Miller PULSET CONTROL Owner's manual

cover 8/92 − ST-111 669-A PRINTED IN USA

Read and follow these instructions and all

safety blocks carefully.

Have only trained and qualified persons

install, operate, or service this unit.

Call your distributor if you do not understand

the directions.

Give this manual to the operator.

For help, call your distributor

or: MILLER ELECTRIC Mfg. Co., P.O. Box

1079, Appleton, WI 54912 414-734-9821

OWNER’S

MANUAL

June 1993 Form: OM-537A

Effective With Serial No. JJ-8

PULSET™ Control

OM-537A - 6/93

TABLE OF CONTENTS

SECTION 1 − INTRODUCTION

1-1. General Information And Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Receiving-Handling 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Description 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − INSTALLATION

2-1. Installation Of Pulset Control 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. 115 Volts AC Connection To Wire Feeder 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Remote Control Connection To Wire Feeder 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. 115 VAC/Contactor Connection To Pulstar 450 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Remote Output Control Connection 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − OPERATION CONTROLS

3-1. Wire Selector Control 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Volts/Arc Power Control 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Arc Length Control 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Arc Power Start Control 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Time(s) Control 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − SEQUENCE OF OPERATION

4-1. Gas Metal Arc Welding-Nonpulsed Arc (GMAW), Flux Cored Arc Welding-Nonpulsed Arc

(FCAW), And Gas Metal Arc Welding-Pulsed Arc (GMAW-P) 5. . . . . . . . . . . . . . . . . . . . . . . .

4-2. Shutting Down 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − MAINTENANCE & TROUBLESHOOTING

5-1. Inspection And Upkeep 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Overload Protection 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Circuit Board Testing 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Circuit Board PC1 Replacement 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Start Module Circuit Board PC4 Replacement 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − ELECTRICAL DIAGRAMS

Diagram 6-1. Circuit Diagram For PULSET 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 6-2. PULSET Wiring Diagram 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − PARTS LIST

Figure 7-1. Main Assembly 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF CHARTS AND TABLES

Table 5-1. Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-537 Page 1

SECTION 1 − INTRODUCTION

Weight

Net Ship

8-1/4 lbs.

(3.7 kg)

12-1/2 in.

(5.7 kg)

ST-111 669-A

10-1/4 in.

(260.4 mm)

11-1/2 in.

(292.1 mm)

4 in.

(101.6 mm)

Figure 1-1. Dimensions

1-1. GENERAL INFORMATION AND SAFETY

A. General

Information presented in this manual and on various la-

bels, tags, and plates on the unit pertains to equipment

design, installation, operation, maintenance, and trou-

bleshooting which should be read, understood, and fol-

lowed for the safe and effective use of this equipment.

B. Safety

The installation, operation, maintenance, and trouble-

shooting of arc welding equipment requires practices

and procedures which ensure personal safety and the

safety of others. Therefore, this equipment is to be in-

stalled, operated, and maintained only be qualified per-

sons in accordance with this manual and all applicable

codes such as, but not limited to, those listed in the Arc

Welding Safety Precautions in the welding power

source Owner’s Manual.

Safety instructions specifically pertaining to this unit ap-

pear throughout this manual highlighted by the signal

words WARNING and CAUTION which identify differ-

ent levels of hazard.

WARNING statements include installation, operation,

and maintenance procedures or practices which if not

carefully followed could result in serious personal injury

or loss of life.

CAUTION statements include installation, operation,

and maintenance procedures or practices which if not

carefully followed could result in minor personal injury or

damage to this equipment.

A third signal word, IMPORTANT, highlights instructions

which need special emphasis to obtain the most efficient

operation of this equipment.

1-2. RECEIVING-HANDLING

Before installing this equipment, clean all packing mate-

rial from around the unit, and carefully inspect for any

damage that may have occurred during shipment. Any

claims for loss or damage that may have occurred in

transit must be filed by the purchaser with the carrier.

A copy of the bill of lading will be furnished by the man-

ufacturer on request if occasion to file claim arises.

When requesting information concerning this equip-

ment, it is essential that Model Description and Style

Number of the equipment be supplied.

1-3. DESCRIPTION

The PULSET is a synergic control designed to be used

with the PULSTAR 450 welding power source and a digi-

tal wire feeder. This unit is functional in both nonpulsed

and pulsed dc arc welding modes. When the Mode Se-

lector switch on the PULSTAR 450 is in STANDARD

mode, the PULSET controls output voltage. When the

Mode Selector switch is in 60 or 120 PPS mode, the

PULSET provides single-knob control of background

voltage, peak amperes, and wire feed speed for opti-

mum welding conditions with various electrode types

and sizes. The PULSET is also equipped with a start cir-

cuit and controls which enable the operator to set start

parameters different than welding parameters.

The PULSET provides a convenient means to set and

adjust welding parameters at initial setup and while

welding.

OM-537 Page 2

SECTION 2 − INSTALLATION

Fuse F1

Remote Output

Control Receptacle

Output Control Plugs

And Cord To PULSET

And Power Source

115 VAC Plug And

Cord To Wire Feeder

Remote Output

Control Plug And

Cord To Wire Feeder

115 VAC/Contactor

Control Receptacle

Receptacle For Dual Schedule Control Switch

Control Cord (See Dual Schedule Control

Owner’s Manual For Installation Information)

ST-111 668-A

Figure 2-1. Rear Panel View

PULSTAR 450 POWER SOURCE

115 VAC/Contactor

Cord (An Adapter

Cord May Be Required

Output Control

Cord

PULSET

Rear View

Feeder

115 VAC Cord

Rear View

Remote

Control

Cord

Front View

WIRE FEEDER

Weld

Cables

Wire Drive

Assembly

Connected

To Motor

Gun

Trigger

WORK

ST-111 797-A

Figure 2-2. PULSET Installation

OM-537 Page 3

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down wire feeder and welding power

source, and disconnect input power employing

lockout/tagging procedures before inspecting or

installing.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon-

necting device.

IMPORTANT: If power source and wire feeder were

previously installed, it may be necessary to remove

cables from existing units to install PULSET.

2-1. INSTALLATION OF PULSET CONTROL

The PULSET control mounts on top of the digital wire

feeder. To install the control, proceed as follows:

1. Place PULSET on top of digital wire feeder with

front panels facing the same direction.

2. Position PULSET so that the wrapper slots corre-

spond to wire feeder control box screws (4 screws).

3. Slide PULSET down onto screws.

4. Tighten wrapper screws on wire feeder.

2-2. 115 VOLTS AC CONNECTION TO WIRE FEED-

ER (Figures 2-1 and 2-2)

To make connection, align keyways, insert 4-socket

plug on Feeder 115 VAC Cord from PULSET into 4-pin

115 Volts AC Receptacle on rear of wire feeder, and ro-

tate threaded collar fully clockwise.

2-3. REMOTE CONTROL CONNECTION TO WIRE

FEEDER (Figures 2-1 and 2-2)

To make connection, align keyways, insert 4-pin plug on

Remote Output Control Cord from PULSET into 4-sock-

et Remote Control Receptacle on front of wire feeder,

and rotate threaded collar fully clockwise.

2-4. 115 VAC/CONTACTOR CONNECTION TO

PULSTAR 450 (Figures 2-1 and 2-2)

To make connection, align keyways, insert 4-socket

plug on 115 VAC/Contactor Cord (supplied with wire

feeder) into 4-pin receptacle on rear of PULSET, and ro-

tate threaded collar fully clockwise. Connect the 14-pin

plug to the REMOTE 14 receptacle on the Pulstar 450.

IMPORTANT: If the supplied control cord does not

match the welding power source remote control recep-

tacle, obtain the necessary adapter cord from your

welding equipment distributor.

2-5. REMOTE OUTPUT CONTROL CONNECTION

(Figures 2-1 and 2-2)

To make connections, align keyways, insert 10-socket

plug on Output Control Cord (supplied with PULSET)

into 10-pin receptacle on rear of PULSET, and rotate

threaded collar fully clockwise. Insert 10-pin plug on re-

maining end of cord into Remote Output Control Recep-

tacle on PULSTAR 450, and rotate threaded collar fully

clockwise.

SECTION 3 − OPERATION CONTROLS

Wire Selector

Control

Nonpulse

Light

Volts/Arc

Power Control

Pulse

Light

Arc Length

Control

Time(S)

Control

Arc Power

Start Control

ST-111 669-A

Figure 3-1. Front Panel View

OM-537 Page 4

3-1. WIRE SELECTOR CONTROL (Figure 3-1)

The WIRE SELECTOR control is functional only when

the Mode Selector switch on the PULSTAR 450 is in 60

or 120 PPS mode. This control sets the output range of

the power source and wire feeder for the specific type

and size of wire being used. The WIRE SELECTOR set-

ting also determines the relationship of the various pa-

rameters which determine arc power (background volt-

age, peak amperes, and wire feed speed).

3-2. VOLTS/ARC POWER CONTROL (Figure 3-1)

When the Mode Selector switch on the PULSTAR 450 is

in STANDARD mode, the NONPULSE light will be on,

and the VOLTS/ARC POWER control can be used to

select a welding voltage within the welding power

source output range. Rotate the control clockwise to in-

crease welding voltage. The scale surrounding the con-

trol is calibrated in average volts. When the Mode Selec-

tor switch is in STANDARD mode, the wire feed speed

must be set on the digital wire feeder.

When the Mode Selector switch is in 60 or 120 PPS

mode, the PULSE light will be on, and the VOLTS/ARC

POWER control sets arc power (wire feed speed, back-

ground voltage, and peak amperes). Rotate the control

clockwise to increase arc power. the arc power scale is

calibrated from 0 (zero) to 100 percent and corresponds

to a usable range of arc power for the type and size of

wire being used.

IMPORTANT: The VOLTS/ARC POWER control may

be adjusted while welding.

3-3. ARC LENGTH CONTROL (Figure 3-1)

The ARC LENGTH control is functional only when the

Mode Selector switch on the PULSTAR 450 is in 60 or

120 PPS mode. This control allows fine tuning of the

wire feed speed. When this control is set at 0 (zero), the

PULSET maintains a wire feed speed that matches the

background voltage and peak amperes values for a giv-

en arc power and a given type and size of wire. Rotating

the control clockwise decreases the wire feed speed, re-

sulting in a longer arc; rotating the control counterclock-

wise increases wire feed speed, resulting in a shorter

arc. Adjusting this control does not, however, change

background voltage or peak amperes values. the scale

surrounding the ARC LENGTH control is a relative scale

only; it does not represent a specific wire feed speed or

arc length value.

IMPORTANT: The ARC LENGTH control may be ad-

justed while welding.

3-4. ARC POWER START CONTROL (Figure 3-1)

The ARC POWER START control is functional only

when the Mode Selector switch on the PULSTAR 450 is

in 60 or 120 PPS mode. This control allows the operator

to set start parameters different than those set on the

main VOLTS/ARC POWER control. The control has the

same range of parameters as the VOLTS/ARC POWER

control. The parameters set on the ARC POWER

START control can be set higher or lower than those set

on the VOLTS/ARC POWER control, resulting in a hot

start or soft start, respectively.

IMPORTANT: When the Mode Selector Switch on the

Pulstar 450 is in the STANDARD position, the ARC

POWER START control must be set at zero.

When the start circuit is functional (see Section 3-5), the

wire feed speed displayed on the meter of the wire feed-

er is the start feed speed. After an arc is struck and the

start time elapses, the parameters set by the main

VOLTS/ARC POWER control take effect.

3-5. TIME(S) CONTROL (Figure 3-1)

The TIME(S) control is used to engage the start circuit

and to provide a means of selecting the time period that

the start parameters set by the ARC POWER START

control will be in effect (see Section 3-4). If the control is

rotated fully counterclockwise to the OFF position, the

start circuit is not functional. Rotating the control clock-

wise from the OFF position engages the start circuit and

increases the time period that the start parameters set

on the ARC POWER START control will be in effect. The

scale surrounding the control is calibrated from 0 (zero)

to 1.75 seconds in 0.25 second increments.

OM-537 Page 5

SECTION 4 − SEQUENCE OF OPERATION

WARNING: ELECTRIC SHOCK can kill;

MOVING PARTS can cause serious injury;

AND EXPOSURE TO ENVIRONMENT can

damage internal parts.

• Do not touch live electrical parts.

• Keep away from moving parts.

• Keep all covers and panels in place while

operating.

Warranty is void if the unit is operated with any

portion of the outer enclosure removed.

ARC RAYS, SPARKS, AND HOT SURFACES

can burn eyes and skin; NOISE can damage

hearing.

• Wear correct eye, ear, and body protection.

FUMES AND GASES can seriously harm

your health.

• Keep your head out of the fumes.

• Ventilate to keep from breathing fumes and

gases.

• If ventilation is inadequate, use approved

breathing device.

WELDING WIRE can cause puncture

wounds.

• Do not point gun toward any part of the body,

any conductive surface, or other personnel.

• Wear correct eye, ear, and body protection.

HOT METAL, SPATTER, AND SLAG can

cause fire and burns.

• Watch for fire.

• Keep a fire extinguisher nearby, and know

how to use it.

• Do not use near flammable material.

• Allow work and equipment to cool before han-

dling.

MAGNETIC FIELDS FROM HIGH CUR-

RENTS can affect pacemaker operation.

• Wearers should consult their doctor before

going near arc welding, gouging, or spot welding

operations.

See Arc Welding Safety Precautions in the

welding power source Owner’s Manual for basic

welding safety information.

4-1. GAS METAL ARC WELDING-NONPULSED

ARC (GMAW), FLUX CORED ARC WELDING-NON-

PULSED ARC (FCAW), AND GAS METAL ARC WEL-

DING-PULSED ARC (GMAW-P)

1. Install and connect unit according to Section 2.

2. Place REMOTE OUTPUT CONTROL switch on

welding power source in REMOTE position.

3. Place REMOTE CONTACTOR CONTROL switch

on welding power source in REMOTE position.

4. Place Mode Selector switch on welding power

source in STANDARD mode if nonpulse welding

and in 60 or 120 PPS mode if pulse welding.

5. Place Remote Control switch on wire feeder in RE-

MOTE position.

6. Set WIRE SELECTOR control on PULSET for size

and type of wire being used on wire feeder (see Sec-

tion 3-1).

7. Set VOLTS/ARC POWER control on PULSET to

desired value (see Section 3-2). Use VOLTS scale if

nonpulse welding and ARC POWER scale if pulse

welding.

8. Set ARC POWER START and TIME(S) controls on

PULSET to desired settings (see Sections 3-4 and

3-5).

9. Set ARC LENGTH control at 0 (zero) (see Section

3-3)

10. Turn on shielding gas supply, if applicable.

11. Energize welding power source and wire feeder.

12. If nonpulse welding, set the wire feed speed on wire

feeder.

13. Begin welding.

14. Adjust VOLTS/ARC POWER and ARC LENGTH

controls as necessary (see Sections 3-2 and 3-3).

4-2. SHUTTING DOWN

1. Stop welding.

2. Shut down welding power source and wire feeder.

3. Turn off shielding gas at the source, if applicable.

WARNING: HIGH CONCENTRATION OF

SHIELDING GAS can harm health or kill.

• Shut off gas supply when not in use.

OM-537 Page 6

SECTION 5 − MAINTENANCE & TROUBLESHOOTING

IMPORTANT: Every six months inspect the labels on

this unit for legibility. All precautionary labels must be

maintained in a clearly readable state and replaced

when necessary. See Parts List for part number of

precautionary labels.

5-1. INSPECTION AND UPKEEP

Usage and shop conditions will determine the frequency

and type of maintenance. At minimum, inspect equip-

ment every three months as follows:

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down wire feeder and welding power

source, and disconnect input power employing

lockout/tagging procedures before inspecting,

maintaining, or servicing.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon-

necting device.

Troubleshooting of internal parts to be performed only

by qualified persons.

1. Inspect all interconnecting cords for damage to or

breaks in the insulation jacket, particularly at the

plugs. Repair or replace the cord(s) as necessary.

2. Remove grease and dirt from components and

moisture from electrical parts and cables.

5-2. OVERLOAD PROTECTION

For overload protection this unit is equipped with a fuse

F1 located on the rear panel of the PULSET (see Figure

2-1 for location). If this fuse should open, the unit would

be completely inoperative. If F1 opens repeatedly, con-

tact the nearest Factory Authorized Service Station/

Service Distributor. To replace fuse F1, proceed as fol-

lows:

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down wire feeder and welding power

source, and disconnect input power employing

lockout/tagging procedures before inspecting,

maintaining, or servicing.

Lockout/tagging procedures consist of padlock-

ing line disconnect switch in open position, re-

moving fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect-

ing device.

INCORRECT FUSE can damage unit.

• Use only replacement fuses of same size,

type, and rating (see Parts List).

1. Depress and rotate fuse holder cover counterclock-

wise.

2. Pull fuse out with fuse holder cover when cover is

free.

3. Insert new fuse into fuse holder cover.

4. Install fuse with fuse holder cover back into unit.

5. Depress and rotate fuse holder cover clockwise un-

til cover is secure.

5-3. CIRCUIT BOARD TESTING

IMPORTANT: If all other possible sources of PULSET

failure have been checked (see section 5-6), perform

the following procedure to test the PULSET main circuit

board PC1 and adjoining circuit boards PC2 and PC3 for

proper operation. If a defect is found, replace only PC1

(see Section 5-4).

1. Place REMOTE OUTPUT CONTROL switch on

welding power source in STANDARD position.

2. Place feeder Remote Control switch in STANDARD

position.

3. Energize welding power source and wire feeder.

4. Set PEAK AMPERAGE ADJUSTMENT (if pulsed

welding) and BACKGROUND VOLTAGE ADJUST-

MENT controls on welding power source to desired

values, and set WIRE SPEED control on wire feed-

er to desired value.

5. Begin welding, adjusting PEAK AMPERAGE AD-

JUSTMENT, BACKGROUND VOLTAGE ADJUST-

MENT, and WIRE SPEED controls as necessary.

6. If pulsing operations do not work correctly, but non-

pulsing operations work correctly, replace PC1 (see

Section 5-4).

5-4. CIRCUIT BOARD PC1 REPLACEMENT

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down wire feeder and welding power

source, and disconnect input power employing

lockout/tagging procedures before inspecting,

maintaining, or servicing.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon-

necting device.

If circuit board PC1 is at fault for a problem with the unit,

replace the board using the following procedure. Do not

attempt board repair. Contact the nearest Factory Au-

thorized Service Station/Service Distirbutor for correct

replacement part.

OM-537 Page 7

CAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage circuit boards.

• Put on properly grounded wrist strap BE-

FORE handling circuit boards.

• Transport circuit boards in proper static-

shielding carriers or packages.

• Perform work only at a static-safe work area.

INCORRECT INSTALLATION or misaligned

plugs can damage circuit board.

• Be sure that plugs are properly installed and

aligned.

EXCESSIVE PRESSURE can break circuit

board.

• Use only minimal pressure and gentle move-

ment when disconnecting or connecting board

plugs and removing or installing board.

1. Remove wrapper.

2. Disconnect any edge connectors or plugs from

PC1.

3. Remove circuit board mounting screws and circuit

board.

4. Install new circuit board, and reinstall mounting

screws, edge connectors, and plugs.

5. Reinstall wrapper.

5-5. START MODULE CIRCUIT BOARD PC4

REPLACEMENT

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down wire feeder and welding power

source, and disconnect input power employing

lockout/tagging procedures before inspecting,

maintaining, or servicing.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon-

necting device.

If the Start Module circuit board PC4 is at fault for a prob-

lem with the unit, replace the board using the following

procedure. Do not attempt board repair. Contact the

nearest Factory Authorized Service Station/Service

Distributor for correct replacement part.

CAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage circuit boards.

• Put on properly grounded wrist strap BE-

FORE handling circuit boards.

• Transport circuit boards in proper static-

shielding carriers or packages.

• Perform work only at a static-safe work area.

INCORRECT INSTALLATION or misaligned

plugs can damage circuit board.

• Be sure that plugs are properly installed and

aligned.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon-

necting device.

EXCESSIVE PRESSURE can break circuit

board.

• Use only minimal pressure and gentle move-

ment when disconnecting or connecting board

plugs and removing or installing board.

1. Remove wrapper.

2. Disconnect plug PLG53 from terminal header on

circuit board PC4.

3. Loosen securing screws in TIME(S) and ARC

POWER START control knobs, and remove control

knobs from PC4 potentiometer shafts.

4. Remove PC4 from unit.

5. Install new circuit board, and reinstall control knobs

and plug PLG53.

6. Reinstall wrapper.

5-6. TROUBLESHOOTING

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down wire feeder and welding power

source, and disconnect input power employing

lockout/tagging procedures before inspecting,

maintaining, or servicing.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

and red-tagging circuit breaker or other discon-

necting device.

HOT SURFACES can cause severe burns.

• Allow cooling period before servicing.

Troubleshooting to be performed only by quali-

fied persons.

It is assumed that proper installation has been made,

according to Section 2 of this manual, and that the unit

has been functioning properly until trouble developed.

The following chart is designed to diagnose and provide

remedies for some of the troubles that may develop in

this unit.

Use this chart in conjunction with the circuit diagram

while performing troubleshooting procedures. If the

trouble is not remedied after performing these proce-

dures, the nearest Factory Authorized Service Station,

should be contacted. In all cases of equipment malfunc-

tion, the manufacturer’s recommendations should be

strictly followed.

OM-537 Page 8

Table 5-1. Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

No weld output Power switch on PULSTAR 450 power

source OFF.

Place power switch on PULSTAR 450

ON.

Fuse F1. Check and replace F1 if necessary (see

Section 5-2).

Cord not secure in 115 VAC/ Contactor

Receptacle RC1 in rear of PULSET.

Secure 4-socket plug to RC1.

Circuit Board PC1. Check and replace PC1 if necessary

(see Sections 5-3 and 5-4).

115 VAC/Contactor Cord (or adapter

cord, if applicable) not secure in RE-

MOTE 14 Receptacle on welding power

source.

Secure 14-pin plug to REMOTE 14 re-

ceptacle on welding power source.

Output Control Cord not secure in Re-

mote Output Control Receptacle on

welding power source.

Secure 10-socket plug to RC2.

Output Control Cord not secure in RE-

MOTE OUTPUT CONTROL Recep-

tacle on welding power source.

Secure 10-pin plug into 10-pin Remote

Output Control Receptacle on welding

power source.

PULSET controls not function-

al.

REMOTE OUTPUT CONTROL switch

on welding power source in STAN-

DARD position.

Place REMOTE OUTPUT CONTROL

switch in REMOTE position.

Erratic weld/incorrect weld

characteristics.

Incorrect WIRE SELECTOR setting on

PULSET.

Set WIRE SELECTOR control for size

and type of wire being used on wire

feeder (see Section 3-1).

Incorrect voltage/arc power value. Adjust VOLTS/ARC POWER control R1

on PULSET as necessary (see Section

3-2).

Incorrect arc length. Adjust ARC LENGTH control R2 on

PULSET as necessary (See Section

3-3).

Circuit Board PC1. Check and replace PC1 if necessary

(see Sections 5-3 and 5-4).

Wire feeder Remote Control switch in

STANDARD position.

Place wire feeder Remote Control

Switch in REMOTE position.

Poor or incorrect start charac-

teristics.

Incorrect ARC POWER START and/or

TIME(S) control(s) setting(s).

Adjust ARC POWER START and

TIME(S) controls as necessary (see

Sections 3-4 and 3-5).

Start Module circuit board PC4. Check and replace PC4 if necessary

(see Section 5-5).

OM-537 Page 9

SECTION 6 − ELECTRICAL DIAGRAMS

Circuit Diagram No. SB-110 747-B

Diagram 6-1. Circuit Diagram For PULSET

OM-537 Page 10

Wiring Diagram No. SC-111 343-A

Diagram 6-2. PULSET Wiring Diagram

OM-537 Page 11

SECTION 7 − PARTS LIST

OM-537 Page 12

ST-111 596-B

1234

12 14

28 24 27 25 26 24 25 24 23 22

OM-537 Page 13

Figure 7-1. Main Assembly

Description Quantity

Part

No.

Dia.

Mkgs.

Figure 7-1. Main Assembly

Item

No.

1 046 432 HOLDER, fuse 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 F1 *012 643 FUSE, minat-gl slo blo 1A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 C2,3 115 192 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 RC2 089 646 RECEPTACLE, 10 pin MS-3102A-18-1P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

089 647 PLUG, 10skt amphenol MS-3106A-18-1S. . . . . . . . . . . . . . . . . . . .

073 332 CLAMP, cable AN-3057-10. . . . . . . . . . . . . . . . . . . .

5 604 571 CABLE, port No. 18 4/c (order by ft) 4ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 079 531 CLAMP, cable strain relief 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PLG1 048 284 HOUSING PLUG & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079 534 TERMINAL, female 1skt 14-18 wire 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 RC1 048 283 RECEPTACLE w/PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079 535 TERMINAL, male 1 pin sz 16 18-14 wire 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PLG2 053 075 PLUG, 4 pin MS-3106A-14S-2P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 039 828 CLAMP, cable AN-3057-6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 604 571 CABLE, port No. 18 4/c (order by ft) 4ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 PC1 108 451 CIRCUIT CARD, mother board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 D1,2 026 202 DIODE, 1A 400V SP 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 RC3 039 718 RECEPTACLE, 10skt MS-3102A-18-1S 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 716 PLUG, 10 pin Amphenol MS-3106A-18-1P. . . . . . . . . . . . . . . . . . . .

073 332 CLAMP, Amphenol AN-3057-10. . . . . . . . . . . . . . . . . . . .

15 079 844 SPRING, holddown-relay 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

048 029 CLIP, retaining-skt 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

027 811 SOCKET, relay 14 pin 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 CR1,2 027 810 RELAY, encl 24VDC 4PDT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

048 588 BRACKET, mtg-relay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 PC3 108 449 CIRCUIT CARD, program board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 PC2 108 450 CIRCUIT CARD, program board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 PC53 105 673 CONNECTOR, plug 6 posn 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 PC4 110 655 CIRCUIT CARD, relay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 +110 802 CASE SECTION, front/bottom/rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 093 551 KNOB 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 R1,2 035 897 POTENTIOMETER, C 1/T 2W 1000 ohm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 097 922 KNOB, pointer 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 LED1,2 083 850 LIGHT, ind-red lens 24V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 PLG52 079 748 HOUSING, term header 18 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 072 253 STUD, ground 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 PC5,S1 109 207 CIRCUIT CARD, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 SR1 035 704 RECTIFIER, integ 40A 800V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 C1 000 859 CAPACITOR, elctlt 220uf 35VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 T1 035 759 TRANSFORMER, control 115/36VCT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 TE1 038 772 BLOCK, term 20A 6P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 C4 115 193 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R3 074 060 RESISTOR, C .5W 1K ohm 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

070 026 STAND-OFF, No. 6-32 x 7/16 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 756 STAND-OFF, No. 6-32 x 5/8 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 476 BUSHING, strain relief 5/8 x .570 hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049 173 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134 327 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NAMEPLATE, (order by model & style number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

089 870 CABLE, interconnecting 10ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

089 647 PLUG, 10skt Amphenol MS-3102A-18-1S 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 332 CLAMP, cable Amphenol AN-3057-10 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 140 CABLE, port No. 18 10/c (order by ft) 10ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 716 PLUG, 10 pin Amphenol MS-3106A-18-1P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

OM-537 Page 14

BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.

Miller PULSET CONTROL, JG26 Owner's manual

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