MultiPower 460
Pulse Control Panel Kit
P/N 0558002671
F-15-699
February, 2002
Installation and Operation
Instructions
Read and understand the entire contents of this manual, the power source manual, and the wire
feeder manual used with this unit. Special emphasis should be given to the safety material
throughout all manuals, before installation, operation, or maintenance of this equipment. This
unit and these instructions are for use only by persons trained and experienced in the safe
operation of welding equipment. Do not allow untrained persons to install, operate, or maintain
this unit. Contact your distributor if you do not fully understand these instructions.
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 and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the
instructions provided. This equipment must be checked periodically. Defective equipment should not be used.
Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such
repair or replacement become necessary, the manufacturer recommends that a telephone or written request
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 the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a
service facility designated by the manufacturer.
TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH
SAFETY .................................................................................................................................... 3
1 DESCRIPTION ......................................................................................................................... 10
2 INSTALLATION ........................................................................................................................ 12
3 OPERATION ............................................................................................................................. 13
4 MAINTENANCE........................................................................................................................ 26
2
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable nonflammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
F-15-660
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is confined, or if there is
danger of falling.
1. Be sure the power source frame (chassis) is connected
to 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 fatal
shock.
4. Use well-maintained equipment. Replace worn or damaged 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 from
work
and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an 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 mistake
the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current
flowing through any conductor causes
localized Electric and Magnetic Fields
(EMF). Welding and cutting current
creates EMF around welding cables
and welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure 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.
3
10/98
SAFETY PRECAUTIONS
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive
mechanical ventilation is provided. Do not breathe fumes
from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to
operate 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 or
cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety Code
CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder,
valve, or relief device can injure or kill.
Therefore:
1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand 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 in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
§25249.5 et seq.)
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment 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 position
and in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for electric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami, 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 Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert!
Your safety is involved.
Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.
Means potential hazards which could
result in personal injury or loss of life.
Means hazards which could result in
minor personal injury.
4
SP98-10
PRECAUCION DE SEGURIDAD
ADVERTENCIA: Estas Precauciones de
Seguridad son para su protección. Ellas hacen
referencias listadas en la sección "Información Adicional Sobre La
Seguridad". Antes de hacer cualquier instalación o procedimiento de
operación , asegúrese de leer y seguir las precauciones de seguridad
listadas a continuación así como también todo manual, hoja de datos
de seguridad del material, calcomanias, etc. El no observar las
Precauciones de Seguridad puede resultar en daño a la persona o
muerte
.
resumen de información proveniente de las
PROTEJASE USTED Y A LOS DEMAS--
Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco, como
el sol , emite rayos ultravioleta (UV) y
otras radiaciones que pueden dañar la piel y los ojos. El
metal caliente causa quemaduras. EL entrenamiento en
el uso propio de los equipos y sus procesos es esencial
para prevenir accidentes. Por lo tanto:
Utilice gafas de seguridad con protección a los lados siempre que
1.
esté en el área de trabajo, aún cuando esté usando careta de
soldar, protector para su cara u otro tipo de protección.
2. Use una careta que tenga el filtro correcto y lente para proteger
sus ojos, cara, cuello, y oídos de las chispas y rayos del arco
cuando se esté operando y observando las operaciones. Alerte a
todas las personas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa pesada de
mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y
careta de soldar con capucha para el pelo, para proteger el
cuerpo de los rayos y chispas calientes provenientes del metal
fundido. En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las chispas.
4. Chispas y partículas de metal caliente puede alojarse en las
mangas enrolladas de la camisa , el ruedo del pantalón o los
bolsillos. Mangas y cuellos deberán mantenerse abotonados,
bolsillos al frente de la camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chispas calientes
con una cortina adecuada no-flamable como división.
6. Use careta protectora además de sus gafas de seguridad cuando
esté removiendo escoria o puliendo. La escoria puede estar
caliente y desprenderse con velocidad. Personas cercanas
deberán usar gafas de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de
las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
Remueva todo material combustible lejos del área de trabajo o
1.
cubra los materiales con una cobija a prueba de fuego. Materiales
combustibles incluyen madera, ropa, líquidos y gases flamables,
solventes, pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en las grietas
y agujeros de pisos y paredes causando fuegos escondidos en
otros niveles o espacios. Asegúrese de que toda grieta y agujero
esté cubierto para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo relacionado hasta
que la pieza de trabajo esté totalmente limpia y libre de substancias
que puedan producir gases inflamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques cerrados. Estos
pueden explotar si contienen vapores inflamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso
instantáneo, como por ejemplo una manguera con agua, cubeta
con agua, cubeta con arena, o extintor portátil. Asegúrese que
usted esta entrenado para su uso.
5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor
causado por cable sobrecarga en los cables de soldar pueden
ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área de
trabajo para cerciorarse de que las chispas o metal caliente ocasionen
un fuego más tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la publicación NFPA
Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto con las
partes eléctricas energizadas y tierra puede
causar daño severo o muerte. NO use
soldadura de corriente alterna (AC) en áreas
húmedas, de movimiento confinado en
lugares estrechos o si hay
posibilidad de caer al suelo.
1. Asegúrese de que el chasis de la fuente de poder esté conectado
a tierra através del sistema de electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de tierra física.
3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores
expuestos o con malas conexiones pueden exponer al operador u
otras personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condiciones. Reemplaze
cables rotos, dañados o con conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los
cables, antorchas, pinza del electrodo, y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están insuladas de
ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en
lugares estrechos o áreas húmedas; trabaje sobre un pedazo de
madera seco o una plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC Standard Z49.1
(listado en la próxima página) para recomendaciones específicas de
como conectar el equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETICOS Son peligrosos. La corriente eléctrica fluye
através de cualquier conductor causando a
nivel local Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y
soldadura, crean EMF alrrededor de los
cables de soldar y las maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para el corazón
deberán consultar a su médico antes de soldar. El Campo
Electromagnético (EMF) puede interferir con algunos marca-pasos.
2. Exponerse a campos electromagnéticos (EMF) puede causar otros
efectos de salud aún desconocidos.
3. Los soldadores deberán usar los siguientes procedimientos para
minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de trabajo juntos, hasta
llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al
otro con cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza de
trabajo. Mantega los cables a un sólo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano
posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar lo más lejos
posible de su cuerpo.
5
HUMO Y GASES -- El humo y los gases,
pueden causar malestar o daño,
particularmente en espacios sin
ventilación. No inhale el humo o gases. El
gas de protección puede causar falta de
oxígeno. Por lo tanto:
1. Siempre provea ventilación adecuada en el área de trabajo
por medio natural o mecánico. No solde, corte, o ranure
materiales con hierro galvanizado, acero inoxidable, cobre,
zinc, plomo, berílio, o cadmio a menos que provea
ventilación mecánica positiva . No respire los gases
producidos por estos materiales.
2. No opere cerca de lugares donde se aplique substancias
químicas en aerosol. El calor de los rayos del arco pueden
reaccionar con los vapores de hidrocarburo clorinado para
formar un fosfógeno, o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de ojos, nariz
o garganta mientras est á operando, es indicación de que
la ventilación no es apropiada. Pare de trabajar y tome
las medidas necesarias para mejorar la ventilación en
el área de trabajo. No continúe operando si el malestar
físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard Z49.1
(Vea la lista a continuación) para recomendaciones
específicas en la ventilación.
5. ADVERTENCIA-- Este producto cuando se utiliza para
soldaduras o cortes, produce humos
o gases, los cuales contienen
químicos conocidos por el Estado
de California de causar defectos en el
nacimiento, o en algunos casos, Cancer. (California Health & Safety Code
§25249.5 et seq.)
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romperse y
liberar violentamente gases. Rotura
repentina del cilindro, válvula, o
válvula de escape puede causar daño
o muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize un
regulador diseñado para operar y reducir la presión del
cilindro de gas . No utilice adaptadores. Mantenga las
mangueras y las conexiones en buenas condiciones.
Observe las instrucciones de operación del manufacturero
para montar el regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical y
amárrelos con una correa o cadena adecuada para
asegurar el cilindro al carro, transportes, tablilleros, paredes,
postes, o armazón. Nunca asegure los cilindros a la mesa de
trabajo o las piezas que son parte del circuito de soldadura
. Este puede ser parte del circuito elélectrico.
3. Cuando el cilindro no está en uso, mantenga la válvula del
cilindro cerrada. Ponga el capote de protección sobre la
válvula si el regulador no está conectado. Asegure y
mueva los cilindros utilizando un carro o transporte adecuado.
Evite el manejo brusco de los cilindros.
4. Localize los cilindros lejos del calor, chispas, y flamas.
Nunca establezca un arco en el cilindro.
5. Para información adicional, haga referencia a la publicación
CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", disponible através del Compressed Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
1. Siempre tenga personal cualificado para efectuar l a
instalación, diagnóstico, y mantenimiento del equipo. No
ejecute ningún trabajo eléctrico a menos que usted esté
cualificado para hacer el trabajo.
2. Antes de dar mantenimiento en el interior de la fuente
de poder, desconecte la fuente de poder del suministro de
electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones, cable
primario, y cualquier otra fuente de poder en buen
estado operacional. No opere ningún equipo en malas
condiciones.
4. No abuse del equipo y sus accesorios. Mantenga el
equipo lejos de cosas que generen calor como hornos,
también lugares húmedos como charcos de agua , aceite
o grasa, atmósferas corrosivas y las inclemencias del
tiempo.
5. Mantenga todos los artículos de seguridad y coverturas
del equipo en su posición y en buenas condiciones.
6. Use el equipo sólo para el propósito que fue diseñado.
No modifique el equipo en ninguna manera.
INFORMACION ADICIONAL DE SEGURIDAD
-- Para más información sobre las prácticas de
seguridad de los equipos de arco eléctrico
para soldar y cortar, pregunte a su suplidor por
una copia de "Precautions and Safe Practices
for Arc Welding, Cutting and Gouging-Form 52-
529.
Las siguientes publicaciones, disponibles através de la
American Welding Society, 550 N.W. LeJuene Road, Miami,
FL 33126, son recomendadas para usted:
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 Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous
Substances."
SIGNIFICADO DE LOS SIMBOLOS -Según usted avanza en la lectura de
este folleto: Los Símbolos Significan
¡Atención! ¡Esté Alerta! Se trata de su
seguridad.
Significa riesgo inmediato que, de no
ser evadido, puede resultar
inmediatamente en serio daño personal o la muerte.
Significa el riesgo de un peligro potencial
que puede resultar en serio daño personal o la muerte.
Significa el posible riesgo que puede
resultar en menores daños a la persona.
6
PRÉCAUTIONS DE SÉCURITÉ
AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.
1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles
résultant d’une exposition prolongée au soleil. Aussi
convient-il d’observer les précautions suivantes:
a. Portez un écran facial adéquat muni des plaques
protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez l’exécution.
AVERTISSEZ les personnes se trouvant à proximité
de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.
b. Portez des gants ignifugés à crispins, une tunique
épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.
c. Les étincelles ou les projections de métal incandes-
cent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à l’avant.
d. Protégez des étincelles et du rayonnement de l’arc
électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.
e. Ne jamais omettre de porter des lunettes de sécurité
lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.
f. Le gougeage à l’arc et le soudage à l’arc au plasma
produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.
2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:
7
a. Éloigner suffisamment tous les matériaux combus-
tibles du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la
sciure, l’essence, le kérosène, les peintures, les
solvants, le gaz naturel, l’acétylène, le propane et
autres substances combustibles semblables.
b. Les étincelles ou les projections de métal incandes-
cent peuvent tomber dans des fissures du plancher ou
dans des ouvertures des murs et y déclencher une
ignition lente cachée. Veiller à protéger ces
ouvertures des étincelles et des projections de métal.
c. N’exécutez pas de soudures, de coupes, d’opérations
de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.
d. En vue d’assurer la prévention des incendies, il
convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.
e. Une fois le travail à l’arc terminé, inspectez le secteur
de façon à vous assurer qu’aucune étincelle ou
projection de métal incandescent ne risque de
provoquer ultérieurement un feu.
3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous ten-
sion venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.
b. Si vous devez effectuer un travail sur une surface
métallique ou dans un secteur humide, veillez à assurer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.
c. Mettez toujours à la terre le poste de soudage/
coupage en le reliant par un câble à une bonne prise
de terre.
d. N’utilisez jamais de câbles usés ou endommagés. Ne
surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.
e. Mettez l’équipement hors tension lorsqu’il n’est pas en
service. une mise à la masse accidentelle peut en
effet provoquer une surchauffe de l’équipement et un
danger d’incendie. Ne pas enrouler ou passer le câble
autour d’une partie quelconque du corps.
f. Vérifiez si le câble de masse est bien relié à la pièce
en un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de passage d’un courant de sortie par des chaînes de
9/97
PRÉCAUTIONS DE SÉCURITÉ
l evage, des câbles de grue ou divers chemins
électriques.
g. Empêchez l’apparition de toute humidité, notamment
sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute fuite
d’eau.
4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:
a. Assurez en permanence une aération adéquate de
l’emplacement de travail en maintenant une ventilation
naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.
b. N’effectuez jamais de travaux de soudage ou de
coupage à proximité de vapeurs d’hydrocarbure chloré
résultant d’opérations voisines de dégraissage ou de
pulvérisation. La chaleur dégagée ou le rayonnement
de l’arc peut déclencher la formation de phosgène -gaz particulièrement toxique -- et d’autres gaz irritants,
à partir des vapeurs de solvant.
c. Une irritation momentanée des yeux, du nez ou de la
gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtezvous de travailler afin de prendre les mesures nécessaires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.
d. Certaines commandes comportent des canalisations
où circule de l’hydrogène. L’armoire de commande est
munie d’un ventilateur destiné à empêcher la formation de poches d’hydrogène, lesquelles présentent un
danger d’explosion; ce ventilateur ne fonctionne que si
l’interrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manœuvrer cette commande en vérifiant si le
couvercle est bien en place, de façon à assurer
l’efficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.
e. Les fumées produites par l’opération de soudage ou de
coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’élimi-ner
du voisinage de l’opérateur tout dégagement de fumée
visible.
f. Consultez les recommandations particulières en
matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.
5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner des
dommages corporels graves, voire mortels en
déclenchant 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 poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.
b. Ne procédez jamais à une tâche d’entretien
quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.
c. Maintenez en bon état de fonctionnement les câbles,
le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage et
des équipements accessoires. Gardez-les à l’écart
des sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri
des traces d’huile ou de graisse, des atmosphères
corrosives et des intempéries.
e. Laissez en place tous les dispositifs de sécurité et tous
les panneaux de l’armoire de commande en veillant à
les garder en bon état.
f. Utilisez le poste de soudage/coupage conformément à
son usage prévu et n’effectuez aucune modification.
6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--
Pour obtenir des informations complémentaires sur les
règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Welding, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:
a. “Safety in Welding and Cutting” AWS Z49.1
b. “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.
8
9/97
SECTION 1 DESCRIPTION
I. SAFETY
Before the MultiPower 460 Pulse Control Panel Kit is installed, the safety
section at the front of this manual should be read completely. This will help
avoid possible injury due to misuse or improper installation.
The definitions relating to the:
safety notations are described at the end of the Safety Section in the front of
this manual — read them and their specific text references carefully.
II. DESCRIPTION
This manual has been prepared for use by an experienced operator. It
provides information to familiarize the operator with the design, installation
and operation of the MultiPower 460 Pulse Panel. DO NOT attempt to install
or operate this pulse option until you have read and fully understood these
instructions. The information presented here should be given careful consideration to ensure proper installation and optimum weld performance.
The MultiPower 460 Pulse kit upgrades a standard MultiPower 460 power
source to a multi-process power source designed for Mig short circuiting,
spray and pulse spray transfer (GMAW), flux core (FCAW), Tig (GTAW), and
stick (SMAW) welding and air carbon arc cutting/gouging (CAC-A) applications. The following instruction assumes you are familiar with the standard
MultiPower 460 operation and set-up. These instruction are intended to
supplement the original MultiPower 460 instruction book received when the
power source was installed.
Figure -1 MultiPower 460Pulse Control Panel
9
SECTION 1 DESCRIPTION
A. PULSE CONTROL PANEL DESCRIPTION
(Refer to Figure 2-1)
1. FAULT LAMP
The RED fault light on the MultiPower 460 Pulse front panel indicates a
problem with set-up parameters. A "Steady" light "On" indicates there is no
program for the material and wire diameter selected. A "Blinking" light
indicates the wire feed speed is out of the recommended range..
2. TEMPERATURE LAMP
The TEMP lamp illuminates if an over temperature condition occurs within the
MultiPower 460 Pulse power source. This condition may be caused by
excessive duty cycle or over-current conditions. When an over temperature
condition occurs, the welding output is turned off and the unit must be allowed
to cool. The machine will automatically reset when the temperature falls to a
safe level.
3. PROCESS SELECTOR SWITCH
The three position process selector switch is located in the upper right-hand
corner of the control panel. The process selector switch position provides the
visual indication of which weld process (Mig, Tig or stick) has been selected.
ELECTRIC SHOCK CAN KILL! Make
sure that all primary input power to the
power source and wire feeder has been
disconnected at the wall (line) disconnect switch or circuit breaker before
making the following connections.
4. DIGITAL DISPLAYS (WFS, AMPS & VOLTS)
The digital displays located on the left side of the control panel are multifunctional depending on the welding process being used. The top display reads
wire feed speed in inches per minute in the MIG PRESET mode and welding
current (in amps) in the TIG and STICK PRESET mode. During welding both
displays indicate average welding current (amps) and average welding
voltage.
The wire feed speed is displayed in inches per minute (IPM) in the top display
when the PRESET button is pressed and the wire speed adjustment knob on
the wire feeder is turned. The WFS LED beside the top display will light when
the display is showing wire feed speed.
5. VOLTAGE/CURRENT/TRIM ADJUST KNOB
The arc voltage is controlled with this knob when the WELD PROCESS
selector switch is in the MIG position. The Mig arc voltage can be preset by
pressing the PRESET button and reading the arc volts in the bottom digital
display while turning this knob.
The arc current is controlled with this knob when the WELD PROCESS
SWITCH is in the TIG or STICK position. The welding current can be preset
in amperes by pressing the PRESET button and reading the current (amps)
in the top digital display while turning this knob. The average arc current will
be displayed during welding.
For MIG PULSE welding, the arc length (arc voltage) is controlled with this
knob. The WELD PROCESS switch is placed in the MIG position and the MIG
PROCESS switch is placed in the MIG PULSE position. The knob should be
place at the 12 o'clock position as the synergic preset for the wire feed speed,
WIRE TYPE and WIRE DIAMETER chosen by the operator using the PULSE
SELECTION switches. The arc length can then be adjusted by turning the
knob clockwise to increase the arc length or counterclockwise to decrease the
arc.
10
SECTION 1 DESCRIPTION
Digital Meters
Amps/Volts/WFS
Power “ON”
Lamp
Temperature
Lamp
No Program
Out of Range
Lamp
Preset
Button
WFS - IPM
Lamp
Amps
Lamp
Pulse
Standard
Switch
Remote
Standard
Switch
Pulse Trim
Current
Voltage
Weld Process
Switch
Inductance
Adjustment
Pulse
Wire Type
Pulse
Wire Diameter
Figure 3-1- Pulse Mig Control Panel
6. PANEL/REMOTE SWITCH
With this switch in the PANEL position, output voltage in the CV mode and the
output current in the CC mode are controlled by adjusting the VOLTAGE/
CURRENT/TRIM knob on the power source control panel to the desired
output. In the REMOTE position, output is controlled using a remote control
device such as a wire feeder, hand control or foot control depending on the weld
process being used.
7. INDUCTANCE TRIM
This control is used only in the STANDARD MIG process mode and is
deactivated in the TIG, STICK and MIG PULSE mode.
Inductance is used to optimize short circuiting arc performance by changing the
current rise and fall time of each short circuit. This results in improved spatter
control, weld bead wetting and arc stability. The short circuiting Mig arc
performance will change from a high short circuit frequency, fast reacting arc,
to a lower short circuit frequency, soft and less spattering arc as the dial is
turned clockwise. The optimized arc performances will vary depending on
shielding gas, wire type and wire diameter. The operator can adjust this control
to optimize welding characteristics.
8. MIG STANDARD/PULSE SWITCH
This switch enables the Mig pulse operation mode. When this switch is in the
MIG PULSE position, the pulse parameters are determined by the WIRE TYPE
and WIRE DIAMETER position on the PULSE SELECTION switches.
9. PULSE SELECTION SWITCHES
WIRE TYPE
Use this switch to select the WIRE TYPE installed on the wire feeder. The
position of this switch and the WIRE DIAMETER switch selects the pulse
parameters to be used during welding in the Mig pulse mode.
WIRE DIAMETER
Use this switch to select the WIRE DIAMETER installed on the wire feeder. The
position of this switch and the WIRE TYPE switch selects the pulse parameters
to be used during welding in the Mig pulse mode.
11
SECTION 2 INSTALLATION
IV. PULSE CONTROL PANEL INSTALLATION
The standard MultiPower 460 control panel are easily removed and replaced
with the MultiPower 460 Pulse version using the following procedure. Refer to
Figure 4-1.
Step 1. Disconnect ALL primary power from the MultiPower 460 by unplug-
ging the unit or removing the line fuses.
Step 2. Remove the four screws (one at each corner) holding the standard
MultiPower 460 control panel in place.
Step 3. Tilt the panel forward and disconnect the wiring harness plug connec-
tor and remove the control panel from the PC board compartment. Do
not discard this panel is can be used as a spare replacement panel if
problems arise.
Step 4 Connect the NEW MultiPower 460 Pulse control panel harness plug
to the power source harness.
Step 5. Carefully position the control panel over the PC board compartment
and secure with the mounting screws removed from the standard
control panel.
Panel Screws
Panel Harness Plug
Figure 4-1 MultiPower 460 Pulse Harness Connection
12
SECTION 3 OPERATION
V. OPERATION
A. WIRE FEEDER COMPATIBILITY
The MultiPower 460 Pulse power source can be used with several ESAB 42
volt wire feeders. The model wire feeder being used will determine the setup
method and operator interface. The position of the REMOTE/PANEL switch
determines the location of the voltage preset and TRIM locations. The wire
feed speed is always set from the wire feeder using the wire speed knob on the
feeder control panel. To see the preset wire feed speed, press the PRESET
button on the MultiPower 460 control panel. Use Table 5-1 to determine the
switch position of operator preference. In most Mig welding applications, the
switch will be in the REMOTE position and the wire feed speed and voltage will
be adjusted from the wire feed front panel.
B. DIGITAL DISPLAY METERS
The digital displays located on the left side of the control panel are multifunctional depending on the welding process being used. The MultiPower 460
Pulse digital display meters permit preset or the wire feed speed on wire
feeders without digital displays. A Mig 2E, 4HD or DuraDrive 4-30 or 4-48 will
not need digital meters to preset the wire feed speed. The wire feed speed can
be displayed on the MultiPower 460 panel meter.
Wire Feeder
Mig 4HD
Dura Dri ve 4-30
Dura Dri ve 4-48
Mig 2E
Mig 5XL
(Mongoose)
C. MIG WELDING
In the MIG process mode, the digital displays will read preset wire feed speed
in inches per minute and preset arc volts when the PRESET button is pressed.
Once welding begins, the displays will show average welding current and volts
in the top and bottom display, respectively. The displays have a “HOLD” circuit
that retains the welding conditions. After welding stops, the display will
continue to show the last welding current and voltage sampled for 10 seconds,
then returns to “0”.
Table 5-1 Wire Feeder Compatibility
MIG MODE SW ITCH*
MIG ST ANDARD
(MultiPow er 460)
Arc Trim Loca tion
from :
Feeder X X Optional
Remote Pendant X X Optional
MP-460 Panel X X Optional
Feeder X N/A
Remote Pendant X X Optional
MP-460 Panel X X Optional
PANEL REMOTE S yne rgic
MIG PULSE
(MultiPow er 460 Pulse)
Non-
Synergic**
MobileMaster IV
(Off the Arc)
Mini 8
(Off the Arc)
N/A - Not Available
* - Proces s switch MUST be in the MIG position.
** - See Synergic/NonSynergic description section for configuration information
Feeder X N/A N/A X
Remote Pendant X N/A X
MP-460 Panel X N/A X
13
SECTION 3 OPERATION
4
1
Figure4-1 Standard Mig Setup Procedure
2
3
Place MIG STANDARD/MIG PULSE
NOTE
switch in the MIG STANDARD position
when using the Tig, Stick or Arc Gouging
process modes.
D. STANDARD MIG (CV) WELDING
When the PROCESS switch is placed in the MIG position the MultiPower 460
Pulse is set for CV (constant voltage) welding. The power source will output
open circuit voltage (OCV) when the Mig Gun trigger is depressed. The
following procedure assumes the wire feed and voltage adjustments will be
made from the wire feeder front panel and wire and gas have been installed.
Step 1. Connect wire feeder to MultiPower 460 Pulse and set PANEL/RE-
MOTE switch to REMOTE position.
Step 2. Set the MIG STANDARD/PULSE switch to the MIG STANDARD po-
sition.
Step 3. Place the WELD PROCESS switch in the MIG (center) position.
Step 4. Press and release the PRESET button then turn the wire speed
control on the wire feeder to the desired speed shown on the top
digital display window of the MultiPower 460 Pulse.
Step 5. Turn the VOLTAGE knob of the wire feeder to the desired arc
voltage in the bottom digital display window of the MultiPower
460 Pulse.
Step 6. Set the shielding gas flow rate to 35 cfh by activating the gas purge
switch on the wire feeder or pulling the gun trigger and turning the
adjustment knob on the Flowmeter.
Step 7. Connect the work cable to the part top be welded and pull the gun
trigger to start welding. Trim the wire speed and volts as needed for
the desired arc characteristics and weld quality.
14
SECTION 3 OPERATION
E. MIG PULSE WELDING
The MultiPower 460 Pulse is designed to provide simple to use, high quality,
preprogrammed synergic and non-synergic pulsed Mig welding. Synergic
pulsed Mig welding means that pulse parameters (such as pulse height, pulse
width, background current and pulse frequency) are automatically adjusted by
the MultiPower 460 Pulse as the wire feed speed is changed by the operator.
A unique non-synergic Mig pulse mode is also offered for welding applications
and wire feeder combinations that cannot use the preprogrammed synergic
pulse data.
The preprogrammed WIRE TYPES, WIRE DIAMETERS and shielding gases
are listed in Table 5-2
The TRIM allows the operator to fine tune the pulse arc length and optimize the
welding. When the PROCESS switch is placed in the MIG position and the MIG
STANDARD/PULSE switch is place in the MIG PULSE position, the MultiPower 460 Pulse is set for CC over CC (constant current) pulse welding. The
power source will output open circuit voltage (OCV) when the Mig Gun trigger
is depressed. The MultiPower 460 Pulse provides a TRIM from either the wire
feeder or power source depending on the position of the PANEL/REMOTE
Table 5-2 Wire Types, Diameter and Shield Gases
Material Type Shield Gases
035, 040, 045,
Carbon Steel
052, 062
035, 040, 045,
Stainless Steel
4000 & 5000
Aluminum
Metal Core
Carbon Steel
Metal Core
Stainless Steel
035, 040, 3/64,
062
062
035, 040, 045,
052, 062
045, 062
Shielding Gas
(AWS Designation)
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)
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
Ar ( SG-A)
Ar - He 25% (SG-AHe-25)
Ar - He 50% (SG-Ahe-50)
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)
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)
15
SECTION 3 OPERATION
switch characteristics. The TRIM adjustment is calibrated such that the
preprogrammed synergic pulse data is approximately at 12 o'clock of the
TRIM knob position. The operator should preset the voltage control on the
wire feeder to the 12 o'clock position and adjust for best arc characteristics.
The operator can change to STANDARD MIG (CV) by simply moving the MIG
STANDARD/PULSE switch to the STANDARD position.
The following procedure assumes the wire feed and voltage adjustments will
be made from the wire feeder front panel and wire and gas have been installed.
See Table 4-2 for the recommended shielding gases for each wire alloy type.
Set the flowrate at 30 to 40 cfh for argon mixtures.
Place MIG STANDARD/MIG PULSE
NOTE
switch in the MIG STANDARD position
when using the Tig, Stick or Arc Gouging
process modes.
5
2
3
1
4
Figure 4-2 Synergic Pulse MIG Setup
F. PULSE MIG SETUP
Step 1. Place the WELD PROCESS switch in the MIG (center) position
Step 2. Set the MIG STANDARD/PULSE switch to the MIG PULSE position.
Step 3. Set the PANEL/REMOTE switch to the REMOTE position.
Step 4 Set the PULSE SELECTION switches to the WIRE TYPE and WIRE
DIAMETER installed on the wire feeder.
Step 5. Press and release the PRESET button. Turn the wire speed knob
on the wire feeder to the desired speed in the top digital display
window of the MultiPower 460 Pulse.
Step 6. Turn the voltage knob of the wire feeder to the desired arc volt-
age in the bottom digital display window of the MultiPower 460
Pulse.
Step 7. Set the shielding gas flow rate to 35 cfh by activating the gas purge
switch on the wire feeder or pulling the gun trigger and turning the
adjustment knob on the Flowmeter
16
SECTION 3 OPERATION
Step 8 Set the voltage knob on the wire feeder to the "5" or center 12 o'clock
position.
Step 9. Connect the work cable to the workpiece and pull the gun trigger to
start welding.
Step 10 The voltage knob on the wire feeder becomes the ARC TRIM and is
used to fine tune the arc length for best arc performance. Turn the
knob clockwise to increase the arc length or counterclockwise to
decrease the arc. Trim the wire speed and volts as needed for the
desired arc characteristics and weld quality.
G. PULSE PROCESS CONTROL and OPERATION
1. Use a tip-to-work distance (TTW) of 3/8" to 5/8". This refers to the distance
between the end of the Mig gun contact tip and the workpiece or weld
puddle. The tip-to-work distance can also be used to adjust the stability
of the arc. Changes in distance will cause the arc to shorten or lengthen
as desired for best results. Excessive tip to work movement can cause arc
instability. Maintaining a constant TTW will insure the best arc stability and
consistency.
2. For the best arc stability, keep the arc on the front edge of the molten
puddle and use a 5 to 10 degree gun angle from the vertical.
3. If the arc is "crackling" or if spatter is excessive lengthen the arc. If the arc
is "fluttering" or difficult to control then shorten the arc length.
H. PULSE MIG ARC STABILITY
Many variables can affect the arc stability of pulse MIG
welding. Some examples are:
Differences in shielding gas compositions
Differences in weld wire chemistry
Water vs. air cooled guns
Base metal surface condition
Tip-to work distance
Variations on wire feed speed
Wire feedability
Long welding cables
High resistance cables and connections
When adverse conditions are present, the pulse arc stability is sometimes less
than desirable. The arc will "crackle" and produce higher than normal spatter
levels. This occurs when high resistances in the welding circuit cause changes
pulse waveform and average current levels or the wire feed rate is varying
excessively. The TRIM knob adjusts the pulse frequency to accommodate
small changes in the welding equipment set-up and base material variations
to achieve a stable pulse welding condition.
I. SHIELDING GASES
Table 4-3 lists the types of shielding gas mixtures that can be used with the
MultiPower 460 Pulse. The wire burn-off rate and synergic operation can vary
with changes in shielding gas. The TRIM knob is used to compensate for small
changes in shield gas composition.
17
SECTION 3 OPERATION
J. NON-SYNERGIC PULSE OPERATION
The MultiPower 460 Pulse has the unique ability to Pulse MIG weld in the NONSYNERGIC mode. Non-synergic operation means the pulse parameters can
be selected by choosing the WIRE TYPE, WIRE DIAMETER, and presetting
a WIRE FEED SPEED on the MultiPower 460 Pulse panel. The pulse
frequency or arc length (TRIM) is controlled by the TRIM knob. The TRIM knob
is adjustable from the minimum to maximum pulse frequency. By using a
combination of adjusting the wire feed speed on the wire feeder and TRIM
setting on the MultiPower 460 Pulse, the pulse Mig welding arc can be tune in
and stabilized.
The selectable pulse parameters are any combination of WIRE TYPE or WIRE
DIAMETER selected using the PULSE SELECTION switches. Not all combinations will produce acceptable pulse characteristics but by using the pulse
tables provided in this manual, reasonable pulse combinations can be selected
for trial. This will take some trial and error but the added flexibility and
expanded pulse range of the non-synergic mode can be beneficial for many
welding applications.
There are several unique advantages to Non Synergic pulse mig welding. The
Non -Synergic mode of operation permits pulse welding when:
1. A wire feeder without tachometer feedback is used.
2. An "Off the Arc" wire feeder is used
3. The Mig wire type or diameter installed on the wire feeder does not have
a pulse synergic line available..
4. Pulse arc characteristics other than those preprogrammed are desired.
To take advantage of the MultiPower 460 Pulse Non-Synergic mode, it is
necessary to reposition a jumper plug and/or connector in the main control
panel wiring harness. Remove the MultiPower 460 control panel and locate the
jumper plug in the wiring harness in the PC board compartment.
Jumper Plug Installed (Factory Shipped)
Synergic Mode - Pulse circuitry is looking for a 1 volt per 100 inches per minute
signal to determine the pulse parameters required to make the weld.
Jumper Plug Removed and Harness connected
Non-Synergic Mode - The pulse parameters are determined by the position
of the pulse selection switches, the MultiPower 460 Pulse TRIM knob and Wire
Feed Speed preset.
Figure 4-3
Jumper Plug Installed
(Factory Shipped)
18
Figure 4-4
Jumper Plug Removed
and Harness Connected
SECTION 3 OPERATION
K. PULSE PARAMETERS
Tables 5-3 through 5-8 list the approximate pulse weld parameters for each
material and diameter available. These are provided for general reference
only. Actual pulse parameters can vary with the equipment set-up, welding
application and shielding gas being used. The wire feed speed ranges shown
in the tables are the same as programmed into the MultiPower 46 Pulse
program. Attempting to weld outside of the suggested speed ranges will result
in a "blinking" in synergic line indicator light on the UltraPulse front panel. A
"steady" light lite on the panel indicates the wire material and diameter
combination selected does not have any pulse data programmed.
19
SECTION 5 OPERATION
-
-
-
-
Table 5-3 Carbon Steel Pulse Weld Data
.035 Steel .040 Steel
WFS
Range
(IPM)
75 312 1.70 19 52 75 304 2.40 25 42
125 318 1.70 26 70 125 318 2.40 34 58
175 325 1.70 32 87 175 332 2.40 44 75
225 331 1.70 39 105 225 346 2.40 53 92
275 337 1.70 46 123 275 360 2.40 62 108
325 343 1.70 52 141 325 374 2.40 71 125
375 350 1.70 59 158 375 388 2.40 80 141
425 356 1.70 65 176 425 402 2.40 89 158
475 362 1.70 72 194 475 416 2.40 98 174
525 368 1.70 79 212 525 430 2.40 107 191
575 375 1.70 85 229 575 444 2.40 116 207
625 381 1.70 92 247 625 458 2.40 125 224
675 387 1.70 98 265 675 472 2.40 135 241
725
Pulse
Peak
(Amps)
394 1.70 105 283
Pulse
Width
(ms)
Pulse Back
ground
(Amps)
Frequency
Pulse
(Hz)
WFS
Range
(IPM)
725
Pulse Peak
(Amps)
486 2.40 144 257
Pulse
Width
(ms)
Pulse Back
ground
(Amps)
Frequency
.045 Steel .052 Steel
WFS
Range
(IPM)
125 441 2.20 45 64 100 400 2.50 80 56
175 451 2.20 56 85 175 400 2.50 80 93
225 461 2.20 68 106 250 400 2.50 80 131
275 471 2.20 79 128 325 400 2.50 80 169
325 481 2.20 90 149 400 400 2.50 80 207
375
425 501 2.20 113 192 550 400 2.50 80 282
475 511 2.20 124 213 625 400 2.50 80 320
525 521 2.20 135 235 700 400 2.50 80 358
575 531 2.20 146 256
Pulse
Peak
(Amps)
491 2.20 101 171
Pulse
Width
(ms)
Pulse Back
ground
(Amps)
Frequency
Pulse
(Hz)
WFS
Range
(IPM)
475
Pulse Peak
(Amps)
400 2.50 80 244
Pulse
Width
(ms)
Pulse Back
ground
(Amps)
Frequency
Pulse
(Hz)
Pulse
(Hz)
1/16 Steel
WFS
Range
(IPM)
50 518 2.50 45 40
100 524 2.50 80 71
150 529 2.50 114 103
200 534 2.50 148 134
250 540 2.50 182 166
300 545 2.50 216 197
350
400 556 2.50 284 260
Pulse
Peak
(Amps)
550 2.50 250 228
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
20
Pulse
Frequency
(Hz)
SECTION 5 OPERATION
-
-
-
-
Table 5-4 Stainless Steel Pulse Weld Data
.035 Stainless .040 Stainless
WFS
Range
(IPM)
100 300 1.64
150 300 1.71
200 300 1.78
250 300 1.86
300 300 1.93
350 300 2.00
400 300 2.07
450 300 2.14
500 300 2.21
550 300 2.28
600 300 2.35
650 300 2.42
700 300 2.49
Pulse
Peak
(Amps)
.045 Stainless .052 Stainless
WFS
Range
(IPM)
125 305 2.70
175 325 2.70
225 345 2.70
275 365 2.70
325 385 2.70
375 405 2.70
425 426 2.70
475 446 2.70
525 466 2.70
575 486 2.70
625 506 2.70
Pulse
Peak
(Amps)
Pulse
Width
(ms)
Pulse
Width
(ms)
Pulse Back
ground
(Amps)
20
24
27
31
35
39
42
46
50
53
57
61
65
Pulse Back
ground
(Amps)
58
65
71
77
84
90
97
103
110
116
122
Pulse
Frequency
(Hz)
55 100 234 2.80
71 150 244 2.80
88 200 255 2.80
104 250 265 2.80
120 300 275 2.80
136 350 285 2.80
153 400 296 2.80
169 450 306 2.80
185 500 316 2.80
201 550 327 2.80
218 600 337 2.80
234 650 347 2.80
250 700 358 2.80
Pulse
Frequency
(Hz)
81
100
119
138
157
176
195
214
233
252
271
WFS
Range
(IPM)
WFS
Range
(IPM)
Pulse Peak
(Amps)
Pulse Peak
(Amps)
NO PROGRAM
Pulse
Width
(ms)
Pulse
Width
(ms)
Pulse Back
ground
(Amps)
19
45
71
97
123
148
174
200
226
252
277
303
329
Pulse Back
ground
(Amps)
Pulse
Frequency
(Hz)
47
62
78
93
108
124
139
155
170
185
201
216
231
Pulse
Frequency
(Hz)
1/16 Stainless
WFS Range
(IPM)
50
100
150
200
250
300
350
400
450
500
Pulse
Peak
(Amps)
428 2.00 47 72
453 2.00 84 105
478 2.00 122 137
503 2.00 160 170
528 2.00 197 202
553 2.00 235 235
578 2.00 272 267
603 2.00 310 300
627 2.00 347 333
652 2.00 385 365
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
Pulse
Frequency
(Hz)
21
SECTION 5 OPERATION
-
-
Table 5-5 4000 Aluminum Pulse Weld Data
.035 4043 AIuminum .040 4043 Aluminum
WFS
Range
(IPM)
200 239 1.80
250 246 1.80
300 253 1.80
350 260 1.80
400 266 1.80
450 273 1.80
500 280 1.80
550 287 1.80
600 294 1.80
650 301 1.80
WFS
Range
(IPM)
150 206 2.20
200 226 2.20
250 246 2.20
300 267 2.20
350 287 2.20
400 307 2.20
450 327 2.20
500 347 2.20
550 367 2.20
600 387 2.20
Pulse
Peak
(Amps)
Pulse
Peak
(Amps)
Pulse
Width
(ms)
Pulse
Width
(ms)
Pulse Back-
ground
(Amps)
32
44
56
67
79
90
102
113
125
137
Pulse Back-
ground
(Amps)
22
47
73
98
123
149
174
199
225
250
Pulse
Frequency
(Hz)
89 150 218 1.80
105 200 232 1.80
121 250 246 1.80
137 300 259 1.80
152 350 273 1.80
168 400 287 1.80
184 450 300 1.80
200 500 314 1.80
216 550 328 1.80
231 600 341 1.80
WFS
Range
(IPM)
Pulse Peak
(Amps)
650 355 1.80
.052 4043 Aluminum3/64 4043 Aluminum
Pulse
Frequency
(Hz)
138
156
174
192
210
228
245
263
281
299
WFS
Range
(IPM)
Pulse Peak
(Amps)
NO PROGRAM
Pulse
Width
(ms)
Pulse
Width
(ms)
Pulse Back
ground
(Amps)
33
45
56
67
78
89
100
111
123
134
145
Pulse Back
ground
(Amps)
Pulse
Frequency
(Hz)
70
89
108
127
146
165
184
203
222
242
261
Pulse
Frequency
(Hz)
1/16 4043 Aluminum
WFS Range
(IPM)
175
225
275
325
375
425
475
525
Pulse Peak
(Amps)
376 2.30 89 117
407 2.30 119 142
437 2.30 149 167
468 2.30 179 191
499 2.30 209 216
530 2.30 239 240
561 2.30 269 265
592 2.30 299 289
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
22
Pulse
Frequency
(Hz)
SECTION 5 OPERATION
Table 5-6 5000 Aluminum Pulse Weld Data
.035 5356 Aluminum .040 5356 Aluminum
WFS
Range
(IPM)
200
250
300
350
400
450
500
550
600
650
Pulse
Peak
(Amps)
260 1.70
264 1.70
268 1.70
272 1.70
276 1.70
280 1.70
284 1.70
288 1.70
292 1.70
296 1.70
Pulse
Width
(ms)
Pulse Back-
ground
(Amps)
14
20
26
31
37
43
48
54
60
66
Pulse
Frequency
(Hz)
66
81
97
112
127
142
157
173
188
203
WFS
Range
(IPM)
150
200
250
300
350
400
450
500
550
600
650
700
Pulse Peak
(Amps)
236 1.70
245 1.70
254 1.70
263 1.70
272 1.70
281 1.70
290 1.70
299 1.70
308 1.70
317 1.70
326 1.70
335 1.70
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
26
33
40
47
54
61
68
75
82
89
96
103
Pulse
Frequency
(Hz)
53
70
86
103
119
135
152
168
185
201
218
234
150
200
250
300
350
400
450
500
Pulse
Peak
(Amps)
248 1.90
260 1.90
271 1.90
282 1.90
294 1.90
305 1.90
316 1.90
328 1.90
Pulse
Width
(ms)
Pulse Back-
ground
(Amps)
33
44
54
64
75
85
95
106
WFS Range
(IPM)
175
225
275
325
375
425
475
525
Pulse
Frequency
(Hz)
64
90
115
140
166
191
217
242
WFS
Range
(IPM)
1/16 5356 Aluminum
Pulse
Peak
(Amps)
376 2.30 68 96
407 2.30 78 116
438 2.30 88 135
469 2.30 99 155
499 2.30 109 175
530 2.30 119 194
561 2.30 129 214
592 2.30 139 234
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
.052 5356 Aluminum3/64 5356 Aluminum
Pulse Peak
(Amps)
Pulse
Width
(ms)
NO PROGRAM
Pulse
Frequency
(Hz)
Pulse
Back-
ground
(Amps)
Pulse
Frequency
(Hz)
23
SECTION 3 OPERATION
Table 5-7 Metal Core Carbon Steel Pulse Weld Data
.035 Metal Core CS .040 Metal Core CS
WFS
Range
(IPM)
300 300 2.50 39 129
350 306 2.50 49 143
400 313 2.50 58 157
450 320 2.50 68 171
500
550 333 2.50 86 199
600 340 2.50 96 213
Pulse
Peak
(Amps)
326 2.50 77 185
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
Pulse
Frequency
(Hz)
WFS
Range
(IPM)
Pulse Peak
(Amps)
Pulse
Width
(ms)
NO PROGRAM
.045 Metal Core CS .052 Metal Core CS
WFS
Range
(IPM)
100 334 2.50 21 74 75 357 2.70 18 76
175 361 2.50 46 95 125 384 2.70 47 93
250 388 2.50 70 117 175 410 2.70 77 111
325 415 2.50 95 138 225 437 2.70 106 129
400 442 2.50 119 159 275 464 2.70 136 147
475 468 2.50 144 180 325 491 2.70 165 164
550 495 2.50 168 201 375 518 2.70 194 182
625
700 549 2.50 217 244 475 572 2.70 253 217
Pulse
Peak
(Amps)
522 2.50 193 223
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
Pulse
Frequency
(Hz)
WFS
Range
Pulse Peak
(IPM)
425
525 599 2.70 283 235
(Amps)
545 2.70 224 200
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
Pulse
Back-
ground
(Amps)
Pulse
Frequency
(Hz)
Pulse
Frequency
(Hz)
1/16 Metal Core CS
WFS
Range
(IPM)
75 388 3.20 9 86
125 411 3.20 53 106
175 435 3.20 97 127
225 459 3.20 141 148
275 483 3.20 186 168
325 507 3.20 230 189
375 531 3.20 274 210
425 555 3.20 318 230
475 579 3.20 363 251
525 603 3.20 407 272
Pulse
Peak
(Amps)
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
Frequency
24
Pulse
(Hz)
SECTION 3 OPERATION
Table 5-8 Metal Core Stainless Steel Pulse Weld Data
.035 Metal Core SS .040 Metal Core SS
WFS Range
(IPM)
Pulse
Peak
(Amps)
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
Pulse
Frequency
(Hz)
WFS
Range
(IPM)
Pulse Peak
(Amps)
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
Pulse
Frequency
(Hz)
NO PROGRAM
.045 Metal Core SS .052 Metal Core SS
WFS Range
(IPM)
125 343 1.90 32 70
200 357 1.90 52 101
275 370 1.90 72 133
350 384 1.90 92 164
425 397 1.90 112 195
500 411 1.90 133 226
575 425 1.90 153 258
650 438 1.90 173 289
725 452 1.90 193 320
Pulse
Peak
(Amps)
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
WFS
Range
(IPM)
150 434 2.80 57 143
200 443 2.80 69 167
250 452 2.80 81 191
300 461 2.80 93 214
350 470 2.80 105 238
400 479 2.80 117 262
Pulse
Frequency
(Hz)
WFS
Range
(IPM)
1/16 Metal Core SS
Pulse
Peak
(Amps)
Pulse
Width
(ms)
Pulse
Back-
ground
(Amps)
NO PROGRAM
Pulse Peak
(Amps)
Pulse
Width
(ms)
NO PROGRAM
Pulse
Frequency
(Hz)
Pulse
Back-
ground
(Amps)
Pulse
Frequency
(Hz)
25
SECTION 4 MAINTENANCE
26
Figure 3. MultiPower 460 Pulse Schematic Diagram
NOTES
27
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