Miller PULSET CONTROL Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller PULSET CONTROL is a synergic control designed to be used with the PULSTAR 450 welding power source and a digital wire feeder. It provides single-knob control of background voltage, peak amperes, and wire feed speed for optimum welding conditions with various electrode types and sizes. The PULSET is also equipped with a start circuit and controls which enable the operator to set start parameters different than welding parameters.

Miller PULSET CONTROL is a synergic control designed to be used with the PULSTAR 450 welding power source and a digital wire feeder. It provides single-knob control of background voltage, peak amperes, and wire feed speed for optimum welding conditions with various electrode types and sizes. The PULSET is also equipped with a start circuit and controls which enable the operator to set start parameters different than welding parameters.

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
5
6
7
8
9
10
11
12 14
15
16
17
18
19
20
21
33
32
31
30
29
28 24 27 25 26 24 25 24 23 22
13
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.
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Miller PULSET CONTROL Owner's manual

Category
Welding System
Type
Owner's manual
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Miller PULSET CONTROL is a synergic control designed to be used with the PULSTAR 450 welding power source and a digital wire feeder. It provides single-knob control of background voltage, peak amperes, and wire feed speed for optimum welding conditions with various electrode types and sizes. The PULSET is also equipped with a start circuit and controls which enable the operator to set start parameters different than welding parameters.

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