Ultra-Pulse 350MPiMIG Pulse Pendant Control

Instruction Manual

This manual provides installation and operation instructions forthe following Ultra-Pulse 350MPi MIG Pulse Pendant Control:P/N 36988

F15-606-A 10 / 2003

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These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principlesof operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet,"Precautions and Safe Practices for Arc Welding, Cutting, and Gouging," Form 52-529. Do NOT permituntrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operatethis equipment until you have read and fully understand these instructions. If you do not fully understandthese instructions, contact your supplier for further information. Be sure to read the Safety Precautionsbefore installing or operating this equipment.

BE SURE THIS INFORMATION REACHES THE OPERATOR.YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual andaccompanying labels and/or inserts when installed, operated, maintained and repaired inaccordance with the instructions provided. This equipment must be checked periodically.Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing,worn, distorted or contaminated should be replaced immediately. Should such repair orreplacement become necessary, the manufacturer recommends that a telephone or writtenrequest for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of themanufacturer. The user of this equipment shall have the sole responsibility for any malfunctionwhich results from improper use, faulty maintenance, damage, improper repair or alteration byanyone other than the manufacturer or a service facility designated by the manufacturer.

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TABLE OF CONTENTS

SECTION TITLE PAGEPARAGRAPH

SECTION 1 DESCRIPTION ................................................................................................. 101.1 General ............................................................................................................. 10

SECTION 2 INSTALLATION................................................................................................ 102.1 General ............................................................................................................. 102.2 Cable Connections............................................................................................ 102.3 Power Source Set-Up ....................................................................................... 11

SECTION 3 PULSE OPERATION........................................................................................ 113.1 Pulsed MIG Operation ...................................................................................... 11

SECTION 4 PULSE TECHNICAL DATA ............................................................................. 124.1 Standard CV Operation ..................................................................................... 124.2 Pulse MIG Arc Stability .................................................................................... 134.3 Shielding Gases ................................................................................................ 134.4 Pulse Parameters ............................................................................................. 13

SECTION 5 ULTRAPULSE MOUNTING OPTIONS ............................................................ 16

SECTION 6 WIRING DIAGRAMS & REPLACEMENT PARTS ........................................... 17

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TABLE OF CONTENTS

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SAFETY PRECAUTIONSWARNING: These Safety Precautions are foryour protection. They summarize precaution-ary information from the references listed inAdditional Safety Information section. Before

performing any installation or operating procedures, besure to read and follow the safety precautions listed belowas well as all other manuals, material safety data sheets,labels, etc. Failure to observe Safety Precautions can resultin injury or death.

PROTECT YOURSELF AND OTHERS --Some welding, cutting, and gougingprocesses are noisy and require earprotection. The arc, like the sun, emitsultraviolet (UV) and other radiation and

can injure skin and eyes. Hot metal can cause burns.Training in the proper use of the processes and equip-ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any workarea, even if welding helmets, face shields, and gogglesare also required.

2. Use a face shield fitted with the correct filter and coverplates to protect your eyes, face, neck, and ears fromsparks and rays of the arc when operating or observingoperations. Warn bystanders not to watch the arc andnot to expose themselves to the rays of the electric-arcor hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeveshirt, cuffless trousers, high-topped shoes, and a weld-ing helmet or cap for hair protection, to protect againstarc rays and hot sparks or hot metal. A flameproof apronmay also be desirable as protection against radiatedheat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,trouser cuffs, or pockets. Sleeves and collars should bekept buttoned, and open pockets eliminated from thefront of clothing

5. Protect other personnel from arc rays and hot sparkswith a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag orgrinding. Chipped slag may be hot and can fly far.Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat fromflames and arcs can start fires. Hot slagor sparks can also cause fires and ex-plosions. Therefore:

1. Remove all combustible materials well away from thework area or cover the materials with a protective non-flammable covering. Combustible materials include wood,cloth, sawdust, liquid and gas fuels, solvents, paints andcoatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks orcrevices in floors or wall openings and cause a hiddensmoldering fire or fires on the floor below. Make certainthat such openings are protected from hot sparks andmetal.“

3. Do not weld, cut or perform other hot work until theworkpiece has been completely cleaned so that thereare no substances on the workpiece which might pro-duce flammable or toxic vapors. Do not do hot work onclosed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,such as a garden hose, water pail, sand bucket, orportable fire extinguisher. Be sure you are trained in itsuse.

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5. Do not use equipment beyond its ratings. For example,overloaded welding cable can overheat and create a firehazard.

6. After completing operations, inspect the work area tomake certain there are no hot sparks or hot metal whichcould cause a later fire. Use fire watchers when neces-sary.

7. For additional information, refer to NFPA Standard 51B,"Fire Prevention in Use of Cutting and Welding Pro-cesses", available from the National Fire Protection Asso-ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with liveelectrical parts and ground can causesevere injury or death. DO NOT use ACwelding current in damp areas, if move-ment is confined, or if there is danger offalling.

1. Be sure the power source frame (chassis) is connectedto the ground system of the input power.

2. Connect the workpiece to a good electrical ground.3. Connect the work cable to the workpiece. A poor or

missing connection can expose you or others to a fatalshock.

4. Use well-maintained equipment. Replace worn or dam-aged cables.

5. Keep everything dry, including clothing, work area,cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated fromwork and from ground.

7. Do not stand directly on metal or the earth while workingin tight quarters or a damp area; stand on dry boards oran insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)for specific grounding recommendations. Do not mis-take the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —May be dangerous. Electric current flow-ing through any conductor causes lo-calized Electric and Magnetic Fields(EMF). Welding and cutting current cre-ates EMF around welding cables andwelding machines. Therefore:

1. Welders having pacemakers should consult their physi-cian before welding. EMF may interfere with some pace-makers.

2. Exposure to EMF may have other health effects which areunknown.

3. Welders should use the following procedures to minimizeexposure to EMF:A. Route the electrode and work cables together. Secure

them with tape when possible.B. Never coil the torch or work cable around your body.C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.D. Connect the work cable to the workpiece as close as

possible to the area being welded.E. Keep welding power source and cables as far away

from your body as possible.

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FUMES AND GASES -- Fumes andgases, can cause discomfort or harm,particularly in confined spaces. Donot breathe fumes and gases. Shield-ing gases can cause asphyxiation.Therefore:

1. Always provide adequate ventilation in the work area bynatural or mechanical means. Do not weld, cut, or gougeon materials such as galvanized steel, stainless steel,copper, zinc, lead, beryllium, or cadmium unless posi-tive mechanical ventilation is provided. Do not breathefumes from these materials.

2. Do not operate near degreasing and spraying opera-tions. The heat or arc rays can react with chlorinatedhydrocarbon vapors to form phosgene, a highly toxicgas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritationwhile operating, this is an indication that ventilation is notadequate. Stop work and take necessary steps to im-prove ventilation in the work area. Do not continue tooperate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)for specific ventilation recommendations.

5. WARNING: This product, when used for welding orcutting, produces fumes or gases whichcontain chemicals known to the State ofCalifornia to cause birth defects and, insome cases, cancer. (California Health &Safety Code §25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, ifmishandled, can rupture and violentlyrelease gas. Sudden rupture of cylin-der, valve, or relief device can injure orkill. Therefore:

1. Use the proper gas for the process and use the properpressure reducing regulator designed to operate fromthe compressed gas cylinder. Do not use adaptors.Maintain hoses and fittings in good condition. Followmanufacturer's operating instructions for mounting regu-lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chainor strap to suitable hand trucks, undercarriages, benches,walls, post, or racks. Never secure cylinders to worktables or fixtures where they may become part of anelectrical circuit.

3. When not in use, keep cylinder valves closed. Havevalve protection cap in place if regulator is not con-nected. Secure and move cylinders by using suitablehand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,"Precautions for Safe Handling of Compressed Gases inCylinders", which is available from Compressed GasAssociation, 1235 Jefferson Davis Highway, Arlington,VA 22202.

EQUIPMENT MAINTENANCE -- Faulty orimproperly maintained equipment cancause injury or death. Therefore:

1. Always have qualified personnel perform the installa-tion, troubleshooting, and maintenance work. Do notperform any electrical work unless you are qualified toperform such work.

2. Before performing any maintenance work inside a powersource, disconnect the power source from the incomingelectrical power.

3. Maintain cables, grounding wire, connections, powercord, and power supply in safe working order. Do notoperate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keepequipment away from heat sources such as furnaces,wet conditions such as water puddles, oil or grease,corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in positionand in good repair.

6. Use equipment only for its intended purpose. Do notmodify it in any manner.

ADDITIONAL SAFETY INFORMATION -- Formore information on safe practices for elec-tric arc welding and cutting equipment, askyour supplier for a copy of "Precautions andSafe Practices for Arc Welding, Cutting andGouging", Form 52-529.

The following publications, which are available from theAmerican Welding Society, 550 N.W. LeJuene Road, Mi-ami, FL 33126, are recommended to you:1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"5. AWS C5.5 - "Recommended Practices for Gas Tungsten

Arc Welding“6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have HeldHazardous Substances."

MEANING OF SYMBOLS - As used through-out this manual: Means Attention! Be Alert!Your safety is involved.

Means immediate hazards which, ifnot avoided, will result in immediate,serious personal injury or loss of life.

Means potential hazards which couldresult in personal injury or loss of life.

Means hazards which could result inminor personal injury.

SP98-10

SAFETY PRECAUTIONS

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tibles du secteur où l’on exécute des soudures oudes coupes à l’arc, à moins de les recouvrircomplètement d’une bâche non-inflammable. Cetype de matériaux comprend notamment le bois, lesvêtements, la sciure, l’essence, le kérosène, lespeintures, les solvants, le gaz naturel, l’acétylène, lepropane et autres substances combustiblessemblables.

b. Les étincelles ou les projections de métal incandes-cent peuvent tomber dans des fissures du plancherou dans des ouvertures des murs et y déclencherune ignition lente cachée. Veiller à protéger cesouvertures des étincelles et des projections demétal.

c. N’exécutez pas de soudures, de coupes,d’opérations de gougeage ou autres travaux à chaudà la surface de barils, bidons, réservoirs ou autrescontenants usagés, avant de les avoir nettoyés detoute trace de substance susceptible de produiredes vapeurs inflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, ilconvient de disposer d’un matériel d’extinction prêt àservir immédiatement, tel qu’un tuyau d’arrosage, unseau à eau, un seau de sable ou un extincteurportatif.

e. Une fois le travail à l’arc terminé, inspectez lesecteur de façon à vous assurer qu’aucune étincelleou projection de métal incandescent ne risque deprovoquer ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arcau plasma exige l’emploi de tensions à viderelativement importantes; or, celles-ci risquent decauser des dommages corporels graves et mêmemortels en cas d’utilisation inadéquate. La gravité duchoc électrique reçu dépend du chemin suivi par lecourant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques soustension venir au contact direct de la peau ou devêtements humides. Veillez à porter des gants biensecs.

b. Si vous devez effectuer un travail sur une surfacemétallique ou dans un secteur humide, veillez àassu-rer votre isolation corporelle en portant desgants secs et des chaussures à semelles de ca-outchouc et en vous tenant sur une planche ou uneplate-forme sèche.

c. Mettez toujours à la terre le poste de soudage/coupage en le reliant par un câble à une bonne prisede terre.

d. N’utilisez jamais de câbles usés ou endommagés.Ne surchargez jamais le câble. Utilisez toujours unéquipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pasen service. une mise à la masse accidentelle peut eneffet provoquer une surchauffe de l’équipement et undanger d’incendie. Ne pas enrouler ou passer lecâble autour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièceen un point aussi proche que possible de la zone de

PRÉCAUTIONS DE SÉCURITÉAVERTISSEMENT: Ces règles de sécurité ont pour objetd’ assurer votre protection. Veillez à lire et à observer lesprécautions énoncées ci-dessous avant de monter l’équipement ou de commercer à l’utiliser. Tout défautd’observation de ces précautions risque d’entraîner desblessures graves ou mortelles.1. PROTECTION INDIVIDUELLE-- Les brûlures de la

peau et des yeux dues au rayonnement de l’arcélectrique ou du métal incandescent, lors du soudageau plasma ou à l’électrode ou lors du gougeage àl’arc, peuvent s’avérer plus graves que cellesrésultant d’une exposition prolongée au soleil. Aussiconvient-il d’observer les précautions suivantes:

a. Portez un écran facial adéquat muni des plaquesprotectrices et des verres filtrants appropriés afin devous protéger les yeux, le visage, le cou et les oreillesdes étincelles et du rayonnement de l’arc électriquelorsque vous effectuez des soudures ou des coupesou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximitéde façon à ce qu’elles ne regardent pas l’arc et à cequ’elles ne s’exposent pas à son rayonnement, ni àcelui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tuniqueépaisse à manches longues, des pantalons sansrebord, des chaussures à embout d’acier et uncasque de soudage ou une calotte de protection, afind’éviter d’exposer la peau au rayonnement de l’arcélectrique ou du métal incandescent. ll est égalementsouhaitable d’utiliser un tablier ininflammable defaçon à se protéger des étincelles et du rayonnementthermique.

c. Les étincelles ou les projections de métal incandes-cent risquent de se loger dans des manchesretroussées, des bords relevés de pantalons ou dansdes poches. Aussi convient-il de garder boutonnés lecol et les manches et de porter des vêtements sanspoches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arcélectrique les autres personnes travaillant à proximitéà l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécuritélorsque vous vous trouvez dans un secteur où l’oneffectue des opérations de soudage ou de coupage àl’arc. Utilisez des lunettes de sécurité à écrans ouverres latéraux pour piquer ou meûler le laitier. Lespiquetures incandescentes de laitier peuvent êtreprojetées à des distances considérables. Lespersonnes se trouvant à proximité doivent égalementporter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasmaproduisent un niveau de bruit extrêmement élevé (de100 à 114 dB) et exigent par conséquent l’emploi dedispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections delaitier incandescent ou d’étincelles peuventprovoquer de graves incendies au contact dematériaux combustibles solides, liquides ou gazeux.Aussi faut-il observer les précautions suivantes:

a. Éloigner suffisamment tous les matériaux combus-

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levage, des câbles de grue ou divers cheminsélectriques.

g. Empêchez l’apparition de toute humidité, notammentsur vos vêtements, à la surface de l’emplacement detravail, des câbles, du porte-électrode et du poste desoudage/coupage. Réparez immédiatement toutefuite d’eau.

4. VENTILATION-- La respiration prolongée des fuméesrésultant des opérations de soudage/coupage, àl’intérieur, d’un local clos, peut provoquer des mal-aises et des dommages corporels. Aussi convient-ild’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate del’emplacement de travail en maintenant une ventila-tion naturelle ou à l’aide de moyens mécaniques.N’effectuez jamais de travaux de soudage ou decoupage sur des matériaux de zinc, de plomb, deberyllium ou de cadmium en l’absence de moyensmécaniques de ventilation capables d’empêcherl’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou decoupage à proximité de vapeurs d’hydrocarburechloré résultant d’opérations voisines de dégraissageou de pulvérisation. La chaleur dégagée ou lerayonnement de l’arc peut déclencher la formation dephosgène -- gaz particulièrement toxique -- etd’autres gaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de lagorge constatée au cours de l’utilisation del’équipement dénote un défaut de ventilation. Arrêtez-vous de travailler afin de prendre les mesures néces-saires à l’amélioration de la ventilation. Nepoursuivez pas l’opération entreprise si le malaisepersiste.

d. Certaines commandes comportent des canalisationsoù circule de l’hydrogène. L’armoire de commandeest munie d’un ventilateur destiné à empêcher laformation de poches d’hydrogène, lesquellesprésentent un danger d’explosion; ce ventilateur nefonctionne que si l’interrupteur correspondant dupanneau avant se trouve placé en position ON(Marche). Veillez à manœuvrer cette commande envérifiant si le couvercle est bien en place, de façon àassurer l’efficacité de la ventilation ainsi réalisée. Nejamais débrancher le ventilateur.

e. Les fumées produites par l’opération de soudage oude coupage peuvent s’avérer toxiques. Aussi est-ilnécessaire de disposer en permanence d’undispositif adéquat de ventilation de type aspirant, afind’élimi-ner du voisinage de l’opérateur toutdégagement de fumée visible.

f. Consultez les recommandations particulières enmatière de ventilation indiquées à l’alinéa 6 de lanorme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipemententretenu de façon défectueuse ou inadéquate risque

non seulement de réaliser un travail de mauvaisequalité mais, chose plus grave encore, d’entraîner desdommages corporels graves, voire mortels endéclenchant des incendies ou des chocs électriques.Observez par conséquent les précautions suivantes:

a. Efforcez-vous de toujours confier à un personnel qua-lifié l’installation, le dépannage et l’entretien du postede soudage et de coupage. N’effectuez aucuneréparation électrique sur l’équipement à moins d’êtrequa-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretienquelconque à l’intérieur du poste de soudage/coupage, avant d’avoir débranché l’alimentationélectrique.

c. Maintenez en bon état de fonctionnement les câbles,le câble de masse, les branchements, le cordond’alimentation et le poste de soudage/coupage.N’utilisez jamais le poste ou l’équipement s’il présenteune défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage etdes équipements accessoires. Gardez-les à l’écartdes sources de charleur, notamment des fours, del’humidité, des flaques d’eau maintenez-les à l’abri destraces d’huile ou de graisse, des atmosphères corro-sives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tousles panneaux de l’armoire de commande en veillant àles garder en bon état.

f. Utilisez le poste de soudage/coupage conformément àson usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVESÀ LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur lesrègles de sécurité à observer pour le montage etl’utilisation d’équipements de soudage et de coupageélectriques et sur les méthodes de travailrecommandées, demandez un exemplaire du livret N°52529 “Precautions and Safe Practices for Arc Weld-ing, Cutting and Gouging” publié par ESAB. Nousconseillons également de consulter les publicationssui-vantes, tenues à votre disposition par l’AmericanWelding Society, 550 N.W. LeJuene Road, Miami, FL32126:

a. “Safety in Welding and Cutting” AWS Z49.1b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.d. “Recommended Safe Practices for Plasma Arc Cut-

ting” AWS-A6. 3.e. “Recommended Safe Practices for Plasma Arc Weld-

ing” AWS-C5. 1.f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.g. “Code For Safety in Welding and Cutting”

CSA-Standard W117. 2.

PRÉCAUTIONS DE SÉCURITÉ

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PROCESS SELECTIONSWITCH

WIRE SPEED RANGE&

"NO PROGRAM"INDICATOR

WIRE MATERIALSELECTOR

WIRE DIAMETERSELECTOR

ARC LENGTHTRIM

ULTRAPULSE 350 PULSE CONTROL PENDANT(FOR 350MPi POWER SOURCE ONLY)

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SECTION 1 DESCRIPTION

1.1 General

The Ultra-Pulse 350 pendant is designed to providesimple to use, high quality, synergic pulsed Mig weldingwhen used with a 350MPi inverter power source and aMig 4HD, 4HD Dual or Mig 5XL "Mongoose" wire feeder.Synergic pulsed Mig welding means that pulse param-eters (such as pulse height, pulse width, backgroundcurrent and pulse frequency) are automatically adjustedby the Ultra-Pulse 300i pendant as you change wire feedspeed.

The Ultra-Pulse 350 pendant also provides a PULSEARC TRIM that allows the operator to fine tune the pulsearc length. The operator can change to standard weldingby simply moving the PULSE /STANDARD switch to theSTANDARD position. The system can then be used fornon-pulsed Mig (GMAW), Tig (GTAW) or stick electrodewelding (SMAW) by changing the 350MPi PROCESSSELECTOR switch to the desired welding process andconnecting the appropriate welding torch or electrodeholder.

SECTION 2 INSTALLATION

2.1 General

ELECTRIC SHOCK CAN KILL! Make sure that allprimary input power to the power source and wirefeeder has been disconnected at the wall (line) dis-connect switch or circuit breaker before making thefollowing connections.

The following instructions are intended to supplementthe manuals supplied with the wire feeder and powersource. Be sure to follow all installation, operation andsafety information provided by these manuals.

2.2 Cable Connections

Refer to Figure 1.

The Ultra-Pulse 350 pendant is supplied with a 8-ft (2.4m) control cable with a 19 pin male amphenol styleconnector and a 19 pin female amphenol receptacle.

1. Connect the 19 pin plug to the mating receptacleon the 350MPi power source.

2. Connect the UltraPulse 19 pin female amphenolreceptacle to the wire feeder control cable maleamphenol plug.

FIGURE 1. Connection to Feeder & Power Supply

19-Pin MaleConnectorto 350 MPi

Ultra-Pulse350

Pendant

19-Pin Female Connector to:Mig 4HDMig 4HD DualMig 5XL "Mongoose"

From Ultra-Pulse350 MPi Pendant

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2. Use output cables that are as short as possible.Do not loop or coil the work cables. Excessivecable lengths and coiled cables could result inless than optimum performance.

3. Proper connection of the work cables to thework is essential for high quality results. Under-sized ground clamps, poor connects, frayedcables, cable splices or clamps attached torusting or dirty surfaces will result in unstableconditions.

4. Turn the power source "ON" and initiate thewelding process by closing the torch trigger.

3. Be sure that the secondary output connections(welding cables) are connected so the positivecable goes to the wire feeder and the negativecable goes to the work piece.

2.3 Power Source Set-Up

1. The 350MPi power source is "Pulse Mig Ready"and requires no additional configuration or ad-justments. Place the 350MPi power sourcePROCESS SELECTOR switch in the Mig posi-tion and the MIG SELECTOR switch to the typeof Mig wire to be used. The position of theREMOTE/PANEL switch is dependant on thewire feeder and process (STANDARD orPULSE) being used. Refer to TABLE 1.

SECTION 3 PULSE OPERATION3.1 Pulsed Mig Operation

A. UltraPulse 350 pendant Set-Up.

1. Set the MATERIAL SELECTOR dial to the wiretype and wire diameter that is being used on thewire feeder.

NOTE: See Table 2 for the recommended shield- ing gasses for each wire alloy type.

2. Set Panel Remote Switch to (Remote).

NOTE:The RED light on the UltraPulse pendant will "Blink" when the wire feed speed is out of

range. A "Steady" light "On" indicates there is no program for the material and wire diameter selected.

3. Place the PULSE/STANDARD toggle switch tothe PULSE position.

REMOTECONTROL

PANELCONTROL

STANDARD / PULSE SWITCH350 MPi FRONT PANEL

Wire UltraPulse Process 350MPi Voltage Control From:Feeder Switch Power Source

Mig 4HD STANDARD REMOTE Mig 4HD VOLTS POTPULSE REMOTE UltraPuse 350 TRIM

Mig 4HD DUAL STANDARD REMOTE Mig 4HD VOLTS POTPULSE REMOTE UltraPuse 350 TRIM

Mig 5XL STANDARD PANEL 350MPi Panel VOLTS"Mongoose" PULSE REMOTE UltraPuse 350 TRIM

TABLE 1 - UltraPulse 350 and 350MPi Power Source Set-Up

SECTION 2 INSTALLATION

DIGITALAMMETER

DIGITALVOLTMETER

VOLTAGECONTROL

PANEL/REMOTETOGGLE SWITCH

MATERIALSELECTORSWITCH

INDUCTANCE (CV)ARC FORCE (CC)

PROCESSSELECTORSWITCH

OUTPUT PRESET SWITCH

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SECTION 3 PULSE OPERATION4. Set the ARC TRIM knob to the "0" or center

position.

The ARC TRIM is used to fine tune the arclength performance. Turn the knob clockwise toincrease the arc length or counterclockwise todecrease the arc length.

B. Mig 4HD Wire Feeder

1. Set the WIRE FEED SPEED dial to a wire feedrate that is within the range of the UltraPusependant control.

NOTE-----The RED light on the UltraPulse pen-dant will "Blink" when the wire feed speed is outof range.

2. Pull the gun trigger. Begin Welding. Trim thearc voltage with the UltraPulse pendant TRIMknob to the desired arc length

C. Mig 4HD Dual Wire Feeder

1. Pulse operation is the same as the standard Mig4HD except BOTH guns on the Mig 4HD Dualwill have pulse parameters sent to them basedon the wire type and diameter seletcted on theUltraPulse Pendant. Each gun CANNOT beindependently controlled for different wire typesor sizes.

D. Mig 5XL "Mongoose" Wire Feeder

1. To pulse with the Mongoose "push/Pull" Sys-tem, be sure you have the Mig 5XL PulseVersion wire feeder (PN-37487).

2. Set the 350MPi PANEL/REMOTE switch to theREMOTE position (See TABLE 1).

3. Set the wire feed speed on the MT-300XL gun.

NOTE-----The RED light on the UltraPulse pen-dant will "Blink" when the wire feed speed is outof range.

4. Adjust the UltraPuse Arc Trim to the desired arccharacteristics.

E. Process control

1. Use a tip-to-work distance of 3/8" to 5/8". Thisrefers to the distance between the end of the Miggun contact tip and the plate or weld puddle.

2. For the best arc stability, keep the arc on thefront edge of the molten puddle and use a 5 to 10degree gun angle from the vertical.

3. The TRIM knob on the UltraPulse 350 pendantis used to fine tune the arc length by turning thedial clockwise to lengthen the arc or counter-clockwise to shorten the arc. If the arc is "crack-ling" or if spatter is excessive lengthen the arc.If the arc is "fluttering" or difficult to control thenshorten the arc length.

SECTION 4 PULSE TECHNICAL DATA

4.1 Standard CV Operation

The Ultra-Pulse 350 pendant provides for both standardwelding and pulsed Mig welding. When the STAN-DARD/PULSE switch is in the STANDARD position thewire feeder and power source are ready for standardnon-pulsed CV Mig welding. Follow the basic instruc-tions provided with the power source to change to otherwelding processes, such as, Tig or Stick welding .

1. For standard CV Mig welding the wire feedspeed and power source output (voltage) areindependent.

2. On a Mig 4HD, set the voltage on the front panelof the feeder. On a Mig 5XL, set the arc voltageon the front panel of the power source. Refer toTable 1.

13

SECTION 4 PULSE TECHNICAL DATA

4.2 Pulse MIG Arc Stability

Many variables can affect the arc stability of pulse MIGwelding. Some examples are:

Long welding cablesHigh resistance cables and connectionsDifferences in shielding gas compositionsDifferences in weld wire chemistryWater vs. air cooled gunsBase metal surface condition

When adverse conditions are present, the pulse arcstability is sometimes less than desirable. The arc will"crackle" and produce higher than normal spatter levels.This occurs due to higher resistances in the weldingcircuit causing changes pulse waveform and averagecurrent levels. The TRIM knob on the UltraPulse pen-dant adjusts the pulse frequency to accommodate smallchanges in the welding equipment set-up and basematerial variations to achieve a stable pulse weldingcondition.

4.3 Shielding Gases

Table 2 lists the range of shielding gases that can beused with the UltraPuse pendant. The wire burn-off rateand synergic operation will vary with changes in shield-ing gas. The UtraPulse TRIM knob is used to compen-sate for changes in shield gas composition.

4.4 Pulse Parameters

Tables 3 through 7 list the approximate pulse weldingparmeters for each material and diameter. These areprovided for general reference only. Actual pulse pa-rameters can vary with the equipment set-up, weldingapplication and shielding gases being used. The wirefeed speed ranges shown in the tables are the same asprogrammed into the UltraPulse 350 pendant. Attempt-ing to weld outside of the suggested speed ranges willresult in a "blinking" indicator light on the UltraPulse frontpanel. A "steady" light lite on the panel indicates the wirematerial and diameter combination selected does nothave any pulse data programmed.

TABLE 2 - UltraPulse 350 Material, Diameter and Shielding Gases

Material Type

Wire Diameter (In.)

Shielding Gas (AWS Designation)

Carbon Steel

.030, .035, .040, .045

Ar - 5% CO2 (SG-AC-5) Ar - 8% CO2 (SG-AC-8)

Ar - 10% CO2 (SG-AC-10) Ar - 2% O2 (SG-AO-2)

Ar - 8% CO2 - 2% O2 (SG-ACO-8/2)

Stainless Steel

.030, .035, .040, .045

Ar -2% CO2 (SG-AC-2) Ar - 8% CO2 (SG-AC-8) Ar - 2% O2 (SG-AO-2)

Ar - 8% CO2 - 2% O2 (SG-ACO-8/2) Ar - He 50% - 2% CO2 (SG-AHeC-50/2)

4000 & 5000

Aluminum

.030, .035, 3/64 (.047)

Ar ( SG-A) Ar - He 25% (SG-AHe-25) Ar - He 50% (SG-Ahe-50)

Metal Core Carbon Steel

.040, .045, .052

Ar - 5% CO2 (SG-AC-5) Ar - 8% CO2 (SG-AC-8)

Ar - 10% CO2 (SG-AC-10) Ar - 2% O2 (SG-AO-2)

Ar - 8% CO2 - 2% O2 (SG-ACO-8/2)

Metal Core Stainless

Steel0.045

Ar - 2% CO2 (SG-AC-2) Ar - 8% CO2 (SG-AC-8) Ar - 1% O2 (SG-AO-1)

Ar - He 50% - 2% CO2 (SG-AHeC-50/2)

14

SECTION 4 PULSE TECHNICAL DATA - STEEL

.030 Steel .035 Steel

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

75 273 2.00 11 34 75 257 2.40 0 59125 279 2.00 15 47 125 272 2.40 18 75175 285 2.00 19 61 175 287 2.40 36 92225 292 2.00 23 75 225 302 2.40 54 108275 298 2.00 27 89 275 317 2.40 72 125325 304 2.00 31 103 325 332 2.40 90 141375 311 2.00 35 117 375 347 2.40 108 158425 317 2.00 39 131 425 362 2.40 126 174475 323 2.00 43 145 475 377 2.40 144 191525 330 2.00 47 158 525 392 2.40 162 207575 336 2.00 51 172 575 407 2.40 180 224625 342 2.00 55 186 625 422 2.40 198 240675 349 2.00 59 200725 355 2.00 63 214775 361 2.00 67 228

.040 Steel .045 Steel

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

75 367 2.60 13 54 125 348 3.00 32 88125 370 2.60 30 73 175 363 3.00 55 105175 374 2.60 46 92 225 378 3.00 77 123225 378 2.60 63 111 275 393 3.00 100 140275 382 2.60 80 129 325 408 3.00 122 158325 386 2.60 97 148 375 423 3.00 145 175375 389 2.60 113 167 425 438 3.00 167 193425 393 2.60 130 186 475 453 3.00 190 210475 397 2.60 147 205525 401 2.60 164 223575 404 2.60 180 242625 408 2.60 197 261

.030 Stainless .035 Stainless

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

200 239 1.90 27 64 75 224 2.30 8 50250 246 1.90 35 77 125 233 2.30 17 70300 252 1.90 44 89 175 242 2.30 26 90350 258 1.90 52 102 225 251 2.30 35 110400 265 1.90 61 115 275 260 2.30 44 130450 271 1.90 69 127 325 269 2.30 53 150500 278 1.90 78 140 375 278 2.30 62 170550 284 1.90 86 152 425 287 2.30 71 190600 290 1.90 95 165 475 296 2.30 80 210650 297 1.90 103 177 525 305 2.30 89 230700 303 1.90 112 190 575 314 2.30 98 250750 309 1.90 120 202 625 323 2.30 107 270

675 332 2.30 116 290725 341 2.30 125 310

.040 Stainless .045 Stainless

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

75 214 2.80 24 52 75 285 2.70 39 62125 234 2.80 41 63 125 306 2.70 50 81175 254 2.80 57 74 175 326 2.70 60 100225 275 2.80 74 85 225 347 2.70 71 119275 295 2.80 90 96 275 367 2.70 81 138325 316 2.80 107 107 325 388 2.70 92 157375 336 2.80 124 118 375 409 2.70 102 176425 356 2.80 140 129 425 429 2.70 113 195475 377 2.80 157 140525 397 2.80 174 151

TABLE 3 - UltraPulse 350 Carbon Steel Pulse Parameters

TABLE 4 - UltraPulse 350 Stainless Steel Pulse Parameters

15

SECTION 4 PULSE TECHNICAL DATA - ALUMINUM

.030 4043 AI .035 4043 AI

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

200 236 1.10 20 109 150 194 1.59 26 60250 251 1.10 25 131 200 209 1.61 36 80300 266 1.10 30 152 250 225 1.62 46 101350 281 1.10 34 174 300 241 1.64 55 121400 296 1.10 39 196 350 256 1.65 65 142450 311 1.10 44 218 400 272 1.67 75 162500 325 1.10 48 240 450 288 1.68 84 183550 340 1.10 53 262 500 303 1.70 94 203600 355 1.10 58 284 550 319 1.71 104 224650 370 1.10 63 306 600 334 1.73 113 244700 385 1.10 67 328 650 350 1.74 123 265

700 366 1.76 133 286

.040 4043 AI .047 4043 AI

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

80 260 1.50 30 38130 280 1.60 44 62180 300 1.69 58 86230 320 1.79 73 110

Not Programmed 280 340 1.88 87 134330 360 1.98 101 159380 380 2.07 115 183430 400 2.17 130 207480 420 2.26 144 231530 440 2.36 158 255

030 5356 AI .035 5356 AI

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

225 310 1.15 25 60 200 256 1.70 28 56275 318 1.15 31 69 250 261 1.70 33 74325 326 1.15 38 77 300 266 1.70 38 92375 335 1.15 44 86 350 271 1.70 43 110425 343 1.15 51 94 400 276 1.70 48 128475 351 1.15 57 103 450 280 1.70 53 147525 359 1.15 64 112 500 285 1.70 58 165575 368 1.15 70 120 550 290 1.70 63 183625 376 1.15 77 129 600 295 1.70 68 201675 384 1.15 83 137 650 300 1.70 73 219725 392 1.15 90 146 700 305 1.70 78 237

750 310 1.70 83 255800 315 1.70 88 273

.040 5356 AI .047 5356 AI

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

150 303 1.50 35 74200 316 1.50 50 101250 328 1.50 65 127

Not Programmed 300 341 1.50 80 154350 353 1.50 95 181400 366 1.50 110 208450 379 1.50 125 235500 391 1.50 140 262550 404 1.50 155 289

TABLE 5 - UltraPulse 350 4000 Aluminum Pulse Parameters

TABLE 6 - UltraPulse 350 5000 Aluminum Pulse Parameters

12

16

SECTION 5 ULTRAPULSE MOUNTING OPTIONSFIGURE 2 - UltraPulse Bracket Assemblies

(Included with Pendant - mount with existing hardware)

Mounted UltraPulse Assemblies

Mig 4HD BoomMig 4HD DualMig 4HD

Figure 2. UltraPulse 350 Mounting Options

SECTION 4 PULSE TECHNICAL DATA - METAL CORE

.040 Metal Core CS .045 Metal Core CS

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

100 255 2.50 33 80 100 335 2.50 16 101150 278 2.50 44 100 150 352 2.50 27 122200 300 2.50 55 120 200 370 2.50 37 144250 323 2.50 66 140 250 388 2.50 48 166300 345 2.50 77 160 300 406 2.50 59 187350 368 2.50 89 180 350 424 2.50 70 209400 390 2.50 100 200 400 441 2.50 80 231450 413 2.50 111 220500 436 2.50 122 240

.052 Metal Core CS .045 Metal Core SS

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

WFS Range

Pulse Peak

Pulse Width

Pulse Background

Pulse Frequency

75 358 2.70 16 76 100 407 1.80 35 71125 385 2.70 45 94 150 418 1.86 44 90175 412 2.70 74 112 200 429 1.91 53 109225 438 2.70 103 130 250 440 1.97 62 128275 465 2.70 132 148 300 451 2.02 70 146325 492 2.70 160 166 350 462 2.08 79 165

400 473 2.13 88 184450 484 2.19 97 203500 495 2.24 105 222550 506 2.30 114 241

TABLE 7 - UltraPulse 350 Metal CorePulse Parameters Steel and Stainless

PN 0558001589 - Hanger BracketMig 4HD

PN 0558001590 - Hanger BracketMig 4HD Dual

17

0558001437 - HANDLE

(8)2062018 - POTENTIOMETER0558001019 - KNOB

634515 - SWITCH(8)951474 - COVER

0558001595 - KNOB952993 - SWITCH

23607860 - BUMPER, RUBBER

951032 - LIGHT

0558001587 - BACK PANEL

FIGURE 3 - UltraPulse 350 Replacement Parts (Front and Back View)

0558001591 - HANGER

SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS

18

0558001022 - CABLE, COMPLETE, 8 FT (P3)0558001586 - STRAIN RELIEF

(8)38170 - PC BOARD (PCB1)

0558001588 - COVER

952988 - TRANSFORMER

FIGURE 4 - UltraPulse 350 Replacement Parts (Inside View)

SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS

19

SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS

CA

BLE

ASS

EMB

LY 0

5580

0102

2

FIG

UR

E 5

- U

ltraP

ulse

350

Cab

le W

iring

Dia

gram

0558

0010

22-C

20

SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS

FIG

UR

E 6

- U

ltraP

ulse

350

Wiri

ng D

iagr

am

0558

0015

93-B

21

SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS05

5800

1592

22

NOTES

23

REVISION HISTORY

1. Revision "A" updated wiring/schematic diagrams in Section 6, added Table of Contents, andincluded various editorial updates.

F-15-606-A 10/03 Printed in U.S.A.

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