Maxtar 200 La-Zz

TM-2226V 2014−03
Eff w/Serial Number LA230402
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
115/230/400/460 Volt Models W/Autoline

Arc Welding Power Source
Maxstar 200 SD, DX, And LX

(Including Optional Cart And Cooler)
CE And Non-CE Models
File: TIG (GTAW)
Visit our website at

www.MillerWelds.com
INFORMATION ON OLDER UNITS
This manual includes operating information for current units. To obtain specific operating information for older models, download the applicable
Owner’s Manual from www.MillerWelds.com
Factory Parameter Defaults And Range And Resolution Prior To LJ280222L

Parameter Default Range And Resolution
PROCESS TIG HF Impulse TIG HF Impulse / TIG Lift / Stick
** Stick OCV Low OCV Low OCV / Normal OCV
**Stick Stuck Check ScI (On) ScI (On) / Sc0 (Off)
OUTPUT RMT STD RMT STD / RMT 2T / ON
**RMT 2T 2T RMT 2T can be reconfigured for: 2T / 4T / Mini Logic

/ 4T Momentary / Spot (see Section 6-2C)
A MAIN / PEAK
DC TIG 150 A 1 − 200 Amps
DC STICK 110 A 1 − 200 Amps
Spot Time 1.0 S 0.1 − 25.0 Seconds
***Weld Time 0S Dual Range And Resolution
0.0 − 99.9 / 100 − 999 Seconds
PULSER Off ON / OFF
PPS 100 Hz Dual Range And Resolution
0.1 − 9.9 / 10 − 500 Hertz
PEAK t 40% 5 − 95 Percent
BKGND A 25% 5 − 95 Percent
**Meter “PPP” Display −−− (Off) −−− (Off) / PPPP (On)
SEQUENCER
INITIAL A 20 A 1 − 200 Amps
***Initial Time 0 S 0.0 − 25.0 Seconds
INITIAL SLOPE t 0S 0.0 − 25.0 Seconds
FINAL SLOPE t 0S 0.0 − 25.0 Seconds
FINAL A 5A 1 − 200 Amps
***Final Time 0S 0.0 − 25.0 Seconds
ADJUST
**PREFLOW 0.2 S 0.0 − 25.0 Seconds
POST FLOW 10.0 S 0.0 − 50.0 Seconds @ 0.2 Second Resolution
DIG 30% 0 − 100 Percent
MAXSTAR:
**Amperage 25 A 1 − 200 Amps
**Time 1 mS 1 − 200 Milliseconds
** Parameter adjusted using a power up configuration only
*** Parameter used with the automation option (LX models only)
TM-2226 Page 2 Maxstar 200 SD, DX, LX

Effective with Serial Number LJ280222L, changes were made to the Advanced Function section.
Effective with Serial Number LK450045L, changes were again made to the Advanced Function section.
Maxstar 200 SD, DX, LX TM-2226 Page 3

TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − DEFINITIONS (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-6. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-7. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-8. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-9. Automation 10-Pin Connection (LX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-10. Typical Automation Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-11. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-12. TIG HF Impulse/ Lift-Arc DCEN (Direct Current Electrode Negative) Connections . . . . . . . . . . . . . . 14
3-13. Stick DCEP (Direct Current Electrode Positive) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-14. TIGRunner Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-16. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-17. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-2. Encoder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-3. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-4. Ammeter And Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-5. Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-6. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-7. Lift-Arc™ And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-8. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-9. Pulser Control (DX And LX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4-10. Sequencer Controls (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-11. Adjust Controls (Preflow/Post Flow/DIG/Purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-12. Factory Parameter Defaults And Range And Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-13. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-14. Arc Timer/Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 5 − ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-1. Accessing Advanced Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-2. Programmable TIG Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5-3. Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5-4. Setting Preflow Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5-5. Spot Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5-6. Stick Open-Circuit Voltage (OCV) Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5-7. Stick Stuck Check Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5-8. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5-9. Setting Unit To Display PPP While Pulse Welding (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5-10. External Pulse Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 6 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TABLE OF CONTENTS
SECTION 7 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7-1. Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7-2. Measuring Input Capacitor Voltage (Prior To LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7-3. Measuring Input Capacitor Voltage (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7-4. Power Module PM1 (Prior To LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7-5. Power Module PM1 (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7-6. Power Interconnecting Board PC2 (Prior To LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7-7. Power Interconnecting Board PC2 (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7-8. Boost Control Board PC10 (Prior To LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7-9. Boost Control Board PC10 (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7-10. Inverter Control Board PC1 (Prior To LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7-11. Inverter Control Board PC1 (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7-12. Arc Starter Board PC7 Testing Information (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7-13. Output Diode D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7-14. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7-15. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7-16. Troubleshooting Circuit Diagram (Eff. w/ Serial No. LA230402 Thru LJ280221L) . . . . . . . . . . . . . . . . 76
7-17. Troubleshooting Circuit Diagram (Eff w/Serial No. LJ280222L And Following) . . . . . . . . . . . . . . . . . . 78
7-18. Waveforms for Sections 7-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7-19. Inverter Control Board PC1 Testing Information (Use with Section 7-20) (Prior To LJ280222L) . . . . 82
7-20. Inverter Control Board PC1 Test Point Values (Prior To LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7-21. Inverter Control Board PC1 Testing Information (Use with Section 7-22) (Eff w/LJ280222L) . . . . . . . 86
7-22. Inverter Control Board PC1 Test Point Values (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7-23. Power Interconnect Board PC2 Testing Information (Use with Section 7-24) (Prior To LJ280222L) . 89
7-24. Power Interconnect Board PC2 Test Point Values (Prior To LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . 90
7-25. Power Interconnect Board PC2 Testing Information (Use with Section 7-26) (Eff w/LJ280222L) . . . 92
7-26. Power Interconnect Board PC2 Test Point Values (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . 93
7-27. Weld Control Board PC3 Testing Information (Use with Section 7-28) (Prior To LJ280222L) . . . . . . . 96
7-28. Weld Control Board PC3 Test Point Values (Prior To LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7-29. Weld Control Board PC3 Testing Information (Use w/Section 7-30) (Eff w/LJ280222L Thru LK450044L) .
100
7-30. Weld Control Board PC3 Test Point Values (Eff w/LJ280222L Thru LK450045L) . . . . . . . . . . . . . . . . 101
7-31. Control And Interface Board PC3 Testing Information (Use with Section 7-32) (Eff w/LK450045L) . . 103
7-32. Control And Interface Board PC3 Test Point Values (Eff w/LK450045LL) . . . . . . . . . . . . . . . . . . . . . . 104
7-33. Arc Starter Board PC7 Testing Information (Use with Section 7-34) (Prior To LJ280222L) . . . . . . . . 106
7-34. Arc Starter Board PC7 Test Point Values (Prior To LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7-35. Arc Starter Board PC7 Testing Information (Use with Section 7-36) (Eff w/LJ280222L) . . . . . . . . . . . 107
7-36. Arc Starter Board PC7 Test Point Values (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7-37. Boost Control Board PC10 Testing Information (Use with Section 7-38) (Prior To LJ280222L) . . . . . 108
7-38. Boost Control Board PC10 Test Point Values (Prior To LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7-39. Membrane Switch Panel Test Procedure (Prior To Serial No. LC374378) . . . . . . . . . . . . . . . . . . . . . . 109
7-40. Boost Control Board PC10 Testing Information (Use with Section 7-41) (Eff w/LJ280222L) . . . . . . . 110
7-41. Boost Control Board PC10 Test Point Values (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7-42. Using Test Mode To Check Machine Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7-43. Checking Unit Output After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
8-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
TABLE OF CONTENTS
SECTION 10 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

10-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10-2. Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10-3. Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
SECTION 11 − POWER SOURCE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
SECTION 12 − COOLER PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
SECTION 13 − CART PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage

OM-2226AS - 2012−10, safety_stm 2013-09
DANGER! − Indicates a hazardous situation which, if Indicates special instructions.

not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.
1-2. Servicing Hazards
The symbols shown below are used throughout this manual FLYING METAL or DIRT can injure eyes.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions Wear safety glasses with side shields or face
to avoid the hazard. shield during servicing.
Only qualified persons should test, maintain, and repair this Be careful not to short metal tools, parts, or
unit. wires together during testing and servicing.
During servicing, keep everybody, especially children, away.

HOT PARTS can burn.
ELECTRIC SHOCK can kill. Do not touch hot parts bare handed.
Allow cooling period before working on
Do not touch live electrical parts. equipment.
Turn Off welding power source and wire feeder To handle hot parts, use proper tools and/or
and disconnect and lockout input power using wear heavy, insulated welding gloves and
line disconnect switch, circuit breakers, or by removing plug from re- clothing to prevent burns.
ceptacle, or stop engine before servicing unless the procedure spe-
cifically requires an energized unit.
Insulate yourself from ground by standing or working on dry insulat-

ing mats big enough to prevent contact with the ground.
Do not leave live unit unattended. EXPLODING PARTS can injure.
If this procedure requires an energized unit, have only personnel Failed parts can explode or cause other parts to
familiar with and following standard safety practices do the job. explode when power is applied to inverters.
When testing a live unit, use the one-hand method. Do not put both Always wear a face shield and long sleeves
hands inside unit. Keep one hand free. when servicing inverters.
Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SHOCK HAZARD from testing.
SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing power sources AFTER removal of input power. Turn Off welding power source and wire feeder
or stop engine before making or changing me-
Turn Off inverter, disconnect input power, and discharge input ter lead connections.
capacitors according to instructions in Troubleshooting Section be- Use at least one meter lead that has a self-
fore touching any parts. retaining spring clip such as an alligator clip.
Read instructions for test equipment.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling FALLING EQUIPMENT can injure.
boards or parts.
Use proper static-proof bags and boxes to Use lifting eye to lift unit only, NOT running
store, move, or ship PC boards. gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
FIRE OR EXPLOSION hazard. If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Do not place unit on, over, or near combustible
Follow the guidelines in the Applications Manual for the Revised
surfaces.
NIOSH Lifting Equation (Publication No. 94−110) when manu-
Do not service unit near flammables. ally lifting heavy parts or equipment.

MOVING PARTS can injure. H.F. RADIATION can cause interference.
Keep away from moving parts such as fans. High-frequency (H.F.) can interfere with radio
Keep away from pinch points such as drive navigation, safety services, computers, and
rolls. communications equipment.
Have only qualified persons remove doors, Have only qualified persons familiar with
panels, covers, or guards for maintenance and electronic equipment install, test, and service
troubleshooting as necessary. H.F. producing units.
Keep hands, hair, loose clothing, and tools The user is responsible for having a qualified electrician prompt-
away from moving parts. ly correct any interference problem resulting from the installa-
Reinstall doors, panels, covers, or guards tion.
when maintenance is finished and before re- If notified by the FCC about interference, stop using the
connecting input power. equipment at once.
Have the installation regularly checked and maintained.
ELECTRIC AND MAGNETIC FIELDS (EMF) Keep high-frequency source doors and panels tightly shut, keep
can affect Implanted Medical Devices. spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away from serv-
icing areas until consulting their doctor and the READ INSTRUCTIONS.
device manufacturer.
Use Testing Booklet (Part No. 150 853) when
servicing this unit.
Consult the Owner’s Manual for welding safety
precautions.
OVERUSE can cause OVERHEATING. Use only genuine replacement parts from the manufacturer.
Read and follow all labels and the Technical Manual carefully be-
Allow cooling period; follow rated duty cycle.
fore installing, operating, or servicing unit. Read the safety in-
Reduce current or reduce duty cycle before formation at the beginning of the manual and in each section.
starting to weld again. Perform maintenance and service according to the Technical
Do not block or filter airflow to unit. Manual, industry standards, and national, state, and local codes.
1-3. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
1-4. EMF Information

Electric current flowing through any conductor causes localized electric 3. Do not coil or drape cables around your body.
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and 4. Keep head and trunk as far away from the equipment in the
induction heating operations) creates an EMF field around the welding welding circuit as possible.
circuit. EMF fields may interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants 5. Connect work clamp to workpiece as close to the weld as
have to be taken. For example, restrict access for passers−by or con- possible.
duct individual risk assessment for welders. All welders should use the
6. Do not work next to, sit or lean on the welding power source.
following procedures in order to minimize exposure to EMF fields from
the welding circuit: 7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
1. Keep cables close together by twisting or taping them, or using a
cable cover. Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
2. Do not place your body between welding cables. Arrange cables If cleared by your doctor, then following the above procedures is recom-
to one side and away from the operator. mended.

SECTION 2 − DEFINITIONS (CE Models)
2-1. Additional Safety Symbols And Definitions

Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05

Do not remove or paint over (cover) the label.
Safe20 2012−05
Do not discard product (where applicable) with general waste.

Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Disconnect input plug or power before working on machine.
Safe30 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
After taking proper precautions as shown, connect power to unit.
Safe29 2012−05
Do not use one handle to lift or support unit.
Safe31 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
= < 60° Always lift and support unit using both handles. Keep angle of lifting
device less than 60 degrees.
Use a proper cart to move unit.
Safe44 2012−05
Hazardous voltage remains on input capacitors after power is turned

V off. Do not touch fully charged capacitors. Always wait 60 seconds
V after power is turned off before working on unit, OR check input ca-
pacitor voltage, and be sure it is near 0 before touching any parts.
>60s V Safe42 2012−05
Become trained and read the instructions before working on the

machine or welding.
Safe40 2012−05

2-2. Miscellaneous Symbols And Definitions
A Amperes Panel−Local
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
V Volts Voltage Input

3 Phase Static Frequency
Converter-Transformer-Rectifier
Lift-Arc Start
Voltage Output Circuit Breaker Remote
(GTAW)
Protective Earth
(Ground)
Postflow Timer Preflow Timer
S Seconds
On Off Positive Negative
Alternating
Current
Gas Input Gas Output
I2 Rated Welding
Current
X Duty Cycle Direct Current Line Connection

U2 Conventional Load
Voltage
U1 Primary Voltage
IP Degree Of
Protection I1max Rated Maximum
Supply Current
I1eff
Maximum Effective
Supply Current
Rated No Load Pulse Background Increase/Decrease

U0 Voltage (Average) Amperage
Initial Amperage
Of Quantity
Normal Trigger Op- Two-Step Trigger Four-Step Trigger

Percent
eration (GTAW) Operation (GTAW) Operation (GTAW)
Hz Hertz
Recall From
Memory
Arc Force (DIG)
HF Impulse Start-
ing (GTAW)
Pulse Percent
Final Slope Final Amperage Initial Slope
On Time
TIG Weld Amps

Contactor Control
Pulser On-Off And Peak Amps Pulse Frequency
(Stick)
While Pulsing
Background Amps Process Pulser Sequence
Suitable For Areas

Output Adjust
S Of Increased
Shock Hazard

SECTION 3 − INSTALLATION
3-1. Important Information Regarding CE Products (Sold Within The EU)

A. Information On Electromagnetic Fields (EMF)
! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
B. Information On Electromagnetic Compatibility (EMC)
! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to
conducted as well as radiated disturbances.
This equipment complies with IEC 61000−3−12 provided that the short−circuit power Ssc is greater than or equal to 1,399,985 at the interface
point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation
with the distribution network operator if necessary, that the equipment is connected only to a supply with a short−circuit power Ssc greater than
or equal to 1,399,985.
ce-emc 1 2010-10
3-2. Serial Number And Rating Label Location

The serial number and rating information for the power source is located on the rear of the machine. Use the rating labels to determine input power
requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
Notes

3-3. Specifications
Max. Rated Peak Amperes Input At Rated Output,
IP Welding 50/60Hz
Open-Cir- Striking
Input Power Rated Output Amperage KVA KW
Rating cuit Voltage Voltage
Range
(U0) (Up) 115 230 400 460
150 A @ 26
Three-Phase VDC, 80∇ 13.1 7.4 6.4 5.2 5.0
23 1 − 200 -−
Stick Process 60% Duty 9-14♦ 15 KV** 0.16* 0.24* 0.25* 0.06* 0.03*
Cycle
175 A @ 17
Three-Phase VDC, 80 10.5 6.0 5.2 4.2 4.0
23 1 − 200
TIG Process 60% Duty 9-14♦ 15 KV** -− 0.16* 0.24* 0.25* 0.06* 0.03*
Cycle
Three-Phase
200 A @ 28 80∇ 15 KV** 18.4 10.3 8.9 7.3 7.0
VDC, 30% 23 1 − 200
Stick Process
Duty Cycle 9-14♦ 0.16* 0.24* 0.25* 0.06* 0.03*
200 A @ 18 80 12.7 7.2 6.2 5.1 4.9

Three-Phase
VDC, 40% 23 1 − 200 15 KV**
TIG Process
Duty Cycle 9-14♦ 0.16* 0.24* 0.25* 0.06* 0.03*
150 A @ 26
Single-Phase VDC, 80∇ 21.7 10.6 5.0 5.0
23 1 − 200 -− -−
Stick Process 60% Duty 9-14♦ 15 KV** 0.23* .25* 0.05* 0.02*
Cycle
175 A @ 17
Single-Phase VDC, 80 17.4 8.5 4.0 4.0
23 1 − 200 15 KV** -−
TIG Process 60% Duty 9-14♦ -− 0.23* .25* 0.05* 0.02*
Cycle
125 A @ 25
Single-Phase VDC, 80∇ 34.1 4.0 3.8
23 1 − 200 15 KV** -− -− -−
Stick Process 50% Duty 9-14♦ 0.42* 0.05* 0.03*
Cycle
150 A @ 16
Single-Phase VDC, 80 29.7 3.4 3.4
23 1 − 200 -− -− -−
TIG Process 70% Duty 9-14♦ 15 KV** 0.42* 0.05* 0.03*
Cycle
100 A @ 24
Single-Phase VDC, 80∇ 28.1 3.2 3.2
23 1 − 200 15 KV** -− -− -−
Stick Process 80% Duty 9-14♦ 0.42* 0.05* 0.03*
Cycle
125 A @ 15
Single-Phase VDC, 80 23.0 2.6 2.6
23 1 − 200 15 KV** -− -− -−
TIG Process 100% Duty 9-14♦ 0.42* 0.05* 0.03*
Cycle
*While idling
** Arc starting device is designed for manual guided operations.
♦Low open-circuit voltage while in TIG Lift Arc, or while in Stick with low open-circuit voltage selected.
∇Normal open-circuit voltage (80 volts) is present while in Stick with normal open-circuit voltage selected.
Duty cycle limitations on units with 115 volt input power are due to the input power cord supplied with the unit.
This unit is equipped with Auto-Linet. The Auto-Line circuitry automatically connects to 120−460 VAC, single- or three-phase power with-
out removing the cover to relink the power source.

3-4. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amper-
age output capabilities of welding
power source. Curves of other set-
tings fall between curves shown.
1 1 5 V A C In p u t
140
120
Stick Max
100
TIG Max
80
Vo lts
60
40
Stick/TIG Min
20 DIG Max
0
0 50 100 150 200 250
Amp eres
O th e r In p u t V o lt a g e s
140
120
Stick Max
100
TIG Max
80
Volts
60
40
Stick/TIG Min
DIG
. Max
20
0
0 50 100 150 200 250
Amperes
*Amperage setting must be reduced to obtain currents less than highlighted data* point. 189 767-A

3-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 7-15), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
90 A @ 100% Duty Cycle For 115 Volt Single-Phase Stick Process

125 A @ 100% Duty Cycle For 115 Volt Single-Phase TIG Process
150 A @ 60% Duty Cycle For Stick Process (Other Voltages)
175 A @ 60% Duty Cycle For TIG Process (Other Voltages)
6 Minutes Welding 4 Minutes Resting
Overheating
0 A or V
15
OR
Minutes Reduce Duty Cycle
189 770-A

3-6. Selecting A Location
1 Line Disconnect Device
Locate unit near correct input
power supply.
Dimensions And Weight ! Special installation may be
34.7 lb (15.7 kg) - without power cord required where gasoline or
37.3 lb (16.9 kg) - with power cord volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
17-1/4 in.
(438 mm)
13-3/8 in.
(333 mm)
7-9/16 in.
(192 mm)
Location And Airflow

1
18 in.
(460 mm)
18 in.
(460 mm)
802 451

3-7. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld

Circuit Not Exceeding
Weld Output
Terminals
! Turn off power before connect-

ing to weld output terminals. 150 ft 200 ft
100 ft (30 m) or Less****
! Do not use worn, damaged, un- (45 m) (60 m)
dersized, or poorly spliced
cables.
10 − 60% Duty 60 − 100% Duty
Welding 10 − 100% Duty Cycle
Cycle Cycle
Amperes*** AWG (mm2)
AWG (mm2) AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30)
150 3 (30) 3 (30) 2 (35) 1 (50)
+ 200 3 (30) 2 (35) 1 (50) 1/0 (60)

−
Output Receptacles
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**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.
( ) = mm2 for metric use
*** Select weld cable size for pulsing application at peak amperage value.
****For distances longer than 100 ft (30 m) and up to 200 ft (60 m), use direct current (DC) output only. For distances longer than those shown
in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-G 2011−07 (TIG)

3-8. Remote 14 Receptacle Information
Socket* Socket Information

A J
K I
B
A Contactor control +15 volts DC.
C L N H 15 VOLTS DC
D M G OUTPUT B Contact closure to A completes 15 volts DC
E F CONTACTOR contactor control circuit and enables output.
C Output to remote control; 0 to +10 volts DC output

to remote control.
REMOTE
OUTPUT D Remote control circuit common.
CONTROL
E 0 to +10 volts DC input command signal from
remote control.
A/V F Current feedback; +1 volt DC per 100 amperes.

AMPERAGE
VOLTAGE H Voltage feedback; +1 volt DC per 10 volts output.
802 541 GND G +15 volts DC GND
CHASSIS K Chassis common.
* The remaining sockets are not used.

If a remote hand control, like the RHC-14, is connected to the Remote 14 receptacle, some current value above min. must be set on the remote
control before the Panel or Remote contactor is turned on. Failure to do so will cause current to be controlled by the panel control, and the remote
hand control will not function.
Notes

3-9. Automation 10-Pin Connection (LX Models)
Socket Socket Information For 10-Pin Receptacle RC2
A Start/Stop
F E
G D
J
C B Gas
H
I
A B
C Output enable
D Chassis ground
E Final slope − collector
F Final slope − emitter
G Pulse lockout − collector
Ref. 802 458 H Pulse lockout − emitter
I Valid arc − collector
J Valid arc − emitter
Definitions Of Inputs And Outputs
Inputs
A - Closure to D starts the weld cycle. Opening closure stops weld cycle. During 2T operation, a momentary closure (greater than 100ms, but
less than 3/4 seconds) starts and stops weld output.
B - Closure to D turns on gas. If a preflow time is entered, the preflow cycle will time out before arc initiation. If a post flow time is entered, the
post flow cycle will time out at the end of the weld, even if B to D closure is opened.
C - Closure to D must be maintained at all times. If the closure between pins C and D is broken, an output disable occurs, Postflow begins to
time out, and HELP 13 will be displayed on the meters.
Outputs
Outputs are isolated open-collector transistor which are able to conduct at least 60 mA of current and 27 VDC peak.
Final Slope - output is on when in Final Slope.
Pulse Lockout - output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, during background time, and when the pulse
frequency is less than 10 Hz.
Arc On - output is on when the contactor is on and amperage is greater than 5 amps, or output voltage is greater than 5 volts but less than 50
volts.
3-10. Typical Automation Application
Coil resistance plus R

should be chosen to CR1 To User Equipment
CR1 limit current to 75 mA
+
User supplied power
up to 27 volts DC
R
peak
Typical 10-Pin Output −
Collector
Emitter

3-11. Gas Connections
1 Gas Fitting
Fittings have 5/8-18 right-hand
threads (3/8-19 BSPP on CE units).
2 Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
3 Regulator/Flowmeter
4 3 2
4 Flow Adjust
Typical flow rate is 15 cubic feet per
hour (7.1 liters per minute).
1 Connect customer supplied gas
hose between regulator/flowmeter
and gas fitting on rear of unit.
Tools Needed:
11/16, 1-1/8 in., (21 mm)
802 452
3-12. TIG HF Impulse/ Lift-Arc DCEN (Direct Current Electrode Negative) Connections
! Turn off power before mak-
ing connections.
1 Negative (−) Weld Output
Terminal
Connect TIG torch to negative weld
output terminal.
2 Gas Out Connection
Connect torch gas hose to gas out
fitting.
3 Positive (+) Weld Output
Terminal
Connect work lead to positive weld
output terminal.
4 Remote 14 Receptacle
Connect desired remote control to
Remote 14 receptacle.
5 Gas In Connection
5
Connect gas hose from gas supply
to gas in fitting.
1
4
Tools Needed:
11/16 in., (21 mm)
Ref. 802 471

3-13. Stick DCEP (Direct Current Electrode Positive) Connections
! Turn off power before mak-
ing connections.
Terminal
Connect work lead to negative weld
output terminal.
Terminal
Connect electrode holder to posi-
tive weld output terminal.
3 Remote 14 Receptacle
If desired, connect remote control
to Remote 14 receptacle (see Sec-
tion 3-8).
Ref. 802 471
Notes
For additional welding information and resources, visit:

www.MillerWelds.com/resources/improving-your skills

3-14. TIGRunner Connections
Cart and cooler are optional equip-
ment.
1 Gas Cylinder
2 Chains
Secure gas cylinder to cart with
chains.
Connect gas hose to welding power
source (see Section 3-11).
Connect work lead and torch to
welding power source (see Section
3-12).
3 Water-Out (To Torch)
1 Connection
Connect torch water-in (blue) hose
to welding power source water-out
connection.
4 Water-In (From Torch)
5 Connection
Connect torch water-out (red) hose
to welding power source water-in
connection.
6 5 115 Or 230 Volt AC Grounded
Receptacle (Depending On
Model)
For 115 volt models, an individual
branch circuit capable of carrying
15 amperes and protected by fuses
or circuit breakers is recom-
mended. Recommended fuse or
2 circuit breaker size is 15 amperes.
4 For 230 volt models, an individual
branch circuit capable of carrying
10 amperes and protected by fuses
or circuit breakers is recom-
3 mended. Recommended fuse or
circuit breaker size is 10 amperes.
6 Power Cord
NOTICE − Do not cut plug from 115
volt cord and attempt to rewire for
230 volts, or do not cut plug from
230 volt cord and attempt to rewire
for 115 volts.
GTAW Or Where
Application
HF* Is Used
Low Conductivity Coolant

No. 043 810**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
Tools Needed:
Coolant
11/16 in., (21 mm for CE units)

*HF: High Frequency Current
**Coolant 043 810, a 50/50 solution, protect to -37° F (-38°C) and resist algae growth.
NOTICE − Use of any coolant other than those listed in the table voids the warranty
on any parts that come in contact with the coolant (pump, radiator, etc.).
805 338-A

3-15. Electrode and Amperage Selection Chart
AMPERAGE
RANGE
ELECTRODE
DIAMETER
100
150
200
250
300
350
400
450
50
PENETRATION
3/32
ELECTRODE
POSITION
1/8
USAGE
6010 5/32
DC*
AC
& 3/16
6011 7/32
1/4
1/16
6010 EP ALL DEEP 5/64
MIN. PREP, ROUGH 3/32
6011 EP ALL DEEP HIGH SPATTER 1/8
6013 5/32
6013 EP,EN ALL LOW GENERAL 3/16
SMOOTH, EASY, 7/32
7014 EP,EN ALL MED FAST 1/4
LOW HYDROGEN, 3/32
7018 EP ALL MED 1/8
STRONG
FLAT 7014 5/32
7024 EP,EN HORIZ LOW SMOOTH, EASY, 3/16
FILLET FASTER 7/32
1/4
NI-CL EP ALL LOW CAST IRON 3/32
308L EP ALL LOW STAINLESS 1/8
7018 5/32
*EP = ELECTRODE POSITIVE (REVERSE POLARITY) 3/16
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY) 7/32
1/4
3/32
1/8
7024 5/32
3/16
7/32
1/4
3/32
Ni-Cl 1/8
5/32
3/16
3/32
308L 1/8
5/32
3-16. Electrical Service Guide

Actual input voltage should not fall below 103 volts AC or rise above 506 volts AC. If actual input voltage is outside this range, unit may not operate
according to specifications.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
Single-Phase, Single-Phase,
Three-Phase, 60% Duty
100% Duty 60% Duty
Cycle
Cycle Cycle
Input Voltage (V)
115 230 230 400 460
Input Amperes (A) At Rated Output 25 22 13.1 7.4 6.4
Max Recommended Standard Fuse Rating In Amperes 1
Time Delay Fuses 2 25 25 15 8 8
Normal Operating Fuses 3 35 30 20 10 10
Min Input Conductor Size In AWG 4 10 12 14 14 14
102 308 407

Max Recommended Input Conductor Length In Feet (Meters) 57 (17) 79 (24)
(31) (94) (124)
Min Grounding Conductor Size In AWG 4 10 12 14 14 14
Reference: 2014 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
3-17. Connecting Input Power
A. Connecting Three-Phase Input Power

! Installation must meet all National
and Local Codes − have only quali-
3 fied persons make this installation.
! Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
= GND/PE Earth Ground
! Always connect green or green/
yellow conductor to supply
4 grounding terminal first, and never
to a line terminal.
The Auto-Line circuitry in this unit au-

tomatically adapts the power source
7 to the primary voltage being applied.
Check input voltage available at site.
This unit can be connected to any in-
put power between 120 and 460 VAC
without removing cover to relink the
power source.
2 See rating label on unit and check input
voltage available at site.
For Three-Phase Operation
1 Input Power Cord.
2 Disconnect Device (switch shown in
the OFF position)
3 Green Or Green/Yellow Grounding
L1 Conductor
3 L2 5 4 Disconnect Device Grounding
Terminal
6 L3 5 Input Conductors (L1, L2 And L3)
6 Disconnect Device Line Terminals
1 Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2, and L3
to disconnect device line terminals.
7 Over-Current Protection
Select type and size of over-current
protection using Section 3-16 (fused dis-
connect switch shown).
Close and secure door on disconnect de-
vice. Remove lockout/tagout device, and
place switch in the On position.
Tools Needed:
2/04 - Ref. 802 136-A

B. Connecting Single-Phase Input Power
! Installation must meet all National
and Local Codes − have only quali-
fied persons make this installation.
! Disconnect and lockout/tagout in-
put power before connecting input
conductors from unit.
! Always connect green or green/
1 yellow conductor to supply
grounding terminal first, and never
to a line terminal.
8 =GND/PE Earth Ground The Auto-Line circuitry in this unit au-

tomatically adapts the power source
to the primary voltage being applied.
10 Check input voltage available at site.
This unit can be connected to any in-
put power between 120 and 460 VAC
without removing cover to relink the
power source.
7
See rating label on unit and check input
voltage available at site.
9
1 Black And White Input Conductor
(L1 And L2)
L1 2 Red Input Conductor
1
L2 3 Green Or Green/Yellow Grounding
3 Conductor
1 4 Insulation Sleeving
5 Electrical Tape
Insulate and isolate red conductor as
6 shown.
2 6 Input Power Cord.
3 7 Disconnect Device (switch shown in
the OFF position)
8 Disconnect Device Grounding
6 Terminal
9 Disconnect Device Line Terminals
4
5 Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 and L2 to
disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current
protection using Section 3-16 (fused dis-
connect switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed: 2/04 - Ref. 802 136-A

SECTION 4 − OPERATION
4-1. Controls
3 2
4 5 9 10 7
For all front panel switch pad controls: press See Section 4-4. 7 Adjust Controls
switch pad to turn on light and enable 3 Voltmeter See Section 4-11.
function. See Section 4-5. 8 Power Switch
Green on nameplate indicates a TIG func- 4 Process Controls Use switch to turn unit On/Off.
tion, Gray indicates a Stick function. See Section 4-6. 9 Pulser Controls (DX And
1 Encoder Control 5 Output Controls LX Models)
See Section 4-8. See Section 4-9.
Use encoder control in conjunction with applica-
ble front panel function switch pads to change 6 Amperage And Spot Time Control 10 Sequencer Controls (DX, LX
values for that function. See Section 4-2. For Amperage control, see Section 4-3. And All CE Models)
2 Ammeter And Parameter Display For Spot Enable, see Section 5-5. See Section 4-10.
207 690-A / 802 452

4-2. Encoder Control
1 Encoder Control
Use control in conjunction with ap-
plicable front panel function switch
pad to set values for that function.
4-3. Amperage Control

1 A (Amperage Control)
2 Encoder Control
3 Ammeter
See Section 4-12 for Amperage
control range.
3
Press Amperage switch pad and
turn Encoder control to set weld
amperage. Weld amperage setting
2 is also peak amperage when Pulser
function is active (see Section 4-9).
4-4. Ammeter And Parameter Display

1 Ammeter
Displays actual amperage while
welding. Meter also displays preset
parameters for any of the following
units of measure when they are ac-
1 tive: amperage, time, percentage or
frequency. The corresponding
LED, located directly below the am-
meter, will also illuminate.

4-5. Voltmeter
1 Volt Meter
Displays output or open circuit volt-
age. If output is off, the voltmeter will
display a series of three dashes
(-−−). Open circuit voltage is dis-
played if power is on and output is
available.
1
4-6. Process Control

1 Process Control
Press switch pad until desired pro-
cess LED is illuminated:
TIG HF Impulse - When selected,
a pulsed HF (non-contact) (see
Section 4-7) arc starting method is
activated. This method can be used
with either AC or DC TIG welding.
Make connections according to
Section 3-12.
TIG Lift-Arc - When selected, is
an arc starting method in which the
electrode must come in contact
with the workpiece to initiate an arc
(see Section 4-7). This method can
be used with either AC or DC TIG
1 welding. Make connections ac-
cording to Section 3-12.
Stick (SMAW) - This method can
be used with either AC or DC Stick
welding. Make connections ac-

4-7. Lift-Arc™ And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arc button light is On, start arc as
follows:
1 TIG Electrode
2 Workpiece
Touch tungsten electrode to workpiece at weld
start point, enable output and shielding gas with
torch trigger, foot control, or hand control. Hold
Lift-Arc Start Method electrode to workpiece for 1-2 seconds, and
1 2 slowly lift electrode. Arc is formed when electrode
is lifted.
Normal open-circuit voltage is not present before
tungsten electrode touches workpiece; only a low
sensing voltage is present between electrode and
workpiece. The solid-state output contactor does
1−2 not energize until after electrode is touching work-
“Touch” Seconds piece. This allows electrode to touch workpiece
without overheating, sticking, or getting
contaminated.
Application:
Lift-Arc is used for the DCEN or AC GTAW pro-
cess when HF Start method is not permitted, or to
replace the scratch method.
HF Start
When HF Start button light is On, start arc as
follows:
Do NOT Strike Like A Match! 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 for the DCEN GTAW process
when a non-contact arc starting method is
required.
4-8. Output Control
1 Output Control controlled at the remote control, not at trigger input is functional (see Section
the welding power source. 5-3B).
Press switch pad until desired parameter
LED is illuminated. If On/Off only type trigger is used, it This switch function can be reconfi-
must be a maintained switch. All Se- gured for 4T, 4T Momentary or Mini
RMT STD (Remote Standard)
quencer functions become active, and Logic See Section 5-3)
Application: Use Remote Trigger (Stan- must be set by the operator.
dard) when the operator desires to use a ON
RMT 2T HOLD
foot pedal or finger amperage control (see
Application: Use Remote Trigger Hold Output will energize two seconds after be-
Section 5-3A).
(2T) when long extended welds are made. ing selected.
When a foot or finger remote current Remote Trigger Hold (2T) can help to re-
duce operator fatigue.
Application: Use Output On for Stick
control is connected to the welding (SMAW) welding, or for Lift-Arc without the
power source, initial amps, initial If a foot or finger current control is con- use of a remote control (see Section
slope, final slope, and final amps are nected to the welding power source, only 5-3G).

4-9. Pulser Control (DX And LX Models)
1 Pulser Control
Pulsing is available only while using
the TIG process, it cannot be se-
lected if the Stick process (see Sec-
tion 4-6) is active. Controls can be ad-
justed while welding.
Press switch pad to enable pulser.
ON - When illuminated, this LED in-
3 dicates the pulser is on.
Press switch pad until desired pa-
rameter LED is illuminated.
2
To turn Pulser off, press and release
switch pad until the On LED turns off.
2 Encoder Control
3 Ammeter
Turn encoder (see Section 4-2) to se-
lect appropriate value for active pulse
parameter. Value selected is shown
on the ammeter (see Section 4-4).
Also, the ammeter LED for the corre-
sponding unit of measure (%, A, s,
Hz) of the active parameter will be il-
luminated.
See Section 4-12 for all Pulser pa-
rameter ranges.
PPS (Pulses Per Second or Pulse
Frequency) - Control is used to de-
1 termine appearance of weld bead.
PEAK t - The percentage of each
pulse cycle that can be spent at the
peak amperage level.
BKGND A (Background Amps) - Use

Background Amps control to set the
low pulse of the weld amperage,
which cools the weld puddle and af-
fects overall heat input. Background
4 Amps is set as a percentage of peak
amperage.
4 Pulsed Output Waveforms
Example shows affect changing the
Peak Time control has on the pulsed
Percent (%) Peak output waveform.
Time Control Setting Pulsed Output Waveforms
Peak amperage is set using the
PPS Amperage control (see Section
Balanced (50%)
4-3). Peak amperage is the high-
Bkg Amp
est welding amperage allowed to
Peak Amp occur in the pulse cycle. Weld
penetration varies directly with
peak amperage.
Application:
Pulsing refers to the alternating rais-
More Time ing and lowering of the weld output at
At Peak (80%) a specific rate. The raised portions of
Amperage the weld output are controlled in
width, height, and frequency, forming
pulses of weld output. These pulses
and the lower amperage level be-
tween them (called the background
More Time amperage) alternately heat and cool
At the molten weld puddle. The com-
(20%) bined effect gives the operator better
Background
Amperage control of penetration, bead width,
crowning, undercutting, and heat in-
put. Controls can be adjusted while
welding.
Pulsing can also be used for filler ma-
terial addition technique training.

4-10. Sequencer Controls (DX Models Only)
1 Sequencer Control
Sequencing is available only while
using the TIG process, but is dis-
abled if a remote foot or finger cur-
rent control is connected to the Re-
mote receptacle while in the RMT
STD mode. Sequencer parameters
cannot be selected if the Stick pro-
cess (see Section 4-6) is active.
Press switch pad until desired pa-
rameter LED is illuminated.
2 Encoder Control
3 Ammeter
3 Turn encoder (see Section 4-2) to
set appropriate value for active se-
quence parameter. Value selected
2 is shown on the ammeter (see Sec-
tion 4-4). Also, the ammeter LED for
the corresponding unit of measure
(A, S) of the active parameter will be
illuminated.
See Section 4-12 for all Sequencer
4 parameter ranges.
INITIAL A (Initial Amperage) - Use
control to select a starting amper-
age that is different from the weld
amperage.
Application:
Initial Amperage can be used while
GTAW welding to assist in preheat-
ing cold material prior to depositing
filler material, or to ensure a soft
start.
INITIAL t (Initial Time)(LX Models
1 Only) - Press control again and turn
Encoder to select amount of time
that is needed at the beginning of
the weld.
INITIAL SLOPE t (Initial Slope
Time) Use control to select amount
of time that it takes to slope up/
down from initial amperage to weld
amperage. To disable, set to 0.
4 Amperage Switch Pad
Weld Time (LX Models Only) -
Press Amperage switch pad twice.
Set desired length of weld time.
FINAL SLOPE t (Final Slope Time)
- Use control to select amount of
time that it takes to slope up/down
from weld amperage to final amper-
age. To disable, set to 0.
Application:
Final Slope 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.
FINAL A (Final Amperage) - Use
control to select amperage to which
weld amperage has sloped up/
down to.
FINAL t (Final Time)(LX Models
Only) - Press control again and turn
Encoder to select amount of time
that is needed at the end of the
weld.

4-11. Adjust Controls (Preflow/Post Flow/DIG/Purge)
1 Adjust
Press switch pad until desired function
LED is illuminated.
2 Encoder Control
3 Ammeter
Turn encoder to set appropriate value for
active Adjust parameter. Value selected is
shown on the ammeter (see Section 4-4).
Also, the ammeter LED for the correspond-
3 ing unit of measure (S, %) of the active pa-
rameter will be illuminated.
See Section 4-12 for all Adjust parameter
ranges.
2
PREFLOW - If the TIG HF process is ac-
tive (see Section 4-6) and Preflow is
shown on the control panel, use control to
set length of time gas flows before arc initi-
ation. To set Preflow time for models that
do not have Preflow Time control on the
front panel, see Section 5-1.
Application: Preflow is used to purge the
immediate weld area of atmosphere. Pre-
flow also aids in consistent arc starts.
POST FLOW - If the TIG process is active
(see Section 4-6), use control to set length
of time gas flows after welding stops.
AUTO POST FLOW - Creates a post flow
time scaled at 1 second per 10 amps amps
of the peak weld amperage for a given weld
cycle. Auto post flow is limited to an 8
second minimum, or to the maximum pre-
set post flow time.
Application:
1
Postflow is required to cool tungsten and
weld, and to prevent contamination of
tungsten and weld. Increase postflow time
if tungsten or weld are dark in appearance.
DIG - If the Stick process is active (see
Section 4-6), use control to set amount of
DIG. When set at 0, short-circuit amperage
at low arc voltage is the same as normal
welding amperage.
When setting is increased, short-circuit
amperage at low arc voltage increases.
Application:
Control helps arc starting or making verti-
cal or overhead welds by increasing am-
perage at low arc voltage, and reduces
electrode sticking while welding.
PURGE - While in the TIG process (see
Section 4-6), to activate the gas valve and
start the purge function, push and hold the
Adjust switch pad for the desired amount of
purge time. To set from 0 to 50 seconds of
additional purge time, continue to hold the
Adjust switch pad while turning the encod-
er control. Factory default setting is 0.
While Purge is active, [PUR] is shown in
the left display, and purge time is shown in
the right display.
Pressing any front panel switch pad will
end the purge time display, but gas will
continue to flow until the preset time has
timed out.
Application: Purge is used to clear the
shielding gas lines of contaminates.

4-12. Factory Parameter Defaults And Range And Resolution
Parameter Default Range And Resolution

PROCESS TIG HF Impulse TIG HF Impulse / TIG Lift / Stick
* Stick OCV Low OCV Low OCV / Normal OCV
*Stick Stuck Check ScI (On) ScI (On) / Sc0 (Off)
OUTPUT RMT STD RMT STD / RMT 2T / ON
RMT 2T1 2T RMT 2T can be reconfigured for: 2T / 4T / Mini Logic

/ 4T Momentary
A MAIN / PEAK
DC TIG 150 A 1 − 200 Amps
DC STICK 110 A 1 − 200 Amps
*Spot Off On/Off
Spot Time 0T 0.0 − 999 Seconds
**Weld Time 0T 0.0 − 999 Seconds
PULSER Off ON / OFF
PPS 100 Hz Dual Range And Resolution
0.1 − 9.9 / 10 − 500 Hertz
PEAK t 40% 5 − 95 Percent
BKGND A 25% 5 − 95 Percent
*Meter “PPP” Display −−− (Off) −−− (Off) / PPPP (On)
SEQUENCER
INITIAL A 20 A 1 − 200 Amps
**Initial Time 0 S 0.0 − 25.0 Seconds
INITIAL SLOPE t 0S 0.0 − 25.0 Seconds
FINAL SLOPE t 0S 0.0 − 25.0 Seconds
FINAL A 5A 1 − 200 Amps
**Final Time 0S 0.0 − 25.0 Seconds
ADJUST
*PREFLOW 0.2 S 0.0 − 25.0 Seconds
POST FLOW Auto Auto 1.0 − 50.0 Seconds @ 0.2 Second Resolu-
DIG 30% tion
0 − 100 Percent
MAXSTAR:
*Tungsten .094 GEN, .020, .040, .062, .094, .125
***Amperage 60 1 − 200 Amps
***Time 1 1 − 200 Milliseconds
***Start Slope Time 40 0 − 250 Milliseconds
***Preset Amperage Minimum 3 1 − 20 Amps
* Parameter adjusted using an Advanced Functions configuration only (see Section 5).
** Parameter used with the automation option (LX models only).
***Parameter adjust using Tungsten GEN only.

4-13. Resetting Unit To Factory Default Settings (All Models)
1 Process Switch Pad
2 Output Switch Pad
3 Adjust Switch Pad
4 Power Switch
To reset all welding power source
functions to original factory settings,
lockout feature must be off (see Sec-
tion 5-8). Next turn power on, then
press the Process, Output, and Ad-
just switch pads before the software
version clears the meters, and hold
the switch pads until software ver-
sion clears the meters.
3
1 2
Rear Panel

4-14. Arc Timer/Counter Display
3/4
123 456
1
And
Rear Panel
1 Output And Amperage Controls 3 Arc Timer Display 4 Arc Counter

2 Power Switch Upon power up as described above, the After 5 seconds, the meter A LED turns on,
meter S LED will turn on, and arc time will and the arc counter will be displayed for the
To display the arc timer/counter, turn power be displayed for 5 seconds as [000 000 ] to next 5 seconds as [000 000] to [999 999].
switch on, and then press the Amperage [999 999]. The first four numbers indicate The maximum arc cycle count is 999 999.
Control and Output switch pads before the hours, and the last two numbers indicate
software version clears the meters, and minutes. Arc time shown in example is read
hold the switch pads until software version as 1,234 hours and 56 minutes. Maximum
clears the meters arc time is 9,999 hours and 59 minutes.

SECTION 5 − ADVANCED FUNCTIONS
5-1. Accessing Advanced Functions
1 Amperage Switch Pad • Output Remote Hold And Trigger Func- is turned off in an attempt to save the rod
2 Adjust tions (see Section 5-3) − For reconfigur- for reuse.
ing RMT 2T Hold for 3T, 4T Momentary,
3 Encoder Control • Lockout Functions (see Section 5-8) −
or Mini Logic
Allows you to turn the lockout function on
To access the advanced functions, press
• Preflow Time (see Section 5-4) − Sets the and off and adjust the lockout levels.
and hold the Amperage (A) switch pad and
gas flow time before TIG arc starts.
then press the Adjust switch pad. To scroll • Meter Displays (see Section 5-9) − Al-
through the advanced functions, press and • Spot Enable (see Section 5-5) − Allows lows you to set meters to display weld
release the Adjust switch pad. Use the En- you to turn the spot function on and be voltage and amperage, or blank meters
coder control to change parameters for available for all programs. while pulse welding.
each function.
• Stick OCV Selection (see Section 5-6) − • External Pulse Control (see Section
Advanced Functions: Allows you to select either low or normal 5-10) − Used for external pulse control
OCV (open circuit voltage). when external pulse control is desired.
• Programmable TIG Start Parameters
(see Section 5-2) − Allows you to set • Stick Stuck Check Selection (See Sec- To exit advanced functions, press and hold
amps, time, and polarity to customize arc tion 5-7) − With Stick Stuck Check on and the Amperage (A) switch pad and then
starts for different tungstens. the welding electrode (rod) stuck, output press the Adjust switch pad.

5-2. Programmable TIG Start Parameters
A. Tungsten Selection
tun 094
1
Current (A)
Start Amperage
Preset Amperage Minimum
Start Time
Start Slope
Time
1 Amperage Switch Pad Preset TIG Start Parameters perage, Start Time, Start Slope Time, and
Use Encoder control to select a tungsten Preset Amperage Minimum. If it is neces-
2 Encoder Control
size from the following: .020, .040, .062 sary or desired to manually set the TIG
3 Amps Meter (1/16 in.), .094 (3/32 in.), or .125 (1/8 in.) starting parameters, turn the encoder until
(.094 is the default). When one of the listed [GEn] is displayed on the amps meter (see
tungsten sizes is selected, the following Section B).
TIG starting parameters are preset: Am-

B. Selecting GEN
1 Encoder Control
2 Amps Meter
3 Amperage Switch Pad
If [GEn] is selected and displayed
on the amps meter, the TIG starting
parameters for a .094 tungsten are
the default: Start Amperage = 60 A,
Start Time = 1 ms, Start Slope Time
2 = 40 ms, Preset Minimum Amps =
3 A. These parameters can be
manually changed by pressing the
1 Amperage switch pad to step
through each adjustable paramet-
GEn er. To change parameters, see Sec-
tions C, D, E, and F.
GEN Default DC TIG Start Parameter Relationships

Current (A)
Start Amperage
60 Amps

3 Amps
Start Time 1 ms
Start Slope Time

40 ms

C. Changing Programmable TIG Start Amperage
StA 20
1
Current (A)
Start
Amperage
1 Amperage Switch Pad To adjust TIG Start Amperage proceed as the amps meter, and can be adjusted (see
follows: Section 4-12) by turning the Encoder con-
2 Encoder Control Press Amperage switch pad. Switch pad trol.
LED turns on, and meter A LED turns on. To change Start Time, proceed to Section
3 Amps Meter The current Start Amperage is displayed on D.
D. Changing Programmable Start Time
Stt 10
Current (A)
1
Start Time
1 Amperage Switch Pad ceed as follows: and can be adjusted by turning the Encoder
2 Encoder Control control (see Section 4-12).
Press Amperage switch pad, and meter S
3 Amps Meter LED turns on. The current Start Time is dis- To change Start Slope Time, proceed to
To adjust Programmable Start Time pro- played in milliseconds on the amps meter, Section E.

E. Changing Start Slope Time
StS 20
Current (A)
Start Slope Time
1 Amperage Switch Pad To adjust Start Slope Time proceed as fol- seconds on the amps meter, and can be ad-
lows: justed (see Section 4-12) by turning the
2 Encoder Control Press Amperage switch pad. Switch pad Encoder control.
LED turns on, and meter S LED turns on. To change Preset Amperage Minimum,
3 Amps Meter The Start Slope Time is displayed in milli- proceed to Section F.
F. Changing Preset Amperage Minimum
PA_ 5
1
Current (A)
1 Amperage Switch Pad Press Amperage switch pad. Switch pad Whatever amperage is selected as the
2 Encoder Control LED turns on, and meter A LED turns on. preset amperage minimum, is the min-
The Preset Minimum Amperage is dis- imum amperage that the machine will
3 Amps Meter played on the amps meter, and can be ad- provide.
To adjust Preset Amperage Minimum pro- justed (see Section 4-12) by turning the
ceed as follows: Encoder control.

5-3. Output Control And Trigger Functions
A. Remote (Standard) Torch Trigger Operation
Current (A)
Main Amps
Initial Slope Final Slope
Initial Amps
Final Amps
Preflow Postflow
P&H R R
Maintained Switch Foot Or Finger
Remote Control
P&H = Push trigger and hold
R = Release trigger.
When a foot or finger remote current control is connected to the welding power source, initial amps, initial slope, final slope and final
amps are controlled by the remote control, not by the welding power source.
B. Remote 2T Torch Trigger Operation
Current (A)
Main Amps
Initial Amps
Final Amps
Preflow Postflow
P&R
P&R
P&R = Push trigger and release.
If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.

C. 3T Specific Trigger Method
1 2
rt 3t = 3T
Current (A)
Remote Trigger Operation
*
*
*
*
*
* *
A B C D E
Preflow Initial Amps /Initial Slope Main Amps Final Slope /Final Amps Postflow
* Arc can be extinguished at any time by pressing and releasing both initial and final switches, or by lifting the torch and breaking the arc.
1 3T (Specific Trigger Operation) Operation: C. When main amperage level is reached,

Sequencer is required to reconfigure for 3T. initial switch can be released.
A. Press and release initial switch within 3/4
3T requires a specific type of remote con- second to start shielding gas flow. To stop D. Press and hold the final switch to de-
trol with two independent momentary- the preflow sequence before preflow time crease amperage at final slope rate (re-
contact switches. One will be designated elapses (25 seconds), press and release lease switch to weld at desired amperage
initial switch, and it must be connected be- final switch. The preflow timer will reset level).
tween Remote 14 receptacle pins A and B. and the weld sequence can be started
The second will be designated as the final E. When final amperage has been reached,
again.
switch, and it must be connected between the arc extinguishes and shielding gas
Remote 14 receptacle pins D and E.
If an initial switch closure is not made flows for the time set on the Postflow con-
trol.
2 Encoder Control again before preflow time ends, gas flow
To select 3T, turn Encoder control. stops, the timer resets, and an initial Application:
Definitions: switch press and release is necessary to
Initial slope rate is the rate of amperage start the weld sequence again.
With the use of two remote switches instead
change determined by the initial amperage, of potentiometers, 3T gives the operator the
initial slope time, and main amperage. B. Press initial switch to start arc at initial ability to infinitely increase, decrease, or
Final slope rate is the rate of amperage amps. Holding switch will change amper- pause and hold amperage within the range
change determined by the main amperage, fi- age at initial slope rate (release switch to determined by the initial, main, and final am-
nal slope time, and final amperage. weld at desired amperage level). perages.

D. 4T Specific Trigger Method
1 4T (Specific Trigger Operation)

2 Encoder Control
To select 4T, turn Encoder control.
Torch trigger operation is as shown.
4T allows the operator to toggle between weld
current and final current.
1 2 When a remote switch is connected to the

welding power source, use the remote
switch to control the weld cycle. Amperage
is controlled by the welding power source.
Application:
rt 4t = 4T Use 4T trigger method when the functions of a
remote current control are desired, but only a
remote on/off control is available.
Current (A)
Torch Trigger Operation

Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Preflow Postflow
P/H R P/R P/R P/H R
P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds

E. Mini Logic Operation
1 Mini Logic Meter Display

2 Encoder Control
To select Mini Logic, turn Encoder control.
Torch trigger operation is as shown.
Mini logic allows the operator to toggle be-
1 2 tween initial slope or main amps and initial
amps. Final Amperage is not available. Final
slope will always slope to minimum amperage
and end the cycle.
rt When a remote switch is connected to the

4tL = Mini Logic welding power source, use the remote
switch to control the weld cycle. Amper-
age is controlled by the welding power
source.
Application: This ability to change current
levels without either initial slope or final slope,
gives the operator the opportunity to adjust
filler metal without breaking the arc.
Torch Trigger Operation
Main Amps

*
Initial Amps
* * *
Preflow Postflow
P/H R P/R P/R P/R P/R P/R P/H
P/H = Push and hold trigger; R = Release trigger; P/R = Push trigger and release in less than 3/4 seconds
* = Arc can be extinguished at final slope rate at any time by pushing and holding trigger

F. 4T Momentary Operation
1 4T Momentary Meter Display

2 Encoder Control
To select 4T Momentary, turn Encoder con-
1 trol.
2
4T Momentary torch trigger operation is as
shown.
When a remote switch is connected to

the welding power source, use the re-
mote switch to control the weld cycle.
Amperage is controlled by the welding
rt 4tE = 4T Momentary Main
power source.
Application:
Use 4T Momentary trigger method when the
functions of a remote current control are de-
sired, but only a remote on/off control is avail-
able.
Current (A)
Main Amps
Initial Amps
Final Amps
*
Preflow Postflow
P/R P/R P/R P/R P/R
P/R = Push and release trigger; * = Push and releasing during final slope will break the arc and go to postflow
For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends.

G. On Trigger Operation
Voltage (V)
ON
2 Sec
Current (A)
Stick
Touch Stick
Electrode Lift Stick
Electrode
Current (A)
Lift
Main Amperage
Initial Amperage Initial Slope
Touch Current
Touch Tungsten
Lift Tungsten Lift Tungsten
Slightly

5-4. Setting Preflow Time
1 Encoder Control
Turn encoder to select from 0 to
25 seconds of preflow. The value
selected is displayed on the am-
1 meter.
Application: Preflow is used to
purge the immediate weld area
of atmosphere. Preflow also aids
in consistent arc starting.
PrE 0.2
5-5. Spot Enable
1 Encoder Control
2 Ammeter Parameter
Selection
3 Amperage Control Switch
Pad
2
Turn encoder to turn Spot on and
off. Once on exist set-up and
press Amperage control switch
pad twice and turn encoder to set
1 spot time. The spot time default
Spot Off is zero for each program. Spot
Enable works in RMT STD and
RMT 2T Hold only. When a foot
control is connected, amperage
is controlled at the machine, not
by the remote control.
3
Application: Used for tacking
and thin sheet joining
5-6. Stick Open-Circuit Voltage (OCV) Selection
1
2
oc LO
1 Encoder Control played on the meters. Application: For most Stick applications
When Stick low OCV is selected, open-cir- use low open-circuit voltage. Use normal
2 Meter Display
cuit voltage is between 9 and 14 volts. open-circuit voltage for hard to start Stick
Turn Encoder to change between low OCV When Stick normal OCV is selected, open- electrodes, or if required for your particular
and normal OCV. Active selection is dis- circuit voltage is approximately 72 volts. application.

5-7. Stick Stuck Check Selection
Stc ON
1 Encoder Control Application: For most Stick applications, when this function is desired.
2 Ammeter Parameters Select Display use Stick Stuck Check off. With Stick
Stuck Check on and the welding electrode
Turn Encoder to change between Stick (rod) stuck, output is turned off in an at- Some applications may require Stick
Stuck Check [ON and [OFF] meter display. tempt to save the rod for reuse. This allows Stuck Check to be turned off. For ex-
When Stick Stuck Check is on and the the operator time to un-stick the rod, or dis- ample: Large stick electrodes operat-
welding electrode (rod) is stuck, output is connect the rod holder from the rod without ing at high amperages would require
turned off. arc occurring. Turn Stick Stuck Check on Stick Stuck Check to be turned off.
5-8. Lockout Functions
A. Accessing Lockout Capability
Toggle
2
Loc oFF
Select Lockout Level
1, 2, 3, or 4
Toggle
cod oFF Select Code Number

1 to 999
See Section 4 for explanation of controls referred to in all of thru [999]. IMPORTANT: remember this code number, as you will
Section 5-8. need it to turn the lockout feature off.
There are four (1−4) different lockout levels. Each successive level Toggle Amperage (A) switch pad until lock is displayed. You may now
allows the operator more flexibility. select a lockout level.
Before activating lockout levels, be sure that all procedures and There are four lockout levels available. Turn Encoder control to se-
parameters are established. Parameter adjustment is limited lect a lockout level (see Sections 5-8B for lockout level descriptions).
while lockout levels are active.
Once the desired three digits have been entered and a lockout level
To turn On the lockout feature, proceed as follows: selected, exit advanced functions mode (see Section 5).
1 Encoder Control
To turn Off the lockout feature, proceed as follows:
2 Amperage (A) Switch Pad
Press Amperage (A) switch pad to toggle between the lock and code Use Encoder control to enter the same code number that was used
displays. Toggle switch pad until code is displayed. to turn on the lockout feature.
Turn Encoder control to select a lockout code number. The code Press the Amperage (A) switch pad. The amperage (right) meter dis-
number will appear on the amp meter. Select any number from [1] play will change to [OFF]. The lockout feature is now off.

B. Lockout Levels
Levels 1, 2, And 3
Use Encoder Control To Adjust

L3 Amperage ±10% Of Preset
Value.
Indicates which functions are available

for the corresponding lockout level.
L2 L1 L3
Level 4
A J
K I
B
C L N H
D M G
E F
Before activating lockout levels, be ited by lock level 1, [LOCK][LEV1] is dis-

played as a reminder.
limits of the machine. If operator tries to go
beyond the ±10%, the amperage (right) me-
sure that all procedures and parame-
ter will display [LOCK][LEV3] as a reminder.
ters are established. Parameter adjust- Level 2
ment is limited while lockout levels are Pulser ON/Off Control
active. Remote amperage control is not avail-
able in level 2. Gives operator the ability to turn on/off the
Level 1 Pulser control.
Includes all the functions of level 1 plus Pro-
Remote amperage control is not avail- cess Selection (see Section 4-6). When parameter change or selection is lim-
able in level 1. ited by lock level 3, [LOCK][LEV3] is dis-
When parameter change or selection is lim- played as a reminder.
TIG Output Selection ited by lock level 2, [LOCK][LEV2] is dis-
played as a reminder. Level 4
If either the TIG HF Impulse or TIG Lift Arc
process (see Section 4-6) was active when Level 3 Includes all the functions of levels 1, 2, and
lockout level 1 was activated, the operator 3 plus the following:
can choose between RMT STD (Remote Remote amperage control is not avail- Remote Amperage Control
Standard) or RMT 2T HOLD (Remote 2T able in level 3.
Hold) (see Section 4-8). The On function is Allows operator to use remote amperage
Includes all the functions of levels 1 and 2
also available if TIG Lift Arc was active. control if desired. Remote control operates
plus the following:
from minimum to maximum of preset am-
Stick Output Selection
+10% adjustment of preset TIG or Stick perage value. Connect remote control de-
If the Stick process was active when lock- Weld Amps vice according to Section 3-8.
out level 1 was activated, the operator can
Select desired process, TIG or Stick, and When parameter change or selection is lim-
choose between RMT STD or On.
use Encoder control to adjust amperage +/− ited by lock level 4, [LOCK][LEV4] is dis-
When parameter change or selection is lim- 10% of preset amperage value, up to the played as a reminder.

5-9. Setting Unit To Display PPP While Pulse Welding (DX Models Only)
1 Encoder Control
2 PPP Meter Display
Turn Encoder to change between
standard and [PPP] meter display.
When the [PPP] meter display fea-
ture is active while pulse welding,
2 the [PPP] will be displayed on the
right meter display, and the Meter
PPP Hold feature is disabled.

The [PPP] meter display feature will
not effect the normal amperage dis-
1 play or Meter Hold capabilities
when in a non-pulse welding mode.
PLS −−−
5-10. External Pulse Control
1 Encoder Control
2 Ammeter Parameter Selection
Turn Encoder to select external pulse
control on or off (off is the default).
When external pulse control is on:
Remote 14-pin amperage control of 0
to 10 volts input will be a minimum 0
amps to the power source, a maxim-
2 um 200 amps with an external direct
amperage control to power source.
EPc oFF 1
For additional welding information and resources, visit: www.MillerWelds.com/resources/improving−your skills

Notes

SECTION 6 − THEORY OF OPERATION
1 Filter Board PC9 (CE Models
Only)
Provides filtering on the input line
from electrical noise generated by
the welding power source.
2 Power Switch S1
Provides on/off control of welding
power source.
3 Power Interconnecting Board
PC2
Provides electrical connections for
S1, PC1, PC10, PM1, L1 and L2. In- 4
put capacitors, precharge relay and Boost Control
resistor, bleed resistors, various fil- Board PC10
ter and snubber components, input
1 6
current transducer, inverter primary
current transformer, and switch- Input
mode power supplies for control 3 Input Inductor
power are mounted on PC2. Single-Phase Filter 2 L1
Or Board
4 Boost Control Board PC10 Three-Phase PC9 Power
Line Input CE Models Switch
Controls and regulates input bus Power Only S1 7
voltage to 810 volts DC. Also con- Power
trols switch mode power supplies Interconnection
Board PC2 Snubber Inductor
for control power. L2
5
5 Power Module PM1
This module contains semiconduc- Power Module 16
tor chips (diodes and IGBTs) that PM1
rectify the input power, boost the in- Main Transformer
put bus voltage, and invert the bus T1
voltage to drive the main transform-
er. There is also a thermistor in PM1 8
to monitor the temperature of PM1. 9 18
6 Input Inductor L1
Fan Motor Boost Relay
Required to boost input bus volt- FM1
age. Inverter Control CR1
7 Snubber Inductor L2 Board PC1
10
Required to ensure soft switching
of the boost IGBT within PM1. Output Current Feedback
Gas Valve
8 Inverter Control Board PC1 GV1
Output Voltage Feedback
Controls the inverter IGBTs within
PM1 and regulates the output cur-
rent. Provides power and signals to
PC3. Also drives the gas valve, fan 11
motor and boost relay. 12
9 Fan Motor FM Membrane 14
Provides cooling of internal compo- Switch
nents. Fan only runs when needed Panel Remote 14
(fan-on-demand). Receptacle RC1
13 Process Control
10 Gas Valve GV1 Board PC3
15♦
Provides shielding gas to the arc Output Heatsink
while TIG welding. Thermistor RT1 Remote 10
Receptacle RC2
11 Process Control Board PC3 (Optional)
Controls welding process, per-
forms thermal management, and
displays various preset values as
well as output voltage and amper-
age. Also controls Arc Starter
Board PC7.
12 Membrane Switch Panel
Allows operator to set machine up
for desired welding process.

13 Output Heatsink Thermistor
RT1
Monitors temperature of the output
heatsink.
14 Remote 14 Receptacle RC1
Receives remote amperage and
output contactor signals. Sends
output voltage and current feed-
back. Used to connect remote am-
perage or voltage, or contactor con-
trols.
24
15 Remote 10 Receptacle RC2
Arc Starter (Optional)
Board PC7 _ Allows machine to be connected to
an automated welding setup.
16 Main Transformer T1
23 25 Driven by IGBTs in PM1. Supplies
power to weld output circuit.
HF Coupling Negative
Transformer Weld Output 17 Output Diode D1
T2 Receptacle Rectifies the main output of T1.
18 Boost Relay CR1
Enables the output boost circuit
while Stick welding.
17 21 22 25 19 Boost Inductor L3
Output Output Current Output Positive Limits the output boost current
Diode Inductor Weld Output while Stick welding.
D1 Transducer HD1 Z1 Receptacle
20 Boost Rectifier SR1
Rectifies the boost output of T1.
19 20 21 Output Current Transducer
HD1
Boost Boost
Inductor Rectifier Provides weld or secondary current
+
L3 SR1 feedback to PC1.
22 Output Inductor Z1
Filters or smooths the DC output or
Output Current Feedback welding current.
23 HF Coupling Transformer T2
Output Voltage Feedback
Couples HF energy created by PC7
to the weld output circuit. Required
for non-contact TIG arc starting.
24 Arc Starter (HF) Board PC7
Creates the high-frequency (HF)
energy to start the arc when TIG
welding.
25 Positive And Negative Weld
Output Receptacles
Provide weld output and allow
changing of output polarity.
AC Or DC Control Circuits
3φ Power
Weld Current Circuit

♦ Optional

PRE-POWER CHECKS
SECTION 7 − TROUBLESHOOTING
7-1. Checking Unit Before Applying Power
See Section 7-17 for test points and values
and Section 11 for parts location.
Use MILLER Testing Booklet (Part No. 150 853) when serv-
icing this unit.
See the Miller Extranet for service memos that may aid in the
repair of this product.
! Discharge input capacitors according to Section 7-2 and be sure voltage is near zero before touching any parts.
! Before troubleshooting or applying power to unit, complete the following checks to avoid causing further damage.
! Although inverter board PC1, power interconnecting board PC2, and boost board PC10 are briefly checked in this proce-
dure, more complete tests may be needed later for these parts. This check is simply to get a basic okay to power up unit.
Notes

PRE-POWER CHECKS
7-2. Measuring Input Capacitor Voltage (Prior To LJ280222L)
! Significant DC voltage can remain
on capacitors after unit is Off. Al-
ways check capacitors as shown to
be sure they have discharged be-
fore working on unit.
! Turn Off welding power source and
disconnect input power.
If applicable, remove wrapper.
1 Power Interconnecting Board PC2
2 Voltmeter
Measure the dc voltage across RC5-1 and
RC5-2 sockets until voltage drops to near
0 (zero) volts. Measure the dc voltage
across RC5-2 and RC5-3 sockets until
voltage drops to near 0 (zero) volts.
If the capacitor voltage does not drop

to near zero after several minutes, use
a bleeder resistor of between 25 and
1000 ohms, at least 5 watts, #16 AWG
1000 volts dc insulating rating wire to
discharge the capacitor(s) .
Proceed with job inside unit. Reinstall
wrapper when finished.
Power Interconnecting
Board PC2
1
3 2 1
Typical Bleeder Resistor
5 watt resistor
2
#16 AWG 1000 volts dc
insulation rating, approx
3 in (76 mm) leads
802 883 / 200 852-B

PRE-POWER CHECKS
7-3. Measuring Input Capacitor Voltage (Eff w/LJ280222L)
! Significant DC voltage can remain
on capacitors after unit is Off. Al-
ways check capacitors as shown to
be sure they have discharged be-
fore working on unit.
! Turn Off welding power source and
disconnect input power.
If applicable, remove wrapper.
1 Power Interconnecting Board PC2
2 Voltmeter
Measure the dc voltage across RC5-1 and
RC5-2 sockets until voltage drops to near
0 (zero) volts. Measure the dc voltage
across RC5-2 and RC5-3 sockets until
voltage drops to near 0 (zero) volts.
If the capacitor voltage does not drop

to near zero after several minutes, use
a bleeder resistor of between 25 and
1000 ohms, at least 5 watts, #16 AWG
1000 volts dc insulating rating wire to
discharge the capacitor(s) .
Proceed with job inside unit. Reinstall
wrapper when finished.
Board PC2
1
3 2 1
Typical Bleeder Resistor
5 watt resistor
2
#16 AWG 1000 volts dc
insulation rating, approx
3 in (76 mm) leads
802 883 / 230 184-E

PRE-POWER CHECKS
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

PRE-POWER CHECKS
7-4. Power Module PM1 (Prior To LJ280222L)
! Read and follow safety information Resistance values are based

in Section 7-1 before proceeding. on in-circuit measurements.
Power Switch S1
Back Of Machine
PM1
RC3
Board PC2
XFMR2 LSNUB LTAP
Line 1
Line 2
Line 3
RC5 3 2 1 RC1
802 883 / 200 852-B

PRE-POWER CHECKS
! Wear an earth grounded wrist strap when performing pre-power checks. Remove wrist strap before performing any
checks or procedures with power applied to the machine.
Press hard enough with tips of meter probes to penetrate varnish on PC board to make good electrical contact. If any of the following
measurements do not read correctly, PM1 is defective. Continue to the end of Section 7-13 before replacing PM1.
1. Visually inspect PM1 for damage. PM1 is located between the top heatsink and the large horizontal power interconnect board
PC2.
2. Check the six input rectifier diodes within PM1 (diode test). Look for a diode drop (.200 to .900 volts) across the following test
points on PC2:
Positive Meter Lead Negative Meter Lead
Line 1 RC1 Pin 12
Line 2 RC1 Pin 12
Line 3 RC1 Pin 12
RC5 Pin 3 Line 1
RC5 Pin 3 Line 2
RC5 Pin 3 Line 3
If the input rectifier diodes are defective, check the three poles of power switch S1 (switch off=OL, switch on =0 ohms).
3. Check boost IGBT within PM1 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on PC2:
RC5 Pin 3 LTAP
4. Check boost diode within PM1 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on PC2:
This test is measuring two diodes in series. Some diode testers may not read this correctly.
LSNUB RC5 Pin 1
5. Check inverter IGBTs within PM1 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on PC2:
RC5 Pin 3 XFMR2
XFMR2 RC5 Pin 1
6. Check thermistor within PM1 (resistance test). Measure the resistance on PC2 from RC3 Pin 1 to RC3 Pin 2. The reading should
measure 1000 ohms at room temperature. The ohms value rises with increase in temperature.

PRE-POWER CHECKS
7-5. Power Module PM1 (Eff w/LJ280222L)

Power Switch S1
Back Of Machine
PM1
RC3 RC4
Board PC2
XFMR2 LSNUB LTAP
Line 1
Line 2
Line 3
RC5 3 2 1 RC1
C12, C13 Test Point
802 883 / 230 184-E

PRE-POWER CHECKS
measurements do not read correctly, PM1 is defective. Continue to the end of Section 7-13 before replacing PM1.
1. Visually inspect PM1 for damage. PM1 is located between the top heatsink and the large horizontal power interconnect board
PC2.
2. Check the six input rectifier diodes within PM1 (diode test). Look for a diode drop (.200 to .900 volts) across the following test
points on PC2:
Line 1 RC1 Pin 12
Line 2 RC1 Pin 12
Line 3 RC1 Pin 12
RC5 Pin 3 Line 1
RC5 Pin 3 Line 2
RC5 Pin 3 Line 3
If the input rectifier diodes are defective, check the three poles of power switch S1 (switch off=OL, switch on =0 ohms).
3. Check boost IGBT within PM1 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on PC2:
RC5 Pin 3 LTAP
4. Check boost diode within PM1 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on PC2:
This test is measuring two diodes in series. Some diode testers may not read this correctly.
LSNUB RC5 Pin 1
5. Check inverter IGBTs within PM1 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on PC2:
Eff w/LK050198L, circuit board PC2 has a test point via located between capacitors C13 and C14. If a machine with a prior serial
number has had PC2 replaced, this test point via may also be present.
RC5 Pin 3 XFMR2
XFMR2 RC5 Pin 1

RC4 Pin6 XFMR2
RC4 Pin6 Test Point Via (Located between C12 and C13 If present)
6. Check thermistor within PM1 (resistance test). Measure the resistance on PC2 from RC3 Pin 1 to RC3 Pin 2. The reading should
measure 1000 ohms at room temperature. The ohms value rises with increase in temperature.

PRE-POWER CHECKS
7-6. Power Interconnecting Board PC2 (Prior To LJ280222L)

Inverter Circuit Boost Circuit

Board PC1 Board PC10
Power Switch S1
Back Of Machine
Power
A K A K 17 in lb 17 in lb Interconnecting Board
(1.92 N⋅m) (1.92 N⋅m) PC2
D3 D5 LINPUT
17 in lb
(1.92 N⋅m)
Q11
D2
K A
RC1
D4 R24 R27
802 883 / 200 852-D

PRE-POWER CHECKS
measurements do not read correctly, PC2 is defective. Proceed to Step 4 before replacing PC2.
1. Visually inspect Power Interconnect Board PC2 for damage. All of the following tests on this page are made on PC2.
2. Check precharge resistors R24 and R27 (resistance test). Measure resistance from LINPUT to RC1 Pin 12. Note: this test is mea-
suring two resistors in series. Resistance should read 200±20 ohms.
3. Check precharge relay CR1 coil resistance (resistance test). Measure resistance from RC1 Pin5 to RC1 Pin 6. Resistance should
read 650 ±50 ohms.
4. Check IGBT Q11 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on PC2:
D2 anode Q11 center pin
D2 anode D2 cathode
If any of the measurements in Step 4 do not read correctly, PC2 and PC10 are defective. Proceed to Step 5 before replacing
PC2 and PC10.
5. Check diode D4 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on PC2:
D4 anode D4 cathode
6. Check flyback output diodes D3 and D5 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on
PC2:
D3 anode D3 cathode
D3 cathode D5 cathode
If any of the measurements in Step 5 or Step 6 do not read correctly, replace PC1, PC2 and PC10. Continue to the end of the
Pre-Power Checklist.

PRE-POWER CHECKS
7-7. Power Interconnecting Board PC2 (Eff w/LJ280222L)

Inverter Circuit Boost Circuit

Board PC1 Board PC10
Power Switch S1
Back Of Machine
A K
K A Power Interconnecting
D5 D3 Board PC2
D10 D9 D8
LINPUT
Q11
D2
K A
D4 R24 R27 RC1
802 883 / 230 184-E

PRE-POWER CHECKS
press hard enough with tips of meter probes to penetrate varnish on PC board to make good electrical contact. If any of the following
measurements do not read correctly, PC2 is faulty. Proceed to Step 4 before replacing PC2.
1. Visually inspect Power Interconnect Board PC2 for damage. All of the following tests on this page are made on PC2.
2. Check precharge resistors R24 and R27 (resistance test). Measure resistance from LINPUT to RC1 Pin 12. Note: this test is mea-
suring two resistors in series. Resistance should read 200±20 ohms.
3. Check precharge relay CR1 coil resistance (resistance test). Measure resistance from RC1 Pin5 to RC1 Pin 6. Resistance should
read 650±50 ohms.
4. Check IGBT Q11 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on PC2:
D2 anode Q11 center pin
D2 anode D2 cathode
If any of the measurements in Step 4 do not read correctly, PC2 and PC10 are faulty. Proceed to Step 5 before replacing
PC2 and PC10.
5. Check diode D4 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on PC2:
D4 anode D4 cathode
6. Check flyback output diodes D3 and D5 (diode test). Look for a diode drop (.200 to .900 volts) across the following test points on
PC2:
D3 anode D3 cathode
D5 anode D5 cathode
If any of the measurements in Step 5 or Step 6 do not read correctly, replace PC1, PC2 and PC10. Proceed to Step 7.
7. Check flyback output diodes D8, D9, and D10 (diode test). Look for a diode drop (.200 to .900 volts) across the following test
points on PC2:
D8 anode D8 cathode
D9 anode D9 cathode
D10 anode D10 cathode
If any of the measurements in Step 7 do not read correctly, replace PC2. Continue to the end of the Pre-Power Checklist.

PRE-POWER CHECKS
7-8. Boost Control Board PC10 (Prior To LJ280222L)

Boost Circuit
Board PC10
Back Of Machine
K
D19 D20 Boost Circuit
Q21 D18 A K A K Board PC10
U1 R8 VR4
A
D26
A K
D27
A K
Q26 Q27 R87 R88 R102 R103
R93 R94
802 883 / 200 843-J

PRE-POWER CHECKS
Press hard enough with tips of meter probes to penetrate varnish on PC board to make good electrical contact.
1. Visually inspect Boost Control Board PC10 for damage. All of the following tests on this page are made on PC10.
2. Look for a diode drop (.200 to 1.00 volts) across the following test points on PC10:
D18 cathode Q21 top pin

Q26 drain Q26 source
Q27 source Q27 drain
3. Check resistor R8. Resistance should read 140 − 160 ohms.
4. Check voltage regulator VR4. Measure resistance from bottom pin to middle pin. Resistance should be greater than 2k ohms.
Measure resistance from top pin to middle pin. Resistance should be greater than 2k ohms.
5. Check integrated circuit U1. Measure resistance from Pin 14 to Pin 7. Resistance should be greater than 2k ohms (see Figure
7-1).
6. Perform this pre-power check only if the machine does not power up as described in Troubleshooting Section.
Check to see that resistors R87, R93, and R102 read between 500K ohms and 650K ohms
If any of the above measurements do not read correctly, replace PC10. If D26 or D27 do not read correctly, disconnect PC10
from power interconnecting board PC2 and recheck D26 and D27. If D26 or D27 still do not read correctly, replace PC10 and
PM1, otherwise replace PM1. Continue to the end of the Pre-Power Checklist.
14 8
1 7
Figure 7-1. Integrated Circuit U1 Pin locations

PRE-POWER CHECKS
7-9. Boost Control Board PC10 (Eff w/LJ280222L)

Boost Circuit
Board PC10
Back Of Machine
A K Boost Circuit
U1 VR4 R8 Q21 Board PC10
D18 D19 D20
A
D26
A K
D27
A K
R87 R88 R102 R103

Q26 Q27
R93 R94
802 883 / 247 838-A

PRE-POWER CHECKS
1. Visually inspect Boost Control Board PC10 for damage. All of the following tests on this page are made on PC10.
2. Look for a diode drop (.200 to 1.00 volts) across the following test points on PC10:
D18 cathode Q21 top pin

Q26 drain Q26 source
Q27 source Q27 drain
3. Check resistor R8. Resistance should read 140 − 160 ohms.
4. Check voltage regulator VR4. Measure resistance from bottom pin to middle pin. Resistance should be greater than 2k ohms.
Measure resistance from top pin to middle pin. Resistance should be greater than 2k ohms.
5. Check integrated circuit U1. Measure resistance from Pin 14 to Pin 7. Resistance should be greater than 2k ohms (see Figure
7-2).
6. Perform this prepower check only if the machine does not power up as described in Troubleshooting Section.
If any of the above measurements do not read correctly, replace PC10. If D26 or D27 do not read correctly, disconnect PC10
from power interconnecting board PC2 and recheck D26 and D27. If D26 or D27 still do not read correctly, replace PC10 and
PM1, otherwise replace PM1. Continue to the end of the Pre-Power Checklist.
14 8
1 7
Figure 7-2. Integrated Circuit U1 Pin locations

PRE-POWER CHECKS
7-10. Inverter Control Board PC1 (Prior To LJ280222L)

RC5
K A
Inverter Control Board PC1
D29 D28 D31 D32
D2 D3 D8 D9 D30
K A K A K A
Back Of Machine
802 883 / 206 130-E

PRE-POWER CHECKS
1. Visually inspect Inverter Control Board PC1 for damage. All of the following tests on this page are made on PC1.
2. Look for a diode drop (.200 to .900 volts) across the following test points on PC1:
D2 anode D2 cathode
D3 anode D3 cathode
D8 anode D8 cathode
D9 anode D9 cathode
3. Check power supplies (+15 VDC, −15 VDC) Measure resistance from RC5 Pin 1 to RC5 Pin 4. Resistance should be greater than
2k ohms. Measure resistance from RC5 Pin 2 to RC5 Pin 4. Resistance should be greater than 2k ohms. If resistance is less than
2K ohms, disconnect plug PLG5 and check again (see Figure 9-2). If resistance is still less than 2K ohms, replace PC1. If resistance
is greater than 2K ohms, replace HD1. (see Section 7-17).
If any of the above measurements do not read correctly, replace PC1. If D2, D3, D8, or D9 do not read correctly, disconnect
PC1 from power interconnect board PC2 and recheck D2, D3, D8, and D9. If D2, D3, D8, or D9 still do not read correctly,
replace PC1 and PM1, otherwise replace PM1. Continue to the end of the Pre-Power Checklist.

PRE-POWER CHECKS
7-11. Inverter Control Board PC1 (Eff w/LJ280222L)

RC5
6 4
K A
Inverter Control Board PC1 3 2 1
D37 D38 D36 D39
D2 D3 D8 D9 D46
K A K A K A
Back Of Machine
802 883 / 233 123-D

PRE-POWER CHECKS
1. Visually inspect Inverter Control Board PC1 for damage. All of the following tests on this page are made on PC1.
D2 anode D2 cathode
D3 anode D3 cathode
D8 anode D8 cathode
D9 anode D9 cathode
3. Check power supplies (+15 VDC, −15 VDC) Measure resistance from RC5 Pin 1 to RC5 Pin 4. Resistance should be greater than
2k ohms. Measure resistance from RC5 Pin 2 to RC5 Pin 4. Resistance should be greater than 2k ohms. If resistance is less than
2K ohms, disconnect plug PLG5 and check again. If resistance is still less than 2K ohms, replace PC1. If resistance is greater than
2K ohms, replace HD1. (see Section 7-17).
If any of the measurements do not read correctly, replace PC1. If D2, D3, D8, or D9 do not read correctly, disconnect PC1
from power interconnect board PC2 and recheck D2, D3, D8, and D9. If D2, D3, D8, or D9 still do not read correctly, replace
PC1 and PM1, otherwise replace PM1. Continue to the end of the Pre-Power Checklist.

PRE-POWER CHECKS
7-12. Arc Starter Board PC7 Testing Information (Eff w/LJ280222L)

Arc Starter Board PC7
Test Equipment Needed:
A K A K A K
802 833 / 212 891-E
D6 D7 D8

PRE-POWER CHECKS
1. This check is necessary only if the machine exhibits symptoms described in Troubleshooting Table (see Section 7-14)
D6 anode D6 cathode
D7 anode D7 cathode
D8 anode D8 cathode
If any of the measurements do not read correctly, replace PC7.

PRE-POWER CHECKS
7-13. Output Diode D1
! Read and follow safety
information in Section 7-1
before proceeding.
! Wear an earth grounded
wrist strap when performing
pre-power checks. Remove
wrist strap before perform-
ing any checks or proce-
dures with power applied to
the machine.
1 Output Diode D1
Terminal
Terminal
Symptoms of a failed output diode
are a front panel meter display of
HE.L P‐1 (see Section 7-15). Look for
a diode drop, approximately .2oo
volts, between the Positive and
Negative weld output terminals.
Place the black meter probe on the
Positive terminal and the red meter
2 probe on the Negative terminal. Re-
place D1 if the meter reading is 0
3
volts.
! Pre-power checks are now
complete. Remove earth
grounded wrist strap before
1 performing any checks or
procedures with power ap-
plied to the machine.
D1 is located on the bottom of

the heat sink and is shown up
side down for illustration purposes.
802 451 / Ref. 199 490 / Ref. 199 497

Always check unit before applying power (see Sections 7-1 thru 7-13).
7-14. Troubleshooting Table
! Before connecting welding equipment to input (primary) power for servicing, be sure the input-power circuit protection is
correct for the welding equipment. Connect equipment to a dedicated circuit sized and fused for the rated output and duty
cycle of the welding equipment you are servicing. See the Electrical Service Guide section in this manual and National Elec-
trical Code (NEC) article 630, Electric Welders.
! Remove earth grounded wrist strap before performing any checks or procedures with power applied to the machine.
See Section 7-17 for test points and values and Section for 11 parts location.
Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit.
See the Miller Extranet for service memos that may aid in the repair of this product.
Equipment serviced may need to meet additional requirements as specified in IEC60974-4, Arc Welding Equipment − Part 4: Periodic
Inspection and Testing.
Trouble Remedy
No weld output; unit completely Place line disconnect switch in On position (see Section 3-17).
inoperative.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-17).
Check for proper input power connections and check condition of power cord (see Section 3-17).
Check inverter control board PC1 for proper seating (see Section 7-10).
Check weld control board PC3 for proper seating (see Section 7-27).
Check boost control board PC10 for proper seating (see Section 7-8).
Check continuity of Power switch S1 (see Section 7-17), and replace if necessary.
Check bus voltage on power interconnect board PC2 receptacle RC5 (see Section 7-24) and replace
PC2 if necessary.
Check ±15 volts DC supplies as follows (see Section 7-17):

Disconnect plug PLG1 from RC1 on PC1 and check for ±15 VDC. If ±15 VDC is now pres
ent, replace PC3
Disconnect plug PLG5 from RC5 on PC1 and check for ±15 VDC. If ±15 VDC is now pres
ent, replace HD1
Disconnect PC1 from PC2, and on PC2 check for ±15 VDC between RC3 pin 5 and RC3
pin 8. If ±15 VDC is now present, replace PC1. If the ±15 VDC is still not present, replace
PC10.
Check +30 volt DC primary voltage on boost control board PC10 (see Section 7-38). Replace PC10 if
necessary.
Check ±15 volt DC primary voltage on boost control board PC10 (see Section 7-38). Replace PC10 if
necessary.
No weld output; unit completely Check +15 volt DC buck voltage on boost control board PC10 (see Section 7-38). If voltage is pres-
inoperative. ent, stop. If voltage is not present, check resistors.
Before checking resistors, discharge and measure input capacitor voltage AC
Disconnect PC10 from PC2 and check resistors R1, R2, R36, and R37 on PC2. Each re
sistor should measure 75K ohms ±10%. If any of the resistors are bad, replace PC2. If the
resistors are good, replace PC10.

Trouble Remedy
No weld output; meter display On. Unit overheated and HELP 3 or HELP 5 screen is displayed. Allow unit to cool with fan On (see Sec-
tions 7-15 and 3-5).
If a remote accessory is connected to remote 14 receptacle RC50:

Check accessory contact closure (continuity), and replace accessory if necessary.
Check accessory amperage control potentiometer resistance and connections,
and replace accessory if necessary.
Check fan motor FM1 for operation (see Section 7-17), and replace if necessary, or replace PC1 if
there is no fan voltage.
Check input and output voltages of hall device HD1 (see Section 7-17). Replace HD1 if necessary.
Check output diode D1, and replace if necessary (see Section 7-13).
Check power module PM1, and replace if necessary (see Section 7-4).
Check inverter control board PC1 and boost control board PC10, and connections, and replace if
necessary (see Section 7-19 and 7-37).
Low weld output with no control. Check input and output voltages of hall device HD1 (see Section 7-17). Replace HD1 if necessary.
Check inverter control board PC1 and connections, and replace if necessary (see Section 7-19).
Check weld control board PC3 and connections, and replace if necessary (see Section 7-27).
Maximum weld output with no control. Check input and output voltages of hall device HD1 (see Section 7-17). Replace HD1 if necessary.
Check inverter control board PC1 and connections, and replace if necessary (see Section 7-19).
Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-7).
Clean and tighten all weld connections.
Check for proper input and output connections.
Replace electrode.
Check resistance and connections of remote amperage control potentiometer, and replace if
necessary.
Check gas valve GS1 (see Section 7-17), and replace if necessary.
Check input and output voltages of hall device HD1 (see Section 7-17). Replace HD1 if necessary.
Erratic or improper weld output (contin- In Stick mode, check boost relay CR1 (see Section 7-17), and replace if necessary.
ued).
Fan motor does not run after approxi- Check and clear blocked fan blade
mately four minutes of operation at
rated load. Check thermistor RT1 on weld control board PC3 (see Section 7-27).
Check fan motor FM (see Section 7-17). If voltage is present, replace fan motor. If fan motor voltage
is not present, replace PC1.
Wandering arc; poor control of arc Use proper size tungsten.

direction.
Use properly prepared tungsten .
Reduce gas flow rate.
Tungsten electrode oxidizing and not Shield weld zone from drafts.
remaining bright after conclusion of
weld. Increase postflow time.
Check and tighten all gas fittings.
Water in torch. Refer to torch manual.
Check gas valve GS1 (see Section 7-17), and replace if necessary.
No weld output; display meter Off. DC Turn power to machine Off, and check input capacitor voltage according to Section 7-2 or 7-3. Per-
bus voltage (input capacitor voltage) form pre-power check on PM1 (see Section 7-4 or 7-5), and Boost Control board PC10 (see Section
as measured in Section 7-23, is less 7-8 or 7-9). Replace PM1 or any of the circuit boards that fail the pre-power check.
than 810 volts.

Trouble Remedy
HELP 1 (see Section 7-15) Visually inspect PC1, PC2, and PC10 for any burnt damage, and replace if necessary.
Perform pre-power check on PM1 (see Section 7-2 or 7-3), Power Interconnecting board PC2 (see
Section 7-6 or 7-7), Boost Control board PC10 (see Section 7-8 or 7-9), and Inverter Control board
PC1 (see Section 7-10 or 7-11). Replace PM1 or any of the circuit boards that fail the pre-power
check.
Inspect cores of transformer T1 for significant chips or cracks, and replace T1 if necessary.
Inspect for signs of corrosion and/or over-heating on the connections surrounding output diode D1.
Perform pre-power check on output diode D1 (see Section 7-13). Replace D1 or connections if ne-
cessary.
Visually inspect Hall Device (HD1) and its cable for signs of excess heat damage. Replace HD1 and
its cable if necessary.
Weak or no high frequency Perform pre-power check on Arc Starter board PC7 (see Section 7-12). Replace PC7 if it fails the
pre-power test.
Check arc starter waveform (see waveform C or E, depending on serial number, in Section 7-18).
Inspect for significant chips or cracks on cores of HF coupling coil, and replace if necessary.

7-15. Voltmeter/Ammeter Help Displays
V A V A
0 6
HEL P-0 HEL P-8

V A V A
1 7
HEL P-1 HEL P-9

V A V A
2 8
HEL P-2 HEL P10

V A V A
3 9
HEL P-3 HEL P12

V A V A
4 10
HEL P-4 HEL P13

V A
V A 11
5
HEL P-5 HEL P21
All directions are in reference to the 3 Help 3 Display 7 Help 9 Display

front of the unit. All circuitry referred to Indicates the bottom heat sink has over- Indicates a short in the thermal protection
is located inside the unit. heated. The unit has shut down to allow the circuitry located on the top heat sink.
fan to cool it (see Section 3-5). Operation 8 Help 10 Display
0 Help 0 Display will continue when the unit has cooled.
Indicates torch trigger is depressed. Re-
4 Help 4 Display lease trigger to continue.
Indicates a short in the thermal protection
circuitry located on the bottom heat sink. Indicates an open in the thermal protection 9 Help 12 Display
circuitry located on the top heat sink.
Indicates an improper set-up. You are trying
1 Help 1 Display 5 Help 5 Display to make an adjustment that is not allowed.
Indicates the top heat sink has overheated. 10 Help 13 Display (LX Models Only)
Indicates a malfunction in the primary pow- The unit has shut down to allow the fan to
er circuit caused by an overcurrent condi- Output enable signal broken causing weld
cool it (see Section 3-5). Operation will con- output to stop, but gas continues to flow if
tion in the primary IGBT switching circuit. tinue when the unit has cooled. Post Flow function is active or gas control
6 Help 8 Display on 10-pin is On (see Section 3-9).
2 Help 2 Display
Indicates a malfunction in the secondary 11 Help Display 21 (Eff w/LJ310418L)
Indicates an open in the thermal protection power circuit of the unit. There is a high Indicates voltage or current feedback has
circuitry located on the bottom heat sink. open circuit condition. been detected with contactor off.

Notes

7-16. Troubleshooting Circuit Diagram (Eff. w/ Serial No. LA230402 Thru LJ280221L)
No calibration available for voltmeter V or ammeter A.
! Discharge input capacitors according to
Section 7-2, and be sure voltage is near zero
before touching any parts.
See Section 7-37 for

PC10 information
See Section 7-23

for PC2 information
123 R4
RC5
R5
See Section
7-19 for
PC1 data
V1, R1
V2, R2
V3, R3
waveform C
(See Section 7-18)
See Section
See Section 7-39 for 7-27 for
Membrane Switch PC3 data
Panel information
See Section 3-8 See Section 3-9 for

for RC1 RC2 information
information

R7
Voltage Readings
a) Tolerance − ±10% unless
V4 specified
b) Reference − single arrow:
reference to circuit common
(lead 42); double arrow: reference
R8 to points indicated
c) Wiring Diagram − see Section 9
V1 +27 volts DC
V2 +24 volts DC
V3 +24 volts DC
V9
See Section 7-18 V4 173 volts AC
for waveforms
A, B V5 0 volts DC (gnd)
V5 V6 −1 volt per 25 amps of weld
output
V6 R9 V7 −15 volts DC
R6
V7 V8 +15 volts DC
V8 V9 68 volts DC open-circuit
voltage
R10
R11 See Section

7-33 for PC7
information
RT1 information
Resistance Values
a) Tolerance − ±10% unless specified
b) Turn Off unit and disconnect input power
before checking resistance
R1 1.5 meg ohms
R2 79 ohms
R3 315 ohms
R4 thru R10 Less than 1 ohm
R11 30K ohms at room temperature
189 769-E

7-17. Troubleshooting Circuit Diagram (Eff w/Serial No. LJ280222L And Following)
No calibration available for voltmeter V or ammeter A.
! Discharge input capacitors
according to Section 7-2, and
be sure voltage is near zero
PC10 information
See Section 7-23

for PC2 informa-
tion
R4
R5
V1, R1
See Section
7-19 for
V2, R2 PC1 data
V3, R3
waveform E
(See Section 7-18)

Membrane Switch
Panel information
See Section
7-27 for
PC3 data
See Section See Section 3-9 for

3-8 for RC1 RC2 information
information

R7
Voltage Readings
a) Tolerance − ±10% unless
specified
V4 b) Reference − single arrow:
reference to circuit common
(lead 42); double arrow: reference
to points indicated
R8
c) Wiring Diagram − see Section 9
V1 +27 volts DC
V2 +24 volts DC
V3 +24 volts DC
V9 V4 173 volts AC
See Section 7-18
for waveforms V5 0 volts DC (gnd)
V5 A, B V6 −1 volt per 25 amps of weld
output
V6 R9 V7 −15 volts DC
R6
V7 V8 +15 volts DC
V8 V9 68 volts DC open-circuit
voltage
R10
See Section
7-33 for PC7
information
R11

RT1 information
Resistance Values
b) Turn Off unit and disconnect input power
before checking resistance
R1 1.5 meg ohms
R2 79 ohms
R3 315 ohms
R4 thru R10 Less than 1 ohm
R11 30K ohms at room temperature
237 566-C

7-18. Waveforms for Sections 7-17
The waveforms represent the output

of the welding power source. When 10 μs 5V
operating properly, the power source
waveforms match those shown here.
gnd
A. DC Open-Circuit Voltage (9 - 14 VDC)
10 μs 20V
gnd
B. 22 Volts DC, 150 Amperes, (Resistive Load)

100 μs 1V
gnd
C. Waveform for arc starter is at PC3 RC3-1 to

RC3-4 with leads from PC7 disconnected. (This
pulse occurs every 50 ms.) (Prior To LJ280222L)
5 ms 5V
gnd
E. Waveform for arc starter HF is at PC3 RC-3 to

RC3-4 (Eff w/LJ280222L).

7-19. Inverter Control Board PC1 Testing Information (Use with Section 7-20) (Prior To LJ280222L)
according to Section 7-2, and
be sure voltage is near zero
Be sure plugs are secure before test-
ing. See Section 7-20 for specific val-
ues during testing.
1 Inverter Control Board PC1
RC2
RC5
RC7
RC6
1
RC1
RC4 RC3
802 883 / 206 130-E

7-20. Inverter Control Board PC1 Test Point Values (Prior To LJ280222L)
PC1 Voltage Readings
b) Reference − to circuit common
(lead 42) unless noted
Receptacle Pin Type Value
RC1 1 Output +5 volts DC @ 1A; regulated with respect to ground
2 Output +5 volts DC output @ 1A; regulated with respect to ground
3 Output +15 volts DC output @ 300 mA; regulated with respect to ground
4 Output Module thermistor +; 1000 ohms ±1% @ 25° C
5 Output Module thermistor - ; 1670 ohms ±1% @ 100° C
6 Input Lift arc pwm; 15 kHz, 15 V squarewave
7 Input Boost enable; 0 volts DC=on, +5 volts DC = off
8 Input Gas enable; 0 volts DC=on, +5 volts DC = off
9 Input Output enable; 0 volts DC=on, +15 volts DC = off
10 Input Fan enable; 0 volts DC=on, +5 volts DC = off
11 Input Output reference; 0 volts DC=1 ampere, 10 volts DC=200 amperes
12 Output Voltage feedback; 1 volt DC per 10 volts DC of weld output
13 Output Power down detect; 0 volts DC=okay, open collector=power down
14 Output Over current detect; 0 volts DC=over current, open collector=okay
15 Output Current feedback; 1volt DC per 50 amperes of weld output
16 GND
17 GND
18 GND
19 GND
20 Output Over voltage detect; 0 V=over voltage, open collector=okay
RC2 1 Input Negative weld output terminal; used for output voltage feedback
2 Not used
3 Input Positive weld output terminal; used for output voltage feedback
RC3 On early versions of the circuit diagram for circuit board PC1, the pins for receptacle RC3 were shown like those listed in
parentheses (). The circuit diagram was changed to match the numbers that are not in parentheses. This is only a change
in how the pins are called out on the circuit. There were no changes made electrically.
(1&2) 1 Input Module thermistor +; 1000 ohms ±1% @ 25° C
(3&4) 2 Input Module thermistor −; 1670 ohms ±1% @ 100° C
(5&6) 3 Input Primary current transformer; 10 amps per 1 volt DC, 200:1 turns ratio, 20 ohm load
(7&8) 4 Input Primary current transformer; 10 amps per 1 volt DC, 200:1 turns ratio, 20 ohm load
(9&10) Input −15 volts DC @ 1.5 amps; regulated with respect to ground
5
(11&12) Input +15 volts DC @ 1.5 amps; regulated with respect to ground
6
(13&14) Input Overpower foldback; folds back output if input bus drops
7
(15&16) GND
8

(17&18) GND
9
(19&20) Not used

10
(21&22) Not used

11
(23&24) Not used

12
RC4
Do not measure − high voltage present.
RC5 1 Output +15 volts DC for LEM
2 Output −15 volts DC for LEM
3 Input −1 volt DC per 25 amps, LEM measure
4 GND LEM return
5 Output Test point, used to test board only − Do Not Measure
RC6 1 Output +15 volts DC for gas valve drive
2 Output +15 volts DC for boost relay drive
3 Output Gas valve drive; +15 volts DC=off, -13 volts DC=on
4 Output Boost relay drive; +15 volts DC=off, -13 volts DC=on
RC7 1 Output Fan motor drive; +15 volts DC
2 Output Fan motor drive; +15 volts DC=off, -13 volts DC=on

Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

7-21. Inverter Control Board PC1 Testing Information (Use with Section 7-22) (Eff w/LJ280222L)
According to Section 7-2,
and be sure voltage is near
zero before touching any
parts.
Be sure plugs are secure before
testing. See Section 7-20 for
specific values during testing.
1 Inverter Control Board PC1
RC5
RC2
RC6
RC7
RC8
1 Pot R125
RC1
RC4 RC3 1 2
IFB
802 883 / 233 123-D

7-22. Inverter Control Board PC1 Test Point Values (Eff w/LJ280222L)
RC1 1 Output +5 volts DC @ 1A; regulated with respect to ground
2 Output +5 volts DC output @ 1A; regulated with respect to ground
3 Output +15 volts DC output @ 300 mA; regulated with respect to ground
4 Output Module thermistor +; 1000 ohms +/- 1% @ 25° C
5 Output Module thermistor - ; 1670 ohms +/- 1% @ 100° C
6 Input Lift arc pwm; 15 kHz, 15 V squarewave
7 Input Boost enable; 0 volts DC=on, +5 volts DC = off
8 Input Gas enable; 0 volts DC=on, +5 volts DC = off
9 Input Output enable; 0 volts DC=on, +15 volts DC = off
10 Input Fan enable; 0 volts DC=on, +5 volts DC = off
11 Input Output reference; 0 volts DC=1 ampere, 10 volts DC=200 amperes
12 Output Voltage feedback; 1 volt DC per 10 volts DC of weld output
13 Output Power down detect; 0 volts DC=okay, open collector=power down
14 Output Over current detect; 0 volts DC=over current, open collector=okay
15 Output Current feedback; 1volt DC per 50 amperes of weld output
16 GND Ground
17 GND Ground
18 GND Ground
19 Not used
20 Output Over voltage detect; 0 V=over voltage, open collector=okay
RC2 1 Input Voltage feedback, negative weld output terminal
Output Sense voltage, negative weld output terminal
2 Not used
3 Input Voltage feedback, positive weld output terminal
Output Sense voltage, positive weld output terminal
RC3 1 Input Module thermistor +; 1000 ohms +/- 1% @ 25° C
2 Input Module thermistor −; 1670 ohms +/- 1% @ 100° C
3 Input Primary current transformer; 10 amps per 1 volt DC, 200:1 turns ratio, 20 ohm load
4 Input Primary current transformer; 10 amps per 1 volt DC, 200:1 turns ratio, 20 ohm load
5 Input −15 volts DC @ 1.5 amps; regulated with respect to ground
6 Input +15 volts DC @ 1.5 amps; regulated with respect to ground
7 Input Overpower foldback; folds back output if input bus drops
8 GND Ground
9 GND Ground
10 Not used

11 Not used
12 Not used
RC4
High voltage present. Voltages on pins on this receptacle can be more than 800 volts DC
from chassis (GND).
Pins 1 and 2 on this receptacle are referenced to RC4-2
1 Input Inverter 1 drive; high side drive for primary inverter
2 Inverter 1 drive reference
3 Not used
4 Not used
Pins 5 through 8 on this receptacle are referenced to RC4-6

5 Input Snubber 2 drive; drive signal for primary inverter snubber
6 Snubber 2 drive reference
9 Not used
10 Not used
Pins 11 and 12 on this receptacle are referenced to −Bus (RC5-3)

11 Input Inverter 2 drive; low side drive for primary inverter
12 −Bus; 0 volts DC
RC5 1 Output +15 volts DC for LEM
2 Output −15 volts DC for LEM
3 Input -1 volt DC per 25 amps, LEM measure
4 GND LEM return
RC6 1 Output +15 volts DC for gas valve drive
2 Output +15 volts DC for boost relay drive
3 Output Gas valve drive; +15 volts DC=off, -13 volts DC=on
4 Output Boost relay drive; +15 volts DC=off, -13 volts DC=on
RC7 1 Output Fan motor drive; +15 volts DC
2 Output Fan motor drive; +15 volts DC=off, -13 volts DC=on
RC8 1 Input Torch weld output terminal; used for output voltage feedback
2 Input Work output terminal; used for output voltage feedback
3 Output Positive sense voltage output terminal
4 Output Negative sense voltage output terminal
IFB 1 Output Current feedback; 1volt DC per 50 amperes of weld output
2 GND Ground

7-23. Power Interconnect Board PC2 Testing Information (Use with Section 7-24) (Prior To LJ280222L)
! Discharge input capaci-
tors according to Section
7-2, and be sure voltage is
near zero before touching
any parts.
1 Power Interconnect Board
PC2
RC3 RC4
1
RC2 RC1
RC5
802 883 / 200 852-B

7-24. Power Interconnect Board PC2 Test Point Values (Prior To LJ280222L)
RC1
High voltage present. Voltages on this receptacle can be more than 800 volts DC from
chassis (GND).
All pins on this receptacle are referenced to the − Bus (RC5-3)
1 Output +Bus; regulated to 810 volts DC
2 Not Used
4 Input Boost control; drive signal for boost IGBT
5 Output +30 volts DC
6 Input Precharge; active low drive for precharge relay
7 Input +15 volts DC; regulated from +30 volts DC
8 Input −15 volts DC, regulated from +30 volts DC
9 Output IFB primary; current feedback for boost regulator control
11 Not Used
12 Output + Rect; rectified AC input
RC2
High voltage present. Voltages on pins 1 through 9 on this receptacle can be more than
800 volts DC from chassis (GND).
1 Output +15 volts DC; regulated from bus
2 Common
3 Input Buck drive; drive signal for +30 volts DC regulator
4 Output IFB buck; current feedback for +30 volts DC regulator
5 Not used
Pins 6 through 8 on this receptacle are referenced to −Bus (RC5-3)

7 Input Flyback drive; control signal to derive regulated supplies on RC3
8 Output Flyback IFB; current feedback for flyback supply
9 Not used
10 Input Overpower foldback; folds back output if input current is greater than 35 amperes
11 Output +15 volts DC; used to regulate +15 volts DC
12 Output −15 volts DC; used to regulate −15 volts DC
RC3 On early versions of the circuit diagram for circuit board PC2, the pins for receptacle RC3 were shown like those listed in
parentheses (). The circuit diagram was changed to match the numbers that are not in parentheses. This is only a change
in how the pins are called out on the circuit. There were no changes made electrically.
(1&2) 1 Output Module thermistor +; 1000 ohms ±1% @ 25° C
(3&4) 2 Output Module thermistor −; 1670 ohms ±1% @ 100° C
(5&6) 3 Output Primary current transformer; 10 amps per 1 volt DC, 200:1 turns ratio, 20 ohm load

(7&8) 4 Output Primary current transformer; 10 amps per 1 volt DC, 200:1 turns ratio, 20 ohm load
(9&10) Output −15 volts DC @ 1.5 amps; regulated with respect to ground
5
(11&12) Output +15 volts DC @ 1.5 amps; regulated with respect to ground
6
(13&14) Output overpower foldback, folds back output if bus droops

7
(15&16) GND Ground

8
(17&18) GND Ground

9
(19&20) Not used

10
(21&22) Not used

11
(23&24) Not used

12
RC4
from chassis (GND).
3 Not used
4 Not used

9 Not used
10 Not used

RC5 High voltage present. Voltages on this receptacle can be more than 800 volts DC from
chassis to ground (GND).
All pins on this receptacle are referenced to the − bus (RC5-3)

1 + bus; regulated to 810 VDC
2 Bus center tap; regulated to 405 VDC
3 − bus; 0 VDC

7-25. Power Interconnect Board PC2 Testing Information (Use with Section 7-26) (Eff w/LJ280222L)
! Discharge input capacit-
ors according to Section
7-2, and be sure voltage is
near zero before touching
any parts.
1 Power Interconnect Board
PC2
RC3 RC6 RC4

1
RC2 RC1
RC5
802 883 / 230 184-E

7-26. Power Interconnect Board PC2 Test Point Values (Eff w/LJ280222L)
RC1
chassis (GND).
1 Output +Bus; regulated to 810 volts DC
2 Not Used
4 Input Boost control; drive signal for boost IGBT
6 Input Precharge; active low drive for precharge relay
7 Input +15 volts DC; regulated from +30 volts DC
8 Input −15 volts DC, regulated from +30 volts DC
9 Output IFB primary; current feedback for boost regulator control
11 Not Used
12 Output + Rect; rectified AC input
RC2
1 Output +15 volts DC; regulated from bus
2 Common
3 Input Buck drive; drive signal for +30 volts DC regulator
4 Output IFB buck; current feedback for +30 volts DC regulator
5 Not used

7 Input Flyback drive; control signal to derive regulated supplies on RC3
8 Output Flyback IFB; current feedback for flyback supply
9 Not used
10 Input Overpower foldback; folds back output if input current is greater than 35 amperes
11 Output +15 volts DC; used to regulate +15 volts DC
12 Output −15 volts DC; used to regulate −15 volts DC
RC3 1 Output Module thermistor +; 1000 ohms +/- 1% @ 25° C
2 Output Module thermistor −; 1670 ohms +/- 1% @ 100° C
3 Output Primary current transformer; 10 amps per 1 volt DC, 200:1 turns ratio, 20 ohm load
4 Output Primary current transformer; 10 amps per 1 volt DC, 200:1 turns ratio, 20 ohm load
5 Output −15 volts DC @ 1.5 amps; regulated with respect to ground

6 Output +15 volts DC @ 1.5 amps; regulated with respect to ground
7 Output Overpower foldback, folds back output if bus droops
8 GND Ground
9 GND Ground
10 Gate control for secondary IGBT; 3 volts DC = on, 0 volts DC = off
11 Gate control for secondary IGBT; 3 volts DC = on, 0 volts DC = off
12 Not used
RC4
from chassis (GND).
3 Not used
4 Not used

9 Not used
10 Not used

RC5 High voltage present. Voltages on this receptacle can be more than 800 volts DC from
chassis to ground (GND).
All pins on this receptacle are referenced to the − bus (RC5-3)

1 + bus; regulated to 810 VDC
2 Bus center tap; regulated to 405 VDC
3 − bus; 0 VDC

RC6 1 Output Gate control input for secondary IGBT’s; 3 volts DC = on, 0 volts DC = off
2 Output Gate control input for secondary IGBT’s; 3 volts DC = on, 0 volts DC = off
3 Not used
4 Output Isolated +20 volts DC supply (A) for high side of inverter drive
5 Output Isolated +20 volts DC supply (B) for low side of inverter drive
6 Output Isolated +20 volts DC supply (C) for high side of inverter drive
7 Output GND, Reference for pins 1 and 2
8 Output GND, Reference for pins 1 and 2
9 Not used
10 Output Reference for pin 4
11 Output Reference for pin 5 (−bus secondary)
12 Output Reference for pin 6

7-27. Weld Control Board PC3 Testing Information (Use with Section 7-28) (Prior To LJ280222L)
according to Section 7-2,
parts.
PLG1 1 Process Control Board PC3
RC2 RC3
1
RC4
RC1
802 883 / 221 141-A

7-28. Weld Control Board PC3 Test Point Values (Prior To LJ280222L)
PLG1 1 Input +5 volts DC @ 1 amp; regulated with respect to ground
2 Input +5 volts DC @ 1 amp; regulated with respect to ground
3 Input +15 volts DC @ 300 mA; regulated with respect to ground
4 Input Module thermistor +; 1000 ohms ±1% @ 25° C
5 Input Module thermistor −; 1670 ohms ±1% @ 100° C
6 Output Lift arc power module; 15KHz, 15 volts DC squarewave
7 Output Boost enable; 0 volts DC=on, +5 volts DC=off
8 Output Gas enable; 0 volts DC−=on, +5 volts DC=off
9 Output Output enable; 0 volts DC−=on, +15 volts DC=off
10 Output Fan enable; 0 volts DC=on, +5 volts DC=off
11 Output Output reference; 0=1 amp, 10 volts=200 amps
12 Input Voltage feedback; 1 volt DC per 10 volts DC of weld output
13 Input Power down detect; 0 volts DC=okay, open collector=power down
14 Input Over current detect; 0 volts DC=over current, open collector=okay
15 Input Current feedback; 1 volt DC per 50 amperes of weld output
16 GND
17 GND
18 GND
19 GND
20 Input Over voltage detect; 0 volts DC=over voltage, open collector=okay
RC1 1 Input output reference; from Remote 14 pin E, 0 − 10 volts DC
2 GND
3 Not used
4 Output Current feedback; 1 volt DC per 100 amperes of weld output
5 Output Remote reference to Remote 14 receptacle RC1 pin C, 0 − 10 volts DC
6 Input Output enable from Remote 14 receptacle RC1 pin B, 15 volts DC=on
7 Output Voltage feedback; 1 volt DC per 10 volts of weld output
8 Output +15 volts DC to Remote 14 receptacle RC1 pin A (short circuit protection)
RC2 1 Input Output thermistor RT1; 30K ohms ±1% @25° C
2 Input Output thermistor RT1; 2K ohms ±1% @100° C
RC3 1 Output Arc starter drive; 0 volts DC=off, pulse train=HF
2 Not Used
3 Not Used
4 GND

RC4 1 Output Pulse lockout emitter; pulse frequency <10 Hz=optocoupler on
2 Output Final slope emitter; final slope=optocoupler on
LX Models 3 Output Valid arc emitter; valid arc=optocoupler on
Only 4 Input Output disable; 0 volts DC=enable output
5 Input Start/stop; 0volts DC=start, open=stop
6 Output Pulse lockout collector; pulse frequency < 10 Hz=optocoupler on
7 Output Final slope collector; final slope=optocoupler on
8 Output Valid arc collector; valid arc=optocoupler on
9 Input Gas enable; 0 volts DC=gas valve on, open=gas valve off
10 Not used
RC5 1 Output MOSI; synchronous serial communication signal
2 Output +5 volts DC; power supply to display board
3 Input ENC A; feedback signal from encoder control
4 GND
5 Input Reset; 0=no microprocessor function, 1=normal microprocessor function
6 Input ENC B; feedback signal from encoder control
7 Output SCK; synchronous serial communication signal
8 Output Display LE; strobe output for displays
9 Input MISO; synchronous serial communication signal
10 Output Switch load; strobe for button push detection

Notes

7-29. Weld Control Board PC3 Testing Information (Use w/Section 7-30) (Eff w/LJ280222L Thru
LK450044L)

parts.
PLG1 1 Process Control Board PC3
RC2 RC3
1
RC4
RC1
802 883 / 235 490-B

7-30. Weld Control Board PC3 Test Point Values (Eff w/LJ280222L Thru LK450045L)
4 Output +5 volts DC, thermistor
Module thermistor −; 1670 ohms ±1% @ 100° C
16 GND
17 GND
18 GND
19 GND
2 GND
3 Not used
Output thermistor RT1; 2K ohms ±1% @100° C
RC3 1 Output Arc starter HF crowbar drive; 0 volts DC=off, pulse train=HF crowbar
3 Output Arc starter HF output drive; +15 volts DC=off, pulse train=HF output
4 GND

LX Models 3 Output Valid arc emitter; valid arc=optocoupler on
Only 4 Input Output disable; 0 volts DC=enable output
10 Not used
RC5 1 Output MOSI; synchronous serial communication signal
2 Output +5 volts DC; power supply to display board
3 Input ENC A; feedback signal from encoder control
4 GND
5 Input Reset; 0=no microprocessor function, 1=normal microprocessor function
6 Input ENC B; feedback signal from encoder control
7 Output SCK; synchronous serial communication signal
8 Output Display LE; strobe output for displays
9 Input MISO; synchronous serial communication signal
10 Output Switch load; strobe for button push detection

7-31. Control And Interface Board PC3 Testing Information (Use with Section 7-32) (Eff w/LK450045L)
1 RC2 1 2 and be sure voltage is near
Bottom Of PC3 zero before touching any
parts.
1 Control And Interface Board
PC3
2 4
PLG3 RC3
1 1 3
RC4
5 10
4 9
3 8
13 5 2 7
1
6 2 1 6
RC1
3 RC5
7
1 8 4
2 10
Top Of PC3 1 9
PLG1
802 883 / 242 275-F

7-32. Control And Interface Board PC3 Test Point Values (Eff w/LK450045LL)
Module thermistor −; 1670 ohms ±1% @ 100° C
16 GND
17 GND
18 GND
19 GND
PLG3 1 Input Sequencer present; +5 VDC
2 Input Pulser present; +5 VDC
3 Input Dynasty/Maxstar; 0 VDC
4 Output +5 VDC
5 GND
6 Input Main/Peak; closure to pin 5 if switch is depressed
7 Input Not used
8 Input Process; closure to pin 5 if switch is depressed
9 Input Output; closure to pin 5 if switch is depressed
10 Input Pulser; closure to pin 5 if switch is depressed
11 Input Sequencer; closure to pin 5 if switch is depressed
12 Input Adjust; closure to pin 5 if switch is depressed
13 Input Not used

2 GND
3 Not used
Output thermistor RT1; 2K ohms ±1% @100° C
RC3 1 Output Arc starter HF crowbar drive; 0 volts DC=off, pulse train=HF crowbar
3 Output Arc starter HF output drive; +15 volts DC=off, pulse train=HF output
4 GND
3 Output Valid arc emitter; valid arc=optocoupler on
4 Input Output disable; 0 volts DC=enable output
10 Input Auto Enable
RC5 1 Input Serial communication signal
2 +5 volts DC
3 Not used
4 GND
5 Input Reset
6 GND
7 Input Serial communication clock
8 GND
9 Output Serial communication
10 GND

7-33. Arc Starter Board PC7 Testing Information (Use with Section 7-34) (Prior To LJ280222L)
parts.
1 Arc Starter Board PC7
802 833 / 189 940-F
RC3 RC2
RC1
7-34. Arc Starter Board PC7 Test Point Values (Prior To LJ280222L)
RC1 1 Input Positive output
2 Not used
3 Input Arc starter drive; optocoupler cathode
4 Input Negative output
5 Not used
6 Input Arc starter drive; optocoupler anode (AC coupled), 0 volts DC=off, pulse train=high frequency
RC2 Output To HF coupling
RC3 Output To HF coupling

7-35. Arc Starter Board PC7 Testing Information (Use with Section 7-36) (Eff w/LJ280222L)
parts.
1 Arc Starter Board PC7
FT2
FT1 Test Equipment Needed:
RC1
802 833 / 212 891-E
7-36. Arc Starter Board PC7 Test Point Values (Eff w/LJ280222L)
RC1 1 Input Arc starter, PWM enable
2 Input +15 volts
3 Input GND
FT1 Output To HF coupling
FT2 Output To HF coupling

7-37. Boost Control Board PC10 Testing Information (Use with Section 7-38) (Prior To LJ280222L)
parts.
1 Boost Control Board PC10
802 833 / 200 843-J
RC2 RC1
7-38. Boost Control Board PC10 Test Point Values (Prior To LJ280222L)
RC1
chassis (GND).
1 Input +Bus; regulated to 810 volts DC
2 Not Used
4 Output Boost control; drive signal for boost IGBT

RC1 5 Input +30 primary volts DC
6 Output Precharge; active low drive for precharge relay
7 Output +15 primary volts DC; regulated from +30 volts DC
8 Output −15 primary volts DC, regulated from +30 volts DC
9 Input IFB primary; current feedback for boost regulator control
11 Not Used
12 Input + Rect; rectified AC input
RC2
1 Input +15 buck volts DC; regulated from bus
2 Common
3 Output Buck drive; drive signal for +30 volts DC regulator
4 Input IFB buck; current feedback for +30 volts DC regulator
5 Not used

7 Output Flyback drive; control signal to derive regulated supplies on RC3
8 Input Flyback IFB; current feedback for flyback supply
9 Not used
10 Output Overpower foldback; folds back output if input current is greater than 35 amperes
11 Input +15 volts DC; used to regulate +15 volts DC
12 Input −15 volts DC; used to regulate −15 volts DC
7-39. Membrane Switch Panel Test Procedure (Prior To Serial No. LC374378)
DX and LX models shown. SD models will not have the Pulser and Sequencer portions. (No test available eff w/LC374378.)
(Push Button Switch)
PLG 1 7 11 3 1 5 9
13 Main Amps Process Output Pulser Sequencer Adjust
Without power applied, there will be continuity between plug PLG1 when corresponding buttons are pushed.
(LED Switch)
PLG1 17 21 4 8 12 14 10
19 TIG HF RMT STD PPS Final Slope t Initial A % LED HZ LED
2 Stick On Pulser On Final A DIG Sec LED Main Peak
15 TIG Lift RMT 2T Hold Peak t BKGND A Initial Slope t Amps LED Post Flow
Without power applied, there will be a diode drop (1.8 volts) between plug PLG1 pins

7-40. Boost Control Board PC10 Testing Information (Use with Section 7-41) (Eff w/LJ280222L)
parts.
1 Boost Control Board PC10
802 833 / 247 838-A
RC2 RC1
7-41. Boost Control Board PC10 Test Point Values (Eff w/LJ280222L)
RC1
chassis (GND).
1 Input +Bus; regulated to 810 volts DC
2 Not Used
4 Output Boost control; drive signal for boost IGBT

RC1 5 Input +30 primary volts DC
6 Output Precharge; active low drive for precharge relay
7 Output +15 primary volts DC; regulated from +30 volts DC
8 Output −15 primary volts DC, regulated from +30 volts DC
9 Input IFB primary; current feedback for boost regulator control
11 Not Used
12 Input + Rect; rectified AC input
RC2
1 Input +15 buck volts DC; regulated from bus
2 Common
3 Output Buck drive; drive signal for +30 volts DC regulator
4 Input IFB buck; current feedback for +30 volts DC regulator
5 Not used

7 Output Flyback drive; control signal to derive regulated supplies on RC3
8 Input Flyback IFB; current feedback for flyback supply
9 Not used
10 Output Overpower foldback; folds back output if input current is greater than 35 amperes
11 Input +15 volts DC; used to regulate +15 volts DC
12 Input −15 volts DC; used to regulate −15 volts DC

7-42. Using Test Mode To Check Machine Output
Turn power on while pressing and holding the A, Process, Output, and Ad-
just switch pads until software number and revision clears the displays.
The displays will now show [tSt] [150] and meter A LED will be lit.
Output Selections: Press the Output switch pad to select RMT STD or ON.
Selecting On or activating the remote contactor (14-Pin B) in RMT STD
turns output on with output voltage shown on left display. A normal OCV
output is approximately 74 VDC.
Output amperage is shown on the right display. A low amperage may be
displayed, typically no more than 1 amp with no actual amperage flow.
The following items are disabled:
Software closed loop amperage control
Sense voltage
HF output
Boost output
Gas output
Pulser
Help 8 (VFB over voltage)
Help 21 (IFB or VFB with contactor off)
Fan turns on and remains on as required after output is turned off to cool
machine.
Amperage Preset:
Amperage preset control defaults at 150 amps, and can be adjusted for the
full range of the machine from 5 to 200 amps.
Remote (14-Pin E) Amperage Control:
When the remote amperage control is set below the 10 VDC maximum in-
put, the left display displays [trt]. The right display displays the preset am-
perage trimmed to the remote input level.
Output amperage is limited to the displayed trimmed amperage.
7-43. Checking Unit Output After Servicing

Use output waveforms to check unit output
after servicing (see Section 7-18).
1 Weld Output Terminals
Check open-circuit voltage between terminals
according to Section 7-17 (voltage V-8)
If correct voltage and/or waveforms are not
present, repeat troubleshooting procedures.
Perform a load bank test to ensure welding

power source operates properly after ser-
vicing. Be sure load bank is capable of
handling the rated output of the welding
power source being tested (see load bank
Owner’s Manual).
The load bank will simulate a weld load and
the electrical demand on the unit. See
Specifications Section for rated output.
If unit does not perform at rated output, re-
peat troubleshooting procedures in
Section 7-14.
Reinstall cover and side panels if removed.
802 451

SECTION 8 − MAINTENANCE
8-1. Routine Maintenance
! Disconnect power before maintaining.
Maintain more often during severe conditions.
A. Welding Power Source

= Check = Change = Clean Δ = Repair
= Replace
* To be done by Factory Authorized Service Agent
Every
3
Months

Labels
Gas Hoses
Every
3
Months
Δ
Cables And Cords
Every ! Do not remove case when

6 blowing out inside of unit
Months (see Section 8-2) .
:Durning heavy service, clean monthly.
B. Optional Cooler
= Check = Change = Clean Δ = Repair
= Replace
* To be done by Factory Authorized Service Agent
Every
3 Blow out heat exchanger fins.
Months Coolant Strainer, Check coolant level. Top off with
durning heavy service, distilled or deionized water if necessary.
clean more frequently.
Every
6
Months

Hoses
Labels
Every
12
Months
Replace coolant.

8-2. Blowing Out Inside Of Unit
! Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
802 451

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
Circuit Diagram For Maxstar 200 LA230402 thru LJ280221L 189 769-E 200 660-C♦♦
SD, DX, LX
LJ280222L and following 237 566-C See Table 9-1
Circuit Diagram For Inverter Con- LA230402 thru LB284900 200 849-A♦♦
trol Board PC1
LB284901 thru LJ280221L 206 131-C♦♦
LJ280222L and following 233 124-F♦♦
Circuit Diagram For Power Inter- LA230402 thru LJ280221L 200 853-B♦♦
connect Board PC2
LJ280222L and following 230 185-E♦♦
Circuit Diagram For Weld Control LA230402 thru LC374377 200 471-A♦♦
Board PC3 (SD, DX Models)
LC374378 thru LC684626 209 233B♦♦
LC684627 thru LJ280221L 221 139-A♦♦
LJ280222L thru LK450044L 235 482-B♦♦
LK450045L and following 242 276-C♦♦
Circuit Diagram For Weld Control LA230402 thru LC374377 200 475-A♦♦
Board PC3 (LX Models)
LC374378 thru LJ280221L 221 142-A♦♦
LJ280222L thru LK450044L 235 491-B♦♦
LK450045L and following 242 276-C♦♦
Circuit Diagram For Arc Starter LA230402 thru LJ280221L 189 941-E♦♦
Board PC7
LJ280222L and following 212 892-B♦♦
Circuit Diagram For Boost Control LA230402 thru LJ280221L 200 845-G♦♦
Board PC10
LJ280222L and following 247 839-B♦♦
♦♦ Not included in this manual

189 769-E
Figure 9-1. Circuit Diagram For Maxstar 200 SD, DX, LX Effective With Serial No. LA230402 Thru LJ280221L

237 566-C
Figure 9-2. Circuit Diagram For Maxstar 200 SD, DX, LX Effective With Serial No. LJ280222L And Following

Table 9-1. Lead List Summary For Maxstar 200 SD, DX, LX Models Eff w/LJ280222L And Following
Table shows physical lead connections and should be used with circuit diagram (table replaces wiring diagram).
Lead Connections Lead Connections
22B . . . . . . . . . . . T1/T2 TAP TO PLG2 (1) 0042B ........ LEFT REAR GND TO REAR UPPER
22D . . . . . . . . . . PLG8 (2) TO PLG8 (4)) 0042E ........ RC1 (G) TO MAGNETICS BOX
0042F ........ RC1 (K) TO MAGNETICS BOX
26B . . . . . . . . . . . POSITIVE OUTPUT STUD TO PLG2 (3)
0042G ........ RC1 (D) TO MAGNETICS BOX
26D . . . . . . . . . . PLG8 (1) TO PLG8 (3)
0042H ........ MAGNETICS BOX TO PLG11 (2)
−−−− . . . . . . . . . . C6 TO SR1 (AC) 0042K ........ RC2 (D) TO LEFT REAR GND
−−−− . . . . . . . . . . R2 TO SR1 (AC) 0042L ........ PC2 (CHASSIS) TO LEFT REAR GND
0001A . . . . . . . . S1 (LEFT) TO PC2 (LINE 1) 0043A ........ GS1 TO PLG6 (1)
0002A . . . . . . . . S1 (MIDDLE) TO PC2 (LINE 2) 0044A ........ GS1 TO PLG6 (3)
0045A ........ CR1 (A) TO PLG6 (2)
0003A . . . . . . . . S1 (RIGHT) TO PC2 (LINE 3)
0046A ........ CR1 (B) TO PLG6 (4)
0006A . . . . . . . . PLG13 (3) TO PLG10 (1)
0061A ........ RC2 (A) TO PLG14 (5)
0007A . . . . . . . . PLG13 (4) TO PLG10 (3) 0062A ........ RC2 (B) TO PL 14 (9)
0008A . . . . . . . . PLG13 (2) TO PLG10 (2) 0063A ........ RC2 (C) TO PLG14 (4)
0019A . . . . . . . . RC1 (A) TO PLG11 (8) 0065A ........ RC2 (E) TO PLG14 (7)
0021A . . . . . . . . RC1 (C) TO PLG11 (5) 0066A ........ RC2 (F) TO PLG14 (2)
0022C . . . . . . . . SR1 (−) TO T1 CENTERTAP 0067A ........ RC2 (H) TO PLG14 (1)
0068A ........ RC2 (I) TO PLG14 (8)
0023A . . . . . . . . SR1 (+) TO STAB/SECONDARY HEATSINK
0069A ........ RC2 (J) TO PLG14 (3)
0025A . . . . . . . . RC1 (H) TO PLG11 (7)
0070A ........ RC2 (G) TO PLG14 (6)
0027A . . . . . . . . RC1 (E) TO PLG11 (1) 0071A ........ PLG14 (10) TO MAGNETIC BOX
0028A . . . . . . . . RC1 (B) TO PLG11 (6) NONE ....... C5 TO D1 (ANODE)
0030A . . . . . . . . RC1 (F) TO PLG11 (4) NONE ....... R1 TO D1 (ANODE)

SECTION 10 − HIGH FREQUENCY
10-1. Welding Processes Requiring High Frequency
1 High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
Work
TIG high_freq 5/10 − S-0693
10-2. Installation Showing Possible Sources Of HF Interference
Weld Zone
11, 12
50 ft
(15 m)
10
9 14
8
13 2
4 5 6
Best Practices
Not Followed
Sources of Direct High-Frequency Sources of Conduction of High Sources of Reradiation of High

Radiation Frequency Frequency
1 High-Frequency Source (welding 7 Input Power Cable 10 Ungrounded Metal Objects
power source with built-in HF or 8 Line Disconnect Device 11 Lighting
separate HF unit)
9 Input Supply Wiring 12 Wiring
2 Weld Cables
13 Water Pipes and Fixtures
3 Torch
4 Work Clamp 14 External Phone and Power Lines
5 Workpiece
6 Work Table
S-0694

10-3. Recommended Installation To Reduce HF Interference
Weld Zone 7
3 50 ft
(15 m)
50 ft
(15 m)
1
6
2
8
8
Ground all metal ob-
jects and all wiring in
welding zone using
#12 AWG wire.
Ground
workpiece if
required by
Nonmetal
Building codes.
9
Best Practices Followed
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1 High-Frequency Source (welding 5 Conduit Joint Bonding and Grounding Metal Building Requirements
power source with built-in HF or
Electrically join (bond) all conduit sections 9 Metal Building Panel Bonding
separate HF unit)
using copper straps or braided wire. Methods
Ground metal machine case (clean paint
Ground conduit every 50 ft (15 m). Bolt or weld building panels together, install
from around hole in case, and use case
screw), work output terminal, line discon- 6 Water Pipes and Fixtures copper straps or braided wire across
nect device, input supply, and worktable. seams, and ground frame.
2 Center Point of Welding Zone Ground water pipes every 50 ft (15 m).
10 Windows and Doorways
Midpoint between high-frequency source 7 External Power or Telephone Lines Cover all windows and doorways with
and welding torch. grounded copper screen of not more than
3 Welding Zone Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines. 1/4 in (6.4 mm) mesh.
A circle 50 ft (15 m) from center point in all 11 Overhead Door Track
directions. 8 Grounding Rod
4 Weld Output Cables Ground the track.
Consult the National Electrical Code for
Keep cables short and close together. specifications.

TM-2226V 2014−03
Eff w/Serial Number LA230402
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
Maxstar 200 SD, DX, And LX

(Including Optional Cart And Cooler)
CE And Non-CE Models
Eff w/LA230402 And Following

For OM-2226 (189 783) Revision * And Following
Visit our website at

www.MillerWelds.com
SECTION 11 − POWER SOURCE PARTS LIST
Hardware is common and
not available unless listed.
12
28
25
615
13
28 39 33 8
11
19
18 35 6
38
16
401
400
402
14 10
2
15 3
37
614
30
17
4
1
7
403
36
600 5
803 227-H
Figure 11-1. Main Assembly

Item Dia. Part
No. Mkgs. No. Description Quantity
1 . . . . . . . . . . . . . . . . . . Fig11-2 . . . . Panel, Front W/Cmpnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . . . . . . . . . . . Fig11-3 . . . . Panel, Rear W/Cmpnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . Fig11-4 . . . . Magnetics Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . . . . . Fig11-5 . . . . Windtunnel, W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 . . . . . . . . . . . . . . . . . . Fig11-7 . . . . Base Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . . . S1 . . . . . 244 920 . . . . Switch, Tgl 3pst 40a 600vac Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . . . . . . . . . . . . 200393 . . . . Insulator, filter board (CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 . . . . . . . PM1 . . . . . . 204821 . . . . Kit, Input/Pre-Regulator Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 . . . . . . . . . . . . . . . . . . 049611 . . . . Tubing, Cop .540 Od X .123 Wall X .687 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . . . . . . . . . . . 196727 . . . . Cable, Power 10 Ft 12ga 4c Blk/Red/Wht/Grnyel . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . . . . . . . . . . +195643 . . . . Wrapper, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 . . . . . . . . . . . . . . . . . 206108 . . . . Handle, Rubberized Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . . . . . . . . . . . . . . . 257270 . . . . Strap, Shoulder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14 . . . . . . . . . . . . . . . . . 189782 . . . . Insulator, Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 . . . . C7, C 8 . . . . 222488 . . . . Capacitor Assy, (Prior to LC426623) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
15 . . . . C7, C 8 . . . . 209997 . . . . Capacitor Assy, (Eff w/LC426623 thru LC504911) . . . . . . . . . . . . . . . . . . 2
15 . . . . . C7,C8 . . . . . 213974 . . . . Capacitor Assy, (Eff wLC504912) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 . . . . . . . . . . . . . . . . . 249635 . . . . Capacitor Assy, (CE Only) (Eff w/490041L) . . . . . . . . . . . . . . . . . . . . . . . 2
16 . . . . . . . . . . . . . . . . . 189778 . . . . Plug W/Leads, Vfb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 . . . . . . . . . . . . . . . . . 189773 . . . . Plug W/Leads, Arc Starter (Prior to LJ280222L) . . . . . . . . . . . . . . . . . . . . 1
17 . . . . . . . . . . . . . . . . . 231376 . . . . Plug W/Leads, Arc Starter (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . 1
18 . . . . . . . . . . . . . . . . . 189768 . . . . Plug W/Leads, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
19 . . . . . . . . . . . . . . . . . 237565 . . . . Cable, Lem W/Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
25 . . . . . . . . . . . . . . . . . 189784 . . . . Insulator, wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
28 . . . . . . . . . . . . . . . . . 203990 . . . . Label, Warning General Precautionary (Non Ce Models) . . . . . . . . . . . . 2
28 . . . . . . . . . . . . . . . . . 179310 . . . . Label, Warning General Precautionary (Ce Models) . . . . . . . . . . . . . . . . . 2
29 . . . . . . . . . . . . . . . . . 138442 . . . . Label, Caution Falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
30 . . . . . . . . . . . . . . . . . 185835 . . . . Label, Warning Electric Shock/Exploding Parts (Non Ce Models) . . . . . 1
30 . . . . . . . . . . . . . . . . . 185836 . . . . Label, Warning Electric Shock/Exploding Parts (Ce Models) . . . . . . . . . 1
31 . . . . . . . . . . . . . . . . . 185836 . . . . Label, GND/PE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
32 . . . . . . . . . . . . . . . . . 207310 . . . . Core, Toroidal (CE Models) (eff w/LC106099 Thru LJ310418L)) . . . . . . 1
33 . . . . . . . . . . . . . . . . . 215002 . . . . Clip, Support PC Mtg (eff w/LC645400) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
35 . . . . . . C10 . . . . . . 213912 . . . . Capacitor, Polye Film .1 UF 1000 VDC w/Terms (CE Models)
................................ Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
36 . . . . . . . L4 . . . . . . 199122 . . . . Core, Toroidal .750 ID X 1.450 OD X .544 Thk (CE Models)
................................ (Eff w/LJ280222L Thru LJ440143L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
36 . . . . . . . L4 . . . . . . 241027 . . . . Core, Toroidal .748 ID X 1.142 OD X .600 THK (Eff w/LJ440144L) . . . . 1
37 . . . . . . . L5 . . . . . . 237542 . . . . Core, Toroidal .540 ID X .875 OD X .500 THhk (CE Models)
................................ (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
38 . . . . . . . . . . . . . . . . . 235497 . . . . Plug, w/Leads (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
39 . . . . . . . L7 . . . . . . 249747 . . . . Core, Ferrite Round Cable .201 ID Clamp-on EMI Supp
................................ (CE Models) (Eff w/MA490041L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
400 . . . . . PC2 . . . . . . 230183 . . . . Circuit Card Assy, Power Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
401 . . . . . PC1 . . . . . . 230166 . . . . Circuit Card Assy, Inverter (Eff w/LA230402 Thru LJ280221L) . . . . . . . . 1
401 . . . . . PC1 . . . . . . 237562 . . . . Kit, Field Circuit Card Inverter Max 200 (Eff w/LJ280222L) . . . . . . . . . . . 1
402 . . . . PC10 . . . . . 230170 . . . . Circuit Card Assy, Boost (Prior to LJ280222L) . . . . . . . . . . . . . . . . . . . . . . 1
402 . . . . PC10 . . . . . 247837 . . . . Circuit Card Assy, Boost (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . 1
403 . . . . . PC9 . . . . . . 199506 . . . . Circuit Card Assy, Filter (CE Models) (Prior To LJ280222L) . . . . . . . . . . 1
403 . . . . . PC 9 . . . . . 230207 . . . . Circuit Card Assy, Filter (CE Models) (Eff w/LH180181L
................................ Thru LJ280221L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
403 . . . . . PC 9 . . . . . 230203 . . . . Circuit Card Assy, Filter (CE Models) (Eff w/LJ280222L) . . . . . . . . . . . . 1
600 . . . . . . . . . . . . . . . . 229333 . . . . Screw, M10−1.5x 20 Hex Hd−pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2
614 . . . . . . . . . . . . . . . . 136343 . . . . Screw, K50x 20 Pan Hd−phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . 2
615 . . . . . . . . . . . . . . . . 229334 . . . . Screw, M 5−.8x 35 Pan hd-phl Stl Pls Sems . . . . . . . . . . . . . . . . . . . . . . . 4
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts.
Model and serial number required when ordering parts from your local distributor.
400
604

1
7
3
603
17
4
5
14
6
13
12
602
9
15
11
8 16
805 151-C
Figure 11-2. Panel, Front w/Components

Item Dia. Part
11-2. Panel, Front w/Components (Figure 11-1 Item 1)
1 . . . . . . . . . . . . . . . . . . 194242 . . . . Panel, Front/Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . . . . . . . . . . . 195647 . . . . Panel, Front Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 192886 . . . . Nameplate/Switch Membrane, Maxstar SD (Non CE Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LC374378L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 192890 . . . . Nameplate/Switch Membrane, Maxstar SD (CE Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LC374378L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 239470 . . . . Nameplate/Switch Membrane, Maxstar SD (CE Or Non CE Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LC374378L Thru LK450044L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 244024 . . . . Nameplate/Switch Membrane, Maxstar SD (CE Or Non CE Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LK450045L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 192884 . . . . Nameplate/Switch Membrane, Maxstar DX & LX (Non CE Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LC374378L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 192888 . . . . Nameplate/Switch Membrane, Maxstar DX & LX (CE Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LC374378L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 231254 . . . . Nameplate/Switch Membrane, Maxstar DX & LX (CE Or Non CE Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LC374378L Thru LK450044L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 244025 . . . . Nameplate/Switch Membrane, Maxstar DX & LX (CE Or Non CE Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Eff w/LK450045L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . . . . . 230052 . . . . Knob, Pointer .840 Dia X 6mm ID W/Spring Clip−4.5 . . . . . . . . . . . . . . . . 1
5 . . . . . . . . . . . . . . . . . . 194243 . . . . Door, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . . . . . . . . . . . . . 199008 . . . . Label, Door Maxstar 200 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . . . . . . . . . . . . . 199009 . . . . Label, Door Maxstar 200 DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . . . . . . . . . . . . . 199010 . . . . Label, Door Maxstar 200 LX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . RC1 . . . . . . 189771 . . . . Receptacle W/Leads & Plug (14 Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 . . . . . . . . . . . . . . . . . . 202553 . . . . Rcpt, Tw Lk Insul Fem(Dinse Type)50/70 Series Wsl . . . . . . . . . . . . . . . . 2
9 . . . . . . . . . . . . . . . . . . 193649 . . . . Ftg, Gas Barbed 1/4 TBG 5/8−18 Female . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 . . . . . . . . . . . . . . . . . . 193650 . . . . Ftg, Gas Barbed 1/4 TBG 3/8−19 BSPP Male (CE Models) . . . . . . . . . . 1
11 . . . . . . . . . . . . . . . . . 185712 . . . . Insulator, Bulkhead Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12 . . . . . . . . . . . . . . . . . 185713 . . . . Insulator, Bulkhead Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
13 . . . . . . . . . . . . . . . . . 229338 . . . . Washer, Domed Load .812 ID X 1.450 OD X .070 Thk. . . . . . . . . . . . . . . 2
14 . . . . . . . . . . . . . . . . . 185717 . . . . Nut, M20 X 1.5 1.0625 Hex .19 H Locking . . . . . . . . . . . . . . . . . . . . . . . . . . 2
15 . . . . . . . . . . . . . . . . . 185718 . . . . O-Ring 0.989 I.D. X 0.070 Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
16 . . . . . . . . . . . . . . . . . 186228 . . . . O-Ring 0.739 I.D. X 0.070 Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
400 . . . . . PC3 . . . . . . 208316 . . . . Circuit Card Assy, Weld Control (SD & DX Models)(Prior to LC374378) 1
400 . . . . . PC3 . . . . . . 233636 . . . . Kit, Field Program Update Dyn/Max 200 SD/DX (Eff w/LC374378
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thru LJ280221L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
400 . . . . . PC3 . . . . . . 235485 . . . . Circuit Card Assy, Control & Interface (SD/DX Models) (Eff w/LJ280222L
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thru LK450044L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
400 . . . . . PC3 . . . . . . 208318 . . . . Circuit Card Assy, Weld Control (LX Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior To LC374378) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
400 . . . . . PC3 . . . . . . 217643 . . . . Kit, Field Program Update (LX Models) (Eff w/LC374378 Thru LJ280221L) 1
400 . . . . . PC3 . . . . . . 235488 . . . . Circuit Card Assy, Control & Interface (LX Models) (Eff w/LJ280222L
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thru LK450044L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
400 . . . . . PC3 . . . . . . 257008 . . . . Kit, Field Update Dyn/Max 200
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (SD, DX, LX Models) (Eff w/LK450045L) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 186914 . . . . LED, red 5.0V 20MA RH DEC 7seg ALGAAS com anode
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Prior to LC374378) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
602 . . . . . . . . . . . . . . . . 166560 . . . . Ring, Rtng Ext .500 Shaft X .042 Thk E Style Bowed . . . . . . . . . . . . . . . 1
603 . . . . . . . . . . . . . . . . 178548 . . . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
604 . . . . . . . . . . . . . . . . 098691 . . . . Stand−off, No 6−32 X .625 Lg .250 Hex Stl M&f . . . . . . . . . . . . . . . . . . . . 4
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Ref. 199 492-C
Figure 11-3.Panel, Rear w/Components
Item Dia. Part

Figure 11-3. Panel, Rear w/Components (Figure 11-1 Item 2)
1 . . . . . . . . . . . . . . . . . . 194242 . . . . Panel, Front/Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . . . . . . . . . . . 195648 . . . . Panel, Rear Lower (Prior to LC336313) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . . . . 206053 . . . . Panel, Rear Lower (Eff w/LC336313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 195646 . . . . Panel, Rear Upper (SD & DX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 197127 . . . . Panel, Rear Upper 10-pin (LX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . . . . . 186440 . . . . Bushing, Strain Relief .350/.630 ID X1.050 Mtg Hol (Prior To LJ280222L)1
4 . . . . . . . . . . . . . . . . . . 201155 . . . . Bushing, Strain Relief .450/ .709 ID X1.608 Mtg Hol (CE Models Prior
................................ To LJ280222L, All Models Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . 1
5 . . . . . . . . . . . . . . . . . . 193649 . . . . Ftg, Gas Barbed 1/4 TBG 5/8−18 Female . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 . . . . . . . . . . . . . . . . . . 193650 . . . . Ftg, Gas Barbed 1/4 TBG 3/8−19 BSPP Male (CE Models . . . ) . . . . . 1
6 . . . . . . . RC2 . . . . . . 199882 . . . . Receptacle, W/Leads 4 Plug 10-pin (LX Models) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 146212 . . . . Conn, Circ Ms/Met 10Pin Sz 18 Plug Cable Solder
................................ (Mates w/RC2) (LX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 200544 . . . . Conn, Circ 97/Met Clamp Str Size 18 (Mates w/ RC2) (LX Models) . . . 1
600 . . . . . . . . . . . . . . . . 198245 . . . . Nut, Conduit .750 Npt Pld 1.388 Od X .150 Thk . . . . . . . . . . . . . . . . . . . . 1
601 . . . . . . . . . . . . . . . . 166560 . . . . Ring, Rtng Ext .500 Shaft X .042 Thk E Style Bowed . . . . . . . . . . . . . . . 1
Hardware is common and 603 604
not available unless listed. 613
613 3
609
19
1
603 17 7
617
13
14
15 10
4
12
5
617
12
9
14 611
13 600
400
17 11
22
6
805 153-C
Figure 11-4. Magnetics Assembly w/Components
Item Dia. Part

(Figure 11-1 Item 3)
1 . . . . . . . . . . . . . . . . . . 195649 . . . . Panel, Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . . . . . . . . . . . 189785 . . . . Insulator, Hf Coil (Prior to LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . . . . 231378 . . . . Insulator, HF PCB (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . FM1 . . . . . . 196887 . . . . Fan, Muffin 24vdc 3000 Rpm 130 Cfm 4.125 Mtg Holes
................................ (Prior to LH140001L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . FM1 . . . . . . 239380 . . . . Fan, Muffin 24vdc 4200 Rpm 140 Cfm 4.125 Mtg Holes
................................ (Eff w/LH140001L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . GS1 . . . . . . 218494 . . . . KIT, valve, 24vdc 2way Custom Port 1/8 Orf W/Frict includes
................................ nut (Prior to LK090395L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . GS1 . . . . . . 238805 . . . . Valve, 24vdc 2way,125 PSI Custom Port.054 ORF w/fr w/friction . . . . . . .
................................ (Eff w/LK090395L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 . . . . . . . . . . . . . . . . . . 197987 . . . . Hose, Nprn Brd No 1 X .250 Id X 10.000 (Prior to LH180181L) . . . . . . . 2
5 . . . . . . . . . . . . . . . . . . 210610 . . . . Hose, Nprn Brd No 1 X .250 Id X 12.250
................................ (Eff w/LH180181L Thru MB260003L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 . . . . . . . . . . . . . . . . . . 210610 . . . . Hose, Nprn Brd No 1 X .250 Id X 12.250 (Eff w/MB260003L) . . . . . . . . . 1
6 . . . . . . . CR1 . . . . . . 198549 . . . . Relay, Encl 24vdc Spst 35a/300vac 4pin Flange Mtg . . . . . . . . . . . . . . . . 1
7 . . . . . . . . . . . . . . . . . . 112863 . . . . Ftg, Hose Brs Barbed M 1/4 Tbg X 5/8−18 Sae Flare . . . . . . . . . . . . . . . 1
8 . . . . . . . . . . . . . . . . . . 196443 . . . . Choke, Output And Coupling Coil Assy (Prior To LJ280222L) . . . . . . . . 1
8 . . . . . . . . Z1 . . . . . . 189790 . . . . Inductor, Output (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
(Figure 11-1 Item 3) (Continued)
9 . . . . . . . . L2 . . . . . . 210599 . . . . Coil, inductor 9T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . L3 . . . . . . 199690 . . . . Inductor, Boost 30uh (Prior to LB284901) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . L3 . . . . . . 206020 . . . . Coil, inductor 14T (Eff w/LB284901 Thru MA460476L) . . . . . . . . . . . . . . 1
10 . . . . . . . L3 . . . . . . 210568 . . . . Coil, inductor 14T (Eff w/MA460477L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . T1 . . . . . . 189795 . . . . Xfmr, Power (Prior to LB284901) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . T1 . . . . . . 206017 . . . . Xfmr, Power (Eff w/LB284901 thru LC336312) . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . T1 . . . . . . 212268 . . . . Xfmr, Power (Eff w/LC336313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 . . . . . . . . . . . . . . . . . 109056 . . . . Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide . . . . . . . . . . . . . . . . . 2
13 . . . . . . . . . . . . . . . . . 196512 . . . . Bracket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
14 . . . . . . . . . . . . . . . . . 196514 . . . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
15 . . . . . . . . . . . . . . . . . 200385 . . . . Bracket, Mtg HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 . . . . . . . . . . . . . . . . . 193415 . . . . Connector, Faston Male (Eff w/LC426623 Thru MA460476L) . . . . . . . . . 1
17 . . . . . . . . . . . . . . . . . 231208 . . . . Connector, Faston 1/4 Ring W/75deg Bend (Eff w/MA460477L) . . . . . . 2
19 . . . . . . . . . . . . . . . . . 251250 . . . . Hose, Nprn Brd No 1 x .250 ID x 9.250 (Eff w/MB260003L) . . . . . . . . . . . 1
22 . . . . . . . . . . . . . . . . . 233190 . . . . Coil, XFMR Coupling (Eff w/LJ280222L) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
400 . . . . . PC7 . . . . . . 189939 . . . . Circuit Card Assy, Arc Starter (Prior to LJ280222L) . . . . . . . . . . . . . . . . . 1
400 . . . . . PC7 . . . . . . 230174 . . . . Circuit Card Assy, Arc Starter (CE Models) (Eff w/LH180181L thru
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LJ280221L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
400 . . . . . PC7 . . . . . . 228593 . . . . Circuit Card Assy, Arc Starter (CE Models) (Eff w/LJ280222L) . . . . . . . 1
600 . . . . . . . . . . . . . . . . 199538 . . . . Grommet, Scr No 8/10 Panel Hole .281 Sq .250 High . . . . . . . . . . . . . . . 4
603 . . . . . . . . . . . . . . . . 057357 . . . . Bushing, Snap−in Nyl .937 Id X 1.125 Mtg Hole . . . . . . . . . . . . . . . . . . . . 2
609 . . . . . . . . . . . . . . . . 137761 . . . . Nut, (eff w/LE105120) (Prior to LE105120, nut is part of Kit 218494
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see item 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
611 . . . . . . . . . . . . . . . . 136343 . . . . Screw, K50x 20 Pan Hd-phl Stl Pld Pt Thread Forming . . . . . . . . . . . . . 2
613 . . . . . . . . . . . . . . . . 083147 . . . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . . 2
617 . . . . . . . . . . . . . . . . 170647 . . . . Bushing, Snap-in Nyl 1.312 ID X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . . 2

1 8 Hardware is common and
602
6
3
Ref. 199 494-F
10
Figure 11-5. Windtunnel w/Components
Item Dia. Part

Figure 11-5. Windtunnel w/Components
1 . . . . . . . . . . . . . . . . . . 195645 . . . . Bracket, heatsink rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . . . . . . . . . . . 198634 . . . . Bracket, Front Heatsink Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . . . . 198633 . . . . Wind Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . . . . . 189777 . . . . . . Rail, Heat Sink (Prior to LH140001L) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 . . . . . . . . . . . . . . . . . . 232856 . . . . . . Rail, Heat Sink (Eff w/LH140001L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 . . . . . . . . . . . . . . . . . . 198652 . . . . Bracket, Windtunnel Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6 . . . . . . . . . . . . . . . . . +209949 . . . . Heat Sink, Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . . . . . . . . . . . . 199497 . . . . Heat Sink, Secondary Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 . . . . . . . . L1 . . . . . . 189787 . . . . Choke, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 083147 . . . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High (CE Models) . . . 4
10 . . . . . . . C9 . . . . . . 151328 . . . . Capacitor, Polyp Met Film .0047Uf 1000 Vdc W/T (CE Models) ..... 1
602 . . . . . . . . . . . . . . . . 154408 . . . . Bushing, Snap−in Nyl .562 Id X .875 Mtg Hole Cent . . . . . . . . . . . . . . . . 1
606
2
604
604
5
6
600
600
601
3 600
1 199 497-K
Figure 11-6. Heat Sink, Secondary Assembly
Item Dia. Part

Figure 11-6. Heat Sink, Secondary Assembly
1 . . . . . . . . . . . . . . . . . . 191851 . . . . Heat Sink, Diode (Prior to LB284901) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . . . . . . . . . . . 206023 . . . . Heat Sink, Diode (Eff w/LB284901) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . D1 . . . . . . 204820 . . . . Kit, Diode, Ultra Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . HD1 . . . . . . 198028 . . . . Transducer, Current 100a Module Supply V+/− 15v . . . . . . . . . . . . . . . . . 1
4 . . . . . . . RT1 . . . . . . 211124 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 18 in Lead . . . . . . . . . . . . . . . . . . 1
5 . . . . . . R2, C6 . . . . 199137 . . . . Resistor/Capacitor (Prior to LB284901) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 . . . . . . R2, C6 . . . . 206021 . . . . Resistor/Capacitor (Eff w/LB284901) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . R1, C5 . . . . 199138 . . . . Resistor/Capacitor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . SR1 . . . . . . 153099 . . . . Rectifier, Integ Bridge 40. Amp 1000v Plstc Cover (Priorto LB284901) . 1
7 . . . . . . . SR1 . . . . . . 199952 . . . . Diode, Power Module 50 Amp 600V (Effw/LB284901) . . . . . . . . . . . . . . . 1
600 . . . . . . . . . . . . . . . . 196726 . . . . Screw, M 5−.8x 18 Pan Hd−Phl Stl Pld Sems (Prior to LB284901) . . . . 2
600 . . . . . . . . . . . . . . . . 143360 . . . . Screw, 008−32x .50 Pan Hd−Phl Stl Pld (Eff w/LB284901 Thru
................................ MB030311L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
600 . . . . . . . . . . . . . . . . 207451 . . . . Screw, 008−32x .50 Pan Hd−Phl Stl Pld (Eff w/MB030312L) . . . . . . . . . . 2
601 . . . . . . . . . . . . . . . . 249847 . . . . Screw, Set # 8-32x .75 Cup Pt Sss (Eff w/MB030312L . . . . . . . . . . . . . . 1
604 . . . . . . . . . . . . . . . . 207450 . . . . Screw, 004−40x .37 Pan Hd−torx Stl Pld Cone Sems (Eff w/MB030312L)4
606 . . . . . . . . . . . . . . . . 229331 . . . . Screw, M 6−1.0x 16 Pan Hd−phl Stl Pld Sems . . . . . . . . . . . . . . . . . . . . . 2
199 493-B
Figure 11-7. Base Assembly
Item Dia. Part

Figure 11-7. Base Assembly
1 . . . . . . . . . . . . . . . . . . 195644 . . . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . . . . 019663 . . . . Mount, Nprn 15/16odx3/8rec 3/16x3/8 (Prior to LJ440144L) . . . . . . . . . . 4
2 . . . . . . . . . . . . . . . . . . 239388 . . . . Bumper, Rbr .875 OD X .188 ID X .39 High Recessed (Eff w/LJ440144L)4

SECTION 12 − COOLER PARTS LIST

10 11
13
3
12
2
7 16 7
18
15
14 19
1
8 13
6
14
9
17
5
22
7
4
21 15 20
25
23
19
24
26
27
28
805 266-A

Item Dia. Part
1 . . . . . . . . . . . . . +235416 . . Wrapper, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 . . . . . . . . . . . . . . 188980 . . Label, Caution Incorrect Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . 203990 . . Label, Warning General Precautionary Static . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . 235422 . . Tank, Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 . . . . . . . . . . . . . . 166608 . . Cap, Tank Screw−on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . . . . . . . . 237535 . . Hose, Rbr Brd No 1 X .375 ID X 2.250 Black . . . . . . . . . . . . . . . . . . . . . . . . . 3
8 . . . . . . . . . . . . . . 166564 . . Filter, In−line Low Profile 100 Screen 3/8 Hose Bar . . . . . . . . . . . . . . . . . . . 1
9 . . . . . . . . . . . . . . 235419 . . Bracket, Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . FM . . 213072 . . Fan, Muffin 115V 60 Hz 3400 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . . . . . 1
10 . . . . . . FM . . 235504 . . Fan, Muffin 230V 60 Hz 3400 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . . . . . . . 235418 . . Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 . . . . . . . . . . . . . 237543 . . Radiator, Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . . . . . . . . . . . 237538 . . Hose, Rbr Brd No 1 X .375 ID X 18.000 Black . . . . . . . . . . . . . . . . . . . . . . . . 1
14 . . . . . . . . . . . . . 237539 . . Hose, Rbr Brd No 1 X .375 ID X 11.50 Black . . . . . . . . . . . . . . . . . . . . . . . . . 2
15 . . . . . . . . . . . . . 237536 . . Hose, Rbr Brd No 1 X .375 ID X 9.00 Black . . . . . . . . . . . . . . . . . . . . . . . . . . 2
16 . . . . . . . . . . . . . 235461 . . Damper, Fluid Pulsation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 . . . . . . MOT . 235457 . . Pump, Assy Coolant (115V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 . . . . . . MOT . 235501 . . Pump, Assy Coolant (230V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18 . . . . . PLG1 . 192457 . . Cable, Power 11 Ft 7 In 16ga 3c (115V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18 . . . . . PLG1 . 192458 . . Cable, Power 11 Ft 7 In 16ga 3c (230V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
19 . . . . . . . . . . . . . 235423 . . Bezel, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
20 . . . . . . . . . . . . . 240279 . . Valve, Check 3/8 Barb Inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
21 . . . . . . . . . . . . . 094263 . . Clamp, 1−ear Type Nom Dim .718 X .276 Wide . . . . . . . . . . . . . . . . . . . . . . 14
22 . . . . . . . . . . . . . 235417 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23 . . . . . . . . . . . . . 235415 . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
24 . . . . . . . . . . . . . 019663 . . Mount, NPRN 15/16 OD x 3/8 Rec 3/16 x 3/8 . . . . . . . . . . . . . . . . . . . . . . . . 4
25 . . . . . . . S1 . . 237540 . . Switch, Rocker Dpst 16 A 115 VAC On−Off . . . . . . . . . . . . . . . . . . . . . . . . . . 1
25 . . . . . . . S1 . . 237541 . . Switch, Rocker Dpst 16 A 230 VAC On−Off . . . . . . . . . . . . . . . . . . . . . . . . . . 1
26 . . . . . . . . . . . . . 235499 . . Ftg, Coolant Barbed 3/8 Tbg 5/8−18 Female . . . . . . . . . . . . . . . . . . . . . . . . . 2
27 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Miller Coolmate 1 (Order By Model And Serial Number) . . . . . 1
28 . . . . . . . . . . . . . 287120 . . Label, Notice Pump Priming Noise Can Occur During . . . . . . . . . . . . . . . . . 1

SECTION 13 − CART PARTS LIST
not available unless listed. 7 17
1
Item 4 can be mounted in 7

alternative position if desired.
3
17 4
16
6
12
9 10
9
11
12
6
15 14 13
805 337-B
Figure 13-1. Cart Main Assembly
Item Dia. Part

Figure 13-1. Cart Main Assembly
1 . . . . . . . . . . . . . . . . . . 235507 . . Handle, Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . . . . . . . . . . . 227147 . . Screw, 250−20x .62 Pan Hd−torx Stl Pld Blk Tap−r
.............................. (Prior to LK090395L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 . . . . . . . . . . . . . . . . . . 227147 . . Screw, 250−20x .62 Pan Hd−torx Stl Pld Blk Tap−r
.............................. (Eff w/LK050395L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 . . . . . . . . . . . . . . . . . +237593 . . Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . . . . . 237594 . . Cable Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5 . . . . . . . . . . . . . . . . . . 235521 . . Strap, Tie Down 1.000 w X 60.000 lg (300lbs) . . . . . . . . . . . . . . . . 2
6 . . . . . . . . . . . . . . . . . . 235527 . . Bolt, Crg Stl .312−18 X 1.500 Gr2 Pld Zinc Clear . . . . . . . . . . . . . 8
7 . . . . . . . . . . . . . . . . . . 195666 . . Screw, 010−32 x .50 Pan Hd−torx W/Gndrng Stl Pld
.............................. (Prior to LK090395L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7 . . . . . . . . . . . . . . . . . . 195666 . . Screw, 010−32 x .50 Pan Hd−torx W/Gndrng Stl Pld
.............................. (Eff w/LK090395L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8 . . . . . . . . . . . . . . . . . . 235515 . . Tray, Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 . . . . . . . . . . . . . . . . . . 602250 . . Washer, Flat .812 ID x 1.469 OD x .134t Stl Pld Ansi.750 . . . . . . 4
10 . . . . . . . . . . . . . . . . . 163463 . . Wheel, Rbr Tire 10.000 OD X 2.000 Wide X .750 Bore . . . . . . . . 2
11 . . . . . . . . . . . . . . . . . 121614 . . Ring, Rtng Ext .750 Shaft X .085 Thk E Style Pld . . . . . . . . . . . . . 2
12 . . . . . . . . . . . . . . . . . 172684 . . Nut, 312-18 .50hex .27h Stl Pld Sem Cone Wshr.76d . . . . . . . . . 8
13 . . . . . . . . . . . . . . . . . 235517 . . Bottle Tray Assy, Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14 . . . . . . . . . . . . . . . . . 168663 . . Hook, spring .250, 2.375 Lg, .312 Snap Opening . . . . . . . . . . . . . 4
15 . . . . . . . . . . . . . . . . . 210224 . . Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Item Dia. Part
Figure 13-1. Cart Main Assembly (continued)
16 . . . . . . . . . . . . . . . . +235518 . . Support, Bottle/Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . . . . . . . . . . . . . 200285 . . Label, Warning Cylinder May Explode If Damaged . . . . . . . . . . . . 2

Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2014 Miller Electric Mfg. Co. 2014−01

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TM-2226V 2014−03

Eff w/Serial Number LA230402

Stick (SMAW) Welding

115/230/400/460 Volt Models W/Autoline

Maxstar 200 SD, DX, And LX

File: TIG (GTAW)

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Factory Parameter Defaults And Range And Resolution Prior To LJ280222L

** Stick OCV Low OCV Low OCV / Normal OCV

**Stick Stuck Check ScI (On) ScI (On) / Sc0 (Off)

OUTPUT RMT STD RMT STD / RMT 2T / ON

**RMT 2T 2T RMT 2T can be reconfigured for: 2T / 4T / Mini Logic

DC TIG 150 A 1 − 200 Amps

DC STICK 110 A 1 − 200 Amps

Spot Time 1.0 S 0.1 − 25.0 Seconds

***Weld Time 0S Dual Range And Resolution

0.0 − 99.9 / 100 − 999 Seconds

PULSER Off ON / OFF

PPS 100 Hz Dual Range And Resolution

0.1 − 9.9 / 10 − 500 Hertz

PEAK t 40% 5 − 95 Percent

BKGND A 25% 5 − 95 Percent

**Meter “PPP” Display −−− (Off) −−− (Off) / PPPP (On)

INITIAL A 20 A 1 − 200 Amps

***Initial Time 0 S 0.0 − 25.0 Seconds

INITIAL SLOPE t 0S 0.0 − 25.0 Seconds

FINAL SLOPE t 0S 0.0 − 25.0 Seconds

FINAL A 5A 1 − 200 Amps

***Final Time 0S 0.0 − 25.0 Seconds

**PREFLOW 0.2 S 0.0 − 25.0 Seconds

POST FLOW 10.0 S 0.0 − 50.0 Seconds @ 0.2 Second Resolution

DIG 30% 0 − 100 Percent

**Amperage 25 A 1 − 200 Amps

**Time 1 mS 1 − 200 Milliseconds

** Parameter adjusted using a power up configuration only

TM-2226 Page 2 Maxstar 200 SD, DX, LX

Maxstar 200 SD, DX, LX TM-2226 Page 3

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 10 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if Indicates special instructions.

1-2. Servicing Hazards

During servicing, keep everybody, especially children, away.

Insulate yourself from ground by standing or working on dry insulat-

Maxstar 200 SD, DX, LX TM-2226 Page 1

1-3. California Proposition 65 Warnings

1-4. EMF Information

TM-2226 Page 2 Maxstar 200 SD, DX, LX

2-1. Additional Safety Symbols And Definitions

Disconnect input plug or power before working on machine.

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Use ventilating fan to remove fumes.

Keep flammables away from welding. Do not weld near flammables.

Do not weld on drums or any closed containers.

Maxstar 200 SD, DX, LX TM-2226 Page 3

Do not discard product (where applicable) with general waste.

The EMF assessment on this equipment was conducted at 0.5 meter.