Miller: 0 Technical Manual
Miller: 0 Technical Manual
Miller: 0 Technical Manual
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
0
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TECHNICAL MANUAL
OM-221X - 2191
TABLE OF CONTENTS
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
1-1. GENERAL INFORMATION AND SAFETY • Shut down unit and disconnect input power
This manual provides theory of operation along with when servicing unless the procedure specifi-
specific operating, testing, and troubleshooting proce- cally requires an energized unit.
dures. It also includes precautionary information rele- • Do not leave live unit unattended.
vant to these procedures. This manual can be an effec- ARC RAYS, SPARKS, AND HOT SURFACES
tive tool in the hands of a trained serviceperson. How- can burn eyes and skin; NOISE can damage
ever, it does not and cannot take the place of previous hearing.
training nor safety-conscious service work. If any doubt • Wear correct eye, ear, and body protection.
arises about the specific application of procedures pre-
sented, or if problems arise which are not covered in this FUMES AND GASES can seriously harm
manual, contact the factory Service Department before your health.
proceeding further. • Keep your head out of the fumes.
• Ventilate to keep from breathing fumes and
1-2. SAFETY ALERT SYMBOL AND SIGNAL gases.
WORDS
• If ventilation is inadequate, use approved
The following safety alert symbol and signal words are breathing device.
used throughoutthis manual to call attention to and iden- • Read Material Safety Data Sheets (MSDSs)
tify different levels of hazard and special instructions. and manufacturer’s instructions for any
This safety alert symbol is used with the signal materials used.
A words WARNING and CAUTION to call atten-
tion to the safety statements.
HOT METAL, SPATTER, AND SLAG can
cause fire and burns.
• Watch for fire.
WARNING statements identify procedures or
A practices which must be followed to avoid seri-
ous personal injury or loss of life.
• Have a fire extinguisher nearby and know
how to use it.
• Do not use near flammable material.
CAUTION statements identify procedures or
A practices which must be followed to avoid minor
personal injury or damage to this equipment.
• Allow work and equipment to cool before
handling.
MOVING PARTS can cause serious injury.
IMPORTANT statements identify special instructions • keep away from moving parts.
necessary for the most efficient operation of this equip-
ment. HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
1-3. SAFETY PRECAUTIONS FALLING EQUIPMENT can cause serious
A WARNING: ELECTRIC SHOCK can kill.
touch live electrical parts.
personal injury and equipment damage.
• Use equipment ofadequate capacity to lift the
unit.
• Protect yourself with dry insulating gloves MAGNETIC FIELDS FROM HIGH CURRENTS
and clothing. can affect pacemaker operation.
• Insulate yourself from ground by using • Wearers should consult their doctor before
rubbergloves and insulating floor mats when going near the servicing ofarc welding equip-
power is applied to the unit. ment or any arc welding operations.
SM-221 Page 1
SECTION 2 — SHIPPING AND STORAGE
5M-221 Page 2
SECTION 3— 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)
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
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.
source is rated at 60 percent duty cycle. This means that X DUTY CYCLE
SB-OOO 865-0
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- 3-3. DESCRIPTION
ing. If the welding Amperes are decreased, the duty cy- This unit is a three-phase dc arc welding power source
cle will increase. Chart 3-2 enables the operatorto deter- with solid-state control. It produces dc weld current and
mine the output of the welding power source at various is designed to be used for Shielded Metal Arc Welding
duty cycles. (SMAW). The number in the model designation refers to
CAUTION: EXCEEDING DUTY CYCLE RAT- the rated welding current in Amperes.
A INGS will damage the welding power source.
• Do not exceed indicated duty cycles.
These units have solid-state contactors and a pilot light
to indicate when the POWER switch is energized.
~J REMOTE 14
IMPORTANT: Although the term CONTACTOR isused
A. Weld Cable Selection
Use the following guidelines to select weld cables:
on the nameplate and throughout this manual, the out- 1. Use the shortest possible cables, and place ca-
put is notswitchedon oroffbya physicalsecondary con- bles close together. Excessive cable lengths may
tactor; rather, the output is controlled by a Silicon Con- reduce output or cause unit overload due to
trolled Rectifier (SCR) stack which functions as a con- added resistance.
tactor.
2. Use weld cable with an insulation voltage rating
REMOTE 14 receptacle RC1 is used to connect any of equal to or greater than the maximum open-
the following equipment to the welding power source cir- circuit voltage (ocv) of the welding power source
cuitry: (see Table 3-i for unit maximum ocv rating).
a. Remote Contactor 3. Select welding cable size according to maximum
b. Remote Amperage control weld output and total length of connecting cables
c. Combination of the above. in weld circuit. For example, if a 25 foot (7.5 m)
electrode holder cable is used with a 25 foot (7.5
To make connections, align keyway, insert plug, and ro- m) work cable, select the cable size recom-
tate threaded collar fully clockwise. mended in Table 4-i for 50 feet (15 in).
The following socket information is included in case the 4. Do not use damaged or frayed cables.
supplied cord is not suitable, and it is necessaryto wire a
plug or cord to interface with REMOTE 14 receptacle B. Weld Cable Preparation
RC1. 1. Install correct size lugs of adequate amperage
IMPORTANT: When contact closure is provided be- capacity onto ends of both cables for connecting
tween sockets A and B, the welding power source out- to work clamp, electrode holder, and weld output
put/contactor control circuit is energized. 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
Ref. S—0004
NEGATIVE POSITIVE
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.
A WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down welding powersource, anddiscon-
nect input power employing lockout/tagging
Socket B: Contactor control switch connection. procedures before inspecting or installing.
Socket C: Amperage control connection (maximum Lockout/tagging procedures consist of padlock-
side). ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
Socket D: Amperage control connection (minimum red—tagging circuit breaker or other disconnect-
side). ing device.
5M-221 Page 6
Table 4-1. Weld Cable Size
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.
•1’ I
TO CONTROL TRANSFORMER
CIF APPLICABLE)
1~I00~~ 0
324 1324 1324
FM FM
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)
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
I I /0
T
TO CONTROL TRANSFORMER
(IF APPLICABLE)
123123456123 AU
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
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
5-1. POWER SWITCH (Figure 5-1) 5-5. REMOTE 14 RECEPTACLE AND AMPERAGE
CONTROL SWITCH (Figure 5-1)
Pressing the POWER switch ON push button energizes
the welding power source. Pressing the POWER switch If a Remote Amperage Control is to be used, make con-
OFF push button shuts down the welding powersource. nections from the control to the REMOTE i 4 receptacle
as instructed in Section 4-3.
IMPORTANT: For models with optional fan control,
when the POWER switch ONpush button ispressed, the When remote control of the amperage is desired, the
pilot light comes on, but the fan motor does not run un- AMPERAGE control switch must be placed in the
less the internal componentsare already warm. The fan REMOTE 14 position. Likewise, if a Remote Amperage
motor is thermostatically controlled and only operates Control is not desired, the switch must be in the PANEL
when additional cooling is required (see Section 10-3). position. When in the PANEL position, only the
AMPERAGE ADJUSTMENT control on the front panel
will control the current.
IMPORTANT: After any interruption ofinput power, the
POWER switch ON push button must be depressed to When a Remote Amperage Control is being used, the
reenergize the welding powersource. control is functioning as a fine current adjustment for the
AMPERAGE ADJUSTMENT control setting on the
welding powersource. For example: If the AMPERAGE
5-2. PILOT LIGHT (Figure 5-1) ADJUSTMENT control on the welding power source is
set at the mid—range position, the Remote Amperage
The pilot light comes on whenever the POWER switch is
in the ON position and indicates that the unit is receiving Control will provide (from its mm. to max. positions) fine
amperage adjustment of one half of the welding power
input power.
source output for the current range selected. If full ad-
justment through use of the remote control of the amper-
5-3. RANGE SWITCH (Figure 5-1) age range selected is desire, the AMPERAGE ADJUST-
MENT control on the welding power source must be set
The RANGE switch provides the means of selecting be- at maximum position.
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- 5-6. REMOTE 14 RECEPTACLE AND OUTPUT
JUSTMENT control. When in the HIGH position, ensure (CONTACTOR) CONTROL SWITCH (Figure
that the HIGH current scale is used when adjusting the 5-1)
AMPERAGE ADJUSTMENT control. WARNING: ELECTRIC SHOCK can kill.
5M-221 Page 10
Amperage
Adjustment
control
Arc control
Remote 14
Receptacle
Power Switch
Pilot Light
Negative (—)
weld Output 5B-094 756-C
Terminal
Figure 5-1. Front Panel View
IMPORTANT: Although the term CONTACTOR is used When the control is set at 100 (maximum), amperage in-
on the nameplate and throughout this manual, the out- creases rapidly as the short-circuit condition is ap-
put is notswitched on oroffbyaphysicalsecondary con- proached. This provides extra amperage for arc starting
tactor; rather, the output is controlled by a Silicon Con- in out of position welding as well as for certain types of
trolled Rectifier (SCR) stack which functions as a con- electrodes.
tactor. When the control is set at 0 (zero), amperage increases
in a linear fashion as the short-circuit condition is ap-
The contactor control circuitry in this welding power proached. This provides amperage characteristics as-
source enables the operator to remotely control the sociated with Gas Tungsten Arc Welding (GTAW).
availability of weld output from the work station.
If a Remote Contactor Control is to be used, make con- 5-8. METERS (Optional)
nections to the REMOTE 14 receptacle as instructed in The meters are provided to monitor the welding opera-
Section 4-3. Place the OUTPUT (CONTACTOR) Con- tion and serve as an indication of the welding process.
trol switch in the REMOTE 14 position. Depress the ON They are not intended for exact amperage or voltage
push button on the welding power source. Weld output measurements. The voltmeter is internally connected to
will be available whenever the Remote Contactor Con- the welding powersource output terminals. The voltme-
trol switch is closed. ter will indicate the voltage at the weld output terminals,
If a Remote Contactor Control is not to be used, place but will not necessarily indicate the actual voltage at the
the OUTPUT (CONTACTOR) Control switch in the ON welding arc (due to cable resistance, poor connections,
position. When in the ON position, weld output will be etc.). The ammeter indicates output amperage of the
available after the ON push button is depressed on the unit.
welding powersource. Weld output will continue until the
OFF push button is depressed on the welding power 5-9. POLARITY SWITCH (Optional)
source. The POLARITY SWITCH provides a means of selecting
either dc ELECTRODE POSITIVE or dc ELECTRODE
5-7. ARC CONTROL (Figure 5-1) NEGATIVE polarity without having to change the weld
output cable connections.
IMPORTANT: Prior to serial number JK674521, the
ARC CONTROL was an ARC CONTROL switch.
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) bridge. The dc output current of the SOR bridge is
not continuous, but consists of pulsed portions of
The basic welding power source operation is not difficult the rectified 3-phase, 50 or 60 Hertz power. Bur-
to understand when it is divided into sections. Diagram den resistor R6 isconnected across the output of
7-1 shows the main componentswhich make up the cir- the SCR bridge to provide a path for a minimum
cuitry of the welding power source. SCR holding current to flow.
IMPORTANT: The following Theory Of Operation is 3. Stabilizer Zi filters the pulsed output current of
written in steps which match the circlednumbers on Dia- the SCR bridge into a more constant dc current.
gram 7-1. Oomponent designators such as Ti, SRi, The filtering action of Zi keeps the welding cur-
P01, P5, 54, and P01 thatare used in the TheoryOfOp- rent from going to zero and the welding arc from
eration apply to components on Diagrams 8-1 through going out.
8-4 in this manual.
4. The POSITIVE (+) and NEGATIVE (—) weld out-
put terminals are located behind an access door
A. Input Power Circuit on the front panel ofthe welding powersource. An
optional POLARITY SWITCH provides a means
1. The welding power source is supplied with 50 or of reversing the polarity of the weld output termi-
60 Hertz, 3-phase voltage at input terminal board nals. An optional voltmeter V and ammeter A dis-
TEl A 3-pole, line contactorW isprovided to con-
.
play the rectified and filtered values ofthe voltage
nect and disconnect input power to main trans- and current provided by this welding power
former Ti. Main transformer Ti has three sec- source.
ondaries which provide the following:
a. A 3-phase, reduced voltage at high current to C. Operator Control Inputs
main rectifier SRi
5. The operator can turn on the dc output voltage of
b. A set of 3-phase synchronization signals to the welding power source by placing OUTPUT
Control Board PCi from which the SCR’s are (CONTACTOR) switch S4 in the ON position. The
gated SCR contactor circuit then enables the six gating
c. A single-phase voltage to the Control Board circuits on Control Board PCi to pulse or turn on
PCi power supplies and pilot light PLi. the SCR bridge. A small current will flow through
burden resistor R6 if no welding current flows.
The POWER ON and OFF push buttons energize The operator can choose to turn the dc output
and deenergize the line contactor W using a volt- voltage off by placing OUTPUT (CONTACTOR)
age from one of the 3-phase synchronization sig- switch S4 in the REMOTE 14 position. See Step 9
nals. Thermal over-temperature protection is pro- for more remote control information.
vided by thermostat TP1 located on main rectifier
SRi and connected in series with the POWER 6. The operator can select the amount of dc output
OFF push button. amperage by placing the AMPERAGE control
switch S2 in the PANEL position and rotating AM-
A single-phase, 230 volts ac circuit provides pow- PERAGE ADJUSTMENT control R5 until the de-
er for fan motor FM. Fan motor FM is always on sired amperage is obtained. The signal from R5 is
when the welding power source is energized un- supplied to the input command circuit on PCi.
less the unit is equipped with the optional FAN ON The operatorcan also select to have the dc output
DEMAND circuitry (see Section 10-3). One of the amperage controlled by a remote adjustment po-
3-phase synchronization signals supplies power tentiometer by placing the AMPERAGE control
to the optional FAN ON DEMAND circuitry. switch S2 in the REMOTE 14 position. See Step9
for additional remote control information.
B. Weld Current Circuit
7. ARC CONTROL R3 allows the operator to
2. A reduced voltage, 3-phase circuit from main choose an increased amperage to clear electro-
transformer Ti provides power to main rectifier de-to-work sticking. The increased amperage
SRi. This SCR bridge rectifies the 50 or 60 Hertz permits the burning free of the electrode at short-
power to provide dc output power. The six silicon- circuit conditions and minimizes the situations
controlled rectifiers SCRi through SCRO are con- which cause the electrodeto stick to the work. R3
trolled by the gating signals from PCi to produce provides an increased amperage as the weld out-
a varying amperage on the output of the SCR put approaches short-circuit conditions.
5M-221 Page 14
D. Automatic Constant Current Control Circuit amperage is therefore maintained at the se-
lected value, regardless of the length of the
8. The welding amperage output is automatically welding arc or the voltage drop across the arc.
controlled to the value selected by the operatoron
R5 by the following means: E. Remote Operations
a. The welding amperage is sensed by current 9. The welding power source is designed to be re-
sensor HOl, and a current feedback signal is motely controlled by signals from a variety of re-
applied to the amperage regulator circuit on mote hand or foot controls.
Control Board PCi. RANGE switch S3 selects REMOTE 14 receptacle RC1 provides on/off con-
either LOW or HIGH range thereby adjusting trol of the welding power source output using a re-
the amount of current feedback to PCi. mote contactor switch when OUTPUT (CON-
b. The amperage regulator circuit on Control TACTOR) switch S4 is in the REMOTE 14 posi-
Board PCi compares this current feedback sig- tion.
nal to the control signal selected by the operator Remote amperage adjustment is also possible up
on AMPERAGE ADJUSTMENT control R5. If a to the value of the amperage selected by AM-
difference exists, the amperage regulator com- PERAGE ADJUSTMENT control R5 when AM-
mands the six gating circuits to change the firing PERAGE switch S2 is in the REMOTE 14 posi-
of the SOR’s. The value of the welding tion.
5M-221 Page 15
3-Phase
Line
Input Power
Synchronization
Signal
SCR
Gating
signal
Current
Feedback
AC Or DC control Signals
34 Power
5M-221 Page 17
SECTION 8— TROUBLESHOOTING
8-1. TESTING INSTRUMENTS AND INFORMA- 8-3. TROUBLESHOOTING (Table 8-1 And Dia-
TION grams 8-1, 8-2, 8-3, And 8-4)
The service procedures in this manual require proper
testing instruments. Use a good quality digital volt-ohm- WARNING: ELECTRIC SHOCK can kill.
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-
A • Do not touch live electrical parts.
• Shutdown weldingpowersource, anddiscon-
fied, use a good quality unit with one megohm input im- nect input power employing lockout/tagging
pedance or greater. If a circuit board has a protective procedures before inspecting, maintaining, or
coating, it will be necessary to remove coating or use servicing.
needle probes in the test area to obtain proper contact. Lockout/tagging procedures consist of padlock-
Recoat areas ifnecessary to retain corrosion protection. ing line disconnect switch in open position, re-
Digital volt-ohmmeters (DVM’s) do not require lead po- moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
larity attention when making connections. However, the ing device.
meter may indicate a — (negative) voltage when the test
procedure specified a + (positive) voltage. If the incor- MOVING PARTS can cause serious injury.
rect polarity appears on the display, reverse meter lead • Keep away from moving parts.
connections to test points.
HOT SURFACES can cause severe burns.
• Allow coollng period before servicing.
8-2. CIRCUIT BOARD HANDLING PRECAUTIONS
Troubleshooting to be performed only by quali-
WARNING: ELECTRIC SHOCK can kill.
A • Do not touch llve electrical parts.
• Shutdownwelding powersource, and discon-
fied persons.
nect input power employing lockout/tagging The troubleshooting table is designed to diagnose some
procedures before inspecting, maintaining, or of the troubles that can develop in this welding power
servicing. source. Any circuit normally tied to ground must be at
ground potential.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and Use the table in conjunction with the diagrams in this
red-tagging circuit breaker or other disconnect- manual and the exploded views and component values
ing device. in the Service Parts Manual while performing trouble-
shooting procedures.
MOVING PARTS can cause serious injury.
• Keep away from moving parts. When replacing components, use only genuine MILLER
HOT SURFACES can cause severe burns. replacement parts. MILLER parts are required for war-
ranty repair by authorized warranty service agency.
• Allow cooling period before servicing.
Resistance and continuity measurements must be
SM-221 Page 19
Table 8-1 Troubleshooting (Continued)
-
5M-221 Page 21
Table 8-1. Troubleshooting (Continued)
5M—221 Page 22
Chart 8-1. Waveforms For Diagrams 8-1 Thru 8-4
gnd gnd
A. DC Open-Circuit Voltage, Range Switch S3 B. DC Open-Circuit Voltage, Range Switch S3
In Low Position In High Position
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.
PC I
/DA
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: 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)
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
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
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.
/ 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 ~
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.
RC
/OA
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.
POSITIVE
Vii
A, B, C, D
CB~
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
RCI
~DA
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.
METERS. Vi2
RF. PROTECTION S. A, B, C, 0
POLARITY SWITCH
(OPTIONAL-EXTRA)
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-
Operational power for Hall Device HD1 of ±15volts dc
TION (Figure 8-1 And Diagram 8-5) should be present at pins 1 and 2 respectively of plug
WARNING: ELECTRIC SHOCK can kill. PLG1 with respect to pin 18 (circuit common) of plug
5M—221 Page 32
Plug PLG1
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
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~<
DBS
—5 volts do output
0
to—5 volts do input
from
/
mm. to max. of AMPERAGE
ADJUSTMENT control R5
2ms iV
gnd
SM-221 Page 35
8-5. HALL DEVICE HD1 TESTING INFORMATION INCORRECT INSTALLATION or misaligned
FOR 300 AND 400 AMPERE MODELS (Figure plugs can damage circuit board.
8-2 And Diagram 8-6) • Be sure that plugs are properly installed and
aligned.
WARNING: ELECTRIC SHOCK can kill.
A • Do not touch live electrical parts.
• Shutdown welding powersource before mak-
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle move-
ing or changing meter lead connections and ment when disconnecting or connecting
before disconnecting or connecting any board plugs and removingor installing board.
leads.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns. IMPORTANT: For all checks, be sure to test and verify
• Allow cooling period before servicing. the continuity of leads between the board and the area
where check is performed. All checks shouldgo through
This procedure requires the unit to be energized. the connections and be actual terminal-to-terminaltests
Only qualified persons familiar with and follow- so thatbad connections or leads and corrosion is not the
ing standard safety practices are to perform this
testing procedure. problem.
Terminal connection
Points
Figure 8-2. Hall Device HD1 Component Locations And Information For 300 And 400 Ampere Models
5M-221 Page 36
01
& ill
V
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01
zo .~ U’
+ OO~ C.) —
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~ 0 CO
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C C 0
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+
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‘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.
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
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CI ~u
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01 ,,~ 01
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o -a’~
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~ ‘-‘~. 0
c Co
0 Co
C
4~01E ~ C
~ U
41
a. 0.
0 U 0
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0, 0,
S
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h.
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001
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‘4 5M-221 Page 39
8-7. DIODES D1O AND Dli TESTING PROCE-
3. Test each diode in the forward and reverse direc-
DURE (Figures 8-4 And 9-1) tion by connecting and then reversing the meter
leads across each diode. A properly functioning
Figure 8-5. Main Rectifier SRi Component Locations And Information For 300 Ampere Models
1. Mark and disconnect SCR pigtail from heat sink.
Cathode Lead
(Small Red) 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
A = Ammeter with 0 To 100 Milliampere S-0489
Figure 8-6. The VOM should then indicate a low
Range (May Be Another VOM) resistance (approximate mid scale) indicating to
you that the SCR gate is okay. If a low reading
Figure 8-6. SCR Lead Identification And Meter cannot be obtained, the SCR gate isbad. The am-
Connection Points meter should indicate current flow meaning that
SM-22i Page 41
the SCR has turned on. When testing small 3. Remove SCR’s from heat sink, and discard. If us-
SCR’s, removal of the gate lead from the anode ing a breakaway nut to install the new SCR, retain
will not change the ammeter reading. This is be- existing internal tooth lock washer. If using a wa-
cause the meter is providing a U~hoIding current.” sher-nut combination, discard lock washer.
On large SCR’s, the meter cannot provide
enough UUholding current,” so the meter will revert 4. Clean surface of heat sink around SCR’s mount-
to a high resistance when the gate lead is re- ing hole.
moved from the anode. 5. Apply a thin layer of supplied heat sink compound
8. If an SCR does not check properly, replace the to SCR face surface (see Figure 8-8).
SCR according to Section 8-8B.
IMPORTANT: Do not apply heat sink compound on the
9. If the SCR’s check properly, reconnect SCR pig- threads of the SCR stud.
tail(s) to heat sink.
10. Reconnect receptacle RC2 to plug PLG2 on Con- 6. Insert new SCR in heat sink and thread break-
trol Board PCi. away nut with internal tooth lock washer, or wa-
sher-nut combination onto SCR stud as illus-
B. SCR Replacement Procedure (Figures 8-7 And trated in Figure 8-8.
8-8)
7. Tighten nut according to type:
Pigtail
Connection Tab
I Locking
Lance
SCR Face
ST.147 699
nect input power employing lockout/tagging 3. If an SCR tester is not available, setVOM function
procedures before inspecting, maintaining, or selector switch to Rxi ohms.
servicing.
Lockout/tagging procedures consist of pad- 4. Connect meter leads to SCR as shown in Figure
locking line disconnect switch in open position, 8-10. Make sure the test lead polarity is as shown.
removing fuses from fuse box, or shutting off and Another meter will be necessary to determine the
red-tagging circuit breaker or other disconnect- output polarity of the lead jacks as not all meters
ing device. have the internal battery negative connected to
MOVING PARTS can cause serious injury. the negative or common output jack. It is a good
idea to mark your meterjacks plus or minus for fu-
• Keep away from moving parts. ture use.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing. 5. A high resistance reading should be indicated
with the gate lead not in the circuit. (A low resis-
Only qualified persons familiar with and follow- tance reading indicates a shorted SCR in which
ing standard safety practices are to perform this
testing procedure. case the SCR should be replaced and the test is
completed.) Proceed to Step 6 ifa high reading is
IMPORTANT: Read and understand meter Owner’s obtained. Leave meter leads connected as
Manual before making measurements. See Figure 9-1 shown in Figure 8-10.
for location of main rectifier SRi in this unit.
6. Connect the gate lead to the anode as shown in
A. SCR Testing Procedure (Figures 8-9 And 8-10) Figure 8-10. The VOM should then indicate a low
resistance (approximate mid scale) indicating to
5M-22i Page 43
spring Indicator Clamp
TOP VIEW
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
9
V~N
——— —
Heat Sink
5CR
spring Pins
I —
U. —
Figure 8-9. Main Rectifier SRi Component Locations And Information For
400, 500, And 600 Ampere Models
SM-221 Page 44
SA-115 688
Figure 8-10. Hockey Puk-Type SCR Lead Identification And Meter Connection Points
B. SCR Replacement Procedure (Figures 8-11 And 3. Note position of leads, and mark mounting sur-
8-12) faces to aid relocation of new SCR on heat sink.
IMPORTANT: If any SCR’s are replaced, be sure to 5. Remove all remaining heat sink compound from
check capacitors C7 through C12 for proper connec- both surfaces on heat sink in area where SCR
tions, shorts, and leakage. Also, visually examine main was removed.
transformer Ti for signs of winding failure (uneven dis-
coloration would be apparent if a short has occurred). 6. Examine surface of heat sinks. Surfaces must be
Check continuity across each winding, and check for thoroughly clean, flat, and true. Surface flatness
proper connections. Check phase-to-phase voltage be- must be within .001 in. If surface is marred or
tween leads 21 and 22, 22 and 23, and 21 and 23 (see damaged, either remachine or replace heat sink.
Diagram 8-1, 8-2, 8-3, or8-4). Replace C7through C12
and Ti if necessary 7. Apply a thin coating of supplied heat sink com-
pound to both contact surfaces of new SOR.
1. Locate and disconnect receptacle RC2 from plug
PLG2 on Control Board PCi. IMPORTANT: Proper contact and mounting pressure
2. Trace the red and white leads from SCR to be re- are necessary for correct operation of new 5CR.
placed to receptacle RC2. Mark and remove the
leads from receptacle RC2 using an AMP 8. Position 5CR correctly according to marked
465199-i pin extraction tool (MILLER part num- leads and mounting surfaces, and place 5CR
ber 099 719) according to Figure 8-il. onto locating pins in heat sinks.
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
Locking and 500 ampere models or 2 kilo lbs. for 600 am-
Lance pere models on indicator (see Figure 8-12).
12. Route and connect leads from new SCR to
Part Number 099 719 marked locations in receptacle RC2.
ST-147 699
13. Reconnect receptacle RC2 to plug PLG2 on Con-
Figure 8-li. Pin Extraction Tool trol Board PCi.
SM-221 Page 45
—c C.)
0.0. (15 a’ 0
Ce
Co
1U’
0
0
~0
0
0.
ul
S
~0
Ce
E
~ ‘U
‘~coi
a,-Jg~—
.0~0
a.
z E
C.)
a-
0
4-
Cu
Ca
.5
C
0,
C
a-
a.
U,
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1-
(0
a)
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ir
z
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uo
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Ce h. 0.
c
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5M-221 Page 46
SECTION 9— COMPONENT IDENTIFICATION AND LOCATION
U a,
(U
—— i~C.IJ
a.(-)
0’
~
a, a,~
(ULL U CD
a, a,
0,
p -o
00.
Cs..
O(U
(~O
m
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4-
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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
5M-221 Page 48
Rear Panel
Fan
Plenum Chamber
Fan Motor FM
SC-004 988-C
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
——
Figure 9-5. Main Rectifier SRi And Component Locations For 400, 500, And 600 Ampere Models
5A—138 574
On Push Button
Compression 5~
Limit Switch
Figure 9-7. Push Button PBi Switch Assembly And Component Locations
SM-221 Page 51
SECTION 10— MAINTENANCE
Every three months inspect cables for breaks in insula- The fan motor is thermostatically controlled to provide
tion Repair or replace cables if insulation breaks are fan cooling of the transformer and rectifier if these com-
present Clean and tighten connections at each inspec- ponents require cooling. Under normal loading, the fan
tion. may not run.
C. Internal Cleaning Three normally-open thermostats, TP2 in the main recti-
fier and TP3 and TP4 in the main transformer, and a re-
5M-221 Page 52
SECTION 11 - ELECTRICAL 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.
SM-221 Page 55
0. 4.
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en~ (a
q):3 4.
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—en
zU,9
0.0. —
6
en~
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oen E
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(0:3
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CD ~ a’
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SM-221 Page 56
0. Co
(0
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4J w —C,) 0
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0.0. U,
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SM-221 Page 58
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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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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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SM-221 Page 68
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SM-221 Page 70
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SM-221 Page 75
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SM-221 Page 76
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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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SM-221 Page 81
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SM-221 Page 83
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SM-221 Page 84
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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
In
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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
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 . .
...8.... TEl 038145 TERMINAL ASSEMBLY, dual voltage (Fig 3) 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
12 080509 GROMMET, scr No. 8/10 panel hole .312sq .375 high . ... 3 ... 3 ... 3 3
....
13 090781 ..CIRCUITCARDBOX
14 138 378 BRACKET, mtg rect (included w/rectifier) 1 ... 1 . ... 1
23 HAi,HD1
. 134 826 CIRCUIT CARD, hall booster (Elf w/JHi 75959) 1 1
...
• •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.
ST-004 988-0
5
Figure 2. Panel, Rear w/Components
7
8
ST—138 574
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
+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)
4,
5
2
5T-080 214-5
Figure 5. Switch, PB
5T-049 529—A
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
CU
0
CI
1
2
1
5
6
6
5T-048 899—K
.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
+Fan Control
• Prior to KE6961 37 for 600A models without Fan Control.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
5N—092 883—B
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Optional Equipment
5PM-221 Page 14
Goldstar Series
PRINTED IN USA © 1997 Miller Electric Mfg. Co.