)
7 2 Emitter (E1)
6
C2, E1 3 Gate 1 (G1) or Base 1 (B1)
E1
4 Collector 2, Emitter 1
5 (C2, E1)
G2 (B2) 5 Emitter 2 (E2)
4
6 Collector 1 (C1)
E2 7 Emitter 2 (E2)
E2
8 Gate 2 (G2) or Base 2 (B2)
Circuit Diagram Symbol Replace part if it fails any test.
Typical Part
A1
C2
C2/E1
1
1 3
5 2
8 6
8
E2
E2
2
4
5
6
212 106 200 392
G2
G2
K1
E2
C1
E2
Circuit Diagram Symbol Circuit Diagram Symbol
NOTE The preferred test is found in the product Technical Manual which also accounts
for any uniquenesses in the actual product procedures.
A. Best Test For IGBT’s

IGBT/MOSFET Tester Information
1 2 3
Yellow To check battery, connect Red and
2 Test Button
Black 3 Test Light (LED)
Red S-0880-A
150 853 Page 30

IGBT Power Module Testing Procedure
Step 1. Hook up ALL tester
leads to perform Test 1.
G1 (B1) LED On = Shorted; replace part
Static Hazard. Step 2. Press button.

Put on grounded wrist strap. LED Off = Fails test; replace part
C1 LED On = Passes test
Test 1
Step 3. Repeat Steps 1 and 2 for
Test 2.
Red
E1
G1 (B1) Gate 1 or Base 1
Black Yellow G2 (B2) Gate 2 or Base 2
C1 Collector 1
C2/E1 Collector 2/Emitter 1
E2 Emitter 2
G2 (B2)
Test 2
E2 Yellow
Black
C2
Red
ST-801 132 / S-0880-A / S-0664
150 853 Page 31

B. Alternative Test For IGBT’s
Static Hazard. Put on grounded wrist strap.
1 Set meter for 2

Diode testing.
= .200 to .900
C1
C1
= .OL
C2, E1
C2, E1

3 4
E2 E2
= .200 to .900 = .OL
C2, E1 C2, E1

Set meter for Resistance

(Ohms) testing.
5 6
E1
E1
= O.L
G1 (B1)
G1 (B1)
= O.L
Gate-To-Emitter Resistance Testing Gate-To-Emitter Resistance Testing

(Open) (Open)
150 853 Page 32

7 8
E2 E2
G2 (B2) G2 (B2)
= O.L = O.L

(Open) (Open)
S-0664 / Ref. S-0398
150 853 Page 33

IGBT Power Module Testing Procedure (212 106)
leads to perform test.
For MOD1, connect yellow meter
lead to lead 27 (PLG5-1)
For MOD2, connect yellow meter
lead to lead 29 (PLG5-4)
LED On = Shorted; replace part
Step 2. Press button.
Static Hazard.
Put on grounded wrist strap. LED Off = Fails test; replace part
G2(E2) LED On = Passes test
G2 (E2) Gate 2/Emmiter 2

C1
C1 Collector 1
E2 C2/E1 Collector 2/Emitter 1
Yellow
Black E2 Emitter 2
C2/E1
Red Finish IGBT Power Module Test-

ing Procedure On Next Page.
If IGBT’s power modules test okay,
reconnect bus bars to capacitor
bank C1, and between MOD1 and
MOD2.
Clean surfaces and apply a small
amount of EJC (electrical joint com-
pound) to connections. Torque
mounting hardware to 40 in-lb (4.5
N⋅m).
Connect gate lead plug PLG5 to re-
ceptacle RC5 on control board
PC1.
If either power module fails, both
IGBT modules and PC1 must be re-
placed. If a failure accurs, also
check diode D7, capacitors C3 and
C4. If D7 must be replaced, heat
sink compound (Miller #604414)
should be applied. Torque D7
mounting hardware to 12 in-lb (1.4
N⋅m).
804 015-A
150 853 Page 34

B. Alternative Test For IGBT’s (212 106)
1 2
Set meter for
Diode testing.
= .200 to .900
C1
C1
C2, E1 = .OL
C2, E1

3 4
E2 E2
= .200 to .900 = .OL
C2, E1 C2, E1

5 6
(Ohms) testing.
G2(E2)
G2(E2)
= O.L
= O.L

(Open) (Open)
804 015-A
150 853 Page 35

4-16. MOSFET Power Transistor Testing Procedure
unit.
1 MOSFET Power Transistor
Remove transistor from circuit
board.
1 D 2 Drain (D)
3 Gate (G)
4 Source (S)
5
5 Alternate Source (AS) − Not
Tested
4 G
AS
3 2 S
NOTE The preferred test is found in the product Technical Manual which also accounts
for any uniquenesses in the actual product procedures.
A. Best Test For MOSFET
IGBT/MOSFET Tester Information
1 2 3
Yellow To check battery, connect Red and
2 Test Button
Black 3 Test Light (LED)
Red S-0880-A
MOSFET Power Transistor Testing Procedure

leads.
LED On = Shorted; replace part
Static Hazard.
Put on grounded wrist strap. Step 2. Press button.
LED Off = Fails test; replace part
Yellow LED On = Passes test
G S
Black G Gate
D Drain
D S Source
Red
S-0880-A / S-0663
150 853 Page 36

B. Alternative Test For MOSFET
1 2
Set meter for

Diode testing.
= .200 to .900
D
D
= .OL
S

3 4

(Ohms) testing.
= O.L
= O.L
S
G
S
G
Gate-To-Source Resistance Testing Gate-To-Source Resistance Testing

(Open) (Open)
S-0663
150 853 Page 37

4-17. Modular Main Rectifier Testing Procedure
1 See Parts List for location of parts in
unit.
AC
1 Small Single-Phase Modular
Main Rectifier
2 Large Single-Phase Modular
+ Main Rectifier
3 Three-Phase Modular Main
Rectifier
4 Rectifier Section
AC
5 4 5 Diode
Actual Part Circuit Diagram Symbol 6 Fusible Link
Look at each rectifier section for
2
any open fusible links on the
diodes. No diode test is required.
If any fusible link is open, replace
+ entire modular rectifier.
AC
AC
5 4
−
3
+
AC
AC
AC
−
5 4
Portion Of Side View
Ref. SC-121 845-A / ST-152 789 / S-0689
150 853 Page 38

SECTION 5 − TOOLS AND PLUGS
NOTE The following extraction tools are available individually through the MILLER Parts
Department. All nine tools can be purchased as a kit (155 809). Contact the Parts
Department at 920-735-4500 for information on the kit.
5-1. Using Tool Part Number 121 481 To Remove Lead

1 Typical Plug
1 2 Contact
3 Tool
2 Insert prongs into plug hole so
prongs are between contact and
wall of plug.
Remove lead.
3
ST-147 971-C

1 1 Typical Plug
2 Contact
3 Tool
4 Push Rod Button
6 5 Handle
2
6 Sleeve
5 Holding handle, insert sleeve into
plug hole, allowing push rod button
to back out of handle.
4 Turn handle to free contact.

Press in push rod button to remove
lead.
3
ST-152 068
4 3 1 Typical Plug
2 Contact
3 Locking Clip
4 Clip Area
2
5 Tool
1 Insert tool into clip area as shown.

Press down locking clip to remove
5 lead.
ST-115 689-B
150 853 Page 39

1 Typical Plug
1
2 Contact
3 Tool
4 Handle
Insert tool into plug hole as shown.
2 Press handle in to remove lead.
4
ST-147 699
1 Typical Plug
1
2 Contact
3 Tool
4 Push Rod Ball
5 Sleeve
2 Insert sleeve into plug hole as
shown.
5
Press push rod ball in to remove
lead.
ST-152 066
1 Typical Plug
1 2 Contact
3 Tool
Insert prongs into plug hole so
prongs are between contact and
wall of plug as shown.
2
Remove lead.
ST-152 067
150 853 Page 40

1 Typical Metal Amphenol Plug
6
2 Tool
5
4 3 Handle
4 Tip
5 Lead
Rear
6 Contact
1
Squeeze handle, place tip around
lead, and release handle. Slide tip
into plug hole over contact until con-
tact and lead unlock from plug. Pull
out lead with contact.
3 2
ST-152 587
2 1 Typical Plug
2 Contact
3 Tool
1
4 Push Rod Button
6 5 Handle
6 Sleeve
Holding handle, insert sleeve into
plug hole, allowing push rod button
5 to back out of handle.
Turn handle to free contact.
4 Press in push rod button to remove
lead.
Ref ST-801 706
5-9. Using Tool Part Number 133 357 To Remove DIP Integrated Circuit
1 1 Typical DIP Integrated Circuit

(IC)
2 Tool
3 Handle
4 Trigger
2
5 Jaws
Holding handle, place tool onto IC.
Pull back trigger allowing jaws to
3 grip IC.
Remove IC.
4 ST-155 564
150 853 Page 41

SECTION 6 − TORQUE SPECIFICATIONS FOR PARTS
Table 6-1. Torque Specifications For Diodes
Part Number Diode Type Torque Value
023 178 Stud 300 in-lb (33.9 N·m)
037 157 Stud 300 in-lb (33.9 N·m)
037 305 Stud 125 in-lb (14.1 N·m)
037 306 Stud 125 in-lb (14.1 N·m)
037 956 Stud 300 in-lb (33.9 N·m)
037 957 Stud 300 in-lb (33.9 N·m)
086 353 Puk *80 in-lb (9.0 N·m)
087 998 Stud 30 in-lb (3.4 N·m)
087 999 Stud 30 in-lb (3.4 N·m)
093 056 Stud 30 in-lb (3.4 N·m)
093 057 Stud 30 in-lb (3.4 N·m)
095 141 Stud 50 in-lb (5.6 N·m)
095 142 Stud 50 in-lb (5.6 N·m)
095 251 Stud 30 in-lb (3.4 N·m)
117 451 Stud 50 in-lb (5.6 N·m)
117 452 Stud 50 in-lb (5.6 N·m)
144 216 Stud 30 in-lb (3.4 N·m)
155 778 Stud 27 in-lb (3.1 N·m)
185 831 Puk 80 in-lb (9.0 N·m)
155 351 Stud 22 in-lb (2.5 N·m)
*Indicator clamping pressure is 1000 lb.
Table 6-2. Torque Specifications For SCR’s

Part Number SCR Type Minimum Torque Value Maximum Torque Value
000 251 Stud 425 in-lb (48 N·m) 450 in-lb (50.8 N·m)
022 260 Stud 125 in-lb (14.1 N·m) 150 in-lb (16.9 N·m)
074 250 Stud −−−− 130 in-lb (14.7 N·m)
150 853 Page 42

Table 6-3. SCR Clamping Pressures
Indicator Clamping Clamping Torque
Part Number SCR Type
Pressure Value Value (Nut)
044 231 Puk 1000 lb 80 in-lb (9.0 N·m)
046 995 Puk 1000 lb 80 in-lb (9.0 N·m)
048 736 Puk 1000 lb 80 in-lb (9.0 N·m)
070 160 Puk 5000 lb NA
070 161 Puk 1000 lb 80 in-lb (9.0 N·m)
071 984 Puk 5000 lb NA
083 937 Puk 1000 lb 80 in-lb (9.0 N·m)
086 926 Puk 1000 lb 80 in-lb (9.0 N·m)
094 387 Puk 1000 lb 80 in-lb (9.0 N·m)
097 397 Puk 1000 lb 80 in-lb (9.0 N·m)
097 959 Puk 2000 lb 140 in-lb (15.8 N·m)
107 588 Puk 1000 lb 80 in-lb (9.0 N·m)
109 091 Puk 2000 lb 140 in-lb (15.8 N·m)
109 270 Puk 1000 lb 80 in-lb (9.0 N·m)
112 940 Puk 2000 lb 140 in-lb (15.8 N·m)
112 941 Puk 2000 lb 140 in-lb (15.8 N·m)
112 942 Puk 2000 lb 140 in-lb (15.8 N·m)
113 010 Puk 2000 lb 140 in-lb (15.8 N·m)
115 114 Puk 1000 lb 50 in-lb (5.6 N·m)
116 661 Puk 2000 lb 140 in-lb (15.8 N·m)
117 720 Puk 1000 lb 80 in-lb (9.0 N·m)
119 371 Puk 1000 lb 50 in-lb (5.6 N·m)
121 430 Puk 2000 lb 140 in-lb (15.8 N·m)
132 147 Puk 2000 lb 80 in-lb (9.0 N·m)
143 818 Puk 1000 lb 50 in-lb (5.6 N·m)
148 091 Puk 2000 lb 90 in-lb (10.2 N·m)
161 668 Puk 1000 lb 55 in-lb (6.1 N·m)
162 516 Puk 800 lb NA
185 830 Puk 80 in-lb (9.0 N·m)
Table 6-4. Torque Specifications For IGBT And MOSFET Transistor Modules
Transistor Replacement Kit
Mounting Screw Torque Value Screw Terminal Torque Value
Part Number
149 202 27 in-lb, ±3 in-lb (3.1 N·m, ±0.3 N·m) 17 in-lb, ±2 in-lb (1.9 N·m, ±0.2 N·m)
150 853 Page 43

Transistor Replacement Kit
Part Number Mounting Screw Torque Value Screw Terminal Torque Value
208 173 25 in-lb, ±2in-lb (2.8 N·m, ±0.2 N·m) 25 in-lb, ±2 in-lb (2.8 N·m, ±0.2 N·m)
212 936 *25 in-lb, ±2 in-lb (2.8 N·m, ±0.2 N·m) 25 in-lb, ±2 in-lb (2.8 N·m, ±0.2 N·m)
*First tighten both screws to 7 in-lb, then torque both screws to final value. Allow ten minutes relax time and re-torque both screws to final value.
Table 6-5. Torque Specifications For Rectifiers
Rectifier Replacement Kit

Part Number
109 373 22 in-lb, ±2 in-lb (2.5 N·m, ±0.2 N·m) NA
149 219 22 in-lb, ±2 in-lb (2.5 N·m, ±0.2 N·m) NA
25 in-lb, ±2 in-lb (2.8 N·m, ±0.2 N·m)
179 629 33 in-lb, ±3 in-lb (3.7 N·m, ±0.3 N·m)
Gate: 15 in-lb, ±1 in-lb (1.7 N·m, ±0.1 N·m)
179 542 37 in-lb, ±4 in-lb (4.2 N·m, ±0.2 N·m) NA
199 034 NA NA
28 in-lb, ±2 in-lb (3.1 N·m, ±0.3 N·m)
173 630 20 in-lb, ±2 in-lb (2.3 N·m, ±0.2 N·m)
Gate: 14 in-lb, ±1 in-lb (1.6 N·m, ±0.1 N·m)
212 937 *25 in-lb, ±2 in-lb (2.8 N·m, ±0.2 N·m) 25 in-lb, ±2 in-lb (2.8 N·m, ±0.2 N·m)
*First tighten both screws to 7 in-lb, then torque both screws to final value. Allow ten minutes relax time and re-torque both screws to final value.
150 853 Page 44

Table 6-6. Torque Specifications For Diode Modules
Diode Replacement Kit

Part Number
149 209 33 in-lb, ±3 in-lb (3.7 N·m, ±0.3 N·m) NA
149 210 33 in-lb, ±3 in-lb (3.7 N·m, ±0.3 N·m) NA
149 211 20 in-lb, ±2 in-lb (2.3 N·m, ±0.2 N·m) NA
149 212 27 in-lb, ±3 in-lb (3.1 N·m, ±0.3 N·m) NA
149 213 27 in-lb, ±3 in-lb (3.1 N·m, ±0.3 N·m) NA
149 216 27 in-lb, ±3 in-lb (3.1 N·m, ±0.3 N·m) NA
**35 in-lb, ±5 in-lb (4.0 N·m, ±0.6 N·m)

151 229 30 in-lb, ±3 in-lb (3.4 N·m, ±0.3 N·m)
Center Screw: *22 in-lb, ±2 in-lb (2.5 N·m, ±0.2 N·m)
**35 in-lb, ±5 in-lb (4.0 N·m, ±0.6 N·m)

151 431 30 in-lb, ±3 in-lb (3.4 N·m, ±0.3 N·m)
155 634 27 in-lb, ±3 in-lb (3.1 N·m, ±0.3 N·m) NA
**26 in-lb, ±2 in-lb (2.9 N·m, ±0.2 N·m)

201 531 ***26 in-lb, ±2 in-lb (2.9 N·m, ±0.2 N·m)
*Tighten the center screw first to this value, followed by the two outside screws to this value.
**Final torque the outside screws to this value.
***Tighten each terminal to one-half this value, then final torque to this value.
150 853 Page 45

Table 6-7. Torque Specifications For Primary/Secondary Modules
Module Replacement Kit
Part Number
204 821 *26 in-lb, ±2 in-lb (2.9 N·m, ±0.2 N·m) NA
201 533 *22 in-lb, ±2 in-lb (2.5 N·m, ±0.2 N·m) NA
201 534 *22 in-lb, ±2 in-lb (2.5 N·m, ±0.2 N·m) NA
217 625 *22 in-lb, ±2 in-lb (2.5 N·m, ±0.2 N·m) NA
*Tighten to one-half this value first, then final torque to this value.
Table 6-8. Torque Specifications For SCR Modules

SCR Replacement Kit
Part Number
197 698 35−50 in-lb (4.0−5.6 N·m) 35−50 in-lb (4.0−5.6 N·m)
218 296 45 in-lb, ±5 in-lb (5.1 N·m, ±0.5 N·m) ** 45 in-lb, ±5 in-lb (5.1 N·m, ±0.5 N·m) **
218 292 45 in-lb, ±5 in-lb (5.1 N·m, ±0.5 N·m) ** 45 in-lb, ±5 in-lb (5.1 N·m, ±0.5 N·m) **
** = Re-torque after 4 hours.
150 853 Page 46

Notes
Notes
Notes
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer St.

P.O. Box 1079
Appleton, WI 54912-1079 USA
Hobart Welding Products

An Illinois Tool Works Company
600 West Main Street
Troy, OH 45373 USA

Manual de Pruebas O150853g

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September 2005 FORM: 150 853G

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

WHO DO I CONTACT FOR HELP?

Always provide Model Name and Serial or Style Number

150 853 2/04

1-1. Symbol Usage

1-2. Servicing Hazards

FLYING PIECES OF METAL or DIRT can FALLING EQUIPMENT can cause

150 853 Page 1

1-3. Engine Hazards

1-4. EMF Information

150 853 Page 2

2-1. Safety Precautions − Read Before Using This Guide

Y WARNING: ELECTRIC SHOCK can kill.

PART NAME FUNCTION PICTURE CIRCUIT SYMBOL

BATTERY A source of DC voltage. Typically used in +

BRUSHES/SLIP Components that allow electrical connections

CAPACITOR A device that stores electrical energy. Large POLARIZED NON-POL.

CHASSIS The green ground wire of a primary cord is

CIRCUIT BREAKER A protection device that breaks a circuit when

CIRCUIT COMMON When many wires are connected together,

150 853 Page 3

CLAMP A spring-loaded connection device. A good

CONTACTOR A heavy duty relay. Usually used to make

CURRENT A transformer that produces an AC voltage CT1

DASHED LINE A dashed line between parts means there is

DIODE A device that allows current to flow in one

FAN MOTOR This device provides cooling of the internal

FUSE A protection device, usually an enclosed

GAS OR WATER These are electromechanical devices used to

HALL DEVICE Produces a small DC voltage proportional to

150 853 Page 4

IGBT A device that is used as an “electronic

INTEGRATED An arrangement of four diodes used to +

INTEGRATED IC’s often called “chips” provide a complete

JUMPER LINK Usually, the jumper link is a piece of brass

LIGHT EMITTING This device usually referred to by its initials

MAGNETIC This device usually referred to as a

METER A measuring device. A “voltmeter” is a good

MOSFET A device that is used as an “electronic D

150 853 Page 5

MOTOR A device that converts electrical energy into

OPERATIONAL Usually referred to as an “Op-Amp”, this IC

OPTICAL A device that uses “light” to get electrical

PILOT LIGHT A light located on the front panel which

POTENTIOMETER Both devices have a moveable brush that

PLUG A connection device that hangs loose with

RECEPTACLE A connection device that is mounted or fixed.

RELAY−−COIL AND This is an electromechanical device whose COIL

RESISTOR A device which resists the flow of electric FIXED R1

150 853 Page 6

RIBBON CABLE A connection device where the wires are laid

SCR A Silicon Controlled Rectifier (SCR) is an

SHUNT A precision low-value resistor typically used

SNUBBER A device used to absorb voltage spikes,

SPARK GAP The arrangement of two electrodes between

STABILIZER/ When placed in a DC circuit, the inductor or

SWITCH A mechanical device that completes or SPST SPDT

A multi-pole switch will use dashed lines to

SPST = Single Pole Single Throw

MOMENTARY A switch that “springs back” to its original

LIMIT SWITCH A switch mounted in the path of a moving

150 853 Page 7