Testing Booklet PDF

September 2005 FORM: 150 853G
Technical
Manual
TESTING BOOKLET
testing 2/04
2005 MILLER Electric Mfg. Co.
PRINTED IN USA
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 EXPLANATION OF ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Needed Test Equipment And Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 PARTS TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Diode Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Integrated Rectifier (Three-Phase) Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Integrated Rectifier (Single-Phase) Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Style 1 Dual Diode Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Style 2 Dual Diode Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Straight And Reverse Polarity Diode Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Hockey-Puk Diode Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Stud-Mount SCR Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Hockey-Puk SCR Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Single SCR Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. NPN Power Transistor Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. SCR/Integrated Rectifier (Single-Phase) Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. SCR/Integrated Rectifier (Three-Phase) Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. SCR Power Module Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. IGBT Power Module Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGBT/MOSFET Tester Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGBT Power Module Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGBT Power Module Testing Procedure (212 106) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. MOSFET Power Transistor Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
3
10
10
11
11
12
14
15
16
17
18
19
20
21
22
24
26
28
30
30
31
34
36
IGBT/MOSFET Tester Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOSFET Power Transistor Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Modular Main Rectifier Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 TOOLS AND PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Using Tool Part Number 121 481 To Remove Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Using Tool Part Number 133 357 To Remove DIP Integrated Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 TORQUE SPECIFICATIONS FOR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
36
38
39
39
39
39
40
40
40
41
41
41
42
WHO DO I CONTACT FOR HELP?

H CALL:
Miller Customer Service
Department at
920-735-4505
H FAX:
920-735-4136
H WRITE:
Miller Electric Mfg. Co.
1635 West Spencer St.
P.O. Box 1079
Appleton, WI 54912-1079 USA
Always provide Model Name and Serial or Style Number

150 853 2/04
SECTION 1 SAFETY PRECAUTIONS FOR SERVICING

safety_testing 1/00
1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.
Y Marks a special safety message.

. Means NOTE; not safety related.
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to
avoid the hazards.
1-2. Servicing Hazards
WARNING
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.
Only qualified persons should service, test, maintain, and repair this unit.
During servicing, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
HOT PARTS can cause severe burns.
1. Do not touch live electrical parts.
1. Do not touch hot parts bare handed.
2. Stop engine or turn OFF power source and wire

feeder and disconnect and lockout input power
using line disconnect switch, circuit breakers, or by
removing plug from receptacle before servicing
unless the procedure specifically requires an
energized unit.
2. Wear protective gloves and clothing when working

on a hot engine.
3. Insulate yourself from ground by standing or

working on dry insulating mats big enough to
prevent contact with the ground.
4. Do not leave live unit unattended.
5. When testing a live unit, use the one-hand method.
Do not put both hands inside unit. Keep one hand
free.
6. Disconnect input power conductors from
deenergized supply line BEFORE moving a
welding power source.
SIGNIFICANT DC VOLTAGE exists after

removal of input power on inverters.
7. Turn Off inverter, disconnect input power, and
discharge input capacitors according to
Maintenance Section of Technical Manual or
Owners Manual before touching any parts.
STATIC ELECTRICITY can

parts on circuit boards.
damage
1. Put on grounded wrist strap BEFORE handling

boards or parts.
2. Use proper static-proof bags to store, move, or ship
PC boards.
FIRE OR EXPLOSION can result from

placing unit on, over, or near
combustible surfaces.
1. Do not place unit on, over, or near combustible
surfaces.
2. Do not service unit near flammables.
FLYING PIECES OF METAL or DIRT can

injure eyes.
1. Wear safety glasses with side shields or face shield
during servicing.
2. Be careful not to short metal tools, parts, or wires
together during testing and servicing.
3. Allow cooling period before servicing gun or torch.
EXPLODING PARTS can cause injury.

1. Failed parts can explode or cause other parts to
explode when power is applied to inverters.
2. Always wear a face shield and long sleeves when
servicing inverters.
ELECTRIC SHOCK HAZARD

incorrect use of test equipment.
from
1. Turn Off power source and wire feeder or stop

engine before making or changing meter lead
connections.
2. At least one meter lead should be a self-retaining
spring clip such as an alligator clamp.
3. Read instructions for test equipment.
HIGH-FREQUENCY RADIATION can

interfere with radio navigation, safety
services,
computers,
and
communications equipment.
1. Have only qualified persons familiar with electronic
equipment perform this installation.
2. The user is responsible for having a qualified
electrician promptly correct any interference
problem resulting from the installation.
3. If notified by the FCC about interference, stop using
the equipment at once.
4. Have the installation regularly checked and
maintained.
5. Keep high-frequency source doors and panels
tightly shut, keep spark gaps at correct setting, and
use grounding and shielding to minimize the
possibility of interference.
FALLING EQUIPMENT can cause

serious personal injury and equipment
damage.
1. Use equipment of adequate capacity to lift unit.
2. Use lifting eye to lift unit only, NOT running gear,
gas cylinders, trailer, or any other accessories.
150 853 Page 1
MAGNETIC
CURRENTS
operation.
FIELDS FROM HIGH

can affect pacemaker
1. Pacemaker wearers keep away from servicing

areas until consulting your doctor.
MOVING PARTS can cause injury.

1. Keep away from moving parts such as fans.
2. Keep all doors, panels, covers, and guards closed
and securely in place.
OVERUSE can cause OVERHEATED

EQUIPMENT.
1. Allow cooling period.
2. Reduce current or reduce duty cycle before
starting to weld again.
3. Follow rated duty cycle.
READ INSTRUCTIONS.
1. Use this information along with the Technical
Manual.
1. Keep away from moving parts.
2. Consult the Owners Manual for welding safety

precautions.
2. Keep away from pinch points such as drive rolls.
3. Use only genuine MILLER replacement parts.
1-3. Engine Hazards

1. Keep away from moving parts such as fans, belts,
and rotors.
2. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
3. Keep hands, hair, loose clothing, and tools away
from moving parts.
4. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
ENGINE EXHAUST GASES can kill.

1. Do not breathe exhaust fumes.
2. Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
ENGINE FUEL can cause fire or explosion.

1. Stop engine before fueling.
2. Do not fuel while smoking or near sparks or flames.
3. Do not overfill tank; clean up any spilled fuel.
UNCONTROLLED TILTING OR TIPPING

OF UNIT can result in personal injury
and equipment damage.
1. Do not put any body part under unit while lifting.
2. Use adequate blocks to support components as
needed during job.
BATTERY EXPLOSION can BLIND and

INJURE.
1. Always wear a face shield when working on a
battery.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when working
on a battery.
4. Do not use welder to charge batteries or jump start
vehicles.
5. Observe correct polarity (+ and ) on batteries.
BATTERY ACID can BURN SKIN.

1. Do not tip.
2. Replace damaged battery.
3. Flush eyes and skin immediately with water.
STEAM AND PRESSURIZED HOT

COOLANT can burn face, eyes, and
skin.
1. Check coolant level when engine is cold to avoid
scalding.
2. If the engine is warm and checking is needed,
follow steps 3 and 4.
3. Wear safety glasses and gloves and put a rag over
cap.
4. Turn cap slightly and let pressure escape slowly
before completely removing cap.
PINCH POINTS can injure.

1. Be careful when working on stator and rotor.
1-4. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause
electromagnetic fields. There has been and still is some concern
about such fields. However, after examining more than 500 studies
spanning 17 years of research, a special blue ribbon committee of the
National Research Council concluded that: The body of evidence,
in the committees judgment, has not demonstrated that exposure to
power-frequency electric and magnetic fields is a human-health
hazard. However, studies are still going forth and evidence
continues to be examined. Until the final conclusions of the research
are reached, you may wish to minimize your exposure to
electromagnetic fields when welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
150 853 Page 2
1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your
doctor, then following the above procedures is recommended.
SECTION 2 EXPLANATION OF ELECTRICAL PARTS

elect_parts 2/04
2-1. Safety Precautions Read Before Using This Guide
Y WARNING: ELECTRIC SHOCK can kill.

D
D
D
D
Disconnect input power or stop engine before servicing.

Do not touch live electrical parts.
Do not operate machines with covers removed.
Have only qualified persons install, use, or service equipment.
PART NAME
FUNCTION
BATTERY
A source of DC voltage. Typically used in

Engine Driven equipment.
BRUSHES/SLIP
RINGS
Components that allow electrical connections

between stationary and rotating contacts.
PICTURE
CIRCUIT SYMBOL
+
SLIP
RINGS
BRUSHES
CAPACITOR
CHASSIS
A device that stores electrical energy. Large

capacitors or a bank of capacitors can be
used to smooth out the DC welding arc in a
MIG welding power source. Smaller disk
capacitors can be used for HF protection.
NON-POL.
C1
C1
The green ground wire of a primary cord is

connected to the machine frame (chassis) for
safety. Also, you may find many HF bypass
capacitors connected to chassis to reduce
High Frequency interference. Expect to see
this symbol used numerous times in circuit
diagrams. The picture shown here is from an
Engine Drive where several wires including
the battery are connected to the chassis.
CIRCUIT BREAKER A protection device that breaks a circuit when

current levels exceed its rating. Unlike a fuse
that needs to be replaced when blown, a
circuit breaker can be reset.
CIRCUIT COMMON
POLARIZED
+
CB1
When many wires are connected together,

rather than showing all the lines and dots,
this symbol may appear on the circuit. Look
for other Circuit Common symbols on a
circuit diagram. For instance, say 10 symbols
are found on a circuit, this means all ten
points are electrically tied together.
150 853 Page 3
PART NAME
FUNCTION
CLAMP
A spring-loaded connection device. A good

example would be the work clamp used to
connect the weld cable from a power source
to the workpiece that will be welded.
CONTACTOR
A heavy duty relay. Usually used to make

and break the welding arc or primary power.
PICTURE
CIRCUIT SYMBOL
COIL
W
NRM OPEN
POINTS
CURRENT
TRANSFORMER
DASHED LINE
A transformer that produces an AC voltage

used for measuring purposes. The primary
winding is in series with the circuit carrying
the current to be measured. Its main use in
engine-driven equipment is to activate the
Automatic Idle circuit by sensing welding
current or auxiliary power current.
A dashed line between parts means there is

a mechanical connection between these
parts. When a dashed line boxes in parts,
this means the parts make up an option or
are combined into one part. In all cases,
dashed lines do not conduct electricity. The
picture shown is a combination fan motor and
transformer in one part.
DIODE
A device that allows current to flow in one

direction only. Most common use is to
change AC to DC.
FAN MOTOR
This device provides cooling of the internal

parts of a welding power source.
CT1
OR
CT1
FM
D1
FM
FUSE
A protection device, usually an enclosed

piece of wire that melts and breaks the circuit
when the current exceeds the fuse rating.
GAS OR WATER
SOLENOID
(VALVE)
These are electromechanical devices used to

start or stop the flow of shielding gas or
water.
HALL DEVICE
Produces a small DC voltage proportional to

the current it is sensing (usually welding
current). This feedback signal can be used to
regulate the welding output (line voltage
compensation). It may even be used to drive
an ammeter.
150 853 Page 4
F1
GS1
OR
WS1
HD1
PART NAME
IGBT
INTEGRATED
BRIDGE
RECTIFIER
FUNCTION
PICTURE
A device that is used as an electronic

switch. When a signal is applied to the gate
(G), current is allowed to flow from the emitter
(E) to the collector (C). This device is typically
used in Inverter designed welding machines
to control the welding output.
An arrangement of four diodes used to
change AC to DC.
C1
G1 (B1)
E1
+
AC
INTEGRATED
CIRCUIT
JUMPER LINK
CIRCUIT SYMBOL
AC
AC
AC
ICs often called chips provide a complete

circuit function with inputs and outputs. A
good example would be the Pulse Width
Modulation chip used in many wire feeder
designs.
U1
Usually, the jumper link is a piece of brass

that connects two terminals together. Dashed
lines indicate possible locations for other
jumper links.
LIGHT EMITTING
DIODE
This device usually referred to by its initials

LED is used to tell you when a particular
circuit is activated. This function is very
helpful for troubleshooting.
MAGNETIC
AMPLIFIER
This device usually referred to as a

Mag-Amp is made up of coil windings and
an iron core similar to a transformer. It
controls a large welding current by varying a
small control current.
TE1
D1
MA1
METER
A measuring device. A voltmeter is a good

example.
V = voltmeter
A = ammeter
HM = hour
meter
MOSFET
A device that is used as an electronic

switch. When a signal is applied to the gate
(G), current is allowed to flow from the source
(S) to the drain (D). This device can be used
to control a relay, the speed of a motor, or
even the output of a welding machine.
G
AS
150 853 Page 5
PART NAME
MOTOR
OPERATIONAL
AMPLIFIER
FUNCTION
M1
= DC
M1
= AC
Usually referred to as an Op-Amp, this IC

chip is very versatile and widely used on PC
boards. A typical use might be as a
comparator, comparing the command
signal to the feedback signal allowing the
welding output to be kept constant.
A device that uses light to get electrical
separation (isolation). This eliminates noise
that might be in one circuit from affecting
another circuit.
PILOT LIGHT
A light located on the front panel which

indicates if the machine is on or off.
PLUG
CIRCUIT SYMBOL
A device that converts electrical energy into

mechanical energy. Typically used to feed
wire in a MIG welding system, or pump
coolant in a recirculating liquid-cooling
system.
OPTICAL
COUPLER
POTENTIOMETER
OR
RHEOSTAT
PICTURE
Both devices have a moveable brush that

makes contact along a resistor, allowing you
to easily change the resistance measured at
the brush (sometimes referred to as a wiper).
Their primary purpose is to give the operator
a way to adjust welding parameters such as
wire speed, preflow time, voltage,
inductance, etc.
+
_
A1
OC1
PL
R1
CW = CLOCKWISE
CCW =COUNTERCLOCKWISE
A connection device that hangs loose with

wires coming out the back of it. Please note
that the plug terminals can be either male or
female.
MALE
FEMALE
PLG =
LOOSE
PLG1
RECEPTACLE
A connection device that is mounted or fixed.

Just like a plug, the terminals can be either
male or female.
MALE
FEMALE
RC =
MOUNTED
RC1
RELAYCOIL AND
CONTACTS,
NORMALLY OPEN
AND NORMALLY
CLOSED
RESISTOR
150 853 Page 6
This is an electromechanical device whose

contacts change state (the normally open
points close and the normally closed points
open) when proper voltage is applied to the
coil. These contact points in turn may control
a fan motor, gas solenoid, contactor, etc.
Circuit diagrams (schematics) always show
the contact points in the power off state.
A device which resists the flow of electric
current. Uses include limiting the current for a
motor brake circuit in a wire feeder and for
discharging a capacitor.
COIL
CR1
CR1
CR1
NRM OPEN NRM CLOSED

POINTS
POINTS
FIXED
R1
FIXED TAPPED
R1
PART NAME
RIBBON CABLE
FUNCTION
A connection device where the wires are laid
out flat. Usually to connect circuits from one
PC board to another PC board.
PICTURE
CIRCUIT SYMBOL
26-CONDUCTOR
CABLE
RC54
SCR
SHUNT
SNUBBER
SPARK GAP
STABILIZER/
REACTOR
SWITCH
RC44
A Silicon Controlled Rectifier (SCR) is an

electrical device with three connections,
anode, cathode, and gate. It will allow current
to flow in only one direction and will only do
so after receiving a signal on the gate lead.
SCRs are used to change AC to DC and to
control the output to a load such as a welding
arc.
A precision low-value resistor typically used

to supply a small voltage to drive an
ammeter.
SHUNT
A device used to absorb voltage spikes,

sometimes found connected across the
points of a relay.
SN1
The arrangement of two electrodes between

which a discharge of electricity will occur.
Typically used to produce high frequency
which can be used for arc starting when TIG
welding.
When placed in a DC circuit, the inductor or

stabilizer as it is usually called, will oppose
any change in existing current. It is therefore
widely used to stabilize the welding arc.
When the inductor is placed in an AC circuit it
is referred to as a reactor where it now acts
to restrict the flow of current. A tapped
reactor is used to create current ranges for
welding.
A mechanical device that completes or
breaks the path of the current or sends it over
a different path.
A multi-pole switch will use dashed lines to
connect poles.
Z1
L1
SPST
DPST
SPDT
DPDT
SPST = Single Pole Single Throw

SPDT = Single Pole Double Throw
DPST = Double Pole Single Throw
DPDT = Double Pole Double Throw
MOMENTARY
SWITCH
A switch that springs back to its original

position.
LIMIT SWITCH
A switch mounted in the path of a moving

object and actuated by its passage.
S1
NRM OPEN
S1
NRM
CLOSED
S1
150 853 Page 7
PART NAME
FUNCTION
PUSH BUTTON
SWITCH
A switch in which a button must be

depressed each time the contacts are to be
opened or closed.
ROTARY SWITCH
A switch in which its shaft must be rotated to

actuate the contacts.
PICTURE
CIRCUIT SYMBOL
NRM
OPEN
PB1
NRM
CLOSED
PB1
S1
PRESSURE
SWITCH
TEMPERATURE
SWITCH
WATER FLOW
SWITCH
TERMINAL
ASSEMBLY
A change in the pressure of a gas or liquid

will actuate this switch.
Typically used to protect engines, this switch

is actuated by heat.
A switch that is actuated by the flow of a

liquid. Typically used to protect
water-cooled torches.
A connection point for primary power and the

jumper links that are used to match the input
voltage to the machine. Usually, the terminal
assembly is marked with the letters TE, but
the electrical symbol looks identical to a
standard terminal strip.
S1
OPENS
ON
INCREASE
CLOSES
ON
INCREASE
S1
S1
OPENS
ON
INCREASE
CLOSES
ON
INCREASE
S1
S1
OPENS
ON
INCREASE
CLOSES
ON
INCREASE
S1
S1
TE1
TE1
TERMINAL STRIP
THERMISTOR
150 853 Page 8
An insulated connection point for wires. They

are used for the ease of making multiple
connections and can be a convenient point
for making electrical checks when
troubleshooting. (Notice the jumper link
connecting terminals A and B together.)
A thermally sensitive resistor. There are two
types of thermistor, PTC (Positive
Temperature Coefficient) and NTC (Negative
Temperature Coefficient). A PTC thermistors
resistance will increase as the temperature
goes up, where as an NTC thermistors
resistance will decrease as the temperature
goes up. Primarily used for Fan on Demand
and Thermal Shutdown circuits.
1T
42 42 104 105 74
A
104
105
RT1
OR
TH1
PART NAME
FUNCTION
THERMOSTAT,
NORMALLY OPEN
AND NORMALLY
CLOSED
This is a switch that closes its normally open

contacts (or opens its normally closed
contacts) when a preset temperature is
reached. When the temperature goes back
down, it will reset itself. Uses of these
devices include turning on a fan motor when
needed and shutting off the output of a
welding power source if it is overheating.
TRANSISTOR
Most commonly used as an electronic switch.

There are two basic types, PNP and NPN.
This refers to their internal design, which
determines current flow direction.
PICTURE
CIRCUIT SYMBOL
TP1
NRM OPEN NRM CLOSED
Q1
TRIAC
TWISTED WIRE
VARISTOR
WIRES WITH
CONNECTION
A device that changes AC voltage from one

magnitude to another. Typically used to
reduce high primary voltages to lower
welding voltages.
Q1
B
NPN
TRANSFORMER
TP1
B
E
T1
IRON
CORE
T1
FERRITE
CORE
T1
AIR
CORE
An electronic AC switch. It is turned on by a

gate signal similar to an SCR.
Wires are twisted to prevent electrical noise

from interfering with the circuit. A good
example is the red and white gate leads
going to an SCR. Typically, these wires are
twisted together to help prevent the SCR
from misfiring.
A protection device whose resistance is
dependent on the voltage applied to it. In
normal operation it has a high resistance;
however, a surge of voltage (voltage spike)
will cause its resistance to go way down and
absorb the spike. These devices are most
often found in rectifying circuits, where they
are used to protect the diodes.
PNP
Q1
RED
WHT
VR1
When lines (wires) cross on a circuit diagram

and there is a black dot, this means that the
two wires are electrically connected together.
The method of connection (bolted, friction
lugs, etc.) is not indicated with this symbol.
However, a white dot indicates that the
method of connection is a terminal strip. Of
course, no dot means no connection.
150 853 Page 9
SECTION 3 INTRODUCTION
3-1. Needed Test Equipment And Description
1
1
Continuity Tester
Grainger Supply Co.
Part #2V544 Or Equivalent
With two D size batteries, minimum

3 volts.
2
FLUKE Digital Multimeter

(DMM) Or Equivalent
One megohm input impedance or

greater and diode test function.
3
One Insulated Jumper Lead
Approximately 6 to 10 in (152 to 254

mm) long.
IGBT/MOSFET Tester
Miller Part #043 553
Before use, install 9 volt batteries.

To check battery, connect Red and
Black leads together; test light
(LED) = On; battery okay.
Yellow
Black
Red
150 853 Page 10
Test Button
Test Light (LED)
SECTION 4 PARTS TESTING PROCEDURES

4-1. Diode Testing Procedure
K
Circuit Diagram Symbol

1
2
See Parts List for location of parts in

unit.
1
Diode
Mark and disconnect one lead of

diode.
2
Cathode (K)
Anode (A)
Replace part if it fails any test.

Actual Part
2
1
179 630
185 775
209 464
1
=
.200 to .900
Set meter for

Diode testing.
K
=
.OL
A
A
Reverse Bias Testing

(Blocking)
Forward Bias Testing

(Conducting)
Ref. 048 894-K / Ref. 803 772-A / S-0149
150 853 Page 11
4-2. Integrated Rectifier (Three-Phase) Testing Procedure

unit.
1
AC
AC
AC
AC
Mark and disconnect leads from

negative () and positive (+) terminals.
AC
Actual Part
AC
AC
AC
AC
Actual Part
AC
AC
AC
Integrated Rectifier (ThreePhase)
179 542
1
=
Set meter for

Diode testing.
.200 to .900
AC
AC

(Conducting)

(Blocking)
AC
AC
=
.200 to .900

(Conducting)
150 853 Page 12
.OL
+
=

(Blocking)
.OL
6
+
AC
+
=
AC
.200 to .900

(Conducting)
.OL

(Blocking)
AC
AC
.200 to .900
.OL

(Conducting)

(Blocking)
10
AC
AC
=
.200 to .900
.OL

(Conducting)
11

(Blocking)
12
AC
.200 to .900

(Conducting)
AC
.OL

(Blocking)
S-0672 / S-0474
150 853 Page 13
4-3. Integrated Rectifier (Single-Phase) Testing Procedure

2
AC
AC
AC
AC
AC
AC
Actual Part
Actual Part
Integrated Rectifier (SinglePhase)
Mark and disconnect all leads from

integrated rectifier.
AC
Anode (A)
Cathode (K)
AC
Actual Part
.200 to .900
_
AC
+

unit.
Set meter for

Diode testing.
AC
201 530
2
AC
AC
+
+

(Conducting)
.OL
.OL
.OL
4
+
.200 to .900
AC
AC

(Conducting)

(Blocking)
.200 to .900
AC
AC

(Conducting)

(Blocking)
AC

(Conducting)
150 853 Page 14
.OL

(Blocking)
8
=
.200 to .900
AC

(Blocking)
Ref. S-0454 / S-0328-A / S-0665-A
4-4. Style 1 Dual Diode Testing Procedure

A1
K1, K2
A2
1

4
3
4
3
1
179 869
Dual Diode

anodes (A1, A2).
2, 5

unit.
Cathode 1 (K1)
Anode 1 (A1)
Anode 2 (A2)
Cathode 2 (K2)
2, 5
204 820
Style 1
Actual Part
AC
3, 5
AC
4
A1
K1
K2
A2
Circuit Diagram
Symbol
198 148
2
Set meter for
Diode testing.
=
.200 to .900
K1
K1
A1
A1

(Conducting)
.OL

(Blocking)
.200 to .900
A2
A2
K2
K2

(Conducting)
.OL

(Blocking)
S-0473
150 853 Page 15
4-5. Style 2 Dual Diode Testing Procedure

unit.
1
1
2
1
5
A2
K1
168 413
A1, K2
Style 2
Actual Part
Cathode 1 (K1)
Anode 1 (A1)
Cathode 2 (K2)
Anode 2 (A2)
4
3
Jumper
Bar
Dual Diode

cathode K1 and anode A2.
A1
K1
A2
K2

2
3
1
A1
K1
A2
K2
190 531
1
2, 4
A1
K1, K2
A2
206 987
212 037
Set meter for

Diode testing.
.200 to .900
A2
A2
K2
.OL
K2

(Conducting)

(Blocking)
4
K1
K1
.200 to .900
A1
A1

(Conducting)

(Blocking)
.OL
S-0472
150 853 Page 16
4-6. Straight And Reverse Polarity Diode Testing Procedure

unit.
Straight Polarity Diode
Reverse Polarity Diode
Cathode (K)
Anode (A)
Actual Part
Actual Part
Straight Polarity Diode
2
Set meter for
Diode testing.
=
.200 to .900
.OL
K
K
(Conducting)

(Blocking)
Reverse Polarity Diode
.200 to .900
Set meter for

Diode testing.
K
A
(Conducting)
.OL
A
(Blocking)
Ref. S-0488
150 853 Page 17
4-7. Hockey-Puk Diode Testing Procedure

unit.
Hockey-Puk Diode
Cathode (K)
Anode (A)
Heat Sink
3
Actual Part
Clamp diode at proper pressure (see Section 6) BEFORE testing.
Set meter for

Diode testing.
.200 to .900
A
(Conducting)
2
K
.OL
A
(Blocking)
S-0675
150 853 Page 18
4-8. Stud-Mount SCR Testing Procedure

unit.
Stud-Mount Silicon-Controlled
Rectifier (SCR)
Anode (A)
Cathode (K)
Auxiliary Cathode (Red Lead)

Not Tested
Gate (G) (White Lead)
4
3
2
Actual Part
A
K
Cathode-To-Anode Testing
(Blocking)
Gate Testing
(Conducting)
Light OFF
Cathode to anode OK
Light OFF
SCR not working properly
Light ON
Cathode to anode shorted
Light ON
SCR is conducting
G
K
Holding Current Test

(Conducting)
Light OFF
Replace tester batteries

or SCR not working
properly
Light ON
Light should remain ON

S-0674
150 853 Page 19
4-9. Hockey-Puk SCR Testing Procedure

unit.
1
2
3
Actual Part
Auxiliary Cathode (Red Lead)

Not Tested
Anode (A)
Heat Sink
Hockey-Puk Type SiliconControlled Rectifier (SCR)

Cathode (K)
Clamp SCR at proper pressure (see Section 6) BEFORE testing.
1
K
K
G
Gate Testing
(Conducting)
(Blocking)
Light OFF
Cathode to anode OK
Light OFF
Light ON
Light ON
SCR is conducting

(Conducting)
Light OFF

or SCR not working
properly
Light ON

S-0654
150 853 Page 20
4-10. Single SCR Testing Procedure

unit.
1
1
3
K
199 988
Single Silicon-Controlled Rectifier (SCR)

Cathode (K)
Anode (A)
A
Clamp SCR at proper pressure (see Section 6) BEFORE testing.
Gate Testing
(Conducting)
(Blocking)
Light OFF
Cathode to anode OK
Light OFF
Light ON
Light ON
SCR is conducting
3
G
Light OFF

or SCR not working
properly
Light ON

(Conducting)
150 853 Page 21
4-11. NPN Power Transistor Testing Procedure

unit.
1
1

transistor.
Collector (C)
Base (B)
Emitter (E)

E
4
3
Actual Part
NPN Power Transistor
Set meter for

Diode testing.
.200 to .900
.OL
E
B
B
Emitter-To-Base Testing
(Blocking)
Emitter-To-Base Testing
(Conducting)
.200 to .900
Collector-To-Base Testing
(Conducting)
Collector-To-Base Testing
(Blocking)
.OL
Collector-To-Emitter Testing
(Blocking)
.OL
.OL
Collector-To-Emitter Testing
(Blocking)
S-0475
150 853 Page 22
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
150 853 Page 23
4-12. SCR/Integrated Rectifier (Single-Phase) Testing Procedure

unit.
1

integrated rectifier.
8
1
7
7
6
Gate 1 (G1)
Negative DC Output ()
Positive DC Output (+)
Gate 2 (G2)
AC Input 2 (AC2)
Varistor Not Tested
Actual Part
AC Input 1 (AC1)
SCR/Integrated Rectifier
(Single-Phase)
Actual Part
+
G1
AC1
G2
AC2
1
=
Set meter for

Diode testing.
.200 to .900
AC1
=
AC1
.OL
Diode Reverse Bias Testing

(Blocking)
Diode Forward Bias Testing

(Conducting)
AC2
AC2
.200 to .900

(Conducting)
150 853 Page 24

(Blocking)
.OL
.200 to .900

(Conducting)

(Blocking)
AC1
AC1
AC1
SCR Cathode-To-Anode Testing

(Blocking)
SCR Gate Testing

(Conducting)
Light OFF
Cathode to anode OK
Light OFF
Light ON
Light ON
SCR is conducting
10
11
AC2
.OL
SCR Holding Current Test

(Conducting)
Light OFF

or SCR not working
properly
Light ON
12
AC2
AC2

(Blocking)
SCR Gate Testing

(Conducting)
Light OFF
Cathode to anode OK
Light OFF
Light ON
Light ON
SCR is conducting

(Conducting)
Light OFF

or SCR not working
properly
Light ON

S-0676 / S-0686
150 853 Page 25
4-13. SCR/Integrated Rectifier (Three-Phase) Testing Procedure

R2

unit.
+
1
4
SCR/Integrated Rectifier
(Three-Phase)

negative (), positive (+), R2, and G
terminals.
R
S
T
AC Input (R, S, T)
SCR Anode (R2)
Gate (G)

6
Actual Part
1
=
Set meter for

Diode testing.
.200 to .900
R
R
R2
R2

(Conducting)

(Blocking)
4
S
R2
S
=
R2
.200 to .900

(Conducting)
.OL

(Blocking)
6
R2

(Conducting)
150 853 Page 26
.OL
R2
=
.200 to .900

(Blocking)
.OL
.200 to .900

(Conducting)
.OL
.OL
.OL

(Blocking)
10
S
S
=
.200 to .900

(Conducting)

(Blocking)
11
12
.200 to .900

(Conducting)
13

(Blocking)
14
15
R2

(Blocking)
R2
R2
SCR Gate Testing

(Conducting)
Light OFF Cathode to anode OK
Light OFF SCR not working properly
Light ON
Light ON
SCR is conducting

(Conducting)
Light OFF

or SCR not working properly
Light ON

S-0881
150 853 Page 27
4-14. SCR Power Module Testing Procedure

unit.
1
AC
1
2
3
4
5
6
7
G1 K1
8
Actual Part
AC Input
Gate 1 (G1)
Cathode 1 (K1)
Cathode 2 (K2)
Gate 2 (G2)

K2 G2
Circuit Diagram
Symbol
AC
218 296
SCR Power Module

module.
AC
3
3
G1
7
K1
2
3
4
196 754
5
6
5
G2
K2
8
Actual Part
Circuit Diagram
Symbol
BASE
Circuit Diagram
Symbol
AC
218 292
7
2
197 698
3
6
Circuit Diagram
Symbol
150 853 Page 28
AC
Circuit Diagram
Symbol
K1
AC
+
G1
K2
+
K2
K1

(Blocking)
SCR Gate Testing

(Conducting)
Light OFF
Cathode to anode OK
Light OFF
Light ON
Cathode to anode
shorted
SCR not working

properly
Light ON
SCR is conducting
AC
G1
K1

(Blocking)

or SCR not working
properly
Light ON
K2

(Conducting)
Light OFF
AC
Light OFF
Cathode to anode OK
Light ON
Cathode to anode
shorted
AC
+
AC
G2
+
SCR Gate Testing

(Conducting)
Light OFF
SCR not working

properly
Light ON
SCR is conducting
G2

(Conducting)
Light OFF

or SCR not working
properly
Light ON

Ref. ST-129 611-A / ST-802 534 / Ref. S-0426
150 853 Page 29
4-15. IGBT Power Module Testing Procedure

unit.
1
1
2
C1
8
7
6

power module.
G1 (B1)
C2, E1
E1
5
G2 (B2)
E2
E2
Gate 1 (G1) or Base 1 (B1)
Collector 2, Emitter 1
(C2, E1)
Emitter 2 (E2)
Collector 1 (C1)
Emitter 2 (E2)
Gate 2 (G2) or Base 2 (B2)
3
2
6
E2
8
E2
4
5
C2
Emitter (E1)
A1
C2/E1
Typical Part
IGBT Power Module
Check plastic case for cracks in

side of case or a separation of case
from its base plate. Replace any
damaged part.
6
G2
NOTE
E2
K1
200 392
G2
E2
C1
212 106
The preferred test is found in the product Technical Manual which also accounts
for any uniquenesses in the actual product procedures.
A. Best Test For IGBTs

IGBT/MOSFET Tester Information
1
Yellow
Black
Red
150 853 Page 30
IGBT/MOSFET Tester

2
Test Button
Test Light (LED)
S-0880-A
IGBT Power Module Testing Procedure

Step 1. Hook up ALL tester
leads to perform Test 1.
LED On = Shorted; replace part
G1 (B1)
Static Hazard.
Put on grounded wrist strap.
Test 1
Step 2.
Press button.
LED Off = Fails test; replace part

LED On = Passes test
C1
Step 3.
Test 2.
Repeat Steps 1 and 2 for
G1 (B1)
Gate 1 or Base 1
G2 (B2)
Gate 2 or Base 2
C1
Collector 1
Red
E1
Yellow
Black
C2/E1
Collector 2/Emitter 1
E2
Emitter 2
G2 (B2)
Test 2
E2
Black
C2
Yellow
Red
ST-801 132 / S-0880-A / S-0664
150 853 Page 31
B. Alternative Test For IGBTs
Static Hazard. Put on grounded wrist strap.
Set meter for

Diode testing.
=
.200 to .900
C1
C1
C2, E1

(Conducting)
.OL

(Blocking)
E2
E2
=
.200 to .900
.OL
C2, E1
C2, E1

(Conducting)
C2, E1

(Blocking)
Set meter for Resistance

(Ohms) testing.
6
E1
O.L
E1
G1 (B1)
G1 (B1)
=
Gate-To-Emitter Resistance Testing

(Open)
150 853 Page 32
O.L

(Open)
8
E2
E2
G2 (B2)
G2 (B2)
O.L

(Open)
O.L

(Open)
S-0664 / Ref. S-0398
150 853 Page 33
IGBT Power Module Testing Procedure (212 106)

Step 1. Hook up ALL tester
leads to perform test.
For MOD1, connect yellow meter
lead to lead 27 (PLG5-1)
For MOD2, connect yellow meter
lead to lead 29 (PLG5-4)
Static Hazard.
G2(E2)
C1
E2
Black
C2/E1
Red
Yellow
Step 2.
Press button.

G2 (E2)
Gate 2/Emmiter 2
C1
Collector 1
C2/E1
Collector 2/Emitter 1
E2
Emitter 2
Finish IGBT Power Module Testing Procedure On Next Page.

If IGBTs power modules test okay,
reconnect bus bars to capacitor
bank C1, and between MOD1 and
MOD2.
Clean surfaces and apply a small
amount of EJC (electrical joint compound) to connections. Torque
mounting hardware to 40 in-lb (4.5
Nm).
Connect gate lead plug PLG5 to receptacle RC5 on control board
PC1.
If either power module fails, both
IGBT modules and PC1 must be replaced. If a failure accurs, also
check diode D7, capacitors C3 and
C4. If D7 must be replaced, heat
sink compound (Miller #604414)
should be applied. Torque D7
mounting hardware to 12 in-lb (1.4
Nm).
804 015-A
150 853 Page 34
B. Alternative Test For IGBTs (212 106)

Set meter for

Diode testing.
=
.200 to .900
C1
C1
C2, E1
.OL
C2, E1

(Blocking)

(Conducting)
E2
E2
=
.200 to .900
C2, E1
.OL
C2, E1

(Blocking)

(Conducting)
5
(Ohms) testing.
G2(E2)
G2(E2)
O.L
=

(Open)
O.L

(Open)
804 015-A
150 853 Page 35
4-16. MOSFET Power Transistor Testing Procedure

unit.
1
MOSFET Power Transistor
Remove transistor from circuit

board.
D
1
5
4
Actual Part
NOTE
Drain (D)
Gate (G)
Source (S)
Alternate Source (AS) Not

Tested
AS
3
S
The preferred test is found in the product Technical Manual which also accounts
for any uniquenesses in the actual product procedures.
A. Best Test For MOSFET

IGBT/MOSFET Tester Information
1
Yellow
Black
IGBT/MOSFET Tester

2
Test Button
Test Light (LED)
Red
S-0880-A
MOSFET Power Transistor Testing Procedure

Step 1.
leads.
Static Hazard.
Hook up ALL tester

Step 2.
Press button.

Yellow
G
S
Black
D
Red
Gate
Drain
Source
S-0880-A / S-0663
150 853 Page 36
B. Alternative Test For MOSFET

Set meter for

Diode testing.
.200 to .900
D
D
.OL
S
S

(Conducting)

(Blocking)
4
(Ohms) testing.
=
O.L
O.L
S
G
S
G
Gate-To-Source Resistance Testing

(Open)
Gate-To-Source Resistance Testing

(Open)
S-0663
150 853 Page 37
4-17. Modular Main Rectifier Testing Procedure

unit.
1
AC
AC
Actual Part
Small Single-Phase Modular

Main Rectifier
Large Single-Phase Modular

Main Rectifier
Three-Phase Modular Main

Rectifier
Rectifier Section
Diode
Fusible Link
Look at each rectifier section for

any open fusible links on the
diodes. No diode test is required.
If any fusible link is open, replace

entire modular rectifier.
+
AC
AC
4
Actual Part
3
+
AC
AC
AC
5
Actual Part
4
4
5
6
Portion Of Side View
Ref. SC-121 845-A / ST-152 789 / S-0689
150 853 Page 38
SECTION 5 TOOLS AND PLUGS

NOTE
The following extraction tools are available individually through the MILLER Parts
Department. All nine tools can be purchased as a kit (155 809). Contact the Parts
Department at 920-735-4500 for information on the kit.
5-1. Using Tool Part Number 121 481 To Remove Lead

1
2
Typical Plug
Contact
Tool
Insert prongs into plug hole so

prongs are between contact and
wall of plug.
Remove lead.
3
ST-147 971-C

1
Typical Plug
Contact
Tool
Push Rod Button
Handle
Sleeve
Holding handle, insert sleeve into

plug hole, allowing push rod button
to back out of handle.
Turn handle to free contact.
Press in push rod button to remove

lead.
ST-152 068

4
2
1
5
Typical Plug
Contact
Locking Clip
Clip Area
Tool
Insert tool into clip area as shown.

Press down locking clip to remove
lead.
ST-115 689-B
150 853 Page 39

1
Typical Plug
Contact
Tool
Handle
Insert tool into plug hole as shown.

2
Press handle in to remove lead.
ST-147 699

1
Typical Plug
Contact
Tool
Push Rod Ball
Sleeve
Insert sleeve into plug hole as

shown.
Press push rod ball in to remove

lead.
3
ST-152 066

1
Typical Plug
Contact
Tool
Insert prongs into plug hole so

prongs are between contact and
wall of plug as shown.
Remove lead.
3
ST-152 067
150 853 Page 40

6
4
Rear
1
Typical Metal Amphenol Plug
Tool
Handle
Tip
Lead
Contact
Squeeze handle, place tip around

lead, and release handle. Slide tip
into plug hole over contact until contact and lead unlock from plug. Pull
out lead with contact.
ST-152 587

2
1
6
Typical Plug
Contact
Tool
Push Rod Button
Handle
Sleeve
Holding handle, insert sleeve into

plug hole, allowing push rod button
to back out of handle.
Turn handle to free contact.

4
Press in push rod button to remove

lead.
3
Ref ST-801 706
5-9. Using Tool Part Number 133 357 To Remove DIP Integrated Circuit
1
Typical DIP Integrated Circuit

(IC)
Tool
Handle
Trigger
Jaws
Holding handle, place tool onto IC.

Pull back trigger allowing jaws to
grip IC.
Remove IC.
5
ST-155 564
150 853 Page 41
SECTION 6 TORQUE SPECIFICATIONS FOR PARTS

Table 6-1. Torque Specifications For Diodes
Part Number
Diode Type
Torque Value
023 178
Stud
300 in-lb (33.9 Nm)
037 157
Stud
300 in-lb (33.9 Nm)
037 305
Stud
125 in-lb (14.1 Nm)
037 306
Stud
125 in-lb (14.1 Nm)
037 956
Stud
300 in-lb (33.9 Nm)
037 957
Stud
300 in-lb (33.9 Nm)
086 353
Puk
*80 in-lb (9.0 Nm)
087 998
Stud
30 in-lb (3.4 Nm)
087 999
Stud
30 in-lb (3.4 Nm)
093 056
Stud
30 in-lb (3.4 Nm)
093 057
Stud
30 in-lb (3.4 Nm)
095 141
Stud
50 in-lb (5.6 Nm)
095 142
Stud
50 in-lb (5.6 Nm)
095 251
Stud
30 in-lb (3.4 Nm)
117 451
Stud
50 in-lb (5.6 Nm)
117 452
Stud
50 in-lb (5.6 Nm)
144 216
Stud
30 in-lb (3.4 Nm)
155 778
Stud
27 in-lb (3.1 Nm)
185 831
Puk
80 in-lb (9.0 Nm)
155 351
Stud
22 in-lb (2.5 Nm)
*Indicator clamping pressure is 1000 lb.
Table 6-2. Torque Specifications For SCRs

Part Number
SCR Type
000 251
Stud
425 in-lb (48 Nm)
450 in-lb (50.8 Nm)
004 216
Stud
425 in-lb (48 Nm)
450 in-lb (50.8 Nm)
022 260
Stud
125 in-lb (14.1 Nm)
150 in-lb (16.9 Nm)
034 976
Stud
250 in-lb (28.2 Nm)
300 in-lb (33.9 Nm)
037 571
Stud
250 in-lb (28.2 Nm)
300 in-lb (33.9 Nm)
039 526
Stud
425 in-lb (48 Nm)
450 in-lb (50.8 Nm)
044 823
Stud
250 in-lb (28.2 Nm)
300 in-lb (33.9 Nm)
046 020
Stud
250 in-lb (28.2 Nm)
300 in-lb (33.9 Nm)
047 074
Stud
250 in-lb (28.2 Nm)
300 in-lb (33.9 Nm)
052 249
Stud
425 in-lb (48 Nm)
450 in-lb (50.8 Nm)
072 131
Stud
125 in-lb (14.1 Nm)
150 in-lb (16.9 Nm)
074 250
Stud
130 in-lb (14.7 Nm)
082 717
Stud
275 in-lb (31 Nm)
325 in-lb (36.7 Nm)
083 422
Stud
250 in-lb (28.2 Nm)
300 in-lb (33.9 Nm)
083 936
Stud
425 in-lb (48 Nm)
450 in-lb (50.8 Nm)
084 182
Stud
250 in-lb (28.2 Nm)
300 in-lb (33.9 Nm)
091 078
Stud
425 in-lb (48 Nm)
450 in-lb (50.8 Nm)
141 388
Stud
240 in-lb (27.1 Nm)
300 in-lb (33.9 Nm)
180 456
Stud
240 in-lb (27.1 Nm)
300 in-lb (33.9 Nm)
150 853 Page 42
Minimum Torque Value
Maximum Torque Value
Table 6-3. SCR Clamping Pressures

Part Number
SCR Type
Indicator Clamping
Pressure Value
Clamping Torque
Value (Nut)
044 231
Puk
1000 lb
80 in-lb (9.0 Nm)
046 995
Puk
1000 lb
80 in-lb (9.0 Nm)
048 736
Puk
1000 lb
80 in-lb (9.0 Nm)
070 160
Puk
5000 lb
NA
070 161
Puk
1000 lb
80 in-lb (9.0 Nm)
071 984
Puk
5000 lb
NA
083 937
Puk
1000 lb
80 in-lb (9.0 Nm)
086 926
Puk
1000 lb
80 in-lb (9.0 Nm)
094 387
Puk
1000 lb
80 in-lb (9.0 Nm)
097 397
Puk
1000 lb
80 in-lb (9.0 Nm)
097 959
Puk
2000 lb
140 in-lb (15.8 Nm)
107 588
Puk
1000 lb
80 in-lb (9.0 Nm)
109 091
Puk
2000 lb
140 in-lb (15.8 Nm)
109 270
Puk
1000 lb
80 in-lb (9.0 Nm)
112 940
Puk
2000 lb
140 in-lb (15.8 Nm)
112 941
Puk
2000 lb
140 in-lb (15.8 Nm)
112 942
Puk
2000 lb
140 in-lb (15.8 Nm)
113 010
Puk
2000 lb
140 in-lb (15.8 Nm)
115 114
Puk
1000 lb
50 in-lb (5.6 Nm)
116 661
Puk
2000 lb
140 in-lb (15.8 Nm)
117 720
Puk
1000 lb
80 in-lb (9.0 Nm)
119 371
Puk
1000 lb
50 in-lb (5.6 Nm)
121 430
Puk
2000 lb
140 in-lb (15.8 Nm)
132 147
Puk
2000 lb
80 in-lb (9.0 Nm)
143 818
Puk
1000 lb
50 in-lb (5.6 Nm)
148 091
Puk
2000 lb
90 in-lb (10.2 Nm)
161 668
Puk
1000 lb
55 in-lb (6.1 Nm)
162 516
Puk
800 lb
NA
185 830
Puk
80 in-lb (9.0 Nm)
Table 6-4. Torque Specifications For IGBT And MOSFET Transistor Modules
Transistor Replacement Kit
Part Number
Mounting Screw Torque Value
Screw Terminal Torque Value
149 202
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
17 in-lb, 2 in-lb (1.9 Nm, 0.2 Nm)
149 204
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
17 in-lb, 2 in-lb (1.9 Nm, 0.2 Nm)
149 207
16 in-lb, 1 in-lb (1.8 Nm, 0.1 Nm)
16 in-lb, 1 in-lb (1.8 Nm, 0.1 Nm)
149 238
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
150 912
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
150 913
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
151 489
25 in-lb, 2 in-lb (2.8 Nm, 0.3 Nm)
12 in-lb, 1 in-lb (1.4 Nm, 0.1 Nm)

150 853 Page 43
Transistor Replacement Kit

Part Number
157 566
33 in-lb, 3 in-lb (3.7 Nm, 0.3 Nm)
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
179 628
33 in-lb, 3 in-lb (3.7 Nm, 0.3 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
180 110
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
184 258
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
185 776
33 in-lb, 3 in-lb (3.7 Nm, 0.3 Nm)
50 in-lb, 4 in-lb (5.6 Nm, 0.5 Nm)
185 946
13 in-lb, 1 in-lb (1.4 Nm, 0.1 Nm)
16 in-lb, 1 in-lb (1.8 Nm, 0.1 Nm)
185 947
26 in-lb, 3 in-lb (2.9 Nm, 0.3 Nm)
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
191 590
35 in-lb, 2 in-lb (4.0 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
191 591
35 in-lb, 2 in-lb (4.0 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
200 392
35 in-lb, 2 in-lb (4.0 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
206 477
40 in-lb, 4 in-lb (4.5 Nm, 0.4 Nm)
40 in-lb, 4 in-lb (4.5 Nm, 0.4 Nm)
206 478
40 in-lb, 4 in-lb (4.5 Nm, 0.4 Nm)
40 in-lb, 4 in-lb (4.5 Nm, 0.4 Nm)
197 470
26 in-lb, 3 in-lb (2.9 Nm, 0.3 Nm)
26 in-lb, 3 in-lb (2.9 Nm, 0.3 Nm)
208 173
25 in-lb, 2in-lb (2.8 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
186 656
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
171 883
13 in-lb, 1 in-lb (1.4 Nm, 0.1 Nm)
16 in-lb, 1 in-lb (1.8 Nm, 0.1 Nm)
163 472
26 in-lb, 3 in-lb (2.9 Nm, 0.3 Nm)
17 in-lb, 2 in-lb (1.9 Nm, 0.2 Nm)
176 421
26 in-lb, 3 in-lb (2.9 Nm, 0.3 Nm)
17 in-lb, 2 in-lb (1.9 Nm, 0.2 Nm)
188 190
26 in-lb, 3 in-lb (2.9 Nm, 0.3 Nm)
17 in-lb, 2 in-lb (1.9 Nm, 0.2 Nm)
212 106
40 in-lb, 4 in-lb (4.5 Nm, 0.4 Nm)
50 in-lb, 4 in-lb (5.6 Nm, 0.5 Nm)
213 179
40 in-lb, 4 in-lb (4.5 Nm, 0.4 Nm)
40 in-lb, 4 in-lb (4.5 Nm, 0.4 Nm)
212 936
*25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
*First tighten both screws to 7 in-lb, then torque both screws to final value. Allow ten minutes relax time and re-torque both screws to final value.
Table 6-5. Torque Specifications For Rectifiers

Rectifier Replacement Kit
Part Number
109 373
22 in-lb, 2 in-lb (2.5 Nm, 0.2 Nm)
NA
149 217
20 in-lb, 2 in-lb (2.3 Nm, 0.2 Nm)
30 in-lb, 3 in-lb (3.4 Nm, 0.3 Nm)
149 218
20 in-lb, 2 in-lb (2.3 Nm, 0.2 Nm)
30 in-lb, 3 in-lb (3.4 Nm, 0.3 Nm)
149 219
22 in-lb, 2 in-lb (2.5 Nm, 0.2 Nm)
NA
179 629
33 in-lb, 3 in-lb (3.7 Nm, 0.3 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)

Gate: 15 in-lb, 1 in-lb (1.7 Nm, 0.1 Nm)
184 260
35 in-lb, 2 in-lb (4.0 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
192 105
20 in-lb, 2 in-lb (2.3 Nm, 0.2 Nm)
30 in-lb, 3 in-lb (3.4 Nm, 0.3 Nm)
131 828
20 in-lb, 2 in-lb (2.3 Nm, 0.2 Nm)
30 in-lb, 3 in-lb (3.4 Nm, 0.3 Nm)
179 542
37 in-lb, 4 in-lb (4.2 Nm, 0.2 Nm)
NA
199 034
NA
NA
173 630
20 in-lb, 2 in-lb (2.3 Nm, 0.2 Nm)
28 in-lb, 2 in-lb (3.1 Nm, 0.3 Nm)

Gate: 14 in-lb, 1 in-lb (1.6 Nm, 0.1 Nm)
141 317
21 in-lb, 2 in-lb (2.4 Nm, 0.2 Nm)
21 in-lb, 2 in-lb (2.4 Nm, 0.2 Nm)
212 937
*25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
*First tighten both screws to 7 in-lb, then torque both screws to final value. Allow ten minutes relax time and re-torque both screws to final value.
150 853 Page 44
Table 6-6. Torque Specifications For Diode Modules

Diode Replacement Kit
Part Number
149 208
37 in-lb, 4 in-lb (4.2 Nm, 0.5 Nm)
22 in-lb, 3 in-lb (2.5 Nm, 0.3 Nm)
149 209
33 in-lb, 3 in-lb (3.7 Nm, 0.3 Nm)
NA
149 210
33 in-lb, 3 in-lb (3.7 Nm, 0.3 Nm)
NA
149 211
20 in-lb, 2 in-lb (2.3 Nm, 0.2 Nm)
NA
149 212
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
NA
149 213
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
NA
149 215
16 in-lb, 1 in-lb (1.8 Nm, 0.1 Nm)
16 in-lb, 1 in-lb (1.8 Nm, 0.1 Nm)
149 216
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
NA
151 229
**35 in-lb, 5 in-lb (4.0 Nm, 0.6 Nm)

Center Screw: *22 in-lb, 2 in-lb (2.5 Nm, 0.2 Nm)
30 in-lb, 3 in-lb (3.4 Nm, 0.3 Nm)
151 431
**35 in-lb, 5 in-lb (4.0 Nm, 0.6 Nm)

30 in-lb, 3 in-lb (3.4 Nm, 0.3 Nm)
155 634
27 in-lb, 3 in-lb (3.1 Nm, 0.3 Nm)
NA
156 367
20 in-lb, 2 in-lb (2.3 Nm, 0.2 Nm)
30 in-lb, 3 in-lb (3.4 Nm, 0.3 Nm)
179 630
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
185 775
33 in-lb, 3 in-lb (3.7 Nm, 0.3 Nm)
17 in-lb, 2 in-lb (1.9 Nm, 0.2 Nm)
185 940
13 in-lb, 1 in-lb (1.4 Nm, 0.1 Nm)
16 in-lb, 1 in-lb (1.8 Nm, 0.1 Nm)
189 965
26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
20 in-lb, 2 in-lb (2.3 Nm, 0.2 Nm)
191 503
35 in-lb, 2 in-lb (4.0 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
192 116
44 in-lb, 4 in-lb (5.0 Nm, 0.5 Nm)
26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
153 099
14 in-lb, 1 in-lb (1.6 Nm, 0.1 Nm)
12 in-lb, 1 in-lb (1.3 Nm, 0.1 Nm)
199 952
14 in-lb, 1 in-lb (1.6 Nm, 0.1 Nm)
12 in-lb, 1 in-lb (1.3 Nm, 0.1 Nm)
206 987
13 in-lb, 1 in-lb (1.4 Nm, 0.1 Nm)
13 in-lb, 1 in-lb (1.4 Nm, 0.1 Nm)
201 530
12 in-lb, 1 in-lb (1.3 Nm, 0.1 Nm)
12 in-lb, 1 in-lb (1.3 Nm, 0.1 Nm)
168 167
26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
198 148
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
25 in-lb, 2 in-lb (2.8 Nm, 0.2 Nm)
168 413
13 in-lb, 1 in-lb (1.4 Nm, 0.1 Nm)
16 in-lb, 1 in-lb (1.8 Nm, 0.1 Nm)
190 531
13 in-lb, 1 in-lb (1.4 Nm, 0.1 Nm)
16 in-lb, 1 in-lb (1.8 Nm, 0.1 Nm)
170 565
13 in-lb, 1 in-lb (1.4 Nm, 0.1 Nm)
16 in-lb, 1 in-lb (1.8 Nm, 0.1 Nm)
179 869
21 in-lb, 2 in-lb (2.4 Nm, 0.2 Nm)
15 in-lb, 2 in-lb (1.7 Nm, 0.1 Nm)
204 820
26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
212 446
12 in-lb, 1 in-lb (1.3 Nm, 0.1 Nm)
12 in-lb, 1 in-lb (1.3 Nm, 0.1 Nm)
212 037
14 in-lb, 1 in-lb (1.6 Nm, 0.1 Nm)
12 in-lb, 1 in-lb (1.3 Nm, 0.1 Nm)
201 531
**26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)

***26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
*Tighten the center screw first to this value, followed by the two outside screws to this value.
**Final torque the outside screws to this value.
***Tighten each terminal to one-half this value, then final torque to this value.
150 853 Page 45
Table 6-7. Torque Specifications For Primary/Secondary Modules

Module Replacement Kit
Part Number
204 821
*26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
NA
201 533
*22 in-lb, 2 in-lb (2.5 Nm, 0.2 Nm)
NA
201 534
*22 in-lb, 2 in-lb (2.5 Nm, 0.2 Nm)
NA
217 625
*22 in-lb, 2 in-lb (2.5 Nm, 0.2 Nm)
NA
*Tighten to one-half this value first, then final torque to this value.
Table 6-8. Torque Specifications For SCR Modules

SCR Replacement Kit
Part Number
168 065
45 in-lb, 4 in-lb (5.1 Nm, 0.5 Nm)
26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
196 754
44 in-lb, 4 in-lb (5.0 Nm, 0.5 Nm)
26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
196 760
48 in-lb, 4 in-lb (5.4 Nm, 0.5 Nm)
48 in-lb, 4 in-lb (5.4 Nm, 0.5 Nm)
197 698
3550 in-lb (4.05.6 Nm)
3550 in-lb (4.05.6 Nm)
208 384
48 in-lb, 4 in-lb (5.4 Nm, 0.5 Nm)
48 in-lb, 4 in-lb (5.4 Nm, 0.5 Nm)
218 296
45 in-lb, 5 in-lb (5.1 Nm, 0.5 Nm) **
45 in-lb, 5 in-lb (5.1 Nm, 0.5 Nm) **
218 292
45 in-lb, 5 in-lb (5.1 Nm, 0.5 Nm) **
45 in-lb, 5 in-lb (5.1 Nm, 0.5 Nm) **
199 988
26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
26 in-lb, 2 in-lb (2.9 Nm, 0.2 Nm)
** = Re-torque after 4 hours.
150 853 Page 46
Notes
Notes
Notes
Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer St.

P.O. Box 1079
Appleton, WI 54912-1079 USA
Hobart Welding Products

An Illinois Tool Works Company
600 West Main Street
Troy, OH 45373 USA

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September 2005 FORM: 150 853G

2005 MILLER Electric Mfg. Co.

IGBT/MOSFET Tester Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WHO DO I CONTACT FOR HELP?

Always provide Model Name and Serial or Style Number

SECTION 1 SAFETY PRECAUTIONS FOR SERVICING

1-1. Symbol Usage

Y Marks a special safety message.

1-2. Servicing Hazards

HOT PARTS can cause severe burns.

1. Do not touch live electrical parts.

1. Do not touch hot parts bare handed.

2. Stop engine or turn OFF power source and wire

2. Wear protective gloves and clothing when working

3. Insulate yourself from ground by standing or

SIGNIFICANT DC VOLTAGE exists after

STATIC ELECTRICITY can

1. Put on grounded wrist strap BEFORE handling

FIRE OR EXPLOSION can result from

FLYING PIECES OF METAL or DIRT can

3. Allow cooling period before servicing gun or torch.

EXPLODING PARTS can cause injury.

ELECTRIC SHOCK HAZARD

1. Turn Off power source and wire feeder or stop

HIGH-FREQUENCY RADIATION can

FALLING EQUIPMENT can cause

FIELDS FROM HIGH

1. Pacemaker wearers keep away from servicing

MOVING PARTS can cause injury.

MOVING PARTS can cause injury.

OVERUSE can cause OVERHEATED

1. Keep away from moving parts.

2. Consult the Owners Manual for welding safety

2. Keep away from pinch points such as drive rolls.

3. Use only genuine MILLER replacement parts.

1-3. Engine Hazards

ENGINE EXHAUST GASES can kill.

ENGINE FUEL can cause fire or explosion.

UNCONTROLLED TILTING OR TIPPING

BATTERY EXPLOSION can BLIND and

BATTERY ACID can BURN SKIN.

STEAM AND PRESSURIZED HOT

PINCH POINTS can injure.

1-4. EMF Information

150 853 Page 2

1. Keep cables close together by twisting or taping them.

SECTION 2 EXPLANATION OF ELECTRICAL PARTS

2-1. Safety Precautions Read Before Using This Guide

Y WARNING: ELECTRIC SHOCK can kill.

Disconnect input power or stop engine before servicing.

A source of DC voltage. Typically used in

Components that allow electrical connections

A device that stores electrical energy. Large

The green ground wire of a primary cord is

CIRCUIT BREAKER A protection device that breaks a circuit when

When many wires are connected together,

150 853 Page 3

A spring-loaded connection device. A good

A heavy duty relay. Usually used to make

A transformer that produces an AC voltage

A dashed line between parts means there is

A device that allows current to flow in one

This device provides cooling of the internal