Miller Electric Syncrowave 250 Technical Manual 120626

TM-353E January 2001
Eff. w/Serial Number JJ339876
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
Syncrowave 250
60 Hz, 50 Hz
Visit our website at

www.MillerWelds.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. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-5. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-7. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-8. Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . 10
3-10.Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-11.Placing Jumper Links And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-2. Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-3. Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-4. Crater Time Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-5. Spot Time Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-6. AC Balance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-7. Amperage Adjustment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-8. Output (Contactor) Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-9. Arc Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-10.Postflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-11.High Frequency Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-12.Preflow Time Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 5 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-2. Troubleshooting Circuit Diagram For Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-3. Waveforms For Section 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-4. Control Board PC1 Testing Information (Use With Section 6-5) . . . . . . . . . . . . . . . . . . . . . . . . 30
6-5. Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-6. Remote Board PC2 Testing Information (Use With Section 6-7) . . . . . . . . . . . . . . . . . . . . . . . . 33
6-7. Remote 14 Filter Board PC2 Test Point Values (Use With Section 6-2 And Section 6-6) . . . . 34
6-8. Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-9. Input Voltage Labels And Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-3. Fuses F1 And F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-4. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECTION 8 – HIGH FREQUENCY (HF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-1. Welding Processes Using HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-2. Sources Of HF Radiation From Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 10 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
TM-353D
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: Syncrowave 250

conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Electromagnetic Capability Directives: 89/336, 92/31/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
safety_stm1 4/95
1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this Y Marks a special safety message.
procedure! The possible hazards are shown in the adjoining symbols. . Means NOTE; not safety related.
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to
avoid the hazards.
1-2. Servicing Hazards
WARNING
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.
Only qualified persons should service, test, maintain, and repair this unit.
During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill. HOT PARTS can cause severe burns.
1. Do not touch live electrical parts.
1. Do not touch hot parts bare handed.
2. Stop engine or turn OFF welding power source and
wire feeder, and disconnect and lockout input 2. Allow cooling period before servicing welding gun
power using line disconnect switch, circuit or torch.
breakers, or by removing plug from receptacle
before servicing unless the procedure specifically
requires an energized unit.
3. Insulate yourself from ground by standing or
EXPLODING PARTS can cause injury.
working on dry insulating mats big enough to 1. Failed parts can explode or cause other parts to
prevent contact with the ground. explode when power is applied to inverters.
4. Do not leave live unit unattended.
2. Always wear a face shield and long sleeves when
5. When testing a live unit, use the one-hand method.
servicing inverters.
Do not put both hands inside unit. Keep one hand
free.
ELECTRIC SHOCK HAZARD from
6. Disconnect input power conductors from
deenergized supply line BEFORE moving a
incorrect use of test equipment.
welding power source. 1. Turn Off welding power source and wire feeder or
SIGNIFICANT DC VOLTAGE exists after stop engine before making or changing meter lead
connections.
removal of input power on inverters.
7. Turn Off inverter, disconnect input power, and 2. At least one meter lead should be a self-retaining
discharge input capacitors according to spring clip such as an alligator clamp.
instructions in Maintenance Section before
touching any parts. 3. Read instructions for test equipment.
STATIC ELECTRICITY can damage HIGH-FREQUENCY RADIATION can

parts on circuit boards. interfere with radio navigation, safety
1. Put on grounded wrist strap BEFORE handling services, computers, and
boards or parts. communications equipment.
2. Use proper static-proof bags to store, move, or ship
PC boards. 1. Have only qualified persons familiar with electronic
equipment perform this installation.
FIRE OR EXPLOSION can result from
placing unit on, over, or near 2. The user is responsible for having a qualified
combustible surfaces. electrician promptly correct any interference
problem resulting from the installation.
1. Do not place unit on, over, or near combustible
surfaces. 3. If notified by the FCC about interference, stop using
2. Do not service unit near flammables. the equipment at once.
FLYING PIECES OF METAL or DIRT can 4. Have the installation regularly checked and
injure eyes. maintained.
1. Wear safety glasses with side shields or face shield 5. Keep high-frequency source doors and panels
during servicing. tightly shut, keep spark gaps at correct setting, and
2. Be careful not to short metal tools, parts, or wires use grounding and shielding to minimize the
together during testing and servicing. possibility of interference.
Syncrowave 250 TM-353 Page 1

FALLING EQUIPMENT can cause MOVING PARTS can cause injury.
serious personal injury and equipment 1. Keep away from moving parts.
damage. 2. Keep away from pinch points such as drive rolls.
1. Use lifting eye to lift unit only, NOT running gear,
OVERUSE can cause OVERHEATED
gas cylinders, or any other accessories.
EQUIPMENT.
2. Use equipment of adequate capacity to lift unit.
1. Allow cooling period.
MAGNETIC FIELDS FROM HIGH 2. Reduce current or reduce duty cycle before
CURRENTS can affect pacemaker starting to weld again.
operation. 3. Follow rated duty cycle.
1. Pacemaker wearers keep away from servicing READ INSTRUCTIONS.
areas until consulting your doctor.
1. Use MILLER Testing Booklet (Part No. 150 853)
MOVING PARTS can cause injury. when servicing this unit.
1. Keep away from moving parts such as fans. 2. Consult the Owner’s Manual for welding safety
2. Keep all doors, panels, covers, and guards closed precautions.
and securely in place. 3. Use only genuine MILLER replacement parts.
1-3. EMF Information

Considerations About Welding And The Effects Of Low Frequency To reduce magnetic fields in the workplace, use the following
Electric And Magnetic Fields procedures:
1. Keep cables close together by twisting or taping them.
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological 2. Arrange cables to one side and away from the operator.
Effects of Power Frequency Electric & Magnetic Fields – Background
Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing 3. Do not coil or drape cables around the body.
Office, May 1989): “. . . there is now a very large volume of scientific
findings based on experiments at the cellular level and from studies 4. Keep welding power source and cables as far away as
with animals and people which clearly establish that low frequency practical.
magnetic fields can interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the results are 5. Connect work clamp to workpiece as close to the weld as
complex. Current scientific understanding does not yet allow us to possible.
interpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about About Pacemakers:
questions of possible risk or to offer clear science-based advice on The above procedures are also recommended for pacemaker
strategies to minimize or avoid potential risks.” wearers. Consult your doctor for complete information.
TM-353 Page 2 Syncrowave 250

SECTION 2 – DEFINITIONS
2-1. Warning Label Definitions
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.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
1 1.1 1.2 1.3 fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
2 2.1 2.2 2.3 3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
3.3 Do not weld on drums or any
3 3.1 3.2 3.3 closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
4 4.1 filter. Wear complete body
protection.
5 Become trained and read the
+ + + instructions before working on
the machine or welding.
6 Do not remove or paint over
(cover) the label.
5 6
+
S-176 254-A

2-2. Rating Label For CE Products
1 1
ISO/IEC 974-1
7A/10.2V 310A/22.4V
X 25% 60% 100%
I2 310A 200A 155A

U0 = 80V
U2 22.4V 18V 16.2V
5A/20.2V 310A/32.4V
X 25% 60% 100%
I2 310A 200A 155A

U0 = 80V
U2 32.4V 28V 26.2V
1 U1 = 220 I1max = 117.2A I1Eff = 59A

50 Hz
U1 = 380 I1max = 72.2A I1Eff = 36A
U1 = 415 I1max = 63.8A I1Eff = 32A
IP 21S
S-178 813-A

2-3. Symbols And Definitions
NOTE Some symbols are found only on CE products.
A Amperes Panel–Local
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
V Volts
Do Not Switch
While Welding
Arc Force (DIG) Spot Timer
Output Circuit Breaker Remote Temperature
Protective Earth High Frequency -

Alternating Current Input
(Ground) Start
High Frequency -
Postflow Timer Preflow Timer High Frequency
Continuous
Increase/Decrease
Gas (Supply) Gas Input Gas Output
Of Quantity
On Off Percent Direct Current
Maximum
Balance Control Maximum Cleaning Electrode Positive
Penetration
Electrode
Crater Time Meter Single-Phase
Negative
U0 Rated No Load
Voltage (Average) U1 Primary Voltage
U2 Conventional Load
Voltage
Line Connection
Single-Phase
I1 Primary Current
I2 Rated Welding
Current X Duty Cycle 1 1 Combined AC/DC
Power Source
IP Degree Of
Protection I1eff Maximum Effective
Supply Current I1max Rated Maximum
Supply Current Hz Hertz
Electrode Work Thickness Gauge Spark Gap
S Seconds

SECTION 3 – INSTALLATION
3-1. Specifications
Amperes Input at AC Balanced
Rated Load Output,
50/60 Hz, Single-Phase
Rated Amp Max IP
Welding Output PFC** 200 V 230 V 460 V 575 V KVA KW Range OCV Rating
NEMA Class II No 106 92 46 37 21 11.4
(40) – 250 PFC (4.6*) (4*) (2*) (1.6*) (0.89*) (0.68*)
Amperes, 30 Volts 5–310 A 80 V 21
AC, 40% Duty With
76 66 33 26 15.2 11.4
Cycle PFC
*While idling
**Power Factor Correction
Amperes Input at AC Balanced

Rated Load Output,
50/60 Hz, Single-Phase
Rated
Welding PFC 200 220 230 260 380 415 460 520 575 Amp Max IP
Output ** V V V V V V V V V KVA KW Range OCV Rating
NEMA
No 85 77 74 65 45 41 37 33 30 17 8.3
Class I
PFC (4.6*) (4.2*) (4*) (3.5*) (2.4*) (2.2*) (2*) (1.8*) (1.6*) (0.9*) (0.7*)
(60) – 200
Amperes, 5–310 A 80 V 21
28 Volts With 55 64 48 48 37 34 24 48 19 11 8.3
AC, 60% PFC (57*) (51*) (49*) (49*) (30*) (27*) (25*) (49*) (20*) (11*) (0.6*)
Duty Cycle
*While idling
**Power Factor Correction
3-2. Volt-Ampere Curves

The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
A. DC Mode B. AC Mode
ssb1.1 10/91 – SB-116 199 / SB-116 200

3-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, thermostat opens,
output stops, light goes on (CE
models only), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or duty cycle be-
fore welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
40% Duty Cycle At 250 Amperes (60 Hz Models Only)
4 Minutes Welding 6 Minutes Resting
60% Duty Cycle At 200 Amperes
6 Minutes Welding 4 Minutes Resting
Overheating
0 A
15
OR
Minutes Reduce Duty Cycle
duty1 4/95 / SB-116 198

3-4. Selecting A Location
1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement 1 If using lifting forks, extend forks
beyond opposite side of unit.
3 Rating Label (Non CE Models
Only)
4 Rating Label (CE Models
OR Only, See Section 2-2)
2 Use rating label to determine input
power needs. CE label located on
rear panel.
Location And Airflow 5 Plate Label (CE Models Only)
6
6 Line Disconnect Device
Locate unit near correct input pow-
er supply.
Y Special installation may be
3 required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
4 Section 20.
18 in (460
mm)
5
18 in (460
mm) ST-800 402 / ST-117 264-F
3-5. Dimensions And Weights
Dimensions
A Height 30-3/4 in (781 mm)
B
C Width 19-3/4 in (502 mm)
E
D Length 27-1/2 in (698 mm)
A 27 in (686 mm)
B 26 in (661 mm)
F C 25-1/4 in (642 mm)
Front D 1-1/2 in (38 mm)

G
E 1-1/8 (29 mm)
F 17-7/8 (454 mm)
G 19-1/4 (489 mm)
H 1/2 in (13 mm) Dia
H 6 Holes Weight
ST-154 792-B
355 lbs (161 kg)

3-6. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.
3-7. Weld Output Terminals And Selecting Cable Sizes
Y ARC WELDING can cause Electromagnetic Interference.

To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
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)
10 – 60% 60 – 100%
Weld Output Welding
Duty Duty 10 – 100% Duty Cycle
Terminals Amperes
Cycle 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

Work Electrode
ST-154 795-C 500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
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. Contact your dis-
tributor for the mm2 equivalent weld cable sizes. S-0007-E

3-8. Remote 14 Receptacle
Socket* Socket Information
A 24 volts ac.
B Contact closure to A completes 24 volts ac contactor control

circuit.
C Command reference; 0 to +10 volts dc output to remote control.
A J
K I
B D Remote control circuit common.
C L N H A
D M G E 0 to +10 volts dc input command signal from remote control.
E F
ST-154 795-C K Chassis common.
*The remaining sockets are not used.
3-9. 115 Volts AC Duplex Receptacle And Shielding Gas Connections

Y Turn Off power before
connecting to receptacle.
1 115 V AC Receptacle
Receptacle is protected from over-
5 load by circuit breaker CB1 (see
Section 7-2).
2 Gas Valve In Fitting
4 3 Gas Valve Out Fitting
6
Fittings have 5/8-18 right-hand
threads
4 Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
5 Regulator/Flow Gauge
6 Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour) (9.4 L/min)
7 High Frequency Control (see
Section 4-1)
1 7
3 2
Ref. ST-154 795-C / Ref. ST-157 858

3-10. Electrical Service Guide
NOTE All values calculated at 60% duty cycle.
Without Power Factor

60 Hertz Models With Power Factor Correction
Correction
Input Voltage 200 230 460 575 200 230 460 575
Input Amperes At Rated Output 85 74 37 30 55 48 24 19
Max Recommended Standard Fuse Or Circuit

125 110 60 45 80 70 35 30
Breaker Rating In Amperes
Min Input Conductor Size In AWG/Kcmil 4 6 10 10 8 8 12 14
Max Recommended Input Conductor Length 173 158 291 455 86 114 186 189
In Feet (Meters) (53) (48) (89) (139) (26) (35) (58) (48)
Min Grounding Conductor Size In AWG/Kcmil 6 6 10 10 8 8 12 14
Reference: 1996 National Electrical Code (NEC) S-0092-J
With Power Factor

50 Hertz Models Without Power Factor Correction
Correction
Input Voltage 220 260 380 415 520 220 380 415
Input Amperes At Rated Output 77 65 45 41 33 64 37 34
Max Recommended Standard Fuse Or Circuit

125 100 70 60 50 90 60 50
Breaker Rating In Amperes
Min Input Conductor Size In AWG/Kcmil 6 6 8 8 10 6 10 10
Max Recommended Input Conductor Length 145 202 291 347 372 145 291 347
In Feet (Meters) (44) (62) (89) (106) (113) (44) (89) (106)
Min Grounding Conductor Size In AWG/Kcmil 6 8 8 10 10 6 8 10
Reference: 1996 National Electrical Code (NEC) S-0092-J

3-11. Placing Jumper Links And Connecting Input Power
Check input voltage available at
site.
1 Jumper Link Label
Check label inside your unit–
200 VOLTS 230 VOLTS 460 VOLTS only one label is on unit.
Y Only make connections for
the voltages shown on the la-
L L L L L L bel inside your unit. Do not
make connections for any
S-083 566-C other voltages. If jumper link
label is missing from inside
2 unit, check rating label (see
230 VOLTS 460 VOLTS 575 VOLTS Section 3-4) for allowable in-
put voltages.
L L L L L L
2 Jumper Links
Move jumper links to match input
S-010 587-B
voltage.
3 Input And Grounding
220 VOLTS 380 VOLTS 415 VOLTS Conductors
Select size and length using
Section 3-10.
L L L L L L
4 Line Disconnect Device
S-131 783-A
Select type and size of overcurrent
protection using Section 3-10.
260 VOLTS 380 VOLTS 520 VOLTS Reinstall side panel.
Y Special installation may be
L L L L L L required where gasoline or
S-047 672-A volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
1
Connect GND/PE
Conductor First
GND/PE
Earth Ground
4
L1 (U)
L2 (V)
Connect GND/PE
Conductor First
Tools Needed:
3/8 in
3/8, 1/2, 7/16 in
ST-117 263-K

SECTION 4 – OPERATION
4-1. Controls
1 Ammeter
7 8 See Section 4-3.
2 Voltmeter
9 See Section 4-3.
3 High Frequency Switch
See Section 4-11.
6 10
11 4 Output (Contactor) Switch
12 See Section 4-8.
5 5 Spot Time Switch And Control
(Optional)
13
See Section 4-5.
6 Preflow Time Control (Optional)
See Section 4-12.
4
7 AC Balance Control
3
See Section 4-6.
8 Crater Time Control And Switch
See Section 4-4.
14 9 Amperage Adjustment Control And
Switch
See Section 4-7.
10 Arc Force (Dig) Switch And Control
See Section 4-9.
11 Postflow Time Control
See Section 4-10.
2
12 High Temperature Shutdown Light
(CE Models Only)
1
Lights when unit overheats and shuts
down (see Section 3-3).
13 Power Switch And Pilot Light
Use switch to turn unit and light On and
Off.
14 Output Selector Switch
See Section 4-2.
15 High Frequency Control
See Section 4-11.
15
Ref. ST-117 264-F / Ref. ST-154 795-C

4-2. Output Selector Switch
1 Output Selector Switch
Y Do not use AC output in
damp areas, if movement is
confined, or if there is dan-
1 ger of falling. Use AC output
ONLY if required for the
welding process, and then
use a remote control.
Y Do not change position of
switch while welding or
while under load.
Use switch to select (DCEN) Direct
Current Electrode Negative, AC, or
(DCEP) Direct Current Electrode
Positive output without changing
weld output cable connections.
Ref. ST-181 675-A
4-3. Meters
1 Voltmeter
1 2 Voltmeter displays voltage at the
weld output terminals, but not nec-
essarily the welding arc due to
cable resistance, poor connec-
tions, etc.
2 Ammeter
Ammeter displays weld amperage
output of unit.

4-4. Crater Time Controls
1 Crater Time Control
Use control to reduce current over a
set period of time (0–15 seconds) at
the end of the weld cycle when NOT
1 using a remote current control.
2 Crater Time Switch
ON – provides crater time.
OFF – provides no crater time.
Place switch in the OFF position for
Shielded Metal Arc Welding
(SMAW).
Application:
2 Crater Time should be used while
GTAW welding materials that are
crack sensitive, and/or the operator
wants to eliminate the crater at the
end of the weld.
Note: This applies if the operator is
using an on/off only type control to
start and stop the welding process.
4-5. Spot Time Controls

1 Spot Time Switch
Place switch in the ON position to
turn on spot weld circuitry.
2 The (GTAW) TIG Spot process is

generally used with a direct current
electrode negative (DCEN) set-up.
Place switch in the OFF position to
turn off spot weld circuitry. Put
switch in the OFF position while do-
ing Shielded Metal Arc Welding
(SMAW).
2 Spot Time Control
Use control to set time (0–5.7 sec-
1 onds) for Gas Tungsten Arc
(GTAW) spot welds. Spot time be-
gins at arc initiation. If the arc is bro-
ken during the spot time cycle, the
timer stops but does not reset.
When the spot time has ended,
weld output stops. Postflow starts
when the remote contactor is
opened. The spot timer resets after
the contactor opens.
Application:
TIG spot welding is used for joining
thinner materials that are in close
contact, with the fusion method. A
good example would be joining coil
ends.

4-6. AC Balance Control
1 AC Balance Control
Balance Control (AC GTAW):
Control changes the AC output
square wave. Rotating the control
towards 10 provides deeper pene-
tration. Rotating the control towards
1 0 provides more cleaning action of
the workpiece.
When the control is in the Balanced
position, the wave shape provides
equal penetration and cleaning
action.
Application:
When welding on oxide forming ma-
terials such as aluminum or magne-
sium, excess cleaning is not neces-
sary. To produce a good weld, only
a minimal amount, approximately a
0.10 in (2.5mm) of etched zone
along the weld toes is required.
Set control to 7 and adjust as nec-
essary. Joint configuration, set-up,
Setting Output Waveforms Arc process variables, and oxide thick-
ness may affect setting.
Balanced 50% Electrode
Positive Arc rectification can occur when
3
welding above 200 amps and/or
50% Electrode while welding with helium gas. If this
Negative condition occurs, increasing the
Balance control towards maximum
More Penetration penetration, may help to restabilize
32% Electrode
Positive the arc.
68% Electrode
10 Negative
More Cleaning 55% Electrode
Positive
45% Electrode
0 Negative
Ref. S-0795-A

4-7. Amperage Adjustment Controls
1 Amperage Adjustment Control
Use control to adjust amperage,
and preset amperage on ammeter
1 (see Section 4-3). This control may
be adjusted while welding.
For remote amperage control,
front panel control setting is the
maximum amperage available. For
example: If front panel control is set
to 200 A, the range of the remote
amperage control is 5 to 200 A.
For spot welding, use Amperage
Adjust control to select from 5–310
amps of peak amperage (see Sec-
tion 4-5).
2 Amperage Control Switch
Use switch to select way of control-
ling amperage adjustment.
For front panel control, place switch
in the PANEL position.
2 For remote control, place switch in
REMOTE 14 position, and connect
remote control device (see Section
3-8).
4-8. Output (Contactor) Control Switch

Y Weld output terminals are
energized when Output
(Contactor) switch is On and
Power is On.
1 1 Output/Contactor Switch
Use switch to select way of control-
ling unit output.
For front panel control, place switch
in ON position.
When On is selected, HF and gas
control are disabled.
For remote control, place switch in
REMOTE 14 position, and connect
remote control device (see Section
3-8).

4-9. Arc Controls
1 Arc Control (Dig)
For AC And DC SMAW Welding
When set at 0, short-circuit amper-
age at low arc voltage is the same
1 as normal welding amperage.
When setting is increased, short-
circuit amperage at low arc voltage
increases.
Set at 0 for GTAW welding.
2 Arc Control Switch
Place switch in the ON position to
turn on arc control circuitry. When
switch is in the OFF position, no ad-
2 ditional amperage is available at
low arc voltages. Place switch in
the OFF position while performing
Gas Tungsten Arc Welding
(GTAW).
Application:
Control helps arc starting or making
vertical or overhead welds by in-
creasing amperage at low arc volt-
age, and reduces electrode sticking
while welding.
4-10. Postflow Time Control

1 Postflow Time Control
Use control to set length of time
(0–70 seconds) gas flows after
welding stops. It is important to set
enough time to allow gas to flow un-
1 til after the tungsten and weld
puddle has cooled down.
Application:
Postflow is required to cool tung-
sten and weld, and to prevent con-
tamination of tungsten and weld. In-
crease postflow time if tungsten or
weld are dark in appearance.

4-11. High Frequency Controls
Y Place High Frequency
1
switch in Off position before
using the shielded metal arc
welding (SMAW) process.
1 High Frequency Switch
START – (Up position) provides HF
for arc starting only. High frequency
turns on to help start arc when out-
put is enabled. High frequency
turns off when arc is started, and
turns on whenever arc is broken to
help restart arc.
Application:
HF Start is used when the DCEN
GTAW process is required.
OFF – provides no HF. Use OFF for
SMAW (stick electrode) welding.
CONTINUOUS – (Down position)
provides HF continuously through-
out the weld.
Application:
HF Continuous is used when the
AC GTAW process is required.
2 High Frequency Intensity
Control
Use control to change amount of
HF energy used to start and main-
tain the arc. Set as low as practical
2 to prevent interfering with electronic
equipment.
4-12. Preflow Time Control (Optional)

1 Preflow Time Control
Use control to set the length of time
(0–15 seconds) that gas flows be-
fore an arc is started.
Application:
Preflow is used to purge the imme-
diate weld area of atmosphere. Pre-
flow also aids in consistent arc
starting.

SECTION 5 – THEORY OF OPERATION
1 Input Terminal Board TE1 AC 24
Provides means for operation on
1 1φ 2 1φ 4
Input Power Main Background
different input voltages. Power
Terminal Switch Transformer
2 Power Switch S1 Board TE1 S1 T1 Source
1-Phase
Provide on/off control of unit. Line
Input 115 VAC
3 Fan Motor FM Power DC
3 14 23
Provides cooling of internal compo- Fan Circuit Main
nents. Motor Breaker Rectifier
FM CB1 SR1
4 Main Transformer T1
Supplies power to weld output cir-
cuit, various control circuits, main 15
control board PC1, and fan motor 115 VAC Duplex
FM. Receptacle
RC2
5 Control Board PC1
Controls weld output by changing
the SCR gate pulses (conduction
times) after comparing current 115 VAC
feedback to selected amperage
signal.
1φ , 10 VAC
Also provides input connections for Synchronization SCR
switches S3, S5, S6, and S7. Signal Gating
6 Arc Control Switch S6 And Signals
Control R2 6 6 5
R2 selects short-circuit amperage Arc Control Arc Control
when S6 is On, and High Frequen- R2 Switch
S6
cy control R13 is Off. Control
7 Crater Time Switch S7 And Board
PC1
Control R11 7 7
R11 selects crater time when S7 is Crater Time Crater Time
on, and Amperage Control switch Control Switch
S5 is in Panel position. R11 S7
8 Thermostat TP1
If T1 overheats, TP1 opens stop- 16
ping all weld output. 9 8
Output Postflow
9 Output (Contactor) Switch S3 (Contactor) Thermostat Timer
Switch S3 TP1 TD1
Selects On or remote contactor
control.
17
10 AC Balance Control R3 Gas
10
Controls changes to ac output Valve
AC Balance GS1
square wave. Control
11 Ammeter A1 And Voltmeter R3
V1
Display weld amperage and volt- 11♦
age while welding.
12 Amperage Control Switch S5 Ammeter
A1
And Adjustment Control R1
R1 selects weld output amperage
when S5 is in Panel.
12 12 13
13 Remote 14 Filter Board
PC2/Remote 14 Receptacle Amperage Amperage Remote 14
Adjustment Control Filter Board
RC1 Control R1 Switch S5 PC2
PC2 protects unit from high fre-
quency, and RC1 connects remote
amperage and contactor controls to
power source. 13
14 Circuit Breaker CB1 Remote
Amperage
Protects 115 volts ac duplex recep- Control
tacle RC2 from overload.

15 115 Volts AC Duplex Recep-
tacle RC2
28
26 Provides connection point for auxil-
30 iary equipment.
25 Hall Device Work Weld 16 Postflow Timer TD1
HD1 Output
Stabilizer Terminal
11♦
Z1 Controls shielding gas and coolant
postflow time.
Voltmeter 17 Gas Valve GS1
Output V1
Selector Provides shielding gas during the
Switch 30 weld cycle.
S4 21 Electrode
Weld Output 18 Preflow Timer TD3, Control
Terminal R12, And Switch S9
High
Frequency R12 selects time shielding gas
Coupling flows before arc starts. S9 is an in-
Coil T3 tegral part of R12 so that when R12
is turned past zero (0), TD3 is off.
19 Spot Timer TD2, Switch S8,
27 29 22 And Control R10
High R10 selects time output is available
Line Integrated Frequency
Filter Rectifier when spot welding. S8 selects Off
Intensity or spot welding with remote contac-
FL1 SR2 Control R13 tor control.
20 High Frequency Transformer
T2
Current Feedback 21 Steps up input voltage and charges
Spark Gaps G capacitor C4.
Voltage Feedback
Capacitor 21 Spark Gaps G And High Fre-
Voltage Feedback C4
quency Coupling Coil T3
G provides path for C4 to discharge
into T3. T3 supplies high-frequency
to welding circuit.
20
High 22 High Frequency Intensity
Frequency Control R13
Transformer Changes amount of HF energy
T2
used to start and maintain the arc.
23 Main Rectifier SR1
115 VAC Changes the ac output from T1 to
18 ♦ 19 ♦ full-wave rectified dc.
Preflow Spot 24 Background Power Source
Timer Timer
TD3 TD2 Provides reduced weld output rip-
ple at low weld output levels.
25 Stabilizer Z1
18♦ 19 ♦
Smooths dc welding current.
Preflow Time Spot Time
Control Control 26 Hall Device HD1
R12 R10
Provides current feedback signal to
Switch PC1 through line filter FL1.
S9 19 ♦ 27 Line Filter FL1
Spot Time Filters current feedback signal.
Switch
S8 28 Output Selector Switch S4
AC Or DC Control Provides either AC or DC and out-

put polarity.
29 Integrated Rectifier SR2
1φ Power
Provides dc voltage feedback to
PC1.
Weld Current Circuit
30 Electrode And Work Weld
Output Terminals
External Circuits
Provide weld output.
♦ Optional

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

Section 10 for parts location.
. Use MILLER Testing Booklet (Part No. 150 853)

when servicing this unit.
Trouble Remedy
Prior to Serial No. KG164875, no weld Be sure line disconnect switch is in the On position.
output; unit completely inoperative –
Effective with Serial No. KG164875,
no weld output; unit completely inop-
erative; PL2 off.
Replace building line fuse(s) or reset circuit breaker(s) if open.
Check for proper electrical input connections (see Section 3-11).
Check for proper jumper link position (see Section 3-11).
Check Power switch S1 and replace if necessary.
Prior to Serial No. KG164875, no weld If using remote control, place Output (Contactor) switch S3 in Remote 14 position, and connect re-
output; fan runs – Effective with Serial mote control to Remote 14 receptacle RC1 (see Sections 3-8 and Section 4-8). If remote is not being
No. KG164875, no weld output; fan used, place Output switch S3 in On position.
runs; PL2 on.
Check, repair or replace remote control device.
Allow a cooling period of approximately 15 minutes. If thermostats TP1 remain open, check continuity
and replace if necessary (see Section 3-3).
Check circuit breaker CB1, and reset if open (see Section 7-2).
Place Output Selector switch S4 in desired position (see Section 4-2).
Check optional preflow timer board TD3, and replace if necessary.
Check optional spot timer relay TD2 for proper connections and resistance. Replace TD2 if
necessary.
Check continuity of Spot Time switch S8. Check condition of contacts. Repair or replace S8 if neces-
sary.
Check SR1, and replace necessary components. If components are replaced, check capacitors C7
thru C10. Replace capacitor(s) if necessary.
Check control board PC1 and connections, and replace if necessary.
Effective with Serial No. KB110695, check resistance and connections of HD1; HD1 is 1600 ohms
±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if
necessary.
Unit provides only minimum weld Check position of Amperage Control switch S5 (see Section 4-7).
output.
Increase Amperage Adjustment control R1 setting if a remote control is used (see Section 4-7).
Check resistance and connections of Amperage Adjustment control R1; R1 is 1000 ohms ±10%.
Replace R1 if necessary.
Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capac-
itors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10
if necessary.
necessary.
Unit provides only maximum weld Check Amperage Adjustment control R1 for proper connections and resistance; R1 is 1000 ohms
output. ±10%. Replace R1 if necessary.
necessary.
Check connections for continuity to shunt device on units with Serial No. prior to KB110695.
Check bypass capacitors C13, C14, C16, C17, C18, and C19 for broken leads, shorts, and leakage.
Replace if necessary.

Trouble Remedy
if necessary.
Check connections to line filter FL1. Check input to PC1. Replace FL1 if necessary.
Erratic weld output. Check for poor or improper input or output connections. See Sections 3-11 and 3-8.
Replace electrode.
Check torch assembly, and replace if necessary.
Check fuse F2 in rectifier SR3 circuit, and replace if necessary.
If Amperage Control switch S5 is in the Remote position check, repair, or replace remote amperage
control device if necessary.
Check connections for continuity to shunt device on units with Serial No. prior to KB110695.
Check Amperage Adjustment control R1 for proper connections and resistance; R1 is 1000 ohms
±10%. Replace R1 if necessary.
Check bypass capacitors C13, C14, C16, C17, C18, and C19 for broken leads, shorts, and leakage.
Replace if necessary.
if necessary.
No or limited ac balance control. Check AC Balance control R3 for proper connections and resistance; R3 is 5000 ohms ±10%.
if necessary.
No crater fill time. Check position of Crater switch S7 (see Section 4-4).
Check position of Crater control R11 (see Section 4-4).
Be sure arc voltage is below 24 volts (see Section 3-2. Volt-Ampere Curves).
Check position of Amperage Control switch S5, S5 must be in Panel position (see Section 4-7).
Crater fill time too long or does not Check position of Crater control R11 (see Section 4-4).
time out.
Check resistance and connections of Crater control R11; R11 is 5 meg ohms ±10%. Replace R11 if
necessary.
No arc control. Place Arc Control switch S6 in the On position.
Place High Frequency switch S2 in the Off position.
Be sure arc voltage is below 24 volts (see Section 3-2. Volt-Ampere Curves).
Check position of Arc Control R2 (see Section 4-9).
Check resistance and connections of Arc control R2; R2 is 1000 ohms ±10%. Replace R1 if
necessary.
Lack of high frequency at tungsten Use proper size tungsten for welding application.
electrode; difficulty in starting an arc.
Use shortest possible cables (see Section 3-7).
Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace
necessary parts.
Be sure to disconnect SMAW electrode cable from weld output terminal when GTAW welding.
Decrease gas flow setting.
Use properly prepared tungsten.
Increase setting of High Frequency Intensity control R13 (see Section 4-11).
Check spark gaps G, and readjust if necessary (see 7-4).
Trouble Remedy
No high frequency at spark gaps G. Check position of High Frequency switch S2 (see Section 4-11).
Place Output (Contactor) switch S3 in Remote position and be sure remote control is connected to
Remote receptacle RC1 (see Section 3-8).
Check coil voltage and connections of contactor control relay CR1. Check continuity of coil and con-
dition of contacts. Replace CR1 if necessary.
Check coil voltage and connections of contactor control relay CR5. Check continuity of coil and con-
dition of contacts. Replace CR5 if necessary.
Check spark gaps G, and readjust if necessary (see Section 7-4).
Check resistance and connections of High Frequency Intensity control R13; R13 is 1.5 ohms ±10%.
Check capacitor C4 for a short or open, and check for proper connections. Replace C4 if necessary.
Check transformer T2 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T2 if necessary.
Check coupling coil T3 for signs of winding failure. Check continuity across windings, and check for
proper connections. Replace T3 if necessary.
No preflow time (optional). Place Output (Contactor) switch S3 in Remote position and be sure remote control is connected to
Remote receptacle RC1 (see Section 3-8).
Check position of Preflow Time control R12.
Check continuity of Preflow Time switch S9. Check condition of contacts. Repair or replace S9 if nec-
essary.
Remove jumper link 1 on terminal strip 1T.
Check optional preflow timer board TD3, and replace if necessary.
Optional spot timer relay TD2 does not Place Spot Time switch S8 in the On position.
time out.
Remove jumper link 2 from terminal strip 1T.
Place Spot Time control R10 in desired position.
Check coil voltage and connections of spot timer relay TD2. Check continuity of coil and condition of
contacts. Replace TD2 if necessary.
Check coil voltage and connections of control relay CR3. Check continuity of coil and condition of
contacts. Replace CR3 if necessary.
Postflow timer does not time out. Check position of Postflow Time control setting (see Section 4-10).
Check Control relay CR5 contacts 2 and 5 for proper operation. Replace CR5 if necessary.
Check coil voltage and connections of gas valve GS1. Check continuity of coils. Replace GS1 if nec-
essary.
Check input voltage and connections to Postflow timer board TD1. Check continuity of contacts. Re-
place TD1 if necessary.
No postflow time. Check position of Postflow Time control setting (see Section 4-10).
Place Output(Contactor) switch S3 in the Remote position, and connect a remote control to recep-
tacle RC1 according to Section 3-8.
essary.
Check input voltage and connections to Postflow timer board TD1. Check continuity of contacts. Re-
place TD1 if necessary.
No gas flow. Place Output(Contactor) switch S3 in the Remote position, and connect a remote control to recep-
tacle RC1 according to Section 3-8.
Trouble Remedy
Check Control relay CR2 contacts 4 and 7 for proper operation. Replace CR2 if necessary.
essary.
No power output at 115 volts ac recep- Check circuit breaker CB1, and reset if open (see Section 7-2).
tacle RC1; weld output available.
Fan motor FM does not run; weld out- Check and clear fan blade obstruction.
put available. Effective with Serial No.
KG164875, unit is equipped with Fan-
On-Demand, which only runs when
cooling is required.
Check coil voltage and connections of fan motor FM, and replace if necessary.
Line fuse opens immediately when Check diode D1, and replace if necessary.
solid-state contactor SR1 turns on in
DC mode only.
if necessary.
No control of weld output. Check position of Amperage Control switch S5 (see Section 4-7).
Check resistance and connections of Amperage Adjustment control R1; R1 is 1000 ohms ±10%.
necessary.
Tungsten electrode oxidizing and not Check position of Postflow Time control R12 (see Section 4-10).
remaining bright after conclusion of
weld.
Check and tighten all gas fittings if necessary.
Increase gas flow setting.
Shield weld zone from drafts.
Properly prepare tungsten.
Place High Frequency switch S2 in Start or Continuous position.
Wandering arc - poor control of direc- Use proper size tungsten for welding application.
tion of arc.
Properly prepare tungsten.
Controls connected to Remote 14 Check, repair or replace remote control device.
receptacle RC1 do not work properly.
Check Amperage Control switch S5 position (see Section 4-7). Check and replace S5 if necessary.
Check Output (Contactor) switch S3 position (see Section 4-8). Check and replace S3 if necessary.
Check position of jumper links 1 and 2 on terminal strip 1T according to Section 6-2.
Prior to Serial No. KF959379, check choke RFC1 connections. Check continuity of RFC1. Replace if
necessary. Effective with Serial No. KF959379 check remote 14 filter board PC2 (see Section 6-6).
Replace PC2 if necessary.
Ammeter A1 not displaying correct Calibrate ammeter as instructed in Section 6-8.
weld output amperage.
Check ammeter A1 voltage; +1 millivolts dc per 3 ampere of weld output. Replace A1 if necessary.
Effective with Serial No. KB110695, check resistance and connections of hall device HD1; HD1 is
1600 ohms ±10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1
if necessary.
Voltmeter V1 not displaying correct arc Check connections for continuity to voltmeter V1. Replace V1 if necessary.
voltage.
Electronic equipment in welding area HF interference problem. Check for proper installation, and correct problem (see Section 8).
not working properly.

6-2. Troubleshooting Circuit Diagram For Welding Power Source
Y Disable high frequency by placing High Frequency

switch S2 in Off position before testing unit.
R1
R1
R1 V3
V2
V25
V1
V11
V4
V5
R1
V10
V9
V6
V8
V7
Link 1 Link 2
V13
V12
V14 V17
TD1 begins to time out
when CR5 deenergizes
TD3 begins to time out V15 V16

when CR4 energizes CR2 energizes when
remote contactor
See Figure 9-19 switch closes
for PC3 circuit
CR3 energizes during spot time CR4 energizes when remote contactor
when an arc is detected switch closes See Section 3-8
See Section 6-6 for RC1
for PC2 data information

Test Equipment Needed:
Voltage Readings
a) Tolerance – ±10% unless
specified
b) Reference – to circuit
common (lead 42) unless
See Figure 10-1 for noted
No calibration available
HD1 location for voltmeter V1 c) Wiring Diagram – see
Section 10
V1 230 volts ac
V2 77 volts ac
V3 82.5 volts ac
R1 V4 57 volts ac
V5, V6 115 volts ac
V7 24 volts ac
V24
V8, V9 18 volts ac
V10 10 volts ac
V11 80 volts dc
V23, B, V12. V13, V14 115 volts ac

R1
C, D, E V15, V16, V17 24 volts ac
See Section 6-3 V18 115 volts ac with S2
for waveforms in Start or Con-
V25 B, C, D, E tinuous
R3
V22 V19 0 to +10 volts dc
V21 with contactor on
R2 V20, V21 24 volts dc
V22 0-80 volts dc (rec-
tified arc voltage)
V23 maximum 80 volts
ac/dc
V24 24 volts dc
A A V25 16.5 millivolts dc
per 1 ampere of
weld output
A
CR1 energizes
A
when open-circuit voltage
is present; denergizes
when an
arc is struck
V20
See Section 6-3 See also

Sections 6-4 and 6-5
Resistance Values
for waveform A
for PC1 data a) Tolerance – ±10% unless specified
V18 V19 CR5 energizes when b) Turn Off unit and disconnect input
contactor is on power before checking resistance
See Section 6-8
R1 All values for T1, Z1, and T3 are less
for ammeter A1
than 1 ohm
calibration
R2 5.3 ohms
R3 6.1 K ohms
SC-188 161

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

waveforms for 50 Hertz models are similar.
5 ms 1 V 5 ms 50 V
gnd
gnd
A. SR1 Gate Pulse With Respect To Cathode B. DC Open-Circuit Voltage With Amperage
At No Load Adjustment Control At Maximum
5 ms 20 V 5 ms 50 V
gnd gnd
C. DC Output, 100 Amperes, 24 Volts DC D. AC Open-Circuit Voltage With Amperage

(Resistive Load) Adjustment Control At Maximum

5 ms 50 V
gnd
E. AC Output, 100 Amperes, 24 Volts AC (Re-

sistive Load)

6-4. Control Board PC1 Testing Information (Use With Section 6-5)
Y Disable high frequency by
placing High Frequency
switch S2 in Off position
before testing unit.
Be sure plugs are secure before
testing. See Section 6-5 for specific
values during testing.
1 Control Board PC1
2 Receptacle RC51
3 Receptacle RC52
4 Receptacle RC53
5 Receptacle RC54
6 Receptacle RC55
1 2 3
4
6
SB-178 976-A / ST-800 344-A

6-5. Control Board PC1 Test Point Values

specified
PC1 Voltage Readings
b) Reference – to circuit common
(lead 42) unless noted
Receptacle Pin Value
RC51 1 18 volts ac input
2 18 volts ac input
3 +10 volts dc output
4 Circuit common
5 Not used
6 Not used
RC52 1 Circuit common
2 +1 millivolt dc per 3 ampere of weld output
RC53 1 Gate pulse for SCR1 with respect to pin 2 (see Section 6-3)
2 Reference for gate pulse to SCR1
3 Gate pulse for SCR3 with respect to pin 4 (see Section 6-3)
RC54 1 Not used
2 0 to +10 volts dc input from min. to max. of Amperage Adjustment control R1 with Amperage Control
switch S5 in Panel position, and contactor on
3 0 volts with Output (Contactor) switch S3 in On position or +7.8 volts dc with S3 in Remote position
4 0 to +10 volts dc input from min. to max. of Crater Control R11 with Crater Fill switch S7 in On posi-
tion, or +10 volts dc with S7 in Off position
5 +10 volts dc output with Output (Contactor) switch S3 in On position
6 –24 volts dc
7 –24 volts dc with contactor on or off
8 0 to +10 volts dc input from min. to max. of Amperage Adjustment control R1 with contactor on
9 0 to +10 volts dc input from min. to max. of Amperage Adjustment control R1 with contactor on
10 Circuit common
11 +24 volts dc
12 0 volts during open-circuit voltage condition; +24 volts with arc on or contactor off

RC55 1 Circuit common
2 +1.65 volts dc per 100 amperes of weld output with respect to pin 1
3 –15 volts dc output
4 0 to +4 volts dc input from min. to max. of Arc Control R2 with Arc Control switch S6 On
5 10 volts ac input for synchronization
6 +5.8 volts dc output
7 –15 volts dc input from Max. Penetration setting of AC Balance control R3 to +5.8 volts dc input at
Max. Cleaning setting of R3
8 0 to 80 volts dc voltage feedback signal (rectified arc voltage) with respect to pin 9
9 0 to 80 volts dc voltage feedback signal (rectified arc voltage) with respect to pin 8
10 0 to +4 volts dc input from min. to max. of Arc Control R2 with Arc Control switch S6 Off

6-6. Remote Board PC2 Testing Information (Use With Section 6-7)
Y Disable high frequency by
placing High Frequency
switch S2 in Off position
before testing unit.
testing. See Section 6-7 for specific
values during testing.
1 Remote 14 Filter Board PC2
2 Remote 14 receptacle RC1
See Section 3-8 for information.
3 Receptacle RC2
4 Receptacle RC3
4
1
ST-157 960-B / ST-800 344-A

6-7. Remote 14 Filter Board PC2 Test Point Values (Use With Section 6-2 And Section 6-6)

specified
PC2 Voltage Readings
b) Reference – to circuit common
(lead 42) unless noted
RC1 A 24 volts ac
B Contact closure to A completes 24 volts ac contactor control circuit
C Command reference; 0 to +10 volts dc output to remote control
D Remote control circuit common
E 0 to +10 volts dc input command signal from remote control
K Chassis common
RC2 1 Command reference; 0 to +10 volts dc output to remote control
3 Contact closure to A completes 24 volts ac contactor control circuit
4 Remote control circuit common
5 0 to +10 volts dc input command signal from remote control
6 24 volts ac
RC3 1 Chassis common

6-8. Meter Calibration
calibrating meter.
1 Control Board PC1
2 Voltmeter V1
No calibration available for ammeter 3 Ammeter A1
offset, or for voltmeter V1.
Top View
R19
2
Amperes
Adjust R19 for amperage gain to

match external calibrated meter
using load bank set at desired
load.
SB-130 690-D / ST-800 344-A

6-9. Input Voltage Labels And Connections
1 Input Voltage Label And Con-
nection Diagram – Only One
Label Is On Unit
2 Terminal Strip TE1
ST-154 793-A / ST-114 947-A / ST-121 000-A / ST-131 735

SECTION 7 – MAINTENANCE
7-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Replace Repair Or Clean And

Unreadable Replace Tighten
Labels Cracked Weld
Weld Terminals
Cables
Adjust Spark Replace

Gaps Cracked
Parts
14-Pin Cord Gas Hose Torch Cable
6 Months
Blow Out Or Vacuum

Inside,
OR During Heavy Service,
Clean Monthly
7-2. Circuit Breaker CB1

1 Circuit Breaker CB1
If CB1 opens, output to the 115 volts
ac duplex receptacle, high frequen-
cy, and gas flow stop. Press button
to reset breaker.
CB1
Ref. ST-154 795-C

7-3. Fuses F1 And F2
1 Fuse F1 (See Parts List For
Rating)
Fuse F1 (between leads 50 and
150) protects wiring harness from
shorted SR2. If F1 opens, you may
1 experience problems with arc start-
ing and arc performance in the DC
TIG mode.
2
2 Fuse F2 (See Parts List For
Rating)
Fuse F2 (between leads 22 and
149) protects wiring harness from
shorted SR3. If F2 opens, you may
experience problems with arc con-
trol, and no high frequency in start
high frequency.
Tools Needed:
3/8 in
7-4. Adjusting Spark Gaps

Y Turn Off power before
adjusting spark gaps.
4 4 Open access door.
1 Tungsten End Of Point
Replace point if tungsten end dis-
3 appears; do not clean or dress
tungsten.
3 2 Spark Gap
2 1 Normal spark gap is 0.008 in (0.203
mm).
If adjustment is needed, proceed as
follows:
3 Adjustment Screws
Loosen screws. Place gauge of
proper thickness in spark gap.
4 Pressure Point
Apply slight pressure at point until
gauge is held firmly in gap. Tighten
screws to 12 in/lbs torque (overtigh-
tening will deform plastic base). Ad-
just other gap.
Close access door.
Tools Needed:
Ref. ST-154 795-C / Ref. S-0043

SECTION 8 – HIGH FREQUENCY (HF)
8-1. Welding Processes Using HF
1 HF Voltage
GTAW – helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
SAW – helps arc reach workpiece
2 through flux granules.
1
2 Flux
1
Work Work
Gas Tungsten Arc Submerged Arc

Welding (GTAW) Welding (SAW)
high_freq1 7/95 – S-0693
8-2. Sources Of HF Radiation From Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
9 14
8
13 2
4 5 6
S-0694
Sources Of Direct HF Radiation 5 Workpiece Sources Of Reradiation Of HF

1 HF source (welding power source with 6 Work Table 10 Ungrounded Metal Objects
built-in HF or separate HF unit) Sources Of Conduction Of HF 11 Lighting
2 Weld Cables 7 Input Power Cable 12 Wiring
3 Torch 8 Line Disconnect Device 13 Water Pipes And Fixtures
4 Work Clamp 9 Input Supply Wiring 14 External Phone And Power Lines

8-3. Correct Installation
Weld Zone 6
50 ft
(15 m) 50 ft
(15 m)
1
5
2
7
7 Ground All
Metal Objects
And All Wiring
In Welding Zone
Using #12 AWG
Wire Ground
Workpiece
If Required
By Codes 8
Nonmetal
Building
7
7
10
Metal Building
9
Ref. S-0695 / Ref. S-0695
1 HF Source (Welder With Built-In HF Or Electrically join (bond) all conduit sections 8 Metal Building Panel Bonding Methods
Separate HF Unit) using copper straps or braided wire. Ground
conduit every 50 ft (15 m). Bolt or weld building panels together, install
Ground metal machine case, work output copper straps or braided wire across seams,
terminal, line disconnect device, input 5 Water Pipes And Fixtures and ground frame.
supply, and worktable.
Ground water pipes every 50 ft (15 m). 9 Windows And Doorways
2 Welding Zone And Centerpoint
6 External Power Or Telephone Lines Cover all windows and doorways with
A circle 50 ft (15 m) from centerpoint
grounded copper screen of not more than
between HF source and welding torch in all Locate HF source at least 50 ft (15 m) away 1/4 in (6.4 mm) mesh.
directions. from power and phone lines.
3 Weld Output Cables 10 Overhead Door Track
7 Grounding Rod
Keep cables short and close together. Ground the track.
Consult the National Electrical Code for
4 Conduit Joint Bonding And Grounding specifications.

SECTION 9 – 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
Syncrowave 250 JJ339876 thru JJ351864 SC-114 914 D-116 884-B♦♦

JJ351865 thru JJ365633 SC-120 877 D-120 878-B♦♦
JJ365634 thru JJ503983 SC-121 280 D-121 281-D♦♦
JJ503984 thru JK572897 SC-124 314 D-124 307-C♦♦
JK572898 thru JK617846 SC-124 785-B D-124 786-B♦♦
JK617847 thru JK682713 SC-124 785-B D-129 200-B♦♦
JK682714 thru JK690986 SC-124 785-B D-130 576-B♦♦
JK690987 thru KA806712 SC-132 697-A D-132 431-D♦♦
KA806713 thru KA877024 SC-137 431 D-137 430-A♦♦
KA877025 thru KB010829 SC-135 581 D-135 734-A♦♦
KB010830 thru KB110694 SC-142 524 D-142 525-A♦♦
KB110695 thru KC252675 SC-148 144 D-148 145-A♦♦
KC252676 thru KG029204 SC-154 649-C D-154 648-E♦♦
KG029205 thru KG062109 SC-178 835 D-174 039-A♦♦
KG062110 thru KG170300 SC-179 303-A D-179 305-A♦♦
KG170301 thru KH526230 SC-181 109-E SD-181 110-F♦♦
KH526231 and following SC-188 161-A SD-188162-A
Circuit Board PC1 JJ339876 thru JJ399987 D-118 765♦♦

JJ399988 thru JK682713 D-122 270♦♦
JK682714 thru KA797306 D-130 691-A♦♦
KA797307 thru KG062109 D-135 253♦♦
KG062110 thru KH508254 SD-178 975♦♦
KH508255 and following SD-187644
RFC Circuit Board PC2 JJ365634 thru KB010829 SA-121 282
Remote 14 Filter Board PC2 KF959379 and following SA-158 763
Circuit Board PC3♦ JJ351865 and following SA-120 872
Timer TD1 JJ339876 and following SA-044 725-C
Timer TD3♦ JJ339876 and following SA-045 288-D
♦ Optional
♦♦ Not included in this manual

SC-114 914
Figure 9-1. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ339876 Thru JJ351864
SC-120 877
SC-121 280
SC-124 314
Figure 9-4. Circuit Diagram For Syncrowave 250 Effective With Serial No. JJ503984 Thru JK572897
SC-124 785-B
Figure 9-5. Circuit Diagram For Syncrowave 250 Effective With Serial No. JK572898 Thru JK690986
SC-132 697-A
Figure 9-6. Circuit Diagram For Syncrowave 250 Effective With Serial No. JK690987 Thru KA806712
SC-137 431
Figure 9-7. Circuit Diagram For Syncrowave 250 Effective With Serial No. KA806713 Thru KA877024
SC-135 581
Figure 9-8. Circuit Diagram For Syncrowave 250 Effective With Serial No. KA877025 Thru KB010829
SC-142 524
Figure 9-9. Circuit Diagram For Syncrowave 250 Effective With Serial No. KB010830 Thru KB110694
SC-148 144
Figure 9-10. Circuit Diagram For Syncrowave 250 Effective With Serial No. KB110695 Thru KC252675
SC-154 649-C
Figure 9-11. Circuit Diagram For Syncrowave 250 Effective With Serial No. KC252676 Thru KG029204
SC-178 835
Figure 9-12. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG029205 Thru KG062109
SC-179 303-A
Figure 9-13. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG062110 Thru KG170300
SC-181 109-E
Figure 9-14. Circuit Diagram For Syncrowave 250 Effective With Serial No. KG170301 Thru KH526230
SC-188 161-A
Figure 9-15. Circuit Diagram For Syncrowave 250 Effective With Serial No. KH526231 And Following
Notes

Figure 9-16. Wiring Diagram For Syncrowave 250 Effective With Serial No. KH526231 And Following
SD-188 162-A

Figure 9-17. Circuit Diagram For Control Board PC1 Effective With
Serial No. KH508255 And Following (Part 1 Of 2)
SD-187 644 (1 of 2)

Figure 9-18. Circuit Diagram For Control Board PC1 Effective With
Serial No. KH508255 And Following (Part 2 Of 2)
SD-187 644 (2 of 2)

SA-121 282
Figure 9-19. Circuit Diagram For RFC Board PC2 Effective With Serial No. JJ365634 Thru KB010829
SA-158 763
Figure 9-20. Circuit Diagram For Remote 14 Filter Board PC2

Effective With Serial No. KF959379 And Following
SA-120 872
Figure 9-21. Circuit Diagram For Optional Snubber Board PC3

Effective With Serial No. JJ351865 And Following

SA-044 725-C
Figure 9-23. Circuit Diagram For Postflow Timer Board TD1

SA-045 288-D
Figure 9-22. Circuit Diagram For Optional Preflow Timer Board TD3
Notes

TM-353E January 2001
Eff. w/Serial Number JJ339876
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
Syncrowave 250
60 Hz, 50 Hz
Visit our website at

www.MillerWelds.com
SECTION 10 – PARTS LIST
17–Fig.10-4
18
19
20
21
16
30
13
31
14
15
12
11
22
10
24
23
25
9
26
8
7–Fig.10-5
27
6
5
2–Fig.10-3
28
29–Fig.10-2
1
. Hardware is common and ST-120 135-R

not available unless listed. Figure 10-1. Main Assembly

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 10-1. Main Assembly
. 1 . . . . . . . . . . . . . 114 741 . . COVER, top (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. 1 . . . . . . . . . . . . . 182 605 . . COVER, top (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 2 . . . . SR1 . . . . 181 106 . . RECTIFIER, si diode (Fig 10-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 3 . . . . . S4 . . . . 112 630 . . SWITCH, plrty/changeover (Prior to KA759476) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 3 . . . . . S4 . . . . 133 061 . . SWITCH, plrty/changeover (Eff w/KA759476) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG10 . . 164 899 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG11 . . . 168 809 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . C13 . . . . 155 082 . . CAPACITOR, cer disc. .003 200VAC (Prior to JK690987) . . . . . . . . . . . . . . . . . 1
. . . . . . . C13 . . . . 132 433 . . CAPACITOR, cer disc. .05uf 500VDC (Eff w/JK690987) . . . . . . . . . . . . . . . . . . . 1
. 4 . . . . . . . . . . . . . 057 357 . . BUSHING, snap-in nyl .937 ID x 1.125mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 5 . . . . . . . . . . . . . 010 494 . . BUSHING, snap-in nyl 1.375 ID x1.750mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. 6 . . . . . . . . . . . . . 110 375 . . STAND-OFF SUPPORT, PC card No. 6 screw (Prior to KG170301) . . . . . . . . 3
. 6 . . . . . . . . . . . . . 134 201 . . STAND-OFF SUPPORT, PC card No. 6 screw (Eff w/KG170301) . . . . . . . . . . 3
. 7 . . . . . . . . . . . . . Fig 10-4 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 8 . . . . . . . . . . . . . 083 147 . . GROMMET, screw No. 8/10 panel hole .312sq .500 high . . . . . . . . . . . . . . . . . . 4
. 9 . . . . . . . . . . . . . 114 754 . . FRAME, lifting (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. 9 . . . . . . . . . . . . . 181 101 . . FRAME, lifting (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . . . . . . 026 627 . . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . . . . . . 070 026 . . STAND-OFF, 6-32 x .437 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 . . . PC1 . . . . 117 981 . . CIRCUIT CARD, control (Prior to JJ389988) (Fig 10-5) . . . . . . . . . . . . . . . . . . . . 1
12 . . . PC1 . . . . 138 058 . . CIRCUIT CARD, control (Eff w/JJ389988 thru KB110694) (Fig 10-5) . . . . . . . . 1
12 . . . PC1 . . . . 180 014 . . CIRCUIT CARD, control (Eff w/ KB110695 thru KG060803) . . . . . . . . . . . . . . . . 1
12 . . . PC1 . . . . 187 642 . . CIRCUIT CARD, control (Eff w/KG060804) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG51 . . 115 093 . . CONNECTOR PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . R14 . . . . 138 105 . . RESISTOR, (Eff w/KB110695 thru KG062110) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . FL1 . . . . 084 171 . . FILTER, line power 115/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14 . . . HD1 . . . . 156 313 . . TRANSDUCER, current 300A (Eff w/KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . PLG3 . . . 130 204 . . CONNECTOR & SOCKETS, (Eff w/KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 . . . . . . . . . . . . 073 756 . . STAND-OFF, 6-32 x .625 lg (Eff w/KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
16 . . . . Z1 . . . . 114 826 . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 . . . . . . . . . . . . Fig 10-4 . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 109 035 . . LABEL, warning electric shock can kill etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18 . . C11,12 . . 111 634 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 172 078 . . BRACKET, mtg primary board (Eff w/KE727074) . . . . . . . . . . . . . . . . . . . . . . . . . 1
19 . . . TE1 . . . . 034 587 . . TERMINAL ASSEMBLY, pri (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 601 835 . . . . NUT, brs hex 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . 601 836 . . . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . 010 915 . . . . WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . 083 426 . . . . TERMINAL BOARD, primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 038 888 . . . . STUD, primary board brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 010 913 . . . . WASHER, flat brs .218 ID x 460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . 038 887 . . . . STUD, primary board brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . 038 618 . . . . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
20 . . . . . . . . . . . +114 751 . . PANEL, side (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
20 . . . . . . . . . . . +181 097 . . PANEL, side (Eff w/KG170301 thru KG181270) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
20 . . . . . . . . . . . +182 606 . . PANEL, side (Eff w/KG181271 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
21 . . . . T1 . . . . 115 097 . . TRANSFORMER, pwr main 200/230/460 (Prior to KA877025) . . . . . . . . . . . . . 1
21 . . . . T1 . . . . 138 171 . . TRANSFORMER, pwr main 200/230/460 (Eff w/KA877025 thru KG082621) . 1
21 . . . . T1 . . . . 180 674 . . TRANSFORMER, pwr main 200/230/460 (Eff w/KG082622) . . . . . . . . . . . . . . . 1
21 . . . . T1 . . . . 138 175 . . TRANSFORMER, pwr main (220/380/415 (Prior to KG082622) . . . . . . . . . . . . 1
21 . . . . T1 . . . . 121 161 . . TRANSFORMER, pwr main 230/460/575 (Prior to KA877025) . . . . . . . . . . . . . 1
21 . . . . T1 . . . . 138 172 . . TRANSFORMER, pwr main 230/460/575 (Eff w/KA877025 thru KG082621) . 1
21 . . . . T1 . . . . 191 887 . . TRANSFORMER, pwr main 260/380/520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . TP1 . . . . 020 520 . . THERMOSTAT, NC (included w/transformer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . TP2 . . . . 168 891 . . THERMOSTAT, NC (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 10-1. Main Assembly (Continued)
22 . . . . . . . . . . . . 114 755 .. BASE, (Prior to KE727074) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . . . . . . . . 170 748 .. BASE, (Eff w/KE727074 thru KF959176) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22 . . . . . . . . . . . . 171 677 .. BASE, (Eff w/KF959177) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23 . . . . . . . . . . . . 157 196 .. INSULATOR, upright (Eff w/KC307050) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
24 . . . . . . . . . . . . 010 199 .. TUBING, stl .500 OD x 17ga x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
25 . . . . . . . . . . . . 108 105 .. CLAMP, capacitor 2.500dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
26 . . . . C2 . . . . 031 668 .. CAPACITOR, elctlt 4000uf 100VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
27 . . . . R5 . . . . 117 803 .. RESISTOR, WW fxd 10W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
28 . . . . . . . . . . . . 114 722 .. BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
29 . . . . . . . . . . . . Fig 10-2 .. PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
30 . . . . . . . . . . . . 098 376 .. FUSE, holder (Eff w/KH526231) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
31 . . . F1,2 . . . . 085 874 .. FUSE, mintr gl slo-blo 10A (Eff w/KH526231) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 092 368 .. TUBING, stl .250 ID x 16ga x 3 (Prior to JK682714) . . . . . . . . . . . . . . . . . . . . . . 1
................ 130 764 .. TUBING, stl .250 ID x 16ga wall x 1.500 (Eff w/JK682714) . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

8
9
2 10
4 5 6
1
3 7
12
11
13
Includes
Item 26
29 14
28
27 15
1 16
26
25
17
24 23 22
18
Figure 10-6
19
21
20 ST-120 088-G
Figure 10-2. Panel, Front w/Components
Item Dia. Part

Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 29)
. . . 1 . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model & serial number) . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 109 013 . . BUSHING, snap-in nyl .375 ID x .562mtg hole . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . S6,7 . . . 089 085 . . SWITCH, tgl SPST 20A 125VAC (Prior to KF988252) . . . . . . . . . . . . . . . . 2
. . . 4 . . . . S6,7 . . . 176 882 . . SWITCH, tgl SPST 20A 125VAC (Eff w/KF988252) . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 107 983 . . BLANK, snap-in nyl .500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 057 359 . . BLANK, snap-in nyl .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . R3 . . . . 030 109 . . POTENTIOMETER, C sltd sft 1/T 2W 5000 ohm . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . R11 . . . 030 684 . . POTENTIOMETER, C sltd sft 1/T 2W 5 meg ohm . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . R1,2 . . . 035 897 . . POTENTIOMETER, C sltd sft 1/T 2W 1000 ohm . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . S3 . . . . 052 769 . . SWITCH, tgl 4PDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S2 . . . . . 011 610 . . SWITCH, tgl SPDT 15A 125VAC (Prior to JJ503984) . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S2 . . . . 088 409 . . SWITCH, tgl 2PDT 15A 125VAC (Eff w/JJ503984) . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . TD1 . . . 052 192 . . TIMER, delay on make - postflow (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 039 449 . . . . BRACKET, mtg - circuit card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 10-2. Panel, Front w/ Components (Continued)
. . . 13 . . . . . . . . . . . . . 044 723 . . . . CIRCUIT CARD, postflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . . S1 . . . . 045 834 . . SWITCH, tgl DPST 60A 600VAC (Prior to KA759476) . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . S1 . . . . 128 757 . . SWITCH, tgl DPST 60A 600VAC (Eff w/KA759476) . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 106 398 . . PIN, spring CS .156 x .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 114 721 . . SHAFT, extension switch (Prior to KA759476) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 133 276 . . EXTENSION, handle switch (Eff w/KA759476 thru KF959378) . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 171 420 . . EXTENSION, handle switch (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 164 481 . . PANEL, front (Prior to KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 169 476 . . PANEL, front (Eff w/KF959379 thru KG170300) . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 181 096 . . PANEL, front (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . . . . . . . . . . CONTROL PANEL, lower front (Fig 10-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 128 230 . . LABEL, warning electric shock etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 134 327 . . LABEL, warning electric shock etc CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . +114 759 . . DOOR, access front (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . +181 589 . . DOOR, access front (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 605 583 . . CATCH, spring loaded door (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 176 254 . . LABEL, warning general precautionary CE . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . PL2 . . . 157 958 . . LIGHT, ind wht lens 28V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . PL1 . . . 155 500 . . LED, yellow (50 Hz model) (Eff w/ KG060803) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . 135 635 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 (Prior to KF959379) . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 169 136 . . PIN, handle (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 098 279 . . HANDLE, plrty/changeover switch (Prior to KF959379) . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 169 135 . . HANDLE, switch (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 052 370 . . . . KNOB, indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . ♦115 920 . . METER, amp AC/DC 100MV 0-300 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . ♦004 189 . . METER, volt AC/DC 0–100 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦OPTIONAL

Item Dia. Part
Figure 10-3. Rectifier, Si Diode (Fig 10-1 Item 2)
. . . 1 . . . . C7-10 . . 031 689 .. CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 2 . . . . . . . . . . . . . 083 884 .. CLAMP, thyristor rectifier (Prior to KG023560) . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . 166 667 .. CLAMP, spring rectifier (Eff w/KG023560) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . D1 . . . . 037 956 .. DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . TP3 . . . 168 898 .. THERMOSTAT, NC open 125°C (Eff w/KG170301) . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . SCR1-4 . . . 115 114 .. THYRISTOR, SCR 300A 300V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 6 . . . . . . . . . . . . . 176 645 .. CLAMP, thyristor w/o thermostat (Eff w/KG023560) . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . 173 714 .. CLAMP, thyristor with thermostat (Eff w/KG170030) . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 028 516 .. PIN, spring CS .125 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG53 . . . 115 092 .. CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3
2
4 2
1 5
ST-120 205-A
5 6
Figure 10-3. Rectifier, Si Diode
Item Dia. Part

Figure 10-4. Panel, Rear w/Components (Fig 10-1 Item 17)
. . . 1 . . . . . R4 . . . . 186 949 .. RESISTOR, WW fxd 175W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . 032 604 .. BLADE, fan 14 in 3 wing 19deg .375 bore CCW (Prior to KG198783) . . . 1
. . . 2 . . . . . . . . . . . . . 180 165 .. BLADE, fan 14 in 3 wing 19deg .375 bore CCW (Eff w/KG198783) . . . . . 1
. . . 3 . . . . . . . . . . . . . . 114 752 .. PANEL, rear (Prior to KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 181 099 .. PANEL, rear (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 131 361 .. CHAMBER, plenum 14 in (Prior to KG128812) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 173 283 .. CHAMBER, plenum 14 in (Eff w/KG128812) (50 Hz only) . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 124 274 .. BRACKET, mtg fan motor (Eff w/KG128812) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . FM . . . . . 116 190 .. MOTOR, 1/12 hp 230V 1550 RPM 50/60Hz 1.5A . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 026 947 .. STAND-OFF, insul .250-20 x 1.000 lg (Prior to KB110695) . . . . . . . . . . . . 2
. . . . . . . . . . Shunt . . . . 114 723 .. SHUNT, (Prior to KB110695) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 176 272 .. CONNECTOR, clamp cable (50 Hz model) (Eff w/KG060803) . . . . . . . . . 1
2 3
1
4
6 5 ST-120 089-F
Figure 10-4. Panel, Rear w/Components
Item Dia. Part
Figure 10-5. Panel, Mtg Components (Fig 10-1 Item 7)
. . 1 . . . . . R7 . . . . . 186 468 .. RESISTOR, WW fxd 100W 50 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . . 117 721 .. PANEL, mtg relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . CR2,6 . . . . . 110 386 .. RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 4 . . . . . 2T . . . . . 072 253 .. STUD, single connection 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . SR2,3 . . . . 035 704 .. RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 6 . . . SN1,2 . . . . . 118 625 .. SNUBBER, poly metal film .5uf 200VDC 100 ohm . . . . . . . . . . . . . . . . . . . 2
. . 7 . . . . . R6 . . . . . . 117 803 .. RESISTOR, WW fxd 10W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 8 . . . . C20 . . . . . . 119 834 .. CAPACITOR, cer disc .05uf 500V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 9 . . . . . 1T . . . . . . 117 372 .. BLOCK, term 10A 15P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 108 023 .. LINK, jumper term blk 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 10 . . . CR5 . . . . . 000 770 .. RELAY, encl 24VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . CR1 . . . . . 052 964 .. RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11
3
10 3
6
6
9
8 7
ST-120 090-F
Figure 10-5. Panel, Mtg Components
15
14
17
5
16
13
3
6
2 4
7
11
8
1
9
10
18
23
22
19
21
20 ST-120 003-P
Figure 10-6. Control Panel, Lower Front
Item Dia. Part

Figure 10-6. Control Panel, Lower Front (Fig 10-2 Item 18)
. . . . . . . . . . . . . . . . . . . . 116 477 .. CONTROL PANEL, lower (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . 124 647 .. CONTROL PANEL, lower (Eff w/JK572898 thru JK682712) . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 131 217 .. CONTROL PANEL, lower (Eff w/JK682714 thru JK690986) . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 132 430 .. CONTROL PANEL, lower (Eff w/JK690987 thru KA806713) . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 137 516 .. CONTROL PANEL, lower (Eff w/KA806713 thru KA877024) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 147 793 .. CONTROL PANEL, lower (Eff w/KA877025 thru KF959378) . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 174 067 .. CONTROL PANEL, lower (Eff w/KF959379 thru KG170300) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 181 108 .. CONTROL PANEL, lower (Eff w/KG170301) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . . 114 742 .. PANEL, lower front (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . 124 784 .. PANEL, lower front (Eff w/JK572898 thru JK690986) . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . 130 582 .. PANEL, lower front (Eff w/JK690987 thru KB093120) . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . 147 795 .. PANEL, lower front (Eff w/KB093121 thru KF959176) . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . 171 652 .. PANEL, lower front (Eff w/KF959177) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . R25 . . . 137 429 .. RESISTOR, C 2W 3.3K ohm (Eff w/KA806713) . . . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
Figure 10-6. Control Panel, Lower Front (Continued)
... 3 ............. 126 750 .. CAPACITOR ASSEMBLY, (Eff w/JK537589 thru JK690986) . . . . . . . . . . . 1
. . . 3 . . . . C14 . . . 098 566 .. CAPACITOR, (Prior to JK537589) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . C14 . . . 132 433 .. CAPACITOR, (Eff w/JK690987) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
................... 121 270 .. RECEPTACLE/CAPACITOR,w/leads (Prior to JK682714)
(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC2 . . . 035 523 . . . . CONNECTOR, circ 5skt rcpt Amphenol MS-3102A-16S-8S . . . . . . . . . 1
. . . . . . . . . C16-19 . . . 119 856 . . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . PC2/RFC1 121 273 . . . . CIRCUIT CARD, snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 039 273 . . CONNECTOR, circ 5 pin size 16S plug Amphenol MS-3106A-16S-8P
. . . . . . . . . . . . . . . . . . . 039 685 . . CONNECTOR, circ clamp str rlf size 16 Amphenol 97-3057-8
. . . . . . . . . . . . . . . . . . . 142 523 . . CONNECTOR/CAPACITOR, w/leads (Eff w/JK674521 thru
KF959378) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC2 . . . 143 976 . . . . CONNECTOR w/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . C16 . . . 143 899 . . . . LEAD ASSY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . C17 . . . 143 897 . . . . LEAD ASSY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . C18 . . . 143 898 . . . . LEAD ASSY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . C19 . . . 143 900 . . . . LEAD ASSY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . RFC1/PC2 142 522 . . . . CHOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . PC2/RC1 . 157 959 . . CIRCUIT CARD ASSEMBLY, (Eff w/KF959379) (consisting of) . . . . . . . . 1
. . . . . . . . . PLG21 . . 153 501 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 134 734 . . CONNECTOR, circ 14 pin size 20 plug Amp 213571-2
. . . . . . . . . . . . . . . . . . . 079 534 . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6
. . . . . . . . . . . . . . . . . . . 079 739 . . CONNECTOR, circ clamp str rlf size 17-20 Amp 206322-2
. . . 5 . . . . . C6 . . . . 164 290 . . CAPACITOR, polyp film 3.5uf 600VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . PLG3 . . . 131 204 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . RC2 . . . 604 176 . . RECEPTACLE, straight duplex grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 073 690 . . CAP, straight P & S 2P3W 5266 DF
. . . 8 . . . . C15 . . . 170 920 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . CB1 . . . 093 995 . . CIRCUIT BREAKER, man reset 1P 15A 250V . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . R13 . . . 605 828 . . RHEOSTAT, WW 50W 1.5 ohm (Prior to KG170301) . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . R13 . . . 174 037 . . RHEOSTAT, WW 50W 1.5 ohm (Eff w/KG170301 thru LA292998) . . . . . 1
. . . 10 . . . . R13 . . . 198 547 . . RHEOSTAT, WW 25W 1.5 ohm (Eff w/LA292999) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 010 493 . . BUSHING, snap-in nyl .625 ID x .875 mtg hole . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . G . ♦♦020 623 . . SPARK GAP ASSEMBLY (Prior to LA337284) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦♦095 621 . . . . BASE, spark gap (Prior to LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦♦020 622 . . . . HOLDER, points (Prior to LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . ♦♦*020 603 . . . . POINT, spark gap (Prior to LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 11 . . . . . . G . ♦♦203 419 . . SPARK GAP ASSEMBLY SERVICE KIT (for units prior to LA337284)) . 1
. . . 11 . . . . . . G . ♦♦199 854 . . SPARK GAP ASSEMBLY (Eff w/LA337284) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦♦199 855 . . . . BASE, spark gap (Eff w/LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦♦199 856 . . . . HOLDER, points (Eff w/LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . ♦♦*196 455 . . . . POINT, spark gap (Eff w/LA337284) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 088 731 . . BUSHING, snap-in nyl .375 ID x .500mtg hole . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . 097 712 . . STRIP, insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 174 070 . . BRACKET, mtg components (Eff w/KG959379) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . C3 . . . . 106 935 . . CAPACITOR, polyp film 10uf 250VAC (Prior to KK001554) . . . . . . . . . . . . 1
. . . 14 . . . . . C3 . . . . 191 944 . . CAPACITOR, polyp film 10uf 250VAC (Eff w/KK001554) . . . . . . . . . . . . . . 1
. . . 15 . . . . . R8 . . . . 083 784 . . RESISTOR, WW fxd 100W 10 ohm (Prior to KG170301) . . . . . . . . . . . . . 1
. . . 15 . . . . . R8 . . . . 181 107 . . RESISTOR ASSEMBLY w/LEADS, (Eff w/KG170301) . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . C4 . . . . 096 761 . . CAPACITOR, mica .002uf 10000V (CE Models Only) . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . C4 . . . . 096 761 . . CAPACITOR, mica .002uf 10000V
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to KK001554 for nonCE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . C4 . . . . 201 197 . . CAPACITOR, polyp met film .002uf 10000VDC/4400VAC pnl mtg
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/KK001554 for nonCE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 000 681 . . STRIP, mtg HF coil (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 124 649 . . STRIP, mtg HF coil (Eff w/JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 000 682 . . TUBING, fiber vulc .250 ID x .312 OD x .812 (Prior to JK572898) . . . . . . 2
. . . . . . . . . . . . . . . . . . . 125 949 . . TUBING, fiber vulc .250 ID x .312 OD x 1.125 (Eff w/JK572898) . . . . . . . 2
. . . 17 . . . . . T2 . . . . 074 398 . . TRANSFORMER, high voltage 115V pri 3600V sec 30mA . . . . . . . . . . . . 1
Item Dia. Part
Figure 10-6. Control Panel, Lower Front (Fig 10-2 Item 18) (Continued)
. . . 18 . . . . . T3 . . . . . 115 967 .. COIL, HF coupling (Prior to JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . . . T3 . . . . 124 650 .. COIL, HF coupling (Eff w/JK572898 thru KF959378) . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . T3 . . . . 174 692 .. COIL, HF coupling (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . R9 . . . . 030 603 .. RESISTOR, WW fxd 10W 10K ohm (Prior to KA877025) . . . . . . . . . . . . . 1
. . . 19 . . . . Work
Electrode . 039 047 . . TERMINAL, power output (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 601 976 . . . . SCREW, stl hexhd .500-13 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 039 049 . . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 601 880 . . . . NUT, stl hex jam .500 -13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 039 044 . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 601 879 . . . . NUT, stl hex full fnsh .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . GS1 . . . 174 036 . . VALVE, w/fittings & leads (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 010 296 . . . . FITTING, hose brs elbow M 1/4NPT x .625-18 . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 035 601 . . . . VALVE, 115VAC 2 way 1/4 IPS port 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 174 038 . . PANEL, door access HF (Eff w/KF959379) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 097 922 . . KNOB, pointer (Eff w/JK572898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 010 357 . . SPEED NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 605 742 . . CLIP, mtg resistor .500 ID core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
*Recommended Spare Parts

♦♦Effective with Serial No.LA337284, Spark Gap Assembly 020 623 consisting of: Base 095 621, Holder 020 622,
and Points 020 603, is no longer available. If replacement parts are needed for any units with a Serial No. prior to
LA337284, you must first order and install Spark Gap Assembly Service Kit 203 419. To replace spark gap parts in
units with Serial No. LA337284 and following, or for units with Spark Gap Assembly Service Kit 203 419 installed, order
appropriate spark gap parts listed above as, eff/w Serial No. LA337284.

Eff w/KE558763 the Water Valve Option (042 138) is no longer available
and all other options are available as Field Options only.
Dia. Part
Mkgs. No. Description Quantity
Optional Equipment
. . . . . . . . . . . . . . . . . . . . . . 042 138 . . WATER VALVE, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . WSI . . . . . . . . . 035 601 . . . . VALVE, 115VAC 2 way 1/4 IPS port 1/8 orf . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 010 295 . . . . FITTING, pipe brs elbow M 1/4NPT x .625-18 . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 116 201 . . . . BRACKET, mtg valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 042 140 . . METER KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . A . . . . . . . . . . 115 920 . . . . METER, amp AC/DC 100MV 0-300 scale . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . V . . . . . . . . . . 004 189 . . . . METER, volt AC/DC 0-100 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 131 054 . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . 042 142 . . SPOT TIMER, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . CR3 . . . . . . . . . 006 393 . . . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . RFC,VR1/PC3 . . . . . 120 875 . . . . CIRCUIT CARD, snubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R10 . . . . . . . . . 030 108 . . . . POTENTIOMETER, C sltd sft 1/T 2W 100K ohm . . . . . . . . . . . . . . . 1
. . . . . . . . S8 . . . . . . . . . . . 011 611 . . . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . TD2 . . . . . . . . . 047 133 . . . . RELAY, delay adj 120VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 097 922 . . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 042 144 . . PRE-FLOW TIMER, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . CR4 . . . . . . . . . 006 393 . . . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . R12,S9 . . . . . . . . 115 862 . . . . POTENTIOMETER, C sltd sft 1/T .50W 500K ohm . . . . . . . . . . . . . . 1
. . . . . . . . TD3 . . . . . . . . . 116 476 . . . . TIMER, delay on make - preflow (consisting of) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 115 856 . . . . . . CIRCUIT CARD, preflow (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . A50 . . . . . . . . . 008 971 . . . . . . . . IC, linear 741 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . C50 . . . . . . . . . 039 482 . . . . . . . . CAPACITOR, elctlt 100uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . C51 . . . . . . . . . 091 378 . . . . . . . . CAPACITOR, tantlm 33uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . C52 . . . . . . . . . 039 481 . . . . . . . . CAPACITOR, elctlt 3.3uf 50VDC . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . C53 . . . . . . . . . 031 677 . . . . . . . . CAPACITOR, elctlt 5.6uf 35VDC . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . C54 . . . . . . . . . 166 199 . . . . . . . . CAPACITOR, cer disc .05uf 500VDC . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . CR50 . . . . . . . . 039 486 . . . . . . . . RELAY, encl 24VDC SPDT 2.5A . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . D50,51 . . . . . . . . 026 202 . . . . . . . . DIODE, rect 1A 400V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . Q50 . . . . . . . . . 000 088 . . . . . . . . TRANSISTOR, NPN 800mA 400V . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R50 . . . . . . . . . 074 121 . . . . . . . . RESISTOR, C 2W 3.3K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R52 . . . . . . . . . 108 432 . . . . . . . . RESISTOR, MF .25W 2.21K ohm . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R53 . . . . . . . . . 000 342 . . . . . . . . POTENTIOMETER, cermet trmr 1/T .5W 5K ohm . . . . . . . . . . . 1
. . . . . . . . R54 . . . . . . . . . 093 030 . . . . . . . . RESISTOR, MF .25W 15K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R55 . . . . . . . . . 028 273 . . . . . . . . RESISTOR, C .5W 2.7K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R56 . . . . . . . . . 093 037 . . . . . . . . RESISTOR, MF .25W 47.5K ohm . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . R57 . . . . . . . . . 605 919 . . . . . . . . RESISTOR, C .25W 47 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 039 449 . . . . . . BRACKET, mtg circuit card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 097 922 . . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 042 353 . . POWER FACTOR CORRECTION, (consisting of) . . . . . . . . . . . . . . . . 1
. . . . . . . . C1 . . . . . . . . . . 125 781 . . . . CAPACITOR, polyp film 150uf 250VAC . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . 129 201 . . . . BRACKET, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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) 1204-593493
FAX: 44 (0) 1204-598066
PRINTED IN USA  1998 Miller Electric Mfg. Co.

Miller Electric Syncrowave 250 Technical Manual 120626

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What safety precautions are mentioned?

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What are the main sections covered in the document?

What are the main sections covered in the document?

TM-353E January 2001

Eff. w/Serial Number JJ339876

Stick (SMAW) Welding

Arc Welding Power Source

Visit our website at

Manufacturer’s Name: Miller Electric Mfg. Co.

Declares that the product: Syncrowave 250

Low Voltage Directive: 73/23/EEC

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

Electromagnetic Capability Directives: 89/336, 92/31/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

1-1. Symbol Usage

1-2. Servicing Hazards

STATIC ELECTRICITY can damage HIGH-FREQUENCY RADIATION can

Syncrowave 250 TM-353 Page 1

1-3. EMF Information

TM-353 Page 2 Syncrowave 250

Warning! Watch Out! There are

Syncrowave 250 TM-353 Page 3

X 25% 60% 100%

I2 310A 200A 155A

X 25% 60% 100%

I2 310A 200A 155A

1 U1 = 220 I1max = 117.2A I1Eff = 59A

U1 = 415 I1max = 63.8A I1Eff = 32A

TM-353 Page 4 Syncrowave 250

NOTE Some symbols are found only on CE products.

Output Circuit Breaker Remote Temperature

Protective Earth High Frequency -

On Off Percent Direct Current

Electrode Work Thickness Gauge Spark Gap

Syncrowave 250 TM-353 Page 5

Amperes Input at AC Balanced

3-2. Volt-Ampere Curves

ssb1.1 10/91 – SB-116 199 / SB-116 200

TM-353 Page 6 Syncrowave 250

40% Duty Cycle At 250 Amperes (60 Hz Models Only)

4 Minutes Welding 6 Minutes Resting

60% Duty Cycle At 200 Amperes

6 Minutes Welding 4 Minutes Resting

duty1 4/95 / SB-116 198

Syncrowave 250 TM-353 Page 7

3-5. Dimensions And Weights

F C 25-1/4 in (642 mm)

Front D 1-1/2 in (38 mm)

F 17-7/8 (454 mm)

G 19-1/4 (489 mm)

H 1/2 in (13 mm) Dia

TM-353 Page 8 Syncrowave 250

3-7. Weld Output Terminals And Selecting Cable Sizes