Miller Electric Millermatic Pulser M-15 Gun Specifications

ProcessesDescriptionMIG (GMAW) WeldingFlux Cored (FCAW) WeldingArc Welding Power Sourceand Wire FeederTM-1326B 2006−10Eff. w/Serial Number LB170597Mil

TM-1326 Page 8 Millermatic 2513-9. Installing Wire Spool And Adjusting Hub TensionWhen a slight force is neededto turn spool, tension is set.15/16 inU

TM-1326 Page 9Millermatic 2513-11. Electrical Service GuideInput Voltage 200 230 400 460 575Input Amperes At Rated Output 48 42 24 21 17Max Recommende

TM-1326 Page 10 Millermatic 2513-12. Selecting A Location And Connecting Input PowerRef. 802 477-B / 803 766-BL1L2230 VAC, 118 in (457 mm) ofspace for

TM-1326 Page 11Millermatic 2513-13. Threading Welding Wire1 Wire Spool2 Welding Wire3 Inlet Wire Guide4 Pressure Adjustment Knob5 Drive Roll6 Outlet W

TM-1326 Page 12 Millermatic 251Ref. 802 726-A1 Side Panel2 Latch3 Cable HolderPress latch down to release andopen door.4 Holster (2)Wrap cable around

TM-1326 Page 13Millermatic 251Notes

TM-1326 Page 14 Millermatic 2513-15. Weld Parameters

TM-1326 Page 15Millermatic 251201 202-A

TM-1326 Page 16 Millermatic 251SECTION 4 − OPERATION4-1. ControlsRef. 205 6371 Voltage Control Turn control clockwise to increasevoltage.2 Wire Speed

TM-1326 Page 17Millermatic 2514-2. Voltmeter And Wire Feed Speed Meter Operation1 Voltmeter2 Wire Feed Speed MeterPower Up StatusBoth meters display 8

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-

TM-1326 Page 18 Millermatic 251SECTION 5 − THEORY OF OPERATION4Single-PhaseLine Input PowerFan MotorFMPowerSwitchS1InputTerminalBoard TE1Gas ValveGS1C

TM-1326 Page 19Millermatic 251Weld Current CircuitFanControlReceptacleRC7WireGun TriggerReceptacleRC1VoltageControl R2Wire SpeedControl R317467Electro

TM-1326 Page 20 Millermatic 251B. Basic Training Circuit

TM-1326 Page 21Millermatic 251211 408-C. This circuit is for trainingpurposes only. It has beenmodified for that use and maynot reflect the actual cir

TM-1326 Page 22 Millermatic 251SECTION 6 − TROUBLESHOOTING6-1. Troubleshooting Table. See Section 6-2 for test points and values andSection 9 for part

TM-1326 Page 23Millermatic 251Trouble RemedyLow weld output. Connect unit to proper input voltage or check for low line voltage (see Section 3-12).Che

TM-1326 Page 24 Millermatic 251See Section 6-3For Waveform G1V1G1V2R1V3V4V5V8V9V7V6See Section 6-4For PC1 DataFan ControlRelay CR16-2. Troubleshooting

TM-1326 Page 25Millermatic 251Test Equipment Needed:R3R2V11A, B, C,D, E, FSee Section 6-3For WaveformsA, B, C, D, E, FV13Wire DriveMotor MV12V14V15Res

TM-1326 Page 26 Millermatic 2516-3. Waveforms For Section 6-25 ms 5 VA. DC Open-Circuit Voltage, Voltage ControlR2 At Minimum5 ms 5 VB. 9.3 Volts

TM-1326 Page 27Millermatic 251Test Equipment Needed:5 ms 5 VE. DC Open-Circuit Voltage, Voltage ControlR2 At Maximum5 ms 5 VF. 29.4 Volts DC, Volt

TM-1326 Page 1Millermatic 251SECTION 1 − SAFETY PRECAUTIONS FOR SERVICINGY Warning: Protect yourself and others from injury — read and follow these pr

TM-1326 Page 28 Millermatic 2516-4. Main Control Board PC1 Testing Information (Use With Section 6-5)Be sure plugs are secure beforetesting. See Secti

TM-1326 Page 29Millermatic 2516-5. Main Control Board PC1 Test Point ValuesPC1 Voltage Readingsa) Tolerance − ±10% unless specifiedb) Reference − to

TM-1326 Page 30 Millermatic 251Receptacle ValuesPinRC31 Spool gun potentiometer reference output +5 volts dc 2 Spool gun trigger input +35 volts dc w

TM-1326 Page 31Millermatic 2516-6. Pre-Operational Check1 Weld Output TerminalsCheck open-circuit voltage betweenterminals according to Section 6-2(vo

TM-1326 Page 32 Millermatic 251SECTION 7 − MAINTENANCE7-1. Routine MaintenanceY Disconnect power before maintaining.. Maintain more oftenduring severe

TM-1326 Page 33Millermatic 2517-3. Changing Drive Roll and Wire Inlet Guide1 Securing Screw2 Inlet Wire GuideLoosen screw. Slide tip as close todrive

TM-1326 Page 34 Millermatic 2517-5. Removing Knob From Front PanelY Turn Off power.1 Front Panel2 Knob3 Spring Clip4 Control Shaft5 SlotRotate knob to

TM-1326 Page 35Millermatic 251SECTION 8 − ELECTRICAL DIAGRAMS. The circuits in this manual can be used for troubleshooting, but there might be minor c

TM-1326 Page 36 Millermatic 251Figure 8-1. Circuit Diagram For Millermatic 251 Eff w/LB170597 Thru LC507658

TM-1326 Page 37Millermatic 251204 321−E

TM-1326 Page 2 Millermatic 251MOVING PARTS can cause injury.D Keep away from moving parts such as fans.D Keep away from pinch points such as driveroll

TM-1326 Page 38 Millermatic 251Figure 8-2. Circuit Diagram For Millermatic 251 Eff w/LB170597 Thru LF430260B

TM-1326 Page 39Millermatic 251211 406−C

TM-1326 Page 40 Millermatic 251Figure 8-3. Circuit Diagram For Millermatic 251 Eff w/LF430261B And Following

TM-1326 Page 41Millermatic 251226 707-A

TM-1326 Page 42 Millermatic 251Figure 8-4. Circuit Diagram For Main Control Board PC1 Eff w/LC141473 Thru LE152375

TM-1326 Page 43Millermatic 251Part 1 Of 2 207 548

TM-1326 Page 44 Millermatic 251Figure 8-5. Circuit Diagram For Main Control Board PC1 Eff w/LC141473 Thru LE152375

TM-1326 Page 45Millermatic 251Part 2 Of 2 207 548

TM-1326 Page 46 Millermatic 251Figure 8-6. Circuit Diagram For Main Control Board PC1 Eff w/LE152376 And Following

TM-1326 Page 47Millermatic 251Part 1 Of 2 212 363-A

TM-1326 Page 3Millermatic 251SECTION 2 − DEFINITIONS2-1. Symbols And DefinitionsWire Feed OutputXDuty CycleDo Not SwitchWhile WeldingVVolts Increase O

TM-1326 Page 48 Millermatic 251Figure 8-7. Circuit Diagram For Main Control Board PC1 Eff w/LE152376 And Following

TM-1326 Page 49Millermatic 251Part 2 Of 2 212 363-A

TM-1326 Page 50 Millermatic 251Figure 8-8. Circuit Diagram For Meter Board PC2 Eff w/LC324876 Thru LF390239B

TM-1326 Page 51Millermatic 251Figure 8-9. Circuit Diagram For Meter Board PC2 Eff w/LF390239B And Following210 604

TM-1326 Page 52 Millermatic 251Figure 8-10. Circuit Diagram For Meter Board PC2 Eff w/LF390239B And Following+5V+5V+5V+35VGNDVCCPD6/AIN0PD5/T1PD4/T0P

TM-1326 Page 53Millermatic 251224 080-BADRBIBI/RBOLTCGNDVCCBgfaedcbADRBIBI/RBOLTCGNDVCCBgfaedcb+5VGNDFDBKON/OFFVOUTVINE1D1CA1AC1E2C2E3D3CA3AC3DP3 B3A3

TM-1328 Page 54 Millermatic PassportTable 8-1. Lead List Summary For Millermatic Passport Models Eff w/LE300069. Table shows physical lead connections

ProcessesDescriptionMIG (GMAW) WeldingFlux Cored (FCAW) WeldingArc Welding Power Sourceand Wire FeederTM-1326B 2006−10Eff. w/Serial Number LB170597Mil

TM-1326 Page 56 Millermatic 251SECTION 9 − PARTS LIST. Hardware is common andnot available unless listed.803 008-C1821222316171514131094561171281 − Fi

TM-1326 Page 57Millermatic 251DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-1. Main AssemblyQuantity1 Fig 9-2 BAFFLE, center w/components 1. . . . . . .

TM-1326 Page 4 Millermatic 2513-2. Welding Power Source Duty Cycle And OverheatingDuty Cycle is percentage of 10minutes that unit can weld at ratedloa

TM-1326 Page 58 Millermatic 251. Hardware is common andnot available unless listed.803007-E302915149281827262423222120191716111312108765432125 − Fig 9

TM-1326 Page 59Millermatic 251DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-2. Baffle, Center w/Components (Fig 9-1 Item 1)Quantity1 058 427 RING, retain

TM-1326 Page 60 Millermatic 251QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-3. Panel, Front w/Components (Fig 9-1 Item19)(Prior to LC198564)1 +1

TM-1326 Page 61Millermatic 251QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-4. Panel, Front w/Components (Fig 9-1 Item19)(Eff w/LC198564 thru LG3

TM-1326 Page 62 Millermatic 251DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-5. Panel, Front w/Components (Eff w/LG350556B)(Fig 9-1 Item 19)Quantity1 208

TM-1326 Page 63Millermatic 251DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-6. Wire Drive And Gears (Prior to LF430261B)(Fig 9-2 Item 25)Quantity1 602 00

TM-1326 Page 64 Millermatic 251DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-7. Wire Drive And Gears (Eff w/LF430261B)(Fig 9-2 Item 25)Quantity1 602 009

TM-1326 Page 65Millermatic 251DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-8. Panel, Rear w/Components (Fig 9-1 Item 3)Quantity1 148 809 BLADE, fan 9 in

TM-1326 Page 66 Millermatic 2519-9. Drive Roll And Wire Guide KitsNoteBase selection of drive rolls upon the following recommended usages:1 V-Grooved

Notes

TM-1326 Page 5Millermatic 2513-4. Connecting To Weld Output Terminals803 778-AY Turn off power before connecting toweld output terminals.Y Failure to

Notes

Notes

PRINTED IN USA © 2006 Miller Electric Mfg. Co.Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USAInte

TM-1326 Page 6 Millermatic 2513-6. Connecting Spoolmatic) 15A Or 30A Gun804 455-A1 Gun Trigger PlugInsert plug into receptacle, andtighten threaded co

TM-1326 Page 7Millermatic 2513-7. Setting Gun Polarity For Wire Type1 Polarity Changeover LabelInformationAlways read and follow manufacture’srecommen