Miller: 0 Technical Manual

TM-ZZIR October 1997
Miller
Gold Star® 30055 Effective
With Serial No. JC641 296
Gold Star® 4005S Effective
With Serial No. J0590316
ThePower ofBlue. Gold Star® 500SS Effective
With Serial No. JE747791
Gold Star® 600SS Effective
GOLD STAR ®SS
0
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TECHNICAL MANUAL
OM-221X - 2191
TABLE OF CONTENTS
Section No. Page No.

SECTION 1 — SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. General Information And Safety 1
1-2. Safety Alert Symbol And Signal Words 1
1-3. Safety Precautions 1
SECTION 2— SHIPPING AND STORAGE
2-1. Preparation For Reshipment 2
2-2. Storage 2
SECTION 3—SPECIFICATIONS
3-1. Volt-Ampere Curves 5
3-2. Duty Cycle S
3-3. Description 5
SECTION 4—INSTALLATION OR RELOCATION
4-1. Site Selection 5
4-2. Transporting Methods 5
4-3. Remote 14 Receptacle Information And Connections 6
4-4. Weld Output Connections 6
4-5. Electrical Input Connections 7
SECTION 5-OPERATOR CONTROLS
5-1. PowerSwitch 10
5-2. Pilot Light 10
5-3. Range Switch 10
5-4. Amperage Adjustment Control 10
5-5. Remote 14 Receptacle And Amperage Control Switch 10
5-6. Remote 14 Receptacle And Output (Contactor) Control Switch .... 10
5-7. Arc Control 11
5-8. Meters (Optional) 11
5-9. Polarity Switch (Optional) 11
SECTION 6-SEQUENCE OF OPERATION
6-1. Shielded Metal Arc Welding (SMAW) 12
6-2. Shutting Down 12
SECTION 7- THEORY OF OPERATION
7-1. Theory Of Operation ... 14
Diagram 7-1. Block Diagram 16
SECTION 8— TROUBLESHOOTING
8-1. Testing Instruments And Information 18
8-2. Circuit Board Handling Precautions 18
8-3. Troubleshooting 18
Diagram 8-1. Troubleshooting Circuit Diagram For
300 And 400 Ampere Models 24
Diagram 8-2. Troubleshooting Circuit Diagram For 300 And 400
Ampere Models With Demand Fan Control 26
Diagram 8-3. Troubleshooting Circuit Diagram For
Diagram 8-4. Troubleshooting Circuit Diagram For 500 And 600
Ampere Models With Demand Fan Control 30
8-4. Control Board PCi Testing Information 32
Diagram 8-5. Troubleshooting Circuit Diagram For Control Board PCi . . 34
SECTION 8— TROUBLESHOOTING (Continued)
8-5. HaIl Device HOl Testing Information For
Diagram 8-6. Troubleshooting Circuit Diagram For Hall Device HD1
In 300 And 400 Ampere Models 37
8-6. Hall Device HD1 Testing Information For
Diagram 8-7. Troubleshooting Circuit Diagram For Hall Device HD1
In 500 And 600 Ampere Models 39
8-7. Diodes D1O And Dli Testing Procedure 40
8-8. Main Rectifier SRi Testing And Replacement Procedure
For 300 Ampere Models 40
8-9. Main Rectifier SRi Testing And Replacement Procedure
For 400, 500, And 600 Ampere Models 43
SECTION 9— COMPONENT IDENTIFICATION AND LOCATION
Figure 9-1.
Main Assembly And Component Locations 47
Figure 9-2.
Front Panel And Component Locations 48
Figure 9-3.
Rear Panel And Component Locations 49
Figure 9-4.
Main Rectifier SRi And Component Locations
For 300 Ampere Models 49
Figure 9-5. Main Rectifier SRi And Component Locations
For 400, 500, And 600 Ampere Models 50
Figure 9-6. Input Terminal Board TEl And Component Locations 50
Figure 9-7. Push Button PB1 Switch Assembly
And Component Locations 51
SECTION 10— MAINTENANCE
10-1. Routine Maintenance 52
10-2. Rectifier Protection 52
10-3. Demand Fan Control (Optional) 52
SECTION 11 — ELECTRICAL DIAGRAMS
Diagram 11-1. Circuit Diagram For 300 Ampere Models Effective
With Serial No. JC641 296 Thru JG032479 And
400 Ampere Models Effective With Serial No.
JC59O3i6Thru JG032479 56
Diagram 11-2. Circuit Diagram For 300 And 400 Ampere Models
Effective With Serial No. JG032480 Thru JH1 76799 57
Effective With Serial No. JH1 76800 Thru JJ503983 58
Effective With Serial No. JJ503984 Thru JK674520 59
Effective With Serial No. JK674521 Thru KA819072 60
Effective With Serial No. KA819073 And Following 61
Diagram 11-7. Wiring Diagram For 300 Ampere Models Effective
With Serial No. KA81 9073 And Following 62
Diagram 11-8. Wiring Diagram For 400 Ampere Models Effective
With Serial No. KA81 9073 And Following 64
Diagram 11-9. Circuit Diagram For 300 Ampere Models With
Fan Control Effective With Serial No. JC641296 Thru
JF855842 And 400 Ampere Models With Fan Control
Effective With Serial No. JC590316 Thru JF855842 66
Diagram 11-10. Circuit Diagram For 300 And 400 Ampere Models With
Fan Control Effective With Serial No. JF855843
Thru JG032479 67
Fan Control Effective With Serial No JG032480
Thru JH296871 68
SECTION 11 — ELECTRICAL DIAGRAMS (Continued)
Fan Control Effective With Serial No. JH296872
Thru JJ503983 69
Fan Control Effective With Serial No. JJ503984
Thru JK674520 70
Fan Control Effective With Serial No. JK674521
ThruKA8l9O72 71
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
Effective With Serial No. JG032480 Thru JJ503983 75
Effective With Serial No. JJ503984 Thru JK674520 76
Effective With Serial No. JK674521 Thru KA81 9072 77
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
Fan Control Effective With Serial No. JG032480
Thru JJ503983 83
Fan Control Effective With Serial No. JJ503984
ThruJK67452O 84
Fan Control Effective With Serial No. JK674521
Thru KA81 9072 85
Fan Control Effective With Serial No. KA81 9073
And Following 86
Diagram 11-28. Circuit Diagram For Control Board PCi Effective With
Serial No. Thru JF933619 87
Diagram 11-29. Circuit Diagram For Control Board PCi Effective With
Serial No. JF933620 And Following 88
Diagram 11-30. Circuit Diagram For Hall Device HD1 In 300 Ampere
Models Effective With Serial No. JC641 296 Thru
JH176788 And 400 Ampere Models Effective With
Serial No. JC590316 Thru JH176788 89
Diagram 11-31. Circuit Diagram For Hall Device HD1 In 300 And
400 Ampere Models Effective With Serial No.
JH176789 And Following 89
Diagram 11-32. Circuit Diagram For Hall Device HD1 In 500 Ampere
Models Effective With Serial No. JE747791 And Following
And 600 Ampere Models Effective With Serial No.
JE813766 And Following 90
LIST OF CHARTS AND TABLES
Table 3-i. Specifications 3

Table 3-2. Idling Data (No Load) 3
Chart 3-1 - Volt-Ampere Curves 4
Chart 3-2. Duty Cycle 5
Table 4-1. Weld Cable Size 7
Table 4-2. Input Conductor And Fuse Size 9
Table 8-i. Troubleshooting 19
Chart 8-1. Waveforms For Diagrams 8-1 Thru 8-4 23
Table 10-i. Maintenance Schedule 52
Table li-i. List Of Circuit Diagrams And Wiring Diagrams 54
SECTION 1 — SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. GENERAL INFORMATION AND SAFETY • 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
2-1. PREPARATION FOR RESHIPMENT 2-~ STORAGE

WARNING: ELECTRIC SHOCK can kill.
• Do not touch llve electrical parts.
• Shut down welding power source, and
• Do not touch llve electrical parts.
• Shut down welding power source, and
disconnect input power employing lockout/ disconnect input power employing lockout!
tagging procedures before preparing unit for tagging procedures before storing unit.
shipping. Lockout/tagging procedures consist of pad-
Lockout/tagging procedures consist of pad- locking line disconnect switch in open position,
locking line disconnect switch in open position, removing fuses from fuse box, or shutting off
removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other discon-
and red-tagging circuit breaker or other disconnecting device.
necting device.
1. Disconnect input power conductorsfrom deener-
gized supply.
1. Disconnect input power conductors from deener-
gized supply. 2. Clean outside of unit.
2. If applicable, disconnect gas cylinder, water sup- 3. Remove top cover and side panels (or wrapper as
ply, and/or coolant system; remove unit from run- applicable).
ning gear. 4. Using dry compressed air, clean inside of unit.
3. Bolt unit to a proper wooden skid or wooden rails. 5. Reinstall top cover and side panels or wrapper as
4. Tape plastic around top and sides of unit. applicable.
6. Apply touch-up paint to any nicks or scratches to
5. Securely tie and/or tape cardboard over top and
around sides of unit. Use original shipping carton prevent rusting, etc.
if available. 7. Select a storage location that least subjects the
unit to wide temperature variation, dust, dirt, and
IMPORTANT: Do not ship without a cardboard carton. corrosive vapors.
Not only do costs increase dramatically, but the unit is
more subject to loss or damage without a carton. 8. Move unit to storage location.
9. Place unit on suitable blocks such as 2 x 4’s or
6. If sending unit to factory, ship unit as directed by
factory Service Department or Transportation 4 x 4’s to keep it off the floor.
Department. 10. Cover unit with plastic or a suitable tarp.
5M-221 Page 2
SECTION 3— SPECIFICATIONS
Table 3-1. Specifications
Input At Rated
Rated Welding Welding Max. Load Output
Model Current Amperes Current Open- 60 Hz Three-Phase Weight
60% Duty Cycle Ranges Circuit
Amperes Voltage Amperes At
200V 230V 460V 575V KVA KW Net Ship
300 300 @~ 15-200
Ampere 32 Volts 25-385 70 67 58 29 23 23.2 12.9 (209
460 lbs.
kg) 489 lbs.
(222 kg)
400 400 @ 20-270
Ampere 36 Volts 37-510 70 87 75 38 30 30 19.8 473 lbs.
(215 kg) 498 lbs.
(226 kg)
500 500 @ 20-346

Ampere 40 Volts 34-625 70 112 97 49 39 38.8 25.6 (246
543 lbs.
kg) 568 lbs.
(258 kg)
600 600@ 30-415
Ampere 44 Volts 57-775 70 132 114 57 46 45.6 32.7 (287
632 lbs.
kg) 657 lbs.
(298 kg)
Table 3-2. Idling Data (No Load)*
Idling Amperes Input At No Load

60 Hz Three-Phase
Input Input
Model 200(208)V 230V 460V 575V KVA KW
300 4.3(4.1) 3.7 1.9 1.5 1.5 0.92

Ampere
400
Ampere 4.4(4.2) 3.8 1.9 1.5 1.5 0.96
500
Ampere 4.1(3.9) 3.5 1.8 1.4 1.4 1.08
600
Ampere 5.1(4.9) 4.4 2.2 1.8 1.8 0.8
*VaIues are nominal and for 60 Hz models only.
SM-221 Page 3
Chart 3-1. Volt-Ampere Curves
70 70
Low Range
60 400 Amp
60 Model
50 50
0
I- 0
-‘40
0 I.-
~40
685 W3L
830
20 ,~ cG~.
20
10 10
SOFT
0 200 400 600 800 1000 00 50100 150200 260300350400450500550

DC AMPERES Ref. SB—081 870—A DC AMPERES Ref. 55-054 621-A
70
70
60
60
50
50
0
0
~40 I.- 40
0 —J
0
830
20 20
10 10
0 0
DC AMPERES Ref. 55-081 866-A DC AMPERES Ref. SB-084 642-A
50 70
70 60
60
50
oSO 0
I- I—
-a -J
0 40
~40
830 030
0
20
20
10 10
0 0
395—A Ref. SB—081 850-A
70 70
High Range High Range
60 500 Amp 60 600 Amp
Model Model
50 60
0 0
I-
b40 MAX 40
0
030 o 30 502 MAX
0 0
,~ OG~
20 20
p~ c~ SOFT
10 SOFT MAX
10 MAX MAX
0 0
800 1000 0 200 400 600 800 1000 1200 1400
0 200 400 600 Ref SB—081 394—A DC AMPERES Ref. SB—081 848—A
DC AMPERES
SM-221 Page 4
3-1. VOLT-AMPERE CURVES (Chart 3-1) Chart 3-2. Duty Cycle
The volt-ampere curves show the voltage and Amper-
age output capabilities of the welding power source at 120 Model
the mm. and max. values of the AMPERAGE ADJUST-
MENT control setting. Curves of other settings will fall
B0
between the curves shown.
0
-With the use of the volt-ampere curves, it is possible to w
w
determine the weld current at any particular load volt- 0.
age. 600 Amp

400
0
-J 500 Amp
uJ
3-2. DUTY CYCLE (Chart 3-2) 400 Amp
The duty cycle of a welding power source is the percent-
age of a ten minute period that a welding power source 300 Amp
20
can be operated at a given output without causing over- 0
heating and damage to the unit. This welding power U 80 40 80 80 708090m0
source is rated at 60 percent duty cycle. This means that 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.
SECTION 4— INSTALLATION OR RELOCATION
4-1. SITE SELECTION

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

7. Proper temperature that avoids extremes of heat This welding power source is equipped with a lifting eye
or cold for moving the unit during installation. Weight capacityof
the lifting eye only allows for supporting the welding
8. Proper airflow around unit power source.
9. Adequate space for removingtop cover and outer
panels for installation, maintenance, and repair
functions. A WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power conductors from
Base mounting holes provide the capabilityto install and deenergized supply line BEFORE moving
secure the uniton a running gear or in a permanent loca- welding power source.
tion. A permanent installation site for securing the unit FALLING EQUIPMENT can cause serious
should allow sufficient space on all sides and above the personal injury and equipment damage.
unit to open access door(s), or remove top cover and • Use lifting eye to lift unit only, NOT running
outer enclosure panels formaintenance and repair func- gear, gas cylinders, orany otherheavy acces-
tions. sories or devices.
5M-221 Page 5
• Use equipmentofadequate capacity to lift the Socket E: Amperage control connection (wiper con-
unit. tact).
• If llfting or moving this unit with lift forks under IMPORTANT: The remaining sockets in the receptacle
the base, be sure that lift forks are long are not used.
enough to extend beyondopposite side of the
base. 4-4. WELD OUTPUT CONNECTIONS (Figure 5-1)
Using lift forks too short can damage internal
parts if tips of the lift forks penetrate the unit
base, or may cause personal injury and/or
equipment damage if unit falls off the lift forks. Q* RATED OUTPUT
To obtain full rated output from this unit, it is necessary to
4-3. REMOTE 14 RECEPTACLE INFORMATION
select, prepare, and install proper weld cables. Failure to
AND CONNECTIONS (Figures 4-1 And 5-1) comply in any of these areas may result in unsatisfactory
welding performance.
~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.
• 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
Total Cable (Copper) Length In Weld Circuit Not Exceeding*

100 ft. Or Less 150 ft. 200 ft. 250 ft. I 300 ft. 350 ft. 400 ft.
Welding (30 m) (45 m) (60 m) (70 m) j (90 m) I (105 m) (120 m)
Amperes 10 To 60% 60 Thru 100% 10 Thru 100% Duty Cycle
Duty Cycle Duty Cycle
100 1 1 1 1 1 2 1/0 1/0
150 1 1 1 1 1/0 2/0 3/0 3/0
200 1 1 1 1/0 2/0 3/0 4/0 4/0
250 1 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0
800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0
900 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of more than 300 circular
mils per ampere. S-OOO 7/8-88
1. Connect work cable or connector to NEGATIVE tric utility for information about the type of electrical serv-
weld output terminal. ice available, how proper connections should be made,
and inspection required.
2. Connect electrode cable to POSITIVE weld out-
put terminal. B. Jumper Link Installation (Figures 4-2 And 4-3)
IMPORTANT: The connections given are for dc elec-
trode positive polarity. Ifdc electrode negative polarity is
desired, reverse cable connections to weld output termi-
nals (work becomes positive).
A WARNING: Read precautionary information
at beginning of entire Section 4-5 before
proceeding with this installation.
Jumper links are used to allow the equipment to operate
4-5. ELECTRICAL INPUT CONNECTIONS from different line voltages.
1. Remove top cover and right side panel.
—~ INPUT
2. Compare position of jumper links on the input ter-
minal board to the voltage link arrangement
A • Do not touch live electrical parts.
shown on input voltage label.
• Shutdown weldingpowersource, and discon-

procedures before ir7specting or installing.
A CAUTION: INCORRECT INPUT VOLTAGE
JUMPER LINK PLACEMENT can damage
unit.
• Position lumper links as shown on the input
Lockout/tagging procedures consist of padlock- voltage label (see Figures 4-2 and 4-3).
ing line disconnect switch in open position, re- • Store unused]umper links across linked ter-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect- minals.
ing device.
IMPORTANT: Ifthe input voltages stated on nameplate
A. Electrical Input Requirements or rating label are different from those in Figure 4-2,
check the input voltage label in the unit or call Factory
Operate the welding power source from a three-phase, Service Department.
60 Hertz, ac powersupply. The inputvoltage must match
one of the electrical input voltages shown on the input 3. Install jumper links onto the input terminal board
data label on the unit nameplate. Contact the local elec- to match the available input line voltage.
SM-221 Page 7
8 /0
•1’ I
TO CONTROL TRANSFORMER
CIF APPLICABLE)
1~I00~~ 0
324 1324 1324
FM FM
KiLl KiLl KiLl

COIL 3 COTh 2 COIL I
460 VOLTS
o~j~o o~o o~o
000
L L L
a0 19
0
I 00
I
0 0 00 0 0 0 0
(IF APPLICABLE)
514362 514362 514362
FM FM
I 2345 6 I 2345 6 2345 6
COIL #3
KJIILThLJ COIL #2 COIL #1
SIMILAR CONNECTED VOLTAGES
208/230/460
220/230/460
200 VOLTS 230 VOLTS 460 VOLTS

~j~oo~ ~J~oo~j~ ~j0o~ O~~O O~J~O O~~O OV~j~OO OO~OQ OO~OO
OLOLOL OLOLOL OLOLOL
I I /0
T
(IF APPLICABLE)
00 0 TIE TOGETHER 2L5

1m63 45 6 32463 I 3 2 4 6 3 FAN MOTOR ACROSS 1L2
B 5 5 COIL #1
123123456123 AU
COIL #3 COIL #2 COIL dl
230 VOLTS 460 VOLTS 575 VOLTS

~OO ~OQ ~OO o~j~ooo o~ooo e~oeo Oooo~ oooe~ oeoo~
L L L L L L L L L
000 000 000
SA—047 874—A
Ref. SA—047 873—A
Ref. SA-047 881-A
Figure 4-2. Input Voltage Labels And Connection Diagrams
SM-221 Page 8
Input
Terminal
Board
SB-094 762-C
Figure 4-3. Location Of Electrical Input Connections And Components
C. Welding Power Source Input Power Connec- Table 4-2. Input Conductor And Fuse Size*
tions (Figure 4-3)
Input Ground u
• Instali a fusible line disconnect switch in the
Model Input Conductor Conductor
Voltage Size
(AWG)
Size
(AWG)
use
Size In
Amperes
200 6 8 100
input circuit to the welding power source.
• Connect input conductors to the welding 300 230 8 8 90
powersource before connecting to the single- Ampere 460 10 10 45
phase input power.
575 12 12 35
• Read and follow safety information at begin-
ning of entire Section 4-5. 200 4 6 125
The line disconnect switch provides a safe and
convenient means to completely remove all 400 230 6 6 125
electrical power from the welding power source Ampere 460 10 10 60
whenever it is necessary to inspect or service
the unit. 575 10 10 45
1.Use Table 4-2 as a guide to select input conduc- 200 3 6 175
tors for the installation. The input conductors
should be covered with an insulating material that 500 230 4 6 150
complies with national, state, and local electrical Ampere 460 8 8 70
codes. 575 10 10 60
2. Install terminal lugs of adequate Amperage ca- 200 2 6 200
pacity and correct stud size onto the input and
ground conductors. 600 230 3 6 175
WARNING: ELECTRIC SHOCK can kill. Ampere 460 8 8 90

• Do not connect an input conductor to the
575 8 8 70
*Conductorsize is basedon the 1990 Edition of the National
ground terminal in the unit. Electrical Code (NEC) specifications for allowable Ampaci-
ties of insulated copper conductors, having a temperature
• Do not connect the ground conductor to an (750C), with not more than three single cur-
rating of 1 670Fconductors
rent-carrying in a raceway (Article 310 of NEC).
input line terminal. (The ground conductor is not counted as a current-carrying
Incorrect input connections can result in an conductor.)
electrically energized welding power source *Fuse size is based on not more than 200 percent of the
chassis. The ground terminal is connected to rated input Amperage of the welding power source (Article
the welding power source chassis and is for 630 of NEC).
grounding purposes only.
5M-221 Page 9
3. Obtain and install a standard conduit strain relief 7. Connect remaining end of ground conductor to a
connector into the rear panel access hole. suitable ground. Use a grounding method that
complies with all applicable electrical codes.
4. Insert conductors through strain relief installed in 8. Connect remaining ends of input conductors to a
Step 3. Route conductors to the input terminal deenergized line disconnect switch.
board.
9. Secure the input cable in the strain relief.
5. Connect input conductors to line terminals on the 10. Reinstall top cover and right side panel.
input terminal board (see Figure 4-3).
ii. Use Table 4-2 as a guide to select line fuses for
6. Connect the ground conductor to the ground ter— the disconnect switch. Obtain and install proper
minal (see Figure 4-3). fuses.
SECTION 5—OPERATOR CONTROLS
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.
5-4. AMPERAGE ADJUSTMENT CONTROL (Fig-

ure 5-1)
• Do not touch the weld output terminals when
the contactor is energized.
The AMPERAGE ADJUSTMENT control provides the • Do not touch electrode and work clamp at the
means of selecting the exact amperage desired within same time.
the range being used. Rotate the control clockwise to in-
When the OUTPUT (CONTACTOR) Control
crease the current output. switch is in the ON position, open-circuit voltage
IMPORTANT: The AMPERAGEADJUSTMENTcontroI is present at the weld output terminals for as
may be adjusted while welding. long as the welding power source is energized.
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.
The ARC CONTROL provides selection of arc charac-

A CAUTION: ARCING can damage switch con-
tacts.
• Do not change switch position while welding
or under load.
teristics to suit individual welding conditions.
SM-221 Page 11
SECTION 6— SEQUENCE OF OPERATION
3. Connect work clamp to clean, bare metal at work-
A WARNING: ELECTRIC SHOCK can kill;

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

• Keep all covers and panels in place while 5. If a Remote Amperage and/or a Remote Contac-
operating. tor Control are not to be used, place the AM PER-
AGE switch in the PANEL position or the OUT-
Warranty is void if the welding power source is PUT (CONTACTOR) switch in the ON position. If
operated with any portion of the outer enclosure a Remote Amperage and/or a Remote Contactor
removed.
Control are to be used, place the AMPERAGE or
ARC RAYS, SPARKS, AND HOT SURFACES OUTPUT (CONTACTOR) switches in the RE-
can burn eyes and skin; NOISE can damage MOTE 14 position (see Sections 5-5 and 5-6).
hearing.
• Wear correct eye, ear, and body protection. 6. Place the RANGE switch in the desired position
FUMES AND GASES can seriously harm (see Section 5-3).
your health.
7. Place the ARC CONTROL in the desired position
• keep your head out of the fumes.
(see Section 5-7).
• Ventilate to keep from breathing fumes and
gases. 8. Rotate the AMPERAGE ADJUSTMENT control,
• If ventilation is inadequate, use approved or Remote Amperage Control if used, to the de-
breathing device. sired position (see Section 5-5).
HOT METAL, SPATTER, AND SLAG can IMPORTANT: The AMPERA GEADJUSTMENTcontroI
cause fire and burns. may be adjusted while welding.
• Watch for fire.
9. Wear dry welding helmet with proper lens accord-
• Keep a fire extinguisher nearby and know
how to use it. ing to ANSI Z49.i.
• Do not use near flammable material. 10. Insert electrode into electrode holder.
• Allow work and equipment to cool before
handling. ii. Depress the POWER switch ON push button (see
MAGNETIC FIELDS FROM HIGH CURRENTS Section 5-i).
can affect pacemaker operation.
12. Begin welding.
• Wearers should consult their doctor before
going near arc welding, gouging, or spot weld—
ing operations.
6-2. SHUTTING DOWN
See Section 1 - Safety Rules For Operation Of
Arc Welding Power Source in OwneKs Manual
for basic welding safety information. 1. Stopwelding.
6-1. SHIELDED METAL ARC WELDING (SMAW) 2. Allow the welding power source to idle for three
1. Install and connect unit according to Section 4. minutes with no load applied.
2. Wear dry insulating gloves. 3. Depress the POWER switch OFF push button.
5M—221 Page 12
SECTION 7— THEORY OF OPERATION
7-i. THEORY OF OPERATION (Diagram 7-1) 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
Diagram 7-1. Block Diagram

5M-221 Page 16
0
Electrode
SCR
Gating
signal
Current
Feedback
AC Or DC control Signals
34 Power
IMPORTANT: The circled numbers match the

steps in the Theory Of Operation (Section 7-1). weld Current Circuit
Componentdesignators such as Ti, SRi, PCI,
R5, S4, and RC1 apply to components on Either Mechanical Coupling
Diagrams 8-1 through 8-4. Or External Circuits
• Optional Or Not Supplied
5M-221 Page 17
SECTION 8— TROUBLESHOOTING
8-1. TESTING INSTRUMENTS AND INFORMA- 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-
• 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-
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.
• 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.
Resistance and continuity measurements must be
A CAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
made with the unit shut down. Isolate components be-
fore making resistance and continuity measurements.
IMPORTANT: Before beginning troubleshooting proce-
FORE handling circuit boards.
• Transport circuit boards in proper static- dures, visually examine internalcomponentsforsigns of
shielding carriers or packages. overheating and failure. Many major problems, such as
winding(s) failure are usually apparent by discoloration,
• Perform work only at a static-safe work area. smoke, and smell. Fortunately, most electrical problems
INCORRECT INSTALLATION or misaligned are relatively simple: blown fuses, tripped circuit break-
plugs can damage circuit board. ers, incorrectswitch positions, loose connections, corro-
• Be sure that plugs are properly installed and sion, and the like. A complete, careful inspection often
aligned. saves considerable time, money and frustration.
EXCESSIVE PRESSURE can break circuit
board. IMPORTANT: Be sure that all connections are correct
• Use only minimalpressure and gentle move- and secure according to Section 4 and that all controls
ment when disconnecting or connecting and switches are in proper positions before proceeding
board plugs and removing or installing board. with troubleshooting.
5M—221 Page 18
Table 8-i. Troubleshooting
TROUBLE CAUSE REMEDY

No weld output; unit complete- Line disconnect switch in the Place line disconnect switch in the ON posi
ly inoperative. OFF position. tion.
Line fuse(s) open. Check line fuses, and replace if necessary.
Poor and/or improper input See Section 4-5 for proper input connections.
connections.
Input voltage jumper links not See Section 4-5 for proper jumper link position.
in proper position.
Unit overheating causing ther- Allow a cooling period of approximately fifteen
mostat TP1 to open (thermal minutes (see Section 10-2).
shutdown).
POWER switch ON push but- Check push button switch linkage for restriction
ton linkage, or obstruction.
POWER switch OFF push but- Check P61 for proper operation with an ohm-
ton P81 open. meter, and replace if necessary.
Contactor W. Check W for proper coil voltage and connec
tions (see Diagram 8-1, 8-2, 8-3, or 8-4).
Check condition of contacts and continuity of
coil. Replace W if necessary.
Diodes D1O and Dli in main Check D1O and Dli according to Section 8-7,
contactor W circuit. and replace if necessary.
Main transformer Ti. Visually examine main transformer Ti for signs
of winding failure (uneven discoloration would
be apparent if a short has occurred). Check
continuity across each winding, and check for
proper connections. Check Ti for proper volt
ages according to Diagram 8-1, 8-2, 8-3, or
8-4. Replace Ti if necessary.
No weld output; pilot light PLi Poor and/or improper weld See Section 4-4 for proper weld output con-
on. output connections. nections.
OUTPUT (CONTACTOR) Place S4 in ON position or connect Remote
switch S4 in REMOTE 14 p0- Contactor Control to RC1 (see Sections 4-3
sition with no remote contactor and 5-6).
control connected to REMOTE
14 receptacle RC1.
Remote contactor control Check remote contactor control switch for
switch. proper operation with an ohmmeter, and re
place if necessary.
Current feedback from Hall For 300 and 400 ampere models, check HD1
Device HD1 with no load, according to Section 8-5 and Diagram 8-6. For
500 and 600 ampere models, check HD1 ac
cording to Section 8-6 and Diagram 8-7. Re
place HD1 if necessary.
Control Board PCi or poor Check connections for continuity to PCi.
connections to PCi. Check PCi according to Section 8-4 and Dia
gram 8-5. Replace PCi if necessary.
Low or minimum weld output. Low line voltage. Correct low line voltage.
Open line fuse. Replace open line fuse.
Poor and/or improper weld See Section 4-4 for proper weld output con-
output connections. nections.
SM-221 Page 19
Table 8-1 Troubleshooting (Continued)
-

Low or minimum weld output. AMPERAGE control switch Place S2 in desired position (see Section 5-5).
(Continued) S2.
Check S2 for proper operation with an ohm-
meter, and replace if necessary.
AMPERAGE ADJUSTMENT Check R5 for proper connections and resis
control R5. tance; R5 is 1000 ohms ±10%.Replace R5 if
necessary.
Remote amperage control. Check remote amperage control for proper op
eration with an ohmmeter, and replace if nec
essary.
Burden resistor R6. Check R6 for proper connections and resis
tance; R6 is 12 ohms ±10%.Replace R6 if
necessary.
Hall device HD1 or poor con- For 300 and 400 ampere models, check con
nections to HD1. nections for continuity to HD1. Check HDi ac
cording to Section 8-5 and Diagram 8-6. For
SCR in main rectifier SRi. For 300 ampere models, check SCR’s in SRi
according to Section 8-8. For 400, 500, and
600 ampere models, check SCR’s in SRi ac
cording to Section 8-9. Replace SCR’s if nec
essary.
If any SCR’s are replaced, be sure to check
capacitors C7 through C12 and main trans
former Ti. Check C7 through Cl 2 for proper
connections, shorts, and leakage. Replace C7
through Cl 2 if necessary. See next entry for
Ti check.
connections to PCi. Check PCi according to Section 8-4 and Dia-
Maximum weld output. AMPERAGE ADJUSTMENT Check R5 for proper connections and resis-
control R5. tance; R5 is 1000 ohms ±10%.Replace R5 if
necessary.
Hall device HDi or poor con- For 300 and 400 ampere models, check con
nectionsto HDi. nections for continuity to HD1. Check HD1 ac
cording to Section 8-5 and Diagram 8-6. For
connections to PCi. Check PCi according to Section 8-4 and Dia-
SM—221 Page 20
Table 8-i. Troubleshooting (Continued)

Erratic weld output. Poor and/or improper input Refer to Sections 4-4 and 4-5 for proper input
and/or output connections. and output connections.
Electrode. Replace electrode.
SCR in main rectifier SRi. For 300 ampere models, check SCR’s in SRi
cording to Section 8-9. Replace SCRs if nec
essary.
capacitors C7 through Ci 2 and main trans
former Ti. Check C7 through Ci 2 for proper
through Ci 2 if necessary. See next entry for
Ti check.
connections to PCi. Check PCi according to Section 8-4 and Dia
Excessive line current or line Poor and/or improper input See Section 4-5 for proper input connections.
fuse(s) opens repeatedly. connections.
Input voltage jumper links not See Section 4-5 for proper jumper link position.
in proper position.
Fan motor FM. Check and repair shorted fan motor FM leads.
SOR in main rectifier SRi. For 300 ampere models, check SCR’s in SRI
cording to Section 8-9. Replace SCR’s if nec
essary.
capacitors C7 through Ci 2 and main trans
former Ti. Check C7 through Cl 2 for proper
through C12 if necessary.See next entry for Ti
check.
5M-221 Page 21
Table 8-1. Troubleshooting (Continued)

Optional demand fan control Control relay CR1. Check CR1 for proper coil voltage and connec
circuitry not operating properly. tions (see Diagram 8-2 or 8-4). Check condi
tion of contacts and continuity of coil. Replace
CR1 if necessary.
Thermostats TP2, TP3, and Check TP2, TP3, and TP4 for proper opera
TP4. tion, and replace if necessary.
Fan motor FM inoperative Fan blades blocked against Check for and correct blade obstruction.
and/or overheating, plenum.
Fan motor FM. Replace FM.
5M—221 Page 22
Chart 8-1. Waveforms For Diagrams 8-1 Thru 8-4
5ms by 5ms 1OV
gnd gnd
A. DC Open-Circuit Voltage, Range Switch S3 B. DC Open-Circuit Voltage, Range Switch S3
In Low Position In High Position
5ms 1OV 5ms 1OV
gnd gnd
C. 28 Volts DC (Average), 204 Amperes, Range D. 36 Volts DC (Average), 403 Amperes, Range
Switch S3 In Low Position (Resistive Load) Switch S3 In High Position (Resistive Load)
5M-221 Page 23
A WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause
serious injury.
• Do not touch live electricalparts.
• Shut down welding power source before making or changing meter
lead connections and before disconnecting or connecting any leads.
• Have onlyqualified personsfamiliar with and following standardsafety
practices perform troubleshootingprocedures.
• Follow standard ESDprecautions to preventdamaging static-sensitive
parts during testing.
• See Table 5-1 ifvalues are notpresent.
S.. Section 8-8 (300 ampere models) or

Section 8-9(400 ampere models)
for SRi data
YE I
See Section 8-7

for DiD, Dii data
PC I
/DA
See Section 4-3

for RC1 data
Diagram 8-1. Troubleshooting Circuit Diagram For 300 And 400 Ampere Models
5M-221 Page 24
IMPORTANT: For DC, the values are based on a good quality digital
volt-ohmmeter (DVM) or equivalent reading average (not RMS) values.
For AC, the values are RMS readings. The voltages shown are with
respect to circuit common (lead 43) unless otherwise indicated, use
Wiring Diagram (see Section II) to help locate leads and parts.
IMPORTANT: All resistance values for main transformer TI

and stabilizerZl are less than one ohm.
*
IMPORTANT: The A, B, C, and D
testpoints are foruse with letter-
matching waveforms on Chart 8-1.
POSITIVE
• NETERS.
PP. PROTECTION &
POLARITY SWITCH
(~TIONAL-EXTRA)
__I EuEuEuEu ruEuIuEu

C5
NEGATIVE S. POSITIVE STUDS

AND CAPACITC~S DO NET APPLY
WITH POLARITY SWITCH.
+15 volts dc output See also Section 5-5

PCI for HD1 data
CONTROL BOARD —15 volts do output RC2- I 8:
RC2/PLG2
+0.7 volts do output
per 100 amperes output
Eu Eu Eu ,u Eu Eu Eu u Rc2-28
Eu — EU — — Eu Eu Eu
Eu 0’ L.J ~ •. 0’ .o -J
8-4
Voltage Readings
(±10%Unless Specified)
Vi
V2 52 volts ac with contactor W energized
V3
V4 230 volts ac with contactor w energized

V7
vs
CIe C17 18 volts so with contactor w energized
V9
vio 15 volts dc with POWER switch ON
B E C Vii 53 to 67 volts do from mm. to max.
of AMPERAGE ADJUSTMENT control R5
SO-I 37779-A
SM-221 Page 25
serious Injury.
• Do not touch live electrical paris.
• Have onlyqualifiedpersons familiar with and followingstandard safety
• FollowstandardESDprecautions toprevent damaging static-sensitive
• See Table 8-1 if values are not present.
/ RC I
D A
See Section 4-3

for RC1 data
Diagram 8-2. Troubleshooting Circuit Diagram For 300 And 400 Ampere Models With Demand Fan Control
5M-221 Page 26
volt-ohmmeter (DVM) or equivalent reading average (notRMS) values.
For AC, the values are AMS readings. The voltages shown are with
WiringDiagram (see Section II) to help locate leads and parts.
IMPORTANT: All resistance values formain transformer TI

See Section 84 (300 ampere models) or
Section 5-9(400 ampere models)
for SRi data
/ ZI
test points are for use with letter-
matching waveforms on Chart 8-1.
POSITIVE
STR.
• METERS. V12
RF. PROTECTION S. A, B, C, D
POLARITY SWITCH
(OPTIONAL-EXTRA)
CS ~
NEGATIVE & POSITIVE STUDS

AND CAPACITORS DO NOT APPLY
See also Section 8-5

for HD1 data
EuEuEuEu EuEuEuEu
OEu—
—15 volts do output +0.7 volts dc output
PCI
CONTROL BOARD per 100 amperes output
RC2/PLG2
Voltage Readings
(±10%Unless Specified)
for PCi data vi
V3
V4 230 volts ac with control relay CR1 energized
V5 32 volts ac with thermostat TP2, TP3, or TP4 closed
V6
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.
SO-137 925-A
SM-221 Page 27
serious injury.
• Have onlyquallfiedpersons familiar with and foliowingstanda rd safety
practices perform troubleshooting procedures.
• FollowstandardESO precautions topre vent damagingstatic-sensitive
• See Table 8-1 if values are notpresent.
See Section 8-9

for SRi data
See Section 8-7

for Dig, Dli data
RC
/OA
See Section 4-3

for RCi data
Diagram 8-3. Troubleshooting Circuit Diagram For 500 And 600 Ampere Models
SM-221 Page 28
ForAC, the values are RMS readings. The voltages shown are with
WiringDiagram (see Section Ii) to help locate leads and parts.
IMPORTANT: All resistance values for main transformer Ti


matching waveforms on Chart 8-I.
POSITIVE
Vii
A, B, C, D
CB~
NEGATIVE & POSITIVE STLDS

AND CAPACITORS DO NOT APPLY

for HDi data
+0.7 volts do output

per i 00 amperes output
230 volts ac wlth contactor W energized
32 volts ac with contactor w energIzed
ii volts do with POWER switch ON

53 to67 volts dc from mln. to max.
B E of AMPERAGE ADJUSTMENT control R5
SO-i 37 784-A
SM-221 Page 29
WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause
A serious injury.
• Do not touch live electricalparts.
lead connections and before disconnecting or connectinganyleads.
• Have only qualifiedpersons familiarwith and followingstandardsafety
practicespen’orm troubleshootingprocedures.
• Follow standard ESDprecautions to prevent damaging static-sensitive
• See Table 8-1 ifvalues are not present.
ri
See Section 10-3 for

demand fan control data
RCI
~DA
See Section 4-3

for RC1 data
Diagram 8-4. Troubleshooting Circuit Diagram For 500 And 600 Ampere Models With Demand Fan Control
5M-221 Page 30
For AC, the values are RMS readings. The voltages shown are with
respect to circuit common (lead 43) unless otherwise indicated. Use
Wiring Diagram (see Section II) to help locate leads and parts.
IMPORTANT: All resistance values for main transformer Ti

and stabilizer Zi are less than one ohm.
IMPORTANT: The A, B, C, andD

See Section 8-9 matching waveforms on Chart 8-1.
for SRi data
METERS. Vi2
RF. PROTECTION S. A, B, C, 0
POLARITY SWITCH
(OPTIONAL-EXTRA)
NEGATIVE S. POSITIVE STWS

AND CAPACITORS 00 NOT APPLY
+15 volts do
output See also Section 5-6
for HOl data
Eu Eu Eu Eu Eu +0.7 volts do output

W -J .0 per i00 amperes output
+24 volts do PC
—15 volts
output CONTROL BOARD
RC2~PLG2
voltage Readings
(±iO%Unless Specified)
for PCi data Vi
V3
V4 230 volts ac with control relay CRi energized
V5 32 volts ac with thermostat TP2, TP3, or TP4 closed
V6
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.
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

• Shut down welding powersource before mak—
PLG2. Ifthese voltages are not present, replace Control
Board PCi.
B. Voltage Control Circuit
ing or changing meter lead connections and
before disconnecting or connecting any Control Board PC 1 requires several input signals to gen-
leads. erate the gate pulses to the SCR’s at pins 1, 4, 5, 8, 9,
MOVING PARTS can cause serious injury. and 12 of plug PLG2. As AMPERAGE ADJUSTMENT
• Keep away from moving parts. control R5 or the remote amperage control is rotated
clockwise, the gate waveform pulses are moved to the
HOT SURFACES can cause severe burns. leftthereby turning the SCR’s on earlier. As R5 or remote
• Allow cooling period before servicing. amperage control is rotated counterclockwise, the gate
waveform pulses are moved to the right thereby turning
This procedure requires the unit to be energized.
Only qualified persons familiar with and follow- the SCR’s on later. The output amperage is controlled by
ing standard safety practices are to perform this AMPERAGE ADJUSTMENT control R5 when AMPER-
testing procedure. AGE control switch S2 is in the PANEL position or by the
remote amperage control when 52 is in the REMOTE 14
position. The required input signals to PCi are as fol-
A CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
lows:
1. Control Board PCi requires an input command
FORE handling circuit boards. voltage of 0 to —5 volts dc at pin 29 of plug PLG2
• Transport circuit boards in proper static- with respect to circuit common from AMPERAGE
shielding carriers or packages. ADJUSTMENT control R5 or the remote amper-
• Perform work only at a static-safe work area. age control.
INCORRECT INSTALLATION or misaligned 2. Control Board PCi requires a current feedback
plugs can damage circuit board. signal proportional to the weld output of approxi-
• Be sure that plugs are properly installed and mately +0.7 volts dc per 100 amperes output be-
tween pins 28 (+) and 18 (—) of plug PLG2.
aligned
EXCESSIVE PRESSURE can break circuit 3. Control Board PCi requires a synchronization
board. signal of 32 volts ac from main transformer Ti at
• Use only minimal pressure and gentle move- pins 19, 20, and 21 with respect to pin 18 (circuit
ment when disconnecting or connecting common) of plug PLG2.
board plugs and removing or installing board. C. Contactor Control Circuit
IMPORTANT: For all checks, be sure to test and verify Contactor control is provided at pin 13 of plug PLG2 with
the continuity of leads between the board and the area an input voltage of +24 volts dc from pin 22. When OUT-
wherecheck isperformed. All checks shouldgo through PUT (CONTACTOR) switch S4 is in the ON position,
the connections and be actual terminal-to-terminal tests -i-24 volts dc should exist between pins 13 and 16 (circuit
so that bad connections or leads and corrosion isnot the common) of plug PLG2. When S4 is in the REMOTE 14
problem. position and the remote contactor device is closed, +24
volts dc should exist between pins 13 and 16 (circuit
A. Power Supply Circuit common) of plug PLG2.
Operational input power of 18 volts ac should exist at D. Arc Control Circuit
pins 24 and 25 with respect to pin 23 (circuit common) of An output voltage of —13 volts dcto ARC CONTROLR3
plug PLG2. Ifthese voltagesare not present, check main should be present between pins 14 and 16 (circuit com-
transformer Ti for proper voltages according to Dia— mon) of plug PLG2 for selection of the desired arc char-
gram 8-1, 8-2, 8-3, or 8-4. acteristics (see Section 5-7).
5M—221 Page 32
Plug PLG1
C85 RiOl R99 RiO8 Ri 22

hr oc~
Q
7 ~ A56 ED
~ C~C82 R 107 ~ C95
Ri04~ ‘—a ED Ri26 Ri29
R98 ED 085~R137 081
Ri36 ED Ri35
RiOO ED 0
Ri32
133 ~ D86~f~
i3i~~
Co
R5 1
R76
R75~
Eli
0
C-)
C69 R72
+LIZ C62 082 C55
R87 ED 073 061 ___ 065 ___ 053 R58 057
069
+ R96 R74 R81 R6O~ R67~
Rii6
I E~J+0
i3DEIEIJDDD
R88 R95 R73 R80 R59 R66
-~ ~~4O
(11 (Il
o -~
0
Plug PLG2 C-092 883-A
Figure 8-1 Control Board PCi Component Locations And Information

-
SM-221 Page 33
A WARNING: ELECTRIC SHOCK can kill: MOViNG PARTS can cause
serious Injury.
• Shutdown weldingpowersource before makingorchangingmeterlead
connections and before disconnecting or connecting any leads.
• Have only qualifiedpersons familiar with and followingstandard safety
• Follow standard ESO precautions to prevent damagingstatic-sensitive
Circuit common
r~<
—13 volts dc output ~ ~
DBS
—5 volts do output
o to—S volts do input from

mm. to max. of AMPERAGE
ADJUSTMENT control R5
with AMPERAGE control
switch S2 in PANEL Posltlon\
+0.7 volts do Input per —~

100 amperes output
with RANGE switch S3
In LOW position
+24 volts do Input with

OUTPUT (CONTACTOR)
switch S4 In ON position,
+24 volts do input with
54 in REMOTE 14 position
and remote contactor
switch closed, 0 volts do
Input with S4 In REMOTE 14
position and remote
contactor switch open
0
to—5 volts do input
from
/
mm. to max. of AMPERAGE
ADJUSTMENT control R5
0 to —5 volts do output from mm. to

max. of AMPERAGE ADJUSTMENT
control R5
Circuit common
Diagram 8-5. Troubleshooting Circuit Diagram For Control Board PCi
5M-221 Page 34
IMPORTANT: For DC. the values are based on a good quality digital
volt-ohmmeter (OVM) or equivalent reading average (not RMS)
values. For AC. the values are RMS readings. The voltages shown
are with respect to circuit common (lead 43) unless otherwise
indicated and the tolerances are ±10% unless otherwise specified.
IMPORTANT: Test point A is for use with letter-matching waveform.
2ms iV
gnd
A. SRi Gate Pulse At No Load

0-106 339-A
SM-221 Page 35
8-5. HALL DEVICE HD1 TESTING INFORMATION 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.
• Shutdown welding powersource before mak-
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.
• 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.
CAUTION: ELECTROSTATIC DISCHARGE

A (ESD) can damage circuit boards.
Operational input power of +15 volts dc should exist be-
tween pins C and A (circuit common) and —15 volts dc
should exist between pins B and A (circuit common). A
current feedback signal of +0.7 volts dc ±20%for each
• Transport circuit boards in proper static- 100 amperes of weld output (see Diagram 8-6) should
shielding carriers or packages. exist between pins D and A (circuit common). If the out-
• Perform work only at a static-safe work area. put feedback signal is not present, replace HD1.
Terminal connection
Points
Ref. B—134 828
Figure 8-2. Hall Device HD1 Component Locations And Information For 300 And 400 Ampere Models
5M-221 Page 36
01
& ill
V
U
~ 01 01 —
o
Li. CO
— CO CO
~ 01
001 C’)
Os ~
0 — 0.0
:~,.=—.01 0. — —
V 0
~ ~ ~
U E
~01 •0=~ E
01 01~ 0
~0 01
o ~ 0 01 ~
I
~ 0101 .~ in
~ a..! — U
01
zo .~ U’
+ OO~ C.) —
01 u +
~
A ±4 A
Ce
.~ ~
.1;
0
‘- 0101
CO.~
0
1..
0
01 0.
~ ~- E
~01 ~
0
~01i~o ‘- ‘~-
~ CO
0
~ 0 CO
0
4~01E ~ 0
C,,
~ 1~
41 U 0
Ci
z
C C 0
0
3
10 10 0
0
+
i
z
0
U-
ECu
4-
0)
Cu
CO
b
CO
U
2~
e
CO (3
0)
U,
I- CO 4-
e~ CO 0
0~
0•
.~e
~
CO
o~•
-~CO
01 0
U)
‘-0 ~01
z o0~ o~ CO 0
CO .0
0 ‘~01 b
~ ~ 0 0
E~ CO~ 01
x 010 .001 01 I-
.~ .~ 0 0.
U
o 01~5
.001 CO S 0
a~ ~ CO E
CO
~b CO~
0 Cu
I-
0. •~01
COO 0)
Cfl~~ .~0 0
01CO
—— 01 ‘-01
0.-
0
01~ 001 001
~.E ~ 001 010.
Jo 0) •~
~-0
5jJ
~ 0 .c eb
~CO ~
We u
01 ~ .~ ~0.
0
0,01.-— .-~ 01=
Z~ 0
oE ~CO OCO
001
• 6 LLCO
S 6
‘1 5M-221 Page 37
8-6. HALL DEVICE HD1 TESTING INFORMATION INCORRECT INSTALLATION or misaligned
FOR 500 AND 600 AMPERE MODELS (Figure plugs can damage circuit board.
8-3 And Diagram 8-7) • Be sure that plugs are properly installed and
aligned.

• Shutdown welding powersource before mak-
board.
• Use only minimalpressure and gentle move-
ing or changing meter lead connections and ment when disconnecting or connecting
before disconnecting or connecting any board plugs and removing or installing board.
leads.
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
wherecheck isperformed. All checksshould go through
This procedure requiresthe unitto be energized. the connections and be actual terminal-to-terminal tests
Only qualified persons familiar with and follow- so that badconnections or leads and corrosion isnot the
testing procedure. problem.
CAUTION: ELECTROSTATIC DISCHARGE

A (ESD) can damage circuit boards.
Operational input powerof +15 volts dc should exist be-
tween leads 71 and 43 (circuit common) and —15 volts
dc should exist between leads 72 and 43 (circuit com-
mon). A current feedback signal of +0.7 volts dc ±20%
• Transport circuit boards in proper static- for each 100 amperes of weld output (see Diagram 8-7)
shielding carriers or packages. should exist between leads 78 and 43 (circuit common).
• Perform work only at a static-safe work area. Ifthe output feedback signal is not present, replace HD1.
Leads To HD1
ASSEMBLY NC.
/
0
0 0 0
—II-- RS 2
—~--
~ (~n
RS 3
O ==
43 78
=
71
=
72 0
Terminal
Connection
Points
SA—099 1B8.B
Figure 8-3. Hall Device HD1 Component Locations And Information For 500 And 600 Ampere Models
5M—221 Page 38
0~
-- 01
Lj CI 0
— Co
~ 01
U
e
~ -~
CO 0)0101
CI ~u
0~CO0
Ce
.1;
.~ ~ -~
0
CO ~
CO.CI
0
0
01
E
01 ,,~ 01
0w~ .~
o -a’~
01
~ 0101 ~
~ ‘-‘~. 0
c Co
0 Co
C
4~01E ~ C
~ U
41
a. 0.
0 U 0
U U
0, 0,
S
0
a
in
•I.
U,
iz
h.
0
U..
E
Cu
1..
0)
Cu
a
ui 4..
CO U
CI c3
CO 0)
4..
Ce
I-
~ ~
020 ~
0
0
010 Co Co
4 0) Ce
a. C.J~ .~uj
0)
‘-0 ~01 CO
C, 00) 0~ ~ .0
z CO
‘S 0
h.
.~ .~ ~
0 I-
~ CO~. 01 —c’J(t~ ~
.1
010 .010~ ~
01~0
~
~0 0 a
~-
(fllW
E
(U
O
.001
01~ •a•~
CO Co
4~5
C
~ ~C01 ~ Cu
1..
C.) 0. ~ Co~ COO
0)
Cu
0 - .~0 CI’~ U.~
z. ~ 0101 0 01U
cn~’ •o ~ ‘-01
0.—
01 00)
0)~ b~
001 010. U.i,
8CI ~Co ~
ujo
..J.~ •0
Wa, U
0, ~
0 ~ .~. .~
(‘U .0•~ ~
0, —
2::, 0 -01 01 0Co
2W CI
001
cnE ~u LLCo
0 • 0 0
‘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

• Shut down welding powersource, and discon-
diode conducts in the forward direction (meter
reads 0.3 to 0.9V), and blocks in the reverse di-
rection (meter reads OL).
procedures before inspecting, maintaining, or 4. If either diode does not check properly, replace
servicing. the diode.
Lockout/tagging procedures consist of pad- 5. If the diodes check properly, reconnect leads to
locking line disconnect switch in open position, marked locations.
removing fuses from fuse box, or shutting off and
ing device. 8-8. MAIN RECTIFIER SRi TESTING AND RE-
MOVING PARTS can cause serious injury. PLACEMENT PROCEDURE FOR 300 AM-
• Keep away from moving parts. PERE MODELS (Figures 8-5 Thru 8-8)
Only qualified persons familiar with and follow-
• Shutdown welding powersource, anddiscon-
ing standard safety practices are to perform this nect input power employing lockout/tagging
testing procedure. procedures before inspecting, maintaining, or
senilcing.
IMPORTANT: Read and understand meter Owner’s
Manual before making measurements. See Figure 9-1 Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
for location of diodes 010 and Dli in this unit. removing fuses from fuse box, or shutting off and
ing device.
Anode
Only qualified persons familiar with and follow-
Reverse testing procedure.
Biased
IMPORTANT: Read and understand meter Owner’s
cathode Manual before making measurements. See Figure 9-1
for location of main rectifier SR 1 in this unit.
A. SCR Testing Procedure (Figures 8-5 And 8-6)
A WARNING: Read and follow safety informa-

tion at beginning of entire Section 8-8 before
proceeding.
Forward IMPORTANT: The SCR’s of SRi should be checked

with an SCR tester, such as a Handyman269 or equiva-
Biased lent. Ifan SCR tester is not available, usea good quality
VOM, such as a Simpson 260 or equivalent.
Cathode
S—0149
IMPORTANT: The ohmmeter check ofan SCR is nota
Figure 8-4. Diode Testing Procedure conclusive test. More conclusive tests require special-
ized equipment. Hence, even though an SCR checks out
1. Mark and disconnect one lead of diodes D1O and good, the SOP may still be bad. An SCR may be bad at
Dli. the actual applied voltage yetcheck outgoodat the com-
paratively low ohmmeter voltage (usually about 1.5
2. Set meter on Diode Test scale. volts). If in doubt, replace the SOB.
5M—221 Page 40
Rel. C-087 094-B
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:

proceeding.
a. Breakaway Nut: Wrench-tighten until hex por-
tion breaks off. Discard hex portion.
b. Washer-nut Combination: Finger-tighten as
IMPORTANT: If any SCR’s are replaced, be sure to tight as possible. Using a wrench, turn the nut
check capacitors C7 through C12 for proper connec- i/2 turn only. The washer-nut combination will
tions, shorts, and leakage. Also, visually examine main be compressed to its calibrated pressure using
transformer Ti for signs of winding failure (uneven dis-
coloration would be apparent if a short has occurred). this tightening procedure.
Check continuity across each winding, and check for IMPORTANT: Ifusing a standardnutandan inch-pound
proper connections. Check phase-to-phase voltage be- torque wrench, tighten the nut to 275-325 in-lbs. Be sure
tween leads 21 and 22, 22 and 23, and 21 and 23 (see SCR threads are dry; do not lubricate.
Diagram 8-1, 8-2, 8-3, or 8-4). Replace C7 through C12
and Ti if necessary
8. Apply a thin layer of supplied anti-oxidant com-
pound to pigtail connection tab surface (see Fig-
1. Locate and disconnect receptacle RC2 from plug ure 8-8), and connect pigtail to proper location on
PLG2 on Control Board PCi.
heat sink.
2. Trace the red and white leads from SCR to be re-
placed to receptacle RC2. Mark and remove the 9. Route and connect leads from new SCR to
marked locations in receptacle RC2.
leads from receptacle RC2 using an AMP
4651 99-1 pin extraction tool (MILLER part num- 10. Reconnect receptacle RC2 to plug PLG2 on Con-
ber 099 719) according to Figure 8-7. trol Board PCi.
Pigtail
Connection Tab
I Locking
Lance
SCR Face
Part Number 099 719
ST.147 699
Figure 8-7. Pin Extraction Tool Figure 8-8. SCR Installation

5M-221 Page 42
8-9. MAIN RECTIFIER SRi TESTING AND RE- 1. Locate and disconnect receptacle RC2 from plug
PLACEMENT PROCEDURE FOR 400, 500, PLG2 on Control Board PCi.
AND 600 AMPERE MODELS (Figures 8-9
Thru 8-12) 2. If an SCR tester is available, test each SCR ac-
cording to the manufacturer’s instructions. If an

• Shutdown weldingpowersource, anddiscon-
SOR does not check properly, replace the SCR
according to Section 8-9B.
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.
• 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
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

proceeding.
you that the SCR gate is okay. If a low reading
cannot be obtained, the SOR gate isbad. The am-
meter should indicate current flow meaning that
the SCR has turned on. When testing small
IMPORTANT: The SOR’s of SRi should be checked
with an 5CR tester, such as a Handyman 269 or equiva- SCR’s, removal of the gate lead from the anode
lent. Ifan SCR tester is notavailable, use a good quality will not change the ammeter reading. This is be-
VOM, such as a Simpson 260 or equivalent. cause the meter is providing a ~holdingcurrent.”
On large SCR’s, the meter cannot provide
IMPORTANT: When testing hockey puk SCR’s discon- enough “holding current,” so the meter will revert
nectgate lead and cathode oranode connection to heat to a high resistance when the gate lead is re-
sink, but leave SCR clamped in its original heat sink. moved from the anode.
Hockeypuk SCR’s must be under mounting pressure to
allowtesting. The mountingpressureis necessaryfor in- 7. If an SCR does not check properly, replace the
ternal contact between chip and pole pieces. Disregard SCR according to Section 8-9B.
small red cathode lead. Meter readings may be taken at
heatsink(s), ifapplicable. See Figure 8-9 forlead identi- 8. Ifthe SCR’s check properly, reconnect receptacle
fication. RC2 to plug PLG2 on Control Board PCi.
5M-22i Page 43
spring Indicator Clamp
TOP VIEW
Red White Red white (see Figure 8-12) Red White
C SCR2 SCRi
SCR3
C
White
b Red
010
‘11111
Red
- • I
-~:
I
I I IIL~’z~~~I
I j~Jyj’—~~~’
~
‘‘~‘ Jo - I Ill
•••.p.•UU
I
“~“ -
White
SCR6 SCR5 SCR4
Capacitors C7-C12 Heat Sink
9
V~N
——— —
Heat Sink
5CR
spring Pins
I —
U. —
Spring Indicator Clamp

(see Figure 8-12) Ref. 5D.140 121-A
SD—O4~ 899—H
Figure 8-9. Main Rectifier SRi Component Locations And Information For
400, 500, And 600 Ampere Models
SM-221 Page 44
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.

proceeding.
4. Loosen clamping device, and remove 5CR to be
replaced.
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.
9. Place clamp fully into mounting position.
10. Tighten nuts on clamp evenly until finger tight.
ii. Using a wrench, tighten one nut 1/4 turn and then
other nut 1/4 turn until the loweredge of the spring
indicates a mounting force of 0.8 kilo lbs. for 400
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.)
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5M-221 Page 46
SECTION 9— COMPONENT IDENTIFICATION AND LOCATION
U a,
(U
—— i~C.IJ
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5M-22i Page 47
Remote 14
Range Switch S3 Receptacle Rd
Amperage Control
Switch S2
Arc Control R3
Output (Contactor)
Switch S4
Amperage Adjustment
control RS
— N
— N
— N
Push Button
PBI Switch
Assembly
(see Figure 9-7)
2
Pilot Light PLI
Negative Weld
Output Terminal
Front Panel
Positive Weld
Output Terminal
SC—004 907—N
Figure 9-2. Front Panel And Component Locations
5M-221 Page 48
Rear Panel
Fan
Plenum Chamber
Fan Motor FM
SC-004 988-C
Figure 9-3. Rear Panel And Component Locations
capacitors
c7-ci2
SS-049 529-A
Figure 9-4. Main Rectifier SRi And Component Locations For 300 Ampere Models
SM-221 Page 49
Heat Sink
capacitors
c7-c12
—--I
—- I
— I
—— I
I—-
Silicon controlled IncI~cator
Rectifiers clamp
scRl-scR6
-J
——
Spring Pin Stand-Offs

SD-048 899—H
Figure 9-5. Main Rectifier SRi And Component Locations For 400, 500, And 600 Ampere Models
5A—138 574
Figure 9-6. Input Terminal Board TEl And Component Locations

SM—221 Page 50
Bracket
On Push Button
Compression 5~
Limit Switch
Oft Push Button

SA-OBO 214-B
Figure 9-7. Push Button PBi Switch Assembly And Component Locations
SM-221 Page 51
SECTION 10— MAINTENANCE
10-1.ROUTINE MAINTENANCE (Table 10-i) Table 10-i. Maintenance Schedule

IMPORTANT: Every six months inspect the labels on
this unit for legibility All precautionary labels must be Frequency* Maintenance
maintained in a clearly readable state and replaced
when necessary See Service Parts Manual for part Every month. Units in heavy service environ
number ofprecautionary labels. ments:
Check labels, weld cables, clean

eDo not touch live electrical parts.
• Shutdown welding powersource, and discon- Every 3 months.
internal parts.
Check weld cables (see Section
10-i).
procedures before inspecting, maintaining, or Every 6 months. Check all labels (see IMPORT
servicing. ANT block, Section 10-i). Clean
Lockout/tagging procedures consist of pad- internal parts (see Section
locking line disconnect switch in open position, 10-i).
removing fuses from fuse box, or shutting off and *Frequency of service is based on units operated 40
ing device. hours per week. Increase frequency of maintenance if
MOVING PARTS can cause serious injury. usage exceeds 40 hours per week.
10-2. RECTIFIER PROTECTION
The main rectifier SRi in this welding power source is
A. Fan Motor protected by a normally-closed thermostat TP1 wired in
This unit is equipped with an exhaust fan and relies on series with the contactor W coil circuit. Should overheat-
forced draft for adequate cooling. The fan motor is ing of the main rectifier occur, this thermostat would
manufactured with lifetime sealed bearings and requires open causing the contactor to drop out (deenergize)
no maintenance. thereby suspending all output. If this condition occurs, it
will be necessary to allow a cooling period before resum-
B. Weld Cables
ing operation.

tion at beginning of entire Section 10-1 be-
fore proceeding. 10-3. DEMAND FAN CONTROL (Optional)
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-
A ARNING: Read and follow safety informa-

tion at beginning of entire Section 10-i be-
fore proceeding.
lay CR1 regulate the operation of the fan motor FM.
When the transformer and/or rectifier assemblywarm up
Every six months blow out or vacuum dust and dirt from enough to close any of the thermostats, relay CR1 ener-
the inside of the welding power source. Remove the gizes causing the fan motor to start running. The fan mo-
outer enclosure, and use a clean, dry airstream or vac- tor will continue running until the transformer and/or rec-
uum suction for the cleaning operation. If dusty or dirty tifier have cooled down enough to permit thermostats
conditions are present, clean the unit monthly. TP2, TP3, and TP4 to open or until the unit isshut down.
5M-221 Page 52
SECTION 11 - ELECTRICAL DIAGRAMS
Table 11-1. List Of Circuit Diagrams And Wiring Diagrams
The following isa list of all diagrams for models covered bythis manual. To order diagramsneeded, proceed as follows:
1. Know unit Model and Serial or Style Number.
2. Use List to find diagram number.
3. Call the Technical Publications Department at 414-735-4356.
Model Serial Or Style Number Circuit Diagram Wiring Diagram

Gold Star
300SS JC64i 296 thru JG032479 SN-084 604
400SS JC590316 thru JG032479 SN-084 604
300SS, 400SS JG032480 thru JH176799 SC-106 568-A
JH1 76800 thru JJ503983 SC-1i3 576
JJ503984 thru JK674520 SC-i23 911
300SS JK674521 thru KA819072 SC-i 30 406 D-i31 066..
400SS JK674521 thru KA819072 SC-i 30 406 D-131 172,,
300SS KA8i 9073 and following SC-i 37 779-A SD-137 776
400SS KA8i 9073 and following SC-i 37 779-A SD-137 777
300SS w/fan control JC641 296 thru JF855842 SN-086 283

400SS w/fan control JC59031 6 thru JF855842 SN-086 283
300SS, 400SS w/fan control JF855843 thru JG032479 SN-095 291
JG032480 thru JH296871 SC-i06 566-A
JH296872 thru JJ503983 SC-114 061
JJ503984 thru JK674520 SC-123 912
JK674521 thru KA819072 SC-i32 460
KA8i 9073 and following SC-i 37 935-A
SOOSS JE747791 thru JF84688 SN-093 184

JF846889 thru JG032479 SN-096 452
600SS JE813766 thru JG032479 SN-096 452
SOOSS, 600SS JG032480 thru JJ503983 SC-106 567-A
JJ503984 thru JK674520 SC-i23 913
JK674521 thru KA819072 SC-130 409-A D-130 826,,
KA8i 9073 and following SC-137 784-A SD-i37 778
SOOSS w/fan control JE747791 thru JG032479 SN-098 206

600SS w/fan control JE81 3766 thru JG032479 SN-098 206
SOOSS, 600SS w/fan control JG032480 thru JJ503983 SC-106 569-A
JJ503984 thru JK674520 SC-123 914
JK674521 thru KA819072 SC-132 459
KA8i 9073 and following SC-137 936-A
Circuit Board PCi (See Note) thru JF933619 SN-084 219

JF933620 and following SN-106 339-A
SM-221 Page 54
Table 11-1. List Of Circuit Diagrams And Wiring Diagrams (Continued)
Model Serial Or Style Number ~uitJi~gram Wiring Diagram

Hall Device HD1
for 300SS JC641 296 thru JH176788 SN-085 229
JH1 76789 and following SA-1 10 758-A
for 40055 JC59031 6 thru JH1 76788 SN-085 229
JH1 76789 and following SA-1 10 758-A
for SOOSS JE747791 and following SN-085 229
for 60055 JE81 3766 and following SN-085 229
• • Not included in this manual

Note: See the effective serial number for each model on front cover.
SM-221 Page 55
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SM-221 Page 56
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SM-221 Page 58
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SM—221 Page ei
Diagram 11-7. Wiring Diagram For 300 Ampere Models Effective With Serial No. KABI 9073 And Following
SM-221 Page 62
V4-4TCSCRA)
REO(SCR4)
RED (SCR I)
VU? (SCS I
Wi-I? (SC95)
RED?SCSD)
RED(SCQ2)
WI-I? (SCR2)
WWT(5C046)
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REO(SCS3?
CM
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BOA ISA—D04) C-
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CD
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0~
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67(11-83 BEG)
69(T)-fl BEG)
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Wiring Diagram No. SD-i 37 776
SM-221 Page 63
)?
Diagram 11-8. Wiring Diagram For 400 Ampere Models Effective With Serial No. KA819073 And Following
SM—221 Page 64
SM-22t Page 65
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5M—221 Page 66
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SM-221 Page 67
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SM-221 Page 68
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Diagram 11-22. Wiring Diagram For 500 And 600 Ampere Models Effective With Serial No. KA819073 And Following
SM-221 Page 80
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SM-221 Page 81
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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
With Serial No. JC641296
With Serial No. JC590316
The PowerofBlue. Gold Star® 500SS Effective
GOLD STAR ®SS
Visit our website at

PARTS LIST
WWW.MIIIBVWIIIILCOII
(9
a’
a,
In
0
a)
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0
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a)
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Goldstar Series
SPM—221 Page 1
Replace Coils At Factory Or Authorized Factory Service Station
Quantity
Model
Item Dia. Part ~65T~0060~
No. MkQs. No. Description Amo lAm lAmol AmD
Figure 1. Main Assembly

1 •,006 016 PANEL,side
109035 LABEL, warning electric shock can kill etc 1 ... 1 ... 1 .... 1
i •,005 195 PANEL, side 2
006017 .COVER,top
005194 COVER, top 1
•04722i COVER, top w/meter holes 1 ... 1 ... 1
•092498 COVER, top w/meter holes 1
026 627 GASKET,Iiftingeye 1 ...1 ... 1 ....i
004214 BUSHING, snap-in nyl 1.625 ID x 2.OOOmtg hole 1 ... 1 ... 1 .... 1
091 164 - FRAME, upright base (Elf w/JD688393) 1 ... 1
091 164 FRAME, upright base (Elf w/JE747791) 1
091 164 FRAME, upright base (Elf w/JE813766) 1
134 771 PLUG, protective .640sq 2 ... 2 ... 2 . .. . 2
Z 035 279 STABILIZER 1 ... 1
Z 003 007 STABILIZER 1
z 005 380 STABILIZER 1
Fl 088 384 FUSE, crtg lA 600V (Eff w/HJ2i 9398 thru JE747791) 1
070 404 HOLDER, fuse crtg 30A 600V
(Eff w/HJ219398 thru JE747791) 1
Fl 088384 FUSE, crig iA600V(Effw/HJ2193981hwJE813766) 1
070404 HOLDER, fuse crtg 30A 600V
(Elf w/HJ21 9398 thru JE81 3766) 1
082 976 HOLDER, fuse mintr .250 x 1.250 clip
(Prior to JG032480) 1 ... 1 ... 1 .... 1
F2-6 .... 012633 FUSE, mintr gI lA (Prior to JG032480) 5 ... 5 ... 5 . . 5 . .
Fig2 PANEL, rear w/components 1 ... 1 1

... 1 ....
...8.... TEl 038145 TERMINAL ASSEMBLY, dual voltage (Fig 3) 1 ... 1 ... 1 1 ....
...8.... TEl 038138 TERMINAL ASSEMBLY, triple voltage (Fig 3) 1 ... 1 1

... 1 ....
...9...C21-23 ... 129954 CAPACITOR, (Prior to KA819073) 3 ... 3... 3.... 3

...9.... C2i 137674 CAPACITOR, (Elf w/KA8i 9073) 1 ... 1 ... 1 . ... 1
...9...C22,23 ... 137771 CAPACITOR ASSEMBLY, (Elf w/KA8i 9073) 2 ... 2 ... 2 . ... 2
10 084251 BRACKET, mtg term bd LH (Prior to JJ44741 5) 1 ... 1 ... 1 .... 1
10 084252 BRACKET, mtg term bd RH (Prior to JJ44741 5) 1 ... 1 ... 1 .... 1

10 097918 BRACKET, mtg term bd (Elf w/JJ447415) 2 ... 2... 2 .... 2
11 ... PCi 087308 CIRCUIT CARD, root pass (Fig 8) 1
Ii ... PCi 084552 CIRCUIT CARD, root pass (Fig 8) 1
PLGi .... 048280 HOUSING PLUG & PINS, (consisting of) 1 ... 1 ... 1 .... 1
058971 ....TERMINAL,malel pin
RC1 .. “048 281 RECEPTACLE w/SOCKETS, (consisting of) 1 ... 1 ... 1 - 1
...
058972 TERMINAL, female iskt 2 ... 2... 2.... 2

PLG2 .... 035815 TERMINAL, hdr29skt 1 ... 1 ... 1 1
....
12 080509 GROMMET, scr No. 8/10 panel hole .312sq .375 high . ... 3 ... 3 ... 3 3
....
057084 BUSHING, snap-in nyl .250 ID x .37Smtg hole

(Prior to JG071229) 1 ... 1
035 506 -. GUIDE, circuit card 9 in (Prior to JG071229) 2 . . . . 2
13 090781 ..CIRCUITCARDBOX
14 138 378 BRACKET, mtg rect (included w/rectifier) 1 ... 1 . ... 1
15 086 455 BASE, (Prior to JD688393) 1

15 091 034 BASE, (Elf w/JD688393 thru JH296871) 1
15 116 838 BASE, (Elf w/JH296872 thru KBOS51iS) 1
15 140 865 BASE, (Elf w/KB055116 and on) 1
15 091008.. BASE, (Prior to JF855870) 1
SPM-221 Page 2
Goldstar Senes
Quantity
Model
Item Dia. Part
Description
5T~5050~Th~0
No. Mkas. No. AmD lAmo lAmo IAmD
Figure 1. Main Assembly (Continued)
• 15 089 151 BASE,

(Elf w/JF855870 thru JH296871) 1
15 116 840 BASE,
(Elf w/JH296872 thru KBOSS115) 1
15 139 785 BASE,
(Elf w/KB055116 and on) 1
15 089 151 BASE,
(Prior to JH296872) 1
15 116 840 BASE,
(Elf w/JH296872 thru KBO5S11S) 1
15 139 785 BASE,
(Elf w/KB055116) 1
15 091 393 BASE,
(Prior to JH296872) 1
15 116862 BASE,
(Elf w/JH296872 thru KB055115) 1
15 139784 BASE,
(Elf w/KB055116) 1
16 Ti .... +087 355 TRANSFORMER, 230/460 (Prior to JE792690)
(consisting of) 1
17 ++072 221 COIL, pri/sec RH & center 2
18 072220 ...COIL, pri/sec LH 1
16 Ti
.... .... +122876 TRANSFORMER, 230/460 (consisting of) 1
17 ++090799 .... COIL, pri/sec RH & center 2
18 090798 .... COIL, pri/sec LH 1
16 Ti
.... .... +122877 TRANSFORMER, 200/230/460 (consisting of) 1
17 -i-+090 801 .... COIL, pri/sec RH & center 2
18 090800 .... COiL, pri/sec LH 1
16 Ti
.... .... +122878 TRANSFORMER, 230/460/575 (consisting of) 1
17 ++090 803 • ... COIL, pri/sec RH & center 2
18 090802 .... COIL, pri/sec LH 1
16 ....T1 ... +084116 TRANSFORMER, 230/460 (Prior to JE747791)
(consisting of) 1
17 ++035 382 ...COIL, pr/sec RH & center 2
18 035381 .... COIL, pr/sec LH 1
16 .... Ti .... +122886 TRANSFORMER, 230/460 (Elf w/JE747791)
(consisting of) 1
17 ++090 787 COIL, pr/sec RH & center 2
18 090786 ...COIL, pr/sec LH 1
16 .... Ti .... +122881 TRANSFORMER, 200/230/460 (consisting of) 1
17 ++090789 .... COIL, pr/sec RH & center 2
18 090788 COIL, pri/sec LH 1
17 -i-+090791 COIL, pri/sec RH & center 2
18 090790 COIL, pri/sec LH 1
16 Ti
.... .... +092990 TRANSFORMER, 230/460 (Prior to JE791122)
(consisting of) 1
17 ++000977 .... COIL, prVsec RH & center 2
18 000976 ...COIL, pri/sec LH 1
16 .... Ti .... +122888 TRANSFORMER, 230/460 (Elf w/JE791122)
(consisting of) 1
17 +-i-095 221 ...COIL, pri/sec RH & center (Prior to JF877636) 2
17 ++098417 COIL, pri/sec RH & center (Elf w/JF877636) 2
18 095220 COIL, pri/sec LH (Prior to JF877636) 1
18 098416 COIL, pri/sec LH (Elf w/JF877636) 1
17 ++095 223 COIL, pri/sec RH & center (Prior to JF877636) 2
17 ++098 421 .... COIL, pri/sec RH & center (Elf w/JF877636) 2
18 095222 .... COIL, pri/sec LH (Prior to JF877636) 1
18 098420 .... COIL, pri/sec LH (Elf w/JF877636) 1
16 Ti
.... +122889
.... TRANSFORMER, 230/460/575 (consisting of) 1
17 ++095225 OQIL, pr/sec RH & center (Prior to JF877636) 2
17 ++098419 COIL, pri/sec RH & center (Elf w/JF877636) 2
18 095224 .... COIL, pr/sec LH (Prior to JF877636) 1
18 098418 .... COIL, pr/sec LH (Elf w/JF877636) 1
SPM-221 Page 3 Goldstar Series
Quantity
Model
Item Dia. Part
Description
~
AmD IAmD lAmp lAmp
No. Mkgs. No.
16 .... Ti .... +096749 TRANSFORMER, 230/460 (Prior to JE791122)

(consisting of) 1
17 .i-+005 365 COIL, pri/sec RH & center 2
18 005364 COIL,pri/secLH 1
16 .... Ti .... +122892 TRANSFORMER, 230/460 (Elf w/JF848854)
(consisting of) 1
17 +-i-097 584 COIL, prVsec RH & center 2
18 097583 .... COIL, pri/sec LH 1
17 ++097736 COIL, pri/sec RH&center 2
18 097735 ... COIL, pri/sec LH 1
16 .... +122894
Ti .... TRANSFORMER, 230/460/575 (consisting of) 1
17 ++097586 COIL, pn/sec RH & center 2
18 097585 COIL, pri/sec LH
- 1
TP3... •088592 THERMOSTAT, NO (located in Ti w/fan control) 1 ... 1 ... 1 .... 1
TP4... •094352 THERMOSTAT, NO (located in Ti w/fan control) 1 ... 1 ... 1 .... 1
Oil 075 SPRING, pressure (used w/TP4) 1 ... 1 ... 1 .... 1
19 .... R6 . +++039210 RESISTOR,WWfxd375Wi2ohm
-.20 Fig4 PANEL, front w/components 1 ... 1 ... 1 ... - 1
21 SRi
... 087094 RECTIFIER, SCR (Fig 6) 1
21 ... SRi... •087072 RECTIFIER, SCR (Fig 6) (fan control) 1
..21 SRi
... 083910 RECTIFIER, SCR (Fig 7) (Prior to JF855870) 1
21 SRi
... 092723 RECTIFIER, SOR (Fig 7) (Elf w/JF855870 thru KB055115) 1
21 SRi
... 140121 RECTIFIER, 5CR (Fig 7) (Elf w/KBO5Sii6 and on) 1
21 SRi... .086062
.. RECTIFIER, SOR (Fig 7) (fan control)
(Elf w/JC6i 5021 thru JF855842) 1
21 ... SRi... ,099465 RECTIFIER, SCR (Fig 7) (fan control)
(Elf w/JK855843 thru KBO5S1 15) 1
21 ... SRi... •140122 RECTIFIER, SCR (Fig 7) (fan control)
21 ... SRi 045237 RECTIFIER, SCR (Fig 7) (Prior to JE747791) 1
RECTIFIER, SOR (Fig 7)
21 ... SRi 092685 (Elf w/JE747791 thru JF846888) 1
21 ... SRi 097728 RECTIFIER, SCR (Fig 7)
(Elf w/JF846889thru KBO5SiiS) 1
21 SRi ... 139584 RECTIFIER, SCR (Fig 7) (Elf w/KBO5Sii6 and on) 1
..21 ...SRi... •086399 RECTIFIER, SCR (Fig 7) (fan control)
(Eff w/JE747791 thru JF848845) 1
21 ... SRi... .092685 RECTIFIER, SCR (Fig 7) (fan control)
(Eff w/JF848846 thru KBO5Si 15) 1
21 ... SRi... •i39585 RECTIFIER, SCR (Fig 7) (fan control)
21 .. SRi 045007 RECTIFIER, SCR (Fig 7) (Prior to JF846889) 1
21 ... SRi 093145 RECTIFIER, SCR (Fig 7)
(Prior to JF846889 thru KB055115) 1
21 ... SRi 139586 RECTIFIER, SCR (Fig 7) (Elf w/KBO5Si 16 and on) 1
21 ... SRi... .086284 RECTIFIER, SCR (Fig 7) (fan control)
(Elf w/JE8i 3766 thru JF848845) 1
21 ... SRi ... •099 466 RECTIFIER, SCR (Fig 7) (fan control)
(Elf w/JF848846 thru KB0551 15) 1
21 ... SRi... ,139587 - RECTIFIER, SCR (Fig 7) (fan control)
(Elf w/KBOS51i6 and on) 1
CR1 .. .006393 RELAY, end 24VAC DPDT (fan control) 1 ... 1 ... 1 ... 1
.
22 144017 BRACKET, mtg hall (Elf w/KB04471 8) 1 ... 1 1

....
Goldstar Series SPM-221 Page 4

Quantity
Model
Item Dia. Part
Description
i5~T~6~T~0O 600
No. Mkgs. No. Amo lAmo lAmo IAmD
23 . HAi,HD1 085 166 SENSOR, current (Prior to JHi 75959) 1 .- 1

.
23 HAi,HD1
. 134 826 CIRCUIT CARD, hall booster (Elf w/JHi 75959) 1 1
...
23 .HA1,HDi 085 166 SENSOR, current 1 .... 1

137 900 KIT, contactor 1 ... 1
24 .... W 137901 KIT, contactor :1 ...
082 456 DIODE, (consisting of) 1 1

... 1 1... ....
25 .. DiO,li 070 250 DIODE,rect3A600V 2...2...2....2
• •When ordering a component originally displaying a precautionary label, the label should also be ordered.
•OPTIONAL
“Part of Circuit Card
+lf unit has optional duplex receptacle the transformer is special. Contact Factory Parts Department for correct part
numbers.
++Quantity of this item changes to 1 for units w/optional duplex receptacle as the RH coil has ii5V tertiary winding.
+-i-+For the 300 Amp model this resistor is located on the 14 in. Plenum Chamber.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
5PM-221 Page 5 Goldstar Series

Quantity
Model
Item Dia. Part ~
No. Mkas. No. Description AmoIAmD lAmol Am
Figure 2. Panel, Rear wlComponents (Fig 1 Item 7)
FM 116190 MOTOR, i/i2hp230V 1550RPM 1 ... 1

FM 032605 MOTOR, cap perm SP i/4hp 230VAC 1625RPM 1 . ... 1
131 361 CHAMBER, plenum 14 in 1 ... 1
132260 CHAMBER, plenum 14 in 1 .... 1
032611 BLADE, fan 14 in 3wg 23deg .375 bore CCW 1 ... 1
605 799 BLADE, fan 14 in Swg 3odeg .500 bore CW 1 .... 1
158289 PANEL,rear
ST-004 988-0
5
Figure 2. Panel, Rear w/Components
7
8
ST—138 574
Figure 3. Terminal Assembly, Pri
Item Part Quantity

No. No. Description
Figure 3. Terminal Assembly, Pri (Fig 1 Item 8) 038 145 1038 138
601 835 NUT, brs hex 10-32 24 .. 36

038 058 TERMINAL BOARD, primary 1 .... 1
038 887 STUD, pri board brs 10-32 x 1.375 12 .. 18
010 913 WASHER, flat brs .218 ID x .460 OD x .O3ithk 12 .. 18
038 618 LINK, jumper term bd pri 6 - ... 6
601 836 -. NUT,brshex.250-20samh~/y 6.... 6
010 915 WASHER, flat brs .250 ID x .625 OD x .O3ithk 6 .... 6
038 888 STUD, pri board brs .250-20 x 1.500 3 .... 3
Goldstar Series 5PM-221 Page 6
4
— N.
10
Fig 5
24
I 12
ST—004 987-P
Figure 4. Panel, Front wlComponents

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 4. Panel, Front w/Components (Fig 1 Item 20)
... 1 NAMEPLATE, (order by model and serial number) 1

SS 011 610... SWITCH, tgl SPDT 15A i25VAC (Prior to JK674521) 1
R4 030 853 ... RESISTOR, C .5W 2.2K ohm (Prior to JK674521) 1
R3 052 140... RESISTOR, C .5W 3.30 ohm (Prior to JK674521) 1
... 2 R3 009 156 ... POTENTIOMETER, C sltd sft l/T 2W 2.5K ohm (Elf w/JK674521) 1
... 3 084 107 ... PANEL, front (Prior to JF846889) 1
3 092 185... PANEL, front (Elf w/JF846889 thru JK674520) 1
3 158 258... PANEL, front (Elf w/JK674521 and on) 1
.4 S3 089 085 ... SWITCH, tgl SPST 20A i25VAC 1
Ri 084 206 ... RESISTOR, MF .25W 3.32K ohm 1
.5 .. Ci4,i5,
17,i8,RCi ... 087 415... RECEPTACLE w/CAPACITORS, (Prior to JK674521) 1
039 684... CAP, dust connector 97-121-416R (Prior to JK674521) 1
5 130 257 RECEPTACLE w/CAPACITORS, (Elf w/JK674521) (consisting of)
... 1
Ci4 143 935 LEAD ASSEMBLY, elect 1
....RCi 143 976 CONNECTOR w/PINS, (consisting of) 1
079 534 CONNECTOR, circ skt push-in 14-l8ga 14
134734 HOUSING, term plug i4cont 213571-2 Amp
...
134731 TERMINAL, male 1 pin 18-14 wire 213603-i Amp

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

...
011 609 SWITCH, tgl SPDT i5A 12SVAC

... 2
R5 072 462... POTENTIOMETER, w/shaft lock (Prior to KE722876) (consisting of).... 1
072590... LOCK, pot .375-32 x .2SOdia shaft 1
R5 035897... POTENTIOMETER, CP std slot l/T 2W 1K ohm (Elf w/KE722876) 1
10... PB1 046745... SWITCH, PB (Fig 5) 1
ii ... C4,5 087337... CAPACITOR 2
12 ... NEG 039046... TERMINAL, pwr output black (consisting of) 1
13 ... POS 039047... TERMINAL, pwr output red (consisting of) 1
14 601976... SCREW, cap stl hexhd .500-13 x 1.500 - 1
15 039045.. TERMINAL BOARD, black 1
is 039 049 TERMINAL BOARD, red i
16 601 880 NUT, stl hex jam .500-13 1
-. 17 039044 BUS BAR,termbd 1
18 601 879 NUT, stl hex full .500-13 1
19 +084 106 DOOR, access front (Prior to JH296872) 1
19 +109449... DOOR, access front (Elf w/JH296872) 1
20 605583... CATCH, spr loaded door (Elf w/JH296872) 1
21 134327... LABEL, warning general precautionary 1
027628... LIGHT, md red clear (Prior to JF846889) 1
22 ... PLi 027632... LENS, light md red clear (Prior to JF846889) 1
027631 HOUSING, light md slide base (Prior to JF846889) 1
22 ... PLi 048573... LIGHT, md red lens 28V (Elf w/JF846889) 1
23 097926... KNOB, pointer 1
24 097922... KNOB, pointer (Elf w!JK67452i) 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
SPM-221 Page 8
Goldstar Series
Item Part
No. No. Description Quantity
046 745 Figure 5. Switch, PB (Fig 4 Item 10)
1 059 885 ... BUTTON, push reset red 1

2 018 606 ... SPRING, cprsn .430 OD x .040 wire x 1 .SOOstnls 1
3 045 546 ... PUSH BUTTON SET, w/cable & housing 1
4 081 008 ... BRACKET, mtg switch PB 1
5 027 878 ... SWITCH, lim leaf actg SPDT 1
4,
5
2
5T-080 214-5
Figure 5. Switch, PB
5T-049 529—A
Figure 6. Rectifier, SCR (300A)
Item Dia. Part

Figure 6. Rectifier, 5CR (300 Amp) (Fig 1 Item 21) 0870941087072
SCRi-6 ....034976... THYRISTOR, SCR 175A 300V 6 . ... 6
...2... C7-i2 053372... CAPACITOR 6 .... 6
...3.... TP1 032810... THERMOSTAT, NC 1 .... 1
TP2 086323... THERMOSTAT, NO 1
Item Dia. Part
(U,
I
0 ‘- RI
Figure 7. Rectifier, SCR (400A) (Fig 1 Item 21) ~ 0
CU
0
CI
.1 ..C7-i2... 031 688 CAPACITOR 6.. 6

.1 ..C7-i2... 048 420 ..CAPACITOR
.2 082 852 BUS BAR, (Prior to JH220869) 4 4...
.2 114 530 BAR, mtg rect (Eff w/JH220869) 2 2... 2

... .. 2
010381 CONNECTOR,rect 2...2...2 .. 2
.3 083 908 HEATSINK,rect 6 .. 6
.3 048 779 HEATSINK,rect 6...6... 6 .. 6
.4 083 884 CLAMP, thyristor 3 .. 3
.4 082 694 CLAMP,thyristor 3... 3... 3 3 ..
.5 028 516 PIN,springCS.125x.250 12.. 12 .12. 12. 12..i2

6 SCRi-6
. 046 995 THYRISTOR, SCR 300A 300V 6 ..6
6 SCRi-6
. 097 397 THYRISTOR, SCR 300A 300V 6 ... 6... 6 6 ..
.7 083 909 HEATSINK,rect 3 .. 3

.7 045 109 HEATSINK,rect 3... 3... 3 3 ..
083 907 BUSBAR,rect 2.. 2

037 087 BUS BAR, (PriortoJJ4855O4) 6 12
.. 1 1
.. ...
TP1.... 601 066 ThERMOSTAT, NC 1

TPi.... 117 275 ..THERMOSTAT,NC i...i...i...i 1 ..
TP2.... 012 631 ..THERMOSTAT,NO 1 1 1

.8 083 906 CHANNEL,mtgrect 2 ..2
.8 082 852 BUS BAR, (Elf w/JH220869) 2 2... 2 2 ... ..
026 947 STAND-OFF, insul .250-20 x 1.00 Ig 4 4 ...
025 248 STAND-OFF, insul .250-20 x 1.250 Ig 6 ..6

i 38 378 BRACKET, mtg rect (see Fig 1 Item 17) 2... 2 2 ..
1
2
1
5
6
6
5T-048 899—K
Figure 7. Rectifier, SCR

Goldstar Series 5PM-221 Page 10
Item Dia. Part
~- ~‘ C
Figure 7. Rectifier, SCR (500A) ,, CU, ~
(Fig 1 Item 21) + +
.1 ..C7-12...048420..CAPACITOR,rect
048 775 .. BUS BAR, tab connecting 8 8
048 774 .. BUS BAR, tab connecting 4 4
• 2 082 852 .. BUS BAR, (Prior to JH220869) 4 4 ... 4
2 114530 .. BAR,mtgrect(Effw/JH220869) 2 2... 2... 2 .. 2
010381 .. CONNECTOR,rect 2 2... 2... 2 .. 2
.3 048779.. HEATSINK,rect 6..6.. 6...6...6...6..6
.4 082694..CLAMP,thyristor
- 5 028516 .. PIN,springCS.125x.250 i2 .. 12.. 12 . 12 . 12 . 12.. 12
6 . SCR1-6 .. 046 995 .. THYRISTOR, SCR 300A 300V 6 6
6 . SCR1-6 .. 097397 .. THYRISTOR,SCR300A300V 6 6... 6... 6 .. 6
7 048777 .. HEATSINK,rect 3 .. 3 .. 3 ...3 ... 3... 3 .. 3
037 087 .. BUS BAR, (Prior to JJ485504) 1 1 ... 1
TP1....601066..THERMOSTAT,NC
TP2.... 012631 .. THERMOSTAT,NO 1.. 1 1 1
8 048 372 .. CHANNEL, mtg rect 2 2
8 082852 .. BUS BAR, (Eff w/JH220869) 2 2... 2... 2 .. 2
026 947 .. STAND-OFF, insul .250-20 x 1.00 Ig 4 4 ... 4
138 378 .. BRACKET, mtg rect (see Fig 1 Item 17) 2 .. 2
Item Dia. Part

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

+
1 .. C7-12 ... 048420 CAPACITOR,rectifier 6.. 6 ...6... 6... 6 6 ..
048 376 BUS BAR, tab connecting 8 8

..
049 728 BUS BAR, tab connecting 4 4

..
2 082852 BUS BAR, (Prior to JH220869) 4 4 ...
2 114530 BAR, mtg rect (Elf w/JH220869) 2 2 2 2 ... ... ..
010381 CONNECTOR,rect 2...2... 2.. 2

• 3 •048373 ..HEATSINK,rect 6.. 6...6...6...6 ..6
3 166785 HEAT SINK, rect (Elf w/KE696137) 6
4 082693 CLAMP, thyristor rectifier 8.500 3 3
.. 3 3... 3
... 3 ... ..
5 .028516 PIN,springCS.125x.25012 12..i2 .12.12. 12..12

• 6 . SCRi-6 .. 112942 THYRISTOR,SCR600A300V 6.. 6 ...6... 6... 6 6 ..
.7 •048375 HEATSINK,rect 3.. 3...3...3...3 3 ..
7 166786 • -HEAT SINK, rect (Elf w/KE6961 37) 3

037 087 BUS BAR, (Prior to JJ485504) 1 1 ...
TPi.... 601 066 ..THERMOSTAT,NC 1.. i...1...i...1 ..1

TP2.... 012 631 ..THERMOSTAT,NO 1 1 1
.8 048 372 CHANNEL, mtg rect 2 2..
.8 082 852 BUSBAR,(Elfw/JH220869) 2... 2... 2 2 ..
026 947 STAND-OFF, insul .250-20 x 1.00 Ig 4 4 ...
138 378 BRACKET, mtg rect (see Fig 1 Item 17) 2 2 ..
+Fan Control
• Prior to KE6961 37 for 600A models without Fan Control.

Dia. Part
Mkas. No. Description Quantity
Figure 8. Circuit Card, Root Pass (Fig 1 Item 11)
ASO-59 035 845 ... IC, linear 307 10
C5i-53 035834... CAPACITOR, polye film 1 .Suf 1 OOV 3
C54,56,59-6i ,63,
66-68,70,73,74 035 833 ... CAPACITOR, polye film .033uf 100VDC 12
C55,62,69 035 835 ... CAPACITOR, elctlt 4.7uf 35VDC 3
C57,58,64,65,
71,72,77,80,82 053991 CAPACITOR, cer disc .OSuf SOOVDC 9
C75 038585... CAPACITOR, polye film .22uf 50V 1
C76,79 000 859 CAPACITOR, elctlt 220uf 35VDC
... 2
C78,8i 031 630 CAPACITOR, elctlt 22uf 5OVDC 2
5N—092 883—B
Figure 8. Circuit Card, Root Pass

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

Quantity
Model
Dia. Part ~5T~50500 600
Mkgs. No. Description Amp Amp Amp Amp
Optional Equipment
041 884 METER (consisting of)

KIT, 1
KIT, 1
KIT, 1
041 887 METER KIT,
(consisting of) 1
098 669 .... METER SET, (consisting of) 1
096 893 METER SET, (consisting of) 1
096 894 .... METER SET, (consisting of) 1 .... 1
025 608 METER, amp dc 5OMV 0-500 scale 3.5 in 1
025 611 METER, amp dc 0-600 scale 3.5 in 1
025610 METER, amp dc 5OMV 0-800 scale 3.5 in 1 1
....
-. P1 025 701 FILTER, HFdcvolt&ampmeter3.Sin 2...2... 2....2

025 604 METER,voltdco-i0oscale 3.5 in 1 1
... ... 1.... 1
103 966 PANEL, front meter box 2 meters 1 ... 1 ... 1 1
....
103 967 PANEL, rear meter box2 meters 1 1

... ... 1 ....1
103 965 WRAPPER,meterbox2meters 1 1
... ... 1 1
....
010 323 .... CLAMP, hose .250-.625c1p dia 1

010859 CLAMP, hose .562-i .062c1p dia 1 .... 1
010493 BUSHING, snap-in nyl .625 ID x .87Smtg hole 1 ... 1 1
015 712 - GROMMET, rbr .625 ID x .875mtg hole 1
030 084 .... SHUNT, meter SOMV 600A It wt 1
... S8 ... Oil 974 SWITCH, polarity (consisting of) 1 ... 1 ... 1
S8 ... 053 049 SWITCH, polarity (consisting of) 1
017 288 .... BRACKET, mtg switch 2 ... 2 ... 2
053 044 BRACKET, mtg switch 2
103 634 .... MOUNTING BOARD, cmpnt polarity switch 1 1 ... 1
... .... 1
103 633 BUS BAR, shorting switch polarity 2 ... 2 2 ... .... 4
023 119 BUS BAR, switch 1
023 120 BUS BAR, switch 2
011 948 ... GUIDE, contact movable switch 2 ... 2 ... 2 .. ..2
021 193 GUIDE, contact 2
011 645 CONTACT ASSEMBLY, movable switch 1 1
... ... 1
024 694 BEARING, polarity switch 1 1
... ... 1 .... 2
010 805 ... HANDLE, switch polarity 1 ... 1 ... 1 . ... 1
0i9 603 KNOB, balI 1.250 OD w/.250-20fthrd 1 i
... ... 1 .... 1
020 484 - ... TUBING, stl .625 OD x l2ga wall x .250 1
010086 SPACER, polarity switch 2
011 080 SPACER, contact switch i/8 in 4
023 i2i PLATE, tgl switch polarity 1
Oil 953 CONTACT, switch 8
011 075 ... SPRING, pressure contact switch 4
011 074 .... SPRING, pressure contact switch 4
021 932 STRIP, insul switch polarity 1 1 ... 1
... .... 1
• . C6. +053 296 CAPACITOR,ign.Suf 1... 1... 1 ....i
CB1.. +093 995 CIRCUITBREAKER,manresetiP
..RC3.. +604 176 RECEPTACLE,strdxgrd2P3WiSAi2SV i ... 1 ... 1 .... 1
+Auxiliary Power 2kVA Prior to JJ503984

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

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TM-ZZIR October 1997

GOLD STAR ®SS

Section No. Page No.

SECTION 11 — ELECTRICAL DIAGRAMS (Continued)

Table 3-i. Specifications 3

2-1. PREPARATION FOR RESHIPMENT 2-~ STORAGE

Table 3-1. Specifications

500 500 @ 20-346

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

Idling Amperes Input At No Load

300 4.3(4.1) 3.7 1.9 1.5 1.5 0.92

0 200 400 600 800 1000 00 50100 150200 260300350400450500550

age. 600 Amp

SECTION 4— INSTALLATION OR RELOCATION

4-1. SITE SELECTION

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

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

• Shutdown weldingpowersource, and discon-

KiLl KiLl KiLl

514362 514362 514362

200 VOLTS 230 VOLTS 460 VOLTS

OLOLOL OLOLOL OLOLOL

00 0 TIE TOGETHER 2L5

COIL #3 COIL #2 COIL dl

230 VOLTS 460 VOLTS 575 VOLTS

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

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

SECTION 5—OPERATOR CONTROLS

5-4. AMPERAGE ADJUSTMENT CONTROL (Fig-

The ARC CONTROL provides selection of arc charac-

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

A WARNING: ELECTRIC SHOCK can kill;

4. Select proper electrode.

Diagram 7-1. Block Diagram

IMPORTANT: The circled numbers match the

A CAUTION: ELECTROSTATIC DISCHARGE

TROUBLE CAUSE REMEDY

TROUBLE CAUSE REMEDY

TROUBLE CAUSE REMEDY

TROUBLE CAUSE REMEDY

5ms by 5ms 1OV

5ms 1OV 5ms 1OV

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

See Section 8-7

See Section 4-3

IMPORTANT: All resistance values for main transformer TI

__I EuEuEuEu ruEuIuEu

NEGATIVE S. POSITIVE STUDS

+15 volts dc output See also Section 5-5

V6 32 volts ac with contactor W energized

See Section 4-3

IMPORTANT: All resistance values formain transformer TI

NEGATIVE & POSITIVE STUDS

See also Section 8-5

See Section 8-9

See Section 8-7

See Section 4-3