Maxtron 450 KC237305

February 1997 Form: TM-2206
Effective With Serial No. KC237305
TECHNICAL MANUAL
Service And Parts
Maxtron 450
CC/CV DC Welding Power Source For GMAW, GTAW, SMAW, FCAW, CAC-A, GMAW-P, GTAW-P, And SAW Welding
Maximum Amperes Input At Rated Load

Voltage Amperage
Input Rated Welding Open- Output 60 Hz, Three-Phase
Range In Range In
Power Output
O tp t Circ it
Circuit
CV Mode CC Mode 230 V 460 V 575 V KVA KW
Voltage DC
450 A @ 38 Volts
DC, 100% Duty
Three 72 36 29 28 20
Cycle; 565 A, 10 – 38 5 – 565 80
Phase (2.0)* (1.0)* (0.8)* (0.23)* (0.17)*
43 Volts DC,
60% Duty Cycle
325 A @ 33 Volts
DC, 100% Duty
Single 89.6 47.2 37.7 18 13
Cycle; 325 A, 10 – 38 5 – 325 80
Phase (2.0)* (1.0)* (0.8)* (0.23)* (0.17)*
33 Volts DC,
60% Duty Cycle
*While idling
cover_tm 4/95 – ST-150 171-B  1997 MILLER Electric Mfg. Co. PRINTED IN USA
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-3. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-4. Voltage Sensing Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-5. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-6. Remote 17 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-7. 115 Volt AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-9. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-10. Connecting Input Conductors To Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-11. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-2. Process Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 4 – THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 5 – PRE-POWER CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5-1. Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 6 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-2. Troubleshooting Circuit Diagram For Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-3. Waveforms For Section 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-4. Control Board PC1 Testing Information (Use With Section 6-5) . . . . . . . . . . . . . . . . . . . . . . . 28
6-5. Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-6. Digital Meter Board PC5 Testing Information (Use With Section 6-7) . . . . . . . . . . . . . . . . . . . 31
6-7. Digital Meter Board PC5 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-8. Digital Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-9. Optional MMP Board PC7 Testing Information (Use With Section 6-10) . . . . . . . . . . . . . . . . 34
6-10. Optional MMP Board PC7 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6-11. Optional Optima Board PC7 Testing Information (Use With Section 6-12) . . . . . . . . . . . . . . 35
6-12. Optional Optima Board PC7 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6-13. Remote 14 Filter Board PC8 Testing Information (Use With Section 6-14) . . . . . . . . . . . . . . 36
6-14. Remote 14 Filter Board PC8 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
WHO DO I CONTACT FOR HELP?

H CALL: H FAX: H WRITE:
Miller Customer Service 414-735-4136 Miller Electric Mfg. Co.
Department at P.O. Box 1079
414-735-4505 Appleton, WI 54912 USA
Always provide Model Name and Serial or Style Number
OM-2206G-4/96/SPM-2206B-2/95
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-2. Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-3. Optional Ground Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-4. Circuit Breakers And Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 8 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 9 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING
safety_stm1 4/95
1-1. Symbol Usage

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

on circuit boards. interfere with radio navigation, safety
1. Put on grounded wrist strap BEFORE handling services, computers, and
boards or parts. communications equipment.
2. Use proper static-proof bags to store, move, or
ship PC boards. 1. Have only qualified persons familiar with
electronic equipment perform this installation.
FIRE OR EXPLOSION can result from
placing unit on, over, or near 2. The user is responsible for having a qualified
combustible surfaces. electrician promptly correct any interference
problem resulting from the installation.
1. Do not place unit on, over, or near combustible
surfaces. 3. If notified by the FCC about interference, stop
2. Do not service unit near flammables. using the equipment at once.
FLYING PIECES OF METAL or DIRT can 4. Have the installation regularly checked and
injure eyes. maintained.
1. Wear safety glasses with side shields or face 5. Keep high-frequency source doors and panels
shield during servicing. tightly shut, keep spark gaps at correct setting,
2. Be careful not to short metal tools, parts, or wires and use grounding and shielding to minimize the
together during testing and servicing. possibility of interference.
Maxtron 450 TM-2206 Page 1

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

Considerations About Welding And The Effects Of Low Frequency To reduce magnetic fields in the workplace, use the following
Electric And Magnetic Fields procedures:
The following is a quotation from the General Conclusions Section 1. Keep cables close together by twisting or taping them.
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields – 2. Arrange cables to one side and away from the operator.
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very 3. Do not coil or drape cables around the body.
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly 4. Keep welding power source and cables as far away as
establish that low frequency magnetic fields can interact with, and practical.
produce changes in, biological systems. While most of this work is of
very high quality, the results are complex. Current scientific 5. Connect work clamp to workpiece as close to the weld as
understanding does not yet allow us to interpret the evidence in a possible.
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible About Pacemakers:
risk or to offer clear science-based advice on strategies to minimize The above procedures are also recommended for pacemaker
or avoid potential risks.” wearers. Consult your doctor for complete information.
TM-2206 Page 2 Maxtron 450

SECTION 2 – INSTALLATION
2-1. Selecting A Location

1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement If using lifting forks, extend forks
1 beyond opposite side of unit.
3 Rating Label
Use rating label to determine input
power needs. Label is on name-
plate.
OR
2 4 Line Disconnect Device
Locate unit near correct input pow-
er supply.
Y Special installation may be
required where gasoline or
Location volatile liquids are present –
4 see NEC Article 511 or CEC
Section 20.
3
18 in
(460 mm)
ST-800 611 / ST-150 171-C
2-2. Dimensions And Weights
Dimensions
Height 23 in (584 mm)

D
C 6 Holes Width 15-1/2 in (394 mm)
Depth 26-1/8 in (664 mm)
A 24-1/16 in (611 mm)

A
B
B 20-3/4 in (527 mm)
C 12-3/8 in (314 mm)
D 9/32 in (7 mm) Dia
Weight
165 lbs (75 kg)

2-3. Weld Output Terminals And Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

100 ft (30 m) Or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 – 60% 60 – 100%
Weld Output Welding
Duty Duty 10 – 100% Duty Cycle
Terminals Amperes
Cycle Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

Positive N ti
Negative
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
(+) ((–))
600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0
800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D
2-4. Voltage Sensing Terminal Connections

The voltage sensing terminals pro-
vide exact voltage measurement at
the welding arc.
Strip 1/2 in (13 mm) 1 Positive (+) Voltage Sensing
insulation Terminal
6 7 2 Negative (–) Voltage Sensing
Or Terminal
3 Receptacle
3 5 4 Proper Plug (Not Supplied)
5 18 Gauge Lead (Not Sup-
plied)
4 6 Nut
7 Lead Hole
5 For Electrode Positive (DCEP),

connect remaining end of negative
(–) terminal lead to work. Connect
remaining end of positive (+) termi-
nal lead to weld cable conductor at
electrode holder end of weld cable.
2 For Electrode Negative (DCEN),
reverse terminal lead connections.
1
+ –
3
Tools Needed:
Ref. ST-152 069-C / Ref. ST-152 885-A

2-5. Remote 14 Receptacle Information
Socket* Socket Information
A 24 volts ac. Protected by circuit breaker CB2.

24 VOLTS AC
A J
K I B C o cn lt oa sc u-t r e
B t a c t o r c o
C L N H
D M G I 115 volts ac. Protected by circuit breaker CB1.
115 VOLTS AC
E F
J Contact closure to I completes 115 volts ac con-
tactor control circuit.
C Output to remote control; +10 volts dc in CV, 0 to

+10 volts dc in CC.
REMOTE
OUTPUT D Remote control circuit common.
CONTROL
E 0 to +10 volts dc input command signal from re-
mote control.
A/V F Current feedback; +1 volt dc per 100 amperes.

AMPERAGE
VOLTAGE H Voltage feedback; +1 volt dc per 10 arc volts.
ST-800 617
G Circuit common for 24 and 115 volts ac circuits.

GND
K Chassis common.
*The remaining sockets are not used.

2-6. Remote 17 Receptacle Information
REMOTE 17 Socket* Socket Information
D Contactor on/off signal; +13 to +24 volts dc con-

tactor On, 0 volts dc contactor Off.
A +10 volts dc output to remote control.
A B 0 to +10 volts dc input command signal from re-

B M mote control; full control of A/V output from re-
C L
P NT mote control.
D K REMOTE
R S J
E H OUTPUT H +24 volts dc; fused at 1 ampere.
FG CONTROL
K 0 to +10 volts dc set by panel A/V control; remote
control percent of panel A/V control.
L –24 volts dc; fused at 1 ampere.
E Current feedback; +1 volt dc per 100 amperes.

METER
M Voltage feedback; +1 volt dc per 10 arc volts.
C CV/CC select; +13 to +24 volts dc selects CV, 0

CV/CC volts dc selects CC.
G Arc force (dig)/inductance control; 0 to +10 volts

ARC dc set by panel Arc Force (Dig)/Inductance con-
ST-800 617 CONTROL
trol.
F Circuit common for sockets A, B, D, E, K, and M.
GND P Circuit common for sockets H and L.
S Chassis common.
*The remaining sockets are not used.
2-7. 115 Volt AC Duplex Receptacle

1 115 Volt AC Duplex Recep-
tacle RC10
This receptacle supplies up to 10
amperes of 115 volt ac power.
This receptacle has GFI (Ground
Fault Interrupters). If a ground cur-
rent is sensed at RC10, output to
RC10 stops. Check tools con-
nected to RC10 for damage, and
press Reset button.
Power output is shared between
this receptacle and the Remote 14
receptacle (see Section 2-5).
Ref. ST-153 999

2-8. Electrical Service Guide
Three-Phase Single-Phase
Input Voltage 230 460 575 230 460 575
Input Amperes At Rated Output 72 36 29 89.6 47.2 37.7
Max Recommended Standard Fuse Or Circuit

110 50 40 125 60 45
Breaker Rating In Amperes
Min Input Conductor Size In AWG/Kcmil 4 8 10 4 8 8
Max Recommended Input Conductor Length

179 (54) 309 (94) 322 (98) 160 (49) 277 (85) 433 (132)
In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil 6 10 10 6 10 10
Reference: 1993 National Electrical Code (NEC). S-0092J
2-9. Placing Jumper Links

Y Turn Off welding power
source, disconnect input
power, and check voltage on
input capacitors according
to Section 7-2 before pro-
ceeding.
Check input voltage available at
site.
Remove side panel.
1 Jumper Link Label
2 Jumper Links
Move jumper links to match input
voltage, and label on unit.
Continue to Section 2-10, or rein-
stall side panel.
230 VOLTS 460 VOLTS
Do not overtighten.
S-155 568
460 VOLTS 575 VOLTS
S-157 126
Tools Needed:
3/8 in
Ref. ST-150 172-D

2-10. Connecting Input Conductors To Unit
For Standard Units ceeding.
1 Input And Grounding Con-
1
ductors
2 See Section 2-8.
2 Strain Relief Connector
Terminal Block TE2
Obtain and install. Hole in rear pan-
el is 1-3/4 in (44 mm).
L1 3 Reed Relay (Ground Current
L2 Sensor – Optional)
L3
If unit is equipped with optional
L1
ground current sensor, route
L2 grounding conductor through reed
switch two times and connect to
L3 grounding terminal as shown.
Reinstall side panel(s).
=GND/PE
3 Connect to L1, L2, L3
1 Connect to L1, L2
Y Always connect grounding
conductor first.
For Units With Optional Ground Current Sensor
1
2
Terminal Block TE2
L1
L2
L3
L1
L2
L3
=GND/PE
3 Connect to L1, L2, L3
1 Connect to L1, L2
conductor first.
Tools Needed:
7/16 in
3 3/8 in
ssb2.4* 1/94 – ST-150 172-D / ST-156 172-D

2-11. Connecting Input Power
1 Input And Grounding
Conductors
2 Line Disconnect Device
See Section 2-8.
3 1
2
2
L1
L2 L1
L3 L2

conductor first.
1
= GND/PE
Tools Needed:
input_2 – 3/96 / Ref. ST-144 221 / Ref. ST-070 399-C / ST-150 171-C

SECTION 3 – OPERATION
3-1. Controls
1 2 3 4
1 Power Switch For front panel control, place switch in Pan- With process switch in SMAW position, con-
2 Digital Meters el position. For remote control, place switch trol increases short-circuit amperage which
When the contactor is not energized, preset in Remote 14 position (see Section 2-5), or allows the operator to use a very short arc
amperage is displayed in SMAW and GTAW Remote 17 position (see Section 2-6), and length without sticking the electrode. When
modes, and preset voltage is displayed in connect remote device. set towards 0 (zero), short-circuit amperage
GMAW mode. 6 Output (Contactor) Control Switch at low arc voltage is the same as normal
welding amperage. When set towards 100,
3 Amperage/Voltage Adjustment Control For front panel control of output, place
short-circuit amperage is increased at low
Control adjusts voltage with process switch switch in On position. For remote control of
arc voltage.
in GMAW position, and adjusts amperage in output, place switch in Remote 17/14 posi-
SMAW and GTAW positions. tion, and connect remote device (see Sec- Control adjusts inductance with process
tions 2-5 and 2-6). switch in GMAW. Inductance determines
This is a ten turn control. When contactor is
Y Weld output terminals are energized the “wetness” of the weld puddle. When set
not energized, control presets output.
when Output switch is On and Power towards 100, “wetness” (puddle fluidity) in-
4 Process Switch creases.
is On.
Switch selects type of weld output. Use
SMAW position for SMAW. Use GTAW posi- 7 Arc Force/Inductance Control Switch This control is not functional with process
tion for GTAW, GMAW-P, and CAC-A. Use Switch selects panel or remote control of switch in GTAW.
GMAW position for GMAW, and FCAW. arc force/inductance. Numbers around control are for reference
5 Amperage/Voltage Control Switch 8 Dig/Inductance Control only.
Ref. ST-152 069-D

3-2. Process Switch Settings
Shielded Metal Arc Tungsten Inert Gas Gas Metal Arc Gas Metal Arc
(SMAW) Welding; (GTAW) Welding; (GMAW) Welding; (GMAW) Welding With
Panel Amperage Control Remote Amperage Control Remote Voltage Control 60M Series Wire Feeder
For remote control, For panel control, For panel control of

place A/V switch in place A/V switch in voltage, place A/V
Remote 14 position, Panel position, and switch in Panel position.
and Output (Contactor) Output (Contactor)
switch in Remote switch in On position.
17/14 position. Ref. ST-165 852-B
3-3. Duty Cycle And Overheating

Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void war-
ranty.
100% Duty Cycle At 450 Amperes, Three-Phase; 60% Duty Cycle At 565 Amperes, Three-Phase;
325 Amperes, Single-Phase No Increase Beyond 325 Amperes For Single-Phase
Continuous Welding 6 Minutes Welding 4 Minutes Resting
Overheating
0 A/V
15
OR
Minutes Reduce Duty Cycle
duty1 4/95 / ST-145 897

SECTION 4 – THEORY OF OPERATION
1 Input Terminal Board TE1
And Input Terminal Block TE2
TE1 links welding power source for 1 4 5
correct input voltage and TE2 con- 3φ 3φ
nects line input power. 3-Phase Input Terminal
Line Input Board TE1 And Contactor Input
2 Power Switch S1 Power Terminal Block TE2 W1 Rectifier SR1
Provides on/off control of welding

power source.
2 3
3 Precharge Resistors R1 And
R19 Power Precharge
Switch S1 Resistors
Allow initial charge of buss capaci- R1, R19
tors C8, C9, C10, C11, C12, C13,
C18, and C19 through input rectifi-
er SR1 and power switch S1 before
9 7 8
contactor W1 is energized.
4 Contactor W1 GFI Receptacle 115 VAC Fan Motor
RC10 Transformer T2 FM
Enables precharge network R1,
R19, and S1 and connects input
rectifier SR1 to the input line.
5 Input Rectifier SR1 11 10
Changes the ac line input power to Amperage/
full-wave rectified dc. Voltage
Control R3
6 Bus Capacitors C8, C9, C10,
C11, C12, C13, C18, And 12
C19 18
Arc Force (Dig)/
Filter the dc output voltage of SR1. Inductance
Control R2
7 Transformer T2
Remote 14
Supplies power to control board Receptacle 13
PC1, Remote 14 receptacle RC2, RC2
and GFI receptacle RC10. Mode
Switch S2
8 Fan Motor FM
Provides cooling of internal com- 19 14
ponents.
Output
9 GFI Receptacle RC10 (Contactor) Control
Provides 10 amperes of 115 volts Remote 14 Switch S3 Board
Filter Board PC1
ac for auxiliary equipment. PC8
10 Control Board PC1
Controls weld output by changing
the pulse width modulation signal
(wider or narrower pulses meaning 19
more or less voltage) to IGBT pow-
er modules PM1 and PM2 after 15
comparing current and voltage Amperage/
feedbacks to reference levels set Voltage Control
by R3 and R2. Remote 17 Switch S4
Filter Board
11 Amperage/Voltage Control PC10
R3 16
Sets weld output amperage or volt- Arc/Inductance

age level. And CC/CV Control
Switch S5
12 Arc Force (Dig)/Inductance
Control R2 18 17
Sets amount of Dig amperage in Digital Meter
CC mode or amount of inductance Board PC5
in CV mode.
Remote 17
13 Mode Switch S2 Receptacle
Selects volt-ampere characteristic RC1
for process used.
14 Output (Contactor) Switch S3
Selects On or Remote for remote
contactor control.

15 Amperage/Voltage Control
Switch S4
6 Selects front panel or remote am-
Bus 25 perage/voltage control.
Capacitors Output
C8, C9, 16 Arc/Inductance And CC/CV
C10, C11, Diodes Control Switch S5
C12, C13, D1-D8
C18, C19 Allows selection of weld process
and arc/inductance control from
25 26 28 front panel or Remote 17 receptacle
Output Positive (+) RC1.
Diodes Weld Output
D9-D16 Terminal 17 Digital Meter Board PC5
Hall
Device Displays preset and actual amper-
HD1 age and voltage.
18 Remote 14 Receptacle RC2
And Remote 17 Receptacle
Electrode RC1
Connect remote amperage/voltage
Work and contactor controls.
22
19 Remote 14 Filter Board PC8
And Remote 17 Filter Board
IGBT PC10
Power 23 24 27 28
Modules Filter (block) HF and other noise
PM1 And Resonant Stabilizers Negative (–) from getting into power source.
PM2 Tank Z1, Z2 Weld Output
Circuit Terminal 20 Optima Option
Current
Transformer Synergically controls pulsing pa-
Gating CT1 rameters for GMAW-P.
Signals 21 Manual Mig Pulser (MMP) Op-
tion
Manually controls pulsing parame-
Fault Protection ters for GMAW-P.
22 IGBT Power Modules PM1
And PM2
Current Feedback
Use very fast on/off switching action
to effectively turn the dc into ac.
20♦ 23 Current Transformer CT1
Provides a pulsed current signal to
Pulsed
GMAW Optima PC1 for fault protection.
Switch S4 Board PC7
24 Resonant Tank Circuit
A tuned frequency circuit consisting
of capacitors C1-C4, inductors
L1-L4, and main transformer T1. T1
21♦
steps down the high frequency ac in-
put to low voltage and high current.
25 Output Diodes D1 Thru D16
MMP Potentiometers
Board PC7 R1-R4 Rectify output of T1 to provide dc
weld output.
GMAW-P Pulse Control Panel 26 Hall Device HD1
Voltage Feedback Provides current feedback signal to
PC1.
Voltage Feedback
27 Stabilizers Z1 And Z2
Smooth welding current.
28 Positive (+) And Negative (–)
AC Or DC Control Circuits Weld Output Terminals
Provide weld output and allow
3φ Power
changing of output polarity.
Weld Current Circuit

♦ Optional

SECTION 5 – PRE-POWER CHECKLIST
5-1. Checking Unit Before Applying Power
. See Section 6-2 for test points and values and
Section 9 for parts location.
. Use MILLER Testing Booklet (Part No. 150 853)
when servicing this unit.
Y Discharge input capacitors according to Section 7-2 and be sure voltage is near zero before touching any parts.
Y Before troubleshooting or applying power to unit, complete following checks to avoid causing further damage.
Y Although some parts are briefly checked in this procedure, more complete tests may be needed later. This check is simply to get
a basic okay to power up unit.
A. IGBT Modules PM1, PM2
Visually inspect IGBT modules

PM1 and PM2 for damage.
IGBT Module PM1 Or PM2 Isolate terminals C1 and E2 on
PM1 and PM2 for testing. Check
C1 to E1 and C2 to E2 (diode test).
Reassemble IGBTs.
Remove plugs PLG4 and PLG1
from receptacles RC4 and RC1 on
PC1. Check G1 to E1 and G2 to E2
(red to white leads) from PLG4 and
PLG1 for infinite resistance in both
directions. Reinstall PLG4 and
PLG1
For best test, use an IGBT tester
(MILLER Part No. 043 553).
IGBT Module PM1 Or PM2
Terminal Terminal
Terminal E2
C2/E1 C1
G2 (B2)
E2
E1
G1 (B1)
IGBT Module PM1 Or PM2
ST-155 791

B. Control Board PC1
Visually inspect control board PC1
for signs of component failure.
Check 8 diodes on PC1 in loca-
tions shown.
Diodes Diodes Replace PC1 if any diodes are

shorted.
. If any diodes are shorted,

check IGBTs for failure (see
item C).
Receptacle RC1
Diodes Receptacle RC4
Control Board PC1 Diodes
ST-155 791 / Ref. SC-164 972

C. Output Diodes D1-D16
Visually inspect output rectifier
diodes D1-D16 for discolored
Diodes D1-D16 sleeving or signs of heat damage.
First, perform a diode test across
weld output receptacles. If diode
test indicates a short, isolate
diodes D1-D16 and retest them in-
dividually.
Diodes D1-D16
Weld Output
Receptacles
ST-155 791

D. Input Rectifier SR1
1 Visually inspect SR1 for
damage.
2 To isolate SR1 for testing,
disconnect lead 25 from
positive (+) terminal of SR1.
3 Check 6 diodes (diode test).
Check from each ac terminal
to the positive (+) terminal
and from each ac terminal to
the negative (–) terminal.
Input Rectifier SR1
Positive (+) D A AC (L1)
Negative (–) E B AC (L2)

(Not Used)
F C AC (L3)
Negative (–)
Input Rectifier SR1
ST-155 791
E. Clamping Rectifiers SR2 And SR3 Prior To KD414913

1 Check SR2 and SR3
according to MILLER Testing
Booklet (Part No. 150 853).
Clamping Rectifiers
SR2 And SR3
Clamping Rectifiers
SR2 And SR3
ST-155 791

F. Hall Device HD1
Visually inspect hall device HD1.
Remove plug to isolate for testing.
Check from pin 1 to pin 3 for
1500-2000 ohms. Replace HD1 if
Hall Device HD1 necessary.
Hall Device HD1
ST-155 791
G. Bus Capacitors C8, C9, C10, C11, C12, C13, C18, And C19
1 Check C8, C9, C10, C11,
C12, C13, C18, and C19 for
a short (ohms position).
Bus Capacitors C8 – C13,

C18 – C19
Bus Capacitors C8 – C13,

C18 – C19
ST-155 791

H. Tank Capacitors C1, C2, C3, C4
1 Check C1 thru C4 for a short
(ohms position).
Tank Capacitors C1 – C4
Tank Capacitors C1 – C4
ST-155 791
I. Precharge Resistors R1, R19 And Bleeder Resistors R13-R16

1 Check resistance of
Precharge Resistors precharge resistors R1 and
R1, R19 R19; R1 and R19 are each
100 ohms ±10%. Effective
with Serial No. KF907 718,
the values were changed to
25 ohms ±10%
2 Check resistance of bleeder
resistors R13-R16. For
230/460 volt models, each
resistance is 2500 ohms
±10%. For 460/575 volt
models, each resistance is 5k
ohms ±10%.
Bleeder Resistors
R13-R16
ST-155 791

J. Contactor W1
1 Check condition of contacts.
Be sure normally-open
contacts are open. Replace
Contactor W1 contactor W1 if necessary.
ST-155 791

NOTES

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

Section 9 for parts location.
. Use MILLER Testing Booklet (Part No. 150 853)
when servicing this unit.
Trouble Remedy
No weld output; unit completely inop- Place line disconnect device in On position (see Section 2-11).
erative.
Check line fuse(s), and replace if necessary (see Section 2-11).
Check for proper input power connections (see Section 2-10).
Check position of input voltage jumper links (see Section 2-9).
Check fuse F1, and replace if necessary (see Section 7-4).
Check continuity of Power switch S1, and replace if necessary.
Check transformer T2 for signs of winding failure. Check continuity across windings, and check for
proper connections. Check secondary voltages. Replace T2 if necessary.
No weld output; fan motor FM running Place Output (Contactor) switch S3 in the On position or connect remote contactor control to proper
and digital meters illuminated. remote receptacle.
Check remote control device for proper operation, and replace if necessary.
Allow a cooling period of approximately five minutes (see Section 3-3). If thermostats TP1 and/or
TP2 remain open, check continuity and replace if necessary.
Check coil voltage and connections of contactor W1. Check continuity of coil and condition of con-
tacts. Replace W1 if necessary.
Check resistance and connections of hall device HD1; HD1 is 1600 ohms ±10% between pins 1
and 3 of receptacle RC62. Check input and output voltages. Replace HD1 if necessary.
Check output diodes D1 thru D16, and replace if necessary.
Check input rectifier SR1, and replace if necessary.
Check IGBT power modules PM1 and PM2, and replace if necessary.
Check control board PC1 and connections, and replace if necessary (see Section 6-4).
Low weld output with no control. Place Amperage/Voltage Control switch S4 in Panel position or connect remote control to proper
remote receptacle.
Place Mode switch S2 in proper position for weld process (see Section 3-2).
Check resistance and connections of Amperage/Voltage control R3; R3 is 1000 ohms ±10%. Re-
place R3 if necessary.
Maximum weld output with no control. Check resistance and connections of Amperage/Voltage control R3; R3 is 1000 ohms ±10%. Re-
Place Mode switch S2 in proper position for weld process (see Section 3-2). Maximum weld output
would occur if a CC process is attempted with S2 in the GMAW/CV position.

Trouble Remedy
Limited weld output and/or low open- Check incoming power for correct voltage. Replace line fuse if open.
circuit voltage.
Check position of input voltage jumper links (see Section 2-9).
Check for proper input and output connections.
Erratic or improper weld output. Tighten all weld cable connections.
Check for proper size and type of cable.
Check for proper input and output connections.
Replace electrode.
Check resistance and connections of Amperage/Voltage control R3; R3 is 1000 ohms ±10%. Re-
Check resistance and connections of remote amperage/voltage control potentiometer, and replace if
necessary.
Rotate Arc Force (Dig)/Inductance control R2 to proper setting.
Check resistance and connections of Arc Force (Dig)/Inductance control R2; R2 is 1000 ohms
±10%. Replace R2 if necessary.
Remote device for Remote 14 recep- Connect remote control to proper Remote receptacle.
tacle RC2 completely inoperative.
Reset circuit breakers CB1 and/or CB2 (see Section 7-4).
Remote device for Remote 17 recep- Connect remote control to proper Remote receptacle. Be sure pins on remote device are not
tacle RC1 completely inoperative. pushed back into the plug.
Check fuses F3 and/or F4, and replace if necessary (see Section 7-4).
Fan motor FM does not run; weld out- Check and clear blocked fan blade.
put available.
Check fan motor FM, and replace if necessary.
Readings on digital meter not accu- Calibrate digital meter board PC5 (see Section 6-8).
rate.
Wandering arc; poor control of arc di- Reduce gas flow rate.
rection.
Select proper size tungsten.
Properly prepare tungsten.
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.
Properly prepare tungsten.
Check for water in torch, and repair torch if necessary. See torch manual.

6-2. Troubleshooting Circuit Diagram For Welding Power Source
Y Discharge input capacitors according to Section 7-2,
and be sure voltage is near zero before touching any
parts.
See Section 3-9

for TE2
information R5
V6
R2
R1
See Section 3-9 See Section 7-5

for TE1 for PC5 data and
information V1 Section 7-6 for
Contactor meter calibration
V2 W1
V5
See Section 7-9

for PC8 data V3
See Section 3-6

for RC2 data
V4
See Section 3-7

for RC1 data
Test Equipment Needed:
See Section 5
for PC10 information

Resistance Values
a) Tolerance – ±10% unless specified
b) Turn Off unit and disconnect input
power before checking resistance Voltage Readings
R1 and R2 100 ohms

a) Tolerance – ±10%
unless specified
R3 and R4 Less than 2 ohms
b) Reference – to
R5 thru R18 Less than 1 ohm circuit common
(lead 42) unless
noted
R8
c) Wiring Diagram –
R7 see Section 11
R10
V1 230 volts ac
V2 115 volts ac
V3 18 volts ac
V4 18 volts ac
V5 24 volts ac
V6 325 volts dc with
230 volts ac input,
650 volts dc with
460 volts ac input,
812 volts dc with
575 volts ac input
V7 –0.825 volts dc per
R9 100 amperes weld
output
See Section 7-8 V8 –24 volts dc
for PC7 (Optima)
data V9 75 to 80 volts dc
open-circuit
voltage
Effective with Serial No. KD414913,

SR2 and SR3 with capacitors were
removed from unit.
See Section 7-7

for PC7 (MMP)
data
R11 R13 R15 R17
R3
V9, A, B, C, D, E
See Section 7-3
for output waveforms
A, B, C, D, E
R12 R14 R16 R18 R4 V7 V8
SD-167 529

6-3. Waveforms For Section 6-2
5 ms 50 V 20 µs 20 V
gnd gnd
A. DC Open-Circuit Voltage, Mode Switch S2 B. 20.0 Volts DC, 187 Amperes, Mode Switch
In GMAW/CV Position S2 In GMAW/CV Position (Resistive Load)
5 ms 50 V 20 µs 20 V
gnd gnd
C. DC Open-Circuit Voltage, Mode Switch S2 In D. 21.4 Volts DC, 200 Amperes, Mode Switch S2
GTAW/CC Position In GTAW/CC Position (Resistive Load)

5 ms 50 V
gnd
E. DC Open-Circuit Voltage, Mode Switch S2

In SMAW/CC Position

6-4. Control Board PC1 Testing Information (Use With Section 6-5)
Y Discharge input capacitors
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 6-5 for specific
values during testing.
2 1 Control Board PC1
2 Receptacle RC1
3 Receptacle RC2
4 Receptacle RC3
5 Receptacle RC4
6 Receptacle RC5
7 Receptacle RC6
8 Receptacle RC7
9 Receptacle RC8
6 10 Receptacle RC9
10
5
ST-155 791 / Ref. SC-164 972

6-5. Control Board PC1 Test Point Values
a) Tolerance – ±10% unless spe-

cified
PC1 Voltage Readings
b) Reference – to circuit common
(lead 42) unless noted
Receptacle Pin Value
RC1 Make no connections – damage to test equipment or components can occur.
RC2 1 After 4 to 5 seconds of turning Power switch S1 On, 1 to 2 volts ac output
2 Circuit common
3 18 volts ac input
4 24 volts ac input
5 –24 volts dc output
6 18 volts ac input
7 Not used
8 Not used
9 Not used
10 Not used
RC3 1 +24 volts dc output
2 Voltage sensing input from Negative (–) sense jack
3 +15 volts dc output
4 Voltage sensing input from Positive (+) sense jack
5 Circuit common
7 Not used
8 Circuit common
9 Circuit common
10 Circuit common
RC4 Make no connections – damage to test equipment or components can occur.
RC5 1 Circuit common
2 CC/CV select, CV = +15 volts dc input, CC = 0 volts dc input
3 Command input for GTAW/CC mode, 0 to +10 volts dc
4 +15 volts dc input with Output (Contactor) switch S3 in On position, 0 volts dc input with S3 in Off
position
5 +1 volt dc input per 100 amperes of weld output
6 +1 volt dc input per 10 volts of weld output
8 Not used

RC6 1 +1 volt dc output per 100 amperes of weld output
2 +1 volt dc output per 10 volts of weld output
3 Circuit common
4 Circuit common
6 Pulsed command input
7 Same as Positive (+) weld output terminal
8 Same as Negative (–) weld output terminal
9 Pulse reference voltage, 0 to +10 volts dc output
12 +13.6 volts dc input with Amperage/Voltage Control switch S4 in the On position, 0 volts dc input
with S4 in Off position
RC7 1 Input from hall device HD1, –0.825 volts dc per 100 amperes of weld output
2 +24 volts dc input with Mode switch S2 in GMAW/CV position, 0 volts dc input with S2 in SMAW/CC
or GTAW/CC position
3 Arc control, 0 to +10 volts dc input
4 +1 volt dc output per 100 amperes of weld output
6 +1 volt dc output per 10 volts of weld output
7 Remote input, 0 to +10 volts dc
8 Not used
9 Remote output, 0 to +10 volts dc
10 Reference input, 0 to +10 volts dc
11 Same as Positive (+) weld output terminal
12 Same as Negative (–) weld output terminal
13 Not used
14 Not used
15 +24 volts dc input with Mode switch S2 in SMAW/CC position, 0 volts dc input with S2 in GMAW/CV
or GTAW/CC position
RC8 1, 2, 3 Not used
RC9 1 Current transformer CT1 feedback input
2 Current transformer CT1 feedback input
3 Remote contactor input for 115 volts ac
4 Remote contactor input for +24 volts dc
5 Remote contactor input for 24 volts ac
6 +10 volts dc
7 Circuit common
8 Not used

6-6. Digital Meter Board PC5 Testing Information (Use With Section 6-7)

parts.
1 testing. See Section 6-7 for specific
values during testing.
1 Digital Meter Board PC5
2 Receptacle RC50
See Section 6-8

for meter calibration.
ST-155 830 / SA-150 332-A
6-7. Digital Meter Board PC5 Test Point Values

cified
RC50 1 +24 volts dc input
2 Circuit common
3 Not used
4 Current feedback signal, +1 volt dc input per 100 amperes of weld output
5 Command input signal, 0 to +10 volts dc with Mode switch S2 in GTAW/CC position
6 Voltage feedback signal, +1 volt dc input per 10 volts of weld output
7 Input from Mode switch S2, +15 volts dc with S2 in GMAW/CV position, 0 volts dc with S2 in
SMAW/CC or GTAW/CC position
8 Contactor signal, +15 volts dc input with Output (Contactor) switch S3 in On position, 0 volts dc
input with S3 in Off position
9 Not used
10 Not used
11 Not used

6-8. Digital Meter Calibration

calibrating meters.
1 Digital Meter Board PC5
2 Voltmeter
3 Ammeter
4 Access Slot
5 7 8 10 6 9
5 Potentiometer R36
6 Potentiometer R1
7 Potentiometer R6
8 Potentiometer R3
9 Potentiometer R8
10 Potentiometer R4
1
2
Ref. ST-155 830-A / SA-150 332-A

GTAW/CC 1. Set switches 2. Rotate to max 3. Turn On unit
Mode
4. Adjust R36 for voltmeter 5. Adjust R1 for amperage preset

offset or zero
Top View Top View
R36 R1
00.0 565
Volts (±0.5) Amperes (±2)
R36 R6 R3 R4 R1 R8
Top View
6. Adjust R6 for voltage gain R6

to match external cali-
brated meter using load
bank set at desired load
00.0
Volts
GMAW/CV 7. Change top switch 8. Adjust R3 for ammeter offset 9. Adjust R8 for voltage preset
Mode or zero
Top View Top View
R3 R8
000 38.0
Amperes (±2) Volts (±0.5)
R36 R6 R3 R4 R1 R8
Top View
R4
10. Adjust R4 for amperage gain

to match external calibrated 000
meter using load bank set at
desired load Amperes

6-9. Optional MMP Board PC7 Testing Information (Use With Section 6-10)
1 Y Discharge input capacitors
parts.
testing. See Section 6-10 for spe-
cific values during testing.
1 MMP Board PC7
2 Receptacle RC1
3 Receptacle RC2
2 3 Ref. ST-157 330 / SA-155 031
6-10. Optional MMP Board PC7 Test Point Values

cified
RC1 1 0 to +15 volts dc input from Pulse Width control R4
2 Circuit common
5 0 to +15 volts dc input from Pulse Frequency control R1
6 0 to +15 volts dc input from Background Current control R2
7 0 to +15 volts dc input from Peak Current control R3
8 Not used
RC2 1 Not used
2 –24 volts dc input
3 Circuit common
4 +24 volts dc input
5 Not used
6 Pulsed command output to control board PC1
7 Arc voltage feedback, +1 volt dc input per 10 volts of weld output

6-11. Optional Optima Board PC7 Testing Information (Use With Section 6-12)
1 and be sure voltage is near
parts.
1 Optima Board PC7
2 Receptacle RC1
3 Receptacle RC2
4 Receptacle RC3
3 2 4
Ref. ST-157 330 / SB-160 655-B
6-12. Optional Optima Board PC7 Test Point Values

cified
RC1 A Input from Positive (+) weld output receptacle
B Input from Negative (–) weld output receptacle
RC2 A Not used
B Pulse reference, 0 to +10 volts dc input
C Not used
RC3 A Voltage feedback signal, +1 volt dc input per 10 volts of weld output
B Pulse command output to control board PC1
C Current feedback signal, +1 volt dc input per 100 amperes of weld output
D +24 volts dc input
E Circuit common
F –24 volts dc input
G Not used

6-13. Remote 14 Filter Board PC8 Testing Information (Use With Section 6-14)
parts.
1 Remote 14 Filter Board PC8
2 Receptacle RC30
1 3 Receptacle RC31
3 2 4 Receptacle RC32
5 Terminals A, B, C
6 Terminals D, E, F
6 5
Ref. ST-157 330 / SA-142 335-A

6-14. Remote 14 Filter Board PC8 Test Point Values
cified
RC30 1 Not used
2 Not used
3 Not used
4 115 volts ac remote contactor output to control board PC1
5 115 volts ac input from circuit breaker CB1
6 Not used
7 Not used
8 Command voltage output to control board PC1, 0 to +10 volts dc (max.)
9 Command circuit common
10 Remote command input from control board PC1, CV = +10 volts dc input, CC = 0 to +10 volts dc
input
11 Remote contactor output to control board PC1, 24 volts ac output
12 +1 volt dc input per 10 volts of weld output
RC31 1 Not used
2 Command voltage input from Remote 14 receptacle RC2, 0 to +10 volts dc input (max.)
3 Command circuit common
4 Remote command output to Remote 14 receptacle
5 Remote contactor input from Remote 14 receptacle RC2, 24 volts ac input
6 +1 volt dc input per 10 volts of weld output to Remote 14 receptacle RC2
7 Not used
8 Not used
9 Not used
10 Remote contactor input from Remote 14 receptacle RC2, 115 volts ac input
11 115 volts ac output to Remote 14 receptacle RC2
12 Chassis ground
RC32 1 thru 12 Not used
Terminals A Not used
B 24 volts ac input from circuit breaker CB2
C 24 volts ac output to Remote 14 receptacle RC2
D Not used
E Chassis ground
F Circuit common for 24 and 115 volts ac circuits

SECTION 7 – MAINTENANCE
7-1. Routine Maintenance
Y Disconnect power . Maintain more often

before maintaining. during severe conditions.
3 Months
Replace Repair Or
Damaged Or Replace Replace Cracked
Unreadable Cracked Torch Body
Labels Cables
Repair Or Replace
Cracked Cables
And Cords
Clean And
Tighten
Weld
Terminals
6 Months
Blow Out Or
Vacuum Inside

7-2. Measuring Input Capacitor Voltage
Turn Off welding power source,
and disconnect input power.
Remove top cover.
1 Input Rectifier SR1
Significant DC voltage can remain on capacitors after unit is Off. 2 Voltmeter
The input capacitor voltage can be measured across terminals on
input rectifier SR1. Always check the voltage as shown to be sure Measure the dc voltage across the
the input capacitors have discharged before working on unit. positive (+) and negative (–) termi-
nals until voltage drops to near 0
(zero) volts.
Proceed with job inside unit. Rein-
stall top cover when finished.
2 1
Tools Needed:
3/8 in
ST-150 222-F / ST-150 173-C
7-3. Optional Ground Current Sensor

1 Reed Relay (Ground Current
Sensor – Optional)
Defects in external electrical cir-
cuitry may cause the ground wire
to conduct welding current. Relays
CR1 and CR2 sense excessive
current in the ground conductor
and open the solid state contactor,
shutting down weld output.
Open circuit voltage is not avail-
able, but the fan motor FM runs
and the pilot light PL1 stays on. If
the welding power source shuts
down due to the ground current
sensor, disconnect all power, and
correct the problem before welding
again.
ST-156 172-D

7-4. Circuit Breakers And Fuses
ceeding.
1 Circuit Breaker CB1
If CB1 opens, remote devices us-
ing 115 volts from Remote 14 re-
ceptacle stop. Manually reset CB1.
5 2 Circuit Breaker CB2

If CB2 opens, remote devices us-
6 4 ing 24 volts from Remote 14 recep-
tacle stop. Manually reset CB2.
3 Circuit Breaker CB3
If CB3 opens, devices connected
to the 115 volt duplex receptacle
and remote devices using 115 volts
from Remote 14 receptacle stop.
Manually reset CB3.
4 Fuse F1
If F1 opens, the welding power
source shuts down.
5 Fuse F3
6 Fuse F4
If F3 or F4 opens, remote control
devices connected to Remote 17
receptacle RC1 may shut down.
See Parts List for fuse ratings. Use
proper tool when removing fuses.
1 2 3
Tools Needed:
3/8 in
ST-150 222-F / Ref. ST-152 069-C / ST-150 173-C

SECTION 8 – ELECTRICAL DIAGRAMS
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact factory for actual circuit, if needed.
The following is a list of all diagrams for models covered by this manual. To order a copy, proceed as follows:
1 Know unit Model and Serial or Style Number.
2 Use this list to find diagram number.
3 Include your FAX number or mailing address with your request.
4 FAX Technical Publications Department at 414-735-4011 or call 414-735-4356.
Model Serial Or Style Number Circuit Diagram Wiring Diagram

Maxtron 450 (230/460) KC237305 thru KD342941 SD-142 760-H D-143 318-G♦♦
KD342942 thru KD375311 SD-158 709-B D-158 710-A♦♦
KD375312 thru KD414912 SD-159 815-B D-159 814♦♦
KD414913 thru KD433774 SD-160 564-A D-160 565♦♦
KD433775 thru KD485760 SD-164 041 D-160 042♦♦
KD485761 thru KD523654 SD-164 676 D-164 677♦♦
KD523655 thru KE575507 SD-165 760 D-165 761♦♦
KE575508 and following SD-167 529-A SD-167 531
Maxtron 450 (460/575) KC237305 thru KD485760 SD-157 431-B D-157 756-B♦♦
KD485761 thru KD523654 SD-164 680 D-164 681♦♦
KD523655 thru KE575507 SD-165 762 D-165 763♦♦
KE575508 and following SD-167 530-A SD-167 532
Circuit Board PC1 (230/460) KC237305 thru KC301173 D-151 898-B♦♦

KC301174 thru KD350777 D-157 294♦♦
KD350778 thru KE557396 D-159 073♦♦
Circuit Board PC1 (460/575) KC237305 thru KE557396 D-161 113♦♦
Circuit Board PC1 (All) KE557397 thru KF844514 D-164 974♦♦

KF844515 thru KG033270 D-170 847♦♦
KG033271 thru KG111782 D-175 759♦♦
KG111783 and follwing SD-180 871-A
Circuit Board PC5 KC237305 and following SC-150 334-A
Circuit Board PC7 KC237305 thru KC260557 C-150 422♦♦

(Remote Pendant)♦
KC260558 and following SC-155 033
Circuit Board PC7 KC237305 and following SD-160 657

(Pulse Control)♦
Circuit Board PC8 KC237305 and following SB-142 337
Circuit Board PC10 KC237305 and following SA-124 988-B
♦ Optional
♦♦ Not included in this manual

Figure 8-1. Circuit Diagram For Maxtron 450 (230/460 Volts) Effective With
Serial No. KC237305 Thru KD342941
SD-142 760-H

Serial No. KD342942 Thru KD375311
SD-158 709-B

SD-159 815-B

SD-160 564-A

SD-164 041

SD-164 676

Serial No. KD523655 Thru KE575507
SD-165 760

Serial No. KE575508 And Following
SD-167 529-A

Figure 8-9. Wiring Diagram For Maxtron 450 (230/460 Volts) Effective With
SD-167 531

Serial No. KC237305 Thru KD485760
SD-157 431-B

SD-164 680

Serial No. KD523655 Thru KE575507
SD-165 762

SD-167 530-A

Figure 8-14. Wiring Diagram For Maxtron 450 (460/575 Volts) Effective With
SD-167 532

Figure 8-15. Circuit Diagram For Control Board PC1 Effective With
Serial No. KG111783 And Following (Part 1 Of 2)
SD-180 871-A (1 Of 2)

Figure 8-16. Circuit Diagram For Control Board PC1 Effective With
Serial No. KG111783 And Following (Part 2 Of 2)
SD-180 871-A (1 Of 2)

SC-150 334-A
Figure 8-17. Circuit Diagram For Digital Meter Board PC5 Effective With Serial No. KC237305 And Following

SC-155 033
Figure 8-18. Circuit Diagram For Optional MMP Board PC7 Effective With Serial No. KC260558 And Following
Figure 8-19. Circuit Diagram For Optional Optima Board PC7 Effective With
Serial No. KC237305 And Following
SD-160 657

SB-142 337
Figure 8-20. Circuit Diagram For Remote 14 Filter Board PC8 Effective With
SA-124 988-B
Figure 8-21. Circuit Diagram For Remote 17 Filter Board PC10 Effective With

February 1997 Form: TM-2206
Effective With Serial No. KC237305
SECTION 9 – PARTS LIST
Maxtron 450
CC/CV DC Welding Power Source For
GMAW, GTAW, SMAW, FCAW, CAC-A, GMAW-P, GTAW-P, And SAW Welding

25 11
1
23
22
TM-2206 Page 80
21
24
Fig 9-5
21
2
28
Fig 9-4
20 27
26
14
15
3 4 5 6
19
16
41 7
13
8 18
17
40 9 12
10
39
11
29
Figure 9-1. Main Assembly

4
7
30
31
6
5
8
32
35
38 36 Fig 9-3
33
37
Fig 9-2
9 34
ST-150 054-H
Maxtron 450
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 9-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . . 152 346
. . COVER, top w/insulation (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 155 653
. . . . INSULATOR, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . +147 962
. . PANEL, side RH w/insulator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 155 652
. . . . INSULATOR, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . C50,51 . . . . 164 812 . . CAPACITOR, (Eff w/KD523655) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . . . 155 642
. . SCREW, set .250-28 x 1.000 cup pt sch stl (Eff w/KC295487) . . . . . . . 16
. . . 5 . . . . . . . . . . . . . . . . 143 748
. . BUS BAR, (across front of C8,9,18,19 & C10-13) . . . . . . . . . . . . . . . . . . 4
. . . 6 . . . . . . . . . . . . . . . . 145 245
. . INSULATOR, elctlt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 7 . . . . . . . . . . . . . . . . 143 749
. . BUS BAR, (across back of C8,9,18,19 & C10-13) . . . . . . . . . . . . . . . . . . 2
. . . 8 . . C8-13,18,19 . . 135 786 . . CAPACITOR, elctlt 4000uf 250VDC (230/460V) . . . . . . . . . . . . . . . . . . . . 8
. . . 8 . . C8-13,18,19 . . 140 891 . . CAPACITOR, elctlt 2800uf 300VDC (460/575V) . . . . . . . . . . . . . . . . . . . . 8
. . . 9 . . . . . . . . . . . . . . . . 148 556
. . BRACKET, mtg capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . . . 148 553
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 11 . . . . . . . . . . . . . . . . 126 026
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . . 145 743
. . LUG, univ w/scr 600V 2-14 wire .250 stud . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . TE2 . . . . . 147 386 . . BLOCK, term 70A 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . TE1 . . . . . 148 446 . . TERMINAL ASSEMBLY, pri (230/460V) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . TE1 . . . . . 157 322 . . TERMINAL ASSEMBLY, pri (460/575V) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . . 147 899
. . BRACKET, mtg term block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . Z1 . . . . . . 144 050 . . STABILIZER, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . Z2 . . . . . . 147 901 . . STABILIZER, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . T1 . . . . . . 144 274 . . TRANSFORMER, HF (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . T1 . . . . . . 157 501 . . TRANSFORMER, HF (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . . 143 731
. . LIFT EYE, upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . . 604 126
. . SCREW, cap stl hexhd .500-13 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . 153 178
. . LABEL, warning exploding parts can seriously injure . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . . . 144 929
. . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . . 143 732
. . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . . 088 058
. . NUT, .500-13 stl elastic stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . +143 746
. . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . . 145 053
. . WASHER, shldr nyl .298 OD x .203 ID x 1.000 . . . . . . . . . . . . . . . . . . . . . 12
. . . 27 . . . . . . . . . . . . . . . . . Fig 9-4
. . CHASSIS, mid upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . . . Fig 9-5
. . FAN MOTOR/MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG18 . . . . 131 054 . . CONNECTOR & SOCKETS, (part of FM) (consisting of) . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 746
. . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . . 2
. . . . . . . . . . . RC18 . . . . . 135 635. . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 114 656
. . . . CONNECTOR, rect pin 24-18ga Molex 39-00-0040 . . . . . . . . . . . . . . . 2
. . . 29 . . . . . . . . . . . . . . . . 605 603
. . TUBING, gl acryl 1.000-1.036 ID (order by ft) . . . . . . . . . . . . . . . . . . . . . . 3ft
. . . 30 . . . . . . . . . . . . . . . . 143 741
. . SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 31 . . . . . . . . . . . . . . . . 070 592
. . TUBING, gl acryl .500-.524 ID (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . 3ft
. . . 32 . . . . . . . . . . . . . . . . . Fig 9-3
. . CHASSIS, mid lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . . 154 066
. . INSULATOR, capacitor (Eff w/KC234210) . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 34 . . . . . . . . . . . . . . . . 605 538
. . CABLE TIE, 0-4.500 bundle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . C31-38 . . . . 139 849 . . CAPACITOR ASSEMBLY, (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 152 077
. . HEAT SINK, spillover (Prior to KD350778) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 159 257
. . HEAT SINK, spillover (Eff w/KD350778 thru KD414913) . . . . . . . . . . . . 2
. . . . . . . . . . SR2,3 . . . . . 149 219 . . KIT, rectifier integ 35A (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . . . +143 745
. . BASE, (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . +157 427
. . BASE, (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . . 145 477
. . STIFFENER, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . . T2 . . . . . . 148 448 . . TRANSFORMER, control (Prior to KC260558) . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . T2 . . . . . . 154 852 . . TRANSFORMER, control (Eff w/KC260558 thru KD375312) . . . . . . . . . 1
. . . 37 . . . . . . T2 . . . ♦♦154 083 . . TRANSFORMER, kVA 1.5 115-230/230-18/18-24 (230/460V)
(Eff w/KD375312 thru KE575507) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . T2 . . . . . . 167 521 . . TRANSFORMER, kVA 1.5 115/230/230-18-18-24 (230/460V)
(Eff w/KE575508 and on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . T2 . . . . . . 160 978 . . TRANSFORMER, kVA 1.5 115-230/460/575-18/18-24 (460/575V)
(Prior to KE575508) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . T2 . . . . . . 167 522 . . TRANSFORMER, kVA 1.5 115-230/460/575-18/18-24 (460/575V)
(Eff w/KE575508) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 9-1. Main Assembly (Continued)
. . . . . . . . . . PLG21 . . . . 168 165 . . CONNECTOR & SOCKETS, (Eff w/KE575508) (consisting of) . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 114 066 . . . . CONNECTOR, rect skt 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . RC21 . . . . . 130 204 . . CONNECTOR & PINS, (Eff w/KE575508) (consisting of) . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 113 633 . . . . CONNECTOR, rect pin 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 38 . . . . . . . . . . . . . . . . . Fig 9-2 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC11,15 . . . 116 045 . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 113 633 . . . . CONNECTOR, rect pin 20-14ga Amp 350218-1 . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . PLG11,15 . . . 135 556 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 114 066 . . . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . . . . . . 6
. . . 39 . . . . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 40 . . . . . . . . . . . . . . . +147 961 . . PANEL, side LH w/insulator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . . 155 651 . . . . INSULATOR, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 134 756 . . LABEL, warning electric shock can kill (on LH panel) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . CR2 . . . ♦155 757 . . SWITCH, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 010 014 . . CLAMP, stl cush .750dia x .203mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . 010 143 . . CLAMP, nyl .375clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Part of 042 779 (230/460V) and 042 961 (460/575V) Ground Current Sensor Option.
♦♦Eff w/KD375312 these components became standard.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
1 7
2 6
3
4
5 8
17
10
39
48 11
12
47
13 16
46 14
43 15 18
19
42
20
45
44 22 21
23
31 24
25 26
30
27
28
43 29
42 30
41
32
37 33
34
35
31
36
40 39 38
ST-150 167-F
Figure 9-2. Panel, Front w/Components

Item Dia. Part
Figure 9-2. Panel, Front w/Components (Fig 9-1 Item 38)
. . . 1 . . . . . . . . . . . . . . 146 684 . . . INSULATOR, switch pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . S1 . . . . . . 128 756 . . . SWITCH, tgl 3PST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 148 297 . . . NUT, speed U type 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . 071 230 . . . BEZEL/FILTER, blk bezel/red filter 2.000 viewing . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . 135 299 . . . LOCK, shaft pot .375-32 x .250dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . PC5 . . . . . 150 331 . . . CIRCUIT CARD, amp/volt meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG50 . . . . 089 222 . . . CONNECTOR, rect 11skt plug Amp 1-640440-1 . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 153 374 . . . ENCLOSURE, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 134 201 . . . STAND-OFF SUPPORT, PC card .312/.375 . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . . . . . . . . . . . . 604 311 . . . GROMMET, rbr .250 ID x .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . R3 . . . . . 030 856 . . . POTENTIOMETER, WW sltd sft 10/T 2W 1K ohm . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . R2 . . . . . 035 897 . . . POTENTIOMETER, C sltd sft 1/T 2W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . . . . S2 . . . . . . 088 409 . . . SWITCH, tgl DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . S4 . . . . . . 128 808 . . . SWITCH, tgl SPTT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . S3 . . . . . . 011 609 . . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 15 . . . . . S5 . . . . . . 011 611 . . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . R1-4 . . . ♦073 562 . . . POTENTIOMETER, C sltd sft 1/T 2W 10K ohm . . . . . . . . . . . . . . . . . . . . . . . 4
. . 17 . . . . . . . . . . . . ♦141 690 . . . GROMMET, scr No. 8/10 panel hole .281sq .197 high . . . . . . . . . . . . . . . . . 4
. . 17 . . . . . . . . . . . ♦♦153 994 . . . GROMMET, scr No. 8/10 panel hole .281sq .547 high . . . . . . . . . . . . . . . . . 4
. . 18 . . . . . . . . . . . . +153 260 . . . ENCLOSURE, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . . . . . . . . ♦157 453 . . . INSULATOR, PC card (Eff w/KC299794) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . PC7 . . . ♦155 030 . . . CIRCUIT CARD, remote pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . PC7 . . ♦♦162 076 . . . CIRCUIT CARD, pulse control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG1 . . ♦115 092 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113 746 . . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . PLG2 . . +135 558 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 079 747 . . . . . CONNECTOR, rect skt 24-18ga Amp 350980-1 . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . PLG3 . . +079 796 . . . CONNECTOR, rect 3skt plug Amp 640250-3 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . +079 747 . . . CONNECTOR, rect skt 24-18ga Amp 350980-1 . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . PLG4 . . +135 557 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 079 747 . . . . . CONNECTOR, rect skt 24-18ga Amp 350980-1 . . . . . . . . . . . . . . . . . . . . . 2
. . 21 . . . . . S6 . . . . . +011 609 . . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 117 860 . . . BLANK, snap-in nyl .187mtg hole (not used when unit has either option) . 4
. . 22 . . . . RC2 . . . . . 143 976 . . . CONNECTOR w/SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 079 534 . . . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . 134 734 . . . CONNECTOR, circ 14 pin plug Amp 213571-2
. . . . . . . . . . . . . . . . . . . . 134 731 . . . CONNECTOR, circ pin push-in 14-18ga Amp 213603-1
. . . . . . . . . . . . . . . . . . . . 079 739 . . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 (or)
. . . . . . . . . . . . . . . . . . . . 143 922 . . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3
. . 23 . . . . CB1 . . . . . 089 807 . . . CIRCUIT BREAKER, man reset 1P 2.5A 250V . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . CB2 . . . . . 083 432 . . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 25 . . . . CB3 ♦♦♦083 432 . . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 057 359 . . . BLANK, snap-in nyl .375mtg hole (Prior to KD375312) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148 715 . . . STRIP, mtg circuit breakers (Prior to KD375312) . . . . . . . . . . . . . . . . . . . . . . 1
. . 26 . . . . R17 . . . . . 030 945 . . . RESISTOR, C 2W 4.7K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 27 . . . . R5 . . . . . 028 271 . . . RESISTOR, C .5W 100K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . . C39 . . . . . 074 200 . . . CAPACITOR, polye film .047uf 400VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . PC10,RC1 . . 137 542 . . . CIRCUIT CARD, connector 17skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 097 866 . . . CONNECTOR, circ 17 pin plug Amphenol MS-3106A-20-29P
. . . . . . . . . . . . . . . . . . . . 073 296 . . . CONNECTOR, circ clamp str rlf sz 20-22 Amphenol 97-3057-12-6
. . 30 . . . . C6,7 . . . . . 138 115 . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 31 . . . . Neg . . . . . 039 046 . . . TERMINAL, pwr output black (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 31 . . . . Pos . . . . . 039 047 . . . TERMINAL, pwr output red (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . . . . . . . . . . . . . 601 976 . . . . . SCREW, cap stl hexhd .500-13 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . . . . . . . . . . . 039 045 . . . . . TERMINAL BOARD, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 33 . . . . . . . . . . . . . . 039 049 . . . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 34 . . . . . . . . . . . . . . 601 880 . . . . . NUT, stl hex jam .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 . . . . . . . . . . . . . . 039 044 . . . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 36 . . . . . . . . . . . . . . 601 879 . . . . . NUT, stl hex full .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 37 . . . . . . . . . . . . . . 143 747 . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Item Dia. Part
Figure 9-2. Panel, Front w/Components (Fig 9-1 Item 38) (Continued)
. . 38 . . . RC10 ♦♦♦147 939 . . . RECEPTACLE, str dx grd 2P3W 15A 125V GFCI . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 073 690 . . . PLUG, str grd armd 2P3W 15A 125V P & S 5266DF
. . . . . . . . . PLG20 . . . . 168 165 . . . CONNECTOR & SOCKETS, (Eff w/KE575508) (consisting of) . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 114 066 . . . . . CONNECTOR, rect skt 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . RC20 . . . . 130 204 . . . CONNECTOR & PINS, (Eff w/KE575508) (consisting of) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113 633 . . . . . CONNECTOR, rect pin 20-14ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 39 . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . 1
. . 40 . . . . . . . . . ♦♦♦154 022 . . . COVER, receptacle duplex GFCI weather proof . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . . . 039 885 . . . CONNECTOR, circ protective cap Amphenol 9760-20 . . . . . . . . . . . . . . . . . 2
. . 42 . . . . . . . . . . . . . . 039 654 . . . POST, bdg black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 43 . . . . . . . . . . . . . . 039 655 . . . POST, bdg red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 44 . . . . . . . . . . . . ♦097 922 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 44 . . . . . . . . . . . ♦♦097 922 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 45 . . . . . . . . . . . . . . . . . . . . + . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . 1
. . 46 . . . . . . . . . . . . . . 097 922 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 47 . . . . . . . . . . . . . . 143 797 . . . SPACER, nyl .312 OD x .194 ID x .437 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 48 . . . . PC8 . . . . . 167 679 . . . CIRCUIT CARD, receptacle bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG30,31 . . 130 203 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 113 746 . . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . . . . . 12
♦Part of 042 741 (230/460V) MMP Panel Option.
♦♦Part of 042 635 (230/460V) Optima 450 Panel Option.
♦♦♦Eff w/KD375312 these components became standard
+Part of 042 741 (230/460V) MMP Panel Option and 042 635 (230/460V) Optima 450 Panel Option.
Item Dia. Part

Figure 9-3. Chassis, Mid Lower (Fig 9-1 Item 32)
... 1 .............. 153 403 . . . BUSHING, snap-in nyl .750 ID x 1.000mtg hole . . . . . . . . . . . . . . . . . . . . . . 3
... 2 .............. 153 380 . . . BAFFLE, air (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 2 .............. 157 425 . . . BAFFLE, air (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 .............. 145 265 . . . MODULE, pwr LH (230/460V) (Prior to KD414913) (consisting of) . . . . . . 1
... 3 .............. 160 765 . . . MODULE, pwr LH (230/460V) (Eff w/KD414913) (consisting of) . . . . . . . . 1
... 3 .............. 157 571 . . . MODULE, pwr LH (460/575V) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 145 266 . . . MODULE, pwr LH (230/460V) (Prior to KD414913) (consisting of) . . . . . . 1
... 4 .............. 160 766 . . . MODULE, pwr RH (230/460V) (Eff w/KD414913) (consisting of) . . . . . . . 1
... 4 .............. 157 572 . . . MODULE, pwr RH (460/575V) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . C22-29,
40-47 . . . 031 689 . . . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . CM1,2 . . . 157 497 . . . . . MODULE, capacitor (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . D1-16 . . . 149 209 . . . . . KIT, diode fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . PM1,2 . . . 149 238 . . . . . KIT, transistor IGBT module (230/460V) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PM1,2 . . . 157 566 . . . . . KIT, transistor IGBT module (460/575V) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . TP1,2 . . . 006 334 . . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 072 253 . . . . . STUD, connection single 10-32 x .500 x 1.250 . . . . . . . . . . . . . . . . . . . . . 8
.................... 143 722 . . . . . HEAT SINK, pwr module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 .............. 142 592 . . . BAR, support heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 6 .............. 135 661 . . . EDGE TRIM, style 3100-1/16 (order by ft) (Eff w/KD414913) . . . . . . . . . . 2ft
... 7 .............. 047 838 . . . BLANK, snap-in nyl 1.000mtg hole (Eff w/KD414913) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . R9-12 . . . 149 729 . . . RESISTOR, WW fxd 40W 25 ohm (Prior to KD414913) . . . . . . . . . . . . . . . 4
.................... 143 797 . . . SPACER, nyl .312 OD x .194 ID x .437 lg (Prior to KD414913) . . . . . . . . . 3
... 8 .............. 143 738 . . . TRAY, mtg cmpts lower (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .............. 157 426 . . . TRAY, mtg cmpts lower (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 .............. 057 357 . . . BUSHING, snap-in nyl .937 ID x 1.125mtg hole (Prior to KD523655) As Req’d
... 9 .............. 057 358 . . . BUSHING, snap-in nyl 1.000 ID x 1.375mtg hole (Eff w/KD523655) As Req’d
Item Dia. Part
Figure 9-3. Chassis, Mid Lower (Fig 9-1 Item 32) (Continued)
. . . 10 . . . R13-16 . . . 147 902 . . . RESISTOR, WW fxd 30W 2500 ohm (230/460V) . . . . . . . . . . . . . . . . . . . . . 4

. . . 10 . . . R13-16 . . . 139 812 . . . RESISTOR, WW fxd 30W 5K ohm (460/575V) . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . CM1,2 . . . 151 198 . . . MODULE, capacitor 2 polye MF .0047uf 1000V (Prior to KD414913) . . . 2
. . . 11 . . . RM1,2 . . . 153 336 . . . MODULE, resistor 2 2W 100K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . C1-4 . . . . 143 359 . . . CAPACITOR, polyp film .6uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 13 . . . . . . . . . . . . . . 145 162 . . . STRIP, comb mrm .007 x 3.000 x 7.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 14 . . . . . . . . . . . . . . 006 426 . . . CLAMP, capacitor 2.000dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 15 . . . . . . . . . . . . . . 133 405 . . . NUT, speed 10-24 flat rectangular (Prior to KD523655) . . . . . . . . . . . . . . . 4
. . . 15 . . . . . . . . . . . . . . 148 297 . . . NUT, 10-32 push-on stl (Eff w/KD523655) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 16 . . . . L1-4 . . . . 144 325 . . . CHOKE, DVDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . CT1 . . . . 140 328 . . . COIL, current transformer 500/1 (Prior to KD414913) . . . . . . . . . . . . . . . . . 1
.................... 122 681 . . . INSULATOR, coil (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 097 863 . . . CORE, ferrite E (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.................... 097 865 . . . BOLT, U brs 6-32 x 1.925 wide x 2.250 deep (Prior to KD414913) . . . . . . 1
1 2
5
1
7
8
10
11
12
16
13
14
15 ST-150 170-D
Figure 9-3. Chassis, Mid Lower
9
8 12
11
10
6
7
13
5
4 14
3
2 15
1
16
25
24 17
23
19
22
18
21
20
ST-150 169-H
Figure 9-4. Chassis, Mid Upper

Item Dia. Part
Figure 9-4. Chassis, Mid Upper (Fig 9-1 Item 27)
. . . 1 . . . . HD1 . . . . 156 313 . . . TRANSDUCER, current 300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . PLG62 . . . 130 204 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 114 066 . . . . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . . . . . . . . 3
. . . 2 . . . . . C30 . . . . 158 707 . . . LEAD ASSEMBLY, elect (Eff w/KD342492 thru KE575507) . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . 134 058 . . . STAND-OFF SUPPORT, PC card .156dia . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . 098 376 . . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . F3,4 . . . *012 643 . . . FUSE, mintr gl slo-blo 1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . VCRM1 . . . 153 289 . . . MODULE, capacitor/varistor/resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . CT1 . ++157 568 . . . TRANSFORMER, current (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . W1 . . . . . 132 889 . . . CONTACTOR, def prp 40A 3P 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . 170 626 . . . BRACKET, mtg contactor (Eff w/KE678979) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 057 358 . . . BUSHING, snap-in nyl 1.000 ID x 1.375mtg hole . . . . . . . . . . . . . . . . . As Req’d
. . . 11 . . . . . . . . . . . . . . 057 357 . . . BUSHING, snap-in nyl .937 ID x 1.125mtg hole . . . . . . . . . . . . . . . . . . As Req’d
. . . 12 . . . . . PC1 . . . . 180 868 . . . CIRCUIT CARD, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG1,3-5,9 . 148 439 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . PLG2 . . . 153 501 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . ♦158 720 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG7 . . . 152 249 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . 083 147 . . . GROMMET, scr No. 8/10 panel hole .312sq .500 high . . . . . . . . . . . . As Req’d
. . . 14 . . . PLG19 . . . 131 054 . . . CONNECTOR & SOCKETS, (part of CT1) (consisting of) . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113 746 . . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . RC19 . . . 135 635 . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 114 656 . . . . . CONNECTOR, rect pin 24-18ga Molex 39-00-0040 . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . . . . . . . . . +143 737 . . . TRAY, mtg cmpts upper (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . +157 549 . . . TRAY, mtg cmpts upper (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 142 592 . . . BAR, support heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . VCM1 . . . 151 199 . . . MODULE, varistor/capacitor 3 220 joule 730VDC (230/460V)
(Prior to KD523655) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . VCM1 . . . 162 097 . . . MODULE, varistor/capacitor 3 400 joule 1620-1980VDC (460/575V)
(Prior to KD523655) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . VCM1 . . . 164 849 . . . MODULE, varistor/capacitor 4 400 joule (Eff w/KD523655) . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 126 026 . . . LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . R1,19 . **141 424 . . . RESISTOR, WW fxd 30W 25 ohm (230/460V) . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . R1,19 . . . 136 076 . . . RESISTOR, WW fxd 30W 200 ohm (460/575V) . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . . . 095 847 . . . HOLDER, fuse crtg 30A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . F1 . . . . *099 398 . . . FUSE, crtg 3A 500V time delay (230/460V) (Prior to KD375312) . . . . . . . 1
. . . 22 . . . . . F1 . . . . *148 524 . . . FUSE, crtg 9A 500V time delay (230/460V) (Eff w/KD375312) . . . . . . . . . 1
. . . 22 . . . . . F1 . . . . *162 312 . . . FUSE, crtg 5A 600V time delay (460/575V) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . 143 723 . . . HEAT SINK, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . SR1 . . . . 141 317 . . . RECTIFIER, integ 110A 1600V 3ph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 099 037 . . . EDGE TRIM, style 62-1/16 (order by ft)
(Eff w/KD414913 thru KE613733) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1ft
. . . 25 . . . . . . . . . . . . . . 148 001 . . . EDGE TRIM, style 62-3/32 (order by ft) (Eff w/KE613734 and on) . . . . . . 1ft
. . . . . . . . . . CR1 . ♦♦110 386 . . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
♦Part of 042 741 (230/460V) MMP Panel Option and 042 635 (230/460V) Optima 450 Panel Option.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦♦Part of 042 779 (230/460V) and 042 961 (460/575V) Ground Current Sensor Option.
++Prior to KD414913 located on Chassis, Mid lower.
**Note: When replacing resistor, make sure both resistors are of the same value.

Item Dia. Part
Figure 9-5. Fan Motor/Mounting Bracket (Fig 9-1 Item 28)
... 1 . . . . R9-12 . . . 157 297 . . . RESISTOR, WW fxd 55W 25 ohm (Eff w/KD414913) . . . . . . . . . . . . . . . . . 4
... 2 .............. 143 797 . . . SPACER, nylon .312 OD x .194 ID x .437 lg (Eff w/KD414913) . . . . . . . . . 4
... 3 .............. 143 730 . . . INLET, fan (Prior to KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 .............. 157 429 . . . INLET, fan (Eff w/KD414913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 .............. 135 661 . . . EDGE TRIM, style 3100-1/16 (order by ft) (Eff w/KD414913) . . . . . . . . . . 2ft
... 5 .............. 107 983 . . . BLANK, snap-in nyl .500mtg hole (Eff w/KD523655) . . . . . . . . . . . . . . . . . . 1
... 6 .............. 153 219 . . . BLADE, fan 7.600 in 5wg 24deg .312 bore CCW . . . . . . . . . . . . . . . . . . . . . 1
... 7 .............. 143 729 . . . BRACKET, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . FM . . . . . 153 280 . . . MOTOR, fan 230V 3000RPM .312dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4
5
3
2
1
8 7 ST-150 168-C
Figure 9-5. Fan Motor/Mounting Bracket

Maxtron 450 KC237305

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February 1997 Form: TM-2206

Effective With Serial No. KC237305

Maximum Amperes Input At Rated Load

SECTION 1 – SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 5 – PRE-POWER CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

WHO DO I CONTACT FOR HELP?

Always provide Model Name and Serial or Style Number

SECTION 9 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1-1. Symbol Usage

1-2. Servicing Hazards

STATIC ELECTRICITY can damage parts HIGH-FREQUENCY RADIATION can

Maxtron 450 TM-2206 Page 1

1-3. EMF Information

TM-2206 Page 2 Maxtron 450

2-1. Selecting A Location

ST-800 611 / ST-150 171-C

2-2. Dimensions And Weights

Height 23 in (584 mm)

Depth 26-1/8 in (664 mm)

A 24-1/16 in (611 mm)

C 12-3/8 in (314 mm)

D 9/32 in (7 mm) Dia

165 lbs (75 kg)

Maxtron 450 TM-2206 Page 3

Total Cable (Copper) Length In Weld Circuit Not Exceeding

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

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

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

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

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

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

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0

800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0

2-4. Voltage Sensing Terminal Connections

5 For Electrode Positive (DCEP),

Ref. ST-152 069-C / Ref. ST-152 885-A

TM-2206 Page 4 Maxtron 450

Socket* Socket Information

A 24 volts ac. Protected by circuit breaker CB2.

C Output to remote control; +10 volts dc in CV, 0 to

A/V F Current feedback; +1 volt dc per 100 amperes.

G Circuit common for 24 and 115 volts ac circuits.

*The remaining sockets are not used.

Maxtron 450 TM-2206 Page 5

REMOTE 17 Socket* Socket Information

D Contactor on/off signal; +13 to +24 volts dc con-

A +10 volts dc output to remote control.

A B 0 to +10 volts dc input command signal from re-

L –24 volts dc; fused at 1 ampere.

E Current feedback; +1 volt dc per 100 amperes.

C CV/CC select; +13 to +24 volts dc selects CV, 0

G Arc force (dig)/inductance control; 0 to +10 volts

F Circuit common for sockets A, B, D, E, K, and M.

GND P Circuit common for sockets H and L.

*The remaining sockets are not used.

2-7. 115 Volt AC Duplex Receptacle

Ref. ST-153 999

TM-2206 Page 6 Maxtron 450

Input Voltage 230 460 575 230 460 575

Input Amperes At Rated Output 72 36 29 89.6 47.2 37.7

Max Recommended Standard Fuse Or Circuit

Max Recommended Input Conductor Length