TM-ZZIR October 1997

Miller
Gold Star® 30055 Effective
With Serial No. JC641 296
Gold Star® 4005S Effective
With Serial No. J0590316
ThePower ofBlue. Gold Star® 500SS Effective
With Serial No. JE747791
Gold Star® 600SS Effective
With Serial No. JE813766

GOLD STAR ®SS

0
Visit our webatte at
www.MIII#rWhlflLcuu
TECHNICAL MANUAL
 OM-221X - 2191

TABLE OF CONTENTS

Section No. Page No.

SECTION 1 — SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. General Information And Safety 1
1-2. Safety Alert Symbol And Signal Words 1
1-3. Safety Precautions 1
SECTION 2— SHIPPING AND STORAGE
2-1. Preparation For Reshipment 2
2-2. Storage 2
SECTION 3—SPECIFICATIONS
3-1. Volt-Ampere Curves 5
3-2. Duty Cycle S
3-3. Description 5
SECTION 4—INSTALLATION OR RELOCATION
4-1. Site Selection 5
4-2. Transporting Methods 5
4-3. Remote 14 Receptacle Information And Connections 6
4-4. Weld Output Connections 6
4-5. Electrical Input Connections 7
SECTION 5-OPERATOR CONTROLS
5-1. PowerSwitch 10
5-2. Pilot Light 10
5-3. Range Switch 10
5-4. Amperage Adjustment Control 10
5-5. Remote 14 Receptacle And Amperage Control Switch 10
5-6. Remote 14 Receptacle And Output (Contactor) Control Switch .... 10
5-7. Arc Control 11
5-8. Meters (Optional) 11
5-9. Polarity Switch (Optional) 11
SECTION 6-SEQUENCE OF OPERATION
6-1. Shielded Metal Arc Welding (SMAW) 12
6-2. Shutting Down 12
SECTION 7- THEORY OF OPERATION
7-1. Theory Of Operation ... 14
Diagram 7-1. Block Diagram 16
SECTION 8— TROUBLESHOOTING
8-1. Testing Instruments And Information 18
8-2. Circuit Board Handling Precautions 18
8-3. Troubleshooting 18
Diagram 8-1. Troubleshooting Circuit Diagram For
300 And 400 Ampere Models 24
Diagram 8-2. Troubleshooting Circuit Diagram For 300 And 400
Ampere Models With Demand Fan Control 26
Diagram 8-3. Troubleshooting Circuit Diagram For
500 And 600 Ampere Models 28
Diagram 8-4. Troubleshooting Circuit Diagram For 500 And 600
Ampere Models With Demand Fan Control 30
8-4. Control Board PCi Testing Information 32
Diagram 8-5. Troubleshooting Circuit Diagram For Control Board PCi . . 34
 Section No. Page No.
SECTION 8— TROUBLESHOOTING (Continued)
8-5. HaIl Device HOl Testing Information For
300 And 400 Ampere Models 36
Diagram 8-6. Troubleshooting Circuit Diagram For Hall Device HD1
In 300 And 400 Ampere Models 37
8-6. Hall Device HD1 Testing Information For
500 And 600 Ampere Models 38
Diagram 8-7. Troubleshooting Circuit Diagram For Hall Device HD1
In 500 And 600 Ampere Models 39
8-7. Diodes D1O And Dli Testing Procedure 40
8-8. Main Rectifier SRi Testing And Replacement Procedure
For 300 Ampere Models 40
8-9. Main Rectifier SRi Testing And Replacement Procedure
For 400, 500, And 600 Ampere Models 43
SECTION 9— COMPONENT IDENTIFICATION AND LOCATION
Figure 9-1.
Main Assembly And Component Locations 47
Figure 9-2.
Front Panel And Component Locations 48
Figure 9-3.
Rear Panel And Component Locations 49
Figure 9-4.
Main Rectifier SRi And Component Locations
For 300 Ampere Models 49
Figure 9-5. Main Rectifier SRi And Component Locations
For 400, 500, And 600 Ampere Models 50
Figure 9-6. Input Terminal Board TEl And Component Locations 50
Figure 9-7. Push Button PB1 Switch Assembly
And Component Locations 51
SECTION 10— MAINTENANCE
10-1. Routine Maintenance 52
10-2. Rectifier Protection 52
10-3. Demand Fan Control (Optional) 52
SECTION 11 — ELECTRICAL DIAGRAMS
Diagram 11-1. Circuit Diagram For 300 Ampere Models Effective
With Serial No. JC641 296 Thru JG032479 And
400 Ampere Models Effective With Serial No.
JC59O3i6Thru JG032479 56
Diagram 11-2. Circuit Diagram For 300 And 400 Ampere Models
Effective With Serial No. JG032480 Thru JH1 76799 57
Diagram 11-3. Circuit Diagram For 300 And 400 Ampere Models
Effective With Serial No. JH1 76800 Thru JJ503983 58
Diagram 11-4. Circuit Diagram For 300 And 400 Ampere Models
Effective With Serial No. JJ503984 Thru JK674520 59
Diagram 11-5. Circuit Diagram For 300 And 400 Ampere Models
Effective With Serial No. JK674521 Thru KA819072 60
Diagram 11-6. Circuit Diagram For 300 And 400 Ampere Models
Effective With Serial No. KA819073 And Following 61
Diagram 11-7. Wiring Diagram For 300 Ampere Models Effective
With Serial No. KA81 9073 And Following 62
Diagram 11-8. Wiring Diagram For 400 Ampere Models Effective
With Serial No. KA81 9073 And Following 64
Diagram 11-9. Circuit Diagram For 300 Ampere Models With
Fan Control Effective With Serial No. JC641296 Thru
JF855842 And 400 Ampere Models With Fan Control
Effective With Serial No. JC590316 Thru JF855842 66
Diagram 11-10. Circuit Diagram For 300 And 400 Ampere Models With
Fan Control Effective With Serial No. JF855843
Thru JG032479 67
Diagram 11-11. Circuit Diagram For 300 And 400 Ampere Models With
Fan Control Effective With Serial No JG032480
Thru JH296871 68
 Section No. Page No.

SECTION 11 — ELECTRICAL DIAGRAMS (Continued)

Diagram 11-12. Circuit Diagram For 300 And 400 Ampere Models With
Fan Control Effective With Serial No. JH296872
Thru JJ503983 69
Diagram 11-13. Circuit Diagram For 300 And 400 Ampere Models With
Fan Control Effective With Serial No. JJ503984
Thru JK674520 70
Diagram 11-14. Circuit Diagram For 300 And 400 Ampere Models With
Fan Control Effective With Serial No. JK674521
ThruKA8l9O72 71
Diagram 11-15. Circuit Diagram For 300 And 400 Ampere Models With
Fan Control Effective With Serial No. KA81 9073
And Following 72
Diagram 11-16. Circuit Diagram For 500 Ampere Models Effective With
Serial No. JE747791 Thru JF846888 73
Diagram 11-17. Circuit Diagram For 500 Ampere Models Effective With
Serial No. JF846889 Thru JG032479 And 600 Ampere
Models Effective With Serial No. JE81 3766
Thru JG032479 74
Diagram 11-18. Circuit Diagram For 500 And 600 Ampere Models
Effective With Serial No. JG032480 Thru JJ503983 75
Diagram 11-19. Circuit Diagram For 500 And 600 Ampere Models
Effective With Serial No. JJ503984 Thru JK674520 76
Diagram 11-20. Circuit Diagram For 500 And 600 Ampere Models
Effective With Serial No. JK674521 Thru KA81 9072 77
Diagram 11-21. Circuit Diagram For 500 And 600 Ampere Models
Effective With Serial No. KA81 9073 And Following 78
Diagram 11-22. Wiring Diagram For 500 And 600 Ampere Models
Effective With Serial No. KA81 9073 And Following 80
Diagram 11-23. Circuit Diagram For 500 Ampere Models With
Fan Control Effective With Serial No. JE747791 Thru
JG032479 And 600 Ampere Models With Fan Control
Effective With Serial No. JE813766 Thru JG032479 82
Diagram 11-24. Circuit Diagram For 500 And 600 Ampere Models With
Fan Control Effective With Serial No. JG032480
Thru JJ503983 83
Diagram 11-25. Circuit Diagram For 500 And 600 Ampere Models With
Fan Control Effective With Serial No. JJ503984
ThruJK67452O 84
Diagram 11-26. Circuit Diagram For 500 And 600 Ampere Models With
Fan Control Effective With Serial No. JK674521
Thru KA81 9072 85
Diagram 11-27. Circuit Diagram For 500 And 600 Ampere Models With
Fan Control Effective With Serial No. KA81 9073
And Following 86
Diagram 11-28. Circuit Diagram For Control Board PCi Effective With
Serial No. Thru JF933619 87
Diagram 11-29. Circuit Diagram For Control Board PCi Effective With
Serial No. JF933620 And Following 88
Diagram 11-30. Circuit Diagram For Hall Device HD1 In 300 Ampere
Models Effective With Serial No. JC641 296 Thru
JH176788 And 400 Ampere Models Effective With
Serial No. JC590316 Thru JH176788 89
Diagram 11-31. Circuit Diagram For Hall Device HD1 In 300 And
400 Ampere Models Effective With Serial No.
JH176789 And Following 89
Diagram 11-32. Circuit Diagram For Hall Device HD1 In 500 Ampere
Models Effective With Serial No. JE747791 And Following
And 600 Ampere Models Effective With Serial No.
JE813766 And Following 90
 LIST OF CHARTS AND TABLES

Table 3-i. Specifications 3

Table 3-2. Idling Data (No Load) 3
Chart 3-1 - Volt-Ampere Curves 4
Chart 3-2. Duty Cycle 5
Table 4-1. Weld Cable Size 7
Table 4-2. Input Conductor And Fuse Size 9
Table 8-i. Troubleshooting 19
Chart 8-1. Waveforms For Diagrams 8-1 Thru 8-4 23
Table 10-i. Maintenance Schedule 52
Table li-i. List Of Circuit Diagrams And Wiring Diagrams 54
 SECTION 1 — SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. GENERAL INFORMATION AND SAFETY
This manual provides theory of operation along with
specific operating, testing, and troubleshooting proce-
dures. It also includes precautionary information rele-
vant to these procedures. This manual can be an effec-
tive tool in the hands of a trained serviceperson. How-
ever, it does not and cannot take the place of previous
training nor safety-conscious service work. If any doubt
arises about the specific application of procedures pre-
sented, or if problems arise which are not covered in this
manual, contact the factory Service Department before
proceeding further.
1-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
The following safety alert symbol and signal words are
used throughoutthis manual to call attention to and iden-
tify different levels of hazard and special instructions.
This safety alert symbol is used with the signal
A words WARNING and CAUTION to call atten-
tion to the safety statements.
WARNING statements identify procedures or
A practices which must be followed to avoid seri-
ous personal injury or loss of life.
CAUTION statements identify procedures or
A practices which must be followed to avoid minor
personal injury or damage to this equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip-
ment.
1-3. SAFETY PRECAUTIONS
A WARNING: ELECTRIC SHOCK can kill.
touch live electrical parts.
• Protect yourself with dry insulating gloves
and clothing.
• Insulate yourself from ground by using
rubbergloves and insulating floor mats when
power is applied to the unit.
• Shut down unit and disconnect input power
when servicing unless the procedure specifi-
cally requires an energized unit.
• Do not leave live unit unattended.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
hearing.
• Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm
your health.
• Keep your head out of the fumes.
• Ventilate to keep from breathing fumes and
gases.
• If ventilation is inadequate, use approved
breathing device.
• Read Material Safety Data Sheets (MSDSs)
and manufacturer’s instructions for any
materials used.
HOT METAL, SPATTER, AND SLAG can
cause fire and burns.
• Watch for fire.
• Have a fire extinguisher nearby and know
how to use it.
• Do not use near flammable material.
• Allow work and equipment to cool before
handling.
MOVING PARTS can cause serious injury.
• keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.
• Use equipment ofadequate capacity to lift the
unit.
MAGNETIC FIELDS FROM HIGH CURRENTS
can affect pacemaker operation.
• Wearers should consult their doctor before
going near the servicing ofarc welding equip-
ment or any arc welding operations.
SM-221 Page 1
 SECTION 2 — SHIPPING AND STORAGE
2-1. PREPARATION FOR RESHIPMENT
A WARNING: ELECTRIC SHOCK can kill.
• Do not touch llve electrical parts.
• Shut down welding power source, and
disconnect input power employing lockout/
tagging procedures before preparing unit for
shipping.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon-
necting device.
1. Disconnect input power conductors from deener-
gized supply.
2. If applicable, disconnect gas cylinder, water sup-
ply, and/or coolant system; remove unit from run-
ning gear.
3. Bolt unit to a proper wooden skid or wooden rails.
4. Tape plastic around top and sides of unit.
5. Securely tie and/or tape cardboard over top and
around sides of unit. Use original shipping carton
if available.
IMPORTANT: Do not ship without a cardboard carton.
Not only do costs increase dramatically, but the unit is
more subject to loss or damage without a carton.
6. If sending unit to factory, ship unit as directed by
factory Service Department or Transportation
Department.
5M-221 Page 2
2-~ STORAGE
WARNING: ELECTRIC SHOCK can kill.
• Do not touch llve electrical parts.
• Shut down welding power source, and
disconnect input power employing lockout!
tagging procedures before storing unit.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon-
necting device.
1. Disconnect input power conductorsfrom deener-
gized supply.
2. Clean outside of unit.
3. Remove top cover and side panels (or wrapper as
applicable).
4. Using dry compressed air, clean inside of unit.
5. Reinstall top cover and side panels or wrapper as
applicable.
6. Apply touch-up paint to any nicks or scratches to
prevent rusting, etc.
7. Select a storage location that least subjects the
unit to wide temperature variation, dust, dirt, and
corrosive vapors.
8. Move unit to storage location.
9. Place unit on suitable blocks such as 2 x 4’s or
4 x 4’s to keep it off the floor.
10. Cover unit with plastic or a suitable tarp.
 SECTION 3— SPECIFICATIONS

Table 3-1. Specifications

Input At Rated
Rated Welding Welding Max. Load Output
Model Current Amperes Current Open- 60 Hz Three-Phase Weight
60% Duty Cycle Ranges Circuit
Amperes Voltage Amperes At
200V 230V 460V 575V KVA KW Net Ship
300 300 @~ 15-200
Ampere 32 Volts 25-385 70 67 58 29 23 23.2 12.9 (209
460 lbs.
kg) 489 lbs.
(222 kg)
400 400 @ 20-270
Ampere 36 Volts 37-510 70 87 75 38 30 30 19.8 473 lbs.
(215 kg) 498 lbs.
(226 kg)

500 500 @ 20-346

Ampere 40 Volts 34-625 70 112 97 49 39 38.8 25.6 (246
543 lbs.
kg) 568 lbs.
(258 kg)
600 600@ 30-415
Ampere 44 Volts 57-775 70 132 114 57 46 45.6 32.7 (287
632 lbs.
kg) 657 lbs.
(298 kg)

Table 3-2. Idling Data (No Load)*

Idling Amperes Input At No Load

60 Hz Three-Phase
Input Input
Model 200(208)V 230V 460V 575V KVA KW

300 4.3(4.1) 3.7 1.9 1.5 1.5 0.92

Ampere
400
Ampere 4.4(4.2) 3.8 1.9 1.5 1.5 0.96
500
Ampere 4.1(3.9) 3.5 1.8 1.4 1.4 1.08

600
Ampere 5.1(4.9) 4.4 2.2 1.8 1.8 0.8
*VaIues are nominal and for 60 Hz models only.

SM-221 Page 3
 Chart 3-1. Volt-Ampere Curves
70 70
Low Range
60 400 Amp
60 Model
50 50
0
I- 0
-‘40
0 I.-
~40
685 W3L

830
20 ,~ cG~.
20
10 10
SOFT

0 200 400 600 800 1000 00 50100 150200 260300350400450500550

DC AMPERES Ref. SB—081 870—A DC AMPERES Ref. 55-054 621-A

70
70
60
60
50
50
0
0
~40 I.- 40
0 —J
0

830
20 20

10 10

0 0
DC AMPERES Ref. 55-081 866-A DC AMPERES Ref. SB-084 642-A
50 70
70 60
60
50
oSO 0
I- I—
-a -J
0 40
~40
830 030
0
20
20
10 10

0 0
395—A Ref. SB—081 850-A
70 70
High Range High Range
60 500 Amp 60 600 Amp
Model Model
50 60
0 0
I-
b40 MAX 40
0
030 o 30 502 MAX
0 0
,~ OG~
20 20
p~ c~ SOFT
10 SOFT MAX
10 MAX MAX

0 0
800 1000 0 200 400 600 800 1000 1200 1400
0 200 400 600 Ref SB—081 394—A DC AMPERES Ref. SB—081 848—A
DC AMPERES
SM-221 Page 4
3-1. VOLT-AMPERE CURVES (Chart 3-1) Chart 3-2. Duty Cycle
The volt-ampere curves show the voltage and Amper-
age output capabilities of the welding power source at 120 Model
the mm. and max. values of the AMPERAGE ADJUST-
MENT control setting. Curves of other settings will fall
B0
between the curves shown.
0
-With the use of the volt-ampere curves, it is possible to w
w
determine the weld current at any particular load volt- 0.

age. 600 Amp

400
0
-J 500 Amp
uJ
3-2. DUTY CYCLE (Chart 3-2) 400 Amp
The duty cycle of a welding power source is the percent-
age of a ten minute period that a welding power source 300 Amp
20
can be operated at a given output without causing over- 0
heating and damage to the unit. This welding power U 80 40 80 80 708090m0

source is rated at 60 percent duty cycle. This means that
the welding powersource can be operated at rated load
for six minutes out of every ten. During the remaining
four minutes, the unit should idle to permit proper cool-
ing. If the welding Amperes are decreased, the duty cy-
cle will increase. Chart 3-2 enables the operatorto deter-
mine the output of the welding power source at various
duty cycles.
CAUTION: EXCEEDING DUTY CYCLE RAT-
A INGS will damage the welding power source.
• Do not exceed indicated duty cycles.
X DUTY CYCLE
SB-OOO 865-0
3-3. DESCRIPTION
This unit is a three-phase dc arc welding power source
with solid-state control. It produces dc weld current and
is designed to be used for Shielded Metal Arc Welding
(SMAW). The number in the model designation refers to
the rated welding current in Amperes.
These units have solid-state contactors and a pilot light
to indicate when the POWER switch is energized.

SECTION 4— INSTALLATION OR RELOCATION

4-1. SITE SELECTION

Select an installation site which provides the following: A CAUTION: RESTRICTED AIRFLOW can
cause overheating and possible damage to
internal parts.
• Maintain at least 18 inches (457 mm) ofunre-
1. Correct input power supply (see unit nameplate)
stricted space on all sides of unit, and keep
2. Shielding gas supply (if applicable) underside free of obstructions.
• Do not place any filtering device over the in-
3. Water supply (if applicable) take airpassages thatprovide airflow forcool-
ing this unit.
4. Adequate ventilation and fresh air supply Warranty is void if any type of filtering device is
5. No flammables used at intake air passages.

6. A clean and dry area 4-2. TRANSPORTING METHODS

7. Proper temperature that avoids extremes of heat
or cold
8. Proper airflow around unit
9. Adequate space for removingtop cover and outer
panels for installation, maintenance, and repair
functions.
Base mounting holes provide the capabilityto install and
secure the uniton a running gear or in a permanent loca-
tion. A permanent installation site for securing the unit
should allow sufficient space on all sides and above the
unit to open access door(s), or remove top cover and
outer enclosure panels formaintenance and repair func-
tions.
This welding power source is equipped with a lifting eye
for moving the unit during installation. Weight capacityof
the lifting eye only allows for supporting the welding
power source.
A WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power conductors from
deenergized supply line BEFORE moving
welding power source.
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.
• Use lifting eye to lift unit only, NOT running
gear, gas cylinders, orany otherheavy acces-
sories or devices.
5M-221 Page 5
 • Use equipmentofadequate capacity to lift the
unit.
• If llfting or moving this unit with lift forks under
the base, be sure that lift forks are long
enough to extend beyondopposite side of the
base.
Using lift forks too short can damage internal
parts if tips of the lift forks penetrate the unit
base, or may cause personal injury and/or
equipment damage if unit falls off the lift forks.
4-3. REMOTE 14 RECEPTACLE INFORMATION
AND CONNECTIONS (Figures 4-1 And 5-1)
~J REMOTE 14
IMPORTANT: Although the term CONTACTOR isused
on the nameplate and throughout this manual, the out-
put is notswitchedon oroffbya physicalsecondary con-
tactor; rather, the output is controlled by a Silicon Con-
trolled Rectifier (SCR) stack which functions as a con-
tactor.
REMOTE 14 receptacle RC1 is used to connect any of
the following equipment to the welding power source cir-
cuitry:
a. Remote Contactor
b. Remote Amperage control
c. Combination of the above.
To make connections, align keyway, insert plug, and ro-
tate threaded collar fully clockwise.
The following socket information is included in case the
supplied cord is not suitable, and it is necessaryto wire a
plug or cord to interface with REMOTE 14 receptacle
RC1.
IMPORTANT: When contact closure is provided be-
tween sockets A and B, the welding power source out-
put/contactor control circuit is energized.
Ref.
Figure 4-i. Front View Of Remote 14 Receptacle
With Socket Locations
Receptacle RC1 socketconnectionstothewelding pow-
er source control circuitry are as follows:
Socket A: Contactor control switch connection.
Socket B: Contactor control switch connection.
Socket C: Amperage control connection (maximum
side).
Socket D: Amperage control connection (minimum
side).
5M-221 Page 6
Socket E: Amperage control connection (wiper con-
tact).
IMPORTANT: The remaining sockets in the receptacle
are not used.
4-4. WELD OUTPUT CONNECTIONS (Figure 5-1)
Q* RATED OUTPUT
To obtain full rated output from this unit, it is necessary to
select, prepare, and install proper weld cables. Failure to
comply in any of these areas may result in unsatisfactory
welding performance.
A. Weld Cable Selection
Use the following guidelines to select weld cables:
1. Use the shortest possible cables, and place ca-
bles close together. Excessive cable lengths may
reduce output or cause unit overload due to
added resistance.
2. Use weld cable with an insulation voltage rating
equal to or greater than the maximum open-
circuit voltage (ocv) of the welding power source
(see Table 3-i for unit maximum ocv rating).
3. Select welding cable size according to maximum
weld output and total length of connecting cables
in weld circuit. For example, if a 25 foot (7.5 m)
electrode holder cable is used with a 25 foot (7.5
m) work cable, select the cable size recom-
mended in Table 4-i for 50 feet (15 in).
4. Do not use damaged or frayed cables.
B. Weld Cable Preparation
1. Install correct size lugs of adequate amperage
capacity onto ends of both cables for connecting
to work clamp, electrode holder, and weld output
terminals.
2. Install electrode holder onto weld cable following
manufacturer’s instructions. An insulated elec-
trode holder must be used to ensure operator
safety.
3. Install work clamp onto cable.
C. Weld Cable Connections
S—0004
NEGATIVE POSITIVE
— +
A WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down welding powersource, anddiscon-
nect input power employing lockout/tagging
procedures before inspecting or installing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red—tagging circuit breaker or other disconnect-
ing device.
 Table 4-1. Weld Cable Size

Total Cable (Copper) Length In Weld Circuit Not Exceeding*

100 ft. Or Less 150 ft. 200 ft. 250 ft. I 300 ft. 350 ft. 400 ft.
Welding (30 m) (45 m) (60 m) (70 m) j (90 m) I (105 m) (120 m)
Amperes 10 To 60% 60 Thru 100% 10 Thru 100% Duty Cycle
Duty Cycle Duty Cycle
100 1 1 1 1 1 2 1/0 1/0
150 1 1 1 1 1/0 2/0 3/0 3/0
200 1 1 1 1/0 2/0 3/0 4/0 4/0
250 1 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0
800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0
900 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of more than 300 circular
mils per ampere. S-OOO 7/8-88

1. Connect work cable or connector to NEGATIVE tric utility for information about the type of electrical serv-
weld output terminal. ice available, how proper connections should be made,
and inspection required.
2. Connect electrode cable to POSITIVE weld out-
put terminal. B. Jumper Link Installation (Figures 4-2 And 4-3)
IMPORTANT: The connections given are for dc elec-
trode positive polarity. Ifdc electrode negative polarity is
desired, reverse cable connections to weld output termi-
nals (work becomes positive).
A WARNING: Read precautionary information
at beginning of entire Section 4-5 before
proceeding with this installation.
Jumper links are used to allow the equipment to operate
4-5. ELECTRICAL INPUT CONNECTIONS from different line voltages.
1. Remove top cover and right side panel.
—~ INPUT
2. Compare position of jumper links on the input ter-
minal board to the voltage link arrangement
WARNING: ELECTRIC SHOCK can kill.
A • Do not touch live electrical parts.
shown on input voltage label.

• Shutdown weldingpowersource, and discon-

nect input power employing lockout/tagging
procedures before ir7specting or installing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
A. Electrical Input Requirements
Operate the welding power source from a three-phase,
60 Hertz, ac powersupply. The inputvoltage must match
one of the electrical input voltages shown on the input
data label on the unit nameplate. Contact the local elec-
A CAUTION: INCORRECT INPUT VOLTAGE
JUMPER LINK PLACEMENT can damage
unit.
• Position lumper links as shown on the input
voltage label (see Figures 4-2 and 4-3).
• Store unused]umper links across linked ter-
minals.
IMPORTANT: Ifthe input voltages stated on nameplate
or rating label are different from those in Figure 4-2,
check the input voltage label in the unit or call Factory
Service Department.
3. Install jumper links onto the input terminal board
to match the available input line voltage.
SM-221 Page 7
 8 /0

•1’ I
TO CONTROL TRANSFORMER
CIF APPLICABLE)
1~I00~~ 0
324 1324 1324

FM FM

KiLl KiLl KiLl

COIL 3 COTh 2 COIL I

460 VOLTS
o~j~o o~o o~o

000
L L L

a0 19

0
I 00
I
0 0 00 0 0 0 0
TO CONTROL TRANSFORMER
(IF APPLICABLE)

514362 514362 514362

FM FM
I 2345 6 I 2345 6 2345 6

COIL #3
KJIILThLJ COIL #2 COIL #1
SIMILAR CONNECTED VOLTAGES
208/230/460
220/230/460

200 VOLTS 230 VOLTS 460 VOLTS

~j~oo~ ~J~oo~j~ ~j0o~ O~~O O~J~O O~~O OV~j~OO OO~OQ OO~OO

OLOLOL OLOLOL OLOLOL

I I /0

T
TO CONTROL TRANSFORMER
(IF APPLICABLE)

00 0 TIE TOGETHER 2L5

1m63 45 6 32463 I 3 2 4 6 3 FAN MOTOR ACROSS 1L2
B 5 5 COIL #1

123123456123 AU

COIL #3 COIL #2 COIL dl

230 VOLTS 460 VOLTS 575 VOLTS

~OO ~OQ ~OO o~j~ooo o~ooo e~oeo Oooo~ oooe~ oeoo~

L L L L L L L L L
000 000 000
SA—047 874—A
Ref. SA—047 873—A
Ref. SA-047 881-A
Figure 4-2. Input Voltage Labels And Connection Diagrams

SM-221 Page 8
 Input
Terminal
Board

SB-094 762-C

Figure 4-3. Location Of Electrical Input Connections And Components

C. Welding Power Source Input Power Connec- Table 4-2. Input Conductor And Fuse Size*
tions (Figure 4-3)
Input Ground u
WARNING: ELECTRIC SHOCK can kill.
A • Do not touch live electrical parts.
• Instali a fusible line disconnect switch in the
Model Input Conductor Conductor
Voltage Size
(AWG)
Size
(AWG)
use
Size In
Amperes
200 6 8 100
input circuit to the welding power source.
• Connect input conductors to the welding 300 230 8 8 90
powersource before connecting to the single- Ampere 460 10 10 45
phase input power.
575 12 12 35
• Read and follow safety information at begin-
ning of entire Section 4-5. 200 4 6 125
The line disconnect switch provides a safe and
convenient means to completely remove all 400 230 6 6 125
electrical power from the welding power source Ampere 460 10 10 60
whenever it is necessary to inspect or service
the unit. 575 10 10 45
1.Use Table 4-2 as a guide to select input conduc- 200 3 6 175
tors for the installation. The input conductors
should be covered with an insulating material that 500 230 4 6 150
complies with national, state, and local electrical Ampere 460 8 8 70
codes. 575 10 10 60
2. Install terminal lugs of adequate Amperage ca- 200 2 6 200
pacity and correct stud size onto the input and
ground conductors. 600 230 3 6 175

WARNING: ELECTRIC SHOCK can kill. Ampere 460 8 8 90

A • Do not touch live electrical parts.
• Do not connect an input conductor to the
ground terminal in the unit.
• Do not connect the ground conductor to an
input line terminal.
Incorrect input connections can result in an
electrically energized welding power source
chassis. The ground terminal is connected to
the welding power source chassis and is for
grounding purposes only.
575 8 8 70
*Conductorsize is basedon the 1990 Edition of the National
Electrical Code (NEC) specifications for allowable Ampaci-
ties of insulated copper conductors, having a temperature
(750C), with not more than three single cur-
rating of 1 670Fconductors
rent-carrying in a raceway (Article 310 of NEC).
(The ground conductor is not counted as a current-carrying
conductor.)
*Fuse size is based on not more than 200 percent of the
rated input Amperage of the welding power source (Article
630 of NEC).
5M-221 Page 9
 3. Obtain and install a standard conduit strain relief
connector into the rear panel access hole.
4. Insert conductors through strain relief installed in
Step 3. Route conductors to the input terminal
board.
5. Connect input conductors to line terminals on the
input terminal board (see Figure 4-3).
6. Connect the ground conductor to the ground ter—
minal (see Figure 4-3).
SECTION 5—OPERATOR CONTROLS
5-1. POWER SWITCH (Figure 5-1)
Pressing the POWER switch ON push button energizes
the welding power source. Pressing the POWER switch
OFF push button shuts down the welding powersource.
IMPORTANT: For models with optional fan control,
when the POWER switch ONpush button ispressed, the
pilot light comes on, but the fan motor does not run un-
less the internal componentsare already warm. The fan
motor is thermostatically controlled and only operates
when additional cooling is required (see Section 10-3).
IMPORTANT: After any interruption ofinput power, the
POWER switch ON push button must be depressed to
reenergize the welding powersource.
5-2. PILOT LIGHT (Figure 5-1)
The pilot light comes on whenever the POWER switch is
in the ON position and indicates that the unit is receiving
input power.
5-3. RANGE SWITCH (Figure 5-1)
The RANGE switch provides the means of selecting be-
tween the two coarse output ranges. When the RANGE
switch is in the LOW position, ensure that the LOW cur-
rent scale is used when adjusting the AMPERAGE AD-
JUSTMENT control. When in the HIGH position, ensure
that the HIGH current scale is used when adjusting the
AMPERAGE ADJUSTMENT control.
5-4. AMPERAGE ADJUSTMENT CONTROL (Fig-
ure 5-1)
The AMPERAGE ADJUSTMENT control provides the
means of selecting the exact amperage desired within
the range being used. Rotate the control clockwise to in-
crease the current output.
IMPORTANT: The AMPERAGEADJUSTMENTcontroI
may be adjusted while welding.
5M-221 Page 10
7. Connect remaining end of ground conductor to a
suitable ground. Use a grounding method that
complies with all applicable electrical codes.
8. Connect remaining ends of input conductors to a
deenergized line disconnect switch.
9. Secure the input cable in the strain relief.
10. Reinstall top cover and right side panel.
ii. Use Table 4-2 as a guide to select line fuses for
the disconnect switch. Obtain and install proper
fuses.
5-5. REMOTE 14 RECEPTACLE AND AMPERAGE
CONTROL SWITCH (Figure 5-1)
If a Remote Amperage Control is to be used, make con-
nections from the control to the REMOTE i 4 receptacle
as instructed in Section 4-3.
When remote control of the amperage is desired, the
AMPERAGE control switch must be placed in the
REMOTE 14 position. Likewise, if a Remote Amperage
Control is not desired, the switch must be in the PANEL
position. When in the PANEL position, only the
AMPERAGE ADJUSTMENT control on the front panel
will control the current.
When a Remote Amperage Control is being used, the
control is functioning as a fine current adjustment for the
AMPERAGE ADJUSTMENT control setting on the
welding powersource. For example: If the AMPERAGE
ADJUSTMENT control on the welding power source is
set at the mid—range position, the Remote Amperage
Control will provide (from its mm. to max. positions) fine
amperage adjustment of one half of the welding power
source output for the current range selected. If full ad-
justment through use of the remote control of the amper-
age range selected is desire, the AMPERAGE ADJUST-
MENT control on the welding power source must be set
at maximum position.
5-6. REMOTE 14 RECEPTACLE AND OUTPUT
(CONTACTOR) CONTROL SWITCH (Figure
5-1)
WARNING: ELECTRIC SHOCK can kill.
A • Do not touch live electrical parts.
• Do not touch the weld output terminals when
the contactor is energized.
• Do not touch electrode and work clamp at the
same time.
When the OUTPUT (CONTACTOR) Control
switch is in the ON position, open-circuit voltage
is present at the weld output terminals for as
long as the welding power source is energized.

Arc control
Remote 14
Receptacle
Negative (—)
weld Output
Terminal
Figure 5-1. Front Panel View
IMPORTANT: Although the term CONTACTOR is used
on the nameplate and throughout this manual, the out-
put is notswitched on oroffbyaphysicalsecondary con-
tactor; rather, the output is controlled by a Silicon Con-
trolled Rectifier (SCR) stack which functions as a con-
tactor.
The contactor control circuitry in this welding power
source enables the operator to remotely control the
availability of weld output from the work station.
If a Remote Contactor Control is to be used, make con-
nections to the REMOTE 14 receptacle as instructed in
Section 4-3. Place the OUTPUT (CONTACTOR) Con-
trol switch in the REMOTE 14 position. Depress the ON
push button on the welding power source. Weld output
will be available whenever the Remote Contactor Con-
trol switch is closed.
If a Remote Contactor Control is not to be used, place
the OUTPUT (CONTACTOR) Control switch in the ON
position. When in the ON position, weld output will be
available after the ON push button is depressed on the
welding powersource. Weld output will continue until the
OFF push button is depressed on the welding power
source.
5-7. ARC CONTROL (Figure 5-1)
IMPORTANT: Prior to serial number JK674521, the
ARC CONTROL was an ARC CONTROL switch.
The ARC CONTROL provides selection of arc charac-
teristics to suit individual welding conditions.
Amperage
Adjustment
control
Power Switch
Pilot Light
5B-094 756-C
When the control is set at 100 (maximum), amperage in-
creases rapidly as the short-circuit condition is ap-
proached. This provides extra amperage for arc starting
in out of position welding as well as for certain types of
electrodes.
When the control is set at 0 (zero), amperage increases
in a linear fashion as the short-circuit condition is ap-
proached. This provides amperage characteristics as-
sociated with Gas Tungsten Arc Welding (GTAW).
5-8. METERS (Optional)
The meters are provided to monitor the welding opera-
tion and serve as an indication of the welding process.
They are not intended for exact amperage or voltage
measurements. The voltmeter is internally connected to
the welding powersource output terminals. The voltme-
ter will indicate the voltage at the weld output terminals,
but will not necessarily indicate the actual voltage at the
welding arc (due to cable resistance, poor connections,
etc.). The ammeter indicates output amperage of the
unit.
5-9. POLARITY SWITCH (Optional)
The POLARITY SWITCH provides a means of selecting
either dc ELECTRODE POSITIVE or dc ELECTRODE
NEGATIVE polarity without having to change the weld
output cable connections.
A CAUTION: ARCING can damage switch con-
tacts.
• Do not change switch position while welding
or under load.
SM-221 Page 11
 SECTION 6— SEQUENCE OF OPERATION

3. Connect work clamp to clean, bare metal at work-

A WARNING: ELECTRIC SHOCK can kill;

MOVING PARTS can cause serious injury:
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
piece.

4. Select proper electrode.

• Do not touch live electrical parts.
• Keep all covers and panels in place while
operating.
Warranty is void if the welding power source is
operated with any portion of the outer enclosure
removed.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
hearing.
• Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm
your health.
• keep your head out of the fumes.
• Ventilate to keep from breathing fumes and
gases.
• If ventilation is inadequate, use approved
breathing device.
HOT METAL, SPATTER, AND SLAG can
cause fire and burns.
• Watch for fire.
• Keep a fire extinguisher nearby and know
how to use it.
• Do not use near flammable material.
• Allow work and equipment to cool before
handling.
MAGNETIC FIELDS FROM HIGH CURRENTS
can affect pacemaker operation.
• Wearers should consult their doctor before
going near arc welding, gouging, or spot weld—
ing operations.
See Section 1 - Safety Rules For Operation Of
Arc Welding Power Source in OwneKs Manual
for basic welding safety information.
5. If a Remote Amperage and/or a Remote Contac-
tor Control are not to be used, place the AM PER-
AGE switch in the PANEL position or the OUT-
PUT (CONTACTOR) switch in the ON position. If
a Remote Amperage and/or a Remote Contactor
Control are to be used, place the AMPERAGE or
OUTPUT (CONTACTOR) switches in the RE-
MOTE 14 position (see Sections 5-5 and 5-6).
6. Place the RANGE switch in the desired position
(see Section 5-3).
7. Place the ARC CONTROL in the desired position
(see Section 5-7).
8. Rotate the AMPERAGE ADJUSTMENT control,
or Remote Amperage Control if used, to the de-
sired position (see Section 5-5).
IMPORTANT: The AMPERA GEADJUSTMENTcontroI
may be adjusted while welding.
9. Wear dry welding helmet with proper lens accord-
ing to ANSI Z49.i.
10. Insert electrode into electrode holder.
ii. Depress the POWER switch ON push button (see
Section 5-i).
12. Begin welding.
6-2. SHUTTING DOWN
1. Stopwelding.

6-1. SHIELDED METAL ARC WELDING (SMAW) 2. Allow the welding power source to idle for three
1. Install and connect unit according to Section 4. minutes with no load applied.
2. Wear dry insulating gloves. 3. Depress the POWER switch OFF push button.

5M—221 Page 12
 SECTION 7— THEORY OF OPERATION
7-i. THEORY OF OPERATION (Diagram 7-1)
The basic welding power source operation is not difficult
to understand when it is divided into sections. Diagram
7-1 shows the main componentswhich make up the cir-
cuitry of the welding power source.
IMPORTANT: The following Theory Of Operation is
written in steps which match the circlednumbers on Dia-
gram 7-1. Oomponent designators such as Ti, SRi,
P01, P5, 54, and P01 thatare used in the TheoryOfOp-
eration apply to components on Diagrams 8-1 through
8-4 in this manual.
A. Input Power Circuit
1. The welding power source is supplied with 50 or
60 Hertz, 3-phase voltage at input terminal board
TEl A 3-pole, line contactorW isprovided to con-
.
nect and disconnect input power to main trans-
former Ti. Main transformer Ti has three sec-
ondaries which provide the following:
a. A 3-phase, reduced voltage at high current to
main rectifier SRi
b. A set of 3-phase synchronization signals to
Control Board PCi from which the SCR’s are
gated
c. A single-phase voltage to the Control Board
PCi power supplies and pilot light PLi.
The POWER ON and OFF push buttons energize
and deenergize the line contactor W using a volt-
age from one of the 3-phase synchronization sig-
nals. Thermal over-temperature protection is pro-
vided by thermostat TP1 located on main rectifier
SRi and connected in series with the POWER
OFF push button.
A single-phase, 230 volts ac circuit provides pow-
er for fan motor FM. Fan motor FM is always on
when the welding power source is energized un-
less the unit is equipped with the optional FAN ON
DEMAND circuitry (see Section 10-3). One of the
3-phase synchronization signals supplies power
to the optional FAN ON DEMAND circuitry.
B. Weld Current Circuit
2. A reduced voltage, 3-phase circuit from main
transformer Ti provides power to main rectifier
SRi. This SCR bridge rectifies the 50 or 60 Hertz
power to provide dc output power. The six silicon-
controlled rectifiers SCRi through SCRO are con-
trolled by the gating signals from PCi to produce
a varying amperage on the output of the SCR
5M-221 Page 14
bridge. The dc output current of the SOR bridge is
not continuous, but consists of pulsed portions of
the rectified 3-phase, 50 or 60 Hertz power. Bur-
den resistor R6 isconnected across the output of
the SCR bridge to provide a path for a minimum
SCR holding current to flow.
3. Stabilizer Zi filters the pulsed output current of
the SCR bridge into a more constant dc current.
The filtering action of Zi keeps the welding cur-
rent from going to zero and the welding arc from
going out.
4. The POSITIVE (+) and NEGATIVE (—) weld out-
put terminals are located behind an access door
on the front panel ofthe welding powersource. An
optional POLARITY SWITCH provides a means
of reversing the polarity of the weld output termi-
nals. An optional voltmeter V and ammeter A dis-
play the rectified and filtered values ofthe voltage
and current provided by this welding power
source.
C. Operator Control Inputs
5. The operator can turn on the dc output voltage of
the welding power source by placing OUTPUT
(CONTACTOR) switch S4 in the ON position. The
SCR contactor circuit then enables the six gating
circuits on Control Board PCi to pulse or turn on
the SCR bridge. A small current will flow through
burden resistor R6 if no welding current flows.
The operator can choose to turn the dc output
voltage off by placing OUTPUT (CONTACTOR)
switch S4 in the REMOTE 14 position. See Step 9
for more remote control information.
6. The operator can select the amount of dc output
amperage by placing the AMPERAGE control
switch S2 in the PANEL position and rotating AM-
PERAGE ADJUSTMENT control R5 until the de-
sired amperage is obtained. The signal from R5 is
supplied to the input command circuit on PCi.
The operatorcan also select to have the dc output
amperage controlled by a remote adjustment po-
tentiometer by placing the AMPERAGE control
switch S2 in the REMOTE 14 position. See Step9
for additional remote control information.
7. ARC CONTROL R3 allows the operator to
choose an increased amperage to clear electro-
de-to-work sticking. The increased amperage
permits the burning free of the electrode at short-
circuit conditions and minimizes the situations
which cause the electrodeto stick to the work. R3
provides an increased amperage as the weld out-
put approaches short-circuit conditions.
D. Automatic Constant Current Control Circuit
8. The welding amperage output is automatically
controlled to the value selected by the operatoron
R5 by the following means:
a. The welding amperage is sensed by current
sensor HOl, and a current feedback signal is
applied to the amperage regulator circuit on
Control Board PCi. RANGE switch S3 selects
either LOW or HIGH range thereby adjusting
the amount of current feedback to PCi.
b. The amperage regulator circuit on Control
Board PCi compares this current feedback sig-
nal to the control signal selected by the operator
on AMPERAGE ADJUSTMENT control R5. If a
difference exists, the amperage regulator com-
mands the six gating circuits to change the firing
of the SOR’s. The value of the welding
amperage is therefore maintained at the se-
lected value, regardless of the length of the
welding arc or the voltage drop across the arc.
E. Remote Operations
9. The welding power source is designed to be re-
motely controlled by signals from a variety of re-
mote hand or foot controls.
REMOTE 14 receptacle RC1 provides on/off con-
trol of the welding power source output using a re-
mote contactor switch when OUTPUT (CON-
TACTOR) switch S4 is in the REMOTE 14 posi-
tion.
Remote amperage adjustment is also possible up
to the value of the amperage selected by AM-
PERAGE ADJUSTMENT control R5 when AM-
PERAGE switch S2 is in the REMOTE 14 posi-
tion.
5M-221 Page 15
 3-Phase
Line
Input Power

Synchronization
Signal

Diagram 7-1. Block Diagram

5M-221 Page 16
 0
Electrode

SCR
Gating
signal

Current
Feedback

AC Or DC control Signals

34 Power

IMPORTANT: The circled numbers match the

steps in the Theory Of Operation (Section 7-1). weld Current Circuit
Componentdesignators such as Ti, SRi, PCI,
R5, S4, and RC1 apply to components on Either Mechanical Coupling
Diagrams 8-1 through 8-4. Or External Circuits
• Optional Or Not Supplied

5M-221 Page 17
 SECTION 8— TROUBLESHOOTING
8-1. TESTING INSTRUMENTS AND INFORMA-
TION
The service procedures in this manual require proper
testing instruments. Use a good quality digital volt-ohm-
meter (DVM) with one megohm input impedance or
greater and diode check capability (use an analog VOM
for variable resistor testing). If an oscilloscope is speci-
fied, use a good quality unit with one megohm input im-
pedance or greater. If a circuit board has a protective
coating, it will be necessary to remove coating or use
needle probes in the test area to obtain proper contact.
Recoat areas ifnecessary to retain corrosion protection.
Digital volt-ohmmeters (DVM’s) do not require lead po-
larity attention when making connections. However, the
meter may indicate a — (negative) voltage when the test
procedure specified a + (positive) voltage. If the incor-
rect polarity appears on the display, reverse meter lead
connections to test points.
8-2. CIRCUIT BOARD HANDLING PRECAUTIONS
WARNING: ELECTRIC SHOCK can kill.
A • Do not touch llve electrical parts.
• Shutdownwelding powersource, and discon-
nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
A CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• Perform work only at a static-safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned.
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimalpressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
5M—221 Page 18
8-3. TROUBLESHOOTING (Table 8-1 And Dia-
grams 8-1, 8-2, 8-3, And 8-4)
WARNING: ELECTRIC SHOCK can kill.
A • Do not touch live electrical parts.
• Shutdown weldingpowersource, anddiscon-
nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow coollng period before servicing.
Troubleshooting to be performed only by quali-
fied persons.
The troubleshooting table is designed to diagnose some
of the troubles that can develop in this welding power
source. Any circuit normally tied to ground must be at
ground potential.
Use the table in conjunction with the diagrams in this
manual and the exploded views and component values
in the Service Parts Manual while performing trouble-
shooting procedures.
When replacing components, use only genuine MILLER
replacement parts. MILLER parts are required for war-
ranty repair by authorized warranty service agency.
Resistance and continuity measurements must be
made with the unit shut down. Isolate components be-
fore making resistance and continuity measurements.
IMPORTANT: Before beginning troubleshooting proce-
dures, visually examine internalcomponentsforsigns of
overheating and failure. Many major problems, such as
winding(s) failure are usually apparent by discoloration,
smoke, and smell. Fortunately, most electrical problems
are relatively simple: blown fuses, tripped circuit break-
ers, incorrectswitch positions, loose connections, corro-
sion, and the like. A complete, careful inspection often
saves considerable time, money and frustration.
IMPORTANT: Be sure that all connections are correct
and secure according to Section 4 and that all controls
and switches are in proper positions before proceeding
with troubleshooting.
 Table 8-i. Troubleshooting
TROUBLE CAUSE
No weld output; unit complete- Line disconnect switch in the
ly inoperative. OFF position.
Line fuse(s) open.
Poor and/or improper input
connections.
Input voltage jumper links not
in proper position.
Unit overheating causing ther-
mostat TP1 to open (thermal
shutdown).
POWER switch ON push but-
ton linkage,
POWER switch OFF push but-
ton P81 open.
Contactor W.
Diodes D1O and Dli in main
contactor W circuit.
Main transformer Ti.
No weld output; pilot light PLi Poor and/or improper weld
on. output connections.
OUTPUT (CONTACTOR)
switch S4 in REMOTE 14 p0-
sition with no remote contactor
control connected to REMOTE
14 receptacle RC1.
Remote contactor control
switch.
Current feedback from Hall
Device HD1 with no load,
Control Board PCi or poor
connections to PCi.
Low or minimum weld output. Low line voltage.
Open line fuse.
Poor and/or improper weld
output connections.
REMEDY
Place line disconnect switch in the ON posi
tion.
Check line fuses, and replace if necessary.
See Section 4-5 for proper input connections.
See Section 4-5 for proper jumper link position.
Allow a cooling period of approximately fifteen
minutes (see Section 10-2).
Check push button switch linkage for restriction
or obstruction.
Check P61 for proper operation with an ohm-
meter, and replace if necessary.
Check W for proper coil voltage and connec
tions (see Diagram 8-1, 8-2, 8-3, or 8-4).
Check condition of contacts and continuity of
coil. Replace W if necessary.
Check D1O and Dli according to Section 8-7,
and replace if necessary.
Visually examine main transformer Ti for signs
of winding failure (uneven discoloration would
be apparent if a short has occurred). Check
continuity across each winding, and check for
proper connections. Check Ti for proper volt
ages according to Diagram 8-1, 8-2, 8-3, or
8-4. Replace Ti if necessary.
See Section 4-4 for proper weld output con-
nections.
Place S4 in ON position or connect Remote
Contactor Control to RC1 (see Sections 4-3
and 5-6).
Check remote contactor control switch for
proper operation with an ohmmeter, and re
place if necessary.
For 300 and 400 ampere models, check HD1
according to Section 8-5 and Diagram 8-6. For
500 and 600 ampere models, check HD1 ac
cording to Section 8-6 and Diagram 8-7. Re
place HD1 if necessary.
Check connections for continuity to PCi.
Check PCi according to Section 8-4 and Dia
gram 8-5. Replace PCi if necessary.
Correct low line voltage.
Replace open line fuse.
See Section 4-4 for proper weld output con-
nections.
SM-221 Page 19
 Table 8-1 Troubleshooting (Continued)
-

TROUBLE CAUSE REMEDY

Low or minimum weld output.
(Continued)
Maximum weld output.
SM—221 Page 20
AMPERAGE control switch
S2.
AMPERAGE ADJUSTMENT
control R5.
Remote amperage control.
Burden resistor R6.
Hall device HD1 or poor con-
nections to HD1.
SCR in main rectifier SRi.
Main transformer Ti.
Control Board PCi or poor
connections to PCi.
AMPERAGE ADJUSTMENT
control R5.
Hall device HDi or poor con-
nectionsto HDi.
Control Board PCi or poor
connections to PCi.
Place S2 in desired position (see Section 5-5).
Check S2 for proper operation with an ohm-
meter, and replace if necessary.
Check R5 for proper connections and resis
tance; R5 is 1000 ohms ±10%.Replace R5 if
necessary.
Check remote amperage control for proper op
eration with an ohmmeter, and replace if nec
essary.
Check R6 for proper connections and resis
tance; R6 is 12 ohms ±10%.Replace R6 if
necessary.
For 300 and 400 ampere models, check con
nections for continuity to HD1. Check HDi ac
cording to Section 8-5 and Diagram 8-6. For
500 and 600 ampere models, check HD1 ac
cording to Section 8-6 and Diagram 8-7. Re
place HD1 if necessary.
For 300 ampere models, check SCR’s in SRi
according to Section 8-8. For 400, 500, and
600 ampere models, check SCR’s in SRi ac
cording to Section 8-9. Replace SCR’s if nec
essary.
If any SCR’s are replaced, be sure to check
capacitors C7 through C12 and main trans
former Ti. Check C7 through Cl 2 for proper
connections, shorts, and leakage. Replace C7
through Cl 2 if necessary. See next entry for
Ti check.
Visually examine main transformer Ti for signs
of winding failure (uneven discoloration would
be apparent if a short has occurred). Check
continuity across each winding, and check for
proper connections. Check Ti for proper volt
ages according to Diagram 8-1, 8-2, 8-3, or
8-4. Replace Ti if necessary.
Check connections for continuity to PCi.
Check PCi according to Section 8-4 and Dia-
gram 8-5. Replace PCi if necessary.
Check R5 for proper connections and resis-
tance; R5 is 1000 ohms ±10%.Replace R5 if
necessary.
For 300 and 400 ampere models, check con
nections for continuity to HD1. Check HD1 ac
cording to Section 8-5 and Diagram 8-6. For
500 and 600 ampere models, check HD1 ac
cording to Section 8-6 and Diagram 8-7. Re
place HD1 if necessary.
Check connections for continuity to PCi.
Check PCi according to Section 8-4 and Dia-
gram 8-5. Replace PCi if necessary.

TROUBLE
Erratic weld output.
Excessive line current or line
fuse(s) opens repeatedly.
Table 8-i. Troubleshooting (Continued)
CAUSE
Poor and/or improper input
and/or output connections.
Electrode.
SCR in main rectifier SRi.
Main transformer Ti.
Control Board PCi or poor
connections to PCi.
Poor and/or improper input
connections.
Input voltage jumper links not
in proper position.
Fan motor FM.
SOR in main rectifier SRi.
Main transformer Ti.
REMEDY
Refer to Sections 4-4 and 4-5 for proper input
and output connections.
Replace electrode.
For 300 ampere models, check SCR’s in SRi
according to Section 8-8. For 400, 500, and
600 ampere models, check SCR’s in SRi ac
cording to Section 8-9. Replace SCRs if nec
essary.
If any SCR’s are replaced, be sure to check
capacitors C7 through Ci 2 and main trans
former Ti. Check C7 through Ci 2 for proper
connections, shorts, and leakage. Replace C7
through Ci 2 if necessary. See next entry for
Ti check.
Visually examine main transformer Ti for signs
of winding failure (uneven discoloration would
be apparent if a short has occurred). Check
continuity across each winding, and check for
proper connections. Check Ti for proper volt
ages according to Diagram 8-1, 8-2, 8-3, or
8-4. Replace Ti if necessary.
Check connections for continuity to PCi.
Check PCi according to Section 8-4 and Dia
gram 8-5. Replace PCi if necessary.
See Section 4-5 for proper input connections.
See Section 4-5 for proper jumper link position.
Check and repair shorted fan motor FM leads.
For 300 ampere models, check SCR’s in SRI
according to Section 8-8. For 400, 500, and
600 ampere models, check SCR’s in SRi ac
cording to Section 8-9. Replace SCR’s if nec
essary.
If any SCR’s are replaced, be sure to check
capacitors C7 through Ci 2 and main trans
former Ti. Check C7 through Cl 2 for proper
connections, shorts, and leakage. Replace C7
through C12 if necessary.See next entry for Ti
check.
Visually examine main transformer Ti for signs
of winding failure (uneven discoloration would
be apparent if a short has occurred). Check
continuity across each winding, and check for
proper connections. Check Ti for proper volt
ages according to Diagram 8-1, 8-2, 8-3, or
8-4. Replace Ti if necessary.
5M-221 Page 21
 Table 8-1. Troubleshooting (Continued)

TROUBLE CAUSE REMEDY

Optional demand fan control Control relay CR1. Check CR1 for proper coil voltage and connec
circuitry not operating properly. tions (see Diagram 8-2 or 8-4). Check condi
tion of contacts and continuity of coil. Replace
CR1 if necessary.
Thermostats TP2, TP3, and Check TP2, TP3, and TP4 for proper opera
TP4. tion, and replace if necessary.
Fan motor FM inoperative Fan blades blocked against Check for and correct blade obstruction.
and/or overheating, plenum.
Fan motor FM. Replace FM.

5M—221 Page 22
 Chart 8-1. Waveforms For Diagrams 8-1 Thru 8-4

5ms by 5ms 1OV

gnd gnd
A. DC Open-Circuit Voltage, Range Switch S3 B. DC Open-Circuit Voltage, Range Switch S3
In Low Position In High Position

5ms 1OV 5ms 1OV

gnd gnd
C. 28 Volts DC (Average), 204 Amperes, Range D. 36 Volts DC (Average), 403 Amperes, Range
Switch S3 In Low Position (Resistive Load) Switch S3 In High Position (Resistive Load)

5M-221 Page 23
A WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause
serious injury.
• Do not touch live electricalparts.
• Shut down welding power source before making or changing meter
lead connections and before disconnecting or connecting any leads.
• Have onlyqualified personsfamiliar with and following standardsafety
practices perform troubleshootingprocedures.
• Follow standard ESDprecautions to preventdamaging static-sensitive
parts during testing.
• See Table 5-1 ifvalues are notpresent.

S.. Section 8-8 (300 ampere models) or

Section 8-9(400 ampere models)
for SRi data
YE I

See Section 8-7

for DiD, Dii data

PC I
/DA

See Section 4-3

for RC1 data

Diagram 8-1. Troubleshooting Circuit Diagram For 300 And 400 Ampere Models
5M-221 Page 24
 IMPORTANT: For DC, the values are based on a good quality digital
volt-ohmmeter (DVM) or equivalent reading average (not RMS) values.
For AC, the values are RMS readings. The voltages shown are with
respect to circuit common (lead 43) unless otherwise indicated, use
Wiring Diagram (see Section II) to help locate leads and parts.

IMPORTANT: All resistance values for main transformer TI

and stabilizerZl are less than one ohm.

*
IMPORTANT: The A, B, C, and D
testpoints are foruse with letter-
matching waveforms on Chart 8-1.

POSITIVE

• NETERS.
PP. PROTECTION &
POLARITY SWITCH
(~TIONAL-EXTRA)

__I EuEuEuEu ruEuIuEu

C5

NEGATIVE S. POSITIVE STUDS

AND CAPACITC~S DO NET APPLY
WITH POLARITY SWITCH.

+15 volts dc output See also Section 5-5

PCI for HD1 data
CONTROL BOARD —15 volts do output RC2- I 8:
RC2/PLG2
+0.7 volts do output
per 100 amperes output
Eu Eu Eu ,u Eu Eu Eu u Rc2-28
Eu — EU — — Eu Eu Eu
Eu 0’ L.J ~ •. 0’ .o -J

8-4
Voltage Readings
(±10%Unless Specified)
Vi
V2 52 volts ac with contactor W energized
V3
V4 230 volts ac with contactor w energized

V6 32 volts ac with contactor W energized

V7
vs
CIe C17 18 volts so with contactor w energized
V9
vio 15 volts dc with POWER switch ON
B E C Vii 53 to 67 volts do from mm. to max.
of AMPERAGE ADJUSTMENT control R5

SO-I 37779-A

SM-221 Page 25
A WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause
serious Injury.
• Do not touch live electrical paris.
• Shut down welding power source before making or changing meter
lead connections and before disconnecting or connecting any leads.
• Have onlyqualifiedpersons familiar with and followingstandard safety
practices perform troubleshootingprocedures.
• FollowstandardESDprecautions toprevent damaging static-sensitive
parts during testing.
• See Table 8-1 if values are not present.

/ RC I
D A

See Section 4-3

for RC1 data

Diagram 8-2. Troubleshooting Circuit Diagram For 300 And 400 Ampere Models With Demand Fan Control
5M-221 Page 26
 IMPORTANT: For DC, the values are based on a good quality digital
volt-ohmmeter (DVM) or equivalent reading average (notRMS) values.
For AC, the values are AMS readings. The voltages shown are with
respect to circuit common (lead 43) unless otherwise indicated, use
WiringDiagram (see Section II) to help locate leads and parts.

IMPORTANT: All resistance values formain transformer TI

and stabilizerZl are less than one ohm.
See Section 84 (300 ampere models) or
Section 5-9(400 ampere models)
for SRi data

/ ZI
IMPORTANT: The A, B, C, and D
test points are for use with letter-
matching waveforms on Chart 8-1.

POSITIVE

STR.

• METERS. V12
RF. PROTECTION S. A, B, C, D
POLARITY SWITCH
(OPTIONAL-EXTRA)

CS ~

NEGATIVE & POSITIVE STUDS

AND CAPACITORS DO NOT APPLY
WITH POLARITY SWITCH.

See also Section 8-5

for HD1 data
EuEuEuEu EuEuEuEu

OEu—
—15 volts do output +0.7 volts dc output
PCI
CONTROL BOARD per 100 amperes output
RC2/PLG2

Voltage Readings
(±10%Unless Specified)
See also Section 8-4
for PCi data vi
V2 52 volts ac with contactor w energized
V3
V4 230 volts ac with control relay CR1 energized
V5 32 volts ac with thermostat TP2, TP3, or TP4 closed
V6
V7 32 volts ac with contactor W energized

42 VS
~1 C17 V9
18 volts ac with contactor W energized
V1O
A Vii 15 volts dc with POWER switch ON
B E C V12 53 to 67 volts dc from mm. to max.
of AMPERAGE ADJUSTMENT control R5

SO-137 925-A

SM-221 Page 27
A WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause
serious injury.
• Do not touch live electrical parts.
• Shut down welding power source before making or changing meter
lead connections and before disconnecting or connecting any leads.
• Have onlyquallfiedpersons familiar with and foliowingstanda rd safety
practices perform troubleshooting procedures.
• FollowstandardESO precautions topre vent damagingstatic-sensitive
parts during testing.
• See Table 8-1 if values are notpresent.

See Section 8-9

for SRi data

See Section 8-7

for Dig, Dli data

RC
/OA

See Section 4-3

for RCi data

Diagram 8-3. Troubleshooting Circuit Diagram For 500 And 600 Ampere Models
SM-221 Page 28
 IMPORTANT: For DC, the values are based on a good quality digital
volt-ohmmeter (DVM) or equivalent reading average (not RMS) values.
ForAC, the values are RMS readings. The voltages shown are with
respect to circuit common (lead 43) unless otherwise indicated, use
WiringDiagram (see Section Ii) to help locate leads and parts.

IMPORTANT: All resistance values for main transformer Ti

and stabilizerZl are less than one ohm.

IMPORTANT: The A, B, C, and D

test points are for use with letter-
matching waveforms on Chart 8-I.

POSITIVE

Vii
A, B, C, D

CB~

NEGATIVE & POSITIVE STLDS

AND CAPACITORS DO NOT APPLY
WITH POLARITY SWITCH.

See also Section 8-6

for HDi data

+0.7 volts do output

per i 00 amperes output

52 volts ac with contactor W energized

230 volts ac wlth contactor W energized

32 volts ac with contactor w energIzed

15 volts ac with contactor W energized

ii volts do with POWER switch ON

53 to67 volts dc from mln. to max.
B E of AMPERAGE ADJUSTMENT control R5

SO-i 37 784-A

SM-221 Page 29
 WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause
A serious injury.
• Do not touch live electricalparts.
• Shut down welding power source before making or changing meter
lead connections and before disconnecting or connectinganyleads.
• Have only qualifiedpersons familiarwith and followingstandardsafety
practicespen’orm troubleshootingprocedures.
• Follow standard ESDprecautions to prevent damaging static-sensitive
parts during testing.
• See Table 8-1 ifvalues are not present.

ri

See Section 10-3 for

demand fan control data

RCI
~DA

See Section 4-3

for RC1 data

Diagram 8-4. Troubleshooting Circuit Diagram For 500 And 600 Ampere Models With Demand Fan Control
5M-221 Page 30
 IMPORTANT: For DC, the values are based on a good quality digital
volt-ohmmeter (DVM) or equivalent reading average (not RMS) values.
For AC, the values are RMS readings. The voltages shown are with
respect to circuit common (lead 43) unless otherwise indicated. Use
Wiring Diagram (see Section II) to help locate leads and parts.

IMPORTANT: All resistance values for main transformer Ti

and stabilizer Zi are less than one ohm.

IMPORTANT: The A, B, C, andD

test points are for use with letter-
See Section 8-9 matching waveforms on Chart 8-1.
for SRi data

METERS. Vi2
RF. PROTECTION S. A, B, C, 0
POLARITY SWITCH
(OPTIONAL-EXTRA)

NEGATIVE S. POSITIVE STWS

AND CAPACITORS 00 NOT APPLY
WITH POLARITY SWITCH.
+15 volts do
output See also Section 5-6
for HOl data

Eu Eu Eu Eu Eu +0.7 volts do output

W -J .0 per i00 amperes output
+24 volts do PC
—15 volts
output CONTROL BOARD
RC2~PLG2

voltage Readings
(±iO%Unless Specified)
See also Section 8-4
for PCi data Vi
V2 52 volts ac with contactor w energized
V3
V4 230 volts ac with control relay CRi energized
V5 32 volts ac with thermostat TP2, TP3, or TP4 closed
V6
V7 32 volts ac with contactor W energized
46 VB
~1 C 7 V9
iS volts ac with contactor VJ energIzed
ViO
Vii i 5 volts dc with POWER switch ON
E C Vi2 53 to 67 volts dc from mm. to max.
of AMPERAGE ADJUSTMENT control R5

SO-i 37 935-A

SM-221 Page 31
8-4. CONTROL BOARD PCi TESTING INFORMA-
TION (Figure 8-1 And Diagram 8-5)
WARNING: ELECTRIC SHOCK can kill.
A • Do not touch live electrical parts.
• Shut down welding powersource before mak—
ing or changing meter lead connections and
before disconnecting or connecting any
leads.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
This procedure requires the unit to be energized.
Only qualified persons familiar with and follow-
ing standard safety practices are to perform this
testing procedure.
A CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• Perform work only at a static-safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
IMPORTANT: For all checks, be sure to test and verify
the continuity of leads between the board and the area
wherecheck isperformed. All checks shouldgo through
the connections and be actual terminal-to-terminal tests
so that bad connections or leads and corrosion isnot the
problem.
A. Power Supply Circuit
Operational input power of 18 volts ac should exist at
pins 24 and 25 with respect to pin 23 (circuit common) of
plug PLG2. Ifthese voltagesare not present, check main
transformer Ti for proper voltages according to Dia—
gram 8-1, 8-2, 8-3, or 8-4.
5M—221 Page 32
Operational power for Hall Device HD1 of ±15volts dc
should be present at pins 1 and 2 respectively of plug
PLG1 with respect to pin 18 (circuit common) of plug
PLG2. Ifthese voltages are not present, replace Control
Board PCi.
B. Voltage Control Circuit
Control Board PC 1 requires several input signals to gen-
erate the gate pulses to the SCR’s at pins 1, 4, 5, 8, 9,
and 12 of plug PLG2. As AMPERAGE ADJUSTMENT
control R5 or the remote amperage control is rotated
clockwise, the gate waveform pulses are moved to the
leftthereby turning the SCR’s on earlier. As R5 or remote
amperage control is rotated counterclockwise, the gate
waveform pulses are moved to the right thereby turning
the SCR’s on later. The output amperage is controlled by
AMPERAGE ADJUSTMENT control R5 when AMPER-
AGE control switch S2 is in the PANEL position or by the
remote amperage control when 52 is in the REMOTE 14
position. The required input signals to PCi are as fol-
lows:
1. Control Board PCi requires an input command
voltage of 0 to —5 volts dc at pin 29 of plug PLG2
with respect to circuit common from AMPERAGE
ADJUSTMENT control R5 or the remote amper-
age control.
2. Control Board PCi requires a current feedback
signal proportional to the weld output of approxi-
mately +0.7 volts dc per 100 amperes output be-
tween pins 28 (+) and 18 (—) of plug PLG2.
3. Control Board PCi requires a synchronization
signal of 32 volts ac from main transformer Ti at
pins 19, 20, and 21 with respect to pin 18 (circuit
common) of plug PLG2.
C. Contactor Control Circuit
Contactor control is provided at pin 13 of plug PLG2 with
an input voltage of +24 volts dc from pin 22. When OUT-
PUT (CONTACTOR) switch S4 is in the ON position,
-i-24 volts dc should exist between pins 13 and 16 (circuit
common) of plug PLG2. When S4 is in the REMOTE 14
position and the remote contactor device is closed, +24
volts dc should exist between pins 13 and 16 (circuit
common) of plug PLG2.
D. Arc Control Circuit
An output voltage of —13 volts dcto ARC CONTROLR3
should be present between pins 14 and 16 (circuit com-
mon) of plug PLG2 for selection of the desired arc char-
acteristics (see Section 5-7).
 Plug PLG1

C85 RiOl R99 RiO8 Ri 22

hr oc~
Q
7 ~ A56 ED
~ C~C82 R 107 ~ C95
Ri04~ ‘—a ED Ri26 Ri29
R98 ED 085~R137 081
Ri36 ED Ri35
RiOO ED 0
Ri32
133 ~ D86~f~
i3i~~
Co

R5 1
R76
R75~

Eli
0

C-)

C69 R72
+LIZ C62 082 C55
R87 ED 073 061 ___ 065 ___ 053 R58 057
069
+ R96 R74 R81 R6O~ R67~

Rii6
I E~J+0
i3DEIEIJDDD
R88 R95 R73 R80 R59 R66

-~ ~~4O

(11 (Il
o -~

0
Plug PLG2 C-092 883-A

Figure 8-1 Control Board PCi Component Locations And Information

-

SM-221 Page 33
 A WARNING: ELECTRIC SHOCK can kill: MOViNG PARTS can cause
serious Injury.
• Do not touch live electrical parts.
• Shutdown weldingpowersource before makingorchangingmeterlead
connections and before disconnecting or connecting any leads.
• Have only qualifiedpersons familiar with and followingstandard safety
practices perform troubleshootingprocedures.
• Follow standard ESO precautions to prevent damagingstatic-sensitive
parts during testing.

Circuit common

r~<

—13 volts dc output ~ ~

DBS
—5 volts do output

o to—S volts do input from

mm. to max. of AMPERAGE
ADJUSTMENT control R5
with AMPERAGE control
switch S2 in PANEL Posltlon\

+0.7 volts do Input per —~

100 amperes output
with RANGE switch S3
In LOW position

+24 volts do Input with

OUTPUT (CONTACTOR)
switch S4 In ON position,
+24 volts do input with
54 in REMOTE 14 position
and remote contactor
switch closed, 0 volts do
Input with S4 In REMOTE 14
position and remote
contactor switch open

0
to—5 volts do input
from
/
mm. to max. of AMPERAGE
ADJUSTMENT control R5

0 to —5 volts do output from mm. to

max. of AMPERAGE ADJUSTMENT
control R5
Circuit common
Diagram 8-5. Troubleshooting Circuit Diagram For Control Board PCi
5M-221 Page 34
IMPORTANT: For DC. the values are based on a good quality digital
volt-ohmmeter (OVM) or equivalent reading average (not RMS)
values. For AC. the values are RMS readings. The voltages shown
are with respect to circuit common (lead 43) unless otherwise
indicated and the tolerances are ±10% unless otherwise specified.
IMPORTANT: Test point A is for use with letter-matching waveform.

2ms iV

gnd

A. SRi Gate Pulse At No Load

0-106 339-A

SM-221 Page 35
8-5. HALL DEVICE HD1 TESTING INFORMATION
FOR 300 AND 400 AMPERE MODELS (Figure
8-2 And Diagram 8-6)
WARNING: ELECTRIC SHOCK can kill.
A • Do not touch live electrical parts.
• Shutdown welding powersource before mak-
ing or changing meter lead connections and
before disconnecting or connecting any
leads.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
This procedure requires the unit to be energized.
Only qualified persons familiar with and follow-
ing standard safety practices are to perform this
testing procedure.
CAUTION: ELECTROSTATIC DISCHARGE
A (ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• Perform work only at a static-safe work area.
Terminal connection
Points
Figure 8-2. Hall Device HD1 Component Locations And Information For 300 And 400 Ampere Models
5M-221 Page 36
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned.
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle move-
ment when disconnecting or connecting
board plugs and removingor installing board.
IMPORTANT: For all checks, be sure to test and verify
the continuity of leads between the board and the area
where check is performed. All checks shouldgo through
the connections and be actual terminal-to-terminaltests
so thatbad connections or leads and corrosion is not the
problem.
Operational input power of +15 volts dc should exist be-
tween pins C and A (circuit common) and —15 volts dc
should exist between pins B and A (circuit common). A
current feedback signal of +0.7 volts dc ±20%for each
100 amperes of weld output (see Diagram 8-6) should
exist between pins D and A (circuit common). If the out-
put feedback signal is not present, replace HD1.
Ref. B—134 828
 01

& ill
V
U
~ 01 01 —
o
Li. CO
— CO CO
~ 01
001 C’)
Os ~
0 — 0.0
:~,.=—.01 0. — —
V 0
~ ~ ~
U E
~01 •0=~ E
01 01~ 0
~0 01
o ~ 0 01 ~
I
~ 0101 .~ in
~ a..! — U
01
zo .~ U’
+ OO~ C.) —
01 u +
~
A ±4 A
Ce

.~ ~
.1;
0
‘- 0101
CO.~
0
1..
0
01 0.
~ ~- E
~01 ~
0
~01i~o ‘- ‘~-
~ CO
0

~ 0 CO
0
4~01E ~ 0
C,,

~ 1~
41 U 0
Ci
z
C C 0
0
3
10 10 0
0
+
i
z
0
U-
ECu
4-
0)
Cu
CO
b
CO
U
2~
e
CO (3

0)
U,
I- CO 4-
e~ CO 0
0~
0•
.~e
~
CO
o~•
-~CO
01 0
U)
‘-0 ~01
z o0~ o~ CO 0
CO .0
0 ‘~01 b
~ ~ 0 0
E~ CO~ 01
x 010 .001 01 I-
.~ .~ 0 0.
U
o 01~5
.001 CO S 0
a~ ~ CO E
CO
~b CO~
0 Cu
I-
0. •~01
COO 0)
Cfl~~ .~0 0
01CO
—— 01 ‘-01
0.-
0
01~ 001 001
~.E ~ 001 010.
Jo 0) •~
~-0
5jJ

~ 0 .c eb
~CO ~
We u
01 ~ .~ ~0.
0
0,01.-— .-~ 01=
Z~ 0
oE ~CO OCO
001
• 6 LLCO
S 6

‘1 5M-221 Page 37
8-6. HALL DEVICE HD1 TESTING INFORMATION INCORRECT INSTALLATION or misaligned
FOR 500 AND 600 AMPERE MODELS (Figure plugs can damage circuit board.
8-3 And Diagram 8-7) • Be sure that plugs are properly installed and
aligned.

A WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.
• Shutdown welding powersource before mak-
ing or changing meter lead connections and
before disconnecting or connecting any
leads.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
This procedure requiresthe unitto be energized.
Only qualified persons familiar with and follow-
ing standard safety practices are to perform this
testing procedure.
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimalpressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
IMPORTANT: For all checks, be sure to test and verify
the continuity of leads between the board and the area
wherecheck isperformed. All checksshould go through
the connections and be actual terminal-to-terminal tests
so that badconnections or leads and corrosion isnot the
problem.

CAUTION: ELECTROSTATIC DISCHARGE

A (ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• Perform work only at a static-safe work area.
Operational input powerof +15 volts dc should exist be-
tween leads 71 and 43 (circuit common) and —15 volts
dc should exist between leads 72 and 43 (circuit com-
mon). A current feedback signal of +0.7 volts dc ±20%
for each 100 amperes of weld output (see Diagram 8-7)
should exist between leads 78 and 43 (circuit common).
Ifthe output feedback signal is not present, replace HD1.

Leads To HD1

ASSEMBLY NC.
/
0
0 0 0
—II-- RS 2
—~--
~ (~n
RS 3

O ==
43 78
=
71
=
72 0
Terminal
Connection
Points
SA—099 1B8.B

Figure 8-3. Hall Device HD1 Component Locations And Information For 500 And 600 Ampere Models

5M—221 Page 38
 0~
-- 01
Lj CI 0
— Co
~ 01
U
e

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‘4 5M-221 Page 39
8-7. DIODES D1O AND Dli TESTING PROCE-
DURE (Figures 8-4 And 9-1)
A WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down welding powersource, and discon-
nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
Only qualified persons familiar with and follow-
ing standard safety practices are to perform this
testing procedure.
IMPORTANT: Read and understand meter Owner’s
Manual before making measurements. See Figure 9-1
for location of diodes 010 and Dli in this unit.
Anode
Reverse
Biased
cathode
Forward
Biased
Cathode
S—0149
Figure 8-4. Diode Testing Procedure
1. Mark and disconnect one lead of diodes D1O and
Dli.
2. Set meter on Diode Test scale.
5M—221 Page 40
3. Test each diode in the forward and reverse direc-
tion by connecting and then reversing the meter
leads across each diode. A properly functioning
diode conducts in the forward direction (meter
reads 0.3 to 0.9V), and blocks in the reverse di-
rection (meter reads OL).
4. If either diode does not check properly, replace
the diode.
5. If the diodes check properly, reconnect leads to
marked locations.
8-8. MAIN RECTIFIER SRi TESTING AND RE-
PLACEMENT PROCEDURE FOR 300 AM-
PERE MODELS (Figures 8-5 Thru 8-8)
A WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shutdown welding powersource, anddiscon-
nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
senilcing.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
Only qualified persons familiar with and follow-
ing standard safety practices are to perform this
testing procedure.
IMPORTANT: Read and understand meter Owner’s
Manual before making measurements. See Figure 9-1
for location of main rectifier SR 1 in this unit.
A. SCR Testing Procedure (Figures 8-5 And 8-6)
A WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-8 before
proceeding.
IMPORTANT: The SCR’s of SRi should be checked
with an SCR tester, such as a Handyman269 or equiva-
lent. Ifan SCR tester is not available, usea good quality
VOM, such as a Simpson 260 or equivalent.
IMPORTANT: The ohmmeter check ofan SCR is nota
conclusive test. More conclusive tests require special-
ized equipment. Hence, even though an SCR checks out
good, the SOP may still be bad. An SCR may be bad at
the actual applied voltage yetcheck outgoodat the com-
paratively low ohmmeter voltage (usually about 1.5
volts). If in doubt, replace the SOB.

Figure 8-5. Main Rectifier SRi Component Locations And Information For 300 Ampere Models
Cathode Lead
(Small Red)
A = Ammeter with 0 To 100 Milliampere
Range (May Be Another VOM)
Figure 8-6. SCR Lead Identification And Meter
Connection Points
Rel. C-087 094-B
1. Mark and disconnect SCR pigtail from heat sink.
2. Locate and disconnect receptacle RC2 from plug
PLG2 on Control Board PCi.
3. If an SCR tester is available, test each 5CR ac-
cording to the manufacturer’s instructions. If an
SCR does not check properly, replace the SOR
according to Section 8-8B.
4. If an SCR tester isnot available, set VOM function
selector switch to Rxi ohms.
5. Connect meter leads to SOR as shown in Figure
8-6. Make sure the test lead polarity is as shown.
Another meter will be necessary to determinethe
output polarity of the lead jacks as not all meters
have the internal battery negative connected to
the negative or common output jack. It is a good
idea to mark your meter jacks plus or minus for fu-
ture use.
6. A high resistance reading should be indicated
with the gate lead not in the circuit. (A low resis-
tance reading indicates a shorted 5CR in which
case the SCR should be replaced and the test is
completed.) Proceed to Step 7 if a high reading is
obtained. Leave meter leads connected as
shown in Figure 8-6.
7. Connect the gate lead to the anode as shown in
S-0489
Figure 8-6. The VOM should then indicate a low
resistance (approximate mid scale) indicating to
you that the SCR gate is okay. If a low reading
cannot be obtained, the SCR gate isbad. The am-
meter should indicate current flow meaning that
SM-22i Page 41
 the SCR has turned on. When testing small
SCR’s, removal of the gate lead from the anode
will not change the ammeter reading. This is be-
cause the meter is providing a U~hoIding current.”
On large SCR’s, the meter cannot provide
enough UUholding current,” so the meter will revert
to a high resistance when the gate lead is re-
moved from the anode.
8. If an SCR does not check properly, replace the
SCR according to Section 8-8B.
9. If the SCR’s check properly, reconnect SCR pig-
tail(s) to heat sink.
10. Reconnect receptacle RC2 to plug PLG2 on Con-
trol Board PCi.
B. SCR Replacement Procedure (Figures 8-7 And
8-8)
A WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-8 before
proceeding.
IMPORTANT: If any SCR’s are replaced, be sure to
check capacitors C7 through C12 for proper connec-
tions, shorts, and leakage. Also, visually examine main
transformer Ti for signs of winding failure (uneven dis-
coloration would be apparent if a short has occurred).
Check continuity across each winding, and check for
proper connections. Check phase-to-phase voltage be-
tween leads 21 and 22, 22 and 23, and 21 and 23 (see
Diagram 8-1, 8-2, 8-3, or 8-4). Replace C7 through C12
and Ti if necessary
1. Locate and disconnect receptacle RC2 from plug
PLG2 on Control Board PCi.
2. Trace the red and white leads from SCR to be re-
placed to receptacle RC2. Mark and remove the
leads from receptacle RC2 using an AMP
4651 99-1 pin extraction tool (MILLER part num-
ber 099 719) according to Figure 8-7.
I Locking
Lance
Part Number 099 719
ST.147 699
Figure 8-7. Pin Extraction Tool
5M-221 Page 42
3. Remove SCR’s from heat sink, and discard. If us-
ing a breakaway nut to install the new SCR, retain
existing internal tooth lock washer. If using a wa-
sher-nut combination, discard lock washer.
4. Clean surface of heat sink around SCR’s mount-
ing hole.
5. Apply a thin layer of supplied heat sink compound
to SCR face surface (see Figure 8-8).
IMPORTANT: Do not apply heat sink compound on the
threads of the SCR stud.
6. Insert new SCR in heat sink and thread break-
away nut with internal tooth lock washer, or wa-
sher-nut combination onto SCR stud as illus-
trated in Figure 8-8.
7. Tighten nut according to type:
a. Breakaway Nut: Wrench-tighten until hex por-
tion breaks off. Discard hex portion.
b. Washer-nut Combination: Finger-tighten as
tight as possible. Using a wrench, turn the nut
i/2 turn only. The washer-nut combination will
be compressed to its calibrated pressure using
this tightening procedure.
IMPORTANT: Ifusing a standardnutandan inch-pound
torque wrench, tighten the nut to 275-325 in-lbs. Be sure
SCR threads are dry; do not lubricate.
8. Apply a thin layer of supplied anti-oxidant com-
pound to pigtail connection tab surface (see Fig-
ure 8-8), and connect pigtail to proper location on
heat sink.
9. Route and connect leads from new SCR to
marked locations in receptacle RC2.
10. Reconnect receptacle RC2 to plug PLG2 on Con-
trol Board PCi.
Pigtail
Connection Tab
SCR Face
Figure 8-8. SCR Installation
8-9. MAIN RECTIFIER SRi TESTING AND RE-
PLACEMENT PROCEDURE FOR 400, 500,
AND 600 AMPERE MODELS (Figures 8-9
Thru 8-12)
A WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shutdown weldingpowersource, anddiscon-
nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
Only qualified persons familiar with and follow-
ing standard safety practices are to perform this
testing procedure.
IMPORTANT: Read and understand meter Owner’s
Manual before making measurements. See Figure 9-1
for location of main rectifier SRi in this unit.
A. SCR Testing Procedure (Figures 8-9 And 8-10)
A WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-9 before
proceeding.
IMPORTANT: The SOR’s of SRi should be checked
with an 5CR tester, such as a Handyman 269 or equiva-
lent. Ifan SCR tester is notavailable, use a good quality
VOM, such as a Simpson 260 or equivalent.
IMPORTANT: When testing hockey puk SCR’s discon-
nectgate lead and cathode oranode connection to heat
sink, but leave SCR clamped in its original heat sink.
Hockeypuk SCR’s must be under mounting pressure to
allowtesting. The mountingpressureis necessaryfor in-
ternal contact between chip and pole pieces. Disregard
small red cathode lead. Meter readings may be taken at
heatsink(s), ifapplicable. See Figure 8-9 forlead identi-
fication.
1. Locate and disconnect receptacle RC2 from plug
PLG2 on Control Board PCi.
2. If an SCR tester is available, test each SCR ac-
cording to the manufacturer’s instructions. If an
SOR does not check properly, replace the SCR
according to Section 8-9B.
3. If an SCR tester is not available, setVOM function
selector switch to Rxi ohms.
4. Connect meter leads to SCR as shown in Figure
8-10. Make sure the test lead polarity is as shown.
Another meter will be necessary to determine the
output polarity of the lead jacks as not all meters
have the internal battery negative connected to
the negative or common output jack. It is a good
idea to mark your meterjacks plus or minus for fu-
ture use.
5. A high resistance reading should be indicated
with the gate lead not in the circuit. (A low resis-
tance reading indicates a shorted SCR in which
case the SCR should be replaced and the test is
completed.) Proceed to Step 6 ifa high reading is
obtained. Leave meter leads connected as
shown in Figure 8-10.
6. Connect the gate lead to the anode as shown in
Figure 8-10. The VOM should then indicate a low
resistance (approximate mid scale) indicating to
you that the SCR gate is okay. If a low reading
cannot be obtained, the SOR gate isbad. The am-
meter should indicate current flow meaning that
the SCR has turned on. When testing small
SCR’s, removal of the gate lead from the anode
will not change the ammeter reading. This is be-
cause the meter is providing a ~holdingcurrent.”
On large SCR’s, the meter cannot provide
enough “holding current,” so the meter will revert
to a high resistance when the gate lead is re-
moved from the anode.
7. If an SCR does not check properly, replace the
SCR according to Section 8-9B.
8. Ifthe SCR’s check properly, reconnect receptacle
RC2 to plug PLG2 on Control Board PCi.
5M-22i Page 43
 spring Indicator Clamp

TOP VIEW

Red White Red white (see Figure 8-12) Red White

C SCR2 SCRi
SCR3
C
White
b Red

010

‘11111
Red
- • I
-~:
I
I I IIL~’z~~~I
I j~Jyj’—~~~’
~
‘‘~‘ Jo - I Ill
•••.p.•UU

I
“~“ -
White

SCR6 SCR5 SCR4

Capacitors C7-C12 Heat Sink

9
V~N
——— —

Heat Sink

5CR

spring Pins

I —
U. —

Spring Indicator Clamp

(see Figure 8-12) Ref. 5D.140 121-A
SD—O4~ 899—H

Figure 8-9. Main Rectifier SRi Component Locations And Information For
400, 500, And 600 Ampere Models
SM-221 Page 44

Figure 8-10. Hockey Puk-Type SCR Lead Identification And Meter Connection Points
B. SCR Replacement Procedure (Figures 8-11 And
8-12)
A WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-9 before
proceeding.
IMPORTANT: If any SCR’s are replaced, be sure to
check capacitors C7 through C12 for proper connec-
tions, shorts, and leakage. Also, visually examine main
transformer Ti for signs of winding failure (uneven dis-
coloration would be apparent if a short has occurred).
Check continuity across each winding, and check for
proper connections. Check phase-to-phase voltage be-
tween leads 21 and 22, 22 and 23, and 21 and 23 (see
Diagram 8-1, 8-2, 8-3, or8-4). Replace C7through C12
and Ti if necessary
1. Locate and disconnect receptacle RC2 from plug
PLG2 on Control Board PCi.
2. Trace the red and white leads from SCR to be re-
placed to receptacle RC2. Mark and remove the
leads from receptacle RC2 using an AMP
465199-i pin extraction tool (MILLER part num-
ber 099 719) according to Figure 8-il.
Locking
Lance
Part Number 099 719
ST-147 699
Figure 8-li. Pin Extraction Tool
SA-115 688
3. Note position of leads, and mark mounting sur-
faces to aid relocation of new SCR on heat sink.
4. Loosen clamping device, and remove 5CR to be
replaced.
5. Remove all remaining heat sink compound from
both surfaces on heat sink in area where SCR
was removed.
6. Examine surface of heat sinks. Surfaces must be
thoroughly clean, flat, and true. Surface flatness
must be within .001 in. If surface is marred or
damaged, either remachine or replace heat sink.
7. Apply a thin coating of supplied heat sink com-
pound to both contact surfaces of new SOR.
IMPORTANT: Proper contact and mounting pressure
are necessary for correct operation of new 5CR.
8. Position 5CR correctly according to marked
leads and mounting surfaces, and place 5CR
onto locating pins in heat sinks.
9. Place clamp fully into mounting position.
10. Tighten nuts on clamp evenly until finger tight.
ii. Using a wrench, tighten one nut 1/4 turn and then
other nut 1/4 turn until the loweredge of the spring
indicates a mounting force of 0.8 kilo lbs. for 400
and 500 ampere models or 2 kilo lbs. for 600 am-
pere models on indicator (see Figure 8-12).
12. Route and connect leads from new SCR to
marked locations in receptacle RC2.
13. Reconnect receptacle RC2 to plug PLG2 on Con-
trol Board PCi.
SM-221 Page 45
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5M-221 Page 46
 SECTION 9— COMPONENT IDENTIFICATION AND LOCATION

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5M-22i Page 47
 Remote 14
Range Switch S3 Receptacle Rd
Amperage Control
Switch S2
Arc Control R3
Output (Contactor)
Switch S4

Amperage Adjustment
control RS

— N
— N
— N

Push Button
PBI Switch
Assembly
(see Figure 9-7)

2
Pilot Light PLI

Negative Weld
Output Terminal

Front Panel

Positive Weld
Output Terminal
SC—004 907—N

Figure 9-2. Front Panel And Component Locations

5M-221 Page 48
 Rear Panel

Fan

Plenum Chamber

Fan Motor FM

SC-004 988-C

Figure 9-3. Rear Panel And Component Locations

capacitors
c7-ci2

SS-049 529-A

Figure 9-4. Main Rectifier SRi And Component Locations For 300 Ampere Models
SM-221 Page 49
 Heat Sink

capacitors
c7-c12
—--I
—- I
— I

—— I
I—-
Silicon controlled IncI~cator
Rectifiers clamp
scRl-scR6

-J

——

Spring Pin Stand-Offs

SD-048 899—H

Figure 9-5. Main Rectifier SRi And Component Locations For 400, 500, And 600 Ampere Models

5A—138 574

Figure 9-6. Input Terminal Board TEl And Component Locations

SM—221 Page 50
 Bracket

On Push Button

Compression 5~

Limit Switch

Oft Push Button

SA-OBO 214-B

Figure 9-7. Push Button PBi Switch Assembly And Component Locations

SM-221 Page 51
 SECTION 10— MAINTENANCE
10-1.ROUTINE MAINTENANCE (Table 10-i)
IMPORTANT: Every six months inspect the labels on
this unit for legibility All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary See Service Parts Manual for part
number ofprecautionary labels.
A WARNING: ELECTRIC SHOCK can kill.
eDo not touch live electrical parts.
• Shutdown welding powersource, and discon-
nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
A. Fan Motor
This unit is equipped with an exhaust fan and relies on
forced draft for adequate cooling. The fan motor is
manufactured with lifetime sealed bearings and requires
no maintenance.
B. Weld Cables
A WARNING: Read and follow safety informa-
tion at beginning of entire Section 10-1 be-
fore proceeding.
Every three months inspect cables for breaks in insula-
tion Repair or replace cables if insulation breaks are
present Clean and tighten connections at each inspec-
tion.
C. Internal Cleaning
A ARNING: Read and follow safety informa-
tion at beginning of entire Section 10-i be-
fore proceeding.
Every six months blow out or vacuum dust and dirt from
the inside of the welding power source. Remove the
outer enclosure, and use a clean, dry airstream or vac-
uum suction for the cleaning operation. If dusty or dirty
conditions are present, clean the unit monthly.
5M-221 Page 52
Table 10-i. Maintenance Schedule
Frequency* Maintenance
Every month. Units in heavy service environ
ments:
Check labels, weld cables, clean
Every 3 months.
internal parts.
Check weld cables (see Section
10-i).
Every 6 months. Check all labels (see IMPORT
ANT block, Section 10-i). Clean
internal parts (see Section
10-i).
*Frequency of service is based on units operated 40
hours per week. Increase frequency of maintenance if
usage exceeds 40 hours per week.
10-2. RECTIFIER PROTECTION
The main rectifier SRi in this welding power source is
protected by a normally-closed thermostat TP1 wired in
series with the contactor W coil circuit. Should overheat-
ing of the main rectifier occur, this thermostat would
open causing the contactor to drop out (deenergize)
thereby suspending all output. If this condition occurs, it
will be necessary to allow a cooling period before resum-
ing operation.
10-3. DEMAND FAN CONTROL (Optional)
The fan motor is thermostatically controlled to provide
fan cooling of the transformer and rectifier if these com-
ponents require cooling. Under normal loading, the fan
may not run.
Three normally-open thermostats, TP2 in the main recti-
fier and TP3 and TP4 in the main transformer, and a re-
lay CR1 regulate the operation of the fan motor FM.
When the transformer and/or rectifier assemblywarm up
enough to close any of the thermostats, relay CR1 ener-
gizes causing the fan motor to start running. The fan mo-
tor will continue running until the transformer and/or rec-
tifier have cooled down enough to permit thermostats
TP2, TP3, and TP4 to open or until the unit isshut down.
 SECTION 11 - ELECTRICAL DIAGRAMS

Table 11-1. List Of Circuit Diagrams And Wiring Diagrams

The following isa list of all diagrams for models covered bythis manual. To order diagramsneeded, proceed as follows:
1. Know unit Model and Serial or Style Number.
2. Use List to find diagram number.
3. Call the Technical Publications Department at 414-735-4356.

Model Serial Or Style Number Circuit Diagram Wiring Diagram

Gold Star
300SS JC64i 296 thru JG032479 SN-084 604
400SS JC590316 thru JG032479 SN-084 604
300SS, 400SS JG032480 thru JH176799 SC-106 568-A
JH1 76800 thru JJ503983 SC-1i3 576
JJ503984 thru JK674520 SC-i23 911
300SS JK674521 thru KA819072 SC-i 30 406 D-i31 066..
400SS JK674521 thru KA819072 SC-i 30 406 D-131 172,,
300SS KA8i 9073 and following SC-i 37 779-A SD-137 776
400SS KA8i 9073 and following SC-i 37 779-A SD-137 777

300SS w/fan control JC641 296 thru JF855842 SN-086 283

400SS w/fan control JC59031 6 thru JF855842 SN-086 283
300SS, 400SS w/fan control JF855843 thru JG032479 SN-095 291
JG032480 thru JH296871 SC-i06 566-A
JH296872 thru JJ503983 SC-114 061
JJ503984 thru JK674520 SC-123 912
JK674521 thru KA819072 SC-i32 460
KA8i 9073 and following SC-i 37 935-A

SOOSS JE747791 thru JF84688 SN-093 184

JF846889 thru JG032479 SN-096 452
600SS JE813766 thru JG032479 SN-096 452
SOOSS, 600SS JG032480 thru JJ503983 SC-106 567-A
JJ503984 thru JK674520 SC-i23 913
JK674521 thru KA819072 SC-130 409-A D-130 826,,
KA8i 9073 and following SC-137 784-A SD-i37 778

SOOSS w/fan control JE747791 thru JG032479 SN-098 206

600SS w/fan control JE81 3766 thru JG032479 SN-098 206
SOOSS, 600SS w/fan control JG032480 thru JJ503983 SC-106 569-A
JJ503984 thru JK674520 SC-123 914
JK674521 thru KA819072 SC-132 459
KA8i 9073 and following SC-137 936-A

Circuit Board PCi (See Note) thru JF933619 SN-084 219

JF933620 and following SN-106 339-A
SM-221 Page 54
 Table 11-1. List Of Circuit Diagrams And Wiring Diagrams (Continued)

Model Serial Or Style Number ~uitJi~gram Wiring Diagram

Hall Device HD1
for 300SS JC641 296 thru JH176788 SN-085 229
JH1 76789 and following SA-1 10 758-A
for 40055 JC59031 6 thru JH1 76788 SN-085 229
JH1 76789 and following SA-1 10 758-A
for SOOSS JE747791 and following SN-085 229
for 60055 JE81 3766 and following SN-085 229

• • Not included in this manual

Note: See the effective serial number for each model on front cover.

SM-221 Page 55
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SM-221 Page 56
 0. Co
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SM-221 Page 58
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KY I IC 5M—221 Page 59
 Co
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SM—221 Page ei
 Diagram 11-7. Wiring Diagram For 300 Ampere Models Effective With Serial No. KABI 9073 And Following
SM-221 Page 62
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SM-221 Page 63

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 Diagram 11-8. Wiring Diagram For 400 Ampere Models Effective With Serial No. KA819073 And Following
SM—221 Page 64
Wiring Diagram No. SD-i 37 777

SM-22t Page 65
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5M—221 Page 66
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SM-221 Page 67
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SM-221 Page 68
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5M-221 Page 69
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SM-221 Page 70
 0
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5M-221 Page 71
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5M—221 Page 72
 0.
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SM-221 Page 73

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5M-221 Page 74
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SM-221 Page 75
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SM-221 Page 76
 c

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5M-221 Page 77

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Diagram 11-22. Wiring Diagram For 500 And 600 Ampere Models Effective With Serial No. KA819073 And Following
SM-221 Page 80
PC2

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Wiring Diagram No. SD-i 37 778

SM-221 Page 81
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SM-221 Page 82
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SM-221 Page 83
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SM-221 Page 84

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5M—221 Page 86
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5M-221 Page 87
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SM—221 Page 88

-
 +15 V.

SIC. OUT

s C”Th 1 —isv.
7 IMPORTANT: Use test points and values on
qp 3
Diagram 8-7 when troubleshooting this circuit board.
A 50
BOTTOM Circuit Diagram No. SN-085 229
VIEW

Diagram 11-30. Circuit Diagram For Hall Device HD1 In 300 Ampere Models Effective With Serial No.
JC641 296 Thru JH1 76788 And 400 Ampere Models Effective With Serial No. JC590316 Thru JH176788

+15 VOC
C

B
-15 VOC
IMPORTANT: Use test points and values on
Diagram 8-6 when troubleshooting this circuit board. Circuit Diagram No. SA-ilO 758-A
Diagram 11-31. Circuit Diagram For Hall Device HD1 In 300 And 400 Ampere Models
Effective With Serial No. JH1 76789 And Following
SM-221 Page 89
 +15 V.

I —

SIG. OUT

8 1
7
6
and values on
A 50 IMPORTANT: Use test points
BOTTOM Diagram 8-7 when troubleshooting this circuit board.
VIEW
Circuit Diagram No. SN-085 229
Diagram 11-32. Circuit Diagram For Hall Device HD1 In 500 Ampere Models Effective With Serial No.
JE747791 And Following And 600 Ampere Models Effective With Serial No. JEBi 3766 And Following

SM—221 Page 90
 TM-ZZ1A October 1997

Miller
Gold Star® 300SS Effective
With Serial No. JC641296
Gold Star® 400SS Effective
With Serial No. JC590316
The PowerofBlue. Gold Star® 500SS Effective
With Serial No. JE747791
Gold Star® 600SS Effective
With Serial No. JE813766

GOLD STAR ®SS

Visit our website at

PARTS LIST
WWW.MIIIBVWIIIILCOII
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Goldstar Series
SPM—221 Page 1
 Replace Coils At Factory Or Authorized Factory Service Station

Quantity
Model
Item Dia. Part ~65T~0060~
No. MkQs. No. Description Amo lAm lAmol AmD

Figure 1. Main Assembly

1 •,006 016 PANEL,side
109035 LABEL, warning electric shock can kill etc 1 ... 1 ... 1 .... 1
i •,005 195 PANEL, side 2
006017 .COVER,top
005194 COVER, top 1
•04722i COVER, top w/meter holes 1 ... 1 ... 1
•092498 COVER, top w/meter holes 1
026 627 GASKET,Iiftingeye 1 ...1 ... 1 ....i

004214 BUSHING, snap-in nyl 1.625 ID x 2.OOOmtg hole 1 ... 1 ... 1 .... 1
091 164 - FRAME, upright base (Elf w/JD688393) 1 ... 1
091 164 FRAME, upright base (Elf w/JE747791) 1
091 164 FRAME, upright base (Elf w/JE813766) 1
134 771 PLUG, protective .640sq 2 ... 2 ... 2 . .. . 2
Z 035 279 STABILIZER 1 ... 1
Z 003 007 STABILIZER 1
z 005 380 STABILIZER 1
Fl 088 384 FUSE, crtg lA 600V (Eff w/HJ2i 9398 thru JE747791) 1
070 404 HOLDER, fuse crtg 30A 600V
(Eff w/HJ219398 thru JE747791) 1
Fl 088384 FUSE, crig iA600V(Effw/HJ2193981hwJE813766) 1
070404 HOLDER, fuse crtg 30A 600V
(Elf w/HJ21 9398 thru JE81 3766) 1
082 976 HOLDER, fuse mintr .250 x 1.250 clip
(Prior to JG032480) 1 ... 1 ... 1 .... 1
F2-6 .... 012633 FUSE, mintr gI lA (Prior to JG032480) 5 ... 5 ... 5 . . 5 . .

Fig2 PANEL, rear w/components 1 ... 1 1

... 1 ....

...8.... TEl 038145 TERMINAL ASSEMBLY, dual voltage (Fig 3) 1 ... 1 ... 1 1 ....

...8.... TEl 038138 TERMINAL ASSEMBLY, triple voltage (Fig 3) 1 ... 1 1

... 1 ....

...9...C21-23 ... 129954 CAPACITOR, (Prior to KA819073) 3 ... 3... 3.... 3

...9.... C2i 137674 CAPACITOR, (Elf w/KA8i 9073) 1 ... 1 ... 1 . ... 1

...9...C22,23 ... 137771 CAPACITOR ASSEMBLY, (Elf w/KA8i 9073) 2 ... 2 ... 2 . ... 2
10 084251 BRACKET, mtg term bd LH (Prior to JJ44741 5) 1 ... 1 ... 1 .... 1

10 084252 BRACKET, mtg term bd RH (Prior to JJ44741 5) 1 ... 1 ... 1 .... 1

10 097918 BRACKET, mtg term bd (Elf w/JJ447415) 2 ... 2... 2 .... 2
11 ... PCi 087308 CIRCUIT CARD, root pass (Fig 8) 1
Ii ... PCi 084552 CIRCUIT CARD, root pass (Fig 8) 1
11 ... PCi 094089 CIRCUIT CARD, root pass (Fig 8) 1
11 ... PCi 096750 CIRCUIT CARD, root pass (Fig 8) 1
PLGi .... 048280 HOUSING PLUG & PINS, (consisting of) 1 ... 1 ... 1 .... 1
058971 ....TERMINAL,malel pin
RC1 .. “048 281 RECEPTACLE w/SOCKETS, (consisting of) 1 ... 1 ... 1 - 1
...

058972 TERMINAL, female iskt 2 ... 2... 2.... 2

PLG2 .... 035815 TERMINAL, hdr29skt 1 ... 1 ... 1 1
....

12 080509 GROMMET, scr No. 8/10 panel hole .312sq .375 high . ... 3 ... 3 ... 3 3
....

057084 BUSHING, snap-in nyl .250 ID x .37Smtg hole

(Prior to JG071229) 1 ... 1

035 506 -. GUIDE, circuit card 9 in (Prior to JG071229) 2 . . . . 2

13 090781 ..CIRCUITCARDBOX
14 138 378 BRACKET, mtg rect (included w/rectifier) 1 ... 1 . ... 1

15 086 455 BASE, (Prior to JD688393) 1

15 091 034 BASE, (Elf w/JD688393 thru JH296871) 1
15 116 838 BASE, (Elf w/JH296872 thru KBOS51iS) 1
15 140 865 BASE, (Elf w/KB055116 and on) 1
15 091008.. BASE, (Prior to JF855870) 1
SPM-221 Page 2
Goldstar Senes
 Quantity
Model
Item Dia. Part
Description
5T~5050~Th~0
No. Mkas. No. AmD lAmo lAmo IAmD
Figure 1. Main Assembly (Continued)

• 15 089 151 BASE,

(Elf w/JF855870 thru JH296871) 1
15 116 840 BASE,
(Elf w/JH296872 thru KBOSS115) 1
15 139 785 BASE,
(Elf w/KB055116 and on) 1
15 089 151 BASE,
(Prior to JH296872) 1
15 116 840 BASE,
(Elf w/JH296872 thru KBO5S11S) 1
15 139 785 BASE,
(Elf w/KB055116) 1
15 091 393 BASE,
(Prior to JH296872) 1
15 116862 BASE,
(Elf w/JH296872 thru KB055115) 1
15 139784 BASE,
(Elf w/KB055116) 1
16 Ti .... +087 355 TRANSFORMER, 230/460 (Prior to JE792690)
(consisting of) 1
17 ++072 221 COIL, pri/sec RH & center 2
18 072220 ...COIL, pri/sec LH 1
16 Ti
.... .... +122876 TRANSFORMER, 230/460 (consisting of) 1
17 ++090799 .... COIL, pri/sec RH & center 2
18 090798 .... COIL, pri/sec LH 1
16 Ti
.... .... +122877 TRANSFORMER, 200/230/460 (consisting of) 1
17 -i-+090 801 .... COIL, pri/sec RH & center 2
18 090800 .... COiL, pri/sec LH 1
16 Ti
.... .... +122878 TRANSFORMER, 230/460/575 (consisting of) 1
17 ++090 803 • ... COIL, pri/sec RH & center 2
18 090802 .... COIL, pri/sec LH 1
16 ....T1 ... +084116 TRANSFORMER, 230/460 (Prior to JE747791)
(consisting of) 1
17 ++035 382 ...COIL, pr/sec RH & center 2
18 035381 .... COIL, pr/sec LH 1
16 .... Ti .... +122886 TRANSFORMER, 230/460 (Elf w/JE747791)
(consisting of) 1
17 ++090 787 COIL, pr/sec RH & center 2
18 090786 ...COIL, pr/sec LH 1
16 .... Ti .... +122881 TRANSFORMER, 200/230/460 (consisting of) 1
17 ++090789 .... COIL, pr/sec RH & center 2
18 090788 COIL, pri/sec LH 1
16 .... Ti .... +122882 TRANSFORMER, 230/460/575 (consisting of) 1
17 -i-+090791 COIL, pri/sec RH & center 2
18 090790 COIL, pri/sec LH 1
16 Ti
.... .... +092990 TRANSFORMER, 230/460 (Prior to JE791122)
(consisting of) 1
17 ++000977 .... COIL, prVsec RH & center 2
18 000976 ...COIL, pri/sec LH 1
16 .... Ti .... +122888 TRANSFORMER, 230/460 (Elf w/JE791122)
(consisting of) 1
17 +-i-095 221 ...COIL, pri/sec RH & center (Prior to JF877636) 2
17 ++098417 COIL, pri/sec RH & center (Elf w/JF877636) 2
18 095220 COIL, pri/sec LH (Prior to JF877636) 1
18 098416 COIL, pri/sec LH (Elf w/JF877636) 1
16 .... Ti .... +122887 TRANSFORMER, 200/230/460 (consisting of) 1
17 ++095 223 COIL, pri/sec RH & center (Prior to JF877636) 2
17 ++098 421 .... COIL, pri/sec RH & center (Elf w/JF877636) 2
18 095222 .... COIL, pri/sec LH (Prior to JF877636) 1
18 098420 .... COIL, pri/sec LH (Elf w/JF877636) 1
16 Ti
.... +122889
.... TRANSFORMER, 230/460/575 (consisting of) 1
17 ++095225 OQIL, pr/sec RH & center (Prior to JF877636) 2
17 ++098419 COIL, pri/sec RH & center (Elf w/JF877636) 2
18 095224 .... COIL, pr/sec LH (Prior to JF877636) 1
18 098418 .... COIL, pr/sec LH (Elf w/JF877636) 1
SPM-221 Page 3 Goldstar Series
 Quantity
Model
Item Dia. Part
Description
~
AmD IAmD lAmp lAmp
No. Mkgs. No.
Figure 1. Main Assembly (Continued)

16 .... Ti .... +096749 TRANSFORMER, 230/460 (Prior to JE791122)

(consisting of) 1
17 .i-+005 365 COIL, pri/sec RH & center 2
18 005364 COIL,pri/secLH 1
16 .... Ti .... +122892 TRANSFORMER, 230/460 (Elf w/JF848854)
(consisting of) 1
17 +-i-097 584 COIL, prVsec RH & center 2
18 097583 .... COIL, pri/sec LH 1
16 .... Ti .... +122893 TRANSFORMER, 200/230/460 (consisting of) 1
17 ++097736 COIL, pri/sec RH&center 2
18 097735 ... COIL, pri/sec LH 1
16 .... +122894
Ti .... TRANSFORMER, 230/460/575 (consisting of) 1
17 ++097586 COIL, pn/sec RH & center 2
18 097585 COIL, pri/sec LH
- 1
TP3... •088592 THERMOSTAT, NO (located in Ti w/fan control) 1 ... 1 ... 1 .... 1
TP4... •094352 THERMOSTAT, NO (located in Ti w/fan control) 1 ... 1 ... 1 .... 1
Oil 075 SPRING, pressure (used w/TP4) 1 ... 1 ... 1 .... 1
19 .... R6 . +++039210 RESISTOR,WWfxd375Wi2ohm
-.20 Fig4 PANEL, front w/components 1 ... 1 ... 1 ... - 1
21 SRi
... 087094 RECTIFIER, SCR (Fig 6) 1
21 ... SRi... •087072 RECTIFIER, SCR (Fig 6) (fan control) 1
..21 SRi
... 083910 RECTIFIER, SCR (Fig 7) (Prior to JF855870) 1
21 SRi
... 092723 RECTIFIER, SOR (Fig 7) (Elf w/JF855870 thru KB055115) 1
21 SRi
... 140121 RECTIFIER, 5CR (Fig 7) (Elf w/KBO5Sii6 and on) 1
21 SRi... .086062
.. RECTIFIER, SOR (Fig 7) (fan control)
(Elf w/JC6i 5021 thru JF855842) 1
21 ... SRi... ,099465 RECTIFIER, SCR (Fig 7) (fan control)
(Elf w/JK855843 thru KBO5S1 15) 1
21 ... SRi... •140122 RECTIFIER, SCR (Fig 7) (fan control)
(Elf w/KB055115 and on) 1
21 ... SRi 045237 RECTIFIER, SCR (Fig 7) (Prior to JE747791) 1
RECTIFIER, SOR (Fig 7)
21 ... SRi 092685 (Elf w/JE747791 thru JF846888) 1
21 ... SRi 097728 RECTIFIER, SCR (Fig 7)
(Elf w/JF846889thru KBO5SiiS) 1
21 SRi ... 139584 RECTIFIER, SCR (Fig 7) (Elf w/KBO5Sii6 and on) 1
..21 ...SRi... •086399 RECTIFIER, SCR (Fig 7) (fan control)
(Eff w/JE747791 thru JF848845) 1
21 ... SRi... .092685 RECTIFIER, SCR (Fig 7) (fan control)
(Eff w/JF848846 thru KBO5Si 15) 1
21 ... SRi... •i39585 RECTIFIER, SCR (Fig 7) (fan control)
(Elf w/KB055116 and on) 1
21 .. SRi 045007 RECTIFIER, SCR (Fig 7) (Prior to JF846889) 1
21 ... SRi 093145 RECTIFIER, SCR (Fig 7)
(Prior to JF846889 thru KB055115) 1
21 ... SRi 139586 RECTIFIER, SCR (Fig 7) (Elf w/KBO5Si 16 and on) 1
21 ... SRi... .086284 RECTIFIER, SCR (Fig 7) (fan control)
(Elf w/JE8i 3766 thru JF848845) 1
21 ... SRi ... •099 466 RECTIFIER, SCR (Fig 7) (fan control)
(Elf w/JF848846 thru KB0551 15) 1
21 ... SRi... ,139587 - RECTIFIER, SCR (Fig 7) (fan control)
(Elf w/KBOS51i6 and on) 1
CR1 .. .006393 RELAY, end 24VAC DPDT (fan control) 1 ... 1 ... 1 ... 1
.

22 144017 BRACKET, mtg hall (Elf w/KB04471 8) 1 ... 1 1

....

Goldstar Series SPM-221 Page 4

 Quantity
Model
Item Dia. Part
Description
i5~T~6~T~0O 600
No. Mkgs. No. Amo lAmo lAmo IAmD
Figure 1. Main Assembly (Continued)

23 . HAi,HD1 085 166 SENSOR, current (Prior to JHi 75959) 1 .- 1

.

23 HAi,HD1
. 134 826 CIRCUIT CARD, hall booster (Elf w/JHi 75959) 1 1
...

23 .HA1,HDi 085 166 SENSOR, current 1 .... 1

137 900 KIT, contactor 1 ... 1
24 .... W 137901 KIT, contactor :1 ...

082 456 DIODE, (consisting of) 1 1

... 1 1... ....

25 .. DiO,li 070 250 DIODE,rect3A600V 2...2...2....2

• •When ordering a component originally displaying a precautionary label, the label should also be ordered.
•OPTIONAL
“Part of Circuit Card
+lf unit has optional duplex receptacle the transformer is special. Contact Factory Parts Department for correct part
numbers.
++Quantity of this item changes to 1 for units w/optional duplex receptacle as the RH coil has ii5V tertiary winding.
+-i-+For the 300 Amp model this resistor is located on the 14 in. Plenum Chamber.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

5PM-221 Page 5 Goldstar Series

 Quantity
Model
Item Dia. Part ~
No. Mkas. No. Description AmoIAmD lAmol Am

Figure 2. Panel, Rear wlComponents (Fig 1 Item 7)

FM 116190 MOTOR, i/i2hp230V 1550RPM 1 ... 1

FM 032605 MOTOR, cap perm SP i/4hp 230VAC 1625RPM 1 . ... 1
131 361 CHAMBER, plenum 14 in 1 ... 1
132260 CHAMBER, plenum 14 in 1 .... 1
032611 BLADE, fan 14 in 3wg 23deg .375 bore CCW 1 ... 1
605 799 BLADE, fan 14 in Swg 3odeg .500 bore CW 1 .... 1
158289 PANEL,rear

ST-004 988-0
5
Figure 2. Panel, Rear w/Components

7
8

ST—138 574

Figure 3. Terminal Assembly, Pri

Item Part Quantity

No. No. Description
Figure 3. Terminal Assembly, Pri (Fig 1 Item 8) 038 145 1038 138

601 835 NUT, brs hex 10-32 24 .. 36

038 058 TERMINAL BOARD, primary 1 .... 1
038 887 STUD, pri board brs 10-32 x 1.375 12 .. 18
010 913 WASHER, flat brs .218 ID x .460 OD x .O3ithk 12 .. 18
038 618 LINK, jumper term bd pri 6 - ... 6
601 836 -. NUT,brshex.250-20samh~/y 6.... 6
010 915 WASHER, flat brs .250 ID x .625 OD x .O3ithk 6 .... 6
038 888 STUD, pri board brs .250-20 x 1.500 3 .... 3

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Goldstar Series 5PM-221 Page 6
 4

— N.

10
Fig 5

24

I 12

ST—004 987-P

Figure 4. Panel, Front wlComponents

SPM-221 Page 7 Goldstar Series

 Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 4. Panel, Front w/Components (Fig 1 Item 20)

... 1 NAMEPLATE, (order by model and serial number) 1

SS 011 610... SWITCH, tgl SPDT 15A i25VAC (Prior to JK674521) 1
R4 030 853 ... RESISTOR, C .5W 2.2K ohm (Prior to JK674521) 1
R3 052 140... RESISTOR, C .5W 3.30 ohm (Prior to JK674521) 1
... 2 R3 009 156 ... POTENTIOMETER, C sltd sft l/T 2W 2.5K ohm (Elf w/JK674521) 1
... 3 084 107 ... PANEL, front (Prior to JF846889) 1
3 092 185... PANEL, front (Elf w/JF846889 thru JK674520) 1
3 158 258... PANEL, front (Elf w/JK674521 and on) 1
.4 S3 089 085 ... SWITCH, tgl SPST 20A i25VAC 1
Ri 084 206 ... RESISTOR, MF .25W 3.32K ohm 1
.5 .. Ci4,i5,
17,i8,RCi ... 087 415... RECEPTACLE w/CAPACITORS, (Prior to JK674521) 1
039 684... CAP, dust connector 97-121-416R (Prior to JK674521) 1
5 130 257 RECEPTACLE w/CAPACITORS, (Elf w/JK674521) (consisting of)
... 1
Ci4 143 935 LEAD ASSEMBLY, elect 1
Ci5 143 934 LEAD ASSEMBLY, elect 1
Ci7 143 933 LEAD ASSEMBLY, elect 1
Ci8 143 936 LEAD ASSEMBLY, elect 1
....RCi 143 976 CONNECTOR w/PINS, (consisting of) 1
079 534 CONNECTOR, circ skt push-in 14-l8ga 14
134734 HOUSING, term plug i4cont 213571-2 Amp
...

134731 TERMINAL, male 1 pin 18-14 wire 213603-i Amp

...

079 739 CLAMP, cable strain relief sz 17206322-2 Amp

...

011 609 SWITCH, tgl SPDT i5A 12SVAC

... 2
R5 072 462... POTENTIOMETER, w/shaft lock (Prior to KE722876) (consisting of).... 1
072590... LOCK, pot .375-32 x .2SOdia shaft 1
R5 035897... POTENTIOMETER, CP std slot l/T 2W 1K ohm (Elf w/KE722876) 1
10... PB1 046745... SWITCH, PB (Fig 5) 1
ii ... C4,5 087337... CAPACITOR 2
12 ... NEG 039046... TERMINAL, pwr output black (consisting of) 1
13 ... POS 039047... TERMINAL, pwr output red (consisting of) 1
14 601976... SCREW, cap stl hexhd .500-13 x 1.500 - 1
15 039045.. TERMINAL BOARD, black 1
is 039 049 TERMINAL BOARD, red i
16 601 880 NUT, stl hex jam .500-13 1
-. 17 039044 BUS BAR,termbd 1
18 601 879 NUT, stl hex full .500-13 1
19 +084 106 DOOR, access front (Prior to JH296872) 1
19 +109449... DOOR, access front (Elf w/JH296872) 1
20 605583... CATCH, spr loaded door (Elf w/JH296872) 1
21 134327... LABEL, warning general precautionary 1
027628... LIGHT, md red clear (Prior to JF846889) 1
22 ... PLi 027632... LENS, light md red clear (Prior to JF846889) 1
027631 HOUSING, light md slide base (Prior to JF846889) 1
22 ... PLi 048573... LIGHT, md red lens 28V (Elf w/JF846889) 1
23 097926... KNOB, pointer 1
24 097922... KNOB, pointer (Elf w!JK67452i) 1

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

SPM-221 Page 8
Goldstar Series
 Item Part
No. No. Description Quantity
046 745 Figure 5. Switch, PB (Fig 4 Item 10)

1 059 885 ... BUTTON, push reset red 1

2 018 606 ... SPRING, cprsn .430 OD x .040 wire x 1 .SOOstnls 1
3 045 546 ... PUSH BUTTON SET, w/cable & housing 1
4 081 008 ... BRACKET, mtg switch PB 1
5 027 878 ... SWITCH, lim leaf actg SPDT 1

4,

5
2

5T-080 214-5

Figure 5. Switch, PB

5T-049 529—A

Figure 6. Rectifier, SCR (300A)

Item Dia. Part

No. Mkgs. No. Description Quantity
Figure 6. Rectifier, 5CR (300 Amp) (Fig 1 Item 21) 0870941087072
SCRi-6 ....034976... THYRISTOR, SCR 175A 300V 6 . ... 6
...2... C7-i2 053372... CAPACITOR 6 .... 6
...3.... TP1 032810... THERMOSTAT, NC 1 .... 1
TP2 086323... THERMOSTAT, NO 1

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
SPM-221 Page 9 Goldstar Series
Item Dia. Part
No. Mkgs. No. Description Quantity
(U,

I
0 ‘- RI

Figure 7. Rectifier, SCR (400A) (Fig 1 Item 21) ~ 0

CU
0
CI

.1 ..C7-i2... 031 688 CAPACITOR 6.. 6

.1 ..C7-i2... 048 420 ..CAPACITOR
.2 082 852 BUS BAR, (Prior to JH220869) 4 4...

.2 114 530 BAR, mtg rect (Eff w/JH220869) 2 2... 2

... .. 2
010381 CONNECTOR,rect 2...2...2 .. 2
.3 083 908 HEATSINK,rect 6 .. 6
.3 048 779 HEATSINK,rect 6...6... 6 .. 6
.4 083 884 CLAMP, thyristor 3 .. 3
.4 082 694 CLAMP,thyristor 3... 3... 3 3 ..

.5 028 516 PIN,springCS.125x.250 12.. 12 .12. 12. 12..i2

6 SCRi-6
. 046 995 THYRISTOR, SCR 300A 300V 6 ..6
6 SCRi-6
. 097 397 THYRISTOR, SCR 300A 300V 6 ... 6... 6 6 ..

.7 083 909 HEATSINK,rect 3 .. 3

.7 045 109 HEATSINK,rect 3... 3... 3 3 ..

083 907 BUSBAR,rect 2.. 2

037 087 BUS BAR, (PriortoJJ4855O4) 6 12
.. 1 1
.. ...

TP1.... 601 066 ThERMOSTAT, NC 1

TPi.... 117 275 ..THERMOSTAT,NC i...i...i...i 1 ..

TP2.... 012 631 ..THERMOSTAT,NO 1 1 1

.8 083 906 CHANNEL,mtgrect 2 ..2
.8 082 852 BUS BAR, (Elf w/JH220869) 2 2... 2 2 ... ..

026 947 STAND-OFF, insul .250-20 x 1.00 Ig 4 4 ...

025 248 STAND-OFF, insul .250-20 x 1.250 Ig 6 ..6

i 38 378 BRACKET, mtg rect (see Fig 1 Item 17) 2... 2 2 ..

1
2
1

5
6

6
5T-048 899—K

Figure 7. Rectifier, SCR

Goldstar Series 5PM-221 Page 10
Item Dia. Part
No. Mkgs. No. Description Quantity
~- ~‘ C
Figure 7. Rectifier, SCR (500A) ,, CU, ~
(Fig 1 Item 21) + +

.1 ..C7-12...048420..CAPACITOR,rect
048 775 .. BUS BAR, tab connecting 8 8
048 774 .. BUS BAR, tab connecting 4 4
• 2 082 852 .. BUS BAR, (Prior to JH220869) 4 4 ... 4
2 114530 .. BAR,mtgrect(Effw/JH220869) 2 2... 2... 2 .. 2
010381 .. CONNECTOR,rect 2 2... 2... 2 .. 2
.3 048779.. HEATSINK,rect 6..6.. 6...6...6...6..6
.4 082694..CLAMP,thyristor
- 5 028516 .. PIN,springCS.125x.250 i2 .. 12.. 12 . 12 . 12 . 12.. 12
6 . SCR1-6 .. 046 995 .. THYRISTOR, SCR 300A 300V 6 6
6 . SCR1-6 .. 097397 .. THYRISTOR,SCR300A300V 6 6... 6... 6 .. 6
7 048777 .. HEATSINK,rect 3 .. 3 .. 3 ...3 ... 3... 3 .. 3
037 087 .. BUS BAR, (Prior to JJ485504) 1 1 ... 1
TP1....601066..THERMOSTAT,NC
TP2.... 012631 .. THERMOSTAT,NO 1.. 1 1 1
8 048 372 .. CHANNEL, mtg rect 2 2
8 082852 .. BUS BAR, (Eff w/JH220869) 2 2... 2... 2 .. 2
026 947 .. STAND-OFF, insul .250-20 x 1.00 Ig 4 4 ... 4
138 378 .. BRACKET, mtg rect (see Fig 1 Item 17) 2 .. 2

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 7. Rectifier, SCR (600A) (Fig 1 Item 21) ~

+

1 .. C7-12 ... 048420 CAPACITOR,rectifier 6.. 6 ...6... 6... 6 6 ..

048 376 BUS BAR, tab connecting 8 8

..

049 728 BUS BAR, tab connecting 4 4

..

2 082852 BUS BAR, (Prior to JH220869) 4 4 ...

2 114530 BAR, mtg rect (Elf w/JH220869) 2 2 2 2 ... ... ..

010381 CONNECTOR,rect 2...2... 2.. 2

• 3 •048373 ..HEATSINK,rect 6.. 6...6...6...6 ..6
3 166785 HEAT SINK, rect (Elf w/KE696137) 6
4 082693 CLAMP, thyristor rectifier 8.500 3 3
.. 3 3... 3
... 3 ... ..

5 .028516 PIN,springCS.125x.25012 12..i2 .12.12. 12..12

• 6 . SCRi-6 .. 112942 THYRISTOR,SCR600A300V 6.. 6 ...6... 6... 6 6 ..

.7 •048375 HEATSINK,rect 3.. 3...3...3...3 3 ..

7 166786 • -HEAT SINK, rect (Elf w/KE6961 37) 3

037 087 BUS BAR, (Prior to JJ485504) 1 1 ...

TPi.... 601 066 ..THERMOSTAT,NC 1.. i...1...i...1 ..1

TP2.... 012 631 ..THERMOSTAT,NO 1 1 1
.8 048 372 CHANNEL, mtg rect 2 2..

.8 082 852 BUSBAR,(Elfw/JH220869) 2... 2... 2 2 ..

026 947 STAND-OFF, insul .250-20 x 1.00 Ig 4 4 ...

138 378 BRACKET, mtg rect (see Fig 1 Item 17) 2 2 ..

+Fan Control
• Prior to KE6961 37 for 600A models without Fan Control.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

SPM-221 Page 11 Goldstar Series

 Dia. Part
Mkas. No. Description Quantity
Figure 8. Circuit Card, Root Pass (Fig 1 Item 11)
ASO-59 035 845 ... IC, linear 307 10
C5i-53 035834... CAPACITOR, polye film 1 .Suf 1 OOV 3
C54,56,59-6i ,63,
66-68,70,73,74 035 833 ... CAPACITOR, polye film .033uf 100VDC 12
C55,62,69 035 835 ... CAPACITOR, elctlt 4.7uf 35VDC 3
C57,58,64,65,
71,72,77,80,82 053991 CAPACITOR, cer disc .OSuf SOOVDC 9
C75 038585... CAPACITOR, polye film .22uf 50V 1
C76,79 000 859 CAPACITOR, elctlt 220uf 35VDC
... 2
C78,8i 031 630 CAPACITOR, elctlt 22uf 5OVDC 2

5N—092 883—B

Figure 8. Circuit Card, Root Pass

Goldstar Series SPM—221 Page 12
 Dia. Part
Mkgs. No. Description Quantity
Figure 8. Circuit Card, Root Pass (Fig 1 Item 11) (Continued)
... 083,85,88-93,95,96,99 . . - 059 122 ... CAPACITOR, cer disc .Oluf SOOVDC 11
098 007 742 ... CAPACITOR, elctlt lOuf 35V 1
D50-52,54-56,58-60,
62-64,66-68,70-72,
74,75,81,86 028 351 ... DIODE, sig .020A 75V SP 22
D53,57,61 ,65,69,
73,76,77,82,85 026 202 ... DIODE, rect lA 400V SP 10
050,52,54,56,58,60 .... 037 277 TRANSISTOR, NPN 200mA 30V
... 6
... 051,53,55,57,59,61,62 ... 035 842 ... TRANSISTOR, PNP .5A 60V 7
063 000 088 TRANSISTOR, NPN 800mA 40V
... 1
RSO-52,111,112 000885... RESISTOR, MF.2SWlOKohm 5
R53,54,61 ,62,68,75,76,
82,83,90,91,109,124,135 ..035 884... RESISTOR, CF .25W lOOK ohm 14
R55,63,69,77,
84,92,107,126 035 826 RESISTOR, CF .25W 6.8K ohm (300,400,500 amp)
... 8
R55,63,69,77,84,92,126 ... 035 826... RESISTOR, CF .25W 6.8K ohm (600 amp) 7
R56,64,70,78,
85,93,100,129 035 827 RESISTOR, CF .25W 10K ohm
... 8
... R57,65,71 ,79,86,94,99 . 035 825... RESISTOR, CF .25W 1K ohm
. . 7
R58,72,87 035 823 RESISTOR, CF .25W 100 ohm
... 3
.... R59,66,73,80,88,95 . 035 257
... RESISTOR, C .25W 270 ohm
... 6
R60,67,74,81,89,96 605 919
.... RESISTOR, C .25W 47 ohm
... 6
R97,101,133 035885... RESISTOR, CF .25W68Kohm 3
R98,125,137 035 887... RESISTOR, CF .25W 3.3K ohm 3
R102 074060... RESISTOR,C.5W1Kohm 1
Ri 04 035 829 RESISTOR, MF .25W 1.5K ohm
... 1
R106,130,134 035848... POTENTIOMETER, cermettrmr25/T .5W 10K ohm 3
R107 035 888 RESISTOR, CF .25W 2.2K ohm (600 amp)
... 1
RiOB 084 205 RESISTOR, MF .25W 3.32K ohm
... 1
RhO 039108... RESISTOR, CF .2SW82Kohm 1
R113,116 030089... RESISTOR,C.5W2.7ohm 2
R119 030045... RESISTOR, fxd3W 100 ohm 1
R120 039 106... RESISTOR, CF .25W 470 ohm 1
R122 076712...RESISTOR,C.25W22OKohm 1
R127 039 329... RESISTOR, CF .25W 2.7K ohm 1
R131,136,139 039331 RESISTOR, CF .25W4.7K ohm
... 3
R132 039 335... RESISTOR, CF .25W 47K ohm 1
R138 035 886 RESISTOR, CF .25W 22K ohm
... 1
SR5O 021 939 RECTIFIER, integ 1 .5A 400V
... 1
T50-55 035 846 TRANSFORMER, pulse
... 6
VR5O 083 772 IC, linear 7815
... 1
VR51 046 932 IC, linear 7915
... 1
035 849 TERMINAL, hdr 29 pin
... 1
PLG1 048 281 RECEPTACLE w/SOCKETS, (consisting of)
... 1
058 972 TERMINAL, female lskt
.... 2

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

SPM-221 Page 13 Goldstar Series

 Quantity
Model
Dia. Part ~5T~50500 600
Mkgs. No. Description Amp Amp Amp Amp

Optional Equipment

041 884 METER (consisting of)

KIT, 1
041 704 METER (consisting of)
KIT, 1
041 886 METER (consisting of)
KIT, 1
041 887 METER KIT,
(consisting of) 1
098 669 .... METER SET, (consisting of) 1
096 893 METER SET, (consisting of) 1
096 894 .... METER SET, (consisting of) 1 .... 1
025 608 METER, amp dc 5OMV 0-500 scale 3.5 in 1
025 611 METER, amp dc 0-600 scale 3.5 in 1
025610 METER, amp dc 5OMV 0-800 scale 3.5 in 1 1
....

-. P1 025 701 FILTER, HFdcvolt&ampmeter3.Sin 2...2... 2....2

025 604 METER,voltdco-i0oscale 3.5 in 1 1
... ... 1.... 1
103 966 PANEL, front meter box 2 meters 1 ... 1 ... 1 1
....

103 967 PANEL, rear meter box2 meters 1 1

... ... 1 ....1
103 965 WRAPPER,meterbox2meters 1 1
... ... 1 1
....

010 323 .... CLAMP, hose .250-.625c1p dia 1

010859 CLAMP, hose .562-i .062c1p dia 1 .... 1
010493 BUSHING, snap-in nyl .625 ID x .87Smtg hole 1 ... 1 1
015 712 - GROMMET, rbr .625 ID x .875mtg hole 1
030 084 .... SHUNT, meter SOMV 600A It wt 1
... S8 ... Oil 974 SWITCH, polarity (consisting of) 1 ... 1 ... 1
S8 ... 053 049 SWITCH, polarity (consisting of) 1
017 288 .... BRACKET, mtg switch 2 ... 2 ... 2
053 044 BRACKET, mtg switch 2
103 634 .... MOUNTING BOARD, cmpnt polarity switch 1 1 ... 1
... .... 1
103 633 BUS BAR, shorting switch polarity 2 ... 2 2 ... .... 4
023 119 BUS BAR, switch 1
023 120 BUS BAR, switch 2
011 948 ... GUIDE, contact movable switch 2 ... 2 ... 2 .. ..2
021 193 GUIDE, contact 2
011 645 CONTACT ASSEMBLY, movable switch 1 1
... ... 1
024 694 BEARING, polarity switch 1 1
... ... 1 .... 2
010 805 ... HANDLE, switch polarity 1 ... 1 ... 1 . ... 1
0i9 603 KNOB, balI 1.250 OD w/.250-20fthrd 1 i
... ... 1 .... 1
020 484 - ... TUBING, stl .625 OD x l2ga wall x .250 1
010086 SPACER, polarity switch 2
011 080 SPACER, contact switch i/8 in 4
023 i2i PLATE, tgl switch polarity 1
Oil 953 CONTACT, switch 8
011 075 ... SPRING, pressure contact switch 4
011 074 .... SPRING, pressure contact switch 4
021 932 STRIP, insul switch polarity 1 1 ... 1
... .... 1
• . C6. +053 296 CAPACITOR,ign.Suf 1... 1... 1 ....i
CB1.. +093 995 CIRCUITBREAKER,manresetiP
..RC3.. +604 176 RECEPTACLE,strdxgrd2P3WiSAi2SV i ... 1 ... 1 .... 1

+Auxiliary Power 2kVA Prior to JJ503984

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

5PM-221 Page 14
Goldstar Series
PRINTED IN USA © 1997 Miller Electric Mfg. Co.