Gold Star Series: 302, 452, 652 (60 HZ), 402, 602, 852 (50/60 HZ)

TM-222J September 1999
Eff. w/ Serial Number KE752773
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Flux Cored (FCAW) Welding
Air Plasma Cutting

and Gouging
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Arc Welding Power Source
Gold Star Series
302, 452, 652 (60 Hz), 402, 602, 852 (50/60 Hz)
Visit our website at

www.Miller-
Welds.com
TABLE OF CONTENTS
1. Safety Precautions – Read Before Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. General Precautionary Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Input Connection Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-3. Electric Shock And Airflow Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-4. Nameplate Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-5. Manufacturer’s Rating Labels For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-6. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-7. 115 VAC Receptacle And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-8. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-9. Remote 14 Receptacle And Terminal Strip 1T Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-10.Connecting Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-11.Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-12.Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-13.Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-1. Controls (Non CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-2. Controls (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-2. Troubleshooting Circuit Diagram For Welding Power Source (All Models) . . . . . . . . . . . . . . . . 22
6-3. Waveforms For Section 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-4. Control Board PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-5. Control Board PC1 Test Point Values (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-6. Optional Digital Meter Board PC2 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-7. Optional Digital Meter Board PC2 Test Point Values (All Models) . . . . . . . . . . . . . . . . . . . . . . . 30
6-8. Digital Meter Calibration (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-9. Input Voltage Labels And Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7-2. Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 8 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION 9 – PARTS LIST FOR KE752773 Thru K129841 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
SECTION 10 – PARTS LIST FOR KK129842 And Following . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
TM-222J
Declaration of Conformity For
European Community (CE) Products
NOTE This information is provided for units with CE certification (see rating label on unit.)
Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street
Appleton, WI 54914 USA
Declares that the product: Goldstar 402, 602, And 852

conforms to the following Directives and Standards:
Directives
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1

(April 1995 – Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:

Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:

EN50199: August 1995
European Contact: Mr. Luigi Vacchini, Managing Director

MILLER Europe S.P.A.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
Telephone: 39(02)98290-1
Fax: 39(02)98281-552
dec_con1 10/95
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
OM-___ - Date, safety_stm 5/97
Means Warning! Watch Out! There are possible

hazards with this procedure! The possible hazards are
shown in the adjoining symbols.
This group of symbols means Warning! Watch Out! possible

Y Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
. Means “Note”; not safety related. actions to avoid the hazards.
1-2. Servicing Hazards

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

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

D Do not place unit on, over, or near combustible D Keep away from moving parts such as fans.
surfaces. D Keep all doors, panels, covers, and guards
D Do not service unit near flammables. closed and securely in place.
Gold Star Series TM-222 Page 1

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

D Use MILLER Testing Booklet (Part No. 150
D Allow cooling period; follow rated duty cycle.
853) when servicing this unit.
D Reduce current or reduce duty cycle before
D Consult the Owner’s Manual for welding
starting to weld again.
safety precautions.
D Do not block or filter airflow to unit.
D Use only genuine MILLER replacement parts.
1-3. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from opera-
committee’s judgment, has not demonstrated that exposure to power- tor as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as
examined. Until the final conclusions of the research are reached, you possible.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.
TM-222 Page 2 Gold Star Series

SECTION 2 – DEFINITIONS
2-1. General Precautionary Label
1/96
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1 Electric shock from welding
electrode or wiring can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet
or damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or
power before working on
machine.
1 1.1 1.2 1.3
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
2 2.1 2.2 2.3 fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Do not weld near
flammables.
3.2 Welding sparks can cause
3 3.1 3.2 3.3 fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4 4.1 4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
+ + + helmet with correct shade of

filter. Wear complete body
protection.
5 Become trained and read the
instructions before working
5 6 on the machine or welding.
6 Do not remove or paint over
+ (cover) the label.
S-176 254-A

2-2. Input Connection Label
1 2 3 4 1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Electric shock from wiring
can kill.
3 Disconnect input plug or
power before working on
machine.
4 Read the Owner’s Manual
before working on this
machine.
5 Consult rating label for input
1 2 3 ? V power requirements, and
check power available at the
job site – they must match.
6 Read Owner’s Manual and
? V inside labels for connection
ÍÍÍ
points and procedures.
? A 7 Move jumper links as shown
ÍÍÍ
5
on inside label to match
ÍÍÍ ÍÍÍ
voltage at job site.
3 8 Having a loop of extra length,
ÍÍÍ
connect grounding conductor
4 first.
S-179 290 9 Connect line input conductors
as shown on inside label –
double-check all connections,
jumper link positions, and
input voltage before applying
5 6 7 8 9 power.
1/96
2-3. Electric Shock And Airflow Label

1 2 3 1 Warning! Watch Out! There
and exposed weld terminals
can kill.
3 Close door before turning on
S-179 563 unit.
1/96
2-4. Nameplate Safety Symbols

1 Warning! Watch Out! There
1 1 2 Electric shock from welding
electrode or wiring can kill.
3 Sparks from arcing electrode
can cause explosion or fire –
disconnect cable for process
not in use.
4 Read Owner’s Manual for
connection procedures.
can kill.
6 Disconnect input power
5 6
before working on unit or
2 3 4
making terminal strip
connections.
Nameplate D-179 389

2-5. Manufacturer’s Rating Labels For CE Products
. Match label to one on

unit. See Section 3-4.

2-6. Symbols And Definitions
Note Some symbols are found only on CE products.
A Amperes
Amperage Control/
Panel
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
Do Not Switch
Temperature Arc Force (DIG) Percent
While Welding
Output Circuit Breaker Remote V Volts
Protective Earth
Positive Negative Input
(Ground)
On Off Hz Hertz Direct Current
U0 Rated No Load
Voltage (Average) U1 Primary Voltage
U2 Conventional Load
Voltage
Line Connection
Three-Phase
I1 Primary Current
I2 Rated Welding
Current X Duty Cycle Transformer
Rectifier
IP Degree Of
Protection
Three-Phase
S1 KVA Work Connection
Electrode
Wire Feeder
Connection

SECTION 3 – INSTALLATION
3-1. Specifications
Rated Maximum Amperes Input at Rated Load Output, 50 or 60 Hz,

Amp Open- IP Three-Phase
Model Welding
Range DC Circuit Rating
Output 200 V 230 V 380 V 400 V 440 V 460 V 575 V KVA KW
Voltage DC
300 A @
300 32 Volts 72 70 61 35 33 31 31 25 24.5 13.8
15 – 395 21M
Amp DC, 60% (70) 4.0* 3.6* 1.1* 1.1* 1.0* 3.1* 1.5* 1.3* 0.67*
Duty Cycle
450 A @
450 38 Volts 72 102 89 54 51 47 45 36 35.5 23.3
20 – 590 21M
Amp DC, 60% (70) 3.5* 3.1* 1.5* 1.4* 1.2* 1.5* 1.2* 1.2* 0.51*
Duty Cycle
650 A @
650 44 Volts 72 124 75 71 65 62 50 49.4 36
50 – 850 21M ––
Amp DC, 60% (70) 5.2* 1.7* 1.6* 1.5* 2.6* 2.1* 2.1* 0.58*
Duty Cycle
*While idling
( ) Indicates specification differences for CE models
3-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
Example: 60% Duty Cycle =
6 Minutes Welding 4 Minutes Resting
Overheating
0 A
15
OR
Minutes Reduce Duty Cycle duty1 4/95 / Ref. SA-168 919

3-3. Volt-Ampere Curves
Volt-ampere curves show mini-
mum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall
A. 300 Amp Model between curves shown.
B. 450 Amp Model
C. 650 Amp Model
va_curve1 – 4/95 – SA-171 221 / SA-171 222 / SA-171 223

3-4. Selecting A Location
1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
If using lifting forks, extend forks
Movement beyond opposite side of unit.
1 3 Rating Label (Non CE
Models Only)
Use rating label to determine input
power needs. Label located under
front access door.
OR 4 Plate Label (CE Models Only)
2 Label located under front access
door.
5 Rating Label (CE Models
Only)
Location And Airflow
6 Use rating label to determine input
power needs. Label located on
rear access door (see Section
3 2-5).
6 Line Disconnect Device
Locate unit near correct input pow-
er supply.
18 in
Y Special installation may be
(460 mm)
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
4 Section 20.
18 in
(460 mm)
3-5. Dimensions And Weights

Dimensions
Height 27-1/4 in (692 mm)
C
D Width 22-1/4 in (565 mm)
E
4 Holes Depth* 35-3/4 in (908 mm)
A** 35 in (889 mm)
B*** 1-1/4 in (32 mm)
C 21 in (533 mm)
D 1-3/16 in (30 mm)
A E 7/16 in (11 mm) Dia
*300 Amp Model = 28-1/4 in (718 mm)
**300 Amp Model = 27-1/2 in (699 mm)
***300 Amp Model = 3/4 in (19 mm)
Weight
300 Amp 352 lb (160 kg)
450 Amp 404 lb (183 kg)
B Ref. ST-153 556-A 650 Amp 505 lb (299 kg)

3-6. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.
3-7. 115 VAC Receptacle And Circuit Breakers

Y Turn Off power before
connecting to receptacle.
1 115 V 15 A AC Receptacle
RC9
Power is shared between RC9 and
Remote 14 receptacle RC8 or
terminal strip 1T (see Section
3 3-10).
2 Circuit Breaker CB1
2 3 Circuit Breaker CB2
CB1 protects 115 volts ac portion
of RC8, 1T, and RC9 from
overload.
1 CB2 protects 24 volts ac portion of
RC8 and 1T from overload.
Press button to reset breaker.
Ref. ST-800 101-C

3-8. Weld Output Terminals And Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Turn Off power before 10 – 60%

Welding 60 – 100%
connecting to weld output Duty 10 – 100% Duty Cycle
Amperes Duty Cycle
terminals Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

Electrode Work
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0
800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D
3-9. Remote 14 Receptacle And Terminal Strip 1T Information
Socket Terminal Information
A A 24 volts ac. Protected by circuit breaker CB2.

24 VOLTS AC
B B Contact closure to A completes 24 volts ac contactor control circuit.
C C Command reference; 0 to +10 volts dc.
REMOTE OUTPUT CONTROL D D Remote control circuit common.
E E 0 to +10 volts dc input command signal from remote control.
F * Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
H * Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.
I I 115 volts, 15 amperes, 60 Hz ac. Protected by circuit breaker CB1.

115 VOLTS AC
J J Contact closure to I completes 115 volts ac contactor control circuit.
K K Chassis common.
GND
G * Circuit common for 24 and 115 volts ac circuits.
* L
REMOTE POWER ON/OFF To remote On/Off switch.
* M
* N Voltage sensing signal from Negative (-) weld output terminal.

REMOTE VOLTAGE SENSING
* P Voltage sensing signal from Positive (+) weld output terminal.
* Not Used

3-10. Connecting Remote Control
1 Remote 14 Receptacle RC8
Connect remote control to RC8. If
plug does not fit, wire cord to termi-
nal strip 1T.
Y Turn Off power before
opening terminal strip
OR OR cover.
2 Terminal Strip 1T
3 Remote Control Cord
4 Strain Relief (Customer
Supplied)
Secure cord in strain relief. Rein-
stall and secure access panel.
Close door.
A J
K I
B
C L N H
D M G
E F
C E D I J A B N P K M L
REMOTE 115 VAC 24VAC REMOTE GND REMOTE

OUTPUT REMOTE REMOTE VOLTAGE POWER ON/OFF
CONTROL CONTACTOR CONTACTOR SENSE
S-162 895-B
Ref. ST-800 898 / Ref. S-0004-A / Ref. ST-800 451-B

3-11. Electrical Service Guide
60 Hertz Models 300 Amp Model 450 Amp Model 650 Amp Model
Input Voltage 200 230 460 575 200 230 460 575 230 460 575
Input Amperes At Rated Output 71 61 31 25 102 89 45 36 124 62 50
Max Recommended Standard Fuse

Or Circuit Breaker Rating In Am- 110 90 45 35 150 125 70 50 175 90 70
peres
Min Input Conductor Size In AWG/

6 8 10 12 4 4 8 10 3 8 8
Kcmil
Max Recommended Input Conductor 129 114 308 296 118 156 276 290 125 182 284
Length In Feet (Meters) (39) (35) (94) (90) (36) (47) (84) (88) (38) (55) (86)
Min Grounding Conductor Size In

6 8 10 12 6 6 8 10 6 8 8
AWG/Kcmil
Reference: 1996 National Electrical Code (NEC) S-0092-J
50 Hertz Models 300 Amp Model 450 Amp Model 650 Amp Model
Input Voltage 380 400 440 380 400 440 380 400 440
Input Amperes At Rated Output 35 33 31 54 51 47 75 71 65
Max Recommended Standard Fuse Or Circuit

60 50 50 80 80 70 125 110 100
Breaker Rating In Amperes
Min Input Conductor Size In AWG/Kcmil 10 10 10 8 8 8 6 6 6
Max Recommended Input Conductor Length 210 233 282 188 209 253 189 210 254
In Feet (Meters) (64) (71) (86) (57) (64) (77) (58) (64) (77)
Min Grounding Conductor Size In AWG/

10 10 10 8 8 8 6 6 8
Kcmil
Reference: 1996 National Electrical Code (NEC) S-0092-J

3-12. Placing Jumper Links
Check input voltage available at
site.
1 Jumper Link Label
Check label – only one is on unit.
2 Jumper Links
Move jumper links to match input
voltage.
Close access door, or go on to
Section 3-13.
200 VOLTS 230 VOLTS 460 VOLTS
Ref. S-174 976-A
230 VOLTS 460 VOLTS 575 VOLTS
Ref. S-174 973-A

1
220 VOLTS 380 VOLTS 400 VOLTS 440 VOLTS
(FACTORY OPTION) Ref. S-174 975-A
Tools Needed:
3/8 in Do not overtighten

jumper link nuts.
3/8 in
Ref. ST-800 103-A

3-13. Connecting Input Power
1 Input And Grounding
Conductors
See Section 3-11.
2 Line Disconnect Device
See Section 3-11.
3 Reed Switch (Ground
2 Current Sensor) (Optional)
4 Grounding Conductor
If unit is equipped with optional
ground current sensor, route
grounding conductor through reed
switch two times and connect to
ground terminal.
Close access door.
L1 (U)
L2 (V)
L3 (W)
Connect GND/PE 1
Conductor First.
IMPORTANT
3
Input Contactor
4 L1 (U)
L2 (V)
L3 (W)
GND/ Connect GND/PE

PE Conductor First.
Tools Needed:
3/8 in
3/8 in
ST-800 103-A / Ref. ST-801 116

SECTION 4 – OPERATION
4-1. Controls (Non CE Models)
300 Amp Model Shown
1 2 3 4 5
9 8 7 6
Ref. ST-165 596-B
short arc length without sticking the electrode. 8 Remote Amperage Control Switch
1 Polarity Selector Switch (Optional On Set control at 0 for normal welding amperage. For front panel control, place switch in Panel
50 Hz Models) Turn clockwise to increase short-circuit position. For remote control, place switch in
To change polarity on models not equipped amperage. Remote position, and connect remote device
with a Polarity Selector switch, reverse work (see Section 3-10).
3 Hot Start Switch
and electrode cables at the weld output termi- 9 Output Switch (Contactor)
nals (see Section 3-8). Turn switch On for SMAW and Off for GTAW
welding. For front panel control of output, place switch
Y Turn Off Power before reversing in Panel position. For remote control of out-
cables. 4 Amperage Adjustment Control
put, place switch in Remote position, and con-
2 Arc Force (Dig) Control 5 Digital Meters (Optional) nect remote device (see Section 3-10).
Control increases SMAW short-circuit amper- 6 Power Switch With Indicator Light Y Turn Off power before connecting re-
age which allows the operator to use a very 7 High Temperature Shutdown Light mote device.

4-2. Controls (CE Models)
300 Amp Model Shown
1 2 3 4 5
9 8 7 6
Ref. ST-173 450

very short arc length without sticking the elec- 8 Remote Amperage Control Switch
1 Polarity Selector Switch (Optional On trode.
For front panel control, place switch in Panel
50 Hz Models) Set control at 0 for normal welding amperage. position. For remote control, place switch in
To change polarity on models not equipped Turn clockwise to increase short-circuit Remote position, and connect remote device
with a Polarity Selector switch, reverse work amperage. (see Section 3-10).
and electrode cables at the weld output termi- 3 Hot Start Switch 9 Output Switch (Contactor)
nals (see Section 3-8). Turn switch On for SMAW and Off for GTAW
For front panel control of output, place switch
Y Turn Off Power before reversing welding.
in Panel position. For remote control of out-
cables. 4 Amperage Adjustment Control put, place switch in Remote position, and
2 Arc Force (Dig) Control 5 Digital Meters (Optional) connect remote device (see Section 3-10).
Control increases SMAW short-circuit 6 Power Switch With Indicator Light Y Turn Off power before connecting re-
amperage which allows the operator to use a 7 High Temperature Shutdown Light mote device.

SECTION 5 – THEORY OF OPERATION
1 Input Terminal Board TE1 3
Provides means for operation on Fan Motor
different input voltages. FM
2 Line Contactor W
Connects line input power to main ♦CR3
transformer T1.
3 Fan Motor FM 1 3φ 4 230 VAC 3φ
Provides cooling of internal com- Three-Phase W
ponents when TP4, TP5, or TP6 Input Main
Line Input Terminal Transformer
opens thereby deenergizing CR3. Power W Board TE1 T1
4 Main Transformer T1 Primary Secondary
Supplies power to weld output cir- W
cuit, control board PC1, other con- 6
trol circuits, and fan motor FM.
Fuse 1φ 1φ 3φ
5 Control Transformer T2 F1 Synchronization
Signal
Supplies power to contactor W cir-
cuit and fan-on-demand control 5 7 3
relay CR3. Power
Control Switch S2, Thermostats
6 Fuse F1 Transformer TP4, TP5,
T2 Pilot Light TP6
Protects T2 from overload. PL1
7 Power Switch S2, Pilot Light
PL1 2 3
Provides on/off control of welding Control
Contactor Relay
power source. W
8 CR3
8 115 VAC Duplex Receptacle
RC9 115 VAC
Duplex
Connects auxiliary equipment to Receptacle
welding power source. RC9
9 Remote 14 Receptacle RC8 10
9
Connects remote amperage and 115 VAC Circuit
contactor controls. Breaker
CB1
10 Circuit Breaker CB1
Provides overload protection for 11
115 volts ac portion of Remote 14
receptacle RC8 or terminal strip 1T 24 VAC Circuit
and 115 volts ac duplex receptacle Breaker
CB2 36 VAC
RC9. Center-
11 Circuit Breaker CB2 Tapped
Provides overload protection for 24 +10 VDC Output 13
volts ac portion of Remote 14 re- Command Voltage
ceptacle RC8 or terminal strip 1T.
Remote 14 14
12 Contactor Control Relay CR1 Receptacle
Provides means for remote con- RC8 Amperage
tactor switch to turn on and off weld Or Adjustment
output. Terminal Control R1 Control
Strip Board
13 Control Board PC1 1T PC1
9♦ 15
Controls weld output by changing
the SCR gate pulses (conduction Remote Remote
times) after comparing voltage Amperage Amperage
Control Control
feedback to selected voltage Switch S4
signal.
Uses current feedback signal for 9♦ 16 17
foldback circuit to prevent SCR fail-
Remote 24 VAC Arc Force
ure caused by sustained short- Contactor Hot Start (Dig) Control
circuit conditions. Switch Switch S1 R2
14 Amperage Adjustment
Control R1 9♦ 12
Selects weld output amperage
Remote 115 VAC Contactor
level. Contactor Control
Switch Relay CR1

15 Remote Amperage Control
24 25 26 27 Switch S4
Hall Device Electrode Selects front panel or remote
HD1 Stabilizer Weld Output amperage control.
Z1 Terminal 16 Hot Start Switch S1
Provides on/off control of start
22 amperage.
23 17 Arc Force (Dig) Control R2
Polarity Electrode
Main Burden Selector Sets amount of Dig amperage in
Rectifier Resistor Switch SMAW mode.
SR1 R3 S5
Work 18 Thermostats TP1, TP2, TP3
If unit overheats, TP1, TP2, and/or
27 TP3 open stopping all weld output.
Work 19 Output Switch S3
Weld Output
Terminal Selects On or Remote contactor
control.
20 High Temperature Shutdown
Light PL2
Indicates overheated condition
which causes output shutdown.
21 Digital Meter Board PC2
Displays the rectified and filtered
values of the voltage and current.
22 Main Rectifier SR1
Changes the ac output from T1 to
full-wave rectified dc.
23 Burden Resistor R3
SCR Current Voltage Provides a path for a minimum
Gating Feedback Feedback SCR holding current to flow.
Signals Signal Signal
24 Hall Device HD1
Provides current feedback signal
to PC1.
25 Stabilizer Z1
Smooths weld output current.
26 Polarity Selector Switch S5
Selects output polarity of weld
output terminals for welding
process.
21 ♦
27 Electrode And Work Weld
Digital Output Terminals
Meter
Board PC2 Provide weld output.
20
High
Temperature
Shutdown
Light PL2
18
Thermostats
TP1, TP2,
TP3 AC Or DC Control Circuits
19
Weld Current Circuit
Output
Switch S3 External Circuits
3φ Power
CR1
♦ Optional Or Not Supplied

SECTION 6 – TROUBLESHOOTING
6-1. Troubleshooting Table
. See Section 6-2 for test points and values and

Section 9 and following for parts location.
. Use MILLER Testing Booklet (Part No. 150 853)

when servicing this unit.
Trouble Remedy
No weld output; unit completely Place line disconnect device in On position (see Section 3-13).
inoperative.
Check for open line fuse(s), and replace if necessary, or reset circuit breaker (see Section 3-13).
Check for proper input power connections (see Section 3-13).
Check for proper jumper link position (see Section 3-12).
Check fuse F1, and replace if necessary (see Section 7-2).
Check continuity of Power switch S2, and replace if necessary.
Check coil voltage and connections of contactor W. Check continuity of coil and condition of
contacts. Replace W if necessary.
Check control transformer T2 for signs of winding failure. Check continuity across windings, and
check for proper connections. Check secondary voltage. Replace T2 if necessary.
No weld output; pilot light PL1 On; fan Unit overheated. Allow unit to cool with fan On (see Section 3-2).
motor FM On.
If using remote control, place Output switch S3 in Remote 14 position, and connect remote control
to either Remote 14 receptacle RC8 or terminal strip 1T (see Sections 3-9 and 3-10). If remote is
not being used, place Output switch S3 in On position.
Check, repair, or replace remote control.
Check continuity of Output switch S3, and replace if necessary.
Prior to Serial No. KH544879, check coil voltage and connections of contactor control relay CR1.
Check continuity of coil and condition of contacts. Replace CR1 if necessary.
Check coil voltage and connections of contactor W. Check continuity of coil and condition of
contacts. Replace W if necessary.
Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, check ca-
pacitors C7 through C12 for a short or open, and check for proper connections. Replace C7 through
C12 if necessary.
Check main transformer T1 for signs of winding failure. Check continuity across windings, and check
for proper connections. Check secondary voltages. Replace T1 if necessary.
Check control board PC1 and connections, and replace if necessary (see Section 6-4).
Limited weld output and low Check position of Remote Amperage Control switch S4 (see Section 4).
open-circuit voltage.
Check for open line fuse(s), and replace if necessary, or reset circuit breaker (see Section 3-13).
Check for proper input power connections (see Section 3-13).
Check for proper jumper link position (see Section 3-12).
Clean and tighten all weld output connections.
Check continuity of Remote Amperage Control switch S4, and replace if necessary.
Check resistance and connections of Amperage Adjustment control R1; R1 is 0 to 1000 ohms
±10%. Replace R1 if necessary.
C12 if necessary.
Check main transformer T1 for signs of winding failure. Check continuity across windings, and
check for proper connections. Check secondary voltages. Replace T1 if necessary.

Trouble Remedy
Unit provides only maximum or Check position of Remote Amperage Control switch S4 (see Section 4).
minimum weld output.
Check continuity of Remote Amperage Control switch S4, and replace if necessary.
Check resistance and connections of Amperage Adjustment control R1; R1 is 0 to 1000 ohms
±10%. Replace R1 if necessary.
Prior to Serial No. KG283595, check resistance and connections of hall device HD1; HD1 is 1600
ohms ±10% between pins 1 and 3 of plug PLG14. Check input and output voltages. Replace HD1 if
necessary. Effective with Serial No. KG283595, check input and output voltages of HD1. Replace
HD1 if necessary.
Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-8).
Clean and tighten all input and output connections.
Check position of Polarity selector switch S5 (see Section 4).
Check resistance and connections of resistor R3; R3 is 20 ohms ±10%. Replace R3 if necessary.
Check stabilizer Z1 for signs of winding failure. Check continuity across winding, and check for
proper connections. Replace Z1 if necessary.
C12 if necessary.
Check main transformer T1 for signs of winding failure. Check continuity across windings, and check
for proper connections. Check secondary voltages. Replace T1 if necessary.
Prior to Serial No. KG283595, check resistance and connections of hall device HD1; HD1 is 1600
ohms ±10% between pins 1 and 3 of plug PLG14. Check input and output voltages. Replace HD1 if
necessary. Effective with Serial No. KG283595, check input and output voltages of HD1. Replace
HD1 if necessary.
No 115 volts ac output at duplex re- Reset circuit breaker CB1 (see Section 3-7).
ceptacle RC9, Remote 14 receptacle
RC8, or terminal strip 1T. Check wiring of 115 volts ac duplex receptacle RC9, Remote 14 receptacle RC8 and terminal strip
1T. Repair or replace if necessary.
No 24 volts ac output at Remote 14 Reset circuit breaker CB2 (see Section 3-7).
receptacle RC8 or terminal strip 1T.
Check wiring of Remote 14 receptacle RC8 and terminal strip 1T. Repair or replace if necessary.
Fan motor FM not operating properly. Check and clear blocked fan blade.
Check coil voltage and connections of fan motor FM, and replace if necessary.
Check coil voltage and connections of control relay CR3. Check continuity of coil and condition of
contacts. Replace CR3 if necessary.
Check continuity of thermostats TP4, TP5, and TP6. Replace TP4, TP5, and TP6 if necessary.
Wandering arc; poor control of arc Use proper size tungsten.

direction.
Use properly prepared tungsten.
Reduce gas flow rate.
Tungsten electrode oxidizing and not Shield weld zone from drafts.
remaining bright after conclusion of
weld. Increase postflow time.
Check and tighten all gas fittings.
Water in torch. Refer to torch manual.
Optional digital meter not working Check optional digital meter board PC2 and connections, and replace if necessary (see Section
properly. 6-6).
Readings on optional digital meter not Calibrate optional digital meter board PC2 (see Section 6-8).
accurate.

6-2. Troubleshooting Circuit Diagram For Welding Power Source (All Models)
Voltage Readings
a) Tolerance – ±10% unless
specified
b) Reference – to circuit
common (lead 43) unless
noted
c) Wiring Diagram – see
Section 8
See Section 3-13 R1 R1
V1 230 volts ac when TP4, for TE1 information
TP5, or TP6 opens See Section 6-3
V2, V3, 54 volts ac for waveform G
V4
V2
V5, V6, 32 volts ac
V7 V1
V8, V9 18 volts ac V3
V10 115 volts ac
G G
V11, V12, 24 volts ac Ground Current
V13, V14 Sense Control
Relay CR4
V15 24 volts ac with TP4,
TP5, and TP6 closed V4
G G
V16 +15 volts dc
V17 +1 volts dc per 100
amperes of weld output
V18 –15 volts dc V5
V19 +10 volts dc
V20 69 volts dc OCV with V6
S1 Off
71 volts dc OCV with
S1 On V7
V10
V8
V9
V14
V11
Pilot Light
PL1
V12
See Section 3-9 V13

for RC8 information
Ground Current
Fan-On-Demand Sense Control
Control V15 Relay CR5
Relay CR3

Test Equipment Needed: Resistance Values
a) Tolerance – ±10% unless specified
b) Turn Off unit and disconnect input
power before checking resistance
R1 All values for T1 are less than 1 ohm
R2 Less than 1 ohm
R3 Less than 1 ohm
See Section 6-6

for PC2 data and
Section 6-8 for
calibration
V16 R2
V18
V17 R3
V22, A thru F
See Section 6-3

for waveforms
A thru F
G
G
High Temperature
Shutdown Light
PL2
See Section 6-4

for PC1 data
V19
See Section 3-9

for 1T information
See Section 3-9

for RC8 information
SC-188 103-A

6-3. Waveforms For Section 6-2
Waveforms shown are for 60 Hertz models;

waveforms for 50 Hertz models are similar.
Waveforms For Model 302

2 ms 50 V 2 ms 50 V
gnd gnd
A. CC/DC Open-Circuit Voltage, Amperage B. CC/DC Mid-Range, 28 Volts DC, 200

Adjustment Control R1 At Maximum Amperes (Resistive Load)

2 ms 50 V 2 ms 50 V
gnd gnd
C. CC/DC Open-Circuit Voltage, Amperage D. CC/DC Mid-Range, 32 Volts DC, 300 Amperes
Adjustment Control R1 At Maximum (Resistive Load)

2 ms 50 V 2 ms 50 V
gnd gnd
E. CC/DC Open-Circuit Voltage, Amperage F. CC/DC Mid-Range, 36 Volts DC, 400

Adjustment Control R1 At Maximum Amperes (Resistive Load)
5 ms 2 V
gnd
G. SCR Gate Pulses With Respect To Cathode

At No Load, Amperage Adjustment Control
R1 At Maximum
Test Equipment Needed:

6-4. Control Board PC1 Testing Information
Be sure plugs are secure before
Models 452 And 602 Illustrated testing. See Section 6-5 for
specific values during testing.
1 Control Board PC1
2 Receptacle RC1
3 Receptacle RC3
4 Receptacle RC4
1 5 5 Receptacle RC5
2 4
ST-801 063 / SB-186 941-B

6-5. Control Board PC1 Test Point Values (All Models)
specified
PC1 Voltage Readings
b) Reference – to circuit common
(lead 43) unless noted
Receptacle Pin Value

RC1 1 Reference for gate pulse to SCR2
2 Gate pulse to SCR2 with respect to pin 1 (see Section 6-3)
3 Reference for gate pulse to SCR5
RC3 1 Not used
2 +24 volts dc output
3 Prior to Serial No. KG283595, +24 volts dc output to hall device HD1; effective with Serial No.
KG283595 thru KH537910, not used; effective with Serial No. KH537911, 115 volts ac input contact
closure signal
4 18 volts ac input
5 Current feedback: prior to Serial No. KG283595, +1.6 volts dc input per 100 amperes of weld out-
put; effective with Serial No. KG283595, +1 volt dc input per 100 amperes of weld output
6 Not used
7 Circuit common
8 18 volts ac input
9 Not used; effective with Serial No. KH537911, 24 volts ac input contact closure signal
10 Prior to Serial No. KG283595, not used; effective with Serial No. KG283595, +15 volts dc output
11 Prior to Serial No. KG283595, not used; effective with Serial No. KG283595, –15 volts dc output
13 Not used
14 Hot start select input, +24 volts dc input with Hot Start switch S1 in Off position, 0 volts dc input with
S1 in On position
15 32 volts ac input for synchronization
18 Voltage feedback input with respect to pin 19, same as OCV or load voltage
19 Voltage feedback input with respect to pin 18, same as OCV or load voltage
20 Not used

RC4 1 +24 volts dc output
3 Not used
5 Contactor control signal, +15 volts dc output with Output switch S3 in Remote position, 0 volts dc
output with S3 in Panel position
6 Voltage feedback to digital voltmeter, +1 volt dc output per 10 volts of weld output
7 Command reference, 0 to +10 volts dc output from min to max of Amperage Adjustment control R1
with Remote Amperage Control switch S4 in Panel position or 0 to +10 volts dc output from min to
max of remote amperage control with S4 in Remote position
8 Current feedback to digital ammeter, +1 volt dc output per 100 amperes of weld output
9 Not used
10 Not used
RC5 1 Command reference, 0 to +10 volts dc input from min to max of Amperage Adjustment control R1
2 Remote command reference, 0 to +10 volts dc output from min to max of Amperage Adjustment
control R1
3 Contactor control signal, +15 volts dc input with Output switch S3 in Remote position, 0 volts dc
input with S3 in Panel position
4 Circuit common
5 Not used
6 Dig wiper, 0 to +12 volts dc input from min to max of Arc Force (Dig) control R2 with Output (Con-
tactor) switch S3 in Remote position
7 Command reference, 0 to +10 volts dc input from min to max of Amperage Adjustment control R1
with Remote Amperage Control switch S4 in Panel position or 0 to +10 volts dc input from min to
8 Thermal overload, +0.8 volts dc output with high temperature shutdown light PL2 Off, +2 volts dc
output with PL2 On
9 Thermal overload, 0 volts dc with high temperature shutdown light PL2 Off, +15 volts dc with PL2
On
10 Voltage feedback, +1 volt dc output per 10 volts of weld output
11 Dig reference, +12.8 volts dc output with Output switch S3 in Remote position
12 Not used
13 Not used
14 Current feedback, +1 volt dc output per 100 amperes of weld output
15 Not used

6-6. Optional Digital Meter Board PC2 Testing Information
testing. See Section 6-7 for
specific values during testing.
2 Receptacle RC10
3 Receptacle RC11
. See Section 6-8 for digital
meter calibration.
2 3
ST-801 063 / SA-158 792-C

6-7. Optional Digital Meter Board PC2 Test Point Values (All Models)

specified
PC2 Voltage Readings
b) Reference – to circuit common
(lead 43) unless noted
RC10 1 +24 volts dc input
2 Circuit common (lead 43)
3 Not used
4 +15 volts dc input
RC11 1 Command reference, 0 to +10 volts dc input from min to max of Amperage Adjustment control R1
with Remote Amperage Control switch S4 in Panel position or 0 to +10 volts dc input from min to
2 Contactor control signal, +15 volts dc input with Output switch S3 in Remote position, 0 volts dc
input with S3 in Panel position
3 Not used
5 Jumpered to RC11-6
6 Jumpered to RC11-5
7 Not used
8 Current feedback, +1 volt dc input per 100 amperes of weld output
9 Voltage feedback, +1 volt dc input per 10 volts of weld output
10 Not used

6-8. Digital Meter Calibration (All Models)
calibrating meters.
1 Digital Ammeter
2 Digital Voltmeter
Step 3. Adjust R36 for voltmeter Step 4. Adjust R6 for voltage

offset or zero gain to match external
calibrated meter using
load bank set at desired load
Top View Top View

Step 1. Adjust R3 for ammeter
R36 R6 offset or zero
Top View
00.0 00.0 R3
Volts (±0.5)
Volts
2 1
000
Amperes (±2)
Top View
R4 3
000
Amperes
Step 2. Adjust R4 for amperage

gain to match external
calibrated meter using
load bank set at desired
3 load
ST-801 063 / SA-158 792-C

6-9. Input Voltage Labels And Connection Diagrams
Test Equipment Needed: 1 Input Voltage Label And
Connection Diagram
Only one label is on unit.
2 Input Terminal Board TE1
ST-800 104-A / SA-164 171 / SA-168 938 / SA-171 173-A

SECTION 7 – MAINTENANCE
7-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Repair or Clean and

Replace
replace tighten weld
unreadable
cracked terminals.
labels.
weld cable.
6 Months
Blow out or
vacuum inside.
During heavy OR
service, clean monthly.
7-2. Fuse F1
Y Turn Off power before open-
ing rear access door.
1 Fuse F1 (See Parts List For
1 Rating)
Fuse F1 protects control trans-
former from overload. If F1 opens,
weld output and fan motor stops.
Replace F1.
Tools Needed:
3/8 in
Ref. ST-800 101-C

SECTION 8 – ELECTRICAL DIAGRAMS
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model Serial Or Style Number Circuit Diagram Wiring Diagram
Gold Star 302, 402 KE752773 thru KF894169 SC-169 335 D-166 353-C♦♦
KF894170 thru KG283594 SC-175 486 D-175 716♦♦
KG283595 thru KH537588 SC-184 397 SD-184 398♦♦
KH537589 and following SC-188 103-A SD-188 104-A
Gold Star 452, 602 KE752773 thru KF894169 SC-158 980-D D-166 009-C♦♦
KF894170 thru KG283594 SC-175 486 D-175 717♦♦
KG283595 thru KH537588 SC-184 397 SD-184 399♦♦
KH537589 and following SC-188 103-A SD-188 105-A
Gold Star 652, 852 KE752773 thru KF894169 SC-158 980-D D-166 010-C♦♦
KF894170 thru KG283594 SC-175 486 D-175 718♦♦
KG283595 thru KH537588 SC-184 397 SD-184 400♦♦
KH537589 and following SC-188 103-A SD-188106-A
Circuit Board PC1 KE752773 thru KG283594 D-158 761-A♦♦

Gold Star 302, 402
KG283595 thru KH559962 SD-184 389♦♦
KH559963 and following SD-187 827-A
Circuit Board PC1 KE752773 thru KG283594 D-172 184♦♦

Gold Star 452, 602
KG283595 thru KH544878 SD-184 390♦♦
Circuit Board PC1 KE752773 thru KG283594 D-165 907-B♦♦

Gold Star 652, 852
KG283595 thru KH549224 SD-184 391♦♦
Circuit Board PC2♦ KE752773 and following SD-158 796-A
♦ Optional
♦♦ Not included in this manual

For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside wrapper of welding power source.
SC-169 335
Figure 8-1. Circuit Diagram For Gold Star 302 And 402 Effective With Serial No. KE752773 Thru KF894169
SC-158 980-D
Figure 8-2. Circuit Diagram For Gold Star 452, 602, 652, And 852
Effective With Serial No. KE752773 Thru KF894169
SC-175 486
Figure 8-3. Circuit Diagram For Gold Star Series Effective With Serial No. KF894170 Thru KG283594
SC-184 397
Figure 8-4. Circuit Diagram For Gold Star Series Effective With Serial No. KG283595 Thru KH537588
SC-188 103-A
Figure 8-5. Circuit Diagram For Gold Star Series Effective With Serial No. KH537589 And Following
Figure 8-6. Wiring Diagram For Gold Star 302 And 402 Effective With Serial No. KH537589 And Following
SD-188 104-A

SD-188 105-A

SD-188 106-A

Figure 8-9. Circuit Diagram For Control Board PC1 For Gold Star 302 And 402
Effective With Serial No. KH559963 And Following
SD-187 827-A

SD-186 939-A

SD-187 829-A

Figure 8-12. Circuit Diagram For Optional Digital Meter Board PC2 Effective With
Serial No. KE752773 And Following
SD-158 796-A

Notes

TM-222J September 1999
Processes
TIG (GTAW) Welding
Air Plasma Cutting

and Gouging
Air Carbon Arc (CAC-A) Cut-
ting and Gouging
Description
Gold Star Series
Eff w/KE752773 Thru KK129841

For OM-222 (164 850) Thru Revision N

www.Miller-
Welds.com 302, 452, 652 (60 Hz), 402, 602, 852 (50/60 Hz)
SECTION 9 – PARTS LIST FOR KE752773 Thru KK129841
22
. Hardware is common and
20
21
not available unless listed.
Fig 9-5
18
19
3
16 17
14
15
9
13
10
4
12
11
8
7
6
23
5
25
26
24
4
1
27
Fig 9-2
28
Fig 9-3&4
29
22
ST-800 875-C
Figure 9-1. Main Assembly

Quantity
Item Dia. Part Model
No. Mkgs. No. Description 302 452 652
. . . 1 . . . . . . . . . . . . +168 792 .. PANEL, side (Prior to KG062845) . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 1 . . . . . . . . . . . . +179 430 .. PANEL, side (Eff w/KG062845) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 1 . . . . . . . . . . . . +168 805 .. PANEL, side (Prior to KG062845) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 1 . . . . . . . . . . . . +179 432 .. PANEL, side (Eff w/KG062845) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 2 . . . . . . . . . . . . . 162 806 .. COVER, top (Prior to KG062845) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 179 429 .. COVER, top (Eff w/KG062845) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 162 803 .. COVER, top (Prior to KG062845) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 2 . . . . . . . . . . . . . 179 431 .. COVER, top (Eff w/KG062845) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 3 . . . . . . . . . . . . . 164 699 .. BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 3 . . . . . . . . . . . . . 164 700 .. BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 162 816 .. CHANNEL, upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 . . . 4
. . . 5 . . . . . . . . . . . . . 162 820 .. BAR, mtg lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . 6 . . . . . . . . . . . . . 162 830 .. LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 7 . . . . . . . . . . . . . 177 279 .. GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 8 . . . . . . . . . . . . . 604 536 .. SCREW, .312-18 x 1.75 hexhd-pln gr 5 . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . . . . . . . . . . . . . . . . . 134 201 .. STAND-OFF SUPPORT, PC card .312/.375
(Prior to KG283595) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 . . . 4
. . . 9 . . . . . . . . . . . . . 162 821 . . BRACKET, mtg LEM (Prior to KG283595) . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 9 . . . . . . . . . . . . . 173 605 . . BRACKET, mtg LEM (Eff w/KG283595) . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 10 . . . . HD1 . . . . 156 313 . . TRANSDUCER, current 300A module (Prior to KG283595) . . 1 . . . 1
. . . 10 . . . . HD1 . . . . 148 417 . . TRANSDUCER, current 1000A module (Prior to KG283595) . . . . . . . . . . . . 1
. . . 10 . . . . HD1 . . . . 168 829 . . TRANSDUCER, current 1000A module (Eff w/KG283595) . . . 1 . . . 1 . . . 1
. . . . . . . . . PLG14 . . 130 204 . . CONNECTOR & SOCKETS, (Prior to KG283595) . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . PLG14 . . 182 363 . . CONNECTOR & SOCKETS, (Eff w/KG283595) . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 11 . . . . . Z1 . . . . 165 612 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . Z1 . . . . 165 613 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . Z1 . . . . 173 559 . . STABILIZER, (Prior to KG087909) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . Z1 . . . . 180 064 . . STABILIZER, (Eff w/KG087909) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 164 717 . . BUS BAR, stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . C21-23 . . 163 906 . . CAPACITOR, (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 . . . 3
. . . 12 . . . C21-23 . . 179 904 . . CAPACITOR, (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 . . . 3
. . . 13 . . . . . T2 . . . . 159 042 . . TRANSFORMER, control 50VA 24V 230/460/575 (60Hz) . . . 1 . . . 1 . . . 1
. . . 13 . . . . . T2 . . . . 159 041 . . TRANSFORMER, control 50VA 24V 200/230/460 (60Hz) . . . . . . . . . 1
. . . 13 . . . . . T2 . . . . 159 043 . . TRANSFORMER, control 50VA 24V (50Hz) . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 14 . . . . TE1 . . . . 159 244 . . PRIMARY BOX, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 15 . . . . . . . . . . . . . 601 835 . . . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . . 16 . . . . . . . . . . . . . 038 887 . . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . . . . . . . . . . . . . . . . . . 010 913 . . WASHER, flat .218 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . . . . . . . . . . . . . . . . . . 601 835 . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . . . . . . . . . . . . . . . . . . 038 618 . . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . 8 . . . 8
. . . 17 . . . . . . . . . . . . . 159 034 . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 18 . . . . . . . . . . . Figure 9-5 . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 19 . . . . . F1 . . . *156 065 . . FUSE, crtg .5A 600V time delay . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 20 . . . . . W . . . . . 160 760 . . CONTACTOR, def prp 40A 3P 24VAC . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . W . . . . . 160 793 . . CONTACTOR, def prp 60A 3P 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . W . . . . . 160 794 . . CONTACTOR, def prp 75A 3P 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . CR4 . . ♦140 750 . . SWITCH, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 22 . . . . . . . . . . . . . 134 464 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . 23 . . . . . . . . . . . . . 163 533 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 163 359 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 24 . . . . . T1 . . . . 165 719 . . TRANSFORMER, pwr main 200/230/460 (Prior to KJ148978)
(consisting of) .... 1
. . . 24 . . . . . T1 . . . . 189 850 . . TRANSFORMER, pwr main 200/230/460 (Eff w/KJ148978)
(consisting of) .... 1
. . . 25 . . . . . . . . . . . . . 165 234 . . . . COIL, pri/sec 200/230/460 (center & RH) . . . . . . . . . . . . . . . . 2
Quantity
Figure 9-1. Main Assembly (Continued)
. . . 26 . . . . . . . . . . . . . 165 235 . . . . COIL, pri/sec 200/230/460 (LH) . . . . . . . . . . . . . . . . . . . . . . . . 1

(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 172 208 . . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . T1 . . . 189 853 . . TRANSFORMER, pwr main 200/230/46 (Eff w/KJ148978)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 165 232 . . . . COIL, pri/sec 200/230/460 (center & RH) . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 165 233 . . . . COIL, pri/sec 200/230/460 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 172 214 . . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 172 221 . . . . COIL, pri/sec 230/460/575 (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 172 220 . . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 172 404 . . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 172 405 . . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 172 410 . . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 172 409 . . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 172 416 . . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 172 415 . . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . TP1,2 . . . 119 581 . . THERMOSTAT, NC (Included w/T1) . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . . . . . . . PLG13 . . 169 242 . . CONNECTOR & PINS (Prior to KJ148978) . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . PLG13 . . 189 873 . . CONNECTOR & PINS (Eff w/KJ148978) . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . PLG6 . . . 168 847 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . RC6 . . . . 168 845 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 27 . . . . . . . . . . . . . 161 294 . . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2

Quantity
. . . 28 . . . . . . . . . . . Figure 9-2 .. PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1

. . . 29 . . . . SR1 . . . . 175 070 .. RECTIFIER, si diode (Figure 9-3) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . SR1 . . . . 175 071 .. RECTIFIER, SCR main (Figure 9-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . SR1 . . . . 175 072 .. RECTIFIER, SCR main (Figure 9-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG7 . . . 152 249 .. CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . RC7 . . . . 168 846 .. CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦Part of Option 042 983 Ground Current Sensor
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Quantity
Figure 9-2. Panel, Front w/Components (Figure 9-1 Item 28)
... 1 . . . . . S5 . . ♦169 331 .. SWITCH, mode polarity (single deck) . . . . . . . . . . . . . . . . . . . . . 1

... 1 . . . . . S5 . . ♦169 332 .. SWITCH, mode polarity (double deck) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
... 2 . . . . PC1 . . . . 176 555 .. CIRCUIT CARD, control (60Hz) (Prior to KG283595) . . . . . . . 1
... 2 . . . . PC1 . . . . 184 383 .. CIRCUIT CARD, control (60Hz)
(Eff w/KG283595 thru KH544878) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 187 822 . . CIRCUIT CARD, control (60Hz) (Eff w/ KH544879 and on) . . 1
. . . 2 . . . . PC1 . . . . 176 559 . . CIRCUIT CARD, control (60Hz) (Prior to KG283595) . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 184 385 . . CIRCUIT CARD, control (60Hz)
(Eff w/KG283595 thru KH544878) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 186 937 . . CIRCUIT CARD, control (60Hz) (Eff w/KH544879 and on) . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 176 563 . . CIRCUIT CARD, control (60Hz) (Prior to KG283595) . . . . . . . . . . . . . . . . . . 1
(Eff w/KG283595 thru KH544878) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 187 825 . . CIRCUIT CARD, control (60Hz) (Eff w/KH544879 and on) . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 176 556 . . CIRCUIT CARD, control (50Hz) (Prior to KG283595) . . . . . . . 1
(Eff w/KG283595 thru KH544878) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 187 823 . . CIRCUIT CARD, control (50Hz) (Eff w/KH544879 and on) . . . 1
. . . 2 . . . . PC1 . . . . 176 560 . . CIRCUIT CARD, control (50Hz) (Prior to KG283595) . . . . . . . . . . . . . 1
(Eff w/KG283595 thru KH544878) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 187 824 . . CIRCUIT CARD, control (50Hz) (Eff w/KH544879 and on) . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 176 564 . . CIRCUIT CARD, control (50Hz) (Prior to KG283595) . . . . . . . . . . . . . . . . . . 1
(Eff w/KG283595 thru KH544878) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 187 826 . . CIRCUIT CARD, control (50Hz) (Eff w/KH544879 and on) . . . . . . . . . . . . . . 1
1 5
8
6 7
2
9 10
3
11
12
10
24
31
23 22 20
21
24
19 13
18
30
17
14
15
29 25 16
28
27 26
ST-800 876-B
Figure 9-2. Panel, Front w/Components (452 Model Illustrated)

Quantity
Figure 9-2. Panel, Front w/Components
(Figure 9-1 Item 28) (Continued)
. . . . . . . . . PLG1 . . . 158 720 . . CONNECTOR & SOCKETS, (see Figure 9-3 & Figure 9-4)
. . . 3 . . . . CR3 . . . . 006 393 . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 4 . . . . CR5 . ♦♦006 393 . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 5 . . . CB1,2 . . . 093 995 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . 2 . . . 2 . . . 2
. . . 6 . . . . RC9 . . . . 604 176 . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 7 . . RC8, C3,
6,13,14 . . 163 855 . . CONNECTOR/CAPACITOR, w/leads . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 8 . . . . . . . . . . . . . 162 802 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 9 . . . . POS . . . 039 047 . . TERMINAL, pwr output red (Prior to KG177710) . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 9 . . . . POS . . . 181 245 . . TERMINAL, pwr output red (Eff w/KG177710) . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 10 . . . . C4,5 . . . 128 750 . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . 11 . . . . . . . . . . . . . 161 303 . . SPRING, cprsn .600 OD x .072 wire x 1.500 lg . . . . . . . . . . . . 3 . . . 3 . . . 3
. . . 12 . . . . R4,5 . . . 136 076 . . RESISTOR, WW fxd 30W 200 ohm . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . 13 . . . . NEG . . . 039 046 . . TERMINAL, pwr output black (Prior to KG177710) . . . . . . . . . 1 . . . 1 . . . 1
. . . 13 . . . . NEG . . . 181 246 . . TERMINAL, pwr output black (Eff w/KG177710) . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 14 . . . . . . . . . . . . +162 512 . . PLATE, control lower (Prior to KF840452) . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . +162 513 . . PLATE, control lower (Prior to KF840452) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . +162 514 . . PLATE, control lower (Prior to KF840452) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 174 939 . . PLATE, control lower (60Hz) (Eff w/KF840452) . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 14 . . . . . . . . . . . . . 179 387 . . PLATE, control lower (50Hz) (Eff w/KF840452) . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 15 . . . . . 1T . . . . 159 040 . . BLOCK, term 20A 12P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 16 . . . . . . . . . . . . . 162 828 . . PANEL, mtg rcpt/terminal strip . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 17 . . . . . . . . . . . . . 162 891 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 18 . . . . . . . . . . . . +172 587 . . COVER, stud output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 19 . . . . . . . . . . . . . 160 935 . . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 . . . 3
. . . 20 . . . . . . . . . . . . . 601 835 . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . . . . . . . . . . . . . . . . . 010 913 . . WASHER, flat .218 ID x .460 OD x .031thk brs . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 21 . . . . . . . . . . . . . 159 863 . . ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 22 . . . . . . . . . . . . . 038 887 . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 23 . . . S1,3,4 . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 . . . 3
. . . 24 . . . . R1,2 . . . 035 897 . . POTENTIOMETER, CP std slot 1/T 2W 1K ohm . . . . . . . . . . . 2 . . . 2 . . . 2
. . . . . . . . . . CR1 . . . . 134 163 . . RELAY, encl 24/120VAC DPDT (Prior to KH544879) . . . . . . . . 1 . . . 1 . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . 1 . . . 1 . . . 1
. . . 26 . . . . . S2 . . . . 159 039 . . SWITCH, rocker SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . PLG2 . . . 185 626 . . CONNECTOR, body 56 series . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 27 . . . . PL2 . . . . 159 522 . . LED, yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 28 . . . . . . . . . . . . . 159 036 . . LENS, LED clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 29 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 30 . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 31 . . . . . . . . . . . ♦148 956 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . . . . . ♦♦♦043 812 . . DIGITAL METER KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . PC2 . . . . 158 791 . . . . CIRCUIT CARD, digital meter . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . PLG4,11 . . 148 439 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . . . . . . . PLG10 . . 153 501 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . . . . . . . . . . 165 316 . . . . STAND-OFF, No. 6-32 x .875 lg (Prior to KJ209453) . . . . . . 4 . . . 4 . . . 4
. . . . . . . . . . . . . . . . . . . 192 174 . . . . STAND-OFF (Eff w/KJ209453) . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 . . . 4
♦Standard w/60 Hz/Optional w/50 Hz
♦♦Part of Option 042 983 Ground Current Sensor
♦♦♦Optional
Item Dia. Part
No. Mkgs. No. Description Quantity
SR1 Figure 9-3. Rectifier, Si Diode (302 Model) (Figure 9-1 Item 29)
. . . 1 . . . . C7-12 . . . . 031 688 .. CAPACITOR, cer disc .01uf 1000VDC (Prior to KF997417) . . . . . . . . . . 6
. . . 1 . . . . C7-12 . . . . 048 420 .. CAPACITOR, cer disc .01uf 1000VDC (Eff w/KF997417) . . . . . . . . . . . . 6
... 2 ............... 162 826 .. HEAT SINK, rect (Prior to KF997417) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 2 ............... 177 316 .. HEAT SINK, rect (Eff w/KF997417) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 3 ............... 162 825 .. HEAT SINK, rect (Prior to KF997417) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 ............... 177 317 .. HEAT SINK, rect (Eff w/KF997417) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 ............... 083 884 .. CLAMP, thyristor rectifier 4.250 (Prior to KF997417) . . . . . . . . . . . . . . . . 3
... 4 ............... 166 667 .. CLAMP, thyristor rectifier (Eff w/KF997417) . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . . TP3 . . . . . 181 782 .. THERMOSTAT, NC (Prior to KH544917) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . TP3 . . . . . 185 679 .. THERMOSTAT, NC (Eff w/ KH544917) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . TP6 . . . . . 168 898 .. THERMOSTAT, NC (Prior to KH544917) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . TP6 . . . . . 185 680 .. THERMOSTAT, NC (Eff w/ KH544917) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . SCR1-6 . . . 161 668 .. THYRISTOR, SCR 300A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . . 6
... 8 ............... 188 692 .. CLAMP, thyristor rectifier (Eff w/KF997417) . . . . . . . . . . . . . . . . . . . . . . . . 3
..................... 028 516 .. PIN, spring CS .125 x .250 (Prior to KF997417) . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . PLG1 . . . . 158 720 .. CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4
3
5
1 2
ST-800 697-C
Figure 9-3. Rectifier, Si Diode SR1 (302 Model)

2
3
ST-800 696-A
Figure 9-4. Rectifier, SCR Main SR1 (452 & 652 Models)
Item Dia. Part

Figure 9-4. Rectifier, SCR Main (452 & 652 Models)
SR1 452 652
(Figure 9-1 Item 29)
. . . 1 . . . . C7-12 . . . . 151 880 . . CAPACITOR, cer disc .01uf 1000VDC (Prior to KF970957) . . . . . 6 . . . . 6
. . . 1 . . . . C7-12 . . . . 048 420 . . CAPACITOR, cer disc .01uf 1000VDC (Eff w/KF970957) . . . . . . . 6 . . . . 6
. . . 2 . . . . . . . . . . . . . . . 164 634 . . BUS BAR, rectifier (Prior to KF970957) . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 2 . . . . . . . . . . . . . . . 176 168 . . BAR, mtg rectifier (Eff w/KF970957) . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . . . . . . . . . . . . . . . . . . . 161 089 . . BAR, clamp rectifier (Prior to KF970957) . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 3 . . . . . . . . . . . . . . . 082 694 . . CLAMP, thyristor rectifier 5.500 (Prior to KF970957) . . . . . . . . . . . 3 . . . . 3
. . . 3 . . . . . . . . . . . . . . . 166 667 . . CLAMP, spring thyristor rectifier (Eff w/KF970957) . . . . . . . . . . . . . 3 . . . . 3
. . . 4 . . . . . . . . . . . . . . . 160 962 . . HEAT SINK, rectifier snowflake .800 . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . 6
. . . 5 . . . SCR1-6 . . . 161 668 . . THYRISTOR, SCR 300A 300V hockey puck . . . . . . . . . . . . . . . . . . 6
. . . 5 . . . SCR1-6 . . . 148 091 . . THYRISTOR, SCR 865A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 6 . . . . . . . . . . . . . . . 160 961 . . HEAT SINK, rectifier snowflake 1.600 . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3
. . . 7 . . . . . . . . . . . . . . . 188 691 . . CLAMP, thyristor rectifier (Eff w/KF970957) . . . . . . . . . . . . . . . . . . . 3 . . . . 3
. . . . . . . . . . PLG1 . . . . 158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . TP3 . . . . . 168 895 . . THERMOSTAT, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1

Item Dia. Part

Figure 9-5. Panel, Rear w/Components (Figure 9-1 Item 18)
. . . 1 . . . . . . . . . . . . . . . 124 275 .. CHAMBER, plenum 14 in (Prior to KF970957) . . . . . . . . . . . . . . . . . . . . . 1

. . . 1 . . . . . . . . . . . . . . . 173 283 .. CHAMBER, plenum 14 in (Eff w/KF970957) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 180 165 .. BLADE, fan 14 in 3wg 28deg .375 bore CCW . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 162 807 .. PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 168 343 .. HINGE, door primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . +162 818 .. DOOR, access primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 168 384 .. LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 179 290 .. LABEL, warning electric shock (CE models only) . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 602 177 .. SCREW, set .250-20 x .250knrlpt sch stl . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . 124 274 .. BRACKET, mtg fan motor (Eff w/KF970957) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . R3 . . . . . . 097 459 .. RESISTOR, WW fxd 375W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . FM . . . . . 116 190 .. MOTOR, 1/12HP 230V 1550RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 010 467 .. CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3
4
5
6
2
1
10 9
ST-800 707-A
Figure 9-5. Panel, Rear w/Components

TM-222J September1999
Processes
TIG (GTAW) Welding
Air Plasma Cutting

and Gouging
Air Carbon Arc (CAC-A) Cut-
ting and Gouging
Description
Gold Star Series

Eff w/KK129842 And Following
For OM-222 (164 850) Revision P

www.Miller-
Welds.com 302, 452, 652 (60 Hz), 402, 602, 852 (50/60 Hz)
SECTION 10 – PARTS LIST FOR KK129842 And Following
22
18 (Fig.10-5)
21
20
19
3
16 17
14
15
13
12
9
4
10
11
7
8
6
23
5
25
26
24
4
2
27
28 (Fig.10-2)
1
29 (Fig.10-3 & 4)
22
ST-800 875-D
Figure 10-1. Main Assembly (452 Model Illustrated)

Quantity
. . . 1 . . . . . . . . . . . . +179 430 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 1 . . . . . . . . . . . . +179 432 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 2 . . . . . . . . . . . . . 179 429 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 179 431 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 3 . . . . . . . . . . . . . 164 699 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 3 . . . . . . . . . . . . . 164 700 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 162 816 . . CHANNEL, upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 4 . . . 4
. . . 5 . . . . . . . . . . . . . 162 820 . . BAR, mtg lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . 6 . . . . . . . . . . . . . 162 830 . . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 7 . . . . . . . . . . . . . 177 279 . . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 8 . . . . . . . . . . . . . 604 536 . . SCREW, .312-18 x 1.75 hexhd-pln gr 5 . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . 9 . . . . . . . . . . . . . 173 605 . . BRACKET, mtg LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 10 . . . . HD1 . . . . 168 829 . . TRANSDUCER, current 300A module . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . PLG14 . . 182 363 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 11 . . . . . Z1 . . . . 165 612 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . Z1 . . . . 165 613 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . Z1 . . . . 180 064 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 164 717 . . BUS BAR, stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . C21-23 . . 163 906 . . CAPACITOR, 60 and 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3 . . . 3
. . . 13 . . . . . T2 . . . . 159 042 . . TRANSFORMER, control 50VA 24V 230/460/575 (60Hz) . . . 1 . . . 1 . . . 1
. . . 13 . . . . . T2 . . . . 159 041 . . TRANSFORMER, control 50VA 24V 200/230/460 (60Hz) . . . . . . . . . 1
. . . 13 . . . . . T2 . . . . 159 043 . . TRANSFORMER, control 50VA 24V (50Hz) . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 14 . . . . TE1 . . . . 159 244 . . PRIMARY BOX, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 15 . . . . . . . . . . . . . 601 835 . . . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . . 16 . . . . . . . . . . . . . 038 887 . . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . . . . . . . . . . . . . . . . . . 010 913 . . WASHER, flat .218 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . . . . . . . . . . . . . . . . . . 601 835 . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . 24 . . 24
. . . . . . . . . . . . . . . . . . . 038 618 . . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . 8 . . . 8
. . . 17 . . . . . . . . . . . . . 159 034 . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 18 . . . . . . . . . . Figure 10-5 . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 19 . . . . . F1 . . . *156 065 . . FUSE, crtg .5A 600V time delay . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 20 . . . . . W . . . . . 160 760 . . CONTACTOR, def prp 40A 3P 24VAC . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . W . . . . . 160 793 . . CONTACTOR, def prp 60A 3P 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . W . . . . . 160 794 . . CONTACTOR, def prp 75A 3P 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . CR4 . . ♦140 750 . . SWITCH, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 22 . . . . . . . . . . . . . 134 464 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . 23 . . . . . . . . . . . . . 163 533 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 163 359 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 24 . . . . . T1 . . . . 189 850 . . TRANSFORMER, pwr main 200/230/460 (consisting of) . . . . 1
. . . 25 . . . . . . . . . . . . . 165 234 . . . . COIL, pri/sec 200/230/460 (center & RH) . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 165 235 . . . . COIL, pri/sec 200/230/460 (LH) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 172 208 . . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . T1 . . . . 189 853 . . TRANSFORMER, pwr main 200/230/460 (consisting of) . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 165 233 . . . . COIL, pri/sec 200/230/460 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 172 214 . . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . T1 . . . . 189 856 . . TRANSFORMER, pwr main 230/460/575 (consisting of) . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 172 221 . . . . COIL, pri/sec 230/460/575 (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 172 220 . . . . COIL, pri/sec 230/460/575 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Quantity

. . . 25 . . . . . . . . . . . . . 172 404 . . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 172 405 . . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 172 410 . . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 172 409 . . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . T1 . . . . 189 858 . . TRANSFORMER, pwr main 380/400/440 (consisting of) . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 172 416 . . . . COIL, pri/sec (center & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . 172 415 . . . . COIL, pri/sec (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . 189 873 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . RC6 . . . . 168 845 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 27 . . . . . . . . . . . . . 161 294 . . BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2 . . . 2
. . . 28 . . . . . . . . . . Figure 10-2 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 29 . . . . SR1 . . . . 175 070 . . RECTIFIER, si diode (Figure 10-3) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . SR1 . . . . 192 672 . . RECTIFIER, SCR main (Figure 10-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . SR1 . . . . 192 671 . . RECTIFIER, SCR main (Figure 10-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG7 . . . 152 249 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . RC7 . . . . 168 846 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . . . . . . . . . . 010 467 . . CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
*Recommended Spare Parts.
♦Part of Option 042 983 Ground Current Sensor
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Quantity
. . . 1 . . . . . S5 . . ♦169 331 . . SWITCH, mode polarity (single deck) . . . . . . . . . . . . . . . . . . . . . 1

. . . 1 . . . . . S5 . . ♦169 332 . . SWITCH, mode polarity (double deck) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 2 . . . . PC1 . . . . 187 822 . . CIRCUIT CARD, control (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 186 937 . . CIRCUIT CARD, control (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 187 825 . . CIRCUIT CARD, control (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 187 823 . . CIRCUIT CARD, control (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 187 824 . . CIRCUIT CARD, control (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . PC1 . . . . 187 826 . . CIRCUIT CARD, control (50HZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG1 . . . 158 720 . . CONNECTOR & SOCKETS, (see Figure 10-3 & Figure 10-4)
. . . . . . . . . PLG3 . . . 169 240 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . 20 . . 20 . . 20
. . . . . . . . . PLG5 . . . 152 249 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . 15 . . 15 . . 15
. . . 3 . . . . CR3 . . . . 006 393 . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 4 . . . . CR5 . ♦♦006 393 . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 5 . . . CB1,2 . . . 093 995 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . 2 . . . 2 . . . 2
. . . 6 . . . . RC9 . . . . 604 176 . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 7 . . . . . . . . . . . . . 163 855 . . CONNECTOR/CAPACITOR, w/leads (consisting of) . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . RC8 . . . . 143 976 . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . . . . . . . . . . 079 534 . . . . . CONNECTOR, circ skt push-in 14-18ga . . . . . . . . . . . . . . 14 . . 14 . . 14
. . . . . . . . . . . C3 . . . . 163 863 . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . . C6 . . . . 163 861 . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . C13 . . . . 163 858 . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . . . . . . . . C14 . . . . 163 857 . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
. . . 8 . . . . . . . . . . . . . 162 802 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1
1 5
8
6 7
2
9 10
3
11
12
10
24
31
23 22 20
21
24
19 13
18
30
17
14
15
29 16
25
28 ST-800 876-B
27 26
Figure 10-2. Panel, Front w/Components (452 Model Illustrated)

Quantity
(Continued)
. . . 9 . . . . POS . . . 181 245 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1

. . . 10 . . . . C4,5 . . . 128 750 . . CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . 2 ... 2 ... 2
. . . 11 . . . . . . . . . . . . . 161 303 . . SPRING, cprsn .600 OD x .072 wire x 1.500 lg . . . . . . . . . . . . 3 ... 3 ... 3
. . . 12 . . . . R4,5 . . . 136 076 . . RESISTOR, WW fxd 30W 200 ohm . . . . . . . . . . . . . . . . . . . . . . 2 ... 2 ... 2
. . . 13 . . . . NEG . . . 181 246 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 14 . . . . . . . . . . . . . 174 939 . . PLATE, control lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 15 . . . . . 1T . . . . 159 040 . . BLOCK, term 20A 12P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 16 . . . . . . . . . . . . . 162 828 . . PANEL, mtg rcpt/terminal strip . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 17 . . . . . . . . . . . . . 162 891 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 18 . . . . . . . . . . . . +172 587 . . COVER, stud output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 19 . . . . . . . . . . . . . 160 935 . . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ... 3 ... 3
. . . 20 . . . . . . . . . . . . . 601 835 . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ... 2 ... 2
. . . . . . . . . . . . . . . . . . . 010 913 . . WASHER, flat .218 ID x .460 OD x .031thk brs . . . . . . . . . . . . 1 ... 1 ... 1
. . . 21 . . . . . . . . . . . . . 159 863 . . ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 22 . . . . . . . . . . . . . 038 887 . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 23 . . . S1,3,4 . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . 3 ... 3 ... 3
. . . 24 . . . . R1,2 . . . 035 897 . . POTENTIOMETER, CP std slot 1/T 2W 1K ohm . . . . . . . . . . . 2 ... 2 ... 2
. . . 25 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . 1 ... 1 ... 1
. . . 26 . . . . . S2 . . . . 159 039 . . SWITCH, rocker SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . . . . . . . PLG2 . . . 185 626 . . CONNECTOR, body 56 series . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 27 . . . . PL2 . . . . 159 522 . . LED, yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 28 . . . . . . . . . . . . . 159 036 . . LENS, LED clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 29 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 30 . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . 31 . . . . . . . . . . . ♦148 956 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . . . . . . . . . . . . ♦♦♦043 812 . . DIGITAL METER KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . . . . . . . . PC2 . . . . 158 791 . . . . CIRCUIT CARD, digital meter . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . . . . . . PLG4,11 . . 148 439 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ... 2 ... 2
. . . . . . . . . PLG10 . . 153 501 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ... 1 ... 1
. . . . . . . . . . . . . . . . . . . 192 174 . . . . STAND-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ... 4 ... 4
♦Standard w/60 Hz/Optional w/50 Hz

♦♦Part of Option 042 983 Ground Current Sensor
♦♦♦Optional

Item Dia. Part

SR1 175 070 Figure 10-3. Rectifier, Si Diode (302 Model) (Figure 10-1 Item 29)
. . . 1 . . . . C7-12 . . . . 048 420 .. CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

... 2 ............... 177 316 .. HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 3 ............... 177 317 .. HEAT SINK, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 ............... 166 667 .. CLAMP, thyristor rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . . TP3 . . . . . 185 679 .. THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . TP6 . . . . . 185 680 .. THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . SCR1-6 . . . 161 668 .. THYRISTOR, SCR 300A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . PLG1 . . . . 158 720 .. CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 ............... 188 692 .. CLAMP, thyristor rectifier 4.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4
3
5
1 2
7 2 3
ST-800 697-C
8
Figure 10-3. Rectifier, Si Diode SR1 (302 Model)
4
5

6 ST-802 351
Figure 10-4. Rectifier, SCR Main SR1 (452 & 652 Model)
Item Dia. Part

Figure 10-4. Rectifier, SCR Main (452 & 652 Model)
SR1 192 672 192 671
(Figure 10-1 Item 29)
. . . 1 . . . . C7-12 . . . . 048 420 . . CAPACITOR, cer disc .01uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . 6
. . . 2 . . . . . . . . . . . . . . . 191 989 . . BAR, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . 3 . . . . . . . . . . . . . . . 188 691 . . CLAMP, thyristor rectifier 5.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3
. . . 4 . . . . . . . . . . . . . . . 188 839 . . HEAT SINK, rectifier snowflake .800 . . . . . . . . . . . . . . . . . . . . . . . . 12 . . 12
. . . 5 . . . SCR1-6 . . . 161 668 . . THYRISTOR, SCR 300A 300V hockey puck . . . . . . . . . . . . . . . . . . 6
. . . 5 . . . SCR1-6 . . . 148 091 . . THYRISTOR, SCR 865A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 6 . . . . . . . . . . . . . . . 166 667 . . CLAMP, spring thyristor rectifier 5.500 . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3
. . . . . . . . . . PLG1 . . . . 158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Item Dia. Part

Figure 10-5. Panel, Rear w/Components (Figure 10-1 Item 18)
. . . 1 . . . . . . . . . . . . . . . 173 283 .. CHAMBER, plenum 14 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . 180 165 .. BLADE, fan 14 in 3wg 23deg .375 bore CCW . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 162 807 .. PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 168 343 .. HINGE, door primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . +162 818 .. DOOR, access primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 168 384 .. LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 602 177 .. SCREW, set .250-20 x .250knrlpt sch stl . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . 124 274 .. BRACKET, mtg fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . R3 . . . . . . 097 459 .. RESISTOR, WW fxd 375W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . FM . . . . . 116 190 .. MOTOR, 1/12HP 230V 1550RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 010 467 .. CONNECTOR, clamp cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3
. Hardware is common and 4
not available unless listed. 5
6
2
1
10 9
ST-800 707-A
Figure 10-5. Panel, Rear w/Components

Notes
Notes
Notes
Call
1-800-4-A-
MILLER
for your local
Miller distribu-
tor.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
Phone: 920-735-4505
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1625-525556
FAX: 44 (0) 1625-537553
PRINTED IN USA  1998 Miller Electric Mfg. Co.

Gold Star Series: 302, 452, 652 (60 HZ), 402, 602, 852 (50/60 HZ)

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Copyright:

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Gold Star Series: 302, 452, 652 (60 HZ), 402, 602, 852 (50/60 HZ)

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TM-222J September 1999

Eff. w/ Serial Number KE752773

Stick (SMAW) Welding

Flux Cored (FCAW) Welding

Air Plasma Cutting

Arc Welding Power Source

Gold Star Series

Visit our website at

Manufacturer’s Name: Miller Electric Mfg. Co.

Declares that the product: Goldstar 402, 602, And 852

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Low Voltage Directive: 73/23/EEC

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC

Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990

Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1

Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989

Insulation coordination for equipment within low-voltage systems:

Electromagnetic compatibility (EMC) Product standard for arc welding equipment:

European Contact: Mr. Luigi Vacchini, Managing Director

Means Warning! Watch Out! There are possible

This group of symbols means Warning! Watch Out! possible

1-2. Servicing Hazards

HOT PARTS can cause severe burns.

FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

Gold Star Series TM-222 Page 1

OVERUSE can cause OVERHEATING. READ INSTRUCTIONS.

1-3. EMF Information

TM-222 Page 2 Gold Star Series

+ + + helmet with correct shade of

Gold Star Series TM-222 Page 3

2-3. Electric Shock And Airflow Label

2-4. Nameplate Safety Symbols

Nameplate D-179 389

TM-222 Page 4 Gold Star Series

. Match label to one on

Gold Star Series TM-222 Page 5

Note Some symbols are found only on CE products.

Output Circuit Breaker Remote V Volts

On Off Hz Hertz Direct Current

TM-222 Page 6 Gold Star Series

Rated Maximum Amperes Input at Rated Load Output, 50 or 60 Hz,

3-2. Duty Cycle And Overheating

Example: 60% Duty Cycle =

6 Minutes Welding 4 Minutes Resting

Gold Star Series TM-222 Page 7

B. 450 Amp Model

C. 650 Amp Model

va_curve1 – 4/95 – SA-171 221 / SA-171 222 / SA-171 223

TM-222 Page 8 Gold Star Series

3-5. Dimensions And Weights

Gold Star Series TM-222 Page 9

3-7. 115 VAC Receptacle And Circuit Breakers

Ref. ST-800 101-C

TM-222 Page 10 Gold Star Series

Total Cable (Copper) Length In Weld Circuit Not Exceeding

150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

Turn Off power before 10 – 60%

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

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

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

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0