TM-218B May 1999

Eff. w/ Serial Number N315929

Processes
TIG (GTAW) Welding

Stick (SMAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

With Optional Equipment:

MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Plasma Cutting
and Gouging

Description

Arc Welding Power Source

MARK VIII-2

Visit our website at

www.Miller-
Welds.com
 TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WARNING
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
This product, when used
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 for welding or cutting,
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 produces fumes or
SECTION 2 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 gases which contain
chemicals known to the
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 State of California to
2-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 cause birth defects and,
2-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 in some cases, cancer.
(California Health &
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Code Section
3-1. Selecting A Location And Moving Polyweld System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 25249.5 et seq.)
3-2. Dimensions, Weights And Base Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-3. Selecting And Preparing Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-4. Weld Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-5. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-6. Remote Amperage Control Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-7. Remote Contactor Control Connections (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-8. 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-9. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-10.Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-2. Amperage Adjustment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-3. Power Switch Push Buttons And Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-2. Troubleshooting Circuit Diagram For Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-3. Waveforms For Section 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-4. Input Voltage Labels And Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-3. Blank Module Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 8 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 9 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

TM-218B
 SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
OM-___ - Date, safety_stm 7/98

Means Warning! Watch Out! There are possible

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

This group of symbols means Warning! Watch Out! possible

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

1-2. Servicing Hazards

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

HOT PARTS can cause severe burns.

ELECTRIC SHOCK can kill.
D Do not touch hot parts bare handed.
D Do not touch live electrical parts. D Allow cooling period before working on
D Turn Off welding power source and wire feed- welding gun or torch.
er and disconnect and lockout input power us-
ing line disconnect switch, circuit breakers, or by removing plug
from receptacle, or stop engine before servicing unless the proce-
dure specifically requires an energized unit. EXPLODING PARTS can cause injury.

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

FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

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

Mark VIII–2 TM-218 Page 1

 MOVING PARTS can cause injury. H.F. RADIATION can cause interference.
D Keep away from moving parts. D High-frequency (H.F.) can interfere with radio
D Keep away from pinch points such as drive navigation, safety services, computers, and
rolls. communications equipment.
D Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
MAGNETIC FIELDS can affect pacemakers.
D If notified by the FCC about interference, stop using the
D Pacemaker wearers keep away from servicing equipment at once.
areas until consulting your doctor. D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.

OVERUSE can cause OVERHEATING. READ INSTRUCTIONS.

D Use Testing Booklet (Part No. 150 853) when
D Allow cooling period; follow rated duty cycle.
servicing this unit.
D Reduce current or reduce duty cycle before
D Consult the Owner’s Manual for welding
starting to weld again.
safety precautions.
D Do not block or filter airflow to unit.
D Use only genuine replacement parts.

1-3. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from opera-
committee’s judgment, has not demonstrated that exposure to power- tor as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as
examined. Until the final conclusions of the research are reached, you possible.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.

TM-218 Page 2 Mark VIII–2

 SECTION 2 – SPECIFICATIONS

2-1. Specifications
Amperes Input at Rated Load Output,
Rated Welding Rated Welding 60 Hz, Three-Phase
Output For Main Output For Each
Transformer Module Max OCV DC 230 V 460 V 575 V KVA KW

800 A @ 40 Volts DC,

100% Duty Cycle; 200 A @ 40 Volts DC, 170 85 68 68 48.6
80
1600 A @ 40 Volts 60% Duty Cycle 8* 4* 3.2* 3.18* 2.65*
DC, 25% Duty Cycle

*While idling

2-2. Volt-Ampere Curves

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities
of each module. Curves of other
settings fall between the curves
shown.

ssb1.1* 10/91 – SB-083 110-C

Mark VIII-2 TM-218 Page 3

2-3. Duty Cycle And Overheating

For Each Module And Total System Duty Cycle is percentage of 10

minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void
warranty.

60% Duty Cycle At 200 Amperes

6 Minutes Welding 4 Minutes Resting

For Main Transformer

The main transformer of the polyweld system has dual duty cycle ratings, each for a
specific amperage output range. If the unit is operated in the 800 ampere range, the
unit is rated at 100% duty cycle. This means the polyweld system can be operated
at 800 amperes continuously. When the unit is operated in the 1600 ampere range,
it is rated at 25% duty cycle.
The sum of the outputs of each module should not exceed the rated duty cycle of
the main transformer. For example, the polyweld system can be safely operated at
a load of 1000 amperes at 60 percent duty cycle. This value could be obtained by
operating five modules at a load of 200 amperes at 60 percent duty cycle, or by
operating eight modules at a load of 125 amperes at 60 percent duty cycle.

Overheating
Thermostat TP1 protects the polyweld system. If main transformer T1 gets too hot,
TP1 opens and weld output stops. The stabilizer in each of the eight modules is pro-
tected from overheating by thermostat TPX1 (“X” represents the number of the
applicable module, 1–8). If overheating of a stabilizer occurs, the associated ther-
mostat opens, reducing weld output to a minimum that cannot be regulated. The
fans keep running to cool the stabilizer. Wait several minutes before trying to weld.

15

minutes

When overheated, thermostat Let fans run for Start welding.

opens, output decreases or stops, 15 minutes.
and cooling fans keep running.

ssb10.1* 1/94 – SB-002 919-C / ST-144 567-A

TM-218 Page 4 Mark VIII-2

 SECTION 3 – INSTALLATION

3-1. Selecting A Location And Moving Polyweld System

1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
Y Disconnect input power conductors
from deenergized supply BEFORE If using lifting forks, extend forks
moving polyweld system. beyond opposite side of unit.
3 Rating Label
Movement Use rating label to determine input
power needs.
1
4 Line Disconnect Device
Locate unit near correct input pow-
er supply.
OR

Location And Airflow

18 in
(460 mm) 4

18 in
(460 mm)

18 in
(460 mm)

Special installation may be required

where gasoline or volatile liquids are
present – see NEC Article 511 or
CEC Section 20.

18 in 18 in
(460 mm) (460 mm)

Do not block airflow

3 to bottom of unit.

ssb9.1 5/94 – ST-801 180 / ST-144 567-A

Mark VIII-2 TM-218 Page 5

3-2. Dimensions, Weights And Base Mounting Hole Layout

NOTE Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.

Dimensions

A 77-1/4 in (1943 mm)

B 72 in (1829 mm)
H
A C 40 in (1016 mm)

D 52-1/2 in (1334 mm)

C
B Front D E 3/4 in (19 mm)

F 38-1/2 in (978 mm)

G G 26-1/4 in (667 mm)

H 36 in (914 mm)

1/2 in Dia. (13 mm Dia.)

J
4 Holes
J Weight
F E
Ref. ST-144 567-A
4050 lb (1837 kg)

3-3. Selecting And Preparing Weld Output Cables

1 Weld Output Cable
Determine total cable length in
weld circuit and maximum welding
amperes. Use Section 3-4 to select
proper cable size.
Use shortest cables possible.
Do not use damaged cables.
2 Terminal Lug
Use lugs of proper amperage
capacity and hole size for connect-
ing to work clamp, electrode hold-
er, and weld output terminals.
3 Insulated Electrode Holder
Install according to manufacturer’s
instructions.
4 Work Clamp
Install onto work cable.
2
3

2 1

For Example,
10 ft (3 m) Total Cable
Length In Weld Tools Needed:
Circuit = 20 ft (6 m)
4

10 ft (3 m)

sb6.1* 5/94 – Ref. ST-144 570-A / Ref. S-0653

TM-218 Page 6 Mark VIII-2

3-4. Weld Cable Size
Total Cable (Copper) Length In Weld Circuit Not Exceeding*
50 ft Or Less 100 ft 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
(15m) (30m) (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Welding
10 Thru 100% Duty Cycle
Amperes

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 2 2 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 1/0 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 2/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

400 2/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

500 4/0 4/0 4/0 2-2/0 2-3/0 2-4/0 1000 1000

600 4/0 4/0 2-2/0 2-3/0 2-4/0 1000 1000 2-750

700 4/0 2-2/0 2-3/0 2-4/0 1000 1000 2-750 2-750

800 2-2/0 2-2/0 2-3/0 2-4/0 1000 2-750 2-750 2-1000

900 2-3/0 2-3/0 2-4/0 1000 1000 2-750 2-1000 2-1000

1000 2-3/0 2-3/0 2-4/0 1000 2-7500 2-750 2-1000 2-1000

1250 2-4/0 2-4/0 750 2-750 2-750 2-1000 2-1000

1500 500 750 1000 2-750 2-1000 2-1000

1750 750 1000 2-750 2-1000 2-1000

2000 750 1000 2-750 2-1000

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor
for the mm2 equivalent weld cable sizes. S-0008-C

3-5. Connecting To Weld Output Terminals

WARNING
ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical connections.
• Do not touch live electrical parts.
• Turn Off polyweld system by pressing Power Off push button before making any weld output connections.
• Do not connect welding output of different polarities to the same structure.
• See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).
• When Positive or Negative weld output terminal is jumper linked to the Frame Connection terminal and the work cable is
connected to the Common Work Connection stud on the machine base, do not connect a cable between the remaining weld
output terminal and the work.
• Remove jumper link from any module where work and electrode connections are made directly to the Positive and Negative
output studs.
• Do not handle or come in contact with two live electrodes at the same time.
• Connect all paralleled modules for the same polarity.

ELECTRIC SHOCK can kill; TWO TIMES NORMAL OPEN-CIRCUIT VOLTS exist between elec-
trode holders of opposite polarity.
• Do not touch electrode holders of opposite polarity at the same time.
• Separate electrode holders of opposite polarity to prevent contact.
• Consult ANSI Z49.1 for common grounding safe practices.

Mark VIII-2 TM-218 Page 7

A. Standard Module Connections

Y READ SAFETY BLOCKS at start of Section 3-5 before proceeding. 1 Cable Restraint
Route all cables under cable
INADEQUATE WORK CABLE CONNECTIONS can cause serious restraint.
damage to input power service and create a hazardous condition.
Separate Work Connections
Connect an electrical cable of adequate size between the common See Section 3-4 for proper cable
work connection terminal and the workpiece whenever any mod- size.
ule(s) is connected to use the frame connection terminal and the
common work connection terminal. 2 Negative (–) Weld Output
Terminal
3 Work Cable
4 Positive (+) Weld Output
Terminal
5 Electrode Holder Cable
For Electrode Positive (Reverse
4 Polarity/DCEP), connect work
2 cable to Negative (–) terminal and
Separate Work electrode holder cable to Positive
Connections 3 (+) terminal.
For Electrode Negative (Straight
Polarity/DCEN), reverse cable
5 connections.

1 Common Work Connections

6 Common Work Connection
Terminal
8
7 Common Work Cable
9
See Table 3-1 for proper cable
size.
Common Work 8 Frame Connection Terminal
Connections
9 Jumper Link
For Electrode Negative (Straight
Polarity/DCEN), connect jumper
6 link across Positive (+) terminal
and Frame Connection terminal,
7 and connect electrode holder to
Negative (–) terminal.
For Electrode Positive (Reverse
Polarity/DCEP), connect jumper
link across Negative (–) terminal
and Frame Connection terminal,
and connect electrode holder to
For common work connection, work cable must Positive (+) terminal.
be able to carry combined weld output of all
modules using the Common Work Connection
terminal (see Table 3-1 for proper cable size).

Tools Needed:
1-1/4 in
ST-144 568-C

Table 3-1. Common Work Cable Size

Common Work Cable Sizes At Main Transformer

Rated Welding Current
Cable Length Cable Size
50 Feet 2 No. 3/0
100 Feet 2 No. 4/0
150 Feet 3 No. 3/0
200 Feet 3 No. 4/0

TM-218 Page 8 Mark VIII-2

B. Parallel Module Connections

1 Cable Restraint
Route all cables under cable
restraint.
Y READ SAFETY BLOCKS at start of Section 3-5 before proceeding. Separate Work Connections
See Section 3-4 for proper cable
UNDERSIZED WELDING CABLES can cause fire. size.
Use single cables of adequate capacity to carry the total combined am- 2 Negative (–) Weld Output
perage of the paralleled modules (see Section 3-4) . Terminal
3 Electrode Holder Cable
Securely cover common connections with proper insulating materials.
4 Positive (+) Weld Output
Terminal
5 Work Cable
Set the Amperage Adjustment controls
on all paralleled modules to provide the 6 Connection Point
same output. For Electrode Negative (Straight
Polarity/DCEN), connect separate
cables of same size and length
from Positive (+) terminals to the
work or to a suitable connection
point connecting to a single work
cable. Connect separate cables of
same size and length from Nega-
tive (–) terminals to a suitable
connection point connecting to a
single electrode holder cable.
For Electrode Positive (Reverse
Securely cover con-
Polarity/DCEP), reverse cable
nection with proper
insulating material. connections.
Common Work Connections
7 Common Work Connection
Terminal
6 8 Common Work Cable
1 See Table 3-1 for proper size
2 cable.

3 9 Frame Connection Terminal

Separate Work
Connections 10 Jumper Link
For Electrode Negative (Straight
Polarity/DCEN), connect jumper
4 link across Positive (+) terminal
and Frame Connection terminal for
5 each paralleled module. Connect
separate cables of same size and
length from Negative (–) terminals
9 to a suitable connection point con-
necting to a single electrode holder
10 cable.
For Electrode Positive (Reverse
Polarity/DCEP), connect jumper
Common Work link across Negative (–) terminal
Connections and Frame Connection terminal for
7 each paralleled module, and con-
nect separate cables of same size
8 and length from Positive (+) termi-
nals to a suitable connection point
connecting to a single electrode
holder cable.
3

For common work connection, work cable must

be able to carry combined weld output of all
modules using the Common Work Connection
terminal (see Table 3-1 for proper cable size).
Tools Needed:
1-1/4 in
ST-085 152-D

Mark VIII-2 TM-218 Page 9

3-6. Remote Amperage Control Receptacle
1 Remote Amperage Control
Receptacles RCX1 (“X”
Represents The Number Of
The Applicable Module 1–8)
The twistlock receptacle in each
1 module provides a connection
point for an optional remote amper-
age control. To connect to one of
these receptacles, insert plug from
remote amperage control and turn
clockwise.

ST-144 570-A / Ref. ST-174 143

3-7. Remote Contactor Control Connections (Optional)

Terminal strip 1T provides a con-

nection point for connecting a nor-
mally open, momentary contact
switch for remote contactor con-
trol.
Y Turn Off polyweld system, and disconnect input power To connect a remote contactor
before making contactor control connections. control, proceed as follows:

Whenever the Remote Contactor switch is closed with 1 Terminal Strip 1T

Power switch On button pressed, input power is 2 Access Hole Location
applied to all modules.
Drill or punch a hole in lower right
rear panel to provide access to
terminal strip 1T. Hole size should
accept standard strain relief
connector.
Install strain relief into access hole.
3 Jumper Link
Remove jumper link.
4 Lead Connections
Route cord through strain relief
and connect leads to 1T as shown.
Polarity is not important. Connect
2
leads on other end of cord to a
suitable switch.
Close and secure rear panel ac-
1 cess door.

Tools Needed:
3

3/8 in

Ref. ST-144 569-B

TM-218 Page 10 Mark VIII-2

3-8. 115 Volts AC Duplex Receptacle
1 115 Volts AC Duplex
Receptacle RC2
This receptacle supplies up to 10
amperes of 115 volts ac power.
115V AC The duplex receptacle is protected
115V AC
OVERLOAD from overload by Overload Break-
10A BREAKER er CB1 (see Section 7-2A).
CLOSED

OPEN

1 Ref. ST-144 570-A / Ref. SC-085 382

3-9. Connecting Input Power

A. Positioning Jumper Links

Y Turn Off polyweld system, and disconnect input power

before inspecting or installing.

230 VOLTS 460 VOLTS 575 VOLTS

2 TE3 TE2 TE3 TE2 TE3 TE2

S-006 233-A

Jumper links allow operation on

different input voltages and are
factory set for the highest input
voltage.
Check input voltage available at
site.
Open rear panel access door to
check jumper links.
1 Input Voltage Label
Look at jumper links and compare
link position with unit label.
2 Input Voltage Jumper Links
Move links to match input voltage.
For example, use 230 volts posi-
tion when 230 volts input power is
available.
Close rear panel access door or go
on to Section 3-9B.

Tools Needed:

3/8, 1/2 in
ssb5.1* 2/92 – Ref. ST-144 569-B

Mark VIII-2 TM-218 Page 11

B. Connecting Input Power

Have only qualified persons make

this installation.

Y Turn Off polyweld system, and disconnect input 1 Line Disconnect Device Of
power before inspecting or installing. Proper Rating
2 Input Conductors
3 Grounding Conductor
Select size and length using Sec-
tion 3-10. Conductor rating must
comply with national, state, and
local electrical codes. Use lugs of
proper amperage capacity and
correct hole size.
8
4 User-Supplied Strain Relief
Connector
Insert conductors through strain
1
relief.
5 Input Terminal Board
6 Line Terminals
7 Polyweld System Ground
9
Terminal
3 Connect grounding conductor to
ground terminal first. Then connect
input conductors to line terminals.
8 Disconnect Device Ground
Terminal
Install and connect grounding
4 conductor and input conductors in
conduit or equivalent to deener-
gized line disconnect device.
Connect grounding conductor first,
then line input conductors.
Be sure grounding conductor goes
to an earth ground.
7 2 6 5 Close rear panel access door.
9 Overcurrent Protection
Select type and size using Section
3-10. Install into deenergized line
disconnect device (fused discon-
nect switch shown).

Tools Needed:

1-1/16 in

3/8 in
ssb2.4* 1/94 – Ref. ST-144 569-B

3-10. Electrical Service Guide

Input Voltage 230 460 575

Input Amperes At Rated Output 170 85 68

Max Recommended Standard Fuse Or Circuit

250 125 100
Breaker Rating In Amperes
Min Input Conductor Size In AWG/Kcmil 1/0 4 6

Max Recommended Input Conductor Length In

163 (50) 307 (94) 320 (97)
Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil 4 6 8

Reference: 1996 National Electrical Code (NEC). S-0092J

TM-218 Page 12 Mark VIII-2

 SECTION 4 – OPERATION

4-1. Controls
1 Remote Amperage Control
Switch
2 Module Circuit Breaker (See
Section 7-2A)
3 Amperage Adjustment
Control
1 2 4 Power Switch
5 Pilot Light

ST-144 570-A

Mark VIII-2 TM-218 Page 13

4-2. Amperage Adjustment Controls
1 Remote Amperage Control
Switch
Control can be adjusted
while welding. For front panel control of a module,
place switch on that module in Off
position.
For remote control, place switch in
On position. See Example below.
1 2 Amperage Adjustment
Control
Use control at each module to
select weld amperage for that
module. The numbers are weld
amperes.
3 Remote Hand Control

Example Of Combination Remote Amperage Control

Min (35 A)
Max (125 A)

Set Switch Set Desired Maximum Amperage Adjust Remote Control

Ref. ST-174 143

4-3. Power Switch Push Buttons And Pilot Light

1 Pilot Light
2 Power On Push Button
Press button to turn unit, pilot light,
and fan motors On.
1 2
3 Power Off Push Button
Press button to turn unit, pilot light,
and fan motors Off.

TM-218 Page 14 Mark VIII-2

Notes

Mark VIII-2 TM-218 Page 15

 SECTION 5 – THEORY OF OPERATION
1 Primary Input Terminal Board
TE1
Provides means to connect Three-Phase
primary input power to unit. Line Input
Power 1 3 4
2 Main Transformer T1 Primary Input
Terminal Fuses Input Terminal
Supplies power to weld output F3, F4 Board TE3
circuit. Board TE1
3 Fuses F3 And F4
W W W
Protect load lines from overload .
4 Input Terminal Board TE3 10
Provides connection for available
Fan Motors
input voltage to control transformer
FM1, FM2
T3.
5 Control Transformer T3 3φ
Supplies power to the 115 volts ac
duplex receptacle RC2, Power 11
pushbuttons PB1 and PB2, and
CR1
control relay CR1. Input Terminal
6 Circuit Breaker CB1 Board TE2

Protects the 115 volt winding of

control transformer T3 from over-
load.
7 115 VAC Duplex Receptacle 2
RC2 Main
Provides a connection point for Transformer
auxiliary equipment to welding T1
power source.
8 Control Relay CR1
When Power On pushbutton PB1
is pressed, contacts of CR1 close
and power is applied to fan motors
FM1 and FM2, and control trans-
former T2.
9 Power On/Off Push Buttons
PB1 And PB2
Provides on/off control of unit, and
fan motors FM1 and FM2.
20 21
10 Fan Motors FM1 And FM2
Magnetic Module
Provide cooling of internal Amplifier Rectifier
components. MA81 SR81
11 Input Terminal Board TE2
Provides connection for available
input voltage to control transformer
T2.
12 Control Transformer T2.
Supplies power to control circuits
of individual modules, pilot light
PL1, and contactor W.
13 Thermostat TP1
Protects the 115 volts ac winding of
control transformer T2 from over- Current Feedback
load.
14 Contactor W
Connects primary line input power
to main transformer T1.

Figure 5-1. Functional Diagram

TM-218 Page 16 Mark VIII-2
 15 Circuit Breaker CB81 And
8 Thermostat TP81
5
Control Protect the 30 volts ac winding of
Relay CR1 control transformer T2 from over-
6 load. This voltage controls the out-
Control
put of the individual module.
Transformer Circuit 9
T3 Breaker CB1 16 Rectifier SR82
Power On
Push Button CR1 Changes the 30 volts ac control cir-
PB1 cuit voltage from control trans-
7 former T2 to full-wave rectified dc.
115 VAC Duplex 17 Amperage Adjustment
Receptacle 9 Control R81
RC2 Power Off Selects weld output amperage
Push Button level.
PB2
18 Remote Amperage Control
Switch S83
12 13 14 Selects On (remote) or Off (panel)
Control amperage control.
115VAC
Transformer Thermostat Contactor W 19 Remote Amperage Control
T2 TP1
Receptacle RC81
30 VAC Connects remote amperage
control to module.
15 20 Magnetic Amplifier MA81
17
Circuit Breaker Controls output current with satu-
CB81 And Amperage ration of its core. Variation of satu-
Thermostat Adjustment ration changes impedance (hin-
TP81 Control drance) of amperage flow thereby
R81 varying weld output. A small dc
control current controls a large
amount of weld output current.

16 18 19 A current feedback signal from the

Negative (–) terminal is provided to
Remote Remote magnetic amplifier MA81 for
Rectifier Amperage Amperage increased weld output.
SR82 Control Control
Switch S83 Receptacle RC81 21 Module Rectifier SR81
Changes the three-phase ac input
from main transformer T1 to full-
wave rectified dc.
22 23
22 Stabilizer Z81
Positive (+)
Stabilizer Smooths out current to Positive (+)
Weld Output
Z81 weld output terminal.
Terminal
23 Positive (+) And Negative (–)
Weld Output Terminals
Provides weld output and allows
changing of output polarity.
Electrode

Work

23
Negative (–)
Weld Output
Terminal

AC Or DC Control Circuits
1 Of 8 Modules
3φ Power

Weld Current Circuit

Mark VIII-2 TM-218 Page 17

 SECTION 6 – TROUBLESHOOTING

6-1. Troubleshooting Table

. See Sections 6-2 for test points and values and

Section 9 for parts location. Use MILLER Testing
Booklet (Part No. 150 853) when testing solid-
state parts.

Trouble Remedy

No weld output from any module; fan Place line disconnect switch in the On position (see Section 3-9B).
motors off; pilot light off.

Be sure Power On Push button PB1 is pressed (see Section 4-3).

Check and replace open line fuse(s) (see Section 3-9B).

Check for proper input connections (see Section 3-9B).

Check for proper jumper link positions (see Section 3-9A).

Check control fuses F3 and F4, and replace if necessary (see Section 7-2B).

Check coil voltage and connections of control relay CR1. Check continuity of coil and condition of con-
tacts. Replace CR1 if necessary (see Section 6-2).

Check control transformers T2 and T3 for signs of winding failure. Check continuity across windings,
and check for proper connections. Check secondary voltages. Replace T2 and/or T3 if necessary (see
Section 6-2).

No weld output from any module; fan Thermostat TP1 open (overheating). Allow fans to run; thermostat TP1 closes when unit has cooled
motors FM1 and FM2 on; pilot light PL1 (see Section 2-3).
off.

No weld output from any module; fan Check coil voltage and connections of contactor W. Check continuity of coil and condition of contacts.
motors FM1 and FM2 on; pilot light PL1 Replace W if necessary. (see Section 6-2).
on.

Check main transformer T1 for signs of winding failure. Check continuity across windings, and check
for proper connections. Check secondary voltages. Replace T1 if necessary. (see Section 6-2).

Prior to Serial No. JB491735, FMS1 and FMS2 are internal parts of fan motors FM1 and FM2. If problem
is isolated to FMS1 and/or FMS2, replace FM1 and/or FM2.

Limited output and low open-circuit Check incoming power for correct voltage. Replace line fuse if open, or reset circuit breaker. (see Sec-
voltage from all modules. tion 3-9B).

Check position of input voltage jumper links (see Section 3-9A).

No weld output from one module only. Check module fuse links, and replace if necessary (see Section 7-2C).

Check continuity across CF winding. Check voltage across winding (see Section 6-2).

Check main transformer T1 for signs of winding failure. Check continuity across windings, and check
for proper connections. Check secondary voltages. Replace T1 if necessary (see Section 6-2).

Low weld output from one module only. Place Remote Amperage control switch in Off position or connect remote amperage control to Remote
No amperage control. Amperage Control receptacle. (see Section 4-2).

Check module fuse links, and replace if necessary (see Section 7-2C).

Check module circuit breaker, and reset if necessary (see Section 7-2A).

Module thermostat open (overheating). Allow module to cool down; thermostat closes when module
has cooled (see Section 7-2D).

Check module Amperage Adjustment control, and replace if necessary (see Section 6-2).

Check module rectifier, and replace if necessary (see Section 6-2).

Check module stabilizer for signs of failure. Check continuity across windings, and check for proper
connections. Replace if necessary (see Section 6-2).

TM-218 Page 18 Mark VIII-2

 Trouble Remedy

Check module control windings CWA and CWD for signs of failure. Check continuity across windings,
and check for proper connections. Check phase-to-phase voltages. Replace CWA and/or CWD if nec-
essary (see Section 6-2).

Erratic weld output. Tighten all weld cable connections (see Section 3-3).

Check for proper size and type of weld cable (see Section 3-4).

Check for proper input and output connections (see Section 3-9B and 3-3).

Use dry, properly stored electrodes.

No output at 115 volts ac duplex Check circuit breaker CB1, and reset if necessary (see Section 7-2A).
receptacle RC2.

Check control fuses F3 and F4, and replace if necessary (see Section 7-2B).

Fan motor(s) FM1/FM2 does not run Check control fuses F3 and F4, and replace if necessary (see Section 7-2B).
when Power On button PB1 is pressed.

Check coil voltage and connections of control relay CR1. Check continuity of coil and condition of con-
tacts. Replace CR1 if necessary (see Section 6-2).

Check coil voltage and connections of fan motors FM1 and/or FM2, and replace if necessary (see Sec-
tion 6-2).

For GTAW, wandering arc – poor con- Select proper size tungsten.
trol of direction of arc.

Properly prepare tungsten.

Tungsten electrode oxidizing and not Shield weld zone of drafts.

remaining bright after conclusion of
weld.

Properly prepare tungsten.

Replace torch parts if water has leaked into torch.

Mark VIII-2 TM-218 Page 19

6-2. Troubleshooting Circuit Diagram For Welding Power Source

Test Equipment Needed:

TM-218 Page 20 Mark VIII-2

 Voltage Readings
a) Tolerance – ±10% b) Reference – to circuit
unless specified common (lead 14) Resistance Values
unless noted
a) Tolerance – ±10% unless specified
V1 115 volts ac V7, V8,
V9 60 volts ac b) Turn Off unit and disconnect input
V2 230 volts ac power before checking resistance
V10 24 volts dc
V3 120 volts ac R1 All values for T1 are less than 1 ohm
V11 0 to 21.5 volts dc from
V4 115 volts ac min to max of R81 R2 All values for T2 are less than 1 ohm
V5 115 volts ac V12 61 volts ac R3 Less than 1 ohm
V6 30 volts ac V13 81 volts dc
Amperage Readings

Values are shown for one module. Values for other modules are the same. a) Tolerance – ±5% unless specified
I1 0 to 4.6 amperes dc from min to max of R81

V4
V2

V3

V1 R1 V5
Control V6
Relay CR1 V7 V8 V9

Contactor W

R2

V10

V11

I1
V12

R3

See Section 6-3

V13, for waveforms
A, B A, B
SD-082 527-B

Mark VIII-2 TM-218 Page 21

6-3. Waveforms For Section 6-2
10 ms 20 V 10 ms 5 V

gnd
gnd

A. DC Open-Circuit Voltage B. 25 Volts DC, 145 Amperes (Resistive Load)

Test Equipment Needed:

TM-218 Page 22 Mark VIII-2

6-4. Input Voltage Labels and Connection Diagrams

1 Input Voltage Label And

Connection Diagram
2 Input Terminal Board TE1

Test Equipment Needed:

Ref. ST-144 569-B / SA-048 548 / Scan

TM-218 Page 23 Mark VIII-2

 SECTION 7 – MAINTENANCE

7-1. Routine Maintenance

Y Turn Off polyweld system, and disconnect input power

before inspecting, maintaining, or servicing.

3 Months 6 Months
Clean
And Blow Out
Tighten OR Or
See
Weld Vacuum
Section
Terminals Inside
3-5

Tape Or During Heavy Service,

Replace –– Clean Monthly
Cracked
Cables Fan
–– Motor
Sealed
Bearings
Replace – No Oil
Unreadable Needed
Labels ––
9
ST-144 567-A

7-2. Overload Protection

A. Overload Circuit Breaker CB1 And Module Circuit Breakers CB11 Through CB81

Y Turn Off polyweld system, and dis- 1 Overload Circuit Breaker CB1
connect input power before in-
Circuit breaker CB1 protects the
specting, maintaining, or servicing.
115 volts ac windings of control
transformer T3 from overload. If
CB1 opens, the 115 volts ac duplex
receptacle RC2 would not work.
2 Manually reset CB1.
2 Module Circuit Breakers
CB11 Through CB81
The control circuitry in each of the
eight modules is protected from
overload by a circuit breaker CBX1
(“X” represents the number of the
applicable module, 1–8). If a mod-
ule circuit breaker opens, output
from the affected module would
drop to minimum and can not be
regulated. Manually reset the af-
fected breaker.

115V AC
115V AC
OVERLOAD
10A BREAKER
CLOSED

OPEN

1 ST-144 570-A / Ref. ST-174 143 / Ref. SC-085 382

Mark VIII-2 TM-218 Page 24

B. Control Fuses F3 And F4

Turn Off polyweld system and

Y Turn Off polyweld system, and dis- disconnect input power.
connect input power before in-
specting, maintaining, or servicing. 1 Input Terminal Board
2 Fuses F3 And F4 Location
3 Fuse F3 Or F4 (See Parts
List For Rating)
4 Fuse Holder
Check F3 or F4, and replace if
needed. Use proper tool when
removing fuse.
4
Close rear access door.

3
Tools Needed:

3/8 in
1 2
Ref. ST-144 569-B / Ref. ST-146 126-C

C. Module Fuse Links F11 And F12 Through F81 And F82

Y Turn Off polyweld system, and discon- Turn Off polyweld system and
nect input power before inspecting, disconnect input power.
maintaining, or servicing. 1 Fuse Links (Odd Number
Modules)
2 Fuse Links (Even Number
Modules)
Each of the eight modules is pro-
tected from overload by a pair of
link-type fuses FX1 and FX2 (“X”
represents the number of the appli-
cable module, 1–8). If one fuse link
1 for a module opens, low weld
output is available at the applicable
module. If both fuse links open, no
weld output is available at the
affected module.
To replace fuse(s), proceed as
follows: Remove upper rear panel.
Check fuse(s), and replace if nec-
2 essary. Reinstall upper rear panel.

Tools Needed:

3/8, 1/2 in
ST-800 479 / ST-155 300

7-3. Blank Module Panel

Y Turn Off polyweld system, and disconnect input power

before inspecting, maintaining, or servicing.

A blank module panel is included with each polyweld system. If a module is removed, install the blank module panel in
the location where the module was removed before using the remaining modules. This panel prevents the touching of
inside parts and wires, and ensures proper air flow through the polyweld system.
TM-218 Page 25 Mark VIII-2
 SECTION 8 – ELECTRICAL DIAGRAMS

. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.

Model Serial Or Style Number Circuit Diagram

Mark VIII-2 N315929 thru P355220 C-565-B01♦♦

P355221 thru S425069 CC-900 801-1♦♦

S425070 thru HE749989 CC-900 801-1B♦♦

HE749990 thru HG021346 SN-900-801-1C

HG021347 thru HG068089 SN-900-801-1D

HG068090 thru HH072756 SN-900-801-1E

HH072757 thru HH098613 SN-900-801-1F

HH098614 thru HJ176531 SN-900-801-1G

HJ176532 thru JA419869 SN-900-801-1H

JA419870 thru JB491734 SN-044 479

JB491735 and following SD-082 527-B

♦♦ Not included in this manual

Mark VIII-2 TM-218 Page 26

 SN-900 801-1C

Figure 8-1. Circuit Diagram For Mark VIII-2 Effective With Serial No. HE749990 Thru HG021346
TM-218 Page 27 Mark VIII-2
 SN-900 801-1D
Figure 8-2. Circuit Diagram For Mark VIII-2 Effective With Serial No. HG021347 Thru HG068089
Mark VIII-2 TM-218 Page 28
 SN-900 801-1E

Figure 8-3. Circuit Diagram For Mark VIII-2 Effective With Serial No. HG068090 thru HH072756
TM-218 Page 29 Mark VIII-2
 SN-900 801-1F
Figure 8-4. Circuit Diagram For Mark VIII-2 Effective With Serial No. HH072757 Thru HH098613
Mark VIII-2 TM-218 Page 30
 SN-900 801-1G
Figure 8-5. Circuit Diagram For Mark VIII-2 Effective With Serial No. HH098614 Thru HJ176531
TM-218 Page 31 Mark VIII-2
 SN-900 801-1H
Figure 8-6. Circuit Diagram For Mark VIII-2 Effective With Serial No. HJ176532 Thru JA419869
Mark VIII-2 TM-218 Page 32
 SN-044 479
Figure 8-7. Circuit Diagram For Mark VIII-2 Effective With Serial No. JA419870 Thru JB491734
TM-218 Page 33 Mark VIII-2
 Figure 8-8. Circuit Diagram For Mark VIII-2 Effective With Serial No. JB491735 And Following
Mark VIII-2 TM-218 Page 34
 SD-082 527-B

TM-218 Page 35 Mark VIII-2

Notes

Mark VIII-2 TM-218 Page 36

 TM-218B May 1999
Eff. w/ Serial Number N315929

Processes
TIG (GTAW) Welding

Stick (SMAW) Welding

Air Carbon Arc (CAC-A) Cut-

ting and Gouging

With Optional Equipment:

MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Plasma Cutting
and Gouging

Description

Arc Welding Power Source

MARK VIII-2

Visit our website at

www.Miller-
Welds.com
 SECTION 9 – PARTS LIST

18
17
16
14

15
Fig 9-4

13

6
11

12

5
10

8
20

19
21
9

Fig 9-5
8

22
7
6
5
2

4
1

Fig 9-3
24

23

ST-144 531

Figure 9-1. Main Assembly (Section A)

Mark VIII–2 TM-218 Page 38
 Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 9-1. Main Assembly

. . . 1 . . . . FM1,2 . . . . 032 633 . . . MOTOR, SP 1/4 HP 230VAC (Prior to JB491735) (consisting of) . . . . . . . 2
. . . . . . . . FMS1,2 . . . 011 850 . . . . . SWITCH, centrifugal (Prior to JB491735) (GE motor) or . . . . . . . . . . . . . 1
. . . . . . . . FMS1,2 . . . 052 613 . . . . . SWITCH, starting (Prior to JB491735) (Emerson motor) . . . . . . . . . . . . . 1
. . . 1 . . . . FM1,2 . . . . 032 605 . . . MOTOR, cap perm SP 1/4hp 230VAC 1625RPM (Eff w/JB491735) . . . . . 2
. . . 2 . . . . . . . . . . . . . . . 071 763 . . . FRAME, mtg fan motor (Eff w/P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 016 438 . . . BAR, mtg frame fan motor (Eff w/P356194 thru JC614324) . . . . . . . . . . . . 4
. . . 3 . . . . . . . . . . . . . . . 014 192 . . . WINDTUNNEL, (Prior to P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . . 014 544 . . . CHAMBER, plenum (Eff w/P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . . 032 616 . . . BLADE, fan 60 Hz 20 in 3wg 21 deg (Prior to JC615729) . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . . 147 558 . . . BLADE, fan 20 in 3wg 21deg .500 bore CCW (Eff w/JC615729) . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . . 014 984 . . . PANEL, side LH (Prior to P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 014 549 . . . PANEL, side LH (Eff w/P356194 thru S423867) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 016 590 . . . PANEL, side LH (Eff w/S423868 thru JC614324) . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 014 983 . . . PANEL, side RH (Prior to P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 014 550 . . . PANEL, side RH (Eff w/P356194 thru S423867) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 016 592 . . . PANEL, side RH (Eff w/S423868 thru JC614324) . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 016 590 . . . PANEL, side (Eff w/JC614325 thru JF922252) . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . . 087 125 . . . PANEL, side (Eff w/JF922253 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . 014 982 . . . PANEL, front (incl 2 front columns) (Prior to P356194) . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 014 559 . . . COLUMN, LH front (Eff w/P356194 thru JC614324) . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 014 558 . . . COLUMN, RH front (Eff w/P356194 thru JC614324) . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 086 677 . . . COLUMN, corner LH front & RH rear (Eff w/JC614325 and on) . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . 014 189 . . . BASE, (Prior to P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 015 137 . . . BASE, (Eff w/P356194 thru HE752728) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 045 990 . . . BASE, (Eff w/HE752729 thru KB095984) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 144 583 . . . BASE, (Eff w/KB095985 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 014 988 . . . COLUMN, LH & RH rear (Prior to P356194) . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . 014 557 . . . COLUMN, LH rear (Eff w/P356194 thru JC614324) . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 014 555 . . . COLUMN, RH rear (Eff w/P356194 thru JC614324) . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 086 678 . . . COLUMN, corner RH front & LH rear (Eff w/JC614325 and on) . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 601 828 . . . BOLT, eye .875 x 2.250 (Prior to HE752729) . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . . . . . . . . . . . . 032 473 . . . GASKET, lift eye (Eff w/HE752729) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . SR12 . . . . 037 601 . . . RECTIFIER, selenium control (Prior to HH098614) . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . SR12 . . +035 704 . . . RECTIFIER, integ 40A 800V (Eff w/HH098614) . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . C18 . . . . . 003 886 . . . CAPACITOR, cer .01uf 500VDC (Eff w/HJ176532 thru JA419869) . . . . . . 8
. . 10 . . . . . . . . . . . . . . 014 989 . . . COVER, top (Prior to P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 014 188 . . . COVER, top (Eff w/P356194 thru HE752728) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 032 474 . . . COVER, top (Eff w/HE752729 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . MA,Z . . . . 084 934 . . . STABILIZER & AMPLIFIER, (Prior to JF881291) (consisting of) . . . . . . . . 8
. . 11 . . MA,Z,TP . . . 099 480 . . . STABILIZER & AMPLIFIER, (Eff w/JF881291) (consisting of) . . . . . . . . . . 8
. . 12 . . . . . . . . . . . . . . 084 932 . . . . . STABILIZER, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . TP11 . . . . 162 375 . . . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 033 946 . . . . . COIL, ac (Prior to JF881291) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 097 947 . . . . . COIL, ac front (Eff w/JF881291) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 097 948 . . . . . COIL, ac center (Eff w/JF881291) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 097 949 . . . . . COIL, ac rear (Eff w/JF881291) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 033 947 . . . . . COIL, cont dc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . TP11 . . . . 012 605 . . . THERMOSTAT, NC (Prior to P355221) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . TP11-13 . . . 604 180 . . . THERMOSTAT, NC (Eff w/P355221 thru S425069) . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . 030 898 . . . PROTECTOR, current surge (Eff w/P355221 thru S425069) . . . . . . . . . . . 24
. . 13 . . . SR11 . . . . 044 288 . . . RECTIFIER, si diode (Prior to JF883937) (Fig 9-4) . . . . . . . . . . . . . . . . . . . 8
. . 13 . . . SR11 . . . . 087 347 . . . RECTIFIER, si diode (Eff w/JF883937) (Fig 9-4) . . . . . . . . . . . . . . . . . . . . . 8
. . 14 . . . . . . . . . . . . . . 014 986 . . . PANEL, rear RH upper (Prior to P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 014 560 . . . PANEL, rear RH upper (Eff w/P356194 thru U476553) . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 014 987 . . . PANEL, rear LH upper (Prior to P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 014 561 . . . PANEL, rear LH upper (Eff w/P356194 thru U476553) . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . . . . . 018 983 . . . PANEL, rear LH & RH upper (Eff w/U476554 thru JC614324) . . . . . . . . . . 2
. . 14 . . . . . . . . . . . . . . 086 679 . . . PANEL, rear upper (Eff w/JC614325 and on) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 15 . . . . . . . . . . . . . . 014 985 . . . PANEL, rear lower (Prior to P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TM-218 Page 39 Mark VIII–2
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-1. Main Assembly (Section A) (Continued)

. . 15 . . . . . . . . . . . . . . 014 452 . . . PANEL, rear lower (Eff w/P356194 thru U476553) . . . . . . . . . . . . . . . . . . . . 1

. . 15 . . . . . . . . . . . . . . 018 985 . . . PANEL, rear lower (Eff w/U476554 thru JC614324) . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 087 178 . . . PANEL, rear lower (Eff w/JC614325 and on) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . 102 207 . . . PLATE, adapter power cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . 038 132 . . . LOOM, wire (Eff w/P356194 thru KE559651) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 020 279 . . . CLAMP, stl cush .750dia x .281mtg hole (Eff w/KE559651) . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . 087 318 . . . CLAMP, stl cush 1.000dia x .203mtg hole (Eff w/KE559651) . . . . . . . . . . . 6
. . 18 . . . . . . . . . . . . . . 015 088 . . . FRAME, mtg center module (Eff w/P356194 thru HG082139) . . . . . . . . . . 2
. . 18 . . . . . . . . . . . . . . 006 995 . . . FRAME, mtg center module (Eff w/HG082140 thru JF922252) . . . . . . . . . 2
. . 18 . . . . . . . . . . . . . . 087 124 . . . FRAME, mtg center module (Eff w/JF922253 and on) . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 010 971 . . . SPACER, mtg transformer (Prior to JC614325) . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . ++033 151 . . . COIL, pri sec top (Prior to HG068090) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . ++007 933 . . . COIL, pri sec top (Eff w/HG068090 thru HK282696) . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . ++048 492 . . . COIL, pri sec top (Eff w/HK282697 thru JD715080) . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . ++033 945 . . . COIL, pri sec bottom (Prior to HG068090) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . ++007 932 . . . COIL, pri sec bottom (Eff w/HG068090 thru HK282696) . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . ++048 491 . . . COIL, pri sec bottom (Eff w/HK282697 thru JD715080) . . . . . . . . . . . . . . . 3
. . 19 . . . . . T1 . . . . . . 128 490 . . . TRANSFORMER, pwr main (230/460) (Eff w/JD715081) (consisting of) . 1
. . 20 . . . . . . . . . . . . . . 088 705 . . . . . COIL, pri sec top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 21 . . . . . . . . . . . . . . 088 704 . . . . . COIL, pri sec bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 19 . . . . . T1 . . . . . . 128 491 . . . TRANSFORMER, pwr main (208/230/480) (Eff w/JD715081)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . . . 088 709 . . . . . COIL, pri sec top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 21 . . . . . . . . . . . . . . 088 708 . . . . . COIL, pri sec bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 19 . . . . . T1 . . . . . . 128 492 . . . TRANSFORMER, pwr main (230/460/575) (Eff w/JD715081)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . . . 088 713 . . . . . COIL, pri sec top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 21 . . . . . . . . . . . . . . 088 712 . . . . . COIL, pri sec bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . TP1 . . . . . 026 181 . . . THERMOSTAT, NC (incl with TI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . T1 . . . . . . 128 494 . . . TRANSFORMER, pwr main (208/380/415) (consisting of) . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . . . 088 724 . . . . . COIL, pri/sec top (208/380/415) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 21 . . . . . . . . . . . . . . 088 723 . . . . . COIL, pri/sec bottom (208/380/415) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . TP1 . . . . . 026 181 . . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . T1 . . . . . . 128 493 . . . TRANSFORMER, pwr main (220/380/440) (consisting of) . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . . . 088 717 . . . . . COIL, pri/sec top (220/380/440) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 21 . . . . . . . . . . . . . . 088 716 . . . . . COIL, pri/sec bottom (220/380/440) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . TP1 . . . . . 026 181 . . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 103 723 . . . SHIM, mtg transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 22 . . . . . . . . . . . . . . . Fig 9-5 . . . PANEL, front lower w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 086 435 . . . PANEL BLANK, module front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 603 732 . . . NUT, brs hex .750-10 full hvy (grd stud) (Eff w/JJ520016) . . . . . . . . . . . . . 2
. . 23 . . . . . . . . . . . . . . . Fig 9-3 . . . PANEL, front module w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . 086 435 . . . PANEL BLANK, module front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . . . 014 541 . . . SCREEN, intake air (Prior to P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . . . 173 513 . . . SCREEN, front upper (Eff w/S432868) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+Effective with JF881290, this rectifier was relocated to the front panel.
++Prior to JD7115081, order these coils as replacements; be sure to provide the voltage of the unit. When a replace-
ment transformer is required, order according to the transformer listed below. These coils and replacement
transformer coils are not interchangeable.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Mark VIII–2 TM-218 Page 40

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

Figure 9-2. Main Assembly (Section B)

. . . 1 . . . . . CR1 . . . . . 035 732 . . . CONTACTOR, (Prior to HE752722) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 1 . . . . . CR1 . . . . . 605 855 . . . CONTACTOR, def prp 40A 3P 120V (Eff w/HE752722) . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . T3 . . . . . . 030 195 . . . TRANSFORMER, kVA 1 115V (Prior to HG082140) . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . T3 . . . . . . 008 645 . . . TRANSFORMER, kVA 1 115V (Eff w/HG082140 thru JD715080) . . . . . . . 1
. . . 2 . . . . . . T3 . . . . . . 092 326 . . . TRANSFORMER, kVA 1 115-230/460 (Eff w/JD715081 and on) . . . . . . . . 1
. . . 2 . . . . . . T3 . . . . . . 092 320 . . . TRANSFORMER, kVA 1 115-208/230/460 (Eff w/JD715081 and on) . . . . 1
. . . 2 . . . . . . T3 . . . . . . 092 324 . . . TRANSFORMER, kVA 1 115-230/460/575 (Eff w/JD715081 and on) . . . . 1
. . . 2 . . . . . . T3 . . . . . . 092 318 . . . TRANSFORMER, kVA 1 115-208/380/415 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . T3 . . . . . . 092 322 . . . TRANSFORMER, kVA 1 115-220/380/440 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . 1T . . . . . . 038 617 . . . BLOCK, term 30A 2P (Eff w/S423120) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 038 620 . . . LINK, jumper term blk 30A (Eff w/S423120) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 070 404 . . . HOLDER, fuse crtg 30A 600V 1P w/clips (Eff w/P355221) . . . . . . . . . . . . . 2
. . . 5 . . . . . F3,4 . . . . *012 664 . . . FUSE, crtg 15A 600V (Eff w/P355221) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . . 010 117 . . . TUBING, stl .625 OD x .156 wall x 2.625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 7 . . . . . TE1 . . . . . 038 802 . . . TERMINAL ASSEMBLY, pri 3ph dual voltage (Prior to P356194) (Fig 9-7) 1
. . . 7 . . . . . TE1 . . . . . 038 148 . . . TERMINAL ASSEMBLY, pri 3ph dual voltage (Eff w/P356194) (Fig 9-7) . 1
. . . 7 . . . . . TE1 . . . . . 027 096 . . . TERMINAL ASSEMBLY, pri 3ph triple voltage (Eff w/P356194) (Fig 9-7) 1
. . . . . . . . . . . . . . . . . . . . 012 602 . . . HOLDER, fuse (Prior to P355221) (located on base) . . . . . . . . . . . . . . . . . 9
. . . . . . . . F2,11-18 . . *012 601 . . . FUSE, plug 10A 250V (Prior to P355221) (located on base) . . . . . . . . . . . 9

1 2 4 5

3
6 7 Fig 9-7

8 Fig 9-6

9
10

ST-144 660

Figure 9-2. Main Assembly (Section B)

TM-218 Page 41 Mark VIII–2
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-2. Main Assembly (Section B) (Continued)

. . . 8 . . . . F11-82 . . . . 012 237 . . . FUSE PANEL, module (Eff w/S423120 and on (Fig 9-6) . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 177 711 . . . INSULATOR, cover fuse (Eff w/KG045632) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 016 588 . . . BRACKET, mtg fuse & terminal block (Eff w/S423120 thru HH072757) . . 1
. . . . . . . . . . . . . . . . . . . . 012 602 . . . HOLDER, fuse plug (Eff w/S423120 thru HH072757) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F2 . . . . . *012 601 . . . FUSE, plug 10A 250V (Eff w/S423120 thru HH072757) . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . W . . . . . . 034 655 . . . CONTACTOR, (Prior to S422601) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . W . . . . . . 034 658 . . . CONTACTOR, (Eff w/S422601 thru JD668483) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . W . . . . . . 048 597 . . . CONTACTOR, (Eff w/JD668484 thru JF885506) . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . W . . . . . . 099 044 . . . CONTACTOR, sz 3-1/2 3P 110-120/220-240
(Eff w/JF885507 and on) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 048 599 . . . . . COIL, cntor 115/230V sz 3-1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . T2 . . . . . . 036 862 . . . TRANSFORMER, kVA 2 115 (Prior to JD715081) . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . T2 . . . . . . 036 862 . . . TRANSFORMER, kVA 2 115-230/460 (Eff w/JD715081 thru KB095984) 1
. . 10 . . . . . T2 . . . . . . 144 587 . . . TRANSFORMER, kVA 2 115-230/460 (Eff w/KB095985 and on) . . . . . . . 1
. . 10 . . . . . T2 . . . . . . 092 321 . . . TRANSFORMER, kVA 2 115-208/230/460
(Eff w/JD715081 thru KB095984) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . T2 . . . . . . 144 588 . . . TRANSFORMER, kVA 115-208/230/460 (Eff w/KB095985 and on) . . . . . 1
. . 10 . . . . . T2 . . . . . . 092 325 . . . TRANSFORMER, kVA 2 115-230/460/575
(Eff w/JD715081 thru KB095984) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . T2 . . . . . . 144 589 . . . TRANSFORMER, kVA 115-230/460/575) (Eff w/KB095985 and on) . . . . 1
. . 10 . . . . . T2 . . . . . . 144 595 . . . TRANSFORMER, kVA 2 115-208/230/380/415 . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . T2 . . . . . . 144 590 . . . TRANSFORMER, kVA 2 115-220/230/380/440-30 . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 015 722 . . . GROMMET, rbr 1.250 ID x 1.500mtg hole (Eff w/P356194) . . . . . . . . . . . . 2

*Recommended Spare Parts

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

Mark VIII–2 TM-218 Page 42

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

Figure 9-3. Panel, Front Module w/Components (Fig 9-1 Item 23)

. . . 1 . . . . . . . . . . . . . . . 014 990 . . . COVER, terminal sec (Prior to S409113) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 1 . . . . . . . . . . . . . . . 034 253 . . . DOOR, access w/components (Eff w/S409113) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 038 813 . . . BAR, jumper (Prior to P355221) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 038 978 . . . LINK, jumper (Eff w/P355221) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 026 758 . . . BOOT, circuit breaker (Eff w/S425070) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 174 143 . . . PLATE, front module (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 177 618 . . . PLATE, front module (50/60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 013 848 . . . PANEL, indicator module (Prior to P355221) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 084 450 . . . PANEL, front module (Eff w/P355221 thru JF881289) . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 098 899 . . . PANEL, front module (Eff w/JF881290) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . SR12 . ++035 704 . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . S13 . . . . *011 609 . . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 039 047 . . . TERMINAL, pwr output red (Eff w/P355221) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 099 255 . . . TERMINAL, pwr output neutral (Eff w/P355221) . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 039 046 . . . TERMINAL, pwr output black (Eff w/P355221) . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . CB11 . . . *083 432 . . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . R11 . . . . . 030 653 . . . RHEOSTAT, WW 150W 15 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . RC11 . . . . 039 607 . . . RECEPTACLE, twlk 3P3W 20A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 605 797 . . . PLUG, twlk 3P3W 20A 120V Arrow Hart 6312
. . 14 . . . . . . . . . . . . . . 010 828 . . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 097 926 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 038 807 . . . COVER, remote control receptacle (Prior to P355221) . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 016 302 . . . COVER, remote control receptacle (Eff w/P355221) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 010 165 . . . HINGE, cover (Eff w/P355221) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 8
9
6 10

5
11

1 2 3
12

13

15

14

ST-155 304-C

Figure 9-3. Panel, Front Module w/Components

++Prior to Serial No. JF881290 this rectifier was located on amplifier.

*Recommended Spare Parts
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-218 Page 43 Mark VIII–2
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-4. Rectifier, Si Diode (Fig 9-1 Item 13) 044 288 044 288

. . . . . . . . . . . C17 . . . . . 031 683 .. CAPACITOR, paper oil .5uf 200VDC (Prior to JA419870) . . . . 1
. . . 1 . . . . VS11 . . . . . 024 471 .. SUPPRESSOR, 1uf 2.7 ohm (Prior to JA419870) . . . . . . . . . . . 1
. . . 1 . . R12,VR11 . . 044 482 .. SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . R12 . . . . . 030 459 .. RESISTOR, C 2W 3900 ohm (Prior to JA419870) . . . . . . . . . . . 1
... 2 ............... 037 306 .. DIODE, rect 150A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . 3
... 3 ............... 037 305 .. DIODE, rect 150A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . 3
. . . 4 . . . C11-16 . . . . 031 689 .. CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . 6

1 2

4 3

ST-044 773-A

Figure 9-4. Rectifier, Si Diode

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

Mark VIII–2 TM-218 Page 44

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

Figure 9-5. Panel, Front Lower w/Components (Fig 9-1 Item 22)

. . . 1 . . . . . . . . . . . . . +014 562 . . . PANEL, front lower (Prior to P356194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 1 . . . . . . . . . . . . . +018 987 . . . PANEL, front lower (Eff w/P356194 thru JC614324) . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . +086 855 . . . PANEL, front lower (Eff w/JC614325 and on) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 134 327 . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 085 500 . . . LABEL, general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 004 449 . . . RING, spacer switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . . 027 622 . . . LIGHT, ind red lens (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . PL1 . . . . *027 633 . . . . . BULB, incand bayonet base 8V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 027 650 . . . . . LENS, light ind red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . Start . . . . . 011 853 . . . SWITCH, push button 6A 125V red (Prior to S425070) . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . Start . . . . . 011 033 . . . PUSH BUTTON, operator black (Eff w/S425070) . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . Start . . . . . 011 035 . . . CONTACT BLOCK, NO PB (Eff w/S425070) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . Stop . . . . . 011 852 . . . SWITCH, push button 6A 125V black (Prior to S425070) . . . . . . . . . . . . . . 1
. . 10 . . . . Stop . . . . . 011 036 . . . CONTACT BLOCK, NC PB (Eff w/S425070) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . Stop . . . . . 011 034 . . . PUSH BUTTON, operator red (Eff w/S425070) . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . . . . . . . . . . 016 585 . . . COVER, dust (Eff w/S425070) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . RC2 . . . . . 604 176 . . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 073 690 . . . PLUG, str grd armd 2P3W 15A 125V P & S 5266DF
. . 14 . . . . CB1 . . . . . 083 432 . . . CIRCUIT BREAKER, man reset 1P 10A 250V (Eff w/HH072757) . . . . . . . 1
. . 15 . . . . . . . . . . . . . . 026 758 . . . BOOT, circuit breaker (Eff w/HH072757) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . . . . . 038 805 . . . COVER, rcpt weatherproof duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . . . . . . . . . . . 004 450 . . . BOOT, PB red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . . . . . . . . . . . . . 004 451 . . . BOOT, PB black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . 1

5
2
6 Includes
3 Item 7

4
8
9
10
11 12

13

14

7
18
17 15
19
16
ST-155 303

Figure 9-5. Panel, Front Lower w/Components

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-218 Page 45 Mark VIII–2
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-6. Fuse Panel, Module (Fig 9-2 Item 8) 012 237

... 1 . . . . . . . . . . . . . . . 038 888 .. STUD, pri bd brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

... 2 . . . . . . . . . . . . . . . 038 205 .. PANEL, fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . . 010 915 .. WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . . 10
... 4 . . . . . . . . . . . . . . . 601 836 .. NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
... 5 . . . . . . . . . . . . . . *012 207 .. FUSE, link 200A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 6 . . . . . . . . . . . . . . . 602 241 .. WASHER, flat stl SAE .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 7 . . . . . . . . . . . . . . . 602 207 .. WASHER, lock stl split .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 8 . . . . . . . . . . . . . . . 601 835 .. NUT, brs hex 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 9 . . . . . . . . . . . . . . . 010 913 .. WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . 4
... 10 . . . . . . . . . . . . . . . 038 887 .. STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7
6
5
4
2 3

8
9

10

ST-155 301

Figure 9-6. Fuse Panel, Module

*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Mark VIII–2 TM-218 Page 46

 Item Part
No. No. Description Quantity

Figure 9-7. Terminal Assembly, Pri 3ph (Fig 9-2 Item 7) 038 802 038 148 027 096

...1 ......... 038 669 .. TERMINAL BOARD, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

...1 ......... 038 974 .. TERMINAL BOARD, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
...2 ......... 601 836 .. NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . . 24 . . . . . 30
.............. 602 207 .. WASHER, lock stl split .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
...3 ......... 010 915 .. WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . 24 . . . . 12 . . . . . 18
...4 ......... 038 890 .. STUD, pri bd brs .250-20 x 2.125 . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . 12 . . . . . 18
...5 ......... 038 652 .. LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
...5 ......... 038 994 .. LINK, jumper pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . 6
...6 ......... 038 620 .. LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . 2 . . . . . 2
...7 ......... 038 602 .. BLOCK, term 30A 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . 2
...7 ......... 038 622 .. BLOCK, term 30A 5P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
...8 ......... 601 838 .. NUT, brs hex .375-16 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . 9 . . . . . 9
...9 ......... 010 910 .. WASHER, flat stl SAE .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . 3 . . . . . 3
. . 10 . . . . . . . . 602 213 .. WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . 3 . . . . . 3
. . 11 . . . . . . . . 038 804 .. STUD, brs .375-16 x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . 3 . . . . . 3
. . 12 . . . . . . . . 010 913 .. WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4

1
5

4
2
3

12

9
10
11
ST-155 302

Figure 9-7. Terminal Assembly, Pri 3ph

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

TM-218 Page 47 Mark VIII–2

Notes
Notes
 Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066

PRINTED IN USA  1999 Miller Electric Mfg. Co.