cover2 1/92 − ST-151 254 PRINTED IN USA
February 1992 FORM: OM-814
Effective With Serial No. KC199289
MODEL: MMP
IMPORTANT: Read and understand the entire contents of both this manual and
the power source manual used with this unit, with special emphasis on the safety
material throughout the manual, before installing, operating, or maintaining this
equipment. This unit and these instructions are for use only by persons trained
and experienced in the safe operation of welding equipment. Do not allow
untrained persons to install, operate, or maintain this unit. Contact your distributor
if you do not fully understand these instructions.
MILLER ELECTRIC Mfg. Co.
A Miller Group Ltd., Company
P.O. Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
OWNER’S MANUAL
OM-814 − 2/92
TABLE OF CONTENTS
SECTION 1 − SAFETY SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − TROUBLESHOOTING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAMS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-814 Page 1
SECTION 1 − SAFETY SIGNAL WORDS
mod1.1 9/9
The following safety alert symbol and signal words are used throughout this manual to call attention to and identify
different levels of hazard and special instructions.
WARNING
WARNING statements identify procedures or practices which must be followed to avoid serious personal
injury or loss of life.
CAUTION
CAUTION statements identify procedures or practices which must be followed to avoid minor personal
injury or damage to this equipment.
IMPORTANT: statements identify special instructions necessary for the most efficient operation of this equipment.
SECTION 2 − SPECIFICATIONS
Table 2-1. Pulse Control
Specification Description
Overall Dimensions Height: 8-1/4 in. (210 mm); Width: 7-3/8 in. (187 mm); Depth: 4-3/4 in. (121 mm)
Weight Ship: 12 lbs. (5.4 kg); Net: 7 lbs. (3.2 kg)
Input Power Cord With Plug 20 ft. (6.1 m)
Additional Required Equipment Welding Power Source And Wire Feeder
Welding Power Source Type Needed Constant Current (CC) DC, With Suitable Remote 17 Receptacle
Wire Feeder Type Needed Constant Speed
Welding Process Gas Metal Arc Welding - Pulsed (GMAW-P)
SECTION 3 − INSTALLATION
ST-152 642
Turn OFF welding power source.
1 Welding Power Source
2 17-Socket Receptacle
3 Plug PLG3 From Pulse
Control
Insert plug into matching 17-socket
receptacle on welding power
source, and tighten threaded collar.
4 Mounting Bracket
Mounting holes are 4 in. (102 mm)
apart.
5 User-Supplied Mounting Hard-
ware
1
2
3
4
5
Figure 3-1. Connections To Welding Power Source And Optional Wall-Mounting Procedure
OM-814 Page 2
SECTION 4 − OPERATION
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Always wear dry insulating gloves.
• Insulate yourself from work and ground.
• Keep all panels and covers securely in place.
FUMES AND GASES can be hazardous
to your health.
• Keep your head out of the fumes.
• Ventilate area, or use breathing device.
• Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
WELDING can cause fire or explosion.
• Do not weld near flammable material.
• Watch for fire; keep extinguisher nearby.
• Do not locate unit over combustible surfaces.
• Do not weld on closed containers.
• Allow work and equipment to cool before handling.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• Wear welding helmet with correct shade of filter.
• Wear correct eye, ear, and body protection.
MOVING PARTS can cause injury.
• Keep away from pinch points such as drive rolls.
• Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
• Pacemaker wearers keep away.
• Wearers should consult their doctor before going
near any welding operations.
See Safety Precautions at beginning of manual for ba-
sic welding safety information.
wfwarn3.1 10/91
1 Peak Current Control
Use control to select peak current
level during pulsed welding. The
peak current level is defined as a
percentage (25 − 100%) of maxi-
mum output current of the welding
power source in CC mode.
2 Pulse Width Control
Use control to select length of peak
current pulse. The scale around the
control is in milliseconds.
3 Pulse Frequency Control
Use control to select number of
peak current output pulses per sec-
ond. The scale around the control is
in pulses per second.
4 Background Current Control
Use control to select background
current level. The background cur-
rent level is defined as a percent-
age (3 − 25%) of maximum output
current of the welding power source
in the CC mode.
Every month check labels, cord,
and plug for damage.
12
3
4
Ref. SC-147 389-A
Figure 4-1. Controls
1 Welding Power Source
Set OUTPUT (CONTACTOR)
switch in REMOTE position.
Set mode switch in GTAW (CC) po-
sition.
Set Amperage/Voltage Control
switch in REMOTE 17 position.
Turn ARC CONTROL/INDUC-
TANCE control to minimum.
1
Figure 4-2. Welding Power Source
OM-814 Page 3
1
1 Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet
Wear dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct shade
of filter (see ANSI Z49.1).
2 3
sb3.1 10/91
Figure 4-3. Safety Equipment
Install &
Connect
Equipment
Put On
Personal Safety
Equipment
Set
All
Controls
Turn On
Equipment & Gas
(If Applicable)
Do
Sample
Weld
Readjust Controls
And Prepare
For Production
Figure 4-4. Sequence Of Pulsed Gas Metal Arc Welding (GMAW-P)
SECTION 5 − TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn OFF welding power source, and disconnect
pulse control before inspecting, maintaining, or
servicing.
HOT PARTS can cause severe burns.
• Allow cooling period before servicing unit.
Troubleshooting to be performed only by qualified
persons.
Table 5-1. Welding Trouble
Trouble Remedy Section
No weld output. Be sure welding power source POWER switch is ON.
Check welding gun and/or wire feeder according to its manual.
No control of weld output. Check welding power source control settings. Figure 4-2
Be sure plug PLG3 is securely connected to REMOTE 17 re-
ceptacle on welding power source.
Figure 3-1
Check pulse control cord and replace if necessary.
Pulse control does not work. Check pulse control potentiometers.
Have Factory Authorized Service Station check circuit board
PC1.
Erratic weld; incorrect weld char-
acteristics.
Check pulse control settings. Figure 4-1
Check wire feed speed at wire feeder.
OM-814 Page 4
SECTION 6 − ELECTRICAL DIAGRAMS
SA-150 213-A
Figure 6-1. Circuit Diagram
SB-150 218
Figure 6-2. Wiring Diagram
OM-814 Page 5
SECTION 7 − PARTS LIST
Description
Part
No.
Dia.
Mkgs.
Complete Assembly
Quantity
C1 145 697 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC1 150 419 CIRCUIT CARD, remote pendant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
097 132 STAND-OFF, No. 6-32 x .375 lg 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG1 115 092 HOUSING PLUG & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 746 TERMINAL, female 1skt 24-18 wire 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG2 135 558 HOUSING PLUG & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 747 TERMINAL, contact hdr 24-18 wire 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R1-4 073 562 POTENTIOMETER, C sltd sft 1/T 2W 10K ohm 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
097 922 KNOB, pointer .875dia x .250 ID 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
123 531 STRAIN RELIEF, cable flexible .231-.394 cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120 104 CABLE, pwr shld 18ga 6/c (order by ft) 20ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
073 296 CLAMP, cable 97-3057-12-6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
097 866 PLUG, 17 pin MS-3106A-20-29P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
150 211 CASE SECTION, front ends 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
150 210 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
150 208 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
150 212 GUARD, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
150 209 BRACKET, mtg pendant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
019 663 MOUNT, nprn 15/16 OD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
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