TM 221

TM-221 October 1997
Miller.
Gold Star@ 300SS Eff w/
HF833731 thru JC641295
HF833731 thru JC590315
l?k Power oflike. Gold Star@ 500SS Eff wl
HF833731 thru JE747790
HF833731 thru JE813765
GOLD STARSS
Visit out website at

www”MltlrPwtrllr*tmll
OM-221 N 4~32
TABLE OF CONTENTS
Section No Page No
SECTION 1 -SAFETY PRECAUTIONS AND SIGNAL WORDS
l-l. General Information And Safety ....................

l-2. Safety Alert Symbol And Signal Words ............... .
l-3. Safety Precautions ...............................
SECTION 2 - SHIPPING AND STORAGE
2-l. Preparation For Reshipment ...................... 2

2-2. Storage ....................................... 2
SECTION 3 -SPECIFICATIONS
3-l. Volt-Ampere Curves .............................. . 5

3-2. DutyCycle .................................... 5
3-3. Description .................... ............... 5
SECTION 4 - INSTALLATION OR RELOCATION
4-l. Site Selection ...................... ............

4-2. Transporting Methods ...........................
4-3 115 Volts AC Receptacle (Optional) ..................
4-4. Remote Control Receptacle Information And Connections
4-5. Weld Output Connections ........................
4-6. Electrical Input Connections ......................
SECTION 5 -OPERATOR CONTROLS
5-l. Power Switch ...................... ............ 12

5-2. Pilot Light ..................................... 12
5-3. RangeSwitch .................................. 12
5-4. Current Adjustment Control ....................... 12
5-5. Remote Control Receptacle And Current Control Switch . 12
5-6. Remote Control Receptacle And Contactor Control Switch 13
5-7. Arc Control Switch ............................... 13
5-8. Meters (Optional) ............................... 13
5-9. Polarity Switch (Optional) .......................... 13
SECTION 6 - SEQUENCE OF OPERATION
6-l. Shielded Metal Arc Welding (SMAW) ................ 14

6-2. Shutting Down ................................. 14
SECTION 7 -THEORY OF OPERATION
7-1. Theory Of Operation ............................. 14

Diagram 7-1. Block Diagram ............................. 16
Section No. Page No
SECTION 8 -TROUBLESHOOTING
8-l. 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
Models With Fan Control ........................... 26
Models ......................................... 28
Models With Demand Fan Control .................... 30
8-4. Control Board PC1 Testing Information ....................... 32
Diagram 8-5. Troubleshooting Circuit Diagram For Control Board PC1 34
8-5. Feedback Board PC2 Testing Information ..................... 36
Diagram 8-6. Troubleshooting Circuit Diagram For Feedback Board PC2 37
8-6. Diodes DlO And Dll Testing Procedure ...................... 38
8-7. Main Rectifier SRl Testing And Replacement Procedure For 300
Ampere Models ........................................ 38
8-8. Main Rectifier SRl Testing And Replacement Procedure For
400,500, And 600 Ampere Models .......................... 41
SECTION 9 -COMPONENT IDENTIFICATION AND LOCATION
Figure 9-l. Main Assembly And Component Locations ............... 46

Figure 9-2. Front Panel And Component Locations .................. 47
Figure 9-3. Rear Panel And Component Locations .................. 48
Figure 9-4. Main Rectifier SRI And Component Locations For 300 Ampere
Models ........................................... 48
Figure 9-5. Main Rectifier SRl And Component Locations For 400, 500,
And 600 Ampere Models ............................. 49
Figure 9-6. Input Terminal Board TEl And Component Locations ....... 49
Figure 9-7. Push Button PBl Switch Assembly And Component Locations 50
SECTION 10 - MAINTENANCE
10.1. Routine Maintenance ..................................... 51

1O-2, Overload Protection ...................................... 51
10.3. Rectifier Protection ....................................... 52
1O-4. Fan Control For 300 And 400 Ampere Models (Optional) ......... 52
1O-5. Demand Fan Control For 500 And 600 Ampere Models (Optional) . 52
SECTION 11 - ELECTRICAL DIAGRAMS
Diagram 11-l. Circuit Diagram For 300 Ampere Models Effective With
Serial No. JB560387 Thru JC641295 And 400 Ampere Models
Effective With Serial No. JB560387 Thru JC590315 . . . 55
Diagram 11-2. Circuit Diagram For 300 Ampere Models With Fan Control
Effective With Serial No. JB560387 Thru JC641295 And
400 Ampere Models With Fan Control Effective With
Serial No. JB560387 Thru JC590315 . .......... 56
And Polarity Switch Effective With Serial No.
JB478153 Thru JC641295 57
Section No. Page No.
SECTION 11 - ELECTRICAL DIAGRAMS (Continued)
And Polarity Switch Effective With Serial No.
JC615021 Thru JC590315 . 58
Diagram 11-5. Circuit Diagram For 500 Ampere Models Effective With
Serial No. JB560387 Thru JE747790 And 600 Ampere Models
Effective With Serial No. JB560387 Thru JE813765 . . 59
Effective With Serial No. JC615021 Thru JE747790 And
600 Ampere Models With Fan Control Effective With
Serial No. JC615021 Thru JE813765 60
Diagram 11-7. Circuit Diagram For Control Board PC1 Effective With
Serial No. JB487359 Thru (See Note) 61
LIST OF CHARTS AND TABLES
Table 3-l. Specifications 3

Table 3-2. Idling Data (No Load) . 3
Chart 3-l. Volt-Ampere Curves 4
Chart 3-2. Duty Cycle 5
Table 4-l. Weld Cable Size 7
Table 4-2. Input Conductor And Fuse Size 10
Table 8-l. Troubleshooting . 19
Chart 8-l. Waveforms For Diagrams 8-l Thru 8-4 23
Table 1O-1. Maintenance Schedule 51
Table 11-l. List Of Circuit Diagrams 53
SECTION 1 - SAFETY PRECAUTIONS AND SIGNAL WORDS
l-l. GENERAL INFORMATION AND SAFETY l Shut down unit and disconnect input power
This manual provides theory of operation along with when servicing unless the procedure specifi-
cally requires an energized unit.
specific operating, testing, and troubleshooting proce-
dures. It also includes precautionary information rele- l Do nor 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 l 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 throughout this manual tocall attention toand 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.
words WARNING and CAUTION to call atten- HOT METAL, SPATTER, AND SLAG can
e tion to the safety statements. cause fire and burns.
l Watch for fire.
WARNING statements identify procedures or
practices which must be followed to avoid seri- l Have a fire extinguisher nearby, and know
e ous personal injury or loss of life. how to use it.
l Do not use near flammable material.
CAUTION statements identify procedures or l Allow work and equipment to cool before
practices which must be followed to avoid minor
e handling.
personal injury or damage to this equipment.
MOVING PARTS can cause serious injury.
IMPORTANT statements Identify special instructions l Keep away from moving parts.
necessary for the f770.5refficient operation of this equip-
HOT SURFACES can cause severe burns.
ment.
l A//o w cooling period before servicing.
l-3. SAFETY PRECAUTIONS FALLING EQUIPMENT can cause serious
e
personal injury and equipment damage.
WARNING: ELECTRIC SHOCK can kill.
l Use equipment of adequate capacity to /ifi rhe
l Do nor touch live electrical parts. unit.
. Protect yourself with dry insulating gloves MAGNETIC FIELDS FROM HIGH CURRENTS
and clothing. can affect pacemaker operation.
. Insulate yourself from ground by using l Wearers should consult their doctor before
rubber gloves and insulating floor mats when going near theservicing of arc welding equip-
power is applied to the unit. ment or any arc welding operations.
SM-221 Page I
SECTION 2 -SHIPPING AND STORAGE
2-1. PREPARATION FOR RESHIPMENT 2-2. STORAGE
WARNING: ELECTRIC SHOCK can kill. WARNING: ELECTRIC SHOCK can kill.
l Do not touch live electrical parts. e l Do not touch live electrical parts.
e
l Shut down welding power source, and . 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 conductors from 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. applicable.
Tape plastic around top and sides of unit.
6. Apply touch-up paint to any nicks or scratches to
5. Securely tie and/or tape cardboard over top and
prevent rusting, etc.
around sides of unit. Use original shipping carton
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. a. 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
4 x 4’s to keep it off the floor.
factory Service Department or Transportation
Department 10. Cover unit with plastic or a suitable tarp.
SM-221 Page 2
SECTION 3 - SPECIFICATIONS
Table 3-l. Specifications
I I I I I Input At Rated I I I
Welding Lbad Output
Rated Welding Current aye:_ 60 Hz. Three-Phase Weight
Model Current Amperes’ Ranges Circuit
60% Duty CyCh? A Amperes At
mPeres Voltage
200V 230V 460V S75V KVA KW Net Ship
300 300 @I 15-200

25-385 7. 67 58 29 23 23.2 12.9 ;1260091$, ;;;;bksb)
Ampere 32 Volts
400 400 @ 20-270 473 Ibs. 498 Ibs.

70 87 75 38 30
Ampere 36 Volts 37-510 3o 1g’8 (215 kg) (226 kg)
I
600 600 @ 30-415 632 Ibs. 657 Ibs.

Ampere 44 Volts 57-775 7O 132 114 57 46 45.6 32.7 (287 kg) (298 kg)
Table 3-2. Idling Data (No Load)*
*Values are nominal and for 60 Hz models only.
SM-221 Page 3
Chart 3-1. Volt-Ampere Curves
n
70
Low Range
60 60
4EO!i;p
50
2 40
9
g 30
20
10
0
0 200 400 AMPEE 600 1000 0 50 100 150 200 250 300 350 400 450 500 550
DC SB-081 670-A DC AMPERES SB-064 621-A
High Range
60 60
““,“,“,ZP
IO
0
“0 200 400 600 800 loo0 0 lO0 200 300 400 500 600 7ca 6a 0
DC AMPERES SB-061 666-A DC AMPERES SB-064 642-A
80 . 70
60
20
10
0
0 200 400 800 800 lo’00
DC AMPERES SB-OR1 395-A DC AMPERES
SB-061 650-A
High Range
60 60
YO!GP
10
0
400 lOO( 0 200 400 800 800 loo0 1200 1400
DC AMPEE SE-061 394-A DC AMPERES SB -061 646-A
SM-221 Page 4
3-l. VOLT-AMPERE CURVES (Chart 3-1) The duty cycle of a welding power source IS the percent-
age of a ten minute period that a welding power source
The volt-ampere curves show the voltage and amper- can be operated at a given output without causing over-
age output capabilities of the welding power source at heating and damage to the unit. This welding power
the min. and max. values of the CURRENT ADJUST- source is rated at 60 percent duty cycle. This means that
MENT control setting. Curves of other settings will fall the welding power source can be operated at rated load
between the curves shown. for six minutes out of every ten. During the remaining
four minutes, the unit should idle to permit proper cool-
With the use of the volt-ampere curves, it is possible to
ing. If the welding amperes are decreased, the duty cy-
determine the weld current at any particular load volt-
cle will increase. Chart 3-2 enables the operator to deter-
age.
mine the output of the welding power source at various
duty cycles.
3-2. DUTY CYCLE (Chart 3-2)
CAUTION: EXCEEDING DUTY CYCLE RAT-
Chart 3-2. Duty Cycle
INGS will damage the welding power source.
RATED OUTPUT1 e
Models l Do not exceed indicated duty cycles.
3-3. DESCRIPTION
600 Amp This unit is a three-phase dc arc welding power source

500 Amp with solid-state control. It produces dc weld current and
is designed to be used for Shielded Metal Arc Welding
400 Amp
(SMAW). The number in the model designation refers to
the rated welding current in amperes.
300 Amp
These units have solid-state contactors and a pilot light

10 16 20 26 30 40 so flu mmmm to indicate when the POWER switch is energized.
% DUTY CYCLE
SE-000 865-C
SECTION 4 - INSTALLATION OR RELOCATION
4-1. SITE SELECTION should allow sufficient space on all sides and above the
unit to open access door(s), or remove top cover and
Select an installation site which provides the following: outer enclosure panels for maintenance and repairfunc-
1. Correct input power supply (see unit nameplate) tions.
CAUTION: RESTRICTED AIRFLOW can
2. Shielding gas supply (if applicable) cause overheating and possible damage to
e internal parts.
3. Water supply (if applicable)
Maintain at least 18 inches (457mm) of unre-
4. Adequate ventilation and fresh air supply stricted space on all sides of unit, and keep
underside free of obstructions.
5. No flammables
Do not place any filtering device over the in-
6. A clean and dry area take air passages that provide air-f/ow for cool-
ing this unit.
7. Proper temperature that avoids extremes of heat
Warranty is void if any type of filtering device is
or cold
used at intake air passages.
8. Proper airflow around unit
9. Adequate space for removing top cover and outer

panels for installation, maintenance, and repair 4-2. TRANSPORTING METHODS
functions.
This welding power source is equipped with a lifting eye
Base mounting holes provide the capability to install and for moving the unit during installation. Weight capacity of
secure the unit on a running gear or in a permanent loca- the lifting eye only allows for supporting the welding
tion. A permanent installation site for securing the unit power source.
SM-221 Page 5
Receptacle RCI socket connections to the welding pow-
A
l Do not touch live electrical parts. er source control circuitry are as follows:
l D6connect Input power conductors from Socket A. Contactor control switch connectron.
deenergfzed supply line BEFORE moving Socket B Contactor control switch connection.
welding power source.
Socket C Current control connection (maximum
FALLING EQUIPMENT can cause serious side).
personal injury and equipment damage.
Socket D Current control connection (minimum
Use lift/ng eye to lift umt only, NOT running
gear, gas cylinders. oranyother heavyacces- side).
series or devices Socket E: Current control connection (wiper con-
Use equipment ofadequate capaclty to //ft the tact).
unit.
4-5. WELD OUTPUT CONNECTIONS (Figure 5-1)
If Ming or mowng this umt mth lift forks under
the base, be sure that I/ft forks are long To obtain full rated output from this unit, it is necessary to
enough to extend beyond opposite side of the select. prepare, and install proper weld cables. Failure to
base. comply In any of these areas may result In unsatisfactory
Using lift forks too short can damage internal welding performance.
parts if tips of the lift forks penetrate the unit A. Weld Cable Selection
base, or may cause personal injury and/or
equipment damage if unit falls off the lift forks. Use the following guidelines to select weld cables:
1 Use the shortest possible cables, and place ca-
bles close together. Excessive cable lengths may
4-3 115 VOLTS AC RECEPTACLE (Optional) reduce output or cause unit overload due to
added resistance.
This welding power source can be equipped with a 115
2. Use weld cable with an insulation voltage rating
volts ac duplex receptacle located on the right side of the
equal to or greater than the maximum open-
front panel. Up to 2 kva of 115 volts ac IS available at thts
circuit voltage (ocv) of the welding power source
receptacle for operating accessory equipment. This re-
(see Table 3-l for unit maximum ocv rating).
ceptacle IS protected from overload by a circurt breaker
CBl located directly below the receptacle on the front 3. Select welding cable size according to maximum
panel. weld output and total length of connecting cables
In weld circuit. For example, if a 25 foot (7.5 m)
4-4. REMOTE CONTROL RECEPTACLE INFOR- electrode holder cable is used with a 25 foot (7.5
MATION AND CONNECTIONS (Figure 5-l) m) work cable. select the cable size recom-
mended in Table 4-l for 50 feet (15 m).
IMPORTANT: Although the term CONTACTOR is used
4. Do not use damaged or frayed cables.
on the nameplate and throughout this manual. the out-
put isnotswitchedonoroffbyaphysicalsecondarycon- 6. Weld Cable Preparation
tactor; rather. the output IS controlled by a S///con Con- 1 Install correct size lugs of adequate amperage
trolled Rechfier (SCR) stack wh/ch functions as a con- capacity onto ends of both cables for connecting
factor. to work clamp, electrode holder, and weld output
terminals.
REMOTE CONTROL receptacle RCl IS used to connect
2. Install electrode holder onto weld cable following
any of the following equipment to the weldtng power
manufacturer’s instructions. An insulated elec-
source ctrcultry:
trode holder must be used to ensure operator
a. Remote Contactor safety.
b. Remote Current control 3. Install work clamp onto cable

C. Weld Cable Connections
a
c. Combination of the above
To make connections, align keyway, insert plug, and ro- l Do not touch live electrical parts.
tate threaded collar fully clockwise.
l Shutdown weldingpowersource, anddiscon-
The following socket information is Included In case the nect input power employing lockout/tagging
supplied cord is not suitable, and it is necessary to wire a procedures before inspecting or installing.
plug or cord to interface with REMOTE CONTROL re- Lockout/tagging procedures consist of padlock-
ceptacle RCI ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
IMPORTANT: When contact closure IS provided be-
tween sockets A and 6. the welding power source con- red-taggtng circuit breaker or other disconnect-
tactor control circujt IS energized. ing device.
SM-221 Page 6
1. Connect work cable or connector to NEGATIVE Ice available. how proper connections should be made,
weld output termrnal and inspection required.
2. Connect electrode cable to POSITIVE weld out- B. Jumper Link Installation (Figures 4-1, 4-2, And
put termtnal 4-3)
IMPORTANT: The connectrons grven are for dc eiec- WARNING: Read precautionary information
trode posrtrve polarity. lfdc electrode negatrve polanty IS at beginning of entire Section 4-6 before
desrred, reverse cable connectrons to weld output termi- a proceeding with this installation.
nals (work becomes posrtive).
Jumper lrnks are used to allow the equipment to operate
from different line voltages.
4-6. ELECTRICAL INPUT CONNECTIONS
1 Open rear panel access door.
2. Compare position of jumper lrnks on the input ter-
e l Do not touch live electrical parts.
minal board to the voltage link arrangement
l Shutdown weldrngpowersource, anddiscon- shown on input voltage label.
nect rnput power employing lockout/tagging
procedures before rnspectrng or rnstalling.
Lockoutitaggrng procedures consist of padlock-
ing line disconnect switch In open posttion, re-
a CAUTION: INCORRECT INPUT VOLTAGE
JUMPER LINK PLACEMENT
unit.
l
can damage
Posrtron jumper links as shown on the input

moving fuses from fuse box, or shutting off and voltage label (see Figures 4- 1. 4-2. and 4-3).
red-tagging crrcurt breaker or other disconnect-
ing devtce l Store unused jumper links across linked ter-
minals.
A. Electrical Input Requirements
IMPORTANT: If the input voltages stated on nameplate
Operate the welding power source from a three-phase, or rating label are different from those in Figures 4- 1 and
60 Hertz, ac power supply The Input voltage must match 4-2. check the input voltage label in the unit or call Facto-
one of the electrical input voltages shown on the input ry Serv/ce Department.
data label on the unrt nameplate. Contact the local elec- 3. Install jumper links onto the input terminal board
tric utility for information about the type of electrical serv- to match the available input line voltage.
Table 4-1. Weld Cable Size
Total Cable (Copper) Length In Weld Circuit Not Exceeding*

Welding 100 ft. Or Less 150 ft. 200 ft. 250 ft. 300 ft. 350 ft. 400 ft.
(30 m) (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Amperes
10 To 60% 60 Thru 100%
IO Thru 100% Duty Cycle
Duty Cycle Duty Cycle
100 4 4 4 3 2 1 110 l/O

150 3 3 2 1 110 2/o 310 310
200 3 2 1 1/o 2/o 310 410 410
250 2 1 110 2,‘o 310 4/o 2-210 2-210
300 1 l/O 210 3io 4/O 2-210 2-310 2-310
350 l/O 210 310 4io 2-210 2-310 2-310 2-4/O
400 l/O 210 310 4/o 2-2!0 2-310 2-4/O 2-410
500 2i0 310 410 2-2/o 2-3’0 2-4/O 3-310 3-3/o
600 3;‘o 4!0 2-210 2-38’0 2-4,‘0 3-310 3-4/o 3-4/o
700 4/o 2-210 2-3/O 2-41’0 3-3/o 3-410 3-410 4-4/o
800 4/o 2-210 2-310 2-4/O 3-4/o 3-410 4-4/o 4-4/o
900 2-2/o 2-3/O 2-4/O 3-3io 3-4,‘o 4-4/o 4-410
*Weld cable size (AWG) IS based on erther a 4 volts or less drop or a current density of more than 300 circular
mils per ampere. S-0007i8.88
SM.221 Page 7
8 9 IO
!--i-i+%
FAN MOTOR ACROSS J&4
COIL NO 1
TIE TOGETHER 2&S

3 1 4 6 3 1 4 6 3::6
33 38 35 34 37 36
3 4 FM FM
6 1 3 4 6 I 3 4 6
230 VOLTS 460 VOLTS

(pm mm ma ~~&a0 .&Jo o&Jo
8 9 m
t /
FAN MOTOR ACROSS 486
COIL NO 1
0 0 0 0 0 0 0 0 0 0 0 0
241685 241685 24 1685
82 33 38 8, 84 35 54 TIE TOGETHER 387
83 86 37 36 85
200- 208 VOLTS 2 30 VOLTS
+-^ Fc”,WKUO; ACROSS 384
3604073 13:4073
35 34 82 3736 83 TIE TOGETHER 2 B 5
460 VOLTS 575 VOLTS
SIMILAR CONNECTED VOLTAGES

230/460/550 VOLTS GA-902 269.1 B
GA-902 286.181
GA-902 290.18
Figure 4-l. Input Voltage Labels And Connection Diagrams For All 300 Ampere Models And 400 Ampere
Models Effective With Serial No. HJ205706
SM-221 Page 8
FAN MOTOR ACROSS 182
COIL NO 1
6 0 cl 0
12P4 1:;4
33 38 35 34
230 VOLTS 460 VOLTS
ma .&a0 omo
x 10 FAN MOTOR ACROSS 18 3
i I COIL NO 1
1Oo,?
.--.
,-,
i3
7
5 1 4 338 6 81
2 84
514362 3534 W 86
5 I 37
4
82 33 3i 8.5
I PYik
200- 208 VOLTS 2 30 VOLTS 460 VOLTS
10
FAN MOTOR ACROSS 1& 2
COIL NO 1
0 0
132463 1324 6 3
35 5 Bz 37 5 83
34 36
FM FM
460 VOLTS 575 VOLTS

GA-901 690.1A
GA-901 692-181
GA-901 694-l B
Figure 4-2. Input Voltage Labels And Connection Diagrams For All 500 And 600 Ampere Models And 400
Ampere Models Prior to Serial No. HJ205706
SW221 Page 9
C. Welding Power Source Input Power Connec- 8. Connect remaining ends of input conductors to a
tions (Figure 4-3) deenergized line disconnect switch.
WARNING: ELECTRIC SHOCK can kill. 9. Secure the input cable in the strain relief.
e b Do not touch live electrical parts.
IO. Close and secure the rear panel access door.
Install a fusible line disconnect switch in the 11. Use Table 4-2 as a guide to select line fuses for
input circuit to the welding power source.
the disconnect switch. Obtain and install proper
Connect input conductors to the welding fuses
power source before connecting to the single-
phase input power. Table 4-2. Input Conductor And Fuse Size*
Read and follow safety information at begin-

Input Ground
ning of entire Section 4-6. Conductor Conductor Fuse
Model Input
Size Size Size In
The line disconnect switch provides a safe and Voltage
(AWG) (AWG) Amperes
convenient means to completely remove all
electrical power from the welding power source
whenever it is necessary to inspect or service I 200 6
I
8 100
the unit.
300 230 a a 90
Ampere
1. Use Table 4-2 as a guide to select input conduc- 460 10 10 45
tors for the installation. The input conductors
should be covered with an insulating material that 575 12 12 35
complies with national, state, and local electrical
200 4 6 125
codes.
2. Install terminal lugs of adequate amperage ca- 400 230 6 6 125
pacity and correct stud size onto the input and Ampere
ground conductors. 460 10 10 60
e WARNING:
l
l
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Do not connect an input conductor to the
I
575
200
10
13161175
10 45
ground terminal In the unit. 500 230 4 6 150

l Do not connect the ground conductor to an in- Ampere r
put line terminal. 460 a a 70
Incorrect input connections can result in an elec- 575 10 10 60

trically energized welding power source chassis.
The ground terminal is connected to the welding 200 2 6 200
I 1 I
power source chassis and is for grounding pur- I I I I
poses only. 600 230 3 6 175
Ampere
Obtain and install a standard conduit strain relief 460 a a 90
3.
connector into the rear panel access hole.
575 a a 70
4. Insert conductors through strain relief installed in
Step 3. Route conductors to the input terminal ‘Conductor size is based on the 1990 Edltion of the National
board. Electrical Code (NEC) specifications for allowable Ampaci-
:ies of insulated copper conductors, having a temperature
5. Connect input conductors to line terminals on the
,ating of 167°F (75’C), with not more than three single cur-
input terminal board (see Figure 4-3).
rent-carrying conductors in a raceway (Article 310 of NEC).
6. Connect the ground conductor to the ground ter- (The ground conductor is not counted as a current-carrying
minal (see Figure 4-3). conductor.)
7. Connect remaining end of ground conductor to a *Fuse size is based on not more than 200 percent of the
suitable ground. Use a grounding method that rated input Amperage of the welding power source (Article
complies with all applicable electrical codes. 630 of NEC). s-009219-90
SM.221 Page 10
Line Disconnect
Switch
Input Voltage
Label (see Figures
4-1 and 4-2)
\
Input Voltage
Jumper Links
l-314 in. (44.5 mm)

Access Hole
Ground Line
Terminal Terminals
Ret ST-148 032
Figure 4-3. Location Of Electrical Input Connections And Components
SM-221 Page 11
SECTION 5 - OPERATOR CONTROLS
Current Adjustment
Control
Current Control
Arc Control Swltc

Remote Current
And Contactor
Control Receptacl
Contactor Control
Positive Weld
TC-000 599-B
Figure 5-l. Front Panel View

5-1. POWER SWITCH (Figure 5-1) the range being used. Rotate the control clockwise to in-
crease the current output.
Pressing the POWER switch ON push button energizes
the welding power source. Pressing the POWER switch IMPORTANT: The CURRENT ADJUSTMENT control
OFF push button shuts down the welding power source. may be adjusted while welding.
IMPORTANT: After any interruption of input power, the

5-5. REMOTE CONTROL RECEPTACLE AND
POWER switch ON push button must be depressed to
CURRENT CONTROL SWITCH (Figure 5-1)
reenergize the welding power source.
If a Remote Current Control is to be used, make connec-
tions from the control to the REMOTE CONTROL recep-
5-2. PILOT LIGHT (Figure 5-1) tacle as instructed in Section 4-4.
The pilot light comes on whenever the POWER switch IS When remote control of the current is desired, the CUR-
in the ON position and indicates that the unit is receiving RENT CONTROL switch must be placed in the
input power. REMOTE position. Likewise, if a Remote Current Con-
trol IS not desired, the switch must be in the STANDARD
5-3. RANGE SWITCH (Figure 5-1) posItIon. When In the STANDARD position, only the
CURRENTADJUSTMENTcontrol on the front panelwill
The RANGE switch provides the means of selecting be- control the current.
tween the two coarse output ranges. When the RANGE
switch is in the LOW position, ensure that the LOW cur- When a Remote Current Control is being used, the con-
rent scale IS used when adjusting the CURRENT AD- trol IS functioning as a fine current adjustment for the
JUSTMENT control. When In the HIGH position, ensure CURRENT ADJUSTMENT control setting on the weld-
that the HIGH current scale is used when adjusting the ing power source. For example: If the CURRENT AD-
CURRENT ADJUSTMENT control. JUSTMENT control on the welding power source is set
at the mid-range position, the Remote Current Control
will provide (from its min. to max. positions) fine amper-
5-4. CURRENT ADJUSTMENT CONTROL (Figure
age adjustment of one half of the welding power source
5-l)
output for the current range selected. If full adjustment
The CURRENT ADJUSTMENT control provides the through use of the remote control of the current range
means of selecting the exact amperage desired within selected isdesired. theCURRENTADJUSTMENTcon-
SM.221 Page 12
trol on the welding power source must be set at maxi- 5-7. ARC CONTROL SWITCH (Figure 5-1)
mum positlon.
The ARC CONTROL switch provides selection of arc
5-6. REMOTE CONTROL RECEPTACLE AND characteristics to suit individual welding conditions.
CONTACTOR CONTROL SWITCH (Figure When the switch is set at MAX. (maximum). current in-
5-l) creases rapldly as the short-circuit condition is ap-
WARNING: ELECTRIC SHOCK can kill. proached. This provides extra current for arc starting in
l Do not touch I/ve electrical parts. out of position welding as well as for certain types of
e
electrodes.
l Do not touch the weld output terminals when
the contactor is energized. When the switch is set at MED. (medium), current in-
l Do not touch electrode and work clamp at the creases slightly as the short-circuit condition is ap-
same bme. proached This provides a slight increase in current for
arc starting which is necessary for certain types of elec-
When the CONTACTOR CONTROL switch is in
trodes.
the STANDARD posltion, open-circuit voltage is
present at the weld output terminals for as long When the switch is set at SOFT, current increases in a
as the welding power source IS energized. linear fashion as the short-circuit condition is ap-
proached This provides current characteristics associ-
IMPORTANT: Although the term CONTACTOR is used ated with Gas Tungsten Arc Welding (GTAW).
on the nameplafe and throughout this manual. the out-
putisnotswitchedonoroffbyaphysicalsecondarycon- 5-8. METERS (Optional)
tactor; rather, the output LScontrolled by a Silicon Con-
The meters are provided to monitor the welding opera-
trolled Rectifier (SCR) stack which fun&Ions as a con-
tion and serve as an indication of the welding process.
tactor.
They are not intended for exact current or voltage meas-
The contactor control circuitry In this welding power urements. The voltmeter is internally connected to the
source enables the operator to remotely control the welding power source output terminals. The voltmeter
availability of weld output from the work station. will indicate the voltage at the weld output terminals, but
WIII not necessarily Indicate the actual voltage at the
If a Remote Contactor Control IS to be used. make con-
welding arc (due to cable resistance, poor connections,
nections to the REMOTE CONTROL receptacle as in-
etc ) The ammeter indicates output current of the unit.
structed In Section 4-4. Place the CONTACTOR CON-
TROL switch in the REMOTE positlon. Depress the ON
push button on the welding power source. Weld output 5-9. POLARITY SWITCH (Optional)
will be available whenever the Remote Contactor Con- The POLARITY SWITCH provides a means of selecting
trol switch is closed. either dc ELECTRODE POSITIVE or dc ELECTRODE
If a Remote Contactor Control is not to be used, place NEGATIVE polarity without having to change the weld
the CONTACTOR CONTROL switch In the STANDARD output cable connections.
posItIon. When In the STANDARD posItion, weld output
CAUTION: ARCING can damage switch con-
will be available after the ON push button is depressed tacts.
on the welding power source. Weld output will continue a
l Do not change switch position while welding
until the OFF push button IS depressed on the welding
or under load
power source.
SECTION 6 - SEQUENCE OF OPERATION
WARNING: ELECTRIC SHOCK can kill; FUMES AND GASES can seriously harm
MOVING PARTS can cause serious injury; your health.
&A IMPROPER AIRFLOW AND EXPOSURE TO l Keep your head out of the fumes.
ENVIRONMENT can damage internal parts.
l Ventilate to keep from breathing fumes and
l Do not touch iive electrical parts.
gases.
l Keep all covers and panels in place while
l If ventilation is inadequate, use approved
operahng.
breafh/ng device.
Warranty is void if the welding power source is
operated with any portion of the outer enclosure HOT METAL, SPATTER, AND SLAG can
removed. cause fire and burns.
. Watch for fire.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage . Keep a fire extinguisher nearby, and know
hearing. how to use it.
l Wear correct eye. ear, and body protecbon.
SM-221Page13
l Do not use near flammable material. switches In the REMOTE position (see Sections
5-5 and 5-6).
l Allow work and equipment to cool before
handling. 6. Place the RANGE switch in the desired position
(see Section 5-3).
MAGNETIC FIELDS FROM HIGH CURRENTS
can affect pacemaker operation. 7. Place the ARC CONTROL switch in the desired
l Wearers should consult the/r doctor before posltion (see Section 5-7).
going neararc welding, gouging, orspot weld- a. Rotate the CURRENT ADJUSTMENT control, or
ing operations
Remote Current Control if used, to the desired po-
See Section 1 - Safety Rules For Operation Of sition (see Section 5-4).
Arc Welding Power Source in Owner’s Manual
for basic weldlng safety information. IMPORTANT: The CURRENT ADJUSTMENT control
may be adjusted while welding.
6-1. SHIELDED METAL ARC WELDING (SMAW)
9. Wear dry welding helmet with proper lens accord-
1. Install and connect unit according to Section 4. lng to ANSI 249.1.
2. Wear dry insulating gloves. 10. Insert electrode into electrode holder.
3. Connect work clamp to clean, bare metal at work- 11. Depress the POWER switch ON push button (see
piece. Section 5-l ).
4. Select proper electrode. 12 Begtn welding.
5. If a Remote Current and/or a Remote Contactor
Control are not to be used, place the CURRENT 6-2. SHUTTING DOWN
CONTROL switch in the STANDARD position or 1. Stop welding.
the CONTACTOR CONTROL switch in the
2. Allow the welding power source to idle for three
STANDARD position If a Remote Current and/or
minutes with no load applied.
a Remote Contactor Control are to be used, place
the CURRENT or CONTACTOR CONTROL 3. Depress the POWER switch OFF push button.
SECTION 7 -THEORY OF OPERATION
7-l. THEORY OF OPERATION (Diagram 7-l) c. A single-phase voltage protected by fuses F2

and F3 to the Control Board PC1 power sup-
The basic welding power source operation is not difficult plies and pilot light PLl
to understand when it is divided into sections. Diagram
7-1 shows the main components which make up the cir- d. A single-phase voltage for optional 11.5volts ac
cuitry of the welding power source. duplex receptacle RC3 protected by circuit
breaker CBl
IMPORTANT: The following Theory Of Operation is
The POWER ON and OFF push buttons energize
written in steps which match the circled numbers on Dia-
and deenergize the line contactor W using a volt-
gram 7- 1. Component desgnators such as Tl, SRl, age from one of the 3-phase synchronization sig-
PCI, R5,54, and RCl that are used in the Theory OfOp- nals or from control transformer T2 (Not shown).
eration apply to components on circuit diagrams 8-l Thermal over-temperature protection is provided
through 8-4 in th1.smanual.
by thermostat TPl located on main rectifier SRl
and connected in series with the POWER OFF
A. Input Power Circuit push button.
A single-phase, 230 volts ac circuit provides pow-
1. The welding power source is supplied with 50 or
er for fan motor FM. Fan motor FM is always on
60 Hertz, 3-phase voltage at input terminal board
when the welding power source is energized un-
TEl A 3-pole, line contactor W is provided to con-
less the unit is equipped with optional fan control
nect and disconnect input power to main trans-
former Tl Main transformer Tl has four second- circuitry. A 115 volts ac fan motor is used in 300
aries which provide the following: and 400 ampere models with optional fan control.
6. Weld Current Circuit
a. A 3-phase, reduced voltage at high current to
main rectifier SRI 2. A reduced voltage, 3-phase circuit from main
transformer Tl provides power to main rectifier
b. A set of 3-phase synchronization signals pro- SRl This SCR bridge rectifies the 50 or 60 Hertz
tected by fuses F4, F5, and F6 to Control Board power to provide dc output power. The six silicon-
PC1 from which the SCR’s are gated controlled rectifiers SCRI through SCR6 are con-
SM.221 Page 14
trolled by the gating signals from PC1 to produce 7. ARC CONTROL switch S5 allows the operator to
a varying current on the output of the SCR bridge. choose an increased amperage to clear electrode
The dc output current of the SCR bridge is not to work sticking. The increased amperage per-
continuous, but consists of pulsed portions of the mits the burning free of the electrode at short-cir-
rectlfted 3-phase, 50 or 60 Hertz power. Burden cult conditions and minimizes the situations
resistor R6 is connected across the output of the which cause the electrode to stick to the work. S5
SCR bridge to provide a path for a minimum SCR provides an increased amperage as the weld out-
holding current to flow. put approaches short-circuit conditions.
3. Stabilizer Z filters the pulsed output current of the D. Automatic Constant Current Control Circuit
SCR bridge Into a more constant dc current. The 8. The welding current output is automatically con-
filtering actlon of Z keeps the welding current from trolled to the value selected by the operator on R5
going to zero and the welding arc from going out. by the following means:
4. The POSITIVE and NEGATIVE weld output ter- a. The welding current is sensed by current trans-
minals are located behind an access door on the formers CTl, CT2, and CT3. Feedback Board
front panel of the welding power source. An op- PC2 rectifies the ac output of the current trans-
tional POLARITY SWITCH S8 provides a means formers. The resulting current feedback signal
of reversing the polanty of the weld output terml- from PC2 is applied to the current regulator cir-
nals. An optlonal voltmeter V and ammeter A dis- cuit on Control Board PCl. RANGE switch S3
play the rectified and filtered values of the voltage provides selection between two coarse output
and current provided by this welding power ranges by selecting the amount of current feed-
source. back to PCl.
C. Operator Control Inputs b. The current regulator on Control Board PC1

compares this current feedback signal to the
5. The operator can turn on the dc output voltage of control signal selected by the operator on CUR-
the welding power source by placing CONTAC- RENTADJUSTMENTcontrol R5. Ifadifference
TOR CONTROLswitch 54 in the STANDARD po- exists, the current regulator commands the six
sition. The SCR contactor circuit then enables the gating circuits to change the firing of the SCR’s.
SIX gatlng circuits on Control Board PC1 to pulse The value of the welding current is therefore
or turn on the SCR bndge. A small current will flow maintained at the selected value, regardless of
through burden resistor R6 if no welding current the length of the welding arc or the voltage drop
flows. The operator can choose to turn the dc out- across the arc.
put voltage off by placing CONTACTOR CON- E. Remote Operations
TROL switch S4 In the REMOTE position. See
Step 9 for more remote control information. 9. The welding power source is designed to be re-
motely controlled by signals from a variety of re-
6. The operator can select the amount of dc output mote hand or foot controls.
current by placlng the CURRENT CONTROL
REMOTE CONTROL receptacle IX1 provides
switch S2 in the STANDARD posttion and rotating
on/off control of the welding power source output
CURRENT ADJUSTMENT control R5 until the
using a remote contactor switch when CONTAC-
desired current is obtained. The signal from R5 is
TOR CONTROL switch S4 is in the REMOTE po-
supplied to the Input command circuit on PCI.
sition
The operator can also select to have the dc output
current controlled by a remote adjustment poten- Remote current adjustment is also possible up to
tiometer by placing the CURRENT CONTROL the value of the current selected by CURRENT
switch S2 in the REMOTE position. See Step9 for ADJUSTMENT control R5 when CURRENT
additlonal remote control information. CONTROLswitch S2 is in the REMOTE position.
SM.221 Page 15
01 4
0 1
rl
115 VAC
Duplex
Receptacle
R3 r- Fan Motor
FM, 230 VAC
0
1
Input Terminal Line

Board TEI Contactor / Trar$$;er 1 3~
n .
3-Phase
Line n c $
Input Power Secondary 1
-
I
t
I I Fuses 1 I
IBVAC
I I
r------ Remote
Control
qeceptacle
RCI
p7 Circuit
Arc
I 0 To -5 VDC Input
pw;;Th’ c Command (Ref.)
s5 Circuit
CONTROL BOARD PC1
+
6
p
Current
Adjustment+
Control R5
__----
r 0 94 01 6
I
u Remote
Current
Control
- c
Current
Control
Switch S2
Diagram 7-1. Block Diagram

SM.221 Page 16
03 04 +
Stablizer Ammeter 1
B
Z A
0
2
0,2 0,
4 +
‘s”‘~;;‘hy
Electrode
Main Rectifier w
Burden S8
SRI Resistor Voltmeter
(S~JR~sri$-Y R6 V Work
Feedback
Board
PC2
SCR
Gating
Signal
- AC Or DC Control Signals
8-b Weld Current Circuit

IMPORTANT: The crrcled numbers match the steps In
the Theory Of Operation (Sect/on 7- 1). Componentdes- Either Mechanical Coupling
---*
fgnatorssuchas Tl, SRl, PCl, R5, S4. andRC1 apply Or External Circuits
to components on circuit diagrams 8- 1 through 8-4.
+ Optional Or Not Supplied
SM-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 thus manual requrre proper
testing instruments. Use a good quality digital volt-
ohmmeter (DVM) with one megohm input impedance or
greater and diode check capability (use an analog VOM
for variable resistor testing). If an oscilloscope is speci-
a WARNING:
l
l Shut down
ELECTRIC
Do not touch live electrical
welding
SHOCK can kill.
power
parts.
source, and
fied, use a good qualrty unit with one megohm input im- disconnect input power employ/ng lockout/
pedance or greater. If a circuit board has a protective tagging procedures before inspecting,
maintaining, or serviong.
coating, It WIII be necessary to remove coating or use
needle probes in the test area to obtain proper contact. Lockouttagging procedures consist of pad-
Recoat areas if necessary to retain corrosion protectton. locking line disconnect switch in open position,
Digital volt-ohmmeters (DVM‘s) do not require lead po- removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
larity attention when maklng connections. However, the
ing device.
meter may Indicate a (negative) voltage when the test
procedure specrfied a + ( posltrve) voltage. If the incor- MOVING PARTS can cause serious injury.
rect polarity appears on the display, reverse meter lead l Keep away from moving parts.
connections to test porn&
l Allow cooling period before servicing.
8-2. CIRCUIT BOARD HANDLING PRECAUTIONS
Troubleshooting to be performed only by
WARNING: ELECTRIC SHOCK can kill. qualified persons.
The troubleshooting table is designed to diagnose some
nect input power employ/ng lockout/tagging
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 pad-
locking ltne disconnect switch In open position,
removing 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 Servrce Parts Manual while performing trouble-
shooting procedures.
l 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.
l Allow cooling penod before servicing.
Resrstance and continuity measurements must be
e CAUTION:
BEFORE
ELECTROSTATIC
properly
handling
DISCHARGE
(ESD) can damage circuit boards.
Put on grounded
circuit boards.
wnst strap
made with the unit shut down. Isolate components be-
fore making resistance and continuity measurements.
IMPORTANT: Before beginning troubleshootingproce-

dures. visually examine internalcomponents forsigns of
l Transport circuit boards in proper static-
sh/elding carriers or packages. overheating and failure. Many major problems, such as
windIng failure are usually apparent by discoloration,
l Perform work only at a static-safe work area. smoke, and smell. Fortunately, most electricalproblems
INCORRECT INSTALLATION or misaligned are re/at/ve/y simple.. blown fuses, tripped circuit break-
plugs can damage circuit board. ers. /ncorrect switch positions, loose connect/ens, corro-
l 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
l Use on/y mlnimal pressure and gentle move- and secure according to Section 4 and that all controls
ment when disconnecting or connecbng and switches are in proper positions before proceeding
board plugs and removing or installing board. with troubleshooting.
SM.221 Page 18
Table 8-1. Troubleshooting
TROUBLE CAUSE REMEDY
Vo weld output; unrt complete- Line disconnect switch In the Place line disconnect switch in the ON posi-
y Inoperative. OFF position tion
Line fuse(s) open Check line fuses, and replace if necessary.
Poor and/or Improper input See Section 4-6 for proper input connections.
connections
Input voltage jumper links not See Section 4-6 for proper jumper link position
in proper position.
Unit overheatrng causing ther-

mostat TPI to open (thermal
Allow a cooling period of approximately
minutes (see Section 10-3).
fifteen
I
shutdown).
Control fuse Fl open (500 and Check Fl , and replace if necessary (see Sec-
600 ampere models only). tron 1O-2).
Fuse(s) F2, F3, F4, F5. and Check F2, F3, F4, F5. and F6, and replace if
F6 open. necessary (see Section 1O-2).
POWER swttch ON push but- Check push button switch linkage for restrictior
ton linkage. or obstruction.
POWER switch OFF push but- Check PBl for proper operation with an ohm-
ton PBl 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
~011.Replace W if necessary.
Diodes DIO and Dll in main Check DIO and Dll according to Section 8-6,
contactor W circuit. and replace if necessary.
Main transformer Tl Visually examine main transformer Tl for signs

of windlng failure (uneven discoloration would
be apparent if a short has occurred). Check
contrnuity across each winding, and check for
proper connections. Check Tl for proper volt-
ages (see Diagram 8-l ( 8-2, 8-3, or 8-4). Re-
place Tl If necessary.
Control transformer T2 (500 Vsually examine control transformer T2 for

and 600 ampere models only) 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 T2 for
proper voltages (see Diagram 8-3 or 8-4). Re-
place T2 If necessary.
10 weld output; pilot light PLl Poor and/or improper weld See Section 4-5 for proper weld output con-
In. output connections. nections.
CONTACTOR CONTROL Place S4 In ON position or connect Remote

switch S4 in REMOTE positron Contactor Control to RCl (see Sections 4-4
with no Remote Contactor and 5-6).
Control connected to RE-
MOTE CONTROL receptacle
RCI
Remote Contactor Control Check Remote Contactor Control switch for

switch. proper operation with an ohmmeter, and re-
place if necessary.
SM-221 Page 19
Table 8-l. Troubleshooting (Continued)
No weld output; pilot light PLl Control Board PC1 or poor Check connections for continuity to PCl.
on. (Continued) connectlons to PC1 Check PC1 according to Section 8-4 and Dia-
gram 8-5 Replace PC1 if necessary
Low or minimum weld output. Open line fuse. Replace open line fuse.
L
Poor and/or improper Input Refer to Sections 4-5 and 4-6 for proper input
and/or output connectlons. and output connections.
c +
Low line voltage. Correct low line voltage.
c
Improper use of Remote Cur- kefer to Section 5-5 for proper use of Remote
rent Control in conjunction Current Control.
with CURRENT ADJUST-
MENT control R5.
Fuse(s) F2. F3. F4. F5. and Check F2, F3, F4, F5. and F6, and replace if
F6 open. necessary (see Section 1O-2).
+
CURRENT CONTROL switch Place S2 in desired position (see Section 5-5).
s2.
Check S2 for proper operation with an ohm-
meter. and replace if necessary.
CURRENTADJUSTMENT Check R5 for proper connections and resis-
control R5. tance; R5 is 1000 ohms 210% Replace R5 if
necessary.
Remote Current Control. Check Remote Current Control for proper op-
eratlon with an ohmmeter, and replace if nec-
essary.
Burden resistor R6. Check R6 for proper connections and resis-
tance; R6 is 12 ohms 210%. Replace R6 if
necessary.
Current transformer(s) CTl, Check the continuity of CT1 , CT2, and CT3
CT2. and/or CT3. wIndIngs with an ohmmeter between terminals
D and C, C and 8, and B and D on Feeder
Board PC2. Replace CT1 , CT2, and CT3 if
necessary.
Feedback Board PC2 or poor Check connections for continuity to PC2.
connections to PC2. Check PC2 according to Section 8-5 and Dia-
~gram 8-6. Replace PC2 if necessary.
I
SCR in main rectifier SRI. ~For 300 ampere models, check SCR’s in SRl
accordtng to Section 8-7. For 400, 500, and
~600 ampere models, check SCR’s In SRI ac-
cording to Section 8-8. Replace SCR’s If nec-
essary.
-I
If any SCR’s are replaced, be sure to check
capacitors C7 through Cl2 and main trans-
former Tl. Check C7 through Cl2 for proper
connections, shorts, and leakage. Replace C7
through Cl 2 if necessary. See next entry for
Tl check.
SM.221 Page 20
~-
1
L_ow or minimum weld output. Maln transformer Ti I Visually examine main transformer Ti for signs
(Continued) of windrng failure (uneven discoloration would
: be apparent if a short has occurred). Check
continuity across each winding, and check for
i ages according to Diagram 8-1, 8-2, 8-3, or
I 8-4. Replace Tl if necessary.
Control Board PC1 or poor Check connections for continuity to PCl.
connections to PC1 Check PC1 according to Section 8-4 and Dia-
gram 8-5. Replace PC1 if necessary.
Flnaximum weld output. CURRENT ADJUSTMENT Check R5 for proper connections and resis-
control R5. tance; R5 is 1000 ohms ~10% Replace R5 if
necessary.
Current transformer(s) CT1 , Check the continuity of CTl, CT2, and CT3
CT2. and/or CT3. windings with an ohmmeter between terminals
D and C. C and B, and B and D on Feedback
Board PC2. Replace CT1 ( CT2, and CT3 if
necessary.
Feedback Board PC2 or poor , Check connections for continuity to PC2.
fI
connections to PC2. Check PC2 according to Section 8-5 and Dia-
1Control Board PC1 or poor Check connections for continuity to PC1
1connections to PCl. Check PC1 according to Section 8-4 and Dia-
! gram 8-5. Replace PC1 if necessary.
l
Erratic weld output. ~Poor and/or improper Input Refer to Sections 4-5 and 4-6 for proper input
For 300 ampere models, check SCR’s in SRI

according to Section 8-7. For 400, 500, and
600 ampere models, check SCR’s in SRI ac-
cording to Section 8-8. Replace SCR’s if nec-
essary.
_If any SCR’s are replaced, be sure to check
capacitors C7 through Cl2 and main trans-
former Tl Check C7 through Cl 2 for proper
Tl check.
Marn transformer Tl. Vrsually examine main transformer Tl for signs
I of winding failure (uneven discoloration would
i be apparent if a short has occurred). Check
; continuity across each winding, and check for
ages according to Diagram 8-l. 8-2, 8-3, or
~8-4. Replace Tl if necessary.
Check connections for continuity to PC1
L Check PC1 according to Section 8-4 and Dia-

--.
SM-221 Page 21
Excessive line current or line Poor and/or improper input See Section 4-6 for proper input connections.
fuse(s) opens repeatedly. connections.
Input voltage jumper links not See Section 4-6 for proper jumper link position.
In proper posttron.
Fan motor FM. Check and repair shorted fan motor FM leads.
SCR in main rectifier SRI. For 300 ampere models, check SCR’s in SRl
according to Section 8-7. For 400, 500, and
600 ampere models, check SCR’s in SRl ac-
cordrng to Section 8-8. Replace SCR’s if nec-
essary.
If any SCR’s are replaced, be sure to check
capacitors C7 through Cl 2 and main trans-
former Tl Check C7 through Cl 2 for proper
Tl check.
Main transformer Ti Visually examine main transformer Tl for signs
of winding failure (uneven discoloration would
be apparent if a short has occurred). Check
1continuity across each winding, and check for
’ proper connections. Check Tl for proper volt-
ages according to Diagram 8-1, 8-2, 8-3, or
8-4. Replace Tl if necessary.
Fan blades blocked against ~Check for and correct blade obstruction.
and/or overheating. plenum.
Fan motor FM. Replace FM.
~.
No 115 volts ac output at op- Circuit breaker CBl tripped. Reset CBl (see Section 10-2).
tional 115 volts ac duplex re- I
ceptacle.
I.--_-- --
SW221 Page 22
Chart 8-l. Waveforms For Diagrams 8-l Thru 8-4
r TV .__....-T- _~. _ --------

5ms 1OV
I f 1
gnd L -! gnd L--_i-

A. DC Open-Circuit Voltage, Range l3. DC Open-Circuit Voltage, Range
Switch S3 In Low Position Switch S3 In High Position
5ms 1OV 5ms 1OV

-- ---T----- 1
--I -11- -- -7~7 -
-I
i t
gnd ._-L.
C. 28 Volts DC (Average), 204 Amperes, D. 36 Volts DC (Average), 403 Amperes,

Range Switch 53 In Low Position (Resis- Range Switch S3 In High Position (Re-
tive Load) sistive Load)
W-221 Page 23
WARNING: ELECTRICSHOCK can kill; MOVING PARTS
can cause serious injury.
l Do not touch live electrical parts
l Shut down welding power source before making or
changing meter lead connections andbefore disconnect-
ing or connecting any leads.
l Have only qualified persons familiar with and following
standardsafetypracticespetform troubleshootingproce-
dues.
l Follow standard ESD precautions to prevent damaging
static-sensitive parts during testing.
l See Table 8-l if vaiues are not present.
See also Section 8-5

for PC2 data
---_-___5
I “s’E’b
I
0 to about +7 volts dc
See Section 4-4

for RCl data
Diagram 8-l. Troubleshooting Circuit Diagram For 300 And 400 Ampere Models
SM.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 (lead43) unless otherwise
indicated.
IMPORTANT: All resistance values for main transformer TI and

stabilizer 2 are less than one ohm.
IMPORTANT: The A, B, C, and D test points are for use with letter-
matching waveforms on Chart8-1.
See Section 8-7 (300 ampere models) or Voltage Readings

Section 8-8 (400 ampere models) for SRl data ( HO% Unless Specified)
Vl 115 volts ac with contactor

W energized
I v2
v3 52 volts ac with contactor

W energized
v4
V5 230 volts ac with POWER

switch ON
V6 18 volts ac with contactor

W energized
v7
-.
V8
v9 32 volts ac wlth contactor
ELECTRODE
W energized
VlO
Vll 15 volts dc with POWER

switch ON

for PC1 data
C-083 370-A
SM-221 Page 25
WARNING: ELECTRlCSHOCKcan kill;MOVING PARTS
l Do not touch live electhal parts.
changingmeterlead connectionsand before disconnect-
l Have on/y qualified persons familiar with and,fo//owing
standardsafetypracticesperform troubieshootmgproce-
dues.
l Follow standard ESD precautions to prevent damaging
l See Table 8-1 if values are not present.
Sea also Section 8-5

for PC2 data
16
-5, volts dc output
+?4 volts dc output
I
See Section 4-4
for RCl data
Diagram 8-2. Troubleshooting Circuit Diagram For 300 And 400 Ampere Models With Fan Control
SM.221 Page 26
volt-ohmmeter (DVM) or equivalent reading average (not RMS)
are with respect to circuit common (lead 43) unless otherwise
indicated.
IMPORTANT: All resistance values for main transformer Tl and

stabilizer Z are less than one ohm.
IMPORTANT: The A, B, C, and D test points are for use with letter-
matching waveforms on Chart 8- 1.
Voltage Readings
( IfIlO% Unless Specified)
See Section 8-7 (300 ampere models) or
Section 8-8 (400 ampere models) for SRl data Vl 115 volts ac with contactor
W energized
v2 115 volts ac with fan motor FM

running
v3
1
POSITIVE W energized
v5

W energized
v7
v12
A, 8, C, D V8

W energized
VlO
Vll 15 volts dc with POWER

switch ON
-=-wyf NEGATIVE ;I
v12 53 to 67 volts dc from min. to
max. of CURRENT
ADJUSTMENT control R5

for PC1 data
C-084 a51
SM-221 Page 27
WARNING: ELECTRIC SHOCK can kill; MOVING PARTS
l Do not touch live electrical parts.
Shut down welding power source before making or
changing meter lead connections and before disconnect-
Have on/y qualified persons familiar with and following
standardsafetypractices perform troubleshootingproce-
dures.
Foilow standard ESD precautions to prevent damaging
See Table 8- 1 if vakies are not present.

for PC2 data
0 to about +7 volts dc
at maximum output with
-5 volts dc output i24 volts dc output
z9 27 I3
” ” ”
I I
She Section 4-4

for RCl data
_ ,.,. Diagram 8-3. Troubleshooting Circuit Diagram For 500 And 600 Ampere Models
SM.221 rage ztl
IMPORTANT: For DC, the values are based on a goodquality digital
are with respect to circuit common (lead43) unless otherwise
indicated.

IMPORTANT: The A, 8, C, and D test points are for use with letter-
Voltage Readings
( +lO% Unless Specified)
See Section 8-8
Vl 115 volts ac with contactor
for SRl data
W energized
v2

W energized
v4

switch ON
V6 115 volts ac
v13 v7 115 volts ac with POWER
A, S, C, D switch ON

W energized
ELECTRODE
v9
VlO
Vll 32 volts ac with contactor

W energized
v12

max. of CURRENT

for PC1 data
t-
C-083 377
SM.221 Page 29
WARNING: ELECTRIC SHOCK can kill; MOVING PARTS
l Do not touch live electrical parts.
changing meter lead connections andbefore disconnect-
l Have only qualified persons familiar with and foiiowing
standardsafetypracticesperform troubleshootingproce-
dues.
l Follow standard ESD precaubons to prevent damaging
l See Table 8- 7 if values are not present.

for PC2 data
I ri
to about +7 volts dc
RANGE switch S3 in HIGH or
LOW position
PC>
-5 volts dc outout +2A
I L- 1 YY
See Section 4-4
for RCl data
Diagram 8-4. Troubleshooting Circuit Diagram For 500 And 600 Ampere Models With Demand Fan Control
SM.221 Page 30
are with respect to circuit common (lead 43) unless otherwise
indicated.

IMPORTANT: The A, S, C, and D tes? points are for use with letter-
Voltage Readings
( *lo% Unless Specified)
See Section 8-8
for SRl data Vl 115 volts ac with contactor
W energized
v2

W energized
v4

switch ON
V6 115 volts ac

A, B, C, D switch ON
V8 115 volts ac with TP2 and/or

TP3 closed
ELECTRODE v9 18 volts ac with contactor
~OPrlONAL-EY-RA~ W energized
VlO
-.
Vll

W energized
v13

max. of CURRENT
- See also Section 8-4

for PC1 data
C-085 374-A
SM.221 Page 31
8-4. CONTROL BOARD PC1 TESTING INFORMA- B. Voltage Control Circuit
TION (Figure 8-l And Diagram 8-5)
Control Board PC1 requires several input signals togen-
erate the gate pulses to the SCR’s at pins 1, 4, 5, 8, 9,
e l Do not touch live electrical parts. and 12 of the 29-pin plug. As CURRENT ADJUSTMENT
l Shut down weldlngpowersource before mak- control R5 or the remote current control is rotated clock-
/ng or changing meter lead connections and wise. the gate waveform pulses are moved to the left
p,“,;; disconnecting or connecting any thereby turning the SCR’s on earlier. As R5 or remote
current control IS rotated counterclockwise, the gate wa-
MOVING PARTS can cause serious injury. veform pulses are moved to the right thereby turning the
SCR‘s on later. The output current is controlled by CUR-
l Keep away from moving parts
RENT ADJUSTMENT control R5 when CURRENT
HOT SURFACES can cause severe burns. CONTROL switch 52 is in the STANDARD position or by
l Allow cooling period before servicing the remote current control when S2 is in the REMOTE
posrtton. The required input signals to PC1 are as fol-
This procedure requrresthe unrt to be energrzed.
Only qualified persons familiar with and follow- lows
ing standard safety practices are to perform this
1 Control Board PC1 requires an input command
testing procedure.
voltage of 0 to -5 volts dc at pin 29 of the 29-pin
CAUTION: ELECTROSTATIC DISCHARGE
AA
plug with respect to circuit common from CUR-
(ESD) can damage circuit boards. RENT ADJUSTMENT control R5 or the remote
l Put on properly grounded wrist strap BE- current control.
FORE handling circuit boards.
2. Control Board PC1 requires a current feedback
l Transport circurt boards in proper static-
signal proportional to the weld output. Current
sh/elding earners or packages.
feedback should vary from 0 to about +7 volts dc
l Perform work only at a static-safe work area. at maximum output with RANGE switch S3 in
INCORRECT INSTALLATION or misaligned HIGH or LOW position between pins 28 (+) and
plugs can damage circuit board. 18 (-) of the 29-pin plug.
l Be sure that plugs are properly installed and 3. Control Board PC1 requires a synchronization
alIgned.
signal of 32 volts ac from main transformer Ti at
EXCESSIVE PRESSURE can break circuit pins 19, 20, and 21 with respect to pin 18 (circuit
board. common) of the 29-pin plug.
l Use only minimal pressure and gentle move-
ment when disconnecting or connecting C. Contactor Control Circuit
board plugs and removing or installing board.
Contactor control is provided at pin 13 of the 29-pin plug
IMPORTANT: For a// checks, be sure to test and verify with an input voltage of t24 volts dc from pin 22. When
the continuity of leads between the board and the area CONTACTOR CONTROL switch S4 is in the STAN-
where check is performed. All checks should go through DARD position +24 volts dc should exist between pins
the connections and be actual terminal-to-terminal tests 13 and 16 (circuit common) of the 29-pin plug. When S4
so that bad connections or ieads and corrosion is not the is in the REMOTE position and the remote contactor de-
problem. vice is closed. +24 volts dc should exist between pins 13
and 16 (circuit common) of the 29-pin plug.
A. Power Supply Circuit
D. Arc Control Circuit
Operational input power of 18 volts ac should exist at
pins 24 and 25 with respect to pin 23 (circuit common) of An output voltage of -13 volts dc to ARC CONTROL
the 29-pin plug. If these voltages are not present, check switch S5 should be present between pins 14 and 16
main transformer Ti for proper voltages according to (circuit common) of the 29-pin plug for selection of the
Diagram 8-l. 8-2, 8-3, or 8-4. desired arc characteristics (see Section 5-7).
SM-221 Page 32
, c7g I C76
m
4 R67
C60
TB-082 437
Figure 8-1. Control Board PC1 Component Locations And Information
SM.221 Page 33
WARNING: ELECTRIC SHOCK can kill: MOVlNG PARTS
l Do nor touch i/ve eiectrrcai parts
changing meter lead connectIons and before disconnect-
/ng or connect,ng any ieads
l Have only quairfied persons iamlhar wdh and foiiowrng
standardsafetyprer:trces ocrform troubieshootrngproce-
dures
l Follow slandard ES0 precautions to prevent damagrng
s&W-sensftfve parts dur!ng testing
21-P ~--
32 volts ac input
for synchronization
F 20-C---------
19t--_-
pm
I
c51
;;;
--~
c52 ;;cs3
~-___
Circuit common-le<-
T
Circuit common ~16~~~~~
-13volts dcoutput -------)t14f-----
-5 volts dcoutput -15

+l -t---s-
0 to -5 volts dc input from min. to

max. of CURRENT ADJUSTMENT
control R5 with CURRENT CONTROL 2g
-L
switch S2 in STANDARD position
0 to about +7 volts dc Y28

at maxfmum output with
RANGE switch S3 in HIGH or
LOW position
+24 volts dc input with CONTACTOR -13

CONTROL switch S4 in STANDARD
position, +24 volts dc input with S4 in
REMOTE position and remote 7
contactor switch closed, 0 volts dc R R R
input with S4 in REMOTE position
iIS”
and remote contactor switch open Q
0 to -5 volts dc input fromd26m -

min. to max. of CURRENT
22 24 25
18 volts ac input
0 to -5 volts dc output from
L_
-18 volts ac input
min. to max. of CURRENT
+24 volts dc output
Diagram 8-5. Troubleshooting Circuit Diagram For Control Board PC1

SM.221 Page 34
IMPORTANT: For DC. the vaiues a/e basea m a goodquabty digifal
voi!-ohmmeter (DVM) or equvalent readmg average (not RMS)
~arues For AC, the values are RMS readings The voltages shown
are with respect to orcutt common jiead 43) unless otherwse
mkaied and fhe tolerances are k 10% Mess otherwse speofied.
IMPORTANT: Test pomt A is for use w&h the letter-matchrng
L:-?tpfcrm
2ms 1V
_.~__.._._ ._-.. ---~ I
A. SRl Gate Pulse At No Load
C-071 932-A
W-221 Page 35
8-5. FEEDBACK BOARD PC2 TESTING INFORMA- INCORRECT INSTALLATION or misaligned
TION (Figure 8-2 And Diagram 8-6) plugs can damage circuit board.
WARNING: ELECTRIC SHOCK can kill. l Be sure that plugs are properly installed and
aligned.
EXCESSIVE PRESSURE can break circuit
l Shut down weldlngpowersource before mak-
board.
/ng or changing meter lead connectlons and
8,“,;c? disconnecting or connecting any l Use only minimal pressure and gent/e move-
ment when disconnecting or connecting
board plugs and removing or installing board.
l Keep away from moving parts
l Allow cooling period before serv!clng. IMPORTANT: For all checks, be sure to test and verify
This procedure requires the untt to be energized. the cont/nuity of leads between the board and the area
Only qualtfied persons familiar with and follow- where check is performed. All checks should go through
ing standard safety practices are to perform this the connections and be actual terminal-to-terminal tests
testing procedure so that bad connections or leads and corrosion is not the
CAUTION: ELECTROSTATIC DISCHARGE problem.
(ESD) can damage circuit boards.
e
l Put on properly grounded wrist strap BE-
FORE handling circuit boards.
Current feedback should vary from 0 to about +7 volts dc
l Transport orcu/t boards in proper static- at maximum output with RANGE switch S3 in HIGH or
shielding carriers or packages.
LOW position between pins E and A (circuit common). If
l Perform work only at a stat/c-safe work area. the output feedback signal is not present, replace PC2.
0 Rl
.
I L
R2 I
:
Terminal
Connectlon
Points
TA-059 161
Figure 8-2. Feedback Board PC2 Component Locations And Information

SM.221 Page 36
WARNING: ELECTRIC SHOCKcan kill: MOVING PARTS IMPORTANT: for DC. the values are based on a good quality dIgita/
A can cause serious injury.
Do not touch //ve electrical parts
volt-ohmmeter (DVM) or equivalent
For AC. the values are RMS readrngs.
reading average (nof RMS) values.
The voltages shown are with
respect to circu!t common (lead 43) unless otherwise jndicated and the
Shut down welding power source before making or toierances are 2 70°0 uniess otherwIse speofred
chanarno meter leadconnections and before d6connect-
,ng o;c&nectmg any ieads
Have on/y quailhed persons famriiar wfth and following
sfandardsafetypract~ces perform troubieshootfngpfoce-
dures
follow standard ESD precautions to prevent damaging
stat/c-sen.Wve parts dunng teshng
Input from current transformers

CTl, CT2, and CT3
---_ _- - --__
I /\/4/N
BCD
DS 04
I *
I+
D7 06
I,+ 1
I DQ
1
I+-=
I ,,
4R2 } I,
I Fl
I l..'
I-
I PC2
I-_-_-a--_
5, -
0 to about +7 volts dc L Circuit common

RANGE switch 53 in HIGH or
LOW position
Ret C-083 370-A
Diagram 8-6. Troubleshooting Circuit Diagram For Feedback Board PC2
SM-221 Page 37
8-6. DIODES DlO AND Dll TESTING PROCE- leads across each diode. A properly functioning
DURE (Figure 8-3) diode conducts in the forward direction (meter
reads 0.3 to 0.9V), and blocks in the reverse di-
rectlon (meter reads OL).
e l Do not touch live electr;cal parts.
4. If either diode does not check properly, replace
l Shutdown weldingpowersource. anddiscon-
the diode.
nect Input power employing lockout/tagging
procedures before inspecting, maintaining. or 5 If the diodes check properly, reconnect leads to
servicing.
marked locations.
locking line disconnect switch in open position,
8-7. MAIN RECTIFIER SRl TESTING AND RE-
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect- PLACEMENT PROCEDURE FOR 300 AM-
ing device. PERE MODELS (Figures 8-4 Thru 8-7)
MOVING PARTS can cause serious injury. WARNING: ELECTRIC SHOCK can kill.
l Keep away from moving parts. 4A l Do not touch live electrical parts.
HOT SURFACES can cause severe burns. l Shut down weldingpowersource. anddiscon-
l Allow cooling penod before servlcmg. nect input power employing IockouWtagging
procedures before inspecting, maintaining, or
Only qualified persons familiar with and follow- servicing.
testing procedure
locking line disconnect switch in open position,
IMPORTANT: Read and understand meter Owner’s
Manual before making measurements. ing devtce.
Diode Not
l Keep away from moving parts.
Conducting
l Allow cooling period before serv/c/ng.
Only qualified persons familiar with and follow-
testing procedure.
IMPORTANT: Read and understand meter Owner’s

Manual before making measurements. See Figure 9- 1
for /ocat/on of ma/n rectifier SRI in this un/t.
‘u Cathode
A. SCR Testing Procedure (Figures 8-4 And 8-5)
Diode Conducting. WARNING: Read and follow safety informa-

Forward Voltage Drop tion at beginning of entire Section 8-7 before
(0.3 to 0.9V) a proceeding.
IMPORTANT: The SCR’s of SR7 should be checked

with an SCR tester, such as a Handyman 269 or equiva-
lent. If an SCR tester is not available, use a good quality
VOM. such as a Simpson 260 or equivalent.
IMPORTANT: The ohmmeter check of an SCR is not a

I Cathode
conclusive test. More conclusive tests require special-
s 01.19
ized equipment. Hence, even though an SCR checks out
Figure 8-3. Diode Testing Procedure good. the SCR may still be bad. An SCR may be bad at
the actua/app//ed voltage yetcheckoutgoodat the com-
paratively low ohmmeter voltage (usually about 1.5
1. Mark and disconnect one lead of diodes Cl10 and volts). If In doubt, replace the SCR.
Dll
2. Set meter on Diode Test scale. 1. Mark and disconnect SCR pigtail from heat sink.
3. Test each diode In the forward and reverse direc- 2. Locate and disconnect 29-socket receptacle from
tion by connecting and then reversing the meter plug on Root Pass Board PCl.
SM.221 Page 38
b
Sib-221 Page 39
3. If an SCR tester IS available, test each SCR ac- 7. Connect the gate lead to the anode as shown in
cording to the manufacturer’s instructions. If an Figure 8-5. The VOM should then indicate a low
SCR does not check properly, replace the SCR resistance (approximate mid scale) indicating to
accordrng to Section 8-78. you that the SCR gate is okay. If a low reading
cannot be obtained, the SCR gate is bad. The am-
4. If an SCR tester IS not available, set VOM function
meter should indicate current flow meaning that
selector switch to Rx1 ohms.
the SCR has turned on. When testing small
5. Connect meter leads to SCR as shown In Figure SCR’s, removal of the gate lead from the anode
8-5. Make sure the test lead polarity is as shown. will not change the ammeter reading. This is be-
Another meter will be necessary to determine the cause the meter is providing a “holding current.”
output polarity of the lead jacks as not all meters On large SCR’s, the meter cannot provide
have the internal battery negative connected to enough “holding current,” so the meter will revert
the negatrve or common output jack. It is a good to a high resistance when the gate lead is re-
idea to mark your meter jacks plus or minus for fu- moved from the anode.
ture use
8. If an SCR does not check properly, replace the
Cathode Lead SCR according to Section 8-78.
(Small Red)
Gate Lead 9. If the SCR’s check properly, reconnect SCR pig-
\ (Small White)
tail(s) to heat sink.
10. Reconnect 29-socket receptacle to matching

plug on Root Pass Board PC1
VOM
B. SCR Replacement Procedure (Figures 8-6 And
\
8-7)
f
----!--\ e
WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-7 before
proceeding.
IMPORTANT: If any SCRk are replaced, be sure to

check capacitors C7 through C72 for proper connec-
tions, shorts. and leakage. Also, visually examine main
transformer Tl for signs of winding failure (uneven dis-
_
coloration would be apparent if a short has occurred).
Check continuity across each winding, and check for
proper connections. Check phase-to-phase voltage be-
Black tween leads 27 and 22,22 and 23, and 21 and 23 (see
+-
Diagram 8- 1, 8-2.8-3, or 8-4). Rep/ace C7 through C72
and Tl if necessary
Red
1. Locate and disconnect 29-socket receptaclefrom
plug on Root Pass Board PCl.
Anode
2. Trace the red and white leads from SCR to be re-
placed to 29-socket receptacle. Mark and remove
Step 7 Of Testing Procedure Only. the leads from receptacle using an AMP
Touch Gate Lead To Anode.
465199-1 pin extraction tool (MILLER part num-
ber 099 719) according to Figure 8-6.
A = Ammeter With 0 To 100 Milliampere
Range (May Be Another VOM)
Figure 8-5. SCR Lead Identification And Meter

Connection Points
Locking
Lance
6. A high reststance reading should be indicated
with the gate lead not in the circuit. (A low resis- Front Of
tance reading Indicates a shorted SCR in which 29.Socket
Receptacle
case the SCR should be replaced and the test is
completed.) Proceed to Step 7 if a high reading is
ST-1 47 699
obtained. Leave meter leads connected as
shown In Figure 8-5. Figure 8-6. Pin Extraction Tool
SM-221 Page 40
3. Remove SCR’s from heat sink, and discard. If us- 8-8. MAIN RECTIFIER SRl TESTING AND RE-
ing a breakaway nut to install the new SCR, retain PLACEMENT PROCEDURE FOR 400, 500,
existing Internal tooth lock washer. If using a wa- AND 600 AMPERE MODELS (Figures 8-8
sher-nut combination, discard lock washer. Thru 8-11)
4.
5.
Clean surface of heat sink around SCR’s mount-
ing hole.
Apply a thin layer of supplied heat sink compound

e WARNING:
l
l
ELECTRIC SHOCK
Do not touch live electrical parts.
Shut down weldingpowersource,
can kill.
anddiscon-
nect rnput power employing lockout/tagging
to SCR face surface (see Figure 8-7). procedures before inspecting, maintaining, or
sefvxing.
IMPORTANT: Do not apply heat sink compound on the Lockout/tagging procedures consist of pad-
threads of the SCR stud locking line disconnect switch in open position,
6. Insert new SCR in heat sink and thread break- Ing device.
away nut with internal tooth lock washer, or wa-
sher-nut combination onto SCR stud as illus- MOVING PARTS can cause serious injury.
trated in Flqure 8-7 l Keep away from moving parts.
7. Tighten nut according to type:
l Allow cooling period before servicing.
a. Breakaway Nut: Wrench-tighten until hex por- Only qualified persons familtar with and follow-
tlon breaks off. Discard hex portion ing standard safety practices are to perform this
testing procedure.
b. Washer-nut Combination: Finger-tighten as
tight as possible. Using a wrench, turn the nut IMPORTANT: Read and understand meter Owner’s
112 turn only. The washer-nut combination will Manual before making measurements. See Figure 9-l
be compressed to Its calibrated pressure using for location of main rectifier SRl in this unit
this tightening procedure.
A. SCR Testing Procedure (Figures 8-8 And 8-9)
IMPORTANT: If using a standard nutandan /rich-pound
torque wrench, tighten the nut to 275-325 in-lbs. Be sure
SCR threads are dry; do not lubricate e proceeding.
8. Apply a thin layer of supplied anti-oxidant com- IMPORTANT: The SCR’s of SRI should be checked
pound to pigtail connection tab surface (see Fig- with an SGR tester, such as a Handyman 269 or equiva-
ure 8-7), and connect pigtail to proper location on lent. If an SCR tester is not available, use a good quality
heat smk. VOM, such as a Simpson 260 or equivalent.
9. Route and connect leads from new SCR to IMPORTANT: When testing hockeypuk SCR’s discon-
marked locations in receptacle X2. nect gate leadand cathode oranode connection to heat
sink. but leave SCR clamped in its original heat sink.
10. Reconnect 29-socket receptacle to matching Hockeypuk SCR’s must be under mounting pressure to
plug on Root Pass Board PC1 allow testing. The mounting pressure is necessary forin-
ternal contact between chip and pole pieces. Disregard
small red cathode lead. Meter readings may be taken at
heat s,nk(s), if applicable. See Figure 8-8 for lead identi-
ficatfon.
Locate and disconnect 29-socket receptacle from
plug on Root Pass Board PCl.
If an SCR tester is available, test each SCR ac-
cording to the manufacturer‘s instructions. If an
/ , ‘,_, Breakaway SCR does not check properly, replace the SCR
.-’
SCR Face ,’ Nut according to Section 8-8B.
/,Z
If an SCR tester is not available, set VOM function
selector switch to Rx1 ohms.
Lock
Washer Connect meter leads to SCR as shown in Figure
SA-141 402
8-9. Make sure the test lead polarity is as shown.
Another meter will be necessary to determine the
Figure 8-7. SCR Installation output polarity of the lead jacks as not all meters
SM-221 Page 41
have the internal battery negative connected to cannot be obtained, the SCR gate is bad. The am-
the negative or common output jack. It is a good meter should indicate current flow meaning that
idea to mark your meter jacks plus or menus for fu- the SCR has turned on. When testing small
ture use. SCR’s. removal of the gate lead from the anode
5. A high resistance reading should be indicated will not change the ammeter reading. This is be-
with the gate lead not in the crrcuit. (A low resis- cause the meter is providing a “holding current.”
tance reading Indicates a shorted SCR in which On large SCR’s, the meter cannot provide
case the SCR should be replaced and the test is enough “holding current,” so the meter will revert
completed.) Proceed to Step 6 if a high reading is to a high resistance when the gate lead is re-
obtained. Leave meter leads connected as moved from the anode.
shown tn Figure 8-9. 7. If an SCR does not check properly, replace the
6. Connect the gate lead to the anode as shown in SCR according to Section 8-88.
Figure 8-9. The VOM should then indicate a low 8. If the SCR’s check properly, reconnect 29-socket
resistance (approximate mid scale) indicating to receptacle to matching plug on Root Pass Board
you that the SCR gate is okay. If a low reading PCl.
SM-221 Page 42
TOP VIEW
Spring Indicator Clamp

Red White Red White (see Figure 8-11) Red White
\ \ \ \ I / /
SCRG SCRj
Capacitors
C7-Cl2 \
SCR
\
Spring Indicator Clamp Ref SD-140 121-A
Aef TC-049 899-C
(see Figure 8-11)
Figure 8-8. Main Rectifier SRl Component Locations And Information

For 400,500, And 600 Ampere Models
SM-221 Page 43
Cathode Lead
___._-. Cathode (Small Red)
r --.’ 9
_, ”
I
i
z (Small White)
I 1 (
Anode
4 Step 6 Of Testing
Procedure Only. Connect
/
Gate Lead To Anode.
A = Ammeter With 0 to 100

Milliamperes Range (May I
Be Another VOM).
I
SA-115 688
Figure 8-9. Hockey Puk-Type SCR Lead Identification And Meter Connection Points
B. SCR Replacement Procedure (Figures 8-10 And 3. Note position of leads, and mark mounting sur-
8-11) faces to aid relocation of new SCR on heat sink.
WARNING: Read and follow safety informa- 4. Loosen clamping device, and remove SCR to be
e replaced.
proceeding.
5. Remove all remaining heat sink compound from
IMPORTANT: If any SCRs are replaced, be sure to both surfaces on heat sink in area where SCR
check capacitors C7 through Cl2 for proper connec- was removed.
tions, shorts, and leakage. Also, visually examine main
transformer Tl for signs of winding failure (uneven dis- 6. Examine surface of heat sinks. Surfaces must be
coloration would be apparent if a short has occurred). thoroughly clean, flat, and true. Surface flatness
Check continuity across each winding, and check for must be within ,001 in. If surface is marred or
proper connectrons. Check phase-to-phase voltage be- damaged, either remachine or replace heat sink.
tween leads 21 and 22,22 and 23, and 21 and 23 (see
Diagram 8- 1. 8-2,8-3, or 8-4). Replace C7 through Cl 2 7. Apply a thin coating of supplied heat sink com-
and Tl if necessary. pound to both contact surfaces of new SCR.
IMPORTANT: Proper contact and mounting pressure

1. Locate and disconnect 29-socket receptacle from
are necessary for correct operation of new SCR.
plug on Root Pass Board PC1
2. Trace the red and white leads from SCR to be re- 8. Position SCR correctly according to marked
placed to 29socket receptacle. Mark and remove leads and mounting surfaces, and place SCR
the leads from receptacle using an AMP onto locating pins in heat sinks.
465199-l pin extraction tool (MILLER part num-
ber 099 719) accordrng to Figure 8-l 0. 9. Place clamp fully into mounting position.
: -_
“\
10. Tighten nuts on clamp evenly until finger tight.
11. Using a wrench, tighten one nut 114 turn and then
other nut 114turn until the lower edge of the spring
indicates a mounting force of 0.8 kilo Ibs. for 400
and 500 ampere models or 2 kilo Ibs. for 600 am-
pere models on indicator (see Figure 8-11).
Front Of
29-Socket 12. Route and connect leads from new SCR to
Receptacle
marked locations in receptacle RC2.
ST-347 699
13. Reconnect 29-socket receptacle to matching
Figure 8-l 0. Pin Extraction Tool plug on Root Pass Board PC1
SM-221 Page 44
SM-221 Page 45
SECTION 9 - COMPONENT IDENTIFICATION AND LOCATION
*
SM-221 Page 46
Circuit Board
Encloyure
Remote Control Contactor Control
Receptacle RCl Switch S4
Front Panel
Push Button PBl

Switch Assembly
(see Figure 9-7)
Output Terminal
positive Weld
Output Terminal
Lower Front Panel

Access Door
TC-004 9E7-F
Figure 9-2. Front Panel And Component Locations
SM.221 Page 47
Resistor R6 Rear
Panel
Figure 9-3. Rear Panel And Component Locations
Silicon-Controlled
Rectifiers SCRl-SCR6
-1
SE-049 529-A
Figure 9-4. Main Rectifier SRl And Component Locations For 300 Ampere Models
SM-221 Page 48
Silicon Controlled
Rectifiers SCRl - SCR6
Capacitors
q-Cl 2
-
I Heat Sink
Heat’Sink
\ Rd TC-048 899-C
Spring Indicator
Clamp
Figure 9-5. Main Rectifier SRl And Component Locations For 400, 500, And 600 Ampere Models
SA-138 574
Figure 9-6. Input Terminal Board TEI And Component Locations

SM-221 Page 49
Bracket
Limit
Switch
Figure 9-7. Push Button PBl Switch Assembly And Component Locations
SM-221 Page 50
SECTION 10 - MAINTENANCE
10-l. ROUTINE MAINTENANCE (Table 10-l) presen? Clean and tighten connections at each inspec-
tion
IMPORTANT: Every SIX months /nspect the labels on
this unit for /eg/b/hty. All precautionary labels must be C. Internal Cleaning
maintained in a clearly readable state and rep/aced
when necessary. See Service Parts Manual for pat-t tion at beginning of entire Section 10-l be-
number of precautionary labels. a fore proceeding.
WARNING: ELECTRIC SHOCK can kill. Every SIX months blow out or vacuum dust and dirt from
e l Do not touch I/W electrical parts. the tnsrde of the welding power source. Remove the
outer enclosure. and use a clean, dry airstream or vac-
nect /nput power employing lockout/tagging uum suctron for the cleaning operatron. If dusty or dirty
procedures before inspect/ng. maintaining, or conditions are present, clean the unit monthly.
serv/ong.
Lockoutitaggrng procedures consist of pad- 1O-2. OVERLOAD PROTECTION
locking line disconnect switch in open posrtion. WARNING: ELECTRIC SHOCK can kill.
removtng fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect- a l Do not touch live electrical parts.
ing devtce l Shutdown weldingpowersource, anddiscon-
MOVING PARTS can cause serious injury. nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
l Keep away from movjng parts. serwcing.
HOT SURFACES can cause severe burns. Lockout,‘tagging procedures consist of pad-
l Allow cooling period before servicing. locking lrne disconnect switch in open position,
removrng fuses from fuse box, or shutting off and
Table 10-l. Maintenance Schedule
rng devrce.
Frequency* Maintenance INCORRECT FUSE can damage unit.

l Use only replacement fuse ofsame size, type,
Every month. Units In heavy service environ- and rabng (see Service Parts Manual).
ments:
Check labels, weld cables, clean A. Circuit Breaker CBl (Optional)
Internal parts.
Every 3 months. Check weld cables (see Section tion at beginning of entire Section 10-2 be-
e
1 IO-il3) fore proceeding.
Every 6 months. Check all labels (see IMPORT- Crrcuit breaker CBl protects the 115 volts ac duplex re-
ANT block, Sectron 10-I). Clean ceptacle from overload. If CBl opens, reduce the
Internal parts (see Section applied equipment load and manually reset CBl.
lo-1C).
B. Fuse Fl (500 And 600 Ampere Models Only)
*Frequency of servtce IS based on unrts operated Read and follow safety informa-
WARNING:
40 hours per week. Increase frequency of mainte- tion at beginning of entire Section 10-2 be-
nance if usage exceeds 40 hours per week. a fore proceeding.
The entire control circuit of the welding power source is

A. Fan Motor
protected by a cartridge type fuse Fl. This fuse is lo-
This unit is equipped with an exhaust fan and relies on cated behind the rear panel access door. Should this
forced draft for adequate cooling. The fan motor is fuse open. the welding power source would completely
manufactured with lifetime sealed bearingsand requires shut down.
no maintenance.
C. Fuses F2, F3, F4, F5, And F6
B. Weld Cables
WARNING: Read and follow safety information at beginning of entire Section 10-2 be-
a fore proceeding.
tion at beginning of entire Section 10-l be-
e fore proceeding.
Fuses F2, F3. F4, F5, and F6 provide protection for Con-
Every three months inspect cables for breaks in insula- trol Board PC1 These fuses are located on the center
tion. Repair or replace cables if insulation breaks are baffle inside the welding power source. If any one of
SM-221 Page 51
these fuses should open, weld output would either be- and or TP3 close, or before the fan motor trmer TDI
come very erratic or stop completely. times out after the arc is extinguished. The fan motor will
run rnrtlally only if the unit was shut off before the fan mo-
1O-3. RECTIFIER PROTECTION
tor timer TDI timed out. The 115 volts ac fan motor re-
The matn rectifier SRI In this welding power source is places the fan motor on the standard model.
protected by a normally-closed thermostat TPl wired in
senes with the contactor W co11circurt. Should overheat- 10-5. DEMAND FAN CONTROL FOR 500 AND 600
ing of the main rectifier occur, this thermostat would AMPERE MODELS (Optional)
open causing the contactor to drop out (deenergize) The fan motor is thermostatically controlled to provide
thereby suspending all output. If this condition occurs, it fan cooling of the transformer and rectifier If these com-
will be necessary to allow a cooling penod before resum- ponents require cooling. Under normal loading, the fan
ing operation. may not run.
10-4. FAN CONTROL FOR 300 AND 400 AMPERE Two normally-open thermostats, TP2 in the main recti-
MODELS (Optional) fier and TP3 in the main transformer, and a relay CR1
regulate the operation of the fan motor FM
The fan control crrcuttry consists of current relay CR1 , a
five mrnute fan motor timer TDI, and normally-open When the transformer and/or rectifier assembly warm up
thermostats TP2 and TP3. Thermostat TP2 is located in enough to close any of the thermostats, relay CR1 ener-
main rectifier SRI and thermostat TP3 is located in main gizes causing the fan motor to start running. The fan mo-
transformer Tl. These thermostats close when main tor witI contrnue running until the transformer and/or rec-
rectifier SRl and main transformer Tl overheat. Nor- tifier have cooled down enough to permit thermostats
mally the fan will run after arc Initiation, when either TP2 TP2 and TP3 to open or until the unit is shut down.
SM-221 Page 52
SECTION 11 - ELECTRICAL DIAGRAMS
Table 11-l. List Of Circuit Diagrams
The following is a kt of all diagrams for models covered by this manual. To order diagrams needed, 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.
Mpde! Seria! Qr Style Number C_kui_t_Diaaram

Gold Star
3ooss HH020722 thru HH050741 CC-902 288-l A+ +
HH050750, HH058670, HH058681 CC-902 288-l B++
HH050742 thru HJ118411 CC-902 288-l C+ +
HJ118412 thru HJ169760 CC-902 288-l D+ +
HJ169761 thru HJ205705 CC-902 288-l E+ +
HJ205706 thru HK248416 C-080 465-A+ +
HK248417 thru JB478152 c-049 047+ +
JB478153 thru JB522335 C-082 183+ +
JB522336 thru JB560386 C-082 963-A+ +
JB560387 thru JC641295 C-083 370-A
300SS w/fan control JB478153 thru JB522335 C-082 llO++

JB522336 thru JB560386 C-084 088+ +
JB560387 thru JC641295 C-084 851
300SS w/fan control

and polarity switch+ JB478153 thru JC641295 C-082 184
400SS. 5OOSS, 600SS HF833731 thru HF882340 CC-901 690-l Al + +

HF882341 thru HG027820 CC-901 690-l Bi + +
HG027821 thru HG049400 CC-901 690-l C+ +
HG049401 thru HH028862 CC-901 690-l D+ +
HH028863 thru HH044825 CC-901 690-l E++
HH044826 thru HH078219 CC-901 690-l F++
HH078220 thru HJ118411 CC-901 690-lGl++
HJ118412 thru HJ169760 CC-901 690-l H++
HJ169761 thru HJ205705 CC-901 690-l J+ +
4ooss HJ205706 thru HK248416 C-080 465-A+ +

HK248417 thru JB478152 c-049 047+ +
JB478153 thru JB522515 C-082 183+ +
JB522516 thru JB560386 C-082 963-A+ +
JB560387 thru JC590315 C-083 370-A
400SS w/fan control JB478153 thru JB522515 C-082 IlO++

JB522516 thru JB560386 C-084 088+ +
JB560387 thru JC590315 C-084 851
400SS w/fan control

and polarity switch+ JC615021 thru JC590315 C-070 947-A
SM-221 Page 53
Table 11-l. List Of Circuit Diagrams (Continued)
Model Serial Or Style Numbe_r C&wit Diaaram
5ooss HJ205706 thru HK248416 C-080 467-A+ +

HK248417 thru JB524607 C-049 058+ +
JB524608 thru JB560386 C-082 955-A+ +
JB560387 thru JE747790 C-083 377
500SS w/fan control JC615021 thru JE747790 C-085 374-A
600SS HJ205706 thru HK248416 C-080 467-A4 +

HK248417 thru JB524642 C-049 058+ +
JB524643 thru JB560386 C-082 955-A+ +
JB560387 thru JE813765 C-083 377
600SS w/fan control JC615021 thru JE813765 C-085 374-A
Circuit Board PC1 HJ205706 thru HK326237 C-080 562-D+ +

HK326238 thru JB487358 C-047 399-B4 +
JB487359 thru (See Note) C-071 932-A
+Optional
+ +Not included in this manual
Note: See ending serial number for each model on front cover.
SM.221 Page 54
I- I I *
>
>-
>-
>-
;>
:>
SM.221 Page 55
SM-221 Page 56
i it-----7iI’
WORK
ELECTRODE
9 L I I ,
s IMPORTANT: Use test points and values on Circuit Diagram No. C-082 184
q Diagram 8-2 when tfoub/eshoofing this unit.
Diagram 11-3. Circuit Diagram For 300 Ampere Models With Fan Control And Polarity Switch Effective With Serial No. JB478153 Thru JC641295
SM-221 Page 58
-
Y
SM.221 Page 59
POSI TlVE
CO
“Hk-
WORK
-
‘L>
T
r J
IMPORTANT: Use test points and

Diagram 8-4 when
V
ic
SM-221 Page 61
Notes
TM-221 October 1997
Gold Star@ 300SS Eff wl
MilleK HF833731 thru JC641295

?he
Power
$Bliz.
HF833731 thru JC590315
HF833731 thru JE747790
HF833731 thru JE813765
GOLD STARSS
or
.-
LL
v
-uJ
ii
SPM-221 0 Page 1
Replace Coils at Factory or Factory Authorized Service Station Quantity
Model
I?em Dia. Part 300 400 500 600
No. Mkgs. No. Description Amp Amp Amp Amp
Figure A Main Assembly

-
1 024 164 PANEL, side (Prior to HJ128424) .................. 2
1 006 016 PANEL, side (Eff w/HJ128424). ................... 2
1 024 164 PANEL, side (Prior to HG034224) .................. 2 2
1 006 016 PANEL, side (Eff w/HG034224) ................... 2 2
1 005 195 PANEL,side.. .................................. 2
2 035 350 COVER, top (Priorto HJ128424). .................. 1
2 006 017 COVER, top (Eff w/HJ128424) .................... 1
2 035 350 COVER, top (Prior to HG034224) .................. 1 1
2 006 017 COVER, top (Eff w/HG034224). .................. 1 1
2 005 194 COVER, top ................................... 1
3 026 627 GASKET, lifting eye-cover ....................... 1 1 1 1
4 Z 035 279 STABILIZER .................. ................. 1 1
4 Z 003 007 STABILIZER .................. ................. 1
4 Z 005 380 STABILIZER .................................... 1
048 668 BUS BAR, jumper-stabilizer ...................... 1 1
006 697 BUS BAR, jumper-stabilizer ....................... 1 1
5 012 638 HOLDER, fuse (Prior to HJ219398) ............ ... 1 1 1
5 070 404 HOLDER, fuse (Eff wIHJ219398) .................. 1 1
6 Fl “604 259 FUSE, cartridge 3 amp 600 volts (Prior to HJ2 19398) 1 1 1
6 Fl ‘088 384 FUSE, cartridge 1 amp600 volts (Eff w/HJ219398). .. 1 1
7 Figure F PANEL, rear-w/components (Pg 15) ............... 1 1 1 1
8 TEl 038 138 TERMINAL, pri (Prior to HH058670hFig G Pg 16) .... 1
8 TEl 038 145 TERMINAL, pri (Eff w/HH058670)(Fig G Pg 16) ..... 1
8 TEI ,2 035 398 TERMINAL, pri (Prior to HJ205706hFig G Pg 161 .... 1
8 TEl 038 145 TERMINAL, pri (Eff w/HJ205706)(Fig G Pg 16) ...... 1
8 TE1,2 035 398 TERMINAL, pri (Fig G Pg 16) ...................... 1 1
9 C2 l-23 089 634 CAPACITOR, ceramic 0.0022 uf 6000 dc (Eff
w/JB590316) ................................... 3 3 3 3
10 W 009 859 CONTACTOR (Furnas)(Prior to HJ205706)tFig B Pg 4) 1
10 W 081 Cl5 CONTACTOR (Furnas)(Eff w/HJ205706)(Fig B Pg 4) 1
10 W 083 545 CONTACTOR (Furnas)(Prior to HG084782)(Fig B Pg
4). ............................................ 1
10 W 008 552 CONTACTOR (Cutler Hammer)(Eff w/HG084783 thru
HJ205705)lFig B Pg 4) ........................... 1
10 W 081 015 CONTACTOR (FurnasIfEff w/HJ205706 Et on)(Fig B
Pg4) .......................................... 1
10 W +003 305 CONTACTOR (Furnas)(Prior to HF864262hFig B Pg 4) 1
10 W 003 566 CONTACTOR (Furnas)(Eff w/HF864262 thru
HG084782)fFig B Pg 4). .......................... 1
10 W 008 552 CONTACTOR (Cutler Hammer)(Eff w/ HG084783 thru
JE747790)lFig B Pg 4) ........................... 1
10 W 008 708 CONTACTOR (Furnas)(Prior to JA395347)lFig B Pg 4) 1
10 W +044 186 CONTACTOR (Furnas)(Eff w/JA395347 thru
JC598308)(Fig B Pg 4) ........................... 1
10 W 008 552 CONTACTOR (Cutler Hammer)(Eff w/JC598309 thru
813766)iFig B Pg 4) ............................. 1
006 564 BRACKET, contactor (Eff w/HJ183733 thru
HJ194857) .................. ..................
006 158 BRACKET, mtg-contactor ........................ 1
086 438 BUSBAR ......................................
11 Tl 009 822 TRANSFORMER, main (Prior to JA440449)(con-
sisting of) ......................................
i2 009 299 COIL, pri/sec LH ...............................
13 too9 300 COIL, priisec RH b-center L
SPM-221D Page2
--- Quantity
Model
Item Dia. Part
No. Mkgs. ..-- No. Description
Figure A Main Assembly (Cont’d.)

- _.--
11 Tl 072 597 TRANSFORMER, main (Eff w/JA, )449)(consisting
of) ., . . . . . . . .._.............. . . .._.........
12 072 220 .COIL,pri/secLH ..............................
13 to72 221 . COIL, pri/sec RH Et center ......................
to49 121 .COIL,pri/secw/l15voltswinding.. ..............
11 Tl to59 147 TRANSFORMER, main w/fan control (consisting of).
12 009 299 . COIL, pri/sec LH ..............................
13 -too9 300 . COIL, pri/sec RH Et center ....................
t052 738 . COIL, pri/sec w/l 15 voltswinding ................
11 Tl 035 348 TRANSFORMER, main (consisting of) .............. 1
12 035 381 .COIL,pri/secLH ............................... 1
13 t 035 382 COIL, pri/sec RH & center ....................... 2
t006 029 COIL,pri/secw/l15voltswinding .. .......... 1
11 Tl 059 148 TRANSFORMER, main w/fan control (consisting of) ...... 1
12 035 381 .COIL,pri/secLH ............................... 1
13 +035 382 . COIL, pri/sec RH & center ....................... 2
+008 986 COIL,pri/secw/l15voltswinding.. 1
11 Tl 002 994 TRANSFORMER, main (consisting of) ............................ 1
12 000 976 .COIL,pri/secLH ............................... 1
13 +ooo 977 . COIL, pri/sec RH Et center ....................... 2
t004 873 .COIL,pri/secw/l15voltswinding.. .............. 1
11 Tl 005 381 TRANSFORMER, main (consisting of) .............. 1
12 005 364 ,COIL,pri/secLH ............................... 1
13 +005 365 . COIL, pri/sec RH &center ....................... 2
11 Tl to72 595 TRANSFORMER, main w/fan control (consisting of). . 1
12 005 364 ,COIL,pri/secLH ............................... 1
13 +005 365 . COIL, pri/sec RH &center ....................... 2
t049 123 .COIL,pri/secw/l15voltswinding.. ............. 1
048 668 BUS BAR, connecting transformer ................. 1
048 930 BUS BAR, connecting transformer ................. 1 1
14 039 543 BASE (Prior to HJ194858) ........................
14 006 108 BASE (Eff w/HJ194858) .........................
14 035 296 BASE (Prior to HF850480) ........................ 1 1
14 003 404 BASE (Eff w/HF850480 thru HGO19595) ........... 1 1
14 006 108 BASE (Eff w/HF019596 thru JA406708). ........... 1 1
14 046 681 BASE (Eff wlJA406709 Bon). .................... 1 1
14 005 270 BASE (Prior to JA417036) ........................ 1
14 009 810 BASE, w/fan control (Prior to JC615021) ........... 1 1
14 046 909 BASE (Eff w/JA417031) ......................... 1
15 SRl 059 601 RECTIFIER (Fig D Pg 12) .........................
15 SRI + +009 725 RECTIFIER (Priorto JC615021)Fig D Pg 12) .........
15 SRI t +087 072 RECTIFIER (Eff w/JC615021)(Fig D Pg 12). .........
15 SRI 059 602 RECTIFIER (Prior to JA406789)(Fig D Pg 12) ........ 1
15 SRl 045 107 RECTIFIER (Eff w/JA406789 thru JC61502O)(Fig D
Pg12) ........................................ 1
15 SRl 083 910 RECTIFIER (Eff w/JC615021 8 on)(Fig E Pg 14) ..... 1
15 SRl t +059 204 RECTIFIER :Prior to JB478256)(Fig D Pg 12) ........ 1
15 SRI t +070 561 RECTIFIER (Eff w/JB478256 thru JC61502O)(Fig E Pg
14) ............................................ 1
15 SRl 059 603 RECTIFIER (Prior to JA406920)(Fig D Pg 12) ......... 1
15 SRl 045 237 RECTIFIER (Eff w/JA406921 )(Fig E Pg 14) .......... 1
15 SRl t +009 210 RECTIFIER (Prior to JA406920)IFig E Pg 14) ....... 1
15 SRl t + 070 632 RECTIFIER (Eff w/JA406920 thru JC61502O)(Fig E Pg
14) ........................................... 1
15 SRl + +086 399 RECTIFIER (Eff w/JC615021 Et on)(Fig E Pg 14) ..... 1
15 SRl 059 604 RECTIFIER (Prior to JA417031 )(Fig E Pg 14) ....... 1
SPM-221 D Page 3
Quantity
Model
Item Dia. Part
No. Mkgs. No.
_ .~_ Description
Figure A Main Assembly ICont’d.1

-- --
15 SRl 045 007 RECTIFIER (Eff w/JA417031 )(Fig E Pg 14) . . 1
15 SRl +- +046 658 RECTIFIER (Priorto JA417031 )(Fig E Pg 14) . . . 1
15 SRl t +044 705 RECTIFIER (Eff w/JA417031 thru JC61502O)(Fig E Pg
14) ..,,.._...................................~. 1
15 SR: + +086 284 RECTIFIER (Eff w/JC615021 Et on)(Fig E Pg 14) . . 1
16 Figure C PANEL, front-w/components (Pg 6). . . . . 1 1 1 1
17 023 378 CHANNEL, core-clamping (top of Tl 1 . 1 1 1
006 156 CLAMP,core(clamptopofTl) .__....___.__._._.. 1
Cl-3 031 670 CAPACITOR, ceramic 0.05 uf 500 volts dc (Eff
w/HF882341 thru HK248416). .. . . . . 3 3 3 3
Cl-3 031 670 CAPACITOR, ceramic 0.05 uf 500 volts dc (Eff
wIHK248417 thru JB522336). . .... . 3 3 3 3
VSl 000 263 THYRECTOR, 104 Vat 3A (Prior to HK248417)(con-
sisting of) . . .. . .. . . 1 1 1 1
VSl 000 263 THYRECTOR, 104 Vat 3A (Eff w/HK248417 thru
.Jl3522335)(consisting of) . 1 1 1
601 242 INSULATOR, washer ..... . 2 2 2 2
102 363 BRACKET, mounting ..... . 2 2 2 2
18 082 976 HOLDER fuse-clip 5 fuses (Eff w/JB560387). . 1 1 1 1
19 F2-6 012 633 FUSE, miniature-glass 1 amp (Eff w/JB560387), . 5 5 5 5
20 073 756 STAND-OFF, No. 6-32 x 5/8 x l/4 hex (mtg PC21 . 4 4 4 4
21 PC2 007 260 CIRCUIT CARD (Prior to HH078262)tFig H Pg 16) 1
21 PC2 053 908 CIRCUITCARD (Eff w/HH078262)(Fig H Pg 16) . . 1
21 PC2 035 504 CIRCUIT CARD (Prior to HH078262)(Fig H Pg 16) . . 1 1 1
21 PC2 007 260 CIRCUIT CARD (Eff w/HH078262 thru
HJ118411)(FigHPg16) . . . . . . . . . . . . . . . . . . . . . . .,. 1 1 1
21 PC2 053 908 CIRCUIT CARD (Eff wHJ118412 &on)(Fig H Pg 16). 1 1 1
22 CT1 -3 009 830 TRANSFORMER, current 375/l .... . . 3
22 CTl-3 035 454 TRANSFORMER, current 500/l . . . . 3
22 CTl-3 003 008 TRANSFORMER, current 625/l . 3
22 CTl-3 005 379 TRANSFORMER, current 750/l . . 3
23 003 403 BAFFLE, air-center . .. . . . . 1 1 1 1
24 T2 605 856 TRANSFORMER (Prior to HJ219398) . . .. . 1 1 1
24 T2 605 856 TRANSFORMER (Eff w/HJ219398). .. 1 1
D10,ll 070 250 DIODE, 3 amp600 volts SP . . . . . . 2 2
*Recommended Spare Parts.

+ + These rectifiers are used on units with fan control.
tParts For Optional Equipment.
+ Quantity of this item changes to 1 for units with optional fan control and/or duplex receptacle as the right hand coil
has 115 volts tertiary winding.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
SPM-22 10 Page4
Quantity
Part
No. Description Model
Figure B Contactor (Fig A Pg 2 Item 10)

-.-____.-
tt034 895 INTERLOCK, NO.. . . ... 1
028 982 COIL, 120 volts 1 1 1
“003 567 KIT, point. .. .. . .33 3
032 349 COIL, 120 volts ac 40 amp . . 1
035 837 COIL, 120 volts . . 1
003 564 COIL, 120 volts ac 60 amp. . 1
“003 565 KIT, point. ..... . . .. .. . 3
003 710 COIL, 120 volts ac 75 amp. .. .... 1
048 731 INTERLOCK, NO.. . . .. . .. 1
034 910 COIL, 115/230 volts ac . .. . .. . 1
“044 187 KIT, point. . . . . . “. . . .. 3
081 016 BRACKET, mtg-cable. .. ... 1
ttThis interlock was used in the 500 ampere models effective w/HF864262 thru HG084782, and was not included
with contactor for these serial numbers.
11 12
1234
36
I
Fig C2
32* /
7
Figuie C - Panel, Front - W/Components

SPM-221 D Page 5
Quantity
Model
Item Dia. Part 300 400 500 600

No. Mkgs. No. Description Amp Amp Amp Amp
_-___
Figure C Panel, Front-W/Components (Fig A Pg 4 Item 16)
--
1 s5 011 610 SWITCH, toggle SPDT 10A 125V (Eff w/HJ219398) .... 1 1
1 s5 011 610 SWITCH, toggle SPDT 10A 125V (Eff w/HJ205706) .... 1 1
2 R3 052 140 RESISTOR, carbon 0.5W 330 ohm (Eff w/HJ219398) ... 1 1
2 R3 052 140 RESISTOR, carbon 0.5W 330 ohm (Eff w/HJ205706) ... 1 1
3 R4 030 853 RESISTOR, carbon 0.5W 2200 ohm (Eff w/HJ205706) . 1 1 1 1
4 009 755 PANEL, front (Prior to HJ183733) .................... 1
4 059 880 PANEL, front (Eff w/HJ183733 thru JC641295) ........ 1
4 035 355 PANEL, front (Prior to HJ219398) .................... 1
4 059 880 PANEL, front (Eff w/HJ219398 thru JC590315) ........ 1
4 035 355 PANEL, front ...................................... 1 1
5 s3 089 085 SWITCH, toggle SPST 20 amp 125 volts ac ............ 1 1 1 1
6 RCl 035 523 RECEPTACLE, 5 socket 3102A-16S-8S ................ 1 1 1 1
7 C16-18 031 670 CAPACITOR, ceramic 0.05 uf 500 volts dc (Eff
w/HG027821 thru HG049400) ....................... 3 3 3
7 c14,15,
17,18 053 991 CAPACITOR, ceramic 0.05 uf 500 volts (Eff w/HG049400) . . 4 4 4 4
8 S2.4 011 609 SWITCH, toggle SPDT 10A 125V (Eff w/HG049400). .,. 2 2 2 2
9 R5 072 462 POTENTIOMETER, carbon 1 turn 2 watt 1000 ohm (con-
sisting of 1 ......................................... 1 1 1 1
072 590 . LOCK, shaft-potentiometer ........................ 1 1 1 1
10 + 035 283 CONTROL BOX, firing circuit ........................ 1 1 1 1
11 + 035 282 COVER, top-control box ............................ 1 1 1 1
12 057 084 BUSHING,snap1/4ID3/8mtghole.. ................ 1 1 1 1
13 RC2 035 815 TERMINAL, header 29 socket (PC1 1 ................... 1 1 1 1
14 035 506 GUIDE, circuit card 9 inch ............................ 2 2 2 2
039 349 SPRING, retainer-circuit card (Prior to JB498638) ....... 1 1 1 1
15 PC1 059 322 CIRCUIT CARD (Prior to HJ219398)lFig Cl Pg 8) ....... 1
15 PC1 070 606 CIRCUIT CARD (Eff w/HJ219398)(Fig Cl Pg 8) ........ 1
15 PC1 059 323 CIRCUIT CARD (Prior to HJ219398)lFig Cl Pg 8) ....... 1
15 PC1 070 607 CIRCUIT CARD (ER w/HJ219398)(Fig Cl Pg 8) ........ 1
15 PC1 059 324 CIRCUIT CARD (Prior to HJ219398)tFig Cl Pg 8) ....... 1
15 PC1 059 325 CIRCUIT CARD (Prior to HJ205706)fFig Cl Pg 8) ....... I
16 PBl 009 819 BUTTON, push-reset (Prior to HJ183733) .............. 1
009 863 BLOCK, contact-heavy duty (prior to HJ183733) ........ 1
009 861 BASE, button push-red (Prior to HJ183733) ............ 1
009 818 BRACKET, guide rod-push (Prior to HJ183733) ......... 1
059 904 BRACKET, guide-casing (PBl )(Eff w/HJ183733 thru
HK260799) ........................................ 1
16 PBl 046 746 SWITCH (Eff w/HK260800)(Fig C2 Pg 11) ............. 1
16 PBl 011 636 SWITCU 60 amp 100 volts (Prior to HJ219398) ....... 1
16 PBl 046 745 SWITCH (Eff wiHJ219398)tFig C2 Pg 11) ............. 1
16 PBl 011 636 SWITCH, push button 60 amp 100 volts ............... 1 1
17 c4,5 031 670 CAPACITOR, ceramic 0.05 uf 500V dc (Prior to
HF882341) ....................................... 2 2 2
17 c4,5 009 063 CAPACITOR, ceramic 0.05 uf 500V dc (Eff w/HF882341) 2 2 2 2
18 NEG 039 046 TERMINAL (consisting of) ........................... 1 1 1 1
19 601 976 .SCREW,cap-hexhd1/2-13x1-1.12 ................. 1 1 1 1
20 039 045 TERMINAL BOARD, black, ........................ 1 1 1 1
21 601 880 NUT, hex-jam 112-13 .............................. 1 1 1 1
22 039 044 BUS BAR ..................................... 1 1 1 1
23 601 879 . NUT, hex-full 112-13. .............................. 1 1 1 1
24 POS 039 047 TERMINAL (consisting of) ........................... 1 1 1 1
25 601 976 SCRtti,cap-hexhd1/2-13x1-1/2.. ................ 1 1 1 1
26 039 049 TEnlvlINAL BOARD, red ........................... 1 1 1 1
SPM-221 D Page 6
Quantitv
Model
Iten Dia. Part

No. Mkas. No. Description
Panel, Front-Wkomponents (Fig A Pg 4 Item 161

Figure C
(Cont’d)
601 880 . NUT, hex-jam + .!2-13 ............................. 1

039 044 . BUS BAR .. 1
601 879 .NUT,hex-full’ 2:;3::::::::::::‘::::::::::::::::: 1
027 408 DOOR, access+,lnt ............................... 1
605 583 CATCH, spring ! _.aded-access door. .................. 2
PLl “027 632 BULB, iocandescant-slide base 24 volts ...............
027 628 LENS, indicator light-red. ...........................
027 631 HOUSING, indicator light ...........................
32 PLl 027 645 LIGHT, indicator-red lens 125 volts (Prior to HJ219398)
32 PLl l027 632 BULB, indicator-slide base24 volts (Eff w/HJ219398)
027 628 LENS, indicator light-red (Eff w/ H J2 19398) ...........
027 631 HOUSING, indicator light (Eff w/HJ219398) ..........
32 PLl “027 645 LIGHT, indicator-red lens 125 volts. .................. 1
33 019 627 KNOB, pointer (R5) ................................ 1
34 009 571 PLATE, indicator-amperage .........................
34 035 286 PLATE, indicator-amperage .........................
34 003 027 PLATE, indicator-amperage ....... .................
34 005 397 PLATE, indicator-amperage ......................... 1
35 039 684 CAP, dust-connector. .............................. 1
36 NAMEPLATE (order by model and serial number) ....... 1
*Recommended Spare Parts.

SPM-221 D Page 7
Dia. Part
Mkgs. Description Quantity
.- -_ No.
Figure Cl Circuit Card, Root Pass (Fig C Pg 6 item 151

~_ - -_ __-
A50-59 035 845 IC,linear307 ................................................... IO
c5 l-53 035 834 CAPACITOR, metalized film 1.5 uf 100 volts ..................... 3
C55,56,59-61,63,
66-68,70,73,74 035 833 CAPACITOR, mylar 0.033 uf 100 volts dc ........................ 12
C55,62,69 035 835 CAPACITOR, electrolyte 4.7 uf 35 volts. .......................... 3
C57,58,64,65,71,
72,82,87,94 053 991 CAPACITOR, ceramic 0.05 uf 500 volts (Prior to JB522336) ........... 9
C57,58,64,65.
71,72,77,80,
82,87,94 053 991 CAPACITOR, ceramic 0.05 uf 500 volts (Eff w/JB522336) .......... 11
C57,58,64,65,71,
72,77,80,82 053 991 CAPACITOR, ceramic 0.05 uf 500 volts (300 Et 400 amp only) .........
c75 038 585 CAPACITOR, mylar 0.22 uf 50 volts ...............................
C76.79 000 859 CAPACITOR, electrolyte 220 uf 35 volts dc .........................
C77,80 035 832 CAPACITOR, mylar 0.0015 uf 100 volts (Prior to JB522336) ..........
C78.81 031 630 CAPACITOR, electrolyte 20 uf 50 volts dc .......................
C83,88-93,85,
95,96,99 059 122 CAPACITOR, ceramic 0.01 uf 500 volts ............................. 11
C86 034 286 CAPACITOR, poly film 0.1 uf 100 volts dc (Prior to HK362363) ......... 1
C98 007 742 CAPACITOR, electrolyte 10 uf 35 volts ............................. 1
NOTE 1 028 351 DIODE, signal 0.020 amp 75 volts SP ............................... 22
D53,57,61,65.69,
73,76,77,82,85 026 202 DIODE, 1 amp400 volts SP ....................................... IO
Q50,52,54,
56,58,60 037 277 TRANSISTOR, 200MA 30 volts NPN .............................. 6
Q51,53,55,57.
59,61,62 035 842 TRANSISTOR, 6 amp 40 volts PNP ................................ 7
Q63 000 088 TRANSISTOR, 800MA 40 volts NPN ............................... 1
R50,51,52,
111,112 000 885 RESISTOR, carbon film 0.25 watt IOK ohm ............... : ....... 5
NOTE 2 035 884 RESISTOR, carbon film 0.25 watt IOOK ohm ...................... 14
R55,63,69,77,84,
92,108,126,128 t035 826 RESISTOR, carbon film 0.25 watt 6800 ohm. ..................... 9
R55,63,69,77,84,
92,107,126 035826 RESISTOR, carbon film 0.25 watt 6800 ohm (300 Et 400 amp only) ..... 8
R56,64,70,78,85,
93,100,129 035 827 RESISTOR, carbon film 0.25 watt IOK ohm ........................ 8
R57,65,71,79,
86,94,99 035 825 RESISTOR, carbon film 0.25 watt 1 K ohm ........................... 7
R58,72,87 035 823 RESISTOR, carbon film 0.25 watt 100 ohm. ........................ 3
R59,66,73,
80,88,95 035 257 RESISTOR, carbon film 0.25 watt 270 ohm. ......................... 6
R60,67,74,
81,89,96 605 919 RESISTOR, carbon 0.25 watt 47 ohm ............................. 6
R97,101,133 035 885 RESISTOR, carbon film 0.25 watt 68K ohm ........................ 3
R98,125,137 035 887 RESISTOR, carbon film 0.25 watt 3300 ohm. ....................... 3
R102 030 024 RESISTOR, carbon 0.5 wat 1000 ohm .................... .. 1
R104 035 829 RESISTOR, carbon film 0.25 watt 1500 ohm, ........................ 1
R106,130,134 035 848 POTENTIOMETER, cermet 25/T 0.5 watt 1 OK ohm ................... 3
R107 035 888 RESISTOR, carbon film 0.25 watt 2200 ohm. ........................ 1
RIO8 084 205 RESISTOR, carbon film 0.25 watt 3.3K ohm (300 Et 400 amp only)...... 1
RI10 039 108 RESISTOR, carbon film 0.25 watt 82K ohm ........................ 1 ’
R113,116 030 089 RESISTOR, carbon film 0.5 watt 2.7 ohm ........................... 2
Rl15,117 035 822 RESISTOR, carbon film 0.25 watt IO ohm (Prior to JB522336) 2
R118,140 035 820 RESISTOR, carbon film 0.50 watt 470 ohm (prior to JB522336) ........ 2
RI19 030 045 RESISTOR, WW fixed 3.25 watt 100 ohm ........................... 1
SPM-221 D Page 8
c53
-_-___
c52
(-xiq
+ C81
[-i%q I-=-l
+ C78
Q57 j (051) ( 053 ‘!
c79 C76
COMPONENTS TO BE REPLACED
rl3082431
BY QUALIFIED PERSONNEL ONLY
Figure Cl - Circuit Card, Root Pass

SPM-22 1D Page 9
Dia. Part
Mkgs. No. Description Quantity
-___ ~___
Figure Cl Circuit Card, Root Pass (Fig C Pg 6 Item 15HCont’dI
I3120 039 106 RESISTOR, carbon film 0.25 watt 470 ohm. . 1
RI22 076 712 RESISTOR, carbon 0.25 watt 220K ohm . . .. 1
RI27 039 329 RESISTOR, carbon film 0.25 watt 2700 ohm. . .. .. . .. 1
R131,136,139 039 331 RESISTOR, carbon film 0.25 watt 4700 ohm. . . . .. 3
RI32 039 335 RESISTOR, carbon film 0.25 watt 47K ohm . . . . . 1
R138 035 886 RESISTOR, carbon film 0.25 watt22K ohm . .. .. . 1
SR50 035 841 RECTIFIER, integrated 1.5 amp 200 volts. . . . . 1
T50-55 035 846 TRANSFORMER, pulse ... ..... . .. . . . 6
VR50 081 832 IC, linear 78Ml5. ......... . . ........ . . . . 1
VR51 046 932 IC, linear 7915 (Eff w/JB478153) ..... . . . . 1
VR50 035 843 IC, linear 1468 . . . ... ... . 1
035 849 TERMINAL, header 29 pin . . . . . “. . . . . . 1
PLGl 048 281 RECEPTACLE W/SOCKETS (consisting of) . . 1
058 972 TERMINAL, female .... . . ... . .. 2
+Rl28 deleted Eff wlHK326363.

NOTE 1: D50-52,54-56,58-60,62-64,66-68,70-72,74,75,81,86.
NOTE 2: H53,54,61,62,68,75,76,82,83,90,91,109,124,135.
SPM-221D Page 10
Quantity
Model
Item Part
No. No. _-_- Description
Figure C2 Switch, Push Button (Fig C Pg 6 Item 16)
___- -- -_- --_.

1 059 885 BUTTON, push-reset red . . . ., ... . . . 1 ;
2 018 606 SPRING, compression .... . . . .... . .. . . 1
3 045 546 PUSH BUTTON SET, w/cable & housing.. .. ... ... 1
3 044 713 PUSH BUTTON SET, w/cable Et housing . . . . . .. . . . . 1
4 081 008 BRACKET, mounting-switch . . . .. . . . . . .. .. . . .. . . . . . . . . . . . . . . .. . . ...c . 1 i
5 027878 SWITCH.limleafactgSPDT .......... . .._.............,._...,,...,.. 1
~A080214 A
Figure C2 - Switch, Push Button
SPM-221 D Page 11
Quantitv
Model
Item Dia. Part
No. Mkgs. No. Description
Figure D Rectifier, Main (Fig A Pg 3 Item 15)

sz g
2
E
8
(D
$
6
-
g
N
z
s 0”
(0
z
z
w
!z
z
0 g 0 o.,o 0 2
9
1 SCRI-6 034 976 THYRISTOR. 175 amp 300 volts . . ..... .... 66 6 6 6
1 SCRI-6 046 995 THYRISTOR; 300 amp 300 volts .................... 6
1 SCRI-6 004 216 THYRISTOR, 250 amp 300 volts ................... 6 6
004 124 SUPPRESSOR (Prior to HK248632)(consisting of). .... 6 6
R7-12 030 725 . RESISTOR,WWfixed3 watt5 ohm ................ 1 1
C7-12 031 683 CAPACITOR, paper-oil 0.5 uf 200 volts dc ........... 1 1
2 C7-12 053 372 CAPACITOR, ceramic 0.01 uf 500 volts dc (Eff
wlHK248632) ................................... 6 6 6 6 6 6 6
2 C7-12 048 420 CAPACITOR, ceramic 0.01 uf 500 volts dc ........... 6
048 710 CLAMP, thyristor ................................. 3
072 258 INDICATOR, spring (Eff w/JA435859) ............. 3
3 TPI 032 810 THERMOSTAT, NC ............................... 1 1 1 1
3 TPI 012 786 THERMOSTAT, NC ............................... 1
3 TP2 086 323 THERMOSTAT, NO ............................... 1
TP2 011 308 THERMOSTAT, NO ............................... 1 1 1
TB-049 529
Figure D - Rectifier, Main 300, 400 Et 500 Amp Models*
tModels With Fan Control,

*Design of 400 Et 500 amp rectifier changed. When ordering replacement parts use correct illustration. Use Fig D and
E for reference.
SPM-221 D Page 12
,&----I I F
Figure E - Rectifier, Main 400, 500 Et 600 Amp Models*
SPM-22 1 D Page 13
Quantity
Model -
Item Dia. Part l400 l500 600
No. Mkgs. No.
..~_ -. Description Amp Amp Amp
o- b 2 8 g $
g g (0 B z
Figure E Rectifier. Main (Fig A Pg 3 item 151 z g E g i i s $ :: g
o,o B + El 0 E ‘2 e
1 037 087 BUS BAR, tab 1 I8 x 1 x3-l 1 I32 ..... 12
1 048 775 BUSBAR,tab3/16xl x1-1/8 ...... 8 8 8 8
1 048 376 BUSBAR,tab3/16xl-1/8x1/2 .... 8 8 8
1 004 120 BUS BAR, tab 1/8x 1 x 1 ........... 16 16
2 083 907 BUSBAR,tabl/gxl x11-1/4 ...... 2 2
2 048 774 BUSBAR,tab3/16xlx2 .......... 4 4 4 4
2 049 728 BUSBAR,tab3/16xl-1/2x2 ...... 4 4 4
3 C7-12 031 688 CAPACITOR, ceramic 0.01 uf 500V dc 6
3 C7-12 048 420 CAPACITOR, ceramic 0.01 uf 500V dc 6 : 6 6 6 6 6
3 C7-12 049 045 CAPACITOR, ceramic 0.01 uf 500V dc 6 6
4 SCRl-6 046 995 THYRISTOR, SCR 300A 300V ....... 6 6 6 6
4 SCRl -6 030 287 THYRISTOR, SCR 470A 300V ....... 6 6 6 6 6
5 083 908 HEAT SINK ....................... 6 6
5 048 779 HEATSINK ....................... 6 6 6 6
5 048 373 HEATSINK ....................... 6 6 6
6 083 884 CLAMP, thyristor .................. 3 3
6 082 694 CLAMP, thyristor .................. 3 3 3 3
6 082 693 CLAMP, thyristor .................. 3 3 3
6 005 214 CLAMP, thyristor .................. 6 6
,7 028 516 PIN,spring1/8x1/4 ............... 12 12 12 12 12 12 12 12 12 12
8 083 906 CHANNEL, mtg-rectifier ............. 2 2 2 2 2
8 048 372 CHANNEL, mtg-rectifier ............. 2 2 2 2 2 2
8 005 300 CHANNEL, mtg-rectifier ............. 2 2
9 083 909 HEATSINK ....................... 3 3
9 045 109 HEATSINK ....................... 3
9 048 777 HEATSINK ...................... 3 3 3
9 048 375 HEATSINK ....................... 3 3 3
TP2 044 702 THERMOSTAT, NO ................ 1 1 1
TP2 011 308 THERMOSTAT, NO ................ 1
TPl 012 786 THERMOSTAT, NC ................ 11 11 1 1 1 1
TPl 021 548 THERMOSTAT, NO ................ 1 1
TPl 032 810 THERMOSTAT, NC ................ 1 1
tWith Fan Control.

*Design of 400 Et 500 amp rectifier changed. When ordering replacement parts use correct illustration. Use Fig D 8 E
for reference.
SPM-221 D Page 14
-- Quantity
Model
Item Dia. part
No. Mkgs. No.
_--- Description
Figure F Panel, Rear-W/Components (Fig A Pg 2 Item 7)
1 FM 079 801 MOTOR, 1 /I2 hp230V 1550 rpm ......... ... 1 1

032 641 MOTOR, fan 115 volts (units w/fan control) . . . . 1 1
1 FM 032 605 MOTOR, SP l/4 hp230V ................ . 1 1
2 016 258 CHAMBER, plenum ..................... ... 1 1
2 003 030 CHAMBER, plenum ..................... .. 1 1
3 R6 039 210 RESISTOR, WW fixed 375 watt 12 ohm .... .. 1 1 1 1
4 032 604 BLADE, fan 14 inch 3 wing 19 deg ......... , 1
4 032 604 BLADE, fan 14 inch 3 wing 19 deg ......... . 1
4 605 799 BLADE,fan14inch5wing30deg ......... . 1 1
5 018 144 PANEL, rear. .......................... 1 1 1 1
TC 004 988
Figure F - Panel, Rear-W/Components
SPM-221 D Page 15
Quantity
Model
Item Part
Description
\>, !!!%-N!.__-.--_--
Figure G Terminal Assembly, Primary (Fig A Pg 2 item 81
--- -___ __~ _____ .-

1 601 835 NUT, brass-hex 1 O-32 . . . .. .. . 36 24 32
2 038 058 TERMINAL BOARD . .. . .. .. .. .. .. . 1 1 1
3 038 887 STUD, brass 10-Z x l-3/8 w/hex collar. .. .. .. .. .. 78 1;
1’ 16
4 010 913 WASHER, flat brass 3/16 ID x l/2 OD . . .. .. .. . 18 16
5 038 618 LINK,jumper.......................... .. .. .. .. . 6 6 8
6 601 836 NUT, brass-hex jam 114-20 ..... ..... . . .. ,. . 6 6 6
7 038 888 STUD, brass l/4-20 x l-l /2 w/hex collar. . .. .. .. . 3 3 3
010 915 WASHER, flat-brass 114 ID x 5/8 OD . . . . . .. .. . 6 6 6
0 I Rl
I 0
TA-036 145
Figure G - Terminal Assembly, Primary
COMPONENTS TO BE
REPLACED BY QUALIFIED
PERSONNEL ONLY
TA-059 161
Figure H - Circuit Card, Feedback

Dia. part
Mkgs. No. ._ --.-___ Description
Figure H Circuit Card, Feedback (Fig A Pg 4 Item 21)

- ~_
04-9 027 369 DIODE, 3A 600V SP . . . . . ... ... 6
R1,2 039 111 RESISTOR,WWfixad 12watt7.5ohm.. . . . 2
R3 028 285 RESISTOR, carbon 0.5 watt 100 ohm . .
R4 035 844 POTENTIOMETER, cermet 1 turn 0.5 watt 500 ohm
D4-9 026 202 DIODE, lA400V SP . .... 6 6
R1.2 007 264 RESISTOR, WWfixed 12 watt6.6 ohm.. . 2 2
“400 Ampere Models Changed Effective With S/N HJ205706, See Page 2 Item 8 For Correct Part Number
SPM-221 D Page 16
-- Quantity
Model
Dia. Part
Mkgs. No. ---- Description
Parts For Optional Equipment
- _~____
A 025 608 METER, amp dc O-500 scale ................................. 1
A 025 611 METER, amp dc O-600 scale ................................. 1
A 025 610 METER, amp dc O-800 scale ................................. 1 1
C6 053 296 CAPACITOR, ignition 5 uf ................................... 1 1 1 1
CBl 020 278 SWITCH, circuit breaker 15 amp ............................. 1 1
CBl 030 280 CIRCUIT BREAKER, manual reset 10 amp 115 volts ac .......... 1 1
CR1 034813 RELAY, reed (Prior to JB478153) ............................ 1 1
CR1 034857 RELAY, reed (Eff w/JB478153) .............................. 1 1
CR1 059 266 RELAY, enclosed 12 volts ac DPDT w/flange ...... , .......... 1 1
CR2 034781 RELAY, 2 pole 12amp ..................................... 1 1
Pl 025 701 FILTER, HF DC volts &amp meter. ........................... 2 2 2 2
RC3 604 176 RECEPTACLE, straight-duplex grounded 2P3W 15 amp 277 volts . 1 1 1 1
S8 011 974 SWITCH, polarity (consisting of) ............................. 1 1
S8 020 292 SWITCH, polarity (consisting of) ............................. 1
S8 053 049 SWITCH, polarity (consisting of) ............................. 1
016 243 BRACKET, mounting-switch ............................... 2 2
015 900 BRACKET, mounting-switch ............................... 1
103 634 ,MOUNTlNGBOARD ...................................... 1 1
038 111 ,MOUNTlNGBOARD.. .................................... 1 1
103 633 BUS BAR, shorting-switch ................................. 2 2 2 4
023 119 BUSBAR,switch ......................................... 1
023 120 BUSBAR,switch ......................................... 1
011 948 GUIDE. contact-movable switch ............................ 2 2 2 2
021 193 .GUIDE,contact ........................................... 2 2
038 769 CONTACT BOARD ASSEMBLY, switch ..................... 1 1 2 2
024 694 .BEARING,polarity ........................................ 1 1 2 2
010 805 .HANDLE,switch ......................................... 1 f 1 1
019 603 KNOB,ball............................................... 1 1 1 1
020 484 TUBING,5/8ODx12gawallx1/4 ......................... 1 1
010 086 SPACER, polarity switch ................................... 2 2
011 080 SPACER, contact-switch l/8 inch. .......................... 4
021 932 STRIP, insulation-switch polarity ............................. 1 1 1 1
TDl 034843 TIMER, 5 minute 120 volts50 cycle ........................... 1 1 1 1
019 515 COVER, dust-timer. ........................................ 1 1 1 1
020 113 BRACKET, mounting-cover dust ............................. 1 f 1 1
TP3 088 592 THERMOSTAT, normally open (located in Tl). ................. 1 7 1 1
V 025 604 METER, volts dc O-100 scale. ................................ 1 1 1 1
010 493 BUSHING,snapin5/8IDx7/8hole.. ........................ 1 1 1 1
010 859 CLAMP,hose9/16-l-1/16clampdia ........................ 1 1 1 1
103 966 PANEL, front-meter box .................................... 1 1 1 1
103 967 PANEL, rear-meter box .................................... 1 1 1 1
103 965 WRAPPER, meter box ...................................... 1 1 1 1
059 040 BAFFLE, air (units w/fan control). ........................... 1 1
009 845 COVER, dust (units w/fan control). .......................... 1 1
BESURETO PROVIDE MODELAND SERIALNUMBERWHEN ORDERING REPLACEMENTPARTS.
SPM-221 D Page 17
The following is a listing of all circuit diagrams for models covered by this manual. Order circuit
diagrams from the factory service department.
Model No. Serial No. Circuit Diagram No.
3ooss Hi-IO20722 thru HH050741 CC-902 288-A

3ooss HH050750, HH058670,liH058681 CC-902 288-1B
3ooss HH050742 thru HJ118411 excluding those models
covered by CC-902 288-1B CC-902 288-1C
3ooss HJ118412 thru HJ169760 CC-902 288-l D
3ooss HJ169761 thru HJ205705 CC-902 288-l E
3ooss, 4ooss HJ205706 thru ilK248416 C-080 465-A

3ooss, 4ooss HK248417 thru 58478152 c-049 047
3ooss JB478153 thru JB522335 C-082 183
4ooss 58478153 thru JB522515 C-082 183
3ooss 58522336 thru JB560386 C-082 963-A
4ooss JB522516 thru JB560386 C-082 963-A
3ooss JB560387 thru JC641295 C -083 370-A
4ooss JB560387 thru JC590315 C-083 370-A
300SS w/fan control &

Polarity switch JB478153 and on C-082 184
300SS w/fan control JB478153 thru JB522335 C-082 110

400SS w/fan control 55522516 thru JB560386 C-084 088
300SS w/fan control 58560387 thru JC641295 C-084 85 1
400SS w/fan control JB560387 thru JC590315 C-084 85 1
400SS w/fan control & C-070 947-A

Polarity switch JC615021 and on
5OOSS, 6OOSS w/fan

control C-085 374-A
4OOSS, 5OOSS, 600SS H F833731 thru H F882340 CC-901 690-1Al

4OOSS, 5OOSS, 600SS HF882341 thru HG027820 CC-901 690-131
4OOSS, 5OOSS, 600SS HG027821 thru HG049400 CC-901 690-1C
4OOSS, 5OOSS, 600SS HG049401 thru HH028862 CC-901 690-l D
4OOSS, 5OOSS, 600SS HH028863 thru HH044825 CC-901 690-l E
4OOSS, 5OOSS, 600SS HH044826 thru HH078219 CC-901 690-l F
4OOSS, 5OOSS, 600SS Hi-1078220 thru HJ118411 CC-901 690-1Gl
4OOSS, 5OOSS, 600SS HJ118412 thru HJ169760 CC-901 690-l H
4OOSS, 5OOSS, 600SS HJ169761 thru HJ205705 CC-901 690-1J
5OOSS, 600SS HJ205706 thru HI<248416 C-080 467-A
5ooss HK248417 thru JB524607 C-049 058
600SS HK248417 thru JB524642 C-049 058
5ooss JB524608 thru JB560386 C-082 955-A
600SS JB524643 thru JB560386 C-082 955-A
5OOSS, 600SS JB560387 and on C-083 377
SPM-221 D Page 18
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SPM-221 D Page 19
4 NEGATIVE
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69
Circuit Diagram No. CC-901 690-161 For Gold Star 4ooSS. 5OOSS. 600SS Models Effective With Serial No. HF8K2341 Thru HGO27820
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I66
Circuit Diagram No. CC-901 6$4f)-lC For Gold Star 4OOSS, 5OOSS. 6OOSS Models Effective With Serial NO. HG027821 Thru HGO4!3400
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Circuit Diagram No. CC-901 @II-1D For Gold Star 4ooSS. 5WSS. 6ooSS Models Effective With Serial No. HGfMg4gl Thru HHlI2MB62
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SPM-221 D Page 23
-
CR
Circuit Diagram No. CC-901 630-1E For Gold Star 4ooSS, WOSS, 6WSS Models Effective With Serial No. HHmrwfi? Thru HH044825
p-b ‘1
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NEGATIVE
Circuit Diagram No. CC-901 690-1F For Gold Star 4OOSS, 6OOSS. 600SS Models Effective With Serial No. HH044826 Thru HH076219
POSITIVE
I II I II I
Circuit Diagram No. CC402 288-18 For Gold Star 300SS For Models Effective With Serial Nos. HH050750, HH-70, And HH-1 Only
SPM-221 D Page 27
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SPM-221 D Page 28
/-r21
1.
PO5ITIVE
p--q/ I I
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Circuit Diagram No. CC-902 288-10 For Gold Star 300SS Models Effective With Serial No. HJ118412 Thru
HJ169760
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SPM-221 D Page 30
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SPM-221 D Page 31
SPM-22 1 D Page 32
“,
Circuit Diagram No. C-060 465-A For Gold Star 3OOSS. 400SS Models Effective With Serial No. HJ205706 Thru HK248416
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SPM-221 D Page 34
SPM-221 D Page 35
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SPM-221 D Page 36
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SPM-221 D Page 37
---___ - -..
BC D
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Circuit Diagram No. C-082 184 For Gold Star 300SS Models With Fan Control & Polarity Switch Effective
With Serial No. 58478153 And Following
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SPM-221 D Page 39
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SPM-221 D Page 40
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SPM-221 D Page 41
Circuit Diagram No. C-083 370-A For Gold Star 3OOSS. 400SS Models Effective With Serial No. 58560387 Thru
JC641295 (3OOSSI JC590315 (4OOSSI
__--_
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SPM-221 D Page 43
r-
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------L
SPM-221 D Page 44
Circuit Diagram No. C-084 088 For Gold Star 3OOSS. 400SS Models With Fan Control Effective With Serial No
Jf3522336 Thru JB560386 (3OOSS) JB522516 Thru JB560386 (4OOSS)
$g------
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SPM-221 D Page 46
ii I
‘2 R ‘(1 . 6 P
Circuit Diagram No. C-085 374-A For Gold Star 5OOSS. 600SS Models With Demand Fan Control Effective With
Serial No. JC615021 And Following
WM.221 D Page 48
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SPM-221 D Page 49
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SPM-221 D Page 50
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SPM-221 D Page 51
SIG. OUT
Circuit Diagram No. A-085 229 For Hall Amplifier Circuit Card HA1
SPM-221 D Page 52
Miller Electric Mfg. Co.
An llllnois T0ol ‘Wwks Company
1635 West Spencer Street
Appleton, WI 54914 USA
lnt#rriational Headquarters-USA
Phone Q20-734~Q&Z1
USA &I Canada FAX: 920-735.4134
Intfmrrational FAX 920-735-4125
European badquarters -
United Kingdom
Phone: 44 (0) 1625-525556
FPX 44 (0) $625-537553
PRINTED IN USA @ 1997 Miller Electric Mfg. Co

TM 221

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TM-221 October 1997

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SECTION 1 -SAFETY PRECAUTIONS AND SIGNAL WORDS

l-l. General Information And Safety ....................

SECTION 2 - SHIPPING AND STORAGE

2-l. Preparation For Reshipment ...................... 2

3-l. Volt-Ampere Curves .............................. . 5

SECTION 4 - INSTALLATION OR RELOCATION

4-l. Site Selection ...................... ............

SECTION 5 -OPERATOR CONTROLS

5-l. Power Switch ...................... ............ 12

SECTION 6 - SEQUENCE OF OPERATION

6-l. Shielded Metal Arc Welding (SMAW) ................ 14

SECTION 7 -THEORY OF OPERATION

7-1. Theory Of Operation ............................. 14

8-l. Testing Instruments And Information ......................... 18

SECTION 9 -COMPONENT IDENTIFICATION AND LOCATION

Figure 9-l. Main Assembly And Component Locations ............... 46

10.1. Routine Maintenance ..................................... 51

SECTION 11 - ELECTRICAL DIAGRAMS

SECTION 11 - ELECTRICAL DIAGRAMS (Continued)

LIST OF CHARTS AND TABLES

Table 3-l. Specifications 3

2-1. PREPARATION FOR RESHIPMENT 2-2. STORAGE

Table 3-l. Specifications

300 300 @I 15-200

400 400 @ 20-270 473 Ibs. 498 Ibs.

600 600 @ 30-415 632 Ibs. 657 Ibs.

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

*Values are nominal and for 60 Hz models only.

600 Amp This unit is a three-phase dc arc welding power source

These units have solid-state contactors and a pilot light

SECTION 4 - INSTALLATION OR RELOCATION

9. Adequate space for removing top cover and outer

b. Remote Current control 3. Install work clamp onto cable

Posrtron jumper links as shown on the input

Table 4-1. Weld Cable Size

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

100 4 4 4 3 2 1 110 l/O

TIE TOGETHER 2&S

230 VOLTS 460 VOLTS

200- 208 VOLTS 2 30 VOLTS

+-^ Fc”,WKUO; ACROSS 384

460 VOLTS 575 VOLTS

SIMILAR CONNECTED VOLTAGES

230 VOLTS 460 VOLTS

x 10 FAN MOTOR ACROSS 18 3

200- 208 VOLTS 2 30 VOLTS 460 VOLTS

460 VOLTS 575 VOLTS

Read and follow safety information at begin-

ground terminal In the unit. 500 230 4 6 150

Incorrect input connections can result in an elec- 575 10 10 60

l-314 in. (44.5 mm)

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

Arc Control Swltc

Figure 5-l. Front Panel View

IMPORTANT: After any interruption of input power, the