TM-207A October 1999

Eff w/ Serial No. KD400224

Processes
TIG (GTAW) Welding

Description

Arc Welding Power Source

Maxstar 91

Visit our website at

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

TABLE OF CONTENTS
SECTION 1 – SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 6 – PRE-POWER CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6-1. Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION 7 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7-2. Troubleshooting Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7-3. Waveforms For Section 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7-4. Troubleshooting Control Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7-5. Troubleshooting Interconnecting Board PC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7-6. Troubleshooting Optional Meter Board PC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7-7. Digital Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SECTION 8 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8-2. Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8-3. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION 10 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

 ARC WELDING SAFETY PRECAUTIONS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
6. Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Noise from some processes
can damage hearing. Chipping, grinding, and welds
cooling throw off pieces of metal or slag.
NOISE
1. Use approved ear plugs or ear muffs if noise level is high.
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
cleaners, and degreasers.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
2. Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical
circuits.
ARC WELDING can be hazardous.
terminal in disconnect box or that cord plug is connected to a
properly grounded receptacle outlet.
7. When making input connections, attach proper grounding
conductor first – double-check connections.
8. Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
9. Turn off all equipment when not in use.
10. Do not use worn, damaged, undersized, or poorly spliced
cables.
11. Do not drape cables over your body.
12. If earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.
13. Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
14. Use only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
15. Wear a safety harness if working above floor level.
16. Keep all panels and covers securely in place.
17. Clamp work cable with good metal-to-metal contact to
workpiece or worktable as near the weld as practical.
ARC RAYS
2. Wear a welding helmet fitted with a proper shade of filter to
protect your face and eyes when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
3. Wear approved safety glasses with side shields.
4. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
5. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace
air and lower the oxygen level causing injury or death. Be sure
the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
4. Never drape a welding torch over a gas cylinder.
5. Never allow a welding electrode to touch any cylinder.
6. Never weld on a pressurized cylinder – explosion will result.
7. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
8. Turn face away from valve outlet when opening cylinder valve.
9. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
10. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
sr1.1.1 2/94
 WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly
off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or
fire. Check and be sure the area is safe before doing
any welding.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1. Stop engine and let it cool off before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteries contain acid and generate explosive
gases.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
It is best to check coolant level when engine is cold
to avoid scalding.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, from American Welding So-
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA 02269.
sr1.1.1 2/94
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks, drums, or
pipes, unless they are properly prepared according to AWS
F4.1 (see Safety Standards).
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock and fire
hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves,
heavy shirt, cuffless trousers, high shoes, and a cap.
12. Remove any combustibles, such as a butane lighter or
matches, from your person before doing any welding.
ENGINES can be hazardous.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and
away from any building air intakes.
3. Do not overfill tank – allow room for fuel to expand.
4. Do not spill fuel. If fuel is spilled, clean up before starting
engine.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative (–) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery
cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
1. If the engine is warm and checking is needed, follow steps 2
and 3.
2. Wear safety glasses and gloves and put a rag over cap.
3. Turn cap slightly and let pressure escape slowly before
completely removing cap.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
 SECTION 1 – SAFETY INFORMATION
mod1.1 2/93

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.

Learn the meaning of WARNING and CAUTION.

1 Safety Alert Symbol

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

Figure 1-1. Safety Information

SECTION 2 – SPECIFICATIONS

Table 2-1. Welding Power Source

Specification Description

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

Rated Weld Output 90 Amperes, 14 Volts DC at 20% Duty Cycle (See Section 2-2)

Type Of Input Power 115 Volts AC; 50/60 Hz; Single-Phase

Input Amperes At Rated Output 19.5 Amperes

Input Amperes While Idling 0.6 Amperes

KVA/KW Used At Rated Output 2.2 kVA/1.5 kW

KVA/KW Used While Idling 0.049 kVA/0.05 kW

Amperage Range Min. – 90 A

Max. Open-Circuit Voltage 95 Volts DC

Welding Process Gas Tungsten Arc Welding (GTAW)

Input Power Cord 7 ft (2.1 m)

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

Weight Net: 31 lb (14 kg); Ship: 35 lb (16 kg)

Maxstar 91 TM-207 Page 1

2-1. Volt-Ampere Curves

The volt-ampere curves show the

minimum and maximum voltage
and amperage output capabilities
of the welding power source.
Curves of other settings fall
between the curves shown.

ssb1.1 10/91 – SA-156 101

Figure 2-1. Volt-Ampere Curves

2-2. Duty Cycle

CAUTION
WELDING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.
• Do not weld at rated load longer than shown below. warn7.1 8/93

Chart
Definition
0

10 Duty Cycle is percentage of 10

minutes that unit can weld at
rated load without overheating.
Minutes

20% Duty Cycle At 90 Amperes

2 Minutes Welding 8 Minutes Resting

sb1.2 8/93 – SB-162 795

Figure 2-2. Duty Cycle

TM-207 Page 2 Maxstar 91
 SECTION 3 – INSTALLATION

3-1. Typical Process Connections

Remote Control

14 Pin GTAW

Welding
Power Source HF Unit
Work

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

Figure 3-1. Typical Process Connections

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

WARNING
ELECTRIC SHOCK can kill. FUMES can be hazardous; LACK OF
• Do not touch live electrical parts. F RESH AI R AND PRO PER VEN-
TILATION can be harmful.
• Disconnect input power conductors from de-
energized supply line BEFORE moving welding • Do not breathe welding fumes.
power source. • Place unit only where there is a good fresh air
supply and proper ventilation.
FIRE OR EXPLOSION can result from
placing unit on, over, or near com-
bustible surfaces.
• Do not locate unit on, over, or near combustible
FAL L I NG EQ UI PM ENT can cau se
surfaces.
• Do not install unit near flammables.
serious personal injury and equipment
damage.
BLOCKED AIRFLOW causes over- • Use handle to lift unit.
heating and possible damage to unit. • Have person of adequate physical strength lift unit.
• Do not block or filter airflow.
• Move unit with hand cart or similar device.
Warranty is void if any type of filter is used. swarn11.1* 3/93

1 10 in (254 mm) Open Space

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

ST-157 356-B

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

Maxstar 91 TM-207 Page 3
3-3. Selecting And Preparing Weld Output Cables

1 Weld Output Cable

3 Determine total cable length in
weld circuit and maximum welding
amperes. Use Table 3-1 to select
proper cable size.
Use shortest cables possible.
Do not use damaged cables.
2 Terminal Lug
2 Use lugs of proper amperage
capacity and hole size for connect-
1 ing to work clamp or electrode
holder.
10 ft (3 m) 3 GTAW Torch
Install according to manufacturer’s
For Example, instructions.
Total Cable
5 Length In Weld 4 Work Clamp
4 Circuit = 20 ft (6 m)
Tools Needed: Install onto work cable.
5 Dinse-Type Connector
10 ft (3 m)
Install onto weld cable as shown in
Figure 3-4.
sb6.2* 5/94 – S-0656

Figure 3-3. Selecting And Preparing Weld Output Cables

Table 3-1. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding

150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Welding 10 To 60% 60 Thru 100%
10 Thru 100% Duty Cycle
Amperes Duty Cycle Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D

1 3 1 Weld Output Cable

2 Handle
2
3 Sleeve
Slide handle onto cable; strip cable
and install sleeve.
1 in
(26 mm) 4 Connector Body
5 Setscrew
5 Insert cable with sleeve fully into
connector body, tighten setscrew,
4 and slide handle over connector.

Tools Needed:

ST-156 496

Figure 3-4. Dinse-Type Connector Assembly

TM-207 Page 4 Maxstar 91
3-4. Connecting To Weld Output Receptacles

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

1 Positive (+) Weld Output

Receptacle
1 2 Negative (–) Weld Output
Receptacle
3 Connector
For Electrode Negative, connect
work cable connector to positive
(+) receptacle and electrode hold-
er cable connector to negative (–)
receptacle.
For Electrode Positive, reverse
cable connections.
See Figure 3-1 for typical polarity
choices.
To connect to receptacle, align
2 3
keyway, insert connector, and turn
clockwise until tight.

Ref. ST-130 215-B / ST-157 359-A

Figure 3-5. Connecting To Weld Output Receptacles

3-5. Remote 14 Receptacle Information And Connections

1 Remote 14 Receptacle RC2

1 2 (See Table 3-2)
2 Keyway
3 Plug
A J
K I 4 Threaded Collar
B
To connect to receptacle, align
C L N H
keyway, insert plug, and tighten
D M G threaded collar.
E F

Rear Panel

sb7.1 5/94 – ST-800 916 / Ref. S-0004-A / S-0750 / Ref. ST-141 127-B

Figure 3-6. Remote 14 Connections

Maxstar 91 TM-207 Page 5
 Table 3-2. Remote 14 Socket Information

Socket* Socket Information

A +15 volts dc.

B Contact closure to A completes +15 volts dc contactor control circuit.
C Output command reference; 0 to +10 volts dc depending on setting of
Amperage Adjustment control R4.
D Remote control circuit common.
E Input command signal (potentiometer wiper or 0 to +10 volts dc).
K Chassis common.
*The remaining sockets are not used.

3-6. Connecting Input Power

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

1 115 VAC Cord/Plug

2 115 VAC Grounded
Receptacle
2
An individual branch circuit capa-
ble of carrying 20 amperes, and
protected by fuses or circuit break-
1 er is required. Recommended fuse
or circuit breaker size is 30
amperes.
Connect input power plug to proper
115 VAC receptacle.

ST-157 357-B

Figure 3-7. Input Power Connections

TM-207 Page 6 Maxstar 91

 SECTION 4 – OPERATION

WARNING
ELECTRIC SHOCK can kill. ARC RAYS can burn eyes and skin;
• Always wear dry insulating gloves. NOISE can damage hearing.
• Insulate yourself from work and ground. • Wear welding helmet with correct shade of filter.
• Do not touch live electrical parts. • Wear correct eye, ear, and body protection.
• Keep all panels and covers securely in place.
MOVING PARTS can cause injury.
FUMES AND GASES can be hazardous
to your health. • Keep away from moving parts.

• Keep your head out of the fumes.

• Keep all doors, panels, covers, and guards closed
and securely in place.
• Ventilate area, or use breathing device.
• Read Material Safety Data Sheets (MSDSs) and MAGNETIC FIELDS FROM HIGH CUR-
manufacturer’s instructions for material used.
RENTS can affect pacemaker operation.
WELDING can cause fire or explosion. • Pacemaker wearers keep away.
• Do not weld near flammable material. • Wearers should consult their doctor before going
• Watch for fire; keep extinguisher nearby. near arc welding, gouging, or spot welding opera-
tions.
• Do not locate unit over combustible surfaces.
• Do not weld on closed containers.
See Safety Precautions at beginning of manual for ba-
• Allow work and equipment to cool before handling. sic welding safety information. swarn6.1 10/91

3 4 5 1 Amperage Adjustment
Control
2
2 Amperage Control Switch
1 3 Output (Contactor) Switch
6
4 Lift-Arc Switch
5 Power Switch
6 Pilot Light
7 Optional Amperage/Voltage
Meter And Switch
7

ST-157 358-A

Figure 4-1. Controls

1 2 3 Wear the following while welding:

1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)

sb3.1 1/94

Figure 4-2. Safety Equipment

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

Figure 4-3. Work Clamp

Maxstar 91 TM-207 Page 7
 WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Do not touch weld output receptacles when contactor is energized.
• Do not touch electrode and work clamp at the same time. swarn7.1* 10/91

1 Output (Contactor) Switch

Use switch to select way of control-
Weld output receptacles are ling output.
energized when switch is On For weld output, place switch in On
and Power is On. position.
1
For remote output control, place
switch in Remote 14 position (see
Section 3-5).

Ref. ST-157 583-B

Figure 4-4. Output (Contactor) Switch

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

5
Unit
Minimum

Control Setting
(50 A)

Set Switches Set Desired Maximum Amperage Adjust Remote Control

ST-159 059 / S-0769

Figure 4-5. Amperage Control Switch

TM-207 Page 8 Maxstar 91
 NOTE Lift-Arc switch must be in Off position when using a High-Frequency unit with this
welding power source.

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

Ref. S-156 279

Figure 4-6. Lift-Arc Switch

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

1 2

Figure 4-7. Power Switch And Pilot Light

Install & Install High- Select Insert Put On

Connect Frequency Unit Tungsten Tungsten Personal Safety Set Controls
Equipment If Applicable Into Torch Equipment

Turn On Turn On High- Turn On

Shielding Gas Frequency Unit Welding Power Begin Welding
If Applicable Source
ssb8.1* 12/92

Figure 4-8. Sequence Of Gas Tungsten Arc Welding (GTAW)

Maxstar 91 TM-207 Page 9
 SECTION 5 – THEORY OF OPERATION
1 Power Switch S1
1 2
Provides on/off control of welding
power source. 1-Phase Line Power Precharge
Input Power Switch Control Relay
2 Precharge Control Relay S1 CR1, Resistor R1
CR1, Precharge Resistor R1
Allows initial charge of filter capaci-
tor(s) C1 and C2.
3
3 Input Integrated Rectifier SR1
Input
Changes the ac line input power to Integrated
half-wave rectified dc. Rectifier SR1
4 Filter Capacitor(s) C1, C2
Filter the dc output voltage of SR1.
12 4
5 Interconnecting Board PC2
Fan Filter
MOSFET power transistors Q1 Motor FM/ Capacitor(s)
and Q2 use very fast on/off switch- Transformer C1, C2
ing action to effectively turn the dc
into ac.
6 Current Transformer CT1
13 14
Provides a polarity sensitive MOSFET Gating Signals
pulsed current signal to PC1 for Amperage Control
fault protection. Adjustment Board
Control R4 PC1
7 Main Transformer T1
Energized by on/off switching of
Q1 and Q2, and supplies power to Fault Protection
15
weld output circuit.
Lift-Arc
8 Output Rectifiers D1 And D2 Switch
Rectifies output of T1. S5
9 Stabilizer Z1
Current Feedback
Smooths out welding current.
10 Positive (+) And Negative (–) 18 16
Weld Output Receptacles Output
Provide weld output and allow (Contactor)
Remote
18♦
changing of output polarity. Switch S3
14
11 Hall Device HD1 Remote Output Receptacle
(Contactor) RC7
Provides current feedback signal Switch
to PC1. Located on PC1.
12 Fan Motor FM/Transformer
Provides cooling of internal com-
ponents and secondary windings 17
provide power to control board
Amperage
PC1. Control
18♦
Switch S4

Remote
Amperage
Control

Voltage Feedback

Voltage Feedback

19♦
Meter
Board
PC3

Figure 5-1. Functional Diagram

TM-207 Page 10 Maxstar 91
 13 Amperage Adjustment Con-
trol R4
Selects weld output amperage lev-
el. Setting defines maximum out-
put when remote amperage control
is used.
14 Control Board PC1
8 9
Controls weld output by changing
Output the pulse width modulation signal
Rectifiers Stabilizer
5 D1, D2 Z1 (wider or narrower pulses meaning
more or less voltage) to MOSFET
Interconnecting power transistors Q1 and Q2 after
Board PC2 comparing current feedback to ref-
6
erence level set by R4.
Current
5 Transformer 7 10 15 Lift-Arc Switch S5
MOSFET Power CT1 Positive (+)
Main Transformer Provides for GTAW welding with
Transistors T1 Weld Output
Q1, Q2 Receptacle Lift-Arc start.
16 Output (Contactor) Switch S3
Selects On or remote contactor
control.
17 Amperage Control Switch S4
Selects front panel or remote am-
Electrode perage control.
18 Remote 14 Receptacle RC7
Work
Connects remote amperage and
contactor controls.
19 Meter Board PC3
Displays preset amperage, weld
11 10 amperage, or weld voltage.
Hall Negative (–)
Device Weld Output
HD1 Receptacle

AC Or DC Control Circuits

1φ Power

Weld Current Circuit

External Circuits

♦ Optional

Maxstar 91 TM-207 Page 11

 SECTION 6 – PRE-POWER CHECKLIST

6-1. Checking Unit Before Applying Power

WARNING
ELECTRIC SHOCK can kill; MOVING PARTS can cause injury.
SIGNIFICANT DC VOLTAGE exists after • Keep away from moving parts.
removal of input power.
• Do not touch live electrical parts.
• Turn Off welding power source, disconnect input
power, wait 60 seconds, measure voltage on input
capacitors according to Section 8-2, and be sure
voltage is near zero before touching any parts. STATIC ELECTRICITY can damage parts
on circuit boards.
EXPLODING PARTS can cause injury.
• Put on grounded wrist strap BEFORE handling
• Failed parts can explode or cause other parts to boards or parts.
explode when power is applied.
• Use proper static-proof bags.
• Always wear a face shield and long sleeves when
servicing.
Have only qualified persons familiar with and following
HOT PARTS can cause severe burns. standard safety practices perform troubleshooting
• Allow cooling period before servicing unit. procedures.

smwarn1.6 2/94

Table 6-1. Pre-Power Checklist

NOTE Visually check parts for signs of failure before beginning pre-power checks.
Use MILLER Testing Booklet (Part No. 150 853) when checking solid-state parts.

Before troubleshooting or applying power to the unit, complete the following checks to avoid causing further damage.
Although control board PC1 is briefly checked in this procedure, a more complete test may be needed later. This check is
simply to get a basic okay to power up the unit.

Component Checks Section

Control Board PC1 Check resistance of resistors R45 (pins 1 and 4), R46 (pins 3 and 7-4
6) at receptacle RC4 on control board PC1; in-circuit resistance
of each resistor is approximately 10 to 12 ohms. Replace PC1 if
necessary.

Interconnecting Board PC2 Check components on interconnecting board PC2 for signs of fail- 7-5
ure, and replace necessary parts.

MOSFET Power Transistors Q1 And Check MOSFET power transistors Q1 and Q2 on interconnecting 7-2, 7-5
Q2 board PC2, and replace if necessary. To check drain (D) to source
(S) of Q1 and Q2, disconnect leads from TAP terminal and –Bus
terminal on PC2. Perform diode test. To check gate (G) to
alternate source (AS) of Q1 and Q2, disconnect plug PLG4 from
receptacle RC4 on control board PC1. In-circuit resistance be-
tween gate (G) and alternate source (AS) is 100K ohms ±10%.

Input Integrated Rectifier SR1 Check input integrated rectifier SR1, and replace if necessary. To 7-2
isolate SR1 for testing, disconnect leads 5 and 6 from SR1.

TM-207 Page 12 Maxstar 91

 Component
Output Rectifier Diodes D1 And D2
Precharge Resistor R1
Precharge Control Relay CR1
Bleeder Resistors R5 And R6
Bus Capacitors C1 And C2
Maxstar 91
Checks Section
Isolate diode module. Check output rectifier diodes D1 and D2 7-2
and replace if necessary. If any diode is replaced, check capaci-
tors C9, C10, and C11 for a short and resistance of resistor R9.
R9 is 5 ohms ±10% Replace C9, C10, C11, and R9 if necessary.
Check resistance of precharge resistor R1; R1 is 200 ohms 7-2
±10%. Replace R1 if necessary.
Check condition of contacts of precharge control relay CR1, and 7-2
replace if necessary. Be sure normally open contacts are not
stuck closed.
Disconnect lead from TAP terminal on interconnecting board 7-5
PC2. Check resistance of resistors R5 and R6 on PC2. In-circuit
resistance of each resistor is approximately 20K ohms ±10%.
Replace PC2 if necessary.
Check bus capacitors C1 and C2 for a short, and replace if neces- 7-2
sary.
Check voltage balance of capacitors C1 and C2 with contactor off; 7-2
voltage difference should be no greater than 10 volts after 10 sec-
onds of warm-up. If proper voltage balance is not present, contact
Factory Service Department.
TM-207 Page 13
 SECTION 7 – TROUBLESHOOTING

7-1. Troubleshooting Table

WARNING
ELECTRIC SHOCK can kill; MOVING PARTS can cause injury.
SIGNIFICANT DC VOLTAGE exists after • Keep away from moving parts.
removal of input power.
• Do not touch live electrical parts.
• Turn Off welding power source, disconnect input
power, wait 60 seconds, measure voltage on input
capacitors according to Section 8-2, and be sure
voltage is near zero before touching any parts. STATIC ELECTRICITY can damage parts
on circuit boards.
EXPLODING PARTS can cause injury.
• Put on grounded wrist strap BEFORE handling
• Failed parts can explode or cause other parts to boards or parts.
explode when power is applied.
• Use proper static-proof bags.
• Always wear a face shield and long sleeves when
servicing.
Have only qualified persons familiar with and following
HOT PARTS can cause severe burns. standard safety practices perform troubleshooting
• Allow cooling period before servicing unit. procedures.

smwarn1.6 2/94

Table 7-1. Troubleshooting

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

Trouble Remedy Section

No weld output; unit completely inop- Secure power cord plug in receptacle. 3-6
erative.
Replace line fuse(s) or reset circuit breaker if open. 3-6
Check for proper input power connections. 3-6
Check continuity of Power switch S1, and replace if necessary. 7-2
Check fan motor FM/transformer for signs of winding failure. 7-2
Check continuity across windings, and check for proper con-
nections. Check secondary voltages. Replace fan motor FM/
transformer if necessary.

No weld output; fan motor FM running Check position of Output (Contactor) switch S3. Figure 4-4
and pilot light on.
Thermostat TP1 open (overheating). Allow fan to run; the ther- 8-3
mostat will close when the unit has cooled.
Check diodes D1 and D2, and replace if necessary. 7-2
Check capacitors C11, C12, and C13 for a short or open, and 7-2
check for proper connections. Replace C11, C12, and C13 if
necessary.
Check input integrated rectifier SR1, and replace if necessary. 7-2
Check MOSFET power transistors Q1 and Q2, and replace if 7-2
necessary.
Check control board PC1 and connections, and replace if 7-4
necessary.

Low weld output with no control. Check position of Amperage Control switch S4. Figure 4-5
Check resistance and connections of Amperage Adjustment 7-2
control R4; R4 is 0 to 10K ohms ±10%. Replace R4 if
necessary.

TM-207 Page 14 Maxstar 91

 Trouble Remedy Section
Low weld output with no control. Check input integrated rectifier SR1, and replace if necessary. 7-2
(Continued)
Check control board PC1 and connections, and replace if 7-4
necessary.

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

Maximum weld output with no control. Check resistance and connections of Amperage Adjustment 7-2
control R4; R4 is 0 to 10K ohms ±10%. Replace R4 if
necessary.
Check control board PC1 and connections, and replace if 7-4
necessary.

Erratic or improper weld output. Tighten all welding cable connections. 3-3, 3-4
Check for proper size and type of cable. 3-3
Check for proper input and output connections. 3-3, 3-4, 3-6
Replace electrode. ––
Check resistance and connections of Amperage Adjustment 7-2
control R4; R4 is 0 to 10K ohms ±10%. Replace R4 if
necessary.
Check resistance and connections of remote amperage control ––
potentiometer, and replace if necessary.
Check capacitors C11, C12, and C13 for a short or open, and 7-2
check for proper connections. Replace C11, C12, and C13 if
necessary.
Check input integrated rectifier SR1, and replace if necessary. 7-2
Check control board PC1 and connections, and replace if 7-4
necessary.

Arc not forming when using Lift-Arc. Check electrode and workpiece; clean as needed to allow good ––
contact.
Check ground clamp connection. ––

Fan motor FM does not run. Check and clear blocked fan blade. ––
Check fan motor FM, and replace if necessary. 7-2

Wandering arc; poor control of arc di- Use proper size tungsten. ––
rection.
Use properly prepared tungsten. ––
Reduce gas flow rate. ––

Tungsten electrode oxidizing and not Shield weld zone from drafts. ––
remaining bright after conclusion of
weld.
Increase postflow time. ––
Check and tighten all gas fittings. ––
Use properly prepared tungsten. ––

Water in torch. Refer to torch manual. ––

Optional digital meter does not work. Check meter board PC3 and connections, and replace if 7-6
necessary.

Maxstar 91 TM-207 Page 15

7-2. Troubleshooting Circuit Diagram

WARNING
ELECTRIC SHOCK can kill; STATIC ELECTRICITY can damage parts
SIGNIFICANT DC VOLTAGE exists after on circuit boards.
removal of input power. • Put on grounded wrist strap BEFORE handling
• Do not touch live electrical parts. boards or parts.
• Turn Off welding power source, wait 60 seconds, • Use proper static-proof bags.
measure voltage on input capacitors according to
Section 8-2, and be sure voltage is near zero before Have only qualified persons familiar with and following
making or changing meter lead connections and standard safety practices perform troubleshooting
before touching any parts. procedures. smwarn2.5 2/94

V2

V6 V3
V1

V4/R1

See Section 3-5

for RC7 data

V5/R2

V8

V7

Test Equipment Needed: See Section 7-6

for PC3 data

See also Section 7-4

for PC1 data

Figure 7-1. Troubleshooting Circuit Diagram

TM-207 Page 16 Maxstar 91
 Resistance Values Voltage Readings
a) Tolerance – ±10% unless specified a) Tolerance – ±10% unless
b) Turn Off unit and disconnect input specified
power before checking resistance b) Reference – to circuit
R1, R2 Less than 2 ohms common (lead 11) unless
noted
R3 thru R5 Less than 1 ohm
c) Wiring Diagram – see
R6 Greater than 1000 ohms
Section 9

V1 115 volts ac
V2,V3 162 volts dc
V4 18 volts ac
V5 18 volts ac
V6 24 volts dc
V7 1 volt dc input per 100
amperes weld output
V8 0 to +10 volts dc from
min. to max. of Amperage
Adjustment control R4
V9 89 to 98 volts dc
open-circuit voltage

V9/R6
A, B, C

See Section 7-3

for output waveforms
A, B, C

R4 R5

R3

See Section 7-5

for PC2 data

SC-175 939

Maxstar 91 TM-207 Page 17

7-3. Waveforms For Section 7-2

WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off welding power source before making or changing any test equipment leads or cable connections.

Have only qualified persons familiar with and following standard safety practices perform troubleshooting procedures.
smwarn3.1 12/93

5 µs 50 V 5 µs 5 V

gnd gnd

A. DC Open-Circuit Voltage, Lift-Arc Switch B. DC Open-Circuit Voltage, Lift-Arc Switch

S5 In Off Position S5 In On Position

5 µs 10 V

gnd

Test Equipment Needed:

C. 13 Volts DC, 45 Amperes (Resistive Load)

Figure 7-2. Waveforms For Section 7-2

TM-207 Page 18 Maxstar 91
 NOTES

Maxstar 91 TM-207 Page 19

7-4. Troubleshooting Control Board PC1

WARNING
ELECTRIC SHOCK can kill; STATIC ELECTRICITY can damage parts
SIGNIFICANT DC VOLTAGE exists after on circuit boards.
removal of input power. • Put on grounded wrist strap BEFORE handling
• Do not touch live electrical parts. boards or parts.
• Turn Off welding power source, wait 60 seconds, • Use proper static-proof bags.
measure voltage on input capacitors according to
Section 8-2, and be sure voltage is near zero before Have only qualified persons familiar with and following
making or changing meter lead connections and standard safety practices perform troubleshooting
before touching any parts. procedures. smwarn2.5 2/94

Be sure plugs are secure before

testing. Use Table 7-2 for specific
values during testing.
1 Control Board PC1
2 Receptacle RC1
3 Receptacle RC2
4 Receptacle RC3
8
1 3 7 5 5 Receptacle RC4
6 Receptacle RC8
7 Resistors R45 And R46
8 Hall Device HD1
7

Test Equipment Needed:

ST-801 513 / SB-175 941-A

Figure 7-3. Control Board PC1 Testing Information (Use With Table 7-2)
TM-207 Page 20 Maxstar 91
 Table 7-2. Control Board PC1 Test Point Values (Use With Figure 7-1 And Figure 7-3)

Voltage Readings:
a) Tolerance – ±10% unless specified b) Reference – to circuit common (lead 11) unless noted
Receptacle Pin Value
RC1 1 Hall Device HD1 test point, 7.5 volts dc per 100 amperes dc output
2 0 volts dc output with Amperage Adjustment control R4 at minimum, +10 volts dc output with R4 at
maximum
3 Not used
4 0 volts dc input with Output (Contactor) switch S3 in Remote 14 position, +15 volts dc input with S3
in On position
5 0 volts dc input with Lift-Arc switch S5 in Off position, +15 volts dc input with S5 in On position
6 Circuit common
7 +15 volts dc output
8 Same as positive (+) weld output receptacle voltage
9 +10 volts dc output
10 Command input signal, 0 to +10 volts dc input
11 0 volts dc output with Amperage Adjustment control R4 at minimum, +10 volts dc output with R4 at
maximum
12 0 volts dc output with Amperage Adjustment control R4 at minimum, +10 volts dc output with R4 at
maximum
13 +15 volts dc output
14 +15 volts dc output
15 Circuit common
16 Same as negative (–) weld output receptacle voltage
RC2 1 +24 volts dc output
2 18 volts ac input
3 18 volts ac input
4, 5, 6, 7 Not used
8 Circuit common
9 Circuit common
10, 11, 12 Not used
13 Approximately 0 volts dc with precharge control relay CR1 energized
14 Not used
RC3 1 CT1 input line
2 CT1 input line

RC4 Make no connections – damage to test equipment or components can occur.

RC8 1 Contactor signal output, 0 or +15 volts dc output

2 Circuit common
3 +24 volts dc output
4 Current feedback signal output, 1 volt dc output per 100 amperes dc weld output
5 Not used
6 Command output signal, 0 to +10 volts dc input
7 Voltage feedback signal output, 1 volt dc output per 10 volts dc weld output
8 Circuit common

Maxstar 91 TM-207 Page 21

7-5. Troubleshooting Interconnecting Board PC2

WARNING
ELECTRIC SHOCK can kill; STATIC ELECTRICITY can damage parts
SIGNIFICANT DC VOLTAGE exists after on circuit boards.
removal of input power. • Put on grounded wrist strap BEFORE handling
• Do not touch live electrical parts. boards or parts.
• Turn Off welding power source, wait 60 seconds, • Use proper static-proof bags.
measure voltage on input capacitors according to
Section 8-2, and be sure voltage is near zero before Have only qualified persons familiar with and following
making or changing meter lead connections and standard safety practices perform troubleshooting
before touching any parts. procedures. smwarn2.5 2/94

1 Interconnecting Board PC2

Make no connections –
damage to test equipment
or components can occur.
2 MOSFET Power Transistors
Q1 and Q2
See MILLER Testing Booklet (Part
No. 150 853) for testing informa-
tion.
3 MOSFET Mounting Locations
And Holes
4 Plug PLG4
5 –BUS And +BUS Terminals
6 TAP Terminal

4 5
3

5
3

Test Equipment Needed:

ST-801 513 / Ref. ST-157 535 / Ref. SB-162 957-C

Figure 7-4. Interconnecting Board PC2 Testing Information

TM-207 Page 22 Maxstar 91
7-6. Troubleshooting Optional Meter Board PC3

WARNING
ELECTRIC SHOCK can kill; STATIC ELECTRICITY can damage parts
SIGNIFICANT DC VOLTAGE exists after on circuit boards.
removal of input power. • Put on grounded wrist strap BEFORE handling
• Do not touch live electrical parts. boards or parts.
• Turn Off welding power source, wait 60 seconds, • Use proper static-proof bags.
measure voltage on input capacitors according to
Section 8-2, and be sure voltage is near zero before Have only qualified persons familiar with and following
making or changing meter lead connections and standard safety practices perform troubleshooting
before touching any parts. procedures. smwarn2.5 2/94

2 Be sure plugs are secure before

testing. Use Table 7-3 for specific
1
values during testing.
1 Meter Board PC3
2 Receptacle RC50
3 Meter Switch S1
4 Hold Function DIP Switch S2
With the hold function On, the dis-
played weld output value stays for
3 15 seconds after welding stops.
With the hold function Off, the dis-
played value leaves when welding
stops.

4
4

1
ON
OFF

2
Hold Not Used
Test Equipment Needed: 3
1

OFF
ON
2

4
Hold Used

ST-800 196 / Ref. SA-166 340-A / Ref. ST-157 355-A

Figure 7-5. Optional Meter Board PC3 Testing Information (Use With Table 7-3)

Table 7-3. Optional Meter Board PC3 Test Point Values (Use With Figure 7-1 And Figure 7-5)
Voltage Readings:
a) Tolerance – ±10% unless specified b) Reference – to circuit common (lead 11) unless noted
Receptacle Pin Value
RC50 1 +24 volts dc input
2 Not used
3 Voltage feedback signal input, 1 volt dc input per 10 volts dc weld output
4 Not used
5 Not used
6 Current feedback signal input, 1 dc volt input per 100 amperes dc weld output
7 Contactor signal input, 0 or +15 volts dc input
8 Command input signal, 0 to +10 volts dc output
9 Circuit common
10 Not used
11 Not used

Maxstar 91 TM-207 Page 23

7-7. Digital Meter Calibration

WARNING
ELECTRIC SHOCK can kill; STATIC ELECTRICITY can damage parts
SIGNIFICANT DC VOLTAGE exists after on circuit boards.
removal of input power. • Put on grounded wrist strap BEFORE handling
• Do not touch live electrical parts. boards or parts.
• Turn Off welding power source, wait 60 seconds, • Use proper static-proof bags.
measure voltage on input capacitors according to
Section 8-2, and be sure voltage is near zero before Have only qualified persons familiar with and following
making or changing meter lead connections and standard safety practices perform troubleshooting
before touching any parts. procedures. smwarn2.5 2/94

Be sure plugs are secure before

No calibration available calibrating meter.
for digital voltmeter.
Top View 1 Control Board PC1
2 Amperage/Voltage Meter
R9
3 Meter Switch S1
Place S1 in Amperage position.
Step 2 Adjust R9 for amperage gain
to match external calibrated 000
meter using load bank set at
desired load. Amperes

Top View
1
R67

000
Amperes (±2)

Step 1 Adjust R67 for

ammeter offset or
zero

ST-800 196 / Ref. SB-154 570

Figure 7-6. Digital Meter Calibration

TM-207 Page 24 Maxstar 91
 SECTION 8 – MAINTENANCE

WARNING
ELECTRIC SHOCK can kill; MOVING PARTS can cause injury.
SIGNIFICANT DC VOLTAGE exists after • Keep away from moving parts.
removal of input power.
• Do not touch live electrical parts.
• Turn Off welding power source, disconnect input
power, wait 60 seconds, measure voltage on input STATIC ELECTRICITY can damage parts
capacitors according to Section 8-2, and be sure
voltage is near zero before touching any parts. on circuit boards.
• Put on grounded wrist strap BEFORE handling
boards or parts.
HOT PARTS can cause severe burns. • Use proper static-proof bags and boxes.
• Allow cooling period before maintaining or
servicing. Maintenance to be performed only by qualified
persons.
swarn8.3 2/94

8-1. Routine Maintenance

3 Months Turn Off all power before maintaining. 3 Months

Tape Or
Replace
Cracked
Cables
3-3

Clean
See And
Replace
Service Tighten
Unreadable
Parts Weld
Labels
Manual Connections
3-4

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

Gas Hose Torch Cable

ST-157 356-A

Figure 8-1. Maintenance Schedule

Maxstar 91 TM-207 Page 25

8-2. Measuring Input Capacitor Voltage

READ SAFETY BLOCKS at start of

WARNING Section 8 before proceeding.

Turn Off welding power source and

disconnect input power.
Significant DC voltage can remain on capacitors after Remove wrapper.
unit is Off. Always check capacitors as shown to be 1 Input Capacitor C1
sure they have discharged before working on unit.
2 Input Capacitor C2
3 Voltmeter
Check input capacitors as shown.
Measure dc voltage across posi-
tive (+) and negative (–) terminals
until voltage drops to near 0 (zero)
volts.
Proceed with job inside unit.
3 Reinstall wrapper when finished.

Tools Needed:

5/16 in
ST-157 355-B

Figure 8-2. Measuring Input Capacitor Voltage

8-3. Overload Protection

15

minutes

When overheated, thermostat Let fan run for Start welding.

opens, output stops, and cooling 15 minutes.
fan keeps running.

ssb10.1 1/94 – ST-157 356-B

Figure 8-3. Overheating

TM-207 Page 26 Maxstar 91
 SECTION 9 – 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 distributor for more information.
The following is a list of all diagrams for models covered by this manual.

Circuit Wiring Main Reason

Model Serial Or Style Number
Diagram Diagram For Change

Maxstar 91 KD400224 thru KF893710 SC-155 804-A D-156 723-A♦♦

KF893711 and following SC-175 939 SD-175 940 Added resistor R6 and new
wiring harness; revised
PC1.

Circuit Board PC1 KD400224 thru KD540405 D-154 572♦♦

KD540406 thru KF893710 D-164 897♦♦

KF893711 and following SD-175 942

Circuit Board PC2 KD400224 thru KD438828 A-155 866♦♦

KD438829 and following SA-162 959

Circuit Board PC3♦ KD400224 thru KD518677 C-157 589-A♦♦

KD518678 and following SC-166 341

♦ Optional
♦♦ Not included in this manual

Maxstar 91 TM-207 Page 27

 SC-155 804-A

Figure 9-1. Circuit Diagram For Maxstar 91 Effective With Serial No. KD400224 Thru KF893710
TM-207 Page 28 Maxstar 91
 SC-175 939

Figure 9-2. Circuit Diagram For Maxstar 91 Effective With Serial No. KF893711 And Following
Maxstar 91 TM-207 Page 29
 Figure 9-3. Wiring Diagram For Maxstar 91 Effective With Serial No. KF893711 And Following
TM-207 Page 30 Maxstar 91
 SD-175 940

Maxstar 91 TM-207 Page 31

 Figure 9-4. Circuit Diagram For Control Board PC1 Effective With Serial No. KF893711 And Following
TM-207 Page 32 Maxstar 91
 SD-175 942

Maxstar 91 TM-207 Page 33

 SA-162 959

Figure 9-5. Circuit Diagram For Interconnecting Board PC2

Effective With Serial No. KD438829 And Following

TM-207 Page 34 Maxstar 91

 SC-166 341

Figure 9-6. Circuit Diagram For Optional Meter Board PC3 Effective With Serial No. KD518678 And Following
Maxstar 91 TM-207 Page 35
 NOTES

TM-207 Page 36 Maxstar 91

 TMĆ207A October 1999

Processes
TIG (GTAW) Welding

Description

Arc Welding Power Source

Maxstar 91
Eff w/KD400224 And Following
For OM-207 (156 615) Revision * And Following

Visit our website at

www.Miller-
Welds.com
 SECTION 10 – PARTS LIST

. Hardware is common and

13
not available unless listed.
Fig 10-2

12

14

Fig 10-2
15
50

16

19
11

23

24
10

17

18
9

20

21

22
8
7

25
6

28 27
26
5

29
48 49

30
47

17
4

43 45 46

31
44

42
3

32
41

33

34
1

40
39

38
37

36

35

ST-157 446-D
Figure 10-1. Main Assembly

TM-207 Page 38 Maxstar 91

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

Figure 10-1. Main Assembly

. . . 1 . . . . . . . . . . . . . . . . 195 585 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . INCLUDED WITH ITEM 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . . 3 . . . . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . +151 755 . . WRAPPER, (Prior to KD447085) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . +163 781 . . WRAPPER, (Prior to KD447085) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . PC1 . . . . . 175 943 . . CIRCUIT CARD, control (Figure 10-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . PLG1 . . . . 131 052 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . 16
. . . . . . . . . . . PLG2 . . . . 131 056 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . 14
. . . . . . . . . . . PLG4 . . ++115 093 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . 6
. . . 6 . . . . . . . . . . . . . . . . 141 690 . . GROMMET, scr No. 8/10 panel hole .281sq .197 high . . . . . . . . . . . . . 4
. . . 7 . . . . . . . . . . . . . . . . 156 103 . . INSULATION, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . 156 102 . . BRACKET, mtg PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . 155 836 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . +128 803 . . BAR, support heat sink top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . CT1 . . . . . 155 939 . . TRANSFORMER, current (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . PLG3 . . . . 131 054 . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . Figure 10-2 . . MODULE, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . . 119 943 . . STRIP, polyest gl lam .187 x .500 x 6.500 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . . 155 837 . . SPACER, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . Figure 10-2 . . MODULE, power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . 119 757 . . BAR, support heat sink bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . Neg, Pos . . . 129 525 . . RECEPTACLE, twlk insul fem (Dinse Type) 50/70 series . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 145 088 . . CONNECTOR KIT, Dinse male 50 series (consisting of) . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 134 746 . . . . WRENCH, hex 5mm short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . . 130 215 . . PLATE, output panel rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . . 131 273 . . CORD SET, 125V 5-15P 14ga 3/c 7ft . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . . . 111 443 . . BUSHING, strain relief .240/.510 ID x .875 mtg hole
(Prior to KD497659) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . . 165 377 . . BUSHING, strain relief .240/.510 ID x .750/.875mtg hole
(Eff w/KD497659) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . 156 480 . . CASE SECTION, bottom/rear (Prior to KD497659) . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . 165 378 . . CASE SECTION, bottom/rear (Eff w/KD497659) . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . . 019 663 . . MOUNT, nprn 15/16 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 23 . . . . . . . Z1 . . . . . . 155 801 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . T1 . . . . . . . 156 111 . . TRANSFORMER, pwr main 325V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . 141 422 . . INSULATOR, flat pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . R1 . . . . . 136 076 . . RESISTOR, WW fxd 30W 200 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . R6 . . . . . 154 132 . . RESISTOR, WW fxd 30W 1000 ohm (Eff w/KF893711) . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . . 047 838 . . BLANK, snap-in nyl 1.000mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . S1 . . . . . 090 328 . . SWITCH, tgl DPST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . PLG11 . . . . 115 094 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . 4
. . . . . . . . . . . RC11 . . . . 115 090 . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 114 656 . . . . CONNECTOR, rect pin 24-18ga Molex 39-00-0040 . . . . . . . . . . . . . . 4
. . . 30 . . . . . . . . . . . . . . . . 148 297 . . NUT, speed U type 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 31 . . . . . . CR1 . . . . . 106 462 . . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . . 156 479 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . PL1 . . . . . 157 958 . . LIGHT, ind white lens 28V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . S3-5 . . . . . 120 376 . . SWITCH, rocker SPDT 4A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 36 . . . . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . . 166 883 . . NAMEPLATE, meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . . 166 881 . . BLANK, meter nameplate backing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . . 136 190 . . NUT, speed U type 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 40 . . . . . . . . . . . . . . . . 133 405 . . NUT, speed 10-24 flat rectangular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maxstar 91 TM-207 Page 39
 Item Dia. Part
No. Mkgs. No.
. . . 41 . . . . . . R4 . . . . . 073 562
. . . 42 . . . . . . . . . . . . . . . . 006 426
. . . 43 . . . . . . C1,2 . . . . . 151 281
. . . 44 . . . . . . . . . . . . . . . . 156 110
. . . 45 . . . . . . C12 . . . . . 135 286
. . . 46 . . . . . . C13 . . . . . 135 289
. . . 47 . . . . . . . . . . . . . . . . 156 358
. . . 48 . . . . . . C14 . . . . . 156 095
. . . 48 . . . . . . C15 . . . . . 141 525
. . . 48 . . . . . . C16 . . . . . 141 522
. . . 48 . . . . . . C17 . . . . . 156 094
. . . 49 . . . . . . RC7 . . . . . 143 976
. . . . . . . . . . . . . . . . . . . . . . 079 534
. . . . . . . . . . . . . . . . . . . . . . 134 734
. . . . . . . . . . . . . . . . . . . . . . 134 731
. . . . . . . . . . . . . . . . . . . . . . 079 739
. . . . . . . . . . . . . . . . . . . . . . 143 922
. . . . . . . . . . . . . . . . . . . . . . 155 748
. . . . . . . . . . . . . . . . . . . . . ♦042 614
. . . . . . . . . . . . PC3 . . . . . 166 339
. . . . . . . . . . . PLG8 . . . . 115 092
. . . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . . . PLG9 . . . . 089 222
. . . . . . . . . . . . . . . . . . . . . . 133 644
. . . 50 . . . . . . . . . . . . . . . . 153 178
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
++Included with the Interconnecting Circuit Card PC2.
♦Eff w/KE558763 Optional Meter Kit is available as Field Option only.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-207 Page 40
Description Quantity
Figure 10-1. Main Assembly (Continued)
. . POTENTIOMETER, C std slot 1/T 2W 10K ohm . . . . . . . . . . . . . . . . . . 1
. . CLAMP, capacitor 2.000dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . CAPACITOR, elctlt 1600uf 400VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . BUS BAR, capacitors (C1,2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR/CAPACITOR, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR w/SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, circ skt push-in 18-14ga Amp 66358-6 . . . . . . . . . 14
. . CONNECTOR, circ 14 pin Amp 213571-2
. . CONNECTOR, circ pin push-in 18-14ga Amp 213603-1
. . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 (or)
. . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3
. . BUS BAR, LEM (used w/HD1 on PC1) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . METER KIT A & V DC, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CIRCUIT CARD, meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . 8
. . . . CONNECTOR, rect 11skt plug 22ga Amp 1-640440-1 . . . . . . . . . . . 1
. . . . FRAME, snap-in switch rocker panel mtg . . . . . . . . . . . . . . . . . . . . . . 1
. . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maxstar 91
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 10-2. Module, Power & Diode (Figure 10-1 Items 12 & 15)

. . . 1 . . . . . . DM1 . . . . . 155 803 . . MODULE, diode (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . C9,10 . . . . 098 325 . . . . CAPACITOR, polyp film .027uf 630V . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . D1,2 . . . . . 151 431 . . . . KIT, diode ultra fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . R9 . . . . . 098 324 . . . . RESISTOR, WW fxd 25W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . . 155 802 . . . . HEAT SINK, diode output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . TP1 . . . . . 006 334 . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . PLG10 . . . . 115 092 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . 8
. . . 8 . . . . . . PM1 . . . . . 156 220 . . MODULE, power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . 156 247 . . . . BLADE, fan 6 in 4wg 30deg .252 bore CCW . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . FM . . . . . 156 246 . . . . MOTOR, fan 120/230V 2600RPM w/36V sec . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . +156 227 . . . . HEAT SINK, module power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . Q1,2 . . . . . 149 207 . . . . KIT, transistor mosfet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . PC2 . . . . . 164 401 . . . . KIT, circuit card replacement (Prior to KD438829) . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . PC2 . . . . . 162 956 . . . . CIRCUIT CARD, interconnecting (Eff w/KD438829) . . . . . . . . . . . . . 1
. . . 14 . . . . . . SR1 . . . . . 156 367 . . . . KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . . 153 178 . . . . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . 146 238 . . . . BRACKET, mtg fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . RC10 . . . . . . . . . . . . . . . . . Included with fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 010 913 . . WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . 601 835 . . NUT, brs hex 10-32reg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 18 . . . . . . C11 . . . . . 093 085 . . CAPACITOR, polye met film .0047uf 1000V . . . . . . . . . . . . . . . . . . . . . . 1

6 7
14
5
2
17

15 16

1 4
3

2
9

18
10

11

12 8
Includes 13
Items
14-17

ST-157 535

Figure 10-2. Module, Power & Diode

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Maxstar 91 TM-207 Page 41
 Dia. Part
Mkgs. No. Description Quantity

PC1 175 943 Figure 10-3. Circuit Card, Control (Figure 10-1 Item 5)

. . . . . . . . . . A1 . . . . . . . . . . . 093 065 .. IC, linear 347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . A2 . . . . . . . . . . . 114 176 .. lC, linear 353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . Note 1 . . . . . . . . . . 119 197 .. CAPACITOR, polye met film .1uf 100V . . . . . . . . . . . . . . . . . . . . . . . 17
. . C3,6,9,10,27,39,40 . . . . 119 194 .. CAPACITOR, polye met film .01uf 100V . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . C4,59 . . . . . . . . . . 093 697 .. CAPACITOR, mica 100pf 300VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . Note 2 . . . . . . . . . . 122 723 .. CAPACITOR, cer mono .1uf 50VDC . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . C11,20,30,34,35 . . . . . 121 685 .. CAPACITOR, polye met film .001uf 100V . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . C19,24,25 . . . . . . . . 119 199 .. CAPACITOR, polye met film 1uf 50V . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . C36,38 . . . . . . . . . 084 018 .. CAPACITOR, cer mono 47pf 100VDC . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . C41,56 . . . . . . . . . 039 482 .. CAPACITOR, elctlt 100uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . C47 . . . . . . . . . . . 091 791 .. CAPACITOR, tantlm 15uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . C54,55 . . . . . . . . . 083 973 .. CAPACITOR, elctlt 1000uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . D1,4-9,14-26,
31-33,40,43 . . . . . . . 028 351 .. DIODE, sig 200mA 75V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . D2,3 . . . . . . . . . . 037 386 .. DIODE, zener 11V 1W SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . D10-13 . . . . . . . . . 095 249 .. DIODE, fast recovery 1A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . D27,28,42 . . . . . . . . 095 250 .. DIODE, fast recovery 1A 100V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . D34 . . . . . . . . . . . 032 210 .. DIODE, zener 10V 1W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . D35 . . . . . . . . . . . 026 202 .. DIODE, rect 1A 400V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . D41 . . . . . . . . . . . 037 243 .. DIODE, zener 18V 1W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . HD1 . . . . . . . . . . . 154 431 .. TRANSDUCER, current 100A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SB-164 895

Figure 10-3. Circuit Card, Control PC1

TM-207 Page 42 Maxstar 91
 Dia. Part
Mkgs. No. Description Quantity
Figure 10-3. Circuit Card, Control (Figure 10-1 Item 5)
PC1 175 943
(Continued)

. . . . . . . . HS1,2 . . . . . . . . . . 105 489 .. HEAT SINK, solderable tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . L1 . . . . . . . . . . . 150 644 .. CHOKE, RF 180uh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . Q5-7,12,14-16,21 . . . . . 037 200 .. TRANSISTOR, NPN 200mA 40V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . Q8-11,13,17,22 . . . . . . 037 201 .. TRANSISTOR, PNP 200mA 40V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . Q18,19 . . . . . . . . . 109 007 .. TRANSISTOR, chan N 1A 100V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . Q20 . . . . . . . . . . . 117 213 .. TRANSISTOR, chan P .8A 60V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . R1 . . . . . . . . . . . 156 555 .. RESISTOR, WW fxd 5W 75 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . R2,8,51 . . . . . . . . . 052 151 .. POTENTIOMETER, cermet trmr 25/T .5W 100K ohm . . . . . . . . . . 3
. . . . . . . . . . R3 . . . . . . . . . . . 052 142 .. RESISTOR, MF .25W 121K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . R4,18,19,23,34,60 . . . . 052 138 .. RESISTOR, MF .25W 20K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . R5,31,35,56 . . . . . . . 044 789 .. RESISTOR, MF .25W 100K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . Note 3 . . . . . . . . . . 000 885 .. RESISTOR, MF .25W 10K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . R9,48,65,67 . . . . . . . 082 178 .. POTENTIOMETER, cermet trmr 25/T .5W 10K ohm . . . . . . . . . . . 4
. . . . . . . . R10,24 . . . . . . . . . 039 327 .. RESISTOR, MF .25W 221 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . R11,26,27 . . . . . . . . 089 176 .. RESISTOR, MF .25W 20K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . R14,15,20,22 . . . . . . . 072 560 .. RESISTOR, MF .25W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . R17 . . . . . . . . . . . 052 144 .. RESISTOR, MF .25W 243K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . R21 . . . . . . . . . . . 035 823 .. RESISTOR, CF .25W 100 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R25,29 . . . . . . . . . 135 663 .. RESISTOR, MF .25W 200K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . R28 . . . . . . . . . . . 144 646 .. RESISTOR, WW fxd 5W 10K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . R30 . . . . . . . . . . . 004 592 .. RESISTOR, WW fxd 3W 150 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . R33 . . . . . . . . . . . 121 714 .. RESISTOR, MF .25W 51.1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . R36 . . . . . . . . . . . 109 336 .. RESISTOR, MF .25W 7.5K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . R39,40,104 . . . . . . . 092 525 .. RESISTOR, MF .25W 2K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . R41 . . . . . . . . . . . 000 038 .. POTENTIOMETER, cermet trmr 25/T .5W 2K ohm . . . . . . . . . . . . 1
. . . . . . . . . R43 . . . . . . . . . . . 052 145 .. RESISTOR, MF .25W 475K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R45,46 . . . . . . . . . 126 327 .. RESISTOR, WW fxd 5W 10 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . R49 . . . . . . . . . . . 089 173 .. RESISTOR, MF .25W 4.99K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . R53,54,62,63 . . . . . . . 094 522 .. RESISTOR, MF .25W 150 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . R57 . . . . . . . . . . . 109 371 .. RESISTOR,WW fxd 5W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . R61 . . . . . . . . . . . 108 441 .. RESISTOR, MF .25W 18.2K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . R66 . . . . . . . . . . . 030 090 .. RESISTOR, C .5W 47 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . R68 . . . . . . . . . . . 121 829 .. RESISTOR, MF .25W 9.09K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . R103 . . . . . . . . . . 154 086 .. RESISTOR, MF .25W 499K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . R105 . . . . . . . . . . 074 060 .. RESISTOR, C .5W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . R106 . . . . . . . . . . 108 435 .. RESISTOR, MF .25W 3.92K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . R107 . . . . . . . . . . 084 205 .. RESISTOR, MF .25W 3.32K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . R108,109 . . . . . . . . 030 089 .. RESISTOR, C .5W 2.7 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . RC1 . . . . . . . . . . . 114 425 .. CONNECTOR, rect 16 pin rcpt Molex 39-28-1163 . . . . . . . . . . . . . . 1
. . . . . . . . . RC2 . . . . . . . . . . . 117 864 .. CONNECTOR, rect 14 pin rcpt Molex 39-28-1143 . . . . . . . . . . . . . . 1
. . . . . . . . . RC3 . . . . . . . . . . . 117 038 .. CONNECTOR, rect 2 pin rcpt Molex 39-28-1023 . . . . . . . . . . . . . . . 1
. . . . . . . . . RC4 . . . . . . . . . . . 114 654 .. CONNECTOR, rect 6 pin rcpt Molex 39-28-1063 . . . . . . . . . . . . . . . 1
. . . . . . . . . RC8 . . . . . . . . . . . 113 749 .. CONNECTOR, rect 8 pin rcpt Molex 39-28-1083 . . . . . . . . . . . . . . . 1
. . . . . . . . . SR1 . . . . . . . . . . . 021 939 .. RECTIFIER, integ 1.5A 400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . T1,2 . . . . . . . . . . . 111 910 .. TRANSFORMER, pulse PC mtg 2600VRMS 60Hz . . . . . . . . . . . . . 2
. . . . . . . . . . U1 . . . . . . . . . . . 094 594 .. IC, digital 4098 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . U2 . . . . . . . . . . . 093 064 .. IC, linear 311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . U4 . . . . . . . . . . . 093 413 .. IC, digital 4013B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . U5 . . . . . . . . . . . 052 147 .. IC, digital 4023 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . U6,7 . . . . . . . . . . 113 461 .. IC, digital 40106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . VR1 . . . . . . . . . . . 083 772 .. IC, rgltr 7815 15V 1.5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . VR2 . . . . . . . . . . . 046 932 .. IC, rgltr 7915 -15V 1.5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . VR3 . . . . . . . . . . . 091 256 .. IC, rgltr 317L adj V 100mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Note 1: C1,2,5,12,13,15-17,21-23,28,48,50-52,57
Note 2: C7,8,14,18,26,29,31-33,37,42-46,49,53,58
Note 3: R6,7,12,13,16,32,37,38,42,44,50,52,55,58,59,64,69
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Maxstar 91 TM-207 Page 43
 Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066

PRINTED IN USA  1999 Miller Electric Mfg. Co.