TM-316B August 1999

Eff. w/Style No. 711-A Or

w/Serial Number JE814567

Processes
Stick (SMAW) Welding

Description
AC/DC, 300/200 AC/DC Models:

225 And 300 Models:

Arc Welding Power Source

Thunderbolt

AC/DC, 300/200 AC/DC, 225, And 300

Visit our website at

www.MillerWelds.com
 TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Duty Cycle Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-4. Selecting A Location And Installing Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-5. Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-6. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-7. Internal Connections For Operating 115/230 Volts, 225 Amperes AC
And AC/DC Models From 115 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-8. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC
Or 300 Amperes AC Models From 230 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-9. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-1. Functional Diagram For AC/DC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-2. Functional Diagram For AC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 5 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-2. Troubleshooting Circuit Diagram For Thunderbolt AC/DC Models . . . . . . . . . . . . . . . . . . . . . . 17
5-3. Troubleshooting Circuit Diagram For Thunderbolt 300/200 AC/DC Models . . . . . . . . . . . . . . . 18
5-4. Troubleshooting Circuit Diagram For Thunderbolt 225 Models
Without Power Factor Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-5. Troubleshooting Circuit Diagram For Thunderbolt 225 Models
With Power Factor Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-6. Waveforms For Thunderbolt AC/DC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-7. Waveforms For Thunderbolt 300/200 AC/DC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-8. Waveforms For Thunderbolt AC 225 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 6 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-2. Lubricating Shunt Block And Anti-Noise Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 7 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Who Do I
SECTION 8 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Contact for
Help?

Call:
Customer Service Dept.
at 920-735-4505

Fax:
Customer Service Dept.
920-735-4136

Write:
Miller Electric Mfg. Co.
P.O. Box 1079
Appleton, WI 54912 USA

Always provide Model

Name and Serial or
Style Number
 SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
OM-316G - 9/97, safety_stm 5/97

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in
the adjoining symbols.

This group of symbols means Warning! Watch Out! possible

Y Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.

1-2. Servicing Hazards

Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see FLYING METAL can injure eyes.
the symbol, watch out, and follow the related instructions to
avoid the hazard. D Wear safety glasses with side shields or face
shield during servicing.
Y Only qualified persons should service, test, maintain, and re-
D Be careful not to short metal tools, parts, or
pair this unit.
wires together during testing and servicing.
Y During servicing, keep everybody, especially children, away.

HOT PARTS can cause severe burns.

ELECTRIC SHOCK can kill.
D Do not touch hot parts bare handed.
D Do not touch live electrical parts. D Allow cooling period before working on welding
gun or torch.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from re-
ceptacle, or stop engine before servicing unless the procedure spe-
cifically requires an energized unit. EXPLODING PARTS can cause injury.

D Insulate yourself from ground by standing or working on dry insulat-
ing mats big enough to prevent contact with the ground.
D Do not leave live unit unattended.
D If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
D Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any parts.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
D Always wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
D Turn Off welding power source and wire feeder
or stop engine before making or changing me-
ter lead connections.
D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
D Read instructions for test equipment.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.

FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

D Do not place unit on, over, or near combustible D Keep away from moving parts such as fans.
surfaces. D Keep all doors, panels, covers, and guards
D Do not service unit near flammables. closed and securely in place.

Thunderbolt Series TM-316 Page 1

 MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
MAGNETIC FIELDS can affect pacemak-
ers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
OVERUSE can cause OVER-
HEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
1-3. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
TM-316 Page 2
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
READ INSTRUCTIONS.
D Use MILLER Testing Booklet (Part No. 150
853) when servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine MILLER replacement parts.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
Thunderbolt Series
 SECTION 2 – INSTALLATION

2-1. Specifications

Table 2-1. AC/DC Models

Maximum Amperes Input at Rated Load Output

Rated Welding Amperage Open- 50 Or 60 Hz, Single-Phase
Mode Weight
Output Range Circuit
Voltage 115 V 220 V 230 V 400 V 460 V
225 A @ 25 Volts AC, Low: 30 – 150
AC 80 VAC
20% Duty Cycle High: 40 – 225
Net: 114 lb (52 kg);
95 47.5 23.7 Ship: 133 lb (60 kg)
150 A @ 25 Volts DC, 4.6* 2.3* 1.2*
DC 30 – 150 72 VDC
20% Duty Cycle

300 A @30 Volts AC, Low: 50 – 230

AC 80 VAC
20% Duty Cycle High: 65 – 300
Net: 135 lbs (61 kg);
70 67 39 34 Ship: 140 lbs (64 kg)
200 A @ 25 Volts DC, 5.4* 3.6* 1.8* 1.3*
DC 25 – 200 72 VDC
20% Duty Cycle

Overall Dimensions
Height: 21-1/2 in (546 mm); Width: 12-1/2 in (318 mm); Depth: 14 in (356 mm)

*While idling

Table 2-2. AC Models

Rated Max Open- Amperes Input at Rated Load

Welding Amperage Circuit Output 50 Or 60 Hz, Single-Phase Weight
Output Range Voltage 115 V 220 V 230 V 400 V KW
225 A @ 25
Low: 30 – 150A 95 47.5 7.2 Net: 100 lb (45 kg)
Volts AC, 20% 80 VAC
High: 40 – 225A 4.6* 2.3* 0.22* Ship: 105 lb (48 kg)
Duty Cycle

300 A @ 30
Low: 35 – 230 70 67 39 11.5 Net: 107 lb (49 kg)
Volts AC, 20% 80 VAC
High: 65 – 300 5.4* 3.6* 1.8* 0.22* Ship: 112 lb (51 kg)
Duty Cycle

Overall Dimensions
Height: 21-1/2 in (546 mm); Width: 12-1/2 in (318 mm); Depth: 14 in (356 mm)

*While idling

Thunderbolt Series TM-316 Page 3

2-2. Duty Cycle Charts

A. For AC/DC Models

Duty Cycle is percentage of 10 minutes
that unit can weld at rated load without
overheating.
Y 20% Duty Cycle at 225 Amperes. Ex-
ceeding duty cycle can damage unit
and void warranty.
2 Minutes Welding 8 Minutes Resting

A. For 115/230, 230, And 460 Volt Models B. For 220, 230/400, And 460 Volt Models
(225/150 Amperes) (300/200 Amperes)

SB-086 727 / SB-099 602-A

B. For AC Models
Duty Cycle is percentage of 10 minutes
that unit can weld at rated load without
overheating.
Y 20% Duty Cycle at 225 Amperes. Ex-
ceeding duty cycle can damage unit
and void warranty.
2 Minutes Welding 8 Minutes Resting

A. For 115/230 And 230 Volt Models B. For 220, And 230/400 Volt Models
(225 Amperes ) (300 Amperes)

ST-001 836-A / SB-099 603-A

TM-316 Page 4 Thunderbolt Series

2-3. Volt-Ampere Curves
A. For AC/DC Models

The volt-ampere curves show the

minimum and maximum voltage
and amperage output capabilities.
Curves of other settings fall be-
tween the curves shown.

A. For 115/230, 230 And 460 Volt Models

(225/150 Amperes)

B. For 220, 230/400, And 460 Volt Models

(300/200 Amperes)

A = LOW RANGE
B = HIGH RANGE

SB-001 844-B / SB-086 728-B / SB-099 689-A / SB-099 702-A

Thunderbolt Series TM-316 Page 5

B. For AC Models

The volt-ampere curves show the

minimum and maximum voltage
and amperage output capabilities.
Curves of other settings fall be-
tween the curves shown.

A. For 115/230 And 230 Volt Models

(225 Amperes)

B. For 220 Volt Model C. For 230/400 Volt Model

(300 Amperes) (300 Amperes)

A = Low Range
B = High Range

SB-001 844-B / SB-099 701-A / SB-099 689-A

TM-316 Page 6 Thunderbolt Series

2-4. Selecting A Location And Installing Handle

1 Lifting Area
Place hands where shown to move
unit. Get help when moving unit.
2 Running Gear Mounting Holes
3 Rating Label
5
Locate unit near correct input
4 power.
6
4 Amperage Adjustment Rod
5 Handle
6 Pin
Install as shown.
Move pin into locked position
shown.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.

1
Locked Pin

2 18 in (457 mm) for airflow

ST-087 026-B / Ref. ST-151 556 / ST-155 573-A

2-5. Weld Output Cables

NOTE For weld output cable replacements or extensions, contact your Factory
Authorized Service Agent.

Thunderbolt Series TM-316 Page 7

2-6. Electrical Service Guide
Input Voltage 115 220 230 400 460

47.5 23.7
Input Amperes At Rated Output 95 [70]
[67]
[39]
[34]

Max Recommended Standard Fuse Or Circuit Breaker Rating 70 35

150 [110] [60]
In Amperes [100] [50]

12 14
Min Input Conductor Size In AWG/Kcmil 8 [8]
[10]
[14]
[14]

87 (26) [101 138 (42)

Max Recommended Input Conductor Length In Feet (Meters) 32 (10) [75 (23)]
[82 (25)] (31)] [87 (27)]

14
Min Grounding Conductor Size In AWG/Kcmil 8 [8] 12 [10] [14]
[14]

[ ] Electrical Service Requirements For 300/200 AC/DC And 300 AC Models

Reference: 1993 National Electrical Code (NEC) Ref. S-0092-J

TM-316 Page 8 Thunderbolt Series

2-7. Internal Connections For Operating 115/230 Volts, 225 Amperes AC
And AC/DC Models From 115 Volts

NOTE Follow applicable electrical codes and have a competent electrician make internal
connections. Note the input amperes as stated in Section 2-6.

230V Connection 115V Connection

3 4 5 13 14 4 5 13 14
2 3
2

6
6

12
12
7 7

11 8
11
3/8 in
10
(cut tie wraps) 10 9

Ref. ST-156 521

Y Turn Off unit and disconnect input 8 Terminal Screw 1 Obtain correct size and length 115 volts input
power. 9 Jumper Lead 1 power cable (see Section 2-6). Install correct
size ring terminals to cable leads.
Remove amperage adjustment handle and Remove screw securing jumper lead 1 to ter-
wrapper. minal on Power switch. Route cable through strain relief, and connect
1 Wrapper green lead to ground terminal.
Route lead 3 to switch terminal, and secure
2 Lead 2 jumper lead 1 and lead 3 to terminal with Connect lead 2, lead 4, and black input power
3 Lead 3 screw. cable lead together, and secure with existing
10 Jumper Lead hardware.
Remove insulated sleeving, and disconnect
lead 2 from lead 3. 11 Terminal Screw 2 Route white input power cable lead to termi-
4 Lead 4 12 Input Power Cable White Lead nal on Power switch where original white lead
was disconnected, and secure white lead and
5 Input Power Cable Black Lead Remove screw securing jumper lead and jumper lead to terminal with existing screw.
6 Input Power Cable Strain Relief (On white lead to switch terminal.
Tighten strain relief, install wrapper and am-
Rear Panel) 13 Ground Terminal
perage adjustment handle.
Remove insulated sleeving, and disconnect 14 Input Power Cable Green Lead
lead 4 from black lead. Connect input power according to Section
Remove green lead from ground terminal, 2-9.
7 Power Switch S1 (As Viewed From loosen strain relief, and remove 230 volts in-
Rear Of Switch) put power cable.

Thunderbolt Series TM-316 Page 9

2-8. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC Or 300
Amperes AC Models From 230 Volts

NOTE Follow applicable electrical codes and have a competent electrician make internal
connections. Note the input amperes as stated in Section 2-6.

Y Turn Off unit and disconnect

input power.
4 1 Primary Coil Lead 4
2 Lead 4 Insulation Sleeving
3 Power Switch Lead 4
4 Lead Connection Hardware
Slide Sleeving down, and discon-
nect one lead 4 from the other. Re-
move sleeving.
5 Fan Motor (FM) Lead 2
6 Lead 2 Insulation Sleeving
Disconnect fan motor lead 2 at fan
motor, and remove sleeving.
Take lead 2 sleeving and secure it
over the end of primary coil lead 4.
3
Replace lead 2 sleeving with lead 4
2 sleeving.
7 Primary Coil Lead 2
1
Slide sleeving out of the way, and
connect power switch Lead 4 to pri-
7 6 5
mary coil lead 2, and secure with
existing hardware. Secure sleeving
over connection.
Connect fan motor lead 2 back onto
fan motor.
Reinstall wrapper and amperage
adjustment handle.

Connected For 400 Volts

3
7 2 5

Connected For 230 Volts

3/8 in

(cut tie wraps)

Ref. ST-087 027-C / Ref. ST-156 374

TM-316 Page 10 Thunderbolt Series

2-9. Connecting Input Power
Y Have only qualified persons
make this installation. See
rating label in Section 2-4, and
be sure to supply correct in-
put power.
1 Plug
2 Receptacle
3 Input And Grounding
Conductors For Models Not
Supplied With Plug
See Section 2-6 for conductor and
fuse size and ratings. Size and
ratings must comply with applicable
codes.

L2
L1

L2
Y Always connect Install conductors into a deenergized line
grounding disconnect device. 2 GND/PE
GND/PE
conductor first.
L1

230 VAC,
1
3

3/8 in

ST-801 298

Thunderbolt Series TM-316 Page 11

 SECTION 3 – OPERATION
3-1. Controls
A. Controls For AC/DC Models

1 Amperage Adjustment Control

2 Amperage Range Indicator
3 Power Switch
For DC Weld Output
4 Positive (+) Weld Output
Terminal
5 Negative (–) Weld Output
Terminal
For Electrode Positive (DCEP),
connect work cable to negative (–)
terminal and electrode holder cable
2 to positive (+) terminal.
For Electrode Negative (DCEN),
reverse cable connections.
For AC Weld Output
6 Low Range Electrode Weld
1 Output Receptacle
7 High Range Electrode Weld
Output Receptacle
When welding below upper amper-
age limit of low range receptacle,
use low range receptacle.
8 Work Weld Output Receptacle

7 4
See unit nameplate for specific AC ranges.

6 8 5 ST-087 026-B / Ref. ST-086 696-F

TM-316 Page 12 Thunderbolt Series

B. Controls For AC Models

1 Amperage Adjustment Control

2 Amperage Range Indicator
3 Low Range Electrode Weld
Output Receptacle
4 High Range Electrode Weld
Output Receptacle
When welding below upper amper-
age limit of low range receptacle,
use low range receptacle.
5 Work Weld Output Receptacle
6 Power Switch

4
See unit nameplate for specific ranges.

3 5

Ref. ST-155 574 / Ref. SC-107 516-F

Thunderbolt Series TM-316 Page 13

 SECTION 4 – THEORY OF OPERATION

4-1. Functional Diagram For AC/DC Models

1 Power Switch S1
1
Provides on/off control of welding
Single-Phase Power power source.
Line Input Switch S1 2 Main Transformer T1
Power
Supplies power to weld output
230 VAC circuit.
3 Movable Shunt
4 2
Provides a path for part of the
Main magnetic field to bypass the core of
Fan Primary Secondary
Transformer transformer T1 thereby varying
Motor FM
T1 weld output amperage. Moving
shunt down into T1 bypasses more
of the magnetic field thereby
lowering amperage output. Moving
3 shunt out of T1 bypasses less of the
magnetic field and increases output
amperage.
Movable
Shunt 4 Fan Motor FM
Provides cooling of internal compo-
nents.
5 Main Rectifier
5 Changes the ac output from T1 to
full-wave rectified dc.
6 Stabilizer Z1
Main Rectifier
Smooths out current to dc weld out-
put receptacles.
7 AC Electrode And Work Weld
Output Receptacles
Provide weld output and selection
of amperage output range.
8 DC Positive (+) And Negative
6 (–) Weld Output Receptacles
Provide weld output and changing
of output polarity.
Stabilizer Z1

8 8 7 7 7
Electrode Electrode Work
Negative (–) Positive (+)
(30-150 A) (40-225 A) Weld Output
Weld Output Weld Output
Weld Output Weld Output Receptacle
Receptacle Receptacle
Receptacle Receptacle

Work Electrode Electrode Work

AC Input Power
AC Weld Current Circuit
DC Weld Current Circuit
Magnetic Coupling

TM-316 Page 14 Thunderbolt Series

4-2. Functional Diagram For AC Models

1
Single-Phase Power 5
Line Input Switch S1 Electrode
Power
230 VAC (30-150 A)
Weld Output
4 2 Receptacle

Fan Main
Motor FM Primary Transformer Secondary 5
T1
Electrode
(40-225 A)
Weld Output Electrode
3 Receptacle
Movable Work
Shunt
5
Work
Weld Output
Receptacle

AC Input Power

Weld Current Circuit

Magnetic Coupling

1 Power Switch S1 shunt down into T1 by-passes more of the magnetic field thereby
lowering amperage output. Moving shunt out of T1 by-passes less
Provides on/off control of welding power source.
of the magnetic field and increases output amperage.
2 Main Transformer T1
4 Fan Motor FM
Supplies power to weld output circuit.
Provides cooling of internal components.
3 Movable Shunt
5 Electrode And Work Weld Output Receptacles
Provides a path for part of the magnetic field to by-pass the core of
transformer T1 thereby varying weld output amperage. Moving Provide weld output and selection of amperage output range.

Thunderbolt Series TM-316 Page 15

 SECTION 5 – TROUBLESHOOTING

5-1. Troubleshooting Table

. See Section 5-2, 5-3, 5-4, or 5-5 for test points

and values and Section 8 for parts location.

NOTE Use MILLER Testing Booklet (Part No. 150 853) when checking solid-state parts.

Table 5-1. Troubleshooting

Trouble Remedy
No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 2-9).

Check and replace line fuses if open. Reset breakers if necessary (see Section 2-9).

Check continuity of Power switch S1, and replace if necessary.

Check main transformer T1 for signs of winding failure. Check continuity across windings, and check
for proper connections. Replace T1 if necessary.

No weld output; fan runs. Clean and tighten all weld cable connections.

Check main transformer T1 for signs of winding failure. Check continuity across windings, and check
for proper connections. Replace T1 if necessary.

Fan does not run; weld output okay. Check and clear blocked fan blade.

Check coil voltage and connections of fan motor FM, and replace if necessary.

Low weld output; Amperage control va- Check for proper input power connections (see Section 2-9).
ries output.

Clean and tighten all weld cable connections.

For AC/DC models, check diodes in main rectifier, and replace if necessary.

Amperage control does not vary weld Check transformer shunt assembly for missing or damaged parts, and replace parts as necessary.
output.

Excessive line current draw; line fuses Check main transformer T1 for signs of winding failure. Check continuity across windings, and check
and/or breakers open repeatedly. for proper connections. Replace T1 if necessary.
For AC/DC models, check diodes in main rectifier, and replace if necessary.

For models with power factor correction: check capacitor C1 for a short or open, and check for proper
connections. Replace C1 if necessary.

For models with power factor correction, check power factor winding on main transformer T1 for signs
of failure. Check continuity across windings, and check for proper connections. Replace T1 if neces-
sary.

Erratic weld current. Clean and tighten all weld cable connections.

Use dry, properly stored electrodes.

Shorten arc length.

Reduce amperage setting (see Section 3-1).

Electrode sticking to work. Use dry, properly stored electrodes.

Increase arc length.

Increase amperage setting (see Section 3-1).

Erratic arc with excessive spatter. Use dry, properly stored electrodes.

Shorten arc length.

Reduce amperage setting (see Section 3-1).

Loud “buzzing” from shunt. Adjust anti-noise blocks. If noise continues, replace shunt (see Section 6-2).

TM-316 Page 16 Thunderbolt Series

5-2. Troubleshooting Circuit Diagram For Thunderbolt AC/DC Models

R1
R2 V4

V2 R3
R4
V1

C, E D, F
See Section 5-6 for
output waveforms C, D, E, F

V3, A, B
See Section 5-6 for
output waveforms A, B

Idle Amperes Input At No Load Resistance Values

60 Hz Single-Phase Input Input a) Tolerance – ±10% unless specified
200V 230V 380V 460V 575V KVA KW
R1, R2, R3, R4 Less than 1 ohms
w/o PFC* 2.76 2.3 1.27 1.2 0.96 0.55 0.25

w/PFC* 9.9 8.6 4.55 4.3 3.44 –– ––

*Power Factor Correction

Voltage Readings
Tolerance – ±10% unless specified
V1 53 to 56 volts ac from min to max of Amperage Control
V2 76 to 80 volts ac from min to max of Amperage Control Test Equipment Needed:
V3 69 to 72 volts dc from min to max of Amperage Control
V4* 460 volts ac

*Models with Power Factor Correction only.

SA-092 527-A / ST-800 180

Thunderbolt Series TM-316 Page 17

5-3. Troubleshooting Circuit Diagram For Thunderbolt 300/200 AC/DC Models

R1

R2 R3

V2

V1

C, E
See Section 5-7 for D, F
output waveforms C, D, E, F
V3, A, B
See Section 5-7 for
output waveforms A, B

Resistance Values Idle Amperes Input At No

Load 50 Hz Single-Phase
a) Tolerance – ±10% unless specified Input Input
220 V 380 V KVA KW
R1, R2, R3 Less than 1 ohms
6.05 3.5 1.3 0.45

Voltage Readings
a) Tolerance – ±10% unless specified
V1 57 to 61 volts ac from min to max of
Amperage Control
Test Equipment Needed:
V2 72 to 76 volts ac from min to max of
Amperage Control
V3 70 to 75 volts dc from min to max of
Amperage Control

SA-179 910 / ST-800 180

TM-316 Page 18 Thunderbolt Series

5-4. Troubleshooting Circuit Diagram For Thunderbolt 225 Models Without Power
Factor Correction

R1

R2
V2

V1

See Section 5-8

B, D for output waveforms
A, B, C, D
A, C

Test Equipment Needed:

Idle Amperes Input At No Load
60 Hz Single-Phase
Input Input
200(208)V 230V 380V 460V 575V KVA KW

2.4 2.3 1.3 1.05 0.84 0.48 0.22

Voltage Readings Resistance Values

Tolerance – ±10% unless specified a) Tolerance – ±10% unless specified
V1 53 to 56 volts ac from min to max of R1, R2 Less than 1 ohms
Amperage Control
V2 76 to 80 volts ac from min to max of
Amperage Control

SA-108 072 / ST-159 049

Thunderbolt Series TM-316 Page 19

5-5. Troubleshooting Circuit Diagram For Thunderbolt 225 Models With Power Factor
Correction

R1

V3

V2 R2

V1

See Section 5-8

for output waveforms
B, D A, B, C, D
A, C

Test Equipment Needed:

Idle Amperes Input At No Load
60 Hz Single-Phase
Input Input
200(208)V 230V 460V 575V KVA KW

9.9 8.6 4.3 3.44 1.97 0.28

Voltage Readings Resistance Values

Tolerance – ±10% unless specified a) Tolerance – ±10% unless specified
V1 53 to 56 volts ac from min to max of R1, R2 Less than 1 ohms
Amperage Control
V2 76 to 80 volts ac from min to max of
Amperage Control
V3 460 volts ac

SA-108 071 / ST-159 049

TM-316 Page 20 Thunderbolt Series

Notes

Thunderbolt Series TM-316 Page 21

5-6. Waveforms For Thunderbolt AC/DC Models (Use With Section 5-2)

10 ms 50 V 10 ms 20 V

gnd gnd

A. DC Open-Circuit Voltage B. 25 Volts DC, 75 Amperes (Resistive Load)

10 ms 50 V 10 ms 50 V

gnd gnd

C. AC Open-Circuit Voltage, High Range AC D. AC Open-Circuit Voltage, Low Range AC

TM-316 Page 22 Thunderbolt Series

 10 ms 20 V 10 ms 20 V

gnd gnd

E. 25 Volts AC, 112 Amperes, High Range AC F. 25 Volts AC, 75 Amperes, Low Range AC
(Resistive Load) (Resistive Load)

Test Equipment Needed:

Thunderbolt Series TM-316 Page 23

5-7. Waveforms For Thunderbolt 300/200 AC/DC Models (Use With Section 5-3)

10 ms 50 V 10 ms 20 V

gnd gnd

A. DC Open-Circuit Voltage B. 25 Volts DC, 75 Amperes (Resistive Load)

10 ms 50 V 10 ms 50 V

gnd gnd

C. AC Open-Circuit Voltage, High Range AC D. AC Open-Circuit Voltage, Low Range AC

TM-316 Page 24 Thunderbolt Series

 10 ms 20 V 10 ms 20 V

gnd gnd

E. 25 Volts AC, 112 Amperes, High Range AC F. 25 Volts AC, 75 Amperes, Low Range AC
(Resistive Load) (Resistive Load)

Test Equipment Needed:

Thunderbolt Series TM-316 Page 25

5-8. Waveforms For Thunderbolt AC 225 Models (Use With Sections 5-4 And 5-5)

10 ms 50 V 10 ms 50 V

gnd gnd

A. Open-Circuit Voltage, Low Range AC B. Open-Circuit Voltage, High Range AC

(30-150 Amperes) (40-225 Amperes)

10 ms 50 V 10 ms 50 V

gnd gnd

C. 25 Volts AC, 75 Amperes, Low Range AC D. 25 Volts AC, 112 Amperes, High Range AC
(30-150 Amperes) (Resistive Load) (40-225 Amperes) (Resistive Load)

Test Equipment Needed:

TM-316 Page 26 Thunderbolt Series

 SECTION 6 – MAINTENANCE
6-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Repair Or
Replace
Replace
Unreadable
Cracked
Labels
Cables

Clean And
Tighten Weld
Connections

6 Months 12 Months

Blow Out Or Vacuum

Inside, Lubricate Shunt Block
OR During Heavy Service, (See Section 6-2)
Clean Monthly

6-2. Lubricating Shunt Block And Anti-Noise Adjustment

Y Turn Off welding power
source and disconnect input
power.
1 Shunt Block
Apply light coating of high-tempera-
ture grease to shaded areas of both
shunt blocks.
Install amperage control handle
and locking pin. Turn handle to
spread grease evenly.
2 Noise Adjustment Screws
If shunt block vibrates and
becomes noisy, tighten adjustment
screws 1/4 turn. Install wrapper,
handle, and pin, turn On unit, and
check for shunt noise. Repeat
procedure until noise stops. Do not
overtighten.
Reinstall wrapper, handle, and pin.
Y Install wrapper before
1 turning On power.

2
1

3/8 in

ST-155 498-A

Thunderbolt Series TM-316 Page 27

 SECTION 7 – ELECTRICAL DIAGRAMS

. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact factory for actual circuit, if needed.
The following is a list of all diagrams for models covered by this manual. To order a copy, proceed as follows:
1 Know unit Model and Serial or Style Number.
2 Use this list to find diagram number.
3 Include your FAX number or mailing address with your request.
4 FAX Technical Publications Department at 920-735-4011 or call 920-735-4356.

Circuit
Model Serial Or Style Number
Diagram

Thunderbolt AC/DC (200 And 230 Volts) Style/Serial No. JC-21/JE814567 thru Serial No. SA-086 726-C♦♦
KH329325

Serial No. KH329326 and following SA-183 994

Thunderbolt AC/DC (380, 460, And 575 Style/Serial No. JC-21/JE814567 and following SA-092 527-A
Volts)

Thunderbolt AC/DC (115/230 Volts) Style/Serial No. JC-21/JE814567 and following SA-089 075-B

Thunderbolt AC/DC [200 (208) Volts] Style/Serial No. JC-21/JE814567 and following SA-087 146-C

Thunderbolt 300/200 (220 Volts) StyleSerial No. JC-21/JE814567 and following SA-107 519

Thunderbolt 300/200 [230/400 (Formerly Style/Serial No. JC-21/JE814567 and following SA-179 909
220/380) Volts]

Thunderbolt 225 (230 Volts) Without Pow- Style/Serial No. 711-A1/JF951892 and following SA-108 072
er Factor Correction

Thunderbolt 225 (230 Volts) With Power Style/Serial No. 711-A1/JF951892 and following SA-108 071
Factor Correction

Thunderbolt 225 (208/230 Volts) Without Style/Serial No. 711-A1/JF951892 and following SA-156 488
Power Factor Correction

Thunderbolt 225 (208/230 Volts) With Style/Serial No. 711-A1/JF951892 and following SN-901 031-1B
Power Factor Correction

Thunderbolt 300 (220 Volts) Style/Serial No. 711-A1/JF951892 and following SA-097 991-D

Thunderbolt 300 [230/400 (Formerly Style/Serial No. 711-A1/JF951892 and following SA-179 910
220/380) Volts]

♦♦ Not included in this manual

TM-316 Page 28 Thunderbolt Series

 SA-183 994

Figure 7-1. Circuit Diagram For Thunderbolt AC/DC (200 And 230 Volts)
Effective With Serial No. KH329326 And Following

SA-092 527-A

Figure 7-2. Circuit Diagram For Thunderbolt AC/DC (380, 460, And 575 Volts)
Effective With Style/Serial No. JC-21/JE814567 And Following
Thunderbolt Series TM-316 Page 29
 SA-089 075-B

Figure 7-3. Circuit Diagram For Thunderbolt AC/DC (115/230 Volts)

Effective With Style/Serial No. JC-21/JE814567 And Following

SA-087 146-C

Figure 7-4. Circuit Diagram For Thunderbolt AC/DC With 200 (208) Volts AC Tap
Effective With Style/Serial No. JC-21/JE814567 And Following
TM-316 Page 30 Thunderbolt Series
 SA-107 519

Figure 7-5. Circuit Diagram For Thunderbolt 300/200 (220 Volts) Effective With
Style/Serial No. JC-21/JE814567 And Following

SA-179 909

Figure 7-6. Circuit Diagram For Thunderbolt 300/200 [230/400 (Formerly 220/380) Volts]
Effective With Style/Serial No. JC-21/JE814567 And Following
Thunderbolt Series TM-316 Page 31
 SA-108 072

Figure 7-7. Circuit Diagram For Thunderbolt 225 (230 Volts) Without Power Factor Correction
Effective With Style/Serial No. 711-A1/JF951892 And Following

SA-108 071

Figure 7-8. Circuit Diagram For 230 Volt Thunderbolt 225 (230 Volts) With Power Factor Correction
Effective With Style/Serial No. 711-A1/JF951892 And Following
TM-316 Page 32 Thunderbolt Series
 SA-156 488

Figure 7-9. Circuit Diagram For Thunderbolt 225 (208/230 Volts) Without Power Factor Correction
Effective With Style/Serial No. 711-A1/JF951892 And Following

SN-901 031-1B

Figure 7-10. Circuit Diagram For Thunderbolt 225 (208/230 Volts) With Power Factor Correction
Effective With Style/Serial No. 711-A1/JF951892 And Following
Thunderbolt Series TM-316 Page 33
 SA-097 991-D

Figure 7-11. Circuit Diagram For Thunderbolt 300 (220 Volts) Effective With
Style/Serial No. 711-A1/JF951892 And Following

SA-179 910

Figure 7-12. Circuit Diagram For Thunderbolt 300 [230/400 (Formerly 220/380) Volts]
Effective With Style/Serial No. 711-A1/JF951892 And Following

TM-316 Page 34 Thunderbolt Series

 TMĆ316B August 1999
Eff. w/Style No. 711-A Or
w/Serial Number JE814567

Processes
Stick (SMAW) Welding

Description
AC/DC, 300/200 AC/DC Models:

225 And 300 Models:

Arc Welding Power Source

Thunderbolt

AC/DC, 300/200 AC/DC, 225, And 300

Visit our website at

www.Miller-
Welds.com
 SECTION 8 – PARTS LIST

15
1 11
16
10 14
9
8
7

2
6
5
4 13
3

12

Rectifier prior to
Serial No. KH329326 for
29 AC/DC 225A models; prior
to KH462160 for 18
25 AC/DC 300A models
28
19
17
. Hardware is common and 26 20
not available unless listed.
24
22 21
27 23

SD-087 027-G / Ref. SD-087 027-E

Figure 8-1. Main Assembly (AC/DC Model Illustrated)

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 8-1. Main Assembly

. . 1 . . . . Z . . . . 086 759 . . STABILIZER, (AC/DC 225A models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 1 . . . . Z . . . . 098 591 . . STABILIZER, (AC/DC 300A models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . 057 608 . . RECEPTACLE, jack plug yellow (consisting of) . . . . . . . . . . . . . . . . . . . . . As Req’d
. . 2 . . . . . . . . . . . 039 801 . . RECEPTACLE, jack plug black (consisting of) . . . . . . . . . . . . . . . . . . . . . . As Req’d
. . 2 . . . . . . . . . . . 039 800 . . RECEPTACLE, jack plug red (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . As Req’d
. . 3 . . . . . . . . . . . 082 654 . . . RECEPTACLE & NUT, jack plug yellow or . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . 169 237 . . . RECEPTACLE & NUT, jack plug black or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . 006 095 . . . RECEPTACLE & NUT, jack plug red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . 010 291 . . . WASHER, flat nylafil .625 ID x 1.250 x .125thk . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . 604 668 . . . NUT, stl slflkg .500-20 (Prior to KH560694) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 5 . . . . . . . . . . . 187 004 . . . NUT, .500-20 brs (Eff w/KH560694) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . 174 491 . . . WASHER, lock stl intl tooth .500 (Prior to KH560694) . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . . . . . . . 602 247 . . . WASHER, flat .531 ID x 1.062 OD (Eff w/ KH560694) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 602 216 . . . WASHER, lock .502 ID x .879 OD (Eff w/KH560694) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 601 881 . . . NUT, stl hex jam .500-20 (Eff w/KH560694) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . . . S1 . . . 025 864 . . SWITCH, tgl DPST 40A 250VAC (All 225A models) (Prior to JD-26) . . . . . . . 1
. . 7 . . . . S1 . . . 124 511 . . SWITCH, tgl DPST 40A 600VAC (All 225A models) (Eff w/JD-26) . . . . . . . . . 1
. . 7 . . . . S1 . . . 045 834 . . SWITCH, tgl DPST 60A 600VAC (All 300A models) . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . R1,VR1 . 044 482 . . SUPPRESSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . (AC/DC 225A eff w/KH329326 and AC/DC 300A eff w/ KH462160) . . . . . . . . 1
TM-316 Page 36 Thunderbolt Series
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 8-1. Main Assembly (Continued)

. . 9 . . . . . . . . . . . 024 103 . . BLANK, snap-in nyl .750mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . 10 . PLG1 . . 023 898 . . CORD SET, 250V 10ga 3/c (115/230V models)(Prior to KJ017713) . . . . . . . . 1
. . 10 . PLG1 . . 088 297 . . CORD SET, 250V 6-50P 12ga 3/c 6ft (115/230V models)(Eff w/KJ017713) . 1
. . 10 . . . . . . . . . . 098 613 . . CABLE, pwr 16ft 10ga 3/c (All 300A models)(Prior to KH568696) . . . . . . . . . . 1
. . 10 . . . . . . . . . . 600 349 . . CABLE, port No. 14 3/c (460V 225A models) (order by ft)(Prior to KH568696)6ft
. . 10 . . . . . . . . . . 186 342 . . CABLE, pwr 10ft 10ga (All 300A models & 460V 225A models)
........................... (Eff w/KH568696) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . PLG1 . . 088 297 . . CORD SET, 250V 6-50P 12ga 3/c 6ft (230V 225A models) . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . 039 778 . . RECEPTACLE, str 2P3W 50A 250V (230V 225A models) . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . 088 299 . . CONNECTOR, clamp cable .450/.800 ID x 1.125mtg hole (All 300A models)
(Eff w/JD-15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . 111 443 . . BUSHING, strain relief .240/.510 ID x .875mtg hole (230V 225A models)
(Eff w/JD-15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . 088 299 . . CONNECTOR, clamp cable .450/800(115/230V models)(Prior to KJ017713) 1
. . 12 . . . . . . . . . . 111 443 . . BUSHING, strain relief .240/.510 ID x .875mtg hole (115/230V models)
(Eff w/KJ017713) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . 010 290 . . BUSHING, strain relief 1.030 ID x 1.090mtg hole (Prior to JD-15)(225A) . . . . 1
. . 12 . . . . . . . . . . 010 325 . . BUSHING, strain relief .840 ID x .875mtg hole (460V 225A models)
(Eff w/JD-15 thru KJ001199) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . 088 299 . . CONNECTOR, clamp cable .450/800 (460V 225A model)(Eff w/KJ011199) . 1
. . 12 . . . . . . . . . . 088 299 . . CONNECTOR, clamp cable .450/800 (All 300A models) . . . . . . . . . . . . . . . . . . 1
. . 13 . . . T1 . . . 117 668 . . TRANSFORMER & SHUNT, (230V 225A model) (Fig 8-2) . . . . . . . . . . . . . . . . 1
. . 13 . . . T1 . . . 117 677 . . TRANSFORMER & SHUNT, (460V 225A model) (Fig 8-2) . . . . . . . . . . . . . . . . 1
. . 13 . . . T1 . . . 117 675 . . TRANSFORMER & SHUNT, (115/230V AC/DC model) (Fig 8-2) . . . . . . . . . . 1
. . 13 . . . T1 . . . 098 640 . . TRANSFORMER, pwr main (220V 300A model) (Fig 8-2) . . . . . . . . . . . . . . . . 1
. . 13 . . . T1 . . . 179 920 . . TRANSFORMER, pwr main (230/400V 300A model) (Fig 8-2) . . . . . . . . . . . . 1
. . 13 . . . T1 . . . 184 305 . . TRANSFORMER, pwr main (460V 300A model) (Fig 8-2) . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . 602 336 . . PIN, cotter (Eff w/711-A2 thru HH-6B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . 009 926 . . PIN, handle control current (Eff w/HH-6C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . 009 433 . . HANDLE, control current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . 082 272 . . WRAPPER, (Eff w/HH-6C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . 088 060 . . RECTIFIER, si diode (AC/DC 225A models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to KH329326) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . 098 592 . . RECTIFIER, si diode (AC/DC 300A models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to KH462160) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . C4,5 . . 031 689 . . . CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 19 . . . . . . . . . . 083 147 . . . GROMMET, scr No. 8/10 panel hole .312sq .500 high . . . . . . . . . . . . . . . . . . 2
. . 20 . . D3,4 . . 087 999 . . . DIODE, rect 85A 300V RP (AC/DC 225A models) right side
. . . . . . . . . . . . . . . . . . . . . . . . . . . . positive stud (pink) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 20 . . D3,4 . . 037 306 . . . DIODE, rect 150A 300V (AC/DC 300A models) right side
. . . . . . . . . . . . . . . . . . . . . . . . . . . . positive stud (pink) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . R1,VR1 . 044 482 . . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . 088 061 . . RECTIFIER, si diode (AC/DC 225A models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to KH329326) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . 098 593 . . RECTIFIER, si diode (AC/DC 300A models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to KH462160) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 23 . . C2,3 . . 031 689 . . . CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 24 . . D1,2 . . 037 305 . . . DIODE, rect 150A 300V SP (AC/DC 300A models) (Prior to JD-15) . . . . . . 2
. . 24 . . D1,2 . . 087 998 . . . DIODE, rect 85A 300V SP (AC/DC 225A models) (Eff w/JD-15) left side
. . . . . . . . . . . . . . . . . . . . . . . . . . . . negative stud (blue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 24 . . D1,2 . . 037 305 . . . DIODE, rect 150A 300V SP (AC/DC 300A models) left side
. . . . . . . . . . . . . . . . . . . . . . . . . . . . negative stud (blue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 083 147 . . . GROMMET, scr No. 8-10 panel hole .312sq .500 high . . . . . . . . . . . . . . . . . . 2

Thunderbolt Series TM-316 Page 37

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 8-1. Main Assembly (Continued)

. . 25 . . SR1 . . 147 536 .. RECTIFIER. si diode (AC/DC 225A models)(Eff w/KH329326) . . . . . . . . . . . . 1

. . 25 . . SR1 . . 172 463 .. RECTIFIER, si diode (AC/DC 300A models)(Eff w/KH462160) . . . . . . . . . . . . 1
. . 26 . . . . . . . . . . 005 656 .. BLADE, fan 6 in 4wg 30deg .175 bore CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . FM . . . 123 468 .. MOTOR, 230V 60/50Hz 3000RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . FM . . . 111 931 .. MOTOR, fan 115V 50/60Hz 2600RPM (115/230V model) . . . . . . . . . . . . . . . . . 1
. . 28 . . . . . . . . . . 088 372 .. CASE SECTION, base/front/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . . . . . . . . 184 622 .. NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . 1
................ 174 453 .. HOLDER, electrode w/cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 174 456 .. GROUND CABLE w/CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 039 608 .. PLUG, jack red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 039 901 .. PLUG, jack black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Note: “225A model” and “300A model” refers to the AC output rating of the AC/DC and the AC only machines.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-316 Page 38 Thunderbolt Series

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 8-2. Transformer & Shunt (Fig 8-1 Item 13)

... 1 . . . . . . . . . . . . . 080 522 . . BLOCK, anti-noise shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

... 2 . . . . . . . . . . . . . 178 254 . . INSULATION, coil sec (All 225A models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 2 . . . . . . . . . . . . . 009 430 . . INSULATION, coil sec (All 300A models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . . SEC . . . . 112 488 . . COIL, sec (All 225A models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . SEC . . . 097 957 . . COIL, sec (220V and 460V 300A models) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . SEC . . . 179 070 . . COIL, sec (230/400V 300A model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . 180 280 . . SHUNT, transformer (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . 009 312 . . . . INDICATOR, (Prior to KG069893) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . 178 258 . . . . INDICATOR, (Eff w/KG069893) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . 009 428 . . . . SCREW, lead shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . . 119 963 . . TUBING, phen .531 ID x .875 OD x .500 (60Hz & 115/230V model) . . . . 1
... 8 . . . . . PRI . . . . 112 498 . . COIL, pri (230V 225A model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . PRI . . . . 112 496 . . COIL, pri (460V 225A model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . PRI . . . . 112 509 . . COIL, pri (115/230V AC/DC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . PRI . . . 097 958 . . COIL, pri (220V 300A model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . PRI . . . 179 071 . . COIL, pri (230/400V 300A model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . PRI . . . 184 306 . . COIL, pri (460V 300A model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . 178 255 . . INSULATION, coil pri (All 225A models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 . . . . . . . . . . . . . 009 431 . . INSULATION, coil pri (All 300A models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 10 . . . . . . . . . . . . . 178 253 . . WEDGE, coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . M010 653 . . BEARING, thr oil imprg .375 ID x .750 OD x .062 . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . 010 929 . . WASHER, flat stl spr .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . 024 869 . . COLLAR, set w/screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . 605 129 . . SCREW, cap stl hexhd .250-20 x 7.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . 178 257 . . WEDGE, rear removable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 16 . . . . . . . . . . . . . 178 256 . . GUIDE, wedge rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . . . . . . . . . 602 241 . . WASHER, flat stl SAE .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . . . . . . . . . 089 800 . . NUT, stl flg lkd hex .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6
. Hardware is common and 5
not available unless listed.

4
9
8
7

3
2

10
11
12
13
1

14
15

16

15
18 17 ST-052 396-H

Figure 8-2. Transformer & Shunt

Note: “225A model” and “300A model” refers to the AC output rating of the AC/DC and the AC only machines.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Thunderbolt Series TM-316 Page 39
Notes

TM-316 Page 40 Thunderbolt Series

Notes

Thunderbolt Series TM-316 Page 41

 Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
Phone: 920-734-9821
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1625-525556
FAX: 44 (0) 1625-537553

PRINTED IN USA  1997 Miller Electric Mfg. Co.