Miller MR-5/PULSTAR 450 - User Manual

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EfiE?:t~vi~ ~ ih Serial NO. J
113Er)904
MODEL
MR-5/PULSTAR 450®
COMPUTER INTERFACE
GAS/CURRENT SENSING
CONTROL
OWNER’S MANUAL
IMPORTANT: Read and understand the entire contents of both this Miller Electric Mfg. Co.
manual and the power source manual used with this unit, with special ~
emphasis on the safety material throughout both manuals, before in- ~a. Box 1079
stalling,operating, or maintaining this equipment. This unit and these Appleton, WI 54912 USA
instructions are for use only by persons trained and experienced in the Tel. 414-734-9821
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®
PRINTED IN U.S.A.
ADDITIONAL COPY PRICE 95 CENTS

Summary

ERRATA SHEET

AMENDMENT TO SECTION 2 - INSTALLATION

Updates to installation instructions in Section 2.

AMENDMENT TO SECTION 5 - MAINTENANCE & TROUBLESHOOTING

Updates to maintenance and troubleshooting sections.

LIMITED WARRANTY

SECTION 1 - INTRODUCTION

General Information and Safety

Overview of manual content and general safety precautions.

Receiving and Handling

Instructions for receiving, inspecting, and handling the equipment.

Description of the Control

Details the computer interface and gas/current sensing control functions.

SECTION 2 - INSTALLATION

Location and Mounting

Guidelines for selecting a suitable installation location.

Gas;Current Sensing Control Connections

Procedures for connecting the gas/current sensing control.

Computer Interface - Welding Power Source Connections

Steps for connecting the computer interface to the power source.

Computer Interface Welding Power Source Interface Connections

Details on interface connections to the power source.

Computer Interface Terminal Strip Connections

Details on making connections at the terminal strip.

SECTION 3 - FUNCTION OF CONTROLS

Power Switch and Overload Protection

Explains the power switch and fuse/breaker protection.

Peak Amperage Control

Describes the function and adjustment of the peak amperage control.

Meters and Indicator Lights

Explains the voltmeter, ammeter, wire speed meter, and indicator lights.

SECTION 4 - SEQUENCE OF OPERATION

Input Signal from Welding Power Source

Describes input signals from the power source and wire drive motor.

Output Signals from Computer Interface

Explains output signals regulating power source and wire feed.

Wire Stick Check Procedure

Details the wire stick check performed after welding.

SECTION 5 - MAINTENANCE & TROUBLESHOOTING

Inspection, Upkeep, and Overload Protection

Routine inspection, cleaning, and overload protection details.

Display Board PC4 Meter Check

Procedures to check meter power supply and input commands.

Board Replacement Procedures

Step-by-step guide for replacing circuit boards.

Troubleshooting Chart

Guide to diagnose and remedy common operational issues.

Use of Indicator Lights for Troubleshooting

How to use indicator lights for diagnosing problems.

PARTS LIST

Miller MR-5/PULSTAR 450 Specifications

General

Brand	Miller
Model	MR-5/PULSTAR 450
Category	Recording Equipment
Language	English