OM-898 128 899D

July 1996

Processes
TIG (GTAW) Welding

Description
Pulser Control

PC-300

Visit our website at

www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
Working as hard as you do
This Owner’s Manual is designed to help you get the most out of your – every power source from
Miller is backed by the most
Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the
help you protect yourself against potential hazards on the worksite. We’ve business.

made installation and operation quick and easy.

With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
Miller is the first welding figure out what the problem is. The parts list
equipment manufacturer in will then help you to decide which exact part
the U.S.A. to be registered to
the ISO 9001 Quality System you may need to fix the problem. Warranty and
Standard. service information for your particular model
are also provided. Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
 TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . 3
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Pulse Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-1. Typical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-2. Mounting Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-3. Setting Pulses Per Second DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-4. Remote 14 Receptacle Information And Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-5. Interconnecting Cord And Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-2. Examples Of Pulsed Output Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-3. Peak Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-4. Background Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-5. Pulses Per Second Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-6. % On Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-7. Amperage Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-8. Availability Of Open-Circuit Voltage When Welding Power Source is Energized . . . . . . . . . . 10
4-9. Output (Contactor) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-10. Pulser Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-11. Power Switch And Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 5 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-3. Circuit Diagram For Pulser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 6 – SELECTING AND PREPARING TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . 14
6-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding . . . . . . . . . . . . . . . . 15
6-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . . 15
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
WARRANTY
 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

Y Marks a special safety message. 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
. Means “Note”; not safety related. to avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to D If earth grounding of the workpiece is required, ground it directly
call attention to and identify possible hazards. When you see with a separate cable – do not use work clamp or work cable.
the symbol, watch out, and follow the related instructions to D Do not touch electrode if you are in contact with the work, ground,
avoid the hazard. The safety information given below is only or another electrode from a different machine.
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all D Use only well-maintained equipment. Repair or replace damaged
Safety Standards. parts at once. Maintain unit according to manual.
Y Only qualified persons should install, operate, maintain, and D Wear a safety harness if working above floor level.
repair this unit. D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away. D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
ELECTRIC SHOCK can kill. contact with any metal object.
D Do not connect more than one electrode or work cable to any
Touching live electrical parts can cause fatal shocks single weld output terminal.
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input SIGNIFICANT DC VOLTAGE exists after removal of
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the input power on inverters.
wire, wire reel, drive roll housing, and all metal parts touching the D Turn Off inverter, disconnect input power, and discharge input
welding wire are electrically live. Incorrectly installed or improperly capacitors according to instructions in Maintenance Section
grounded equipment is a hazard. before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
FUMES AND GASES can be hazardous.
or covers big enough to prevent any physical contact with the work
or ground. Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
D Do not use AC output in damp areas, if movement is confined, or if health.
there is a danger of falling.
D Use AC output ONLY if required for the welding process. D Keep your head out of the fumes. Do not breathe the fumes.
D If AC output is required, use remote output control if present on D If inside, ventilate the area and/or use exhaust at the arc to remove
unit. welding fumes and gases.
D Disconnect input power or stop engine before installing or D If ventilation is poor, use an approved air-supplied respirator.
servicing this equipment. Lockout/tagout input power according to D Read the Material Safety Data Sheets (MSDSs) and the
OSHA 29 CFR 1910.147 (see Safety Standards). manufacturer’s instructions for metals, consumables, coatings,
D Properly install and ground this equipment according to its cleaners, and degreasers.
Owner’s Manual and national, state, and local codes. D Work in a confined space only if it is well ventilated, or while
D Always verify the supply ground – check and be sure that input wearing an air-supplied respirator. Always have a trained watch-
power cord ground wire is properly connected to ground terminal in person nearby. Welding fumes and gases can displace air and
disconnect box or that cord plug is connected to a properly lower the oxygen level causing injury or death. Be sure the breath-
grounded receptacle outlet. ing air is safe.
D When making input connections, attach proper grounding conduc- D Do not weld in locations near degreasing, cleaning, or spraying op-
tor first – double-check connections. erations. The heat and rays of the arc can react with vapors to form
D Frequently inspect input power cord for damage or bare wiring – highly toxic and irritating gases.
replace cord immediately if damaged – bare wiring can kill. D Do not weld on coated metals, such as galvanized, lead, or
D Turn off all equipment when not in use. cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
D Do not use worn, damaged, undersized, or poorly spliced cables. air-supplied respirator. The coatings and any metals containing
D Do not drape cables over your body. these elements can give off toxic fumes if welded.

OM-898 Page 1
 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill.

Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Use protective screens or barriers to protect others from flash and D Allow cooling period before working on gun or
glare; warn others not to watch the arc. torch.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks going near arc welding, gouging, or spot
can fly off from the welding arc. The flying sparks, hot welding operations.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding. NOISE can damage hearing.
D Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
D Do not weld where flying sparks can strike flammable material. damage hearing.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. D Wear approved ear protection if noise level is
high.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can CYLINDERS can explode if damaged.
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes, Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
unless they are properly prepared according to AWS F4.1 (see gas cylinders are normally part of the welding
Safety Standards). process, be sure to treat them carefully.
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly D Protect compressed gas cylinders from excessive heat, mechani-
unknown paths and causing electric shock and fire hazards. cal shocks, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes. D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use. D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy D Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap. D Never allow a welding electrode to touch any cylinder.
D Remove any combustibles, such as a butane lighter or matches, D Never weld on a pressurized cylinder – explosion will result.
from your person before doing any welding.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
FLYING METAL can injure eyes.
D Turn face away from valve outlet when opening cylinder valve.
D Welding, chipping, wire brushing, and grinding D Keep protective cap in place over valve except when cylinder is in
cause sparks and flying metal. As welds cool, use or connected for use.
they can throw off slag.
D Read and follow instructions on compressed gas cylinders,
D Wear approved safety glasses with side associated equipment, and CGA publication P-1 listed in Safety
shields even under your welding helmet. Standards.

OM-898 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

D Do not install or place unit on, over, or near D Keep away from moving parts such as fans.
combustible surfaces. D Keep all doors, panels, covers, and guards
D Do not install unit near flammables. closed and securely in place.
D Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories. D High-frequency (H.F.) can interfere with radio
D Use equipment of adequate capacity to lift and navigation, safety services, computers, and
support unit. communications equipment.
D If using lift forks to move unit, be sure forks are D Have only qualified persons familiar with
long enough to extend beyond opposite side of electronic equipment perform this installation.
unit. D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
OVERUSE can cause OVERHEATING D If notified by the FCC about interference, stop using the
equipment at once.
D Allow cooling period; follow rated duty cycle. D Have the installation regularly checked and maintained.
D Reduce current or reduce duty cycle before D Keep high-frequency source doors and panels tightly shut, keep
starting to weld again. spark gaps at correct setting, and use grounding and shielding to
D Do not block or filter airflow to unit. minimize the possibility of interference.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling
boards or parts. ARC WELDING can cause interference.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards. D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
MOVING PARTS can cause injury. such as robots.
D Be sure all equipment in the welding area is
D Keep away from moving parts. electromagnetically compatible.
D Keep away from pinch points such as drive D To reduce possible interference, keep weld cables as short as
rolls. possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury. D Be sure this welding machine is installed and grounded
according to this manual.
D Do not press gun trigger until instructed to do D If interference still occurs, the user must take extra measures
so. such as moving the welding machine, using shielded cables,
D Do not point gun toward any part of the body, using line filters, or shielding the work area.
other people, or any metal when threading
welding wire.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 from Compressed Gas Association, 1235 Jefferson Davis Highway,
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten- Suite 501, Arlington, VA 22202.
dent of Documents, U.S. Government Printing Office, Washington, D.C. Code for Safety in Welding and Cutting, CSA Standard W117.2, from
20402. Canadian Standards Association, Standards Sales, 178 Rexdale
Recommended Safe Practices for the Preparation for Welding and Cut- Boulevard, Rexdale, Ontario, Canada M9W 1R3.
ting of Containers That Have Held Hazardous Substances, American Safe Practices For Occupation And Educational Eye And Face
Welding Society Standard AWS F4.1, from American Welding Society, Protection, ANSI Standard Z87.1, from American National Standards
550 N.W. LeJeune Rd, Miami, FL 33126 Institute, 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, from National Fire Protec- Cutting And Welding Processes, NFPA Standard 51B, from National
tion Association, Batterymarch Park, Quincy, MA 02269. Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-898 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from opera-
committee’s judgment, has not demonstrated that exposure to power- tor as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as possi-
examined. Until the final conclusions of the research are reached, you ble.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.

OM-898 Page 4
 SECTION 2 – SPECIFICATIONS

2-1. Pulse Control

Specification Description

Overall Dimensions Height: 7-1/8 in (181 mm); Width: 9-1/4 in (235 mm); Length: 5-1/2 in (140 mm)

Weight Net: 7.2 lb (3.3 kg); Ship: 8.8 lb (4 kg)

Input Power Cord With Plug 8 ft (2.4 m)

Additional Required Equipment Welding Power Source And High-Frequency Unit

Welding Power Source Type Needed Constant Current (CC) DC Or AC/DC, With Suitable Remote 14 Receptacle And A Positive Reference
Command Signal Not To Exceed +10 Volts DC

SECTION 3 – INSTALLATION

3-1. Typical Connections

Typical Connections For Welding Power Source Without HF

Remote
Control

To 115 Volt
Optional Extension Cords Supply
Pulser
Control TIG
Torch

Welding Power
Source With HF Unit
Electrode Cable
14-Socket Receptacle
Work Cable Work
To 115 Volt Supply

Typical Connections For Welding Power Source With HF

Remote
Control

To 115 Volt
Supply
Pulser
Control TIG
Torch
Welding Power
Source With HF
And 14-Socket
Receptacle
Work

S-0848 / S-0849

OM-898 Page 5
3-2. Mounting Bracket Installation

1 Pulser Control
Tools Needed:
2 Mounting Bracket
1/4, 3/8 in Bracket may be installed as shown
or it may be turned outward.
5/32, 3/16 in
If welding power source has an external high-fre- 3 Welding Power Source Cover
quency unit, it may be desirable to install pulser 4 Mounting Holes
control on the high-frequency unit.
Remove cover from welding power
source.
Mark location of mounting holes on
1 welding power source cover using
the bracket as a template. Be sure
2 area is free of electrical wiring and
components.
If there is sheet metal under the
cover, drill two 3/16 in (4.7 mm) at
marked location. Place cover on
welding power source, and use as
3 a template to mark holes in unit
sheet metal. Remove cover and
drill two 5/32 in (4 mm) holes in
sheet metal.
If there is no sheet metal under the
cover, drill two 5/32 in (4 mm) holes
in cover.
Reinstall cover.
4 Use two No. 8 sheet metal screws
(not supplied) to secure bracket to
welding power source.
Use two No. 8 sheet metal screws
(not supplied) to secure pulser con-
trol to bracket.

ST-800 532

3-3. Setting Pulses Per Second DIP Switch

1 Pulser Circuit Board PC1

Be sure the selected range matches the pulsing
capability of the welding power source being used. 2 Pulses Per Second DIP
Switch S1
2 Two ranges of pulses per second
control (pulse frequency) are avail-
able. Unit is shipped with switches
1 set for 0.5 to 20 pulses per second.
Set Switches If 10 to 300 pulses per second is de-
sired, set switches as shown.
0.5 To 20 10 To 300 Reinstall wrapper.
Pulses Per Pulses Per
Second Second
2 1 2 1

ST-800 533

OM-898 Page 6
3-4. Remote 14 Receptacle Information And Connections
1 Remote 14 Receptacle RC1
2 Keyway
1
3 Plug
2
4 Threaded Collar
A J To connect to this receptacle, align
K I
B keyway, insert plug, and tighten
threaded collar.
REMOTE 14 C L N H
D M G

A AMPERAGE
E F Socket Information:
A
B
Contactor control switch connection.
Contactor control switch connection.
OUTPUT C Amperage control connection (maximum side).
(CONTACTOR)
D Amperage control connection (minimum side).
3 4 E Amperage control connection (wiper contact).
K Chassis common.
The remaining sockets are not used.

sb7.1* 3/93 – S-129 442 / Ref. S-0004-A / S-0628-A

3-5. Interconnecting Cord And Electrical Input Connections

1 Interconnecting Cord And
The welding power source used with this control must Plug PLG1
provide a positive reference command signal not to
exceed +10 volts dc. Connect plug to matching recep-
tacle on welding power source or
high-frequency unit if welding pow-
er source does not have high-fre-
quency, as follows: align keyway,
insert plug, and tighten threaded
2 collar. See Section 3-1.
2 Input Power Cord And Plug
PLG2
Connect plug to a properly
grounded, 50/60 Hz single-phase,
115 volts ac receptacle, protected
by time-delay fuses or circuit break-
er.

ST-130 261-A

OM-898 Page 7
 SECTION 4 – OPERATION

4-1. Controls

1 1 Peak Amperage Control

2 2 Background Amperage
3 Control
3 Pulses Per Second Control
4 % On Time Control
5 Pilot Light
6 Power Switch
7 Pulser Switch
8 Output (Contactor) Switch
4 9 Amperage Control Switch
9
8
7
6 5 SB-130 261-A

4-2. Examples Of Pulsed Output Waveforms

1 Pulsed Output With 50% On

Time
50% On Time
2 Pulsed Output With 80% On
Time
1 3 Pulsed Output With 20% On
Peak Amperage Time
Level

Background
Amperage Level 2

80% On Time

Total Pulse
Period
Peak Amperage
On Time

20% On Time 3

Background
Amperage Period

Pulses Per
Second S-0259

OM-898 Page 8
4-3. Peak Amperage Control
1 Peak Amperage Control
This control is a fine amperage con-
trol for the Amperage control on the
welding power source. The scale
around the control is for reference
1
only.

This control can be adjusted

while welding.

In Example:
Output Range = Min to 150 A

Set Control On Welding Adjust Control

Power Source Ref. ST-114 018-D / Ref. ST-138 226-A

4-4. Background Amperage Control

1 Background Amperage Con-
trol
Use this control as a way of setting
the weld output background amper-
age level. Background amperage is
set as a percentage of peak amper-
age, and can never be set higher
than peak amperage. Numbers
1 around the control are for reference
only.

This control can be

adjusted while welding.

Ref. ST-138 226-A

4-5. Pulses Per Second Control

1 Pulses Per Second Control
Use this control as a way of select-
ing pulses per second (pulse fre-
quency) when the Pulser switch
(see Section 4-10) is On.
The inner scale is calibrated from
0.5 to 20 pulses per second. The
outer scale is calibrated from 10 to
1 300 pulses per second. The unit is
shipped set for 0.5 to 20 pulses per
second, to change ranges see Sec-
tion 3-3.

This control can be

adjusted while welding.

OM-898 Page 9
4-6. % On Time Control

1 % On Time Control
Use this control as a way of select-
ing pulse width (peak amperage
output time of one pulse). The scale
surrounding the control ranges
from 5 to 95 percent.
1 Pulser switch (see Section 4-10)
must be in the On position.

This control can be

adjusted while welding.

4-7. Amperage Switch

1 Amperage Switch
Use switch to select way of control-
ling amperage adjustment.
For front panel control, place switch
in Panel position. The Peak and
Background Amperage controls
will control the available amperage.
For remote control, make connec-
1
tions to the Remote 14 receptacle
(see Section 3-4), and place switch
in Remote 14 position. When a re-
mote amperage control is used and
the Pulser switch (see Section
4-10) is in the On position, the peak
and background amperage will
change proportionately with the
setting on the remote amperage
control. When the Pulser switch is
in the Off position, the Peak Amper-
age control will be a slave to the re-
mote amperage control, which is a
slave to the Amperage control on
the welding power source. The
Background Amperage control
does not function when Pulser
switch is in the Off position.

4-8. Availability Of Open-Circuit Voltage When Welding Power Source is Energized

Pulser Control Welding Power Source
Power Remote Control Open-Circuit
Output (Contactor) Output (Contactor)
Switch Switch Position Voltage
Switch Position Switch Position
ON ON or OFF ON ON Available
ON ON or OFF ON REMOTE Available
ON ON or OFF REMOTE 14 ON Available
ON OFF REMOTE 14 REMOTE Not Available
ON ON REMOTE 14 REMOTE Available
OFF ON or OFF ON or REMOTE 14 REMOTE Not Available
OFF ON or OFF ON or REMOTE 14 ON Available

OM-898 Page 10
4-9. Output (Contactor) Switch
1 Output (Contactor) Switch
Use switch to select way of control-
ling unit output. Availability of open-
circuit voltage depends on the posi-
tion of the Pulser Control Output
(Contactor) switch and the position
of the welding power source Output
1 (Contactor) switch (see Section
4-8).
For front panel control, place switch
in On position.
For remote control, place switch in
Remote 14 position (see Section
3-4).

4-10. Pulser Switch

1 Pulser Switch
When this switch is in the On posi-
This switch may be turned tion, the welding power source out-
put will pulse between the back-
On and Off while welding.
ground and peak amperage set-
tings of this pulser control (see Sec-
tions 4-4 and 4-3).
When this switch is in the Off posi-
tion, the welding power source out-
put remains at peak amperage lev-
el.
1 This switch may be placed in either
the On or Off position before or dur-
ing welding. If placed in the On posi-
tion before welding, the output am-
perage may begin pulsing at either
the peak or background level. If
placed in the On position while
welding, pulsing begins at the peak
amperage level and pulses to the
background level.

OM-898 Page 11
4-11. Power Switch And Pilot Light
1 Power Switch
2 Pilot Light
Use this switch to turn unit and pilot
light On and Off.
2

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

5-1. Routine Maintenance

3 Months Turn Off all power before maintaining.

Replace
See Unreadable
Section Labels
8

Replace
Cracked
Parts
–– 14-Pin Cord

ST-130 261-A

OM-898 Page 12
5-2. Troubleshooting

Trouble Remedy
No pulsing. Secure cord connections (see Section 3-5).

Be sure Power switch is On (see Section 4-11).

Be sure Pulser switch is On (see Section 4-10).

If remote control is not used, place Amperage switch in Panel position. If remote control is used, place
switch in Remote 14 position, and be sure remote control is connected to Remote 14 receptacle (see Sec-
tions 4-7 and 3-4).

If remote control is not used, place Output (Contactor) switch in On position. If remote control is used,
place switch in Remote 14 position, and be sure remote control is connected to Remote 14 receptacle
(see Sections 4-9 and 3-4).

No amperage control. If remote control is not used, place Amperage switch in Panel position. If remote control is used, place
switch in Remote 14 position, and be sure remote control is connected to Remote 14 receptacle (see Sec-
tions 4-7 and 3-4).

Minimum weld output with no control from Be sure Power switch is On (see Section 4-11).
welding power source.

If remote control is not used, place Amperage switch in Panel position. If remote control is used, place
switch in Remote 14 position, and be sure remote control is connected to Remote 14 receptacle (see Sec-
tions 4-7 and 3-4).

Be sure Peak Amperage control is set above the minimum (0) (see Section 4-3).

Pulsing too fast or too slow. Be sure positions on internal DIP switch are set for proper range to match Pulses Per Second control (see
Sections 3-3 and 4-5).

5-3. Circuit Diagram For Pulser Control

SB-173 603

OM-898 Page 13
 SECTION 6 – SELECTING AND PREPARING
TUNGSTEN ELECTRODE
gtaw 7/97

NOTE For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent
contamination of tungsten electrode.

6-1. Selecting Tungsten Electrode

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter DC – Argon – Electrode DC – Argon – Electrode AC – Argon – Using AC – Argon – Balanced
Negative/Straight Polarity Positive/Reverse Polarity High Frequency Wave Using High Freq.
Pure Tungsten
(Green Band)
.010” Up to 15 * Up to 15 Up to 10
.020” 5-20 * 5-20 10-20
.040” 15-80 * 10-60 20-30
1/16” 70-150 10-20 50-100 30-80
3/32” 125-225 15-30 100-160 60-130
1/8” 225-360 25-40 150-210 100-180
5/32” 360-450 40-55 200-275 160-240
3/16” 450-720 55-80 250-350 190-300
1/4” 720-950 80-125 325-450 250-400
2% Thorium Alloyed
Tungsten (Red Band)
.010” Up to 25 * Up to 20 Up to 15
.020” 15-40 * 15-35 5-20
.040” 25-85 * 20-80 20-60
1/16” 50-160 10-20 50-150 60-120
3/32” 135-235 15-30 130-250 100-180
1/8” 250-400 25-40 225-360 160-250
5/32” 400-500 40-55 300-450 200-320
3/16” 500-750 55-80 400-500 290-390
1/4” 750-1000 80-125 600-800 340-525
Zirconium Alloyed Tung-
sten (Brown Band)
.010” * * Up to 20 Up to 15
.020” * * 15-35 5-20
.040” * * 20-80 20-60
1/16” * * 50-150 60-120
3/32” * * 130-250 100-180
1/8” * * 225-360 160-250
5/32” * * 300-450 200-320
3/16” * * 400-550 290-390
1/4” * * 600-800 340-525

♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
OM-898 Page 14
6-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding
1 Tungsten Electrode
2 Balled End
Y Understand and follow
1 safety symbols at start of
Section NO TAG before pre-
paring tungsten.
Ball end of tungsten before welding
1-1/2 Times by applying either an ac amperage
Electrode Diameter
slightly higher than what is recom-
mended for a given electrode diam-
eter (see Section 6-1), or a dc
2 electrode positive amperage.

Ref. S-0161

6-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding

1 Tungsten Electrode
1 2 2 Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld-
ing. Do not use wheel for other jobs
or tungsten can become contami-
nated causing lower weld quality.

2-1/2 Times
Electrode Diameter

1 Stable Arc
2 Flat
1
Diameter of this flat determines
amperage capacity.
2
3 Grinding Wheel
3 4 Straight Ground

4
Ideal Tungsten Preparation – Stable Arc

1 Arc Wander
2 Point
1 3 Grinding Wheel
4 Radial Ground
2

Wrong Tungsten Preparation – Wandering Arc

Ref. S-0161 / Ref. S-0162

OM-898 Page 15
 SECTION 7 – PARTS LIST
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 7-1. Main Assembly
... 1 . . . . . R1 . . . . . 073 562 . . POTENTIOMETER, C sltd sft 1/T 2W 10K ohm . . . . . . . . . . . . . . . . . . . . . . 1
... 2 . . . . C5,6 . . . . 165 747 . . CAPACITOR, cer mono 1uf 50VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 3 . . . . R2,4 . . . . 030 109 . . POTENTIOMETER, C sltd sft 1/T 2W 5K ohm . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . . R3 . . . . . 004 186 . . POTENTIOMETER, C sltd sft 1/T 2W 5K ohm . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . RC1 . . . . 143 976 . . CONNECTOR w/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . 127 342 . . CASE SECTION, sides/bottom/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . PLG400 . . . 165 896 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . PC1 . . . . 125 601 . . CIRCUIT CARD, pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . 110 375 . . STAND-OFF SUPPORT, PC card No. 6 screw . . . . . . . . . . . . . . . . . . . . . . . 4
... 10 . . . . . . . . . . . . . . 126 368 . . STAND-OFF SUPPORT, PC card No. 6 screw . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . . 070 654 . . BUSHING, strain relief .300 ID x .550mtg hole . . . . . . . . . . . . . . . . . . . . . . . 2
... 12 . . . . . . . . . . . . . . 007 826 . . CABLE, port No.18 3/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8ft
... 13 . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . PLG1 . . . . 141 162 . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . . 143 922 . . . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3 . . . . . . . . . . . . 1
... 16 . . . . . . . . . . . . . . 175 284 . . CABLE, port No. 20ga 5/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8ft
... 17 . . . . . . . . . . . . . . 138 583 . . BRACKET, mtg unit (Eff w/KA861650) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . . . . . . . . . . 601 219 . . LINK, jumper term blk 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . . . 1T . . . . . 038 839 . . BLOCK, term 20A 5P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 . . . . . . . . . . . . . . 138 561 . . TRANSFORMER, control (Eff w/KA861650) . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 21 . . . . . . . . . . . . . . 019 663 . . MOUNT, nprn 15/16 OD X 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 22 . . . . . C1 . . . . . 144 478 . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . . . C2 . . . . . 144 481 . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . . . C3 . . . . . 144 479 . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . . . C4 . . . . . 144 480 . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 . . . . . . . . . . . . . . 131 515 . . LABEL, warning electric shock etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . . . . . . . . . . . +127 343 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 25 . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . 1
... 26 . . . . . PL1 . . . . 027 645 . . LIGHT, ind red lens 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 27 . . . . . S1 . . . . . 131 663 . . SWITCH, rocker DPDT 8A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 28 . . . . S2-4 . . . . 120 376 . . SWITCH, rocker SPDT 4A 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 29 . . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 2 3 2
8
9 10 . Hardware is common and
not available unless listed.
7
4
13
3 12

6 11
5

23 14
15
16
11

24 22
17
21
29 20
25 18

19

28 26
27 ST-130 263-B
Figure 7-1. Main Assembly
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-898 Page 16
Notes
Notes
 Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.

Call LIMITED WARRANTY – Subject to the terms and conditions * APT, ZIPCUT & PLAZCUT Model Plasma Cutting
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches
1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold
* Remote Controls
for your local after the effective date of this limited warranty is free of defects
* Accessory Kits
in material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Replacement Parts (No labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate 185 & Spoolmate 250
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to
you ... Miller’s True Blue Limited Warranty shall not apply to:
such defects in material or workmanship. Miller must be
Service notified in writing within thirty (30) days of such defect or 1. Consumable components; such as contact tips,
failure, at which time Miller will provide instructions on the cutting nozzles, contactors, brushes, slip rings,
You always get the fast, warranty claim procedures to be followed.
reliable response you relays or parts that fail due to normal wear.
need. Most replacement Miller shall honor warranty claims on warranted equipment
2. Items furnished by Miller, but manufactured by others,
parts can be in your listed below in the event of such a failure within the warranty
such as engines or trade accessories. These items are
time periods. All warranty time periods start on the date that
hands in 24 hours. the equipment was delivered to the original retail purchaser, or
covered by the manufacturer’s warranty, if any.
Support one year after the equipment is sent to a North American 3. Equipment that has been modified by any party other
Need fast answers to the distributor or eighteen months after the equipment is sent to an than Miller, or equipment that has been improperly
International distributor. installed, improperly operated or misused based upon
tough welding questions?
Contact your distributor. 1. 5 Years Parts – 3 Years Labor industry standards, or equipment which has not had
The expertise of the reasonable and necessary maintenance, or equipment
* Original main power rectifiers which has been used for operation outside of the
distributor and Miller is specifications for the equipment.
* Inverters (input and output rectifiers only)
there to help you, every
step of the way. 2. 3 Years — Parts and Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Transformer/Rectifier Power Sources PERSONS TRAINED AND EXPERIENCED IN THE USE
* Plasma Arc Cutting Power Sources AND MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Inverter Power Supplies exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Intellitig appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
3. 1 Year — Parts and Labor replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
* Motor Driven Guns (w/exception of Spoolmate transportation costs of any kind will be allowed.
185 & Spoolmate 250)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Process Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Positioners and Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources ANY OTHER LEGAL THEORY.
* Water Coolant Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
* HF Units AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Maxstar 140 OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
* Spot Welders OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Load Banks OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* Miller Cyclomatic Equipment MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
* Running Gear/Trailers EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
* Plasma Cutting Torches (except APT & SAF DISCLAIMED BY MILLER.
Models) Some states in the U.S.A. do not allow limitations of how long
* Field Options an implied warranty lasts, or the exclusion of incidental,
(NOTE: Field options are covered under True indirect, special or consequential damages, so the above
Blue for the remaining warranty period of the limitation or exclusion may not apply to you. This warranty
product they are installed in, or for a minimum of provides specific legal rights, and other rights may be
one year — whichever is greater.) available, but may vary from state to state.

4. 6 Months — Batteries In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,
5. 90 Days — Parts and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
* MIG Guns/TIG Torches Warranty provides specific legal rights, and other rights may
* Induction Heating Coils and Blankets be available, but may vary from province to province.

miller_warr 7/00
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters–USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters –
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com

Contact the Delivering Carrier for: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00