Miller.

November1996 Form: TM-292

Effective With Serial No. JJ367796

TECHNICAL MANUAL
Service And Parts

MaxstarTM 150
DC Welding Power Sources

Use MILLER Testing Booklet (Part No.

A WARNING 150 853) when servicing this unit.
SERVICING can be hazardous. Use only genuine MILLER replacement
• Have all service procedures performed only by parts.
qualified persons following standard safety
practices.

U For help, call Factory U Or FAX: U Or write to:

414-735-4505
Service Department: _____ 414-735-4136 P.O. Box Electric
MILLER 1079 Mfg. Co.
Appleton, WI 54912 USA
cvvertm 1 © 1996 MILLER Electric Mfg. Cc. PRINTED IN ~SA
 SM-292 11169

TABLE OF CONTENTS

Section No. Page No.

SECTION 1 - SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1. General Information 1

1-2. Safety Alert Symbol And Signal Words 1
1-3. Safety Precautions 1

SECTION 2—SPECIFICATIONS

2-1. Volt-Ampere Curves 2

2-2. Duty Cycle 2
2-3. Description 2
2-4. Storage 2
2-5. Preparation For Reshipment 3

SECTION 3- INSTALLATION OR RELOCATION

3-1. Location 3
3-2. Weld Output Connections 3
3-3. Remote Receptacle Information And Connections 4
3-4. Electrical Input Connections 5

SECTION 4- OPERATOR CONTROLS

4-1. Power Switch 5

4-2. Amperage Adjustment Control 5
4-3. Amperage Control Switch 5
4-4. Output/Contactor Switch 6
4-5. Weld Process Switch 6

SECTION 5- SEQUENCE OF OPERATION

5-1. Gas Tungsten Arc Welding (GTAW) 6

5-2. Shielded Metal Arc Welding (SMAW) 7
5-3. Shutting Down 7

SECTION 6— THEORY OF OPERATION

6-1. Theory Of Operation 7

Diagram 6-1. Block Diagram 8

SECTION 7—TROUBLESHOOTING

7-1. Testing Instruments And Information 9

7-2. Circuit Board Handling Precautions 9
7-3. Troubleshooting 9
Diagram 7-1. Troubleshooting Circuit Diagram For Welding Power Source 12
Diagram 7-2. Wiring Diagram For Welding Power Source 14
7-4. Control Board PCi Testing Information 16
Diagram 7-3. Troubleshooting Circuit Diagram For Control Board PCi... 18
7-5. Power Transistor Modules Q1 And 02 Testing Procedure 20
 Section No. Page No.

SECTION 8— COMPONENT IDENTIFICATION AND LOCATION

Figure 8-1. Main Assembly And Component Locations 22

Figure 8-2. Diode/Transistor Modules And Component Locations 23
SECTION 9— MAINTENANCE

9-i. Routine Maintenance 24

9-2. Thermal Protection 24
9-3. Tungsten Electrode 24

SECTION 10— ELECTRICAL DIAGRAMS

Diagram 10-1. Circuit Diagram No. C-i 19 057 For Welding Power Source
Models Effective With Serial No. JJ367796
And Following 27
Diagram 10-2. Wiring Diagram No. D-1 20 963-B For Welding Power Source
Models Effective With Serial No. JJ367796
ThruJK7O5565 28
Diagram 10-3. Wiring Diagram No. D-i32 294 For Welding Power Source
Models Effective With Serial No. JK705566 And Following.. 30
Diagram 10-4. Circuit Diagram No. D-i 20507-C For Control Board PCi
Effective With Serial No. JJ367796 And Following . ... 32
APPENDIX 1 — SERVICE MEMOS

Service Memo No. 744 24

LIST OF CHARTS AND TABLES

Table 2-1. Specifications 2

Table 2-2. Idling Data 2
Chart 2-i. Volt-Ampere Curves 2
Chart 2-2. Duty Cycle 2
Table 7-i. Troubleshooting 10
 SECTION 1 — SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. GENERAL INFORMATION
This manual provides theory of operation along with
specific operating, testing, and troubleshooting proce-
dures. It also includes precautionary information rele-
vant to these procedures. This manual can be an effec-
tive tool in the handsof a trained serviceperson. Howev-
er, itdoesnot and cannottakethe place ofprevious train-
ing nor safety-conscious service work. If any doubt
arises about the specific application ofprocedures pres-
ented, or if problems arise which are not covered in this
manual, contact the factory Service Department before
proceeding further.
1-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
The following safety alert symbol and signal words are
usedthroughout this manual tocall attention to and iden-
tify different levels of hazard and special instructions.
A This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten-
tion to the safety statements.
A WARNING statements identify procedures or
practices which must be followed to avoid seri-
ous personal injury or loss of life.
A CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip-
ment.
1-3. SAFETY PRECAUTIONS
WARNING: ELECTRIC SHOCK can kill.
A • Do not touch live electrical parts.
• Protectyourself with dryinsulating gloves and
clothing.
• Insulate yourselffromground by using rubber
gloves and rubber or wooden floor mats when
power is applied to the unit.
• Turn offpowersource, and remove inputpow-
er plug from receptacle when servicing unless
the procedure specifically requiresan energized
unit.
• Do not leave live unit unattended.
• Do notuse cables ortorch with damaged insu-
lation.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
hearing.
• Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm
your health.
• Keep your head out of the fumes.
• Ventilate to keep from breathing fumes and
gases.
• If ventilation is inadequate, use approved
breathing device.
• Read Material Safety Data Sheets (MSDSs)
and manufacturer’s instructions for any materi-
als used.
HOT METAL, SPLATTER, AND SLAG can
cause fire and burns.
• Watch for fire.
• Have a fire extinguisher nearby, and know
how to use it.
• Do not use near flammable materiaL
• Allow workand equipment to coolbefore han-
dling.
MOVING PARTS can cause serious Injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
MAGNETIC FIELDS FROM HIGH CURRENTS
can affect pacemaker operatIon.
• Wearers should consult their doctor before
going near the servicing of arc welding equip-
ment or any arc welding operations.
TM-292 Page 1
 SECTION 2-SPECIFICATIONS

Table 2-1. Specifications

Rated
Welding Welding Max. Input At Rated Load
Amperes Amperage Open-
Circuit Output 50/60 Hz Single-Phase Weight
At i 00% Range Voltage Amperes A kva kw Net I Ship
Duty Cycle
~0V
i2OAt 0.5-iso 31 lbs. I 36 lbs.
25 Volts DC Amperes 75 3.8

Table 2-2. Idling Data (No Load)

A CAUTION: EXCEEDING DUTY CYCLE RAT-
INGS can causethewelding power source to

]
Idle Amperes Input At No Load shut down fora cooling period thereby inter-
rupting the welding process.
50/60 Hz Single-Phase • Do not exceed indicated duty cycles.

230V
0.5 Ikva.kw
0.12 0.1 Chart 2-2. Duty Cycle
2-1. VOLT-AMPERE CURVES (Chart 2-1)

0*
The volt-ampere curves show the voltage and amper-
RATED OUTPUT
SO

age output capabilities of the welding power source.

SD
Chart 2-1. Volt-Ampere Curves
70~ — — TI

—V —t —----— TI 60
60~I -~ — — —

30
50 — — — — —.——— —-—- —.- —

40 044.04mm
0
35 0 20 AD 60 80 00
400.0020?
30 DUTY CYCLE A-121 591
W00,fl ~E0’00

20 2-3. DESCRIPTION
‘5

r0
0rTh
This unit is a constant current (CC), dc, invertertype arc
201520
~iii 1±1111111 Thu welding power source requiring single-phase electrical
input. It is designed for Gas Tungsten Arc Welding
0 .0 20 30 40 50 60 70 80 90 00 ITO

4WEOES
20 30 40 20 lAO 70 ISO 190 200 210
(GTAW) and Shielded Metal Arc Welding (SMAW) pro-
As the short-circuit condition is approached, the unitautomatically cesses.
provides additionai arc force. This is a momentary arcforce, and is Rated weld output is 120 amperesat 25 volts dc, i 00%
not a selectable or variable value. B-12l 091
duty cycle.
2-2. DUTY CYCLE (Chart 2-2) A REMOTE receptacle is provided forremote contactor
The duty cycle ofa welding powersource isthe percent- and/or remote amperage control.
age ofa ten minute period that a welding powersource 2-4. STORAGE
can be operated at a given output without causing over-
heating and shutdown of the unit. This welding power
source is rated at 100 percent duty cycle. This means
that the welding powersource can be operated at rated
A WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn off welding power source, and remove
load continuously. If the welding amperes are increased inputpower plug from receptacle before storing
beyond rated output, the duty cycle will decrease. This unit.
unit, however, does not offer controllable output in ex- 1. Clean outside of unit.
cess of 150 amperes. Chart 2-2 enablesthe operator to
determine the output of the welding power source at 2. Remove top cover and side panels (orwrapper as
various duty cycles. applicable).
TM-292 Page 2
3. Using dry compressed air, clean inside of unit.
4. Reinstall top cover and side panels or wrapper as
applicable.
5. Select a storage location that least subjects the unit
to wide temperature variation, dust, dirt, and corro-
sive vapors.
6. Carry unit to storage location.
7. Cover unit with plastic or suitable tarp.
2-5. PREPARATION FOR RESHIPMENT
A WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn off welding power source, and remove
input powerplug from receptacle before prepar-
ing unit for shipping.
1. If applicable, disconnect gas cylinder, water supply,
and/or coolant system; remove unit from running
gear.
2. Tape plastic around top and sides of unit.
3. Securely tie and/or tape cardboard over top and
around sides of unit. Use original shipping carton if
available.
IMPORTANT: Do notship without a cardboard carton.
Not only do costs increase dramatically but the unit is
more subject to loss or damage without a carton.
4. If shipping unit to factory, ship unit as directed by
factory Service Department or Transportation De-
part ment.

SECTION 3- INSTALLATION OR RELOCATION

Failureto comply in any ofthese areas may result in less

A WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.
• Turn off welding power source, and remove
than satisfactory welding performance.
A. Weld Cables (Table 3-1)
inputpowerplug from receptacle before moving
unit. Perform the following steps to ensure the best welding
3-1. LOCATION performance:

A WARNING: RESTRICTED AIR FLOWcauses

overheating and possible damage to internal
parts.
• Maintain at least 10 inches (254 mm) ofunre-
stricted space on all sides of unit.
• Do not place any filtering device over the in-
take airpassages ofthis welding power source.
Warranty is void if any type offiltering device is
used.
The location should allow room to remove wrapper for
installation, maintenance, and repairprocedures.
The service life and efficiency of this unit are reduced
when the unit is subjected to high levels of dust, dirt,
moisture, corrosive vapors, and extreme heat.
3-2. WELD OUTPUT CONNECTIONS (Table 3-1,
Figure 3-1, And Figure 3-2)
1. Keep cables as short as possible, and place cables
close together. Excessive cable length adds resis-
tance which may reduce output or cause overload-
ing of the unit.
2. Use weld cable with an insulation voltage rating
equal to or greater than the maximum open-circuit
voltage (ocv) of the welding power source (see
Table 2-1 for unit maximum ocv rating).
3. Select adequate size weld cable forthe anticipated
maximum weld amperage. Use total length ofweld
cablesin circuit to determine cable size. For exam-
ple, if the electrode holder cable is 75 feet (22 m)
long and the work cable is 25 feet(8 m) long, select
the size cable recommended in Table 3-1 for 100

~ RATED OUTPUT
To obtain the full rated output from this unit, it is neces-
feet (30 in). The maximumcable length when using
high frequency is 50 feet (15 in).

sary to select, install, and maintain proper weld cables. 4. Do not use damaged orfrayed cables.
Table 3-1. Weld Cable Size
Total Cable (Copper) Length_In Weld Circuit Not Exceeding*
100 ft. Or Less 150 ft. 200 ft. 250 ft. 300 ft. 350 ft. 400 ft.
Welding
Amperes (30 in) 45 m) (60 m) (70 m) (90 m) 1(105 in) (120 m)
lOTo 60% 6OThru 100% 10 Thru 100% DutyCycle
Duty Cycle Duty Cycle
100 3 3 4 1 2 3 11/0 1/0

150
200 3 3 1/0
1 1/0
2/0 2/0
3/0 4/0 J 4/0
*Weld cable size (AWG) is Dased on either a 4 volts or less drop or a current density of more than 300 circular
mils per ampere. S.00071B-68

TM-292 Page 3
 5. Install electrode holderortorch onto cable following 2. Connect the work weld cable connector to NEGA-
manufacturer’s instructions. An insulated electrode TIVE (—) weld output receptacle.
holder or torch must be used to ensure operator IMPORTANT: For Electrode Negative/Straight Polarity
safety. connections, reverse cable connections to weld output
6. Install a correct size lug onto one end ofwork cable, receptacles; electrode becomes negative.
and install work clamp onto cable.
B. Connector Installation (Figure 3-1)
1. Remove 1 inch (25 mm) of insulation from one end
of cable.
2. Wrap copper strip(s) tightly around stripped end of
cable.
3. Insert cable with copper strip(s) attached into serv-
ice end of connector so that cable is snug and
against bottom of the connector body.
4. Install and tighten setscrew to secure connector
body onto cable.
5. Slide insulator over connector so that setscrew and
locking holes line up. Positive (+) weld
Output Receptacle
6. Secure insulator by driving pin through insulator and Negative (—) weld
connector. Output Receptacle
18.123 265
LockIng
Pin Figure 3-2. Weld Output Connections

Insulator

230 Volts
(=) ~,%%.% Copper Strip* Power Cord And
TwoWeld
strips
Cable
are provided for cable diameters that may require
Figure
3-3. REMOTE 3-3. Rear Panel
RECEPTACLE View
INFORMATION AND
wrapping a second piece around sripped end of cable.
s~o~ CONNECTIONS (Figure 3-3 and Figure 3-4)
Figure 3-1. Connector Installation
~ REMOTE 14
C. Weld Cable Connections (Figure 3-2)

± A AMPERAGE

POSITIVE NEGATIVE
0* OUTPUT
(CONTACTOR)

A WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.
• Turn off welding power source, and remove
input powerplug from receptacle before making
weld output connections.
For Electrode Positive/Reverse Polarity Connections:
1. Connectthe electrode ortorch weld cable connector
IMPORTANT: Prior to serial number JK705566, RE-
MOTEreceptacle RC7was a 5-socketAmphenoirecep-
tacle.
The 14-socket Amphenol REMOTE 14 receptacle RC7
provides a junction point forconnecting a Remote Con-
tactor and/or a Remote Amperage Control to the control
circuitry ofthe welding powersource. To make connec-
tions, align keyway, insert plug, and rotate threaded col- -

to POSITIVE (+) weld output receptacle. lar fully clockwise.

TM-292 Page 4
The sockets on REMOTE receptacle RC7 are desig- 3-4. ELECTRICAL INPUT CONNECTIONS
nated as follows:

Socket A: Contactor control switch connection. 4D INPUT

Socket B: Contactor control switch connection.
A 6-1/2 ft. (2 m) cord with plug attached is provided on
Socket C: Amperage control connection (maximum this unit. Check nameplate forinput voltage requirement
side, fully clockwise). and connect the plug to a properly grounded and pro-
Socket D: Amperage control connection (minimum tected (fuses orcircuit breakers) 230 volts ac receptacle
side, fully counterclockwise). capable of carrying 26 amperes.
Socket E: Amperage control connection (wiper con- The National Electrical Code (Article 630B., 1987 Edi-
nection). tion) provides standards foramperage carrying capabil-
IMPORTANT: The remaining sockets in the receptacle ity of supply conductors based on the duty cycle ofthe
welding powersource. This unit has a 100 percent duty
are not used. cycle and can be operated at rated load continuously;
o therefore, the cord and plug supplied with this unit corn-
AO Oj plywith these standards. Be surethat the building supply
~o K~ 01 and receptacle complywith NEC standards and any ad-
0 ditional state and local codes.
cp~L0N0 0H
M0 0G
0E OF IMPORTANT: The supply wiring for the welding power
o 0 source must be capable of carrying a 26 ampere load.
The welding power source must be the only load con-
nected to the supply circuit. Poor unit performance or
Figure 3-4. Front View Of 14-Socket Receptacle frequently opening line fuses orcircuit breakers can re-
With Socket Locations suIt from an inadequate or impropersupply.

SECTION 4-OPERATOR CONTROLS

4-2. AMPERAGE ADJUSTMENT CONTROL

(Figure 4-1)

A
AMPERAGE ADJUSTMENT

Amperage control The AMPERAGE ADJUSTMENT control provides a

Switch means of selecting an amperage output from minimum
Positive (+) weld to 150 amperes. Rotating the control clockwise in-
Output Receptacle creases the amperage output.
OutputlcontactOr Switch IMPORTANT: The AMPERAGEADJUSTMENTcontroI
may be adjusted while welding.
Negative (—) weld
4-3. AMPERAGE CONTROL SWITCH (Figure 4-1)
Output Receptacle
TB.123265 If remote amperage control is desired, make connec-
tions to the REMOTE receptacle as instructed in Section
Figure 4-1. Front Panel Controls 3-3, and place the AMPERAGE CONTROLswitch in the
REMOTE position. The Remote Control adjusts weld
4-1. POWER SWITCH (Figure 4-1) output from minimum up to the amperage setting on the
AMPERAGE ADJUSTMENT control.
Placingthe POWER switch in the ON position energizes
thewelding powersource. Placing the POWER switch in If remote amperage controlis not desired, place the AM-
the OFF position shuts down thewelding powersource. PERAGE CONTROL switch in the PANEL position.
TM-292 Page 5
4-4. OUTPUT/CONTACTOR SWITCH (Figure 4-1)
A WARNING: ELECTRIC SHOCK can kIll.
• Do not touch live electrical parts.
• Do not touch the weld output terminals when
the contactor is energized.
• Do not touch torch or electrode holder and
work clamp at the same time.
When the OUTPUT/CONTACTOR switch is in
the ON position, open-circuit voltage is present
at weld output receptacles for as long as the
welding power source is energized.
If remote contactor controlis desired, makeconnections
to the REMOTE receptacle as instructed in Section 3-3.
Place the OUTPUT/CONTACTOR switch in the RE-
SECTION 5- SEQUENCE OF OPERATION
A WARNING: ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious Injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage Internal parts.
• Do not touch live electricalparts.
• Keep allcovers and panels in place while op-
erating.
Warranty is void if the welding power source is
operated with any portion ofthe outer enclosure
removed.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
hearing -
• Wear correct eye, ear, and body protection.
FUMES AND GASES can serIously harm
your health.
• Keep your head out of the fumes.
• Ventilate to keep from breathing fumes and
gases.
• If ventilation is inadequate, use approved
breathing device.
HOT METAL, SPATTER, AND SLAG can
cause fire and burns.
• Watch for fire.
• Keep a fire extinguisher nearby, and know
how to use it.
• Do not use near flammable material.
• Allow workand equipment to coolbefore han-
dling.
MAGNETIC FIELDS FROM HIGH CURRENTS
can affect pacemaker operation.
• Wearers should consult their doctor before
going neararc welding, gouging, orspot welding
operations.
TM-292 Page 6
MOTE position. Open-circuit voltage is present at the
weld output receptacleswhenthe remote contactorcon-
trol switch is closed.
If remote contactor control is not desired, placethe OUT-
PUT/CONTACTOR switch in the ON position. Open-cir-
cuit voltage will be available at the weld output recepta-
cles whenever the POWER switch is in the ON position.
4-5. WELD PROCESS SWITCH (Figure 4-1)
Placing the WELD PROCESS switch in the GTAWposi-
tion provides proper weld output characteristics forthe
Gas Tungsten Arc Welding (GTAW) process.
Placing the WELD PROCESS switch in the SMAW posi-
tion provides additional arc force forthe Shielded Metal
Arc Welding (SMAW) process (see Chart 2-i. Volt-Am-
pere Curves).
5-1. GAS TUNGSTEN ARC WELDING (GTAW)
A WARNING: Read and follow safety infornia-
tion at beginning of entire Section 5 before
proceeding.
1. Install and connect unit according to Section 3.
2. Connect shielding gas supply to torch.
3. Install and connect High-Frequency unit according
to its Owner’s Manual, if applicable. Scratch start
Gas Tungsten Am Welding doesnot requirethe use
of external high frequency.
4. Connect a Remote Contactor Control to the RE-
MOTE receptacle (see Section 3-3), and place the
OUTPUT/CONTACTOR switch in the REMOTE po-
sition.
5. If a Remote Amperage Control is not used, place the
AMPERAGE CONTROL switch in the PANEL posi-
tion, and rotate the AMPERAGE ADJUSTMENT
control to the desired position (see Section 4-2).
6. If a Remote Amperage Control is to be used, make
connections to REMOTE receptacle (see Section
3-3). Place the AMPERAGE CONTROL switch in
the REMOTE position, and rotate the AMPERAGE
ADJUSTMENT control to the desired position (see
Section 4-2).
7. Placethe WELD PROCESS switch in the GTAW po-
sition.
8. Weardry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
ANSI Z491 -
9. Prepare forwelding as follows:
a. Connect work clamp to clean, bare metal at
workpiece.
b. Select and obtain proper tungsten electrode
(see Table 9-2).
c. Prepare tungsten electrode according to Sec-
tion 9-3, and insert into torch.
10. Turn on shielding gas supply at the source.
11. Turn on high frequency unit, if applicable.
12. Place the POWER switch in the ON position.
13. Close Remote Contactor Control switch.
14. Begin welding.
5-2. SHIELDED METAL ARC WELDING (SMAW)
A WARNING: Read and follow safety Informa-
tion at beginning of entire Section 5 before
proceeding.
1. Install and connect unit according to Section 3.
2. If a Remote Amperage Control is not used,place the
AMPERAGE CONTROL switch inthe PANEL posi-
tion, and rotate the AMPERAGE ADJUSTMENT
control to the desired position (see Section 4-2).
3. If a Remote Amperage Control is to be used, make
connections to REMOTE receptacle (see Section
3-3). Place the AMPERAGE CONTROL switch in
the REMOTE position, and rotate the AMPERAGE
SECTION 6- THEORY OF OPERATION
6-1. THEORY OF OPERATION (Diagram 6-1)
The basic welding powersource operation is not difficult
to understand when it is divided into sections. The block
diagram shown in Diagram 6-1 includes the main com-
ponents which makeup the circuitry ofthe welding pow-
er source.
1. Input poweris applied to the welding power source.
The line contactors close when POWER switch Si
is placed in the ON position.
2. When POWER switch 51 is placed in the ON posi-
tion, single phase ac is applied to main rectifierSRi.
At the same, control circuitry on Control Board PCi
is energized which can provide gate pulses to turn
on powertransistor modules 01 and 02. Also ener-
gized at the same time is the fan motor FM/trans-
former which provides the input power to the control
circuitry on Control Board PCi.
3. The energizing ofcontrol relay CR1 is delayed for a
very short time period. This delay is sufficient to al-
ADJUSTMENT control to the desired position (see
Section 4-2).
4. Placethe OUTPUT/CONTACTORswitch in the ON
position.
5. Place the WELD PROCESS switch in the SMAW
position.
6. Wear dry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
ANSI Z49.1.
7. Prepare forwelding as follows:
a. Connect work clamp to clean, bare metal at
workpiece.
b. Select and obtain proper electrode, and insert
into electrode holder.
8. Place the POWER switch in the ON position.
9. Begin welding.
5-3. SHUTTING DOWN
1. Stopwelding.
2. Place the POWER switch in the OFF position.
3. Turn off the high frequency unit, if applicable.
4. Turn off the shielding gas supply, if applicable.
A WARNING: HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
• Shut off gas supply when not in use.
low the initial charge of filter capacitor Cl to pass
through the filter precharge network.
4. AMPERAGE ADJUSTMENT control R4 sets the
weld output by varying a reference voltage to circuit-
ryon Control Board PCi.
5. Current transformerCTi senses the amount ofcur-
rent in the primaryof main transformerTi, and pro-
vides a pulsed currentsignal to Control Board PCi.
At Control Board PCi, a portion of the signal is
summed with a ramp signal to provide enhanced
pulse width modulation performance and a portion
ofthe signal is used forfault protection.
6. Output feedback from the weld output receptacles
provides a dc signal to Control Board PCi. This
feedback signal is compared to the set reference or
amperage level from AMPERAGE ADJUSTMENT
control R4. If the output current is too high ortoo low,
Control Board PCi adjusts the triggerpoint ofpower
transistor modules 01 and 02 thereby compensat-
ing forany changein the output currentcomparedto
the setting on AMPERAGE ADJUSTMENT control
R4.
TM-292 Page 7
 7. Thefunction ofControl Board PCi isto usethe infor-
mation received from AMPERAGE ADJUSTMENT
controlR4, the feedback signal, andthe currentsen-
sor LEMi to determine when the power transistor
modules 01 and 02 should be triggered.
8. Main transformerTi is energized by the on and off
switching of the power transistor modules Qi and
02. The on and off time of Qi and 02 is controlled by
circuitry on Control Board PCi to compensate for
any change in the output current.
Diagram 6-i. Block Diagram
TM-292 Page 8
9. The output of main transformerTi is rectified by out-
put rectifier module D2 providing the dc voltage re-
quired at the weld output receptacles.
10. Current sensor LEM 1 provides a dc signalto Control
Board PCi that is proportional to the amount ofcur-
rent flowing through the weld output circuit.
11. The stabilizer Zi (inductor) is designed to smooth
the welding current.
12. The high frequency capacitors Cli, Ci2, and C13
are used to filter any unwanted signals at the weld
output receptacles.
5-0208
 SECTION 7- TROUBLESHOOTING
7-1. TESTING INSTRUMENTS AND INFORMATION
The service procedures in this manual require proper
testing instruments. Use a good quality digital VOM with
one megohin input impedance or greater and diode
check capability (use an analog VOM forvariable resis-
tor testing). If an oscilloscope is specified, use a good
quality unit with one megohm input impedance or
greater. If a circuit board has a protective coating, it will
be necessary to remove coating oruse needleprobes in
the test area to obtain proper contact. Recoat areas if
necessary to retain corrosion protection. Digital VOM’s
do not require lead polarity attention when making con-
nections. However, the meter may indicate a — (nega-
tive) voltage whenthetest procedurespecified a + ( pos-
itive) voltage. If the incorrect polarity appears on the dis-
play, reverse meter lead connections to test points.
7-2. CIRCUIT BOARD HANDLING PRECAUTIONS
A WARNING: ELECTRIC SHOCK can kill.
• Do not touch llve electricalparts.
• Turn off welding power source, and remove
inputpower plug from receptaclebefore inspect-
ing, maintaining, or servicing.
MOVING PARTS can cause serious Injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
A CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on propedy grounded wrist Strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• Perform work only at a static-safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned.
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure andgentle move-
ment when disconnecting or connecting board
plugs and removing or installing board.
7-a TROUBLESHOOTING (Table 7-1)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electricalparts.
• Turn off welding power source, and remove
inputpowerplug from receptacle before inspect-
ing, maintaining, or servicing.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
The troubleshooting table is designedto diagnosesome
of the troubles that can develop in this welding power
source. The table is based on the assumption that no
short circuit exists between any isolated circuits and
groundor between any two isolated circuits. In addition,
any circuit normally tied to ground must be at ground po-
tential.
Use the table in conjunction with the circuit diagram(s)
and wiring diagram(s) in This manual and the exploded
views and component values in the Service Parts Manu-
al while performing troubleshooting procedures.
When replacing components, useonly genuine MILLER
replacement parts. MILLER parts are required for war-
ranty repair by authorized warranty service agency.
Resistance and continuity measurements must be
made with the unit shut down. Isolate components be-
fore making resistance and continuity measurements.
When making continuity checks with an ohmmeter, the
resistance readings can be either extremely low or high
when a component orcircuit is not working properly. If
the readingis high orinfinity, thereis a break in the circuit
or component creating an open circuit. If the reading is
extremely low or zero, the circuit or component may
have a short circuit.
IMPORTANT: Before beginning troubleshooting proce-
dures, visually examine internalcomponents for signs of
overheating and failure. Many major problems, such as
winding(s) failure are usually apparent by discoloration,
smoke, and smefl. Fortunately, mostelectricalproblems
are relatively simple: blown fuses, tripped circuit break-
ers, incorrectswitch positions, looseconnections, corro-
sion, and the like. A complete, careful inspection often
saves considerable time, money, and frustration.
IMPORTANT: Be sure that all connections are correct
and secure according to Section 3 and that all controls
and switches are in proper positions beforeproceeding
with troubleshooting.
TM-292 Page 9
 Table 7-1. Troubleshooting
TROUBLE PROBABLE CAUSE
No weld output; unit Line disconnect switch in the
completely inoperative. OFF position.
Linefuse(s) open.
Power cord plug not secure in
power receptacle.
POWER switch 51.
Improper voltage input.
Fan motor FM/transformer.
No weld output; unit OUTPUT/CONTACTOR switch
completely inoperative; S3 in REMOTE position with no
fan motor FM running. Remote Contactor Control con
nected to REMOTE receptacle
RC7.
Thermostat TP1 open (thermal
shutdown).
Diode D2.
Main rectifierSRi.
Power transistor modules 01 and Check 01 and 02 according to Section 7-5,
02.
Control Board PCi or poor
connections to PCi.
Lowweld output with no AMPERAGE CONTROL switch
control. S4 in REMOTE position with no
Remote Amperage Control con- Section 3-3).
nected to REMOTE receptacle
RC7.
AMPERAGE CONTROL R4.
Current sensor LEMi.
Main rectifier SRi.
Control Board PCi or poor
connections to PCi.
Maximum weld output with AMPERAGE ADJUSTMENT
no control. Control R4.
Current sensor LEMi.
Control Board PCi or poor
connections to PCi.
TM-292 Page 10
REMEDY
Place line disconnect switch in the ON
position.
Check and replace line fuse(s).
Secure power cord plug.
Check 51 for proper operation with an ohmme
ter, and replace if necessary.
Check forproper input voltage of 230 volts ac
(see Section 3-4).
Check FM/transformer, and replace if neces
sary (see Diagram 7-1).
Place S3 in ON position orconnect Remote
Contactor Control To RC7 (see Section 3-3).
Allow a cooling period of approximately five
minutes (see Section 9-2).
Check D2, and replace if necessary.
Check SRi, and replace necessary compo
nents.
and replace if necessary.
Check connections for continuity to PCi.
Check PCi according to Diagram 7-3 and
Section 7-4, and replace if necessary.
Place S4 in the PANEL position or connect
Remote Amperage Control to RC7 (see
Check R4 for proper connections and resis
tance; R4 is 1000 ohms ±10%.Replace R4 if
necessary.
Check LEMi (see Diagram 7-1).
Check SRi, and replace necessary
components.
Check connections forcontinuity to PCi.
Check PCi according to Diagram 7-3 and
Section 7-4, and replace if necessary.
Check R4 for proper connections and resis
tance; R4 is 1000 ohms ±10%.Replace R4
if necessary.
Check LEMi (see Diagram 7-1).
Check connections for continuity to PCi.
Check PCi according to Diagram 7-3 and
Section 7-4, and replace if necessary.

TROUBLE
Erratic or improper weld
output.
Fan does not run; weld
output available.
Tungsten electrode oxidiz-
ing and not remaining
bright after conclusion of
weld.
Difficulty in establishing an
arc; wandering arc; poor
control of direction of arc.
Table 7-1. TroubleshootIng (Continued)
PROBABLE CAUSE REMEDY
Poor or improper output Refer to Section 3-2 for proper output
connections. connections.
Incorrect welding cable size. Use proper size and type of cable (see Section
3-2).
Loose or dirty welding cable Clean and tighten all welding connections.
connections.
Electrode. Replace electrode.
AMPERAGE ADJUSTMENT Check R4 for proper connections and resis
Control R4. tance; R4 is i 000 ohms ±10%.Replace R4 if
necessary.
Remote amperage control poten- Check remote amperage control potentiometer
tiometer not working properly for proper connections and continuity, and
when AMPERAGE CONTROL replace if necessary.
switch S4 is in the REMOTE
position.
Current sensor LEMi. Check LEMI (see Diagram 7-i).
Main rectifier SRi. Check SRi, and replace necessary
components.
Control Board PCi or poor Check connections-for continuity to PCi.
connections to PCi. Check PCi according to Diagram 7-3 and
Section 7-4, and replace if necessary.
Fan blade. Replace fan blade.
Fan motor FM. Replace FM.
Loose gas fittings on regulator or Check and tighten all gas fittings.
gas line. This will siphon oxygen
into the weld zone.
Insufficient gasflow. Increase gas flow setting.
Drafts blowing shield away from Shield weld zone from drafts.
tungsten.
Use oftungsten larger than Use proper size tungsten forwelding amper
recommended forwelding age (see Table 9-2).
amperage.
Improperly prepared tungsten. Prepare tungsten as instructed in Section 9-3.
TM-292 Page 11
 A WARNING: ELECTRIC SHOCK can kill; MOVING PARTS
can cause serious injury.
• Turnoff weIding powersource before making orchanging
meter lead connections and before disconnecting or con-
necting any machine leads.
• Have only qualified persons familiar with and following
standard safety practices perform troubleshooting proce-
dures.
• See Table 7-1 if values are not present. 23OV -

Resistance
Voltage Readings (±10%)
Readings (±10%)
Vi 18 volts ac
Ri I 4.2 ohms
v2 18 volts ac
R2 3.9 ohms
V3 68 volts dc
Less than
V4 24voltsdc R3 lohm
vs a to +10 volts dc R4 Less than
minimum to maximum 1 ohm
V6 325 volts dc R5 Less than
iohm
V7 31 volts ac
V8 96 volts ac RCB-IO »—50
RCI-7
5,
RC5-9 »—

RC2-12

V4
RC6-IO 1>—
52
RC2-13

RC7 53
RC6-9 ~>—

A> 4,7 ~< RCI-6

REMOTE TPI
CONTACTOR < RC2-I
RMT
B 6~3 ,~
C~TACTOR
ON PC
SMAW

RC2-4
GTAW PROCESS
< RC2-6 54
RC6-7 )>—
IMPORTANT: The values are based on a good quality
digital VOM or equivalent reading average (not RMS) < RC2-14 55
RC6—6 ~>~—
values. Use Wiring Diagram (Diagram 7-2) to help locate
parts and leads. < RCI-3

AMPERAGE ~ < RC2-9

IMPORTANT: See Appendix I for output waveforms. AO~AJSTMENT
RCB-7 56
27 <RC2-7 57
RCB-6 »—

PAf~EL /0
CONTROL ~ RC4-~ »—
S4 < RC2-II
23 RC4-2 »—
RMT
RC3- i
RE?4DTE
CURRENT c 20 ~ RC2-IO RC3-3 »—
40
RC2—2 »—
48 RCI-I I 4/
0>
RC2-8 >)—

Diagram 7-1. Troubleshooting Circuit Diagram For Welding Power Source

TM-292 Pagel2
 NEGATIVE

LEN I

C13

x
m

POSITIVE
CI

Ref. SC-119 057-A

TM-292 Page 13
 NOTE

NOTE
SECONDARY LEADS
TO D2 TOP B. BOTTOM
PRIMARY LEADS TO O~ B. 02.
PRIMARY LEADS SINGLE CQNOUCTOR
SECONDARY LEADS 2 CONDUCTOR

PC

RC3/PLO2

CASE ONO
P08 PAN MTO. SCRE4

Diagram 7-2. Wiring Diagram For Welding Power Source

TM-292 Page 14
V

S2 S3 S4

NEGATIVE POSITIVE
STUD STUD

CASE G~
STUD S

Ref. 0-132 294

TM-292 Page 15
7-4. CONTROL BOARD PCi TESTING INFORMA-
TION (Diagram 7-3 And Figure 7-1)
A WARNING: ELECTRIC SHOCK can kill.
@Do not touch live electricalparts.
• Turn off welding power source, and remove
inputpowerplug from receptacle before inspect-
ing, mathtaining, or sen/icing.
• Turn off welding power source, and remove
inputpowerplug from receptacle before making
or changing meter leadconnections.
MOVING PARTS can cause serious Injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allowcooling period before sen/icing.
This procedure requires the unitto be energized.
Only qualified persons familiarwith and follow-
ing standard safety practices are to perform this
testing procedure.
IMPORTANT: For all checks, be sure to test and verify
the continuity of leads between the board and the area
where check isperformed. All checks should go through
the connections andbe actual terminal-to-terminaltests
so that badconnections or leadsand corrosion is not the
problem.
A. Power Supply Circuit
A voltage of +15 volts dc should exist between pin 8 of
receptacle RC1 and circuitcommon, and a voltage of-15
volts dc should exist between pin 4 of receptacle RC1
and circuit common. If +1-15 volts dc are not present,
check for 18 volts ac between pin 5 of receptacle RC1
and circuit common and for 18 volts ac betweenpin 10 of
receptacle RC1 and circuit common. If 18 volts ac are
TM-292 Page 16
present at both pins 5 and 10 of receptacle RC1 and
+1-15 volts dc are not present at pins 8 and 4 of recep-
tacle RC1, replace Control Board PCi.
B. Contactor Circuit
With OUTPUT/CONTACTOR switch S3 in the ON posi-
tion, 0 volts dc should exist between pin 1 of receptacle
RC2 and circuit common. With S3 in the REMOTE posi-
tion, +1.2 volts dc should exist between pin 1 of recep-
tacle RC2 and circuit common.
C. Amperage Control Circuit
Control Board PCi requires several input signals in or-
der to generatethe output gate pulses at pins 10 and 9,
and 7 and 6 ofreceptacles RC5 and RC6for powertran-
sistor modules 01 and 02. The required input signals
are as follows:
1. Control Board PCi requires a voltage of 0 to +10
volts dc at pin 9 ofreceptacle RC2 with respectto cir-
cuit common from AMPERAGE ADJUSTMENT
control R4.
2. With the welding power source under load, Control
Board PCi requires a current feedback signal pro-
portionalto the weld output currentat pins of recep-
tacle RC2 from current sensor LEMi. As AMPER-
AGE ADJUSTMENT controlR4 is rotated from mini-
mum to maximum (150 amperes),the voltage at pin
5 of receptacle RC2 should increase from 0 to +5.6
volts dc with respect to circuit common.
D. Remote Amperage Control Circuit
When AMPERAGE CONTROL switch S4 is in the RE-
MOTE position and the Remote Amperage Adjustment
control is rotated from minimum to maximum, the volt-
age at pin 11 ofreceptacle RC2 should increase from 0 to
+10 volts dc with respect to circuit common.
 Diode D6

Receptacle RC1 (Test Point B) ~. 8-120 929-C

Figure 7-1. Control Board PCi Component Locations And Information

TM-292 Page 17
 wARNING: ELECTRIC SHOCK can kill; MOVING IMPORTANT: The waveforms at test points A and B
A PARTS can cause serious injury.
• Turn off welding power source before making or
changing meter lead connections and before discon-
are shown with AMPERAGE ADJUSTMENT control R4 at
maximum and OUTPUT/CONTACTOR switch S3 in ON
position. See Figure 7-1 for component locations.
necting or connecting any machine leads.
• Have only qualifiedpersons familiar with and fol-
lowing standard safety practices perform trouble-
shooting procedures.

0
F-i-F-ET1 w180 491 m221 491 lSBT
Oto +15 volts dc

+24 volts dc __________________

+15 volts dc Cm

+10 volts dc ~
3 •

L~.
1 —I—-I-—.—- t~—r—p—-- 69

1~ I
69

Circuit

•1
~2-4
69
Common ~l
.4

69- 69

—15 volts dc ~~RVl-4

I ~
-WY.
~CIY.f
-2AV.

18 volts ac
18 volts ac

IMPORTANT: The values are based on a good quality digital

VOM or equivalent reading average (not RMS) values and the
tolerances are ±10% unless otherwise specified. Measure-
ments made with OUTPUT/CONTACTOR switch 53 in ON
position and remote control connected to REMOTE recep-
tacle RC7 unless otherwise specified.

Diagram 7-3. Troubleshooting Circuit Diagram For Control Board PCi

TM-2g2 Page 18
 A
rn cAulloN: Make no con-
nections: damage to test
eqCiCpment or components
can occur.

CAITflON: Make no con-

nections; damage to test
equipment or components
can occur.

o volts dc with OUTPUT/

CONTACTOR switch 53 in
On position; +1.2 volts dc
with 53 in REMOTE posi-
lion

O volts dc with AMPERAGE

ADJUSTMENT control R4
at minimum; +10 volts dc
with R4 at maximum

~/
With contactor On, 0 volts
dc with AMPERAGE
ADJUSTMENT control R4
at minimum; 68 volts dc
with R4 at maximum;
same as arc voltage

With AMPERAGE AD-

JIJ5TMENTcontrol R4 at
maximum, 0 volts dc with
WELD PROCESS switch
52 in GTAW position;
+6.15 volts dc with S2 in
SMAW position

0 volts dc with AMPERAGE

colrrRol. switch 54 in
REMOTE position; +10
volts dc with 54 in PANEL
position

With welding power

• source under load, 0
volts dc with AMPERAGE
ADJUSTMENT control R4
at minimum; +5.6 volts dc
with R4 at maximum (150
amperes)

IMPORTANT: The voltages shown are with respect Test Point A

to circuit common unless otherwise indicated. 5us 500mv

Test Point B
5us 2V
Ret. SD-120 507-0

TM-292 Page 19
7-5. POWER TRANSISTOR MODULES Qi AND 02
TESTING PROCEDURE (Figure 7-2)
A WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn off welding power source, and remove
inputpowerplug from receptacle before inspect-
ing, maintaining, or sen/icing.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow a cooling period before servicing.
Only qualified persons are to perform testing
procedures.
IMPORTANT: See Figure 8-1 for location ofpowertran-
sistor modules in this unit.
IMPORTANT: The ohmmetercheckofpowertransistor
modules 01 and 02 is not a conclusive test. More con-
clusive tests require specialized equipment. Hence,
even though 01 and 02checkout good, 01 and 02 may
stillbe bad. 01 and 02 may be bad at the actual applied
voltage yet check Out good at the comparatively low
ohmmeter voltage (usually about 1.5 volts). If in doubt,
replace 01 and 02.
TM-292 Page 20
To checkpower transistor modulesQi and Q2, proceed
as follows:
1. Turn off welding power source, and remove input
power plug from receptacle.
2. Locate and disconnect plugs PLG5 and PLG6 from
Control Board PCi.
3. Set VOM function selector switch to Rxl ohms.
4. Check the VOM lead polarity with another meter to
determinethe output polarity ofthe leadjacks as not
all meters have the internal battery negative con-
nected to the negative orcommon output jack. It is a
good idea to mark the meter jacks plus orminus for
future use.
5. Check the resistance between the gate (Gi) and
source (51) terminals of 01 and Q2 at plugs PLG5
and PLG6 (see Figure 7-2). If either transistor sec-
tion does not check properly, replace the bad tran-
sistor module.
6. Check the resistance between the gate (G2) and
source (S2) terminals of Qi and 02 at plugs PLG5
and PLG6 (see Figure 7-2). If either transistor sec-
tion does not check properly, replace the bad tran-
sistor module.
 Dl

I-—— —-I
I I
I I
== I I
DZS1

~1
S2
s-oacs

Circuit Diagram For 01 Or 02

Ret. TB-124 571

Qi And 02 Terminal Locations
Figure 7-2. Power Transistor Modules 01 And Q2
TM-292 Page 21
 SECTION 8- COMPONENT IDENTIFICATION AND LOCATION

C,’
a -~
e~~’
C.’
Ca. 03

6
I-
~ir 0L1~
—
—e _______

• 0 0 0
WC.j ~
go
0

60

0
‘U
0
0 0
-J -j
0. e
C)
a. C
~LIID~—~ 0
0.
E
0
C)
~c,I U.
0 o0. C
60
a — a
U
a 0 .0
m E
C)
C)
U C)
0
C

1~

C)
a-
0,
0.O.
U-

TM-292 Page 22
 Transistor
Resistor R9 Rectifier SRi Module 02

Ret. TB-124 571-A

Figure 8-2. DiodeiTransistor Modules And Component Locations

TM-292 Page 23
 SECTION 9— MAINTENANCE

9-1. ROUTINE MAINTENANCE (Table 9-1) Every six months blow out orvacuum dust and dirt from
the intemal components of the welding power source.
IMPORTANT: Every six months inspect the labels on Remove the wrapper from the unit, and use a clean, dry
this unit for legibility All precautionary labels must be airstream or vacuum suction forthe cleaning operation.
maintained in a clearly readable state and replaced If dirty or dusty conditions are present, clean the unit
when necessary. monthly.
WARNING: ELECTRIC SHOCK can kill.
A • Do not touch live electrical parts.
• Turn off welding power source, and remove
9-2. THERMAL PROTECTION
This unit is protected by normally closedthermostat TP1
located on the main transistor heatsink. Should TP1
inputp0 werplugfromreceptacle before inspect- open, thermal shutdown would occur and the unit would
ing, maintaining, or sen/icing. be completely inoperative with no output. The fan motor
MOVING PARTS can cause serious injury. FM would continue to run. A cooling period of approxi-
• Keep away from moving parts. mately five minutes would be required if thermal shut-
down occurs.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing. 9-3. TUNGSTEN ELECTRODE (Table 9-2, Figure
9-1, And Figure 9-2)
Table 9-1. MaIntenance Schedule Use Table 9-2 to select the correct size and type tung-
sten electrode. Prepare the tungsten electrode usingthe
Maintenance following guidelines. A properly preparedtungstenelec-
trode is essential in obtaining a satisfactory weld.
Units in heavy service environ-
ments: Check labels, weld cables, Table 9-2. Tungsten Size
clean internal parts.
Every 3 months. Check weld cables (see
Section 9-1 B). Electrode Diameter Amperage
Polarity Range
- Gas Type
Every 6 months. Check all labels (see IMPORTANT 2% Thorium DC-Argon
block, Section 9-1). Clean internal Alloyed Tungsten Electrode Negative/
parts (see Section 9-1 C).
* Frequency ofservice is based on units operated 40 (Red Band) Straight Polarity
hours perweek. Increase frequencyofmaintenance
.010” Up to 25
if usage exceeds 40 hours per week. .020” 15-40
.040” 25-85
A. Fan Motor 1/16” 50-160
This unit is equipped with an exhaust fan and relies on 3/32” 135-235
forced draft for adequate cooling. The fan motor is The figures are intended as a guide and are a
manufactured with lifetime sealed bearings and re- composite of recommendations from American
quires no maintenance. Welding Society (AWS) and electrode manufacturers.
B. Weld Cables

A WARNING: Read and follow safety informa-

tion at beginning ofentire Section 9-1 before
proceeding.
IE— 2-112 Times
Diameter

Every three months inspect cablesfor breaks in insula-

tion. Repair or replace cables if insulation breaks are
present. Clean and tighten connections at each inspec-
tion.
DC Electrode
C. Internal Cleaning

A WARNING: Read and follow safety informa-

tion at beglnn ing of entire Section 9-1 before
proceeding.
Negative

Figure 9-1. Properly Prepared Tungsten Electrode

Ref. s-oiei

TM-292 Page 24
For DC electrode negative welding, proceed as follows: TUNGSTEN PREPARATION: IDEAL
Stable Arc

A CAUTION: HOT FLYING METAL PARTICLES

can injure personnel, startfires, and damage
equipment; TUNGSTEN CONTAMINATION
can lower weld quality.
Straight Gro~~~
• Shape tungsten electrode only ongrinderwith
properguards in a safe location wearing proper
face, hand, and body protection.
• Do notuse same wheelforany otherjob orthe Flat
tungsten willbecome contaminated. (The Dia. Of This
Flat Governs
Amperage Capacity)
Shape tungsten electrodes on a fine grit, hard abrasive
wheel used only for tungsten shaping. Grind tungsten
electrodes so that grinding marks run lengthwise with TUNGSTEN PREPARATION: WRONG
the electrode. These procedures reduce the possibility
ofthe tungstenelectrode transferringforeign matter into
the weld and help reduce arc wander. Arc Wander—..
Grind the end of the tungsten electrode to a taper for a
distance of2 to 2-1/2 electrode diameters in length. For
example, the ground surface for a 1/8 inch (3.2mm) di-
ameter tungsten electrode would be 1/4 to 5/16inch (6.4
to 8.0 mm) long. -

For additional information, see your distributor for a 5.0162

handbook on the Gas Tungsten Arc Welding (GTAW)

process. Figure 9-2. Tungsten Preparation

TM-292 Page 25
Notes

TM-292 Page 26
 SECTION 10— ELECTRICAL DIAGRAMS

4 U

0
0
0
uJ
0
C)
0
0
U
0
CD
L.
0

‘--3

ncr—s o 0 o 0
N ‘0 — C, — C, C, C
60
nc2-5 U
0
‘0
a
U ~ aaa~~~ 0—
ncr-s
0(1)
5-
0,
Cu
ncr-s 0
no -9
0 0
-5.
C, — —
33 33 C.)

0
1~
E
0
a-
0,
0
0

TM-292 Page 27
 NOTE

NOTE
SECOICAPY LEADS
TO 02 T~ & BOflOI4
PPIn.nRV LEADS TO Dl & 02.
PC7
PRIMAnY LEADS SfrU.E CQC(.CTOR
SECONOASY LEADS 2 ~OXTDS

PC I

PC3/PLG3

CASE ec
P02 Ptt~ IITS. SCREW

Diagram 10-2. Wiring Diagram No. D-120 963-B For Welding Power Source Models Effective With
Serial No. JJ367796 Thru JK705565 And Following
TM-292 Page 28
 S2 S3 $4

NEGATIVE
STUD

CASE SC
STUD B

TM-292 Page 29
 NOTE

NOTE
SEO.ONOARY LEADS
TO 02 TOP & nOTTON
PRIMARY LEADS TO or B. 02.

PnOMARY LEADS SONOLE CQNOUCTOR

SEC~AOARY LEADS 2 CON&JCTOS

PCI

5C3/Pr..03

CASE O~’C
P~S PAIl ATO. SCREW

Diagram 10-3. Wiring Diagram No. D-132 294 For Welding Power Source Models Effective With
Serial No. JK705586 And FollowIng
TM-292 Page 30
 S2 S3 54

NEGATIVE POSITIVE
STUD STUD

CASE GND
STLC B

TM-292 Page 31
 ~I5V.

RC4— I
RC4-2

RC3- I
RC3-2

RC3-3

RC3-4

RC2- 12

PCI-B

PC 1-3

RC2-6
RC2- 13
PC2-7
PC2-I4
RC I - I
PC 1-6
PCT-2
PC 1—7 C33
-g

PC 1-4

RC 1-5
PC 1-10

Diagram 10-4. Circuit Diagram No. D-120 507-C For Control Board PCi Effective With
Serial No. JJ367796 And Following
TM-292 Page 32
 Rc~-5
RcB- TO

RCB-S
Rc5-9

Rc5-7
Rc~-2

RcS-6
RCS- I

RC6-5
RC6- 10

RC6-4
RC6-9
RC6-7
RC6-2

RC6—6
RCA- I

RC2-

4
RC2-IO

RC2-9

RC2-3

RC2-8

RC2-2

.:5V.

RC2-4

RC2-I I

RC2-5

.I5V.
IMPORTANT: Use test points and values
on Diagram 7-3 when troubleshooting this unit.
D32

TM-292 Page 33
Notes

TM-292 Page 34
Mule! November 1996 Form: TM-292
Effective With Serial No. JJ367796

SECTION 11 - PARTS LIST

MaxstarTM 150
DC Welding Power Sources

TM-292 Page 35
 ‘33

0
I-.

B
E
C)
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TM-292 Page 36
 Replace CoIls At Factory Or Factory Authorized Service Station
Item Dia. Part
No. Mkqs. No. Description Quantity
Figure 1. MaIn Assembly
1 +120 456 WRAPPER 1
603 122 WEATHER STRiPPiNG, adh .312x 275 (orderbyft)(Eff ~ik~>~bI ift
2 098 512 HANDLE, (Priorto JK606111) 1
2 121 088 HANDLE, (Eff w/JK606111)
3 123 154 LABEL, warning general precautionarystatic etc 1
4 PLG3 113750 HOUSING, term header40skt 1
5 PCi 119574 CIRCUITCARD, main 1
093 295 GROMMET, scr No. 8/10 4
6 PLG1 113752 HOUSING, term skt 1
7 PLG2 117865 HOUSING, term header 14 skt 1
8 120 126 INSULATION, circuit card 1
9 120 346 BRACKET, mtg-circuit card 1
10 Cl 094961 CAPACITOR, elctlt 2SOOuf 45OVDC 1
11 Ri 120806 RESISTOR, WW fxd 5W 2 ohm 1
12 R2 000 037 RESISTOR, WW fxd lOW 5K ohm 1
13 113 146 CABLE TIE MOUNT, (part of 127 883) 2
14 OTI 120455 TRANSFORMER, current (consisting of) 1
15 PLG4 131 054 HOUSING RECEPTACLE & SOCKETS, (consisting of)
- 1
113746 -TERMINAL, female lskt 18-24wire
- 2
16 127 883 MODULE, transistor (Fig 8-2)
. 1
17 127 882 MODULE, diode (Fig 8-2) 1
18 128 803 BAR, support-heat sink top 1
19 119 943 STRJP,3/16x1/2dx6-1/2 1
20 120 127 BAFFLE, air 1
21 119 757 BAR, support-heat sink bottom 1
22 FM 120 248 MOTOR, fan 230V 50/60Hz 2600 RPM 1
23 118 543 BLADE,fan6in4wing30deg 1
24 120 484 CORDSET,pwr300Vl2ga3/c8ft 1
25 115 104 CONNECTOR, clamp-cable 1/2 in 1
26 Zi 120096 STABILIZER 1
27 LEMi 118 540 LEM, 200A current sense module 1
28 Ti 120 086 TRANSFORMER, pwr-main (consisting of) 1
120 081 COIL, pri/sec
- 2
29 019663 MOUNT, neoprene 15/16 OD x 3/8 4
30 Si 090 328 SWITCH, tgl 2PST 40A 600VAC 1
31 120 183 CAPACITOR, (consisting of) 1
Cli ,12 097750 CAPACITOR, cer .OSuf 500VDC
- 2
32 010907 NUT, Iocldnglin 2
33 NAMEPLATE, (order by model & serial number) 1
34 Ne~/Pos 039 628 RECEPTACLE, twlk-insulated 2
039 630 PLUG, male-twik insulated 2
602 213 WASHER, lock-split 3/8 2
601 838 NUT, brs-hexjam 3/8-16 2
35 S2-4 120 376 SWiTCH, rocker SPOT 4A 230V 3
36. 097922 KNOB 1
37 028291 CAPACITOR,cer.1uf500VDC ..... .jj.. jjj... .......... ii
38 120 457 CASE SECTION, front/bottom/rear (Prior to JK705566) 1
38 132291 CASE SECTION, front/bottom/rear (Eff w/JK705566)
39 R4 035 897 POTENTIOMETER, C 1/T 2W 1000 ohm 1
40 RC7 035 523 RECEPTACLE, Sskt MS-31 02A-1 6S-8S (Priorto JK705566) 1
039 273 PLUG, 5 pin Amphenol MS-3i 06A-1 6S-8P
039 685 CLAMP, cable Amphenol AN-3057-8
40 RC7 109769 RECEPTACLE, l4skt 97-4102A-20-275 (Eff w/JK705566) 1
109 766 PLUG, 14 pin Amphenol 97-4106A-20-27P
109 770 TERMINAL, male 1 pin sz 45 16-22 wire
039734 CLAMP, cable Amphenol AN-3057-1 2
039 684 CAP, dust connector 97-121-416R 1
41 CR1 120349 RELAY, end 12VDC SPOT 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-292 Page 37
 Dia. Part
Mkgs. No. Description Quantity

Figure 2. Module, Diode/Transistor (FIg 1 Item 16 & 17)

127 883 MODULE, transistor (consisting of) 1

C3,8 093 085 • CAPACITOR, poly film .0047uf 1 OOOV 2
C4,7 095 247 • CAPACITOR, MF .068uf 630V 2
PLG5,6 115 091 • HOUSING PLUG & SOCKETS, (consisting of) 2
113 746 TERMINAL, female lskt 18-24 wire 10
01,2 123 884 TRANSISTOR, 50A 450V 2
R5,8 095 240 RESISTOR, WW fxd 50W 35 ohm 2
SRi 126242 RECTIFIER, integ 100A800V 1
TP1 604 515 •THERMOSTAT,NC 1
119978 BUS BAR, interconnecting 2
127852 •H~TSINK 1
127882 MODULE, diode (consisting of) 1
C9,1O 098 325 • CAPACITOR, poly film .027uf 630V 2
D2 118 541 DIODE, fast recovery 200A 200V 1
D3,4 093 056 DIODE, fast recovery 40A 600V 2
R9 098 324 RESISTOR, WW fxd 25W 5 ohm 1
127851 •H~TSINK 1

R9

04

TB-124 57$-A

FIgure 2. Module, Diode/Transistor

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
TM-292 Page 38