ESAB MultiPower 460 Pulse Upgrade Kit Installation manual / Instruction manual

MultiPower 460

Pulse Upgrade Kit

P/N 0558009123

0558009127

June 2009

Installation and Operation

Instructions

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of 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 permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions be­fore installing or operating this equipment.

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. 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 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.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

2

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions ....................................................................................5

1.1 Safety - English ..................................................................................5

1.2 Safety - Spanish .................................................................................9

1.3 Safety - French .................................................................................13

2.0 Description ..........................................................................................17

2.1 Description ......................................................................................17

2.2 Pulse Control Panel Description .................................................................17

3.0 Installation...........................................................................................21

3.1 Pulse Control Panel Installation...................................................................21

4.0 Operation .......................................................................................... 23

4.1 Operation ...................................................................................... 23

3

TABLE OF CONTENTS

4

SECTION 1 SAFETY PRECAUTIONS

1.0 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 tted with the correct lter 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 ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess 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 ameproof apron may also be desirable as protec­tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, 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 non-ammable partition or
curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.

1.1 Safety - English

FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:

1. Remove all combustible materials well away from
the work area or cover the materials with a protec­tive non-ammable 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 oors or wall openings and cause a hid­den smoldering re or res on the oor 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 ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable re extinguisher. Be sure you are trained
in its use.

5. Do not use equipment beyond its ratings. For ex­ample, overloaded welding cable can overheat and
create a re 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 re. Use re 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 conned, or if there is
danger of falling.

5

SECTION 1 SAFETY PRECAUTIONS

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.

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.

FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.

Therefore:

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommenda­tions. Do not mistake the work lead for a ground
cable.

ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur­rent owing 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 eects which

are unknown.

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 specic ventilation recommendations.

6

SECTION 1 SAFETY PRECAUTIONS

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

§25249.5 et seq.)

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 ttings in good
condition. Follow manufacturer's operating instruc­tions for mounting regulator to a compressed gas
cylinder.

1. Always have qualied personnel perform the instal­lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied 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.

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 xtures 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 ames.
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 Jeerson Davis Highway,
Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:

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"

7

SECTION 1 SAFETY PRECAUTIONS

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.

8

SECCION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

resumen de información proveniente de las
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.

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:

1. Utilice gafas de seguridad con protección a los lados

siempre que 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 ltro 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 chis-

pas calientes con una cortina adecuada no-amable
como división.

6. Use careta protectora además de sus gafas de segu-

ridad 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 amas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:

1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases amables, 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 inamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inamables.

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 corri-

ente alterna (AC) en áreas húmedas,
de movimiento connado en lugares estrechos o
si hay posibilidad de caer al suelo.

9

SECCION 1 SEGURIDAD

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 especícas 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 uye 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.

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 sub-

stancias 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 especícas en la ventilación.

10

SECCION 1 SEGURIDAD

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

1. Siempre tenga personal cualicado para efec­tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado 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 modique 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"

MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:

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

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

11

SECCION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura
de este folleto: Los Símbolos Sig­nican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.

Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.

Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.

Signica el posible riesgo que
puede resultar en menores daños
a la persona.

12

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT : Ces règles de sécurité

ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution

provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurez­vous de lire et de suivre les précautions de sécurité ci­dessous, dans les manuels, les ches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ltrants et de

plaques protectrices appropriées an de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas re­garder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes an de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé
de porter un tablier ininammable an de vous proté­ger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recom­mandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininammable.

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
L es p er so n ne s se tr o uv an t à p r ox im it é do ive nt é ga l e­ment porter des lunettes étanches par dessus leur
lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La
chaleur provenant des ammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combus­tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. Les
matériaux combustibles incluent le bois, les vête­ments, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.

2. Les étincelles et les projections de métal incan­descent peuvent tomber dans les ssures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre tra­vail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauer et provoquer un in­cendie.

6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projec­tion de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.

7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-

telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.

13

SECTION 1 SÉCURITÉ

1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de
terre électrique.

3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion an d'éviter le risque
de choc électrique mortel.

4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endom­magés.

5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porte­électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.

7. Si vous devez eectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directe­ment sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever
vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spéciques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉ­TIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conduc-

teur produit des champs électriques
et magnétiques localisés. Le soudage et le cou­rant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour cer­tains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des eets néfastes inconnus pour
la santé.

3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même
côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée
de votre corps.

LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne re­spirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventila­tion naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation ecaces. Ne
respirez pas les vapeurs de ces matériaux.

2. N'eectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lor­sque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ven­tilation n'est pas adéquate. Cessez votre travail an
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spéciques
concernant la ventilation.

14

SECTION 1 SÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques consid­éres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES -­La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un

échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des bles­sures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne xez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas bran­ché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des
ammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre dis­position par le Compressed Gas Association, 1235
Jeerson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe­ment entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.

2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.

3. Maintenez les câbles, les ls de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez ja­mais un équipement s'il présente une défectuosité
quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des aques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.

6. Utilisez l'équipement conformément à son usage
prévu et n'eectuez aucune modication.

INFORMATIONS SUPPLÉMENTAIRES RELA­TIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precau­tions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recomman­dées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

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"

15

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.

DANGER

Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.

ATTENTION

Signie un danger qui peut entraîner des blessures
corporelles mineures.

16

SECTION 2 DESCRIPTION

2.0 Description

2.1 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), ux 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.

2.2 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 o 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.

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.

17

SECTION 2 DESCRIPTION

ELECTRIC SHOCK CAN KILL! Make sure that all primary input power to the power

WARNING

source and wire feeder has been disconnected at the wall (line) disconnect switch or
circuit breaker before making the following connections.

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

Current Voltage

Pulse Frequency

Weld Process

Switch

Inductance

Adjustment

Pulse

Wire Type

Pulse

Wire Diameter

Figure 2-1. MultiPower 460 Pulse Control Panel

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 arc length can then be adjusted by
turning the knob clockwise to increase the arc length or counterclockwise to decrease the arc length.

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.

18

SECTION 2 DESCRIPTION

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.

19

SECTION 2 DESCRIPTION

20

SECTION 3 INSTALLATION

3.0 Installation

3.1 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 3-1.

Step 1. Disconnect ALL primary power from the MultiPower 460 by unplugging 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 connector, remove the meter PCB from the panel

leaving the wire harness connected. Remove the control panel from the PC board compartment. Do not discard
this panel, it 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 and install the

meter PCB.

Step 5. Carefully position the panel harness plug to the left side of the heatsinks on the main PCB, position the control

panel over the PC board compartment and secure with the mounting screws removed from the standard control
panel.

Figure 3-1. MultiPower 460 Pulse Harness Connection

Panel Screws

Heatsinks

Panel Harness Plug

21

SECTION 3 INSTALLATION

22

SECTION 4 OPERATION

4.0 Operation

4.1 OPERATION

A. WIRE FEEDER COMPATIBILITY

The MultiPower 460 Pulse power source can be used with several 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 PULSE FREQUENCY locations. The wire feed speed is always set from the wire feeder using the wire
speed knob on the feeder control panel in the PULSE mode. To see the approximate wire feed speed, which matches the
PULSE FREQUENCY selected, press the PRESET button on the MultiPower 460 control 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.

C. MIG WELDING

In the standard MIG process mode, the digital display will read 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”.

23

SECTION 4 OPERATION

4

1

2

Figure 4-1. Standard Mig Setup Procedure

3

NOTE:

Place MIG STANDARD/MIG PULSE 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 a remote pendant.

Step 1. Connect wire feeder and a remote pendant to MultiPower 460 Pulse and set PANEL/REMOTE switch to REMOTE

position.

Step 2. Set the MIG STANDARD/PULSE switch to the MIG STANDARD position.

Step 3. Place the WELD PROCESS switch in the MIG (center) position.

Step 4. Turn the wire speed control on the wire feeder to the desired speed.

Step 5. Press and release the PRESET button then 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 ow to the desired rate 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 to 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.

24

SECTION 4 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 oered for welding applications and wire feeder combinations that cannot
use the preprogrammed synergic pulse data. This pulse panel is shipped in non-synergic mode.

The preprogrammed WIRE TYPES, WIRE DIAMETERS and shielding gases are listed in Table 4-1.

The TRIM allows the operator to ne 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 Pulse Frequency control from either the remote pendant or
power source depending on the position of the PANEL/REMOTE switch 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
remote control paendant. See Table 4-1 for the recommended shielding gases for each wire alloy type. Set the owrate at
30 to 40 cfh for argon mixtures.

Table 4-1. Wire Types, Diameter and Shield Gases

Material Type

Carbon Steel .035, .045 soft,

Stainless Steel .035, .040,

4000 & 5000

Aluminum

Metal Core

Carbon Steel

Metal Core

Carbon Steel

Wire

Diameters

.045,

.045 med,

.045 strong

.045, .062

.035, .040,

3/64, .062

.035, .040,
.045, .052,

.062

.045, .062 Ar -2% CO2 (SG-AC-2)

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 - 8% CO2 (SG-AC-8)

Ar - 1% O2 (SG-AO-1)

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

25

SECTION 4 OPERATION

5

2

3

1

4

Figure 4-2. Synergic Pulse MIG Setup

NOTE

Place MIG STANDARD/MIG PULSE switch in the MIG STANDARD position when using the Tig, Stick or Arc

Gouging process modes.

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. Turn the wire speed knob on the wire feeder to the desired speed.

Step 6. Press and release the PRESET button. Turn the voltage knob of the remote pendant to the approximate wire speed

in the top digital display window of the MultiPower 460 Pulse.

Step 7. Set the shielding gas ow to the desired rate by activating the gas purge switch on the wire feeder or pulling the

gun trigger and turning the adjustment knob on the owmeter.

Step 8. Connect the work cable to the workpiece and pull the gun trigger to start welding.

Step 9. The voltage knob on the remote pendant becomes the PULSE FREQUENCY CONTROL and is used to ne 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.

26

SECTION 4 OPERATION

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 pulse control panel has an '"adaptive" characteristic which compensates
for normal changes in tip-to-work distance. This is helpful when a long stick out is necessary to reach into corners or
when transversing the weld puddle during weaving of vertical welding.

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 "uttering" or dicult to control then
shorten the arc length.

H. PULSE MIG ARC STABILITY

Many variables can aect the arc stability of pulse MIG
welding. Some examples are:

Dierences in shielding gas compositions
Dierences 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 OUTPUT CONTROL knob adjusts the
pulse frequency to accommodate changes in the welding equipment set-up and base material variations to achieve a stable
pulse welding condition.

I. SHIELDING GASES

Table 4-1 lists the types of shielding gas mixtures that can be used with the MultiPower 460 Pulse. The wire burn-o rate
can vary with changes in shielding gas. The OUTPUT CONTROL knob is used to compensate for changes in shield gas
composition.

27

SECTION 4 OPERATION

J. NON-SYNERGIC PULSE OPERATION

The MultiPower 460 Pulse has the unique ability to Pulse MIG weld in the NON-SYNERGIC 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 (OUTPUT CONTROL) is controlled by the OUTPUT
CONTROL knob. The OUTPUT CONTROL 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 OUTPUT CONTROL setting on the MultiPower 460
Pulse, the pulse Mig welding arc can be tuned 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 exibility
and expanded pulse range of the non-synergic mode can be benecial 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 "O 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

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 (Factory Shipped)

Non-Synergic Mode - The pulse parameters are determined by the position of the pulse selection switches, the MultiPower
460 Pulse OUTPUT CONTROL knob and Wire Feed Speed preset.

Figure 4-3.

Jumper Plug Installed

Jumper Plug Removed and Harness Connected

Figure 4-4.

(Factory Shipped)

K. PULSE PARAMETERS

Tables 4-3 through 4-8 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 460 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.

28

SECTION 4 OPERATION

SECTION 5 OPERATION

Table 5-3 Carbon Steel Pulse Weld Data

.035 Steel .040 Steel

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)

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

394 1.70 105 283

725

486 2.40 144 257

.045 Steel .052 Steel

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)

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

491 2.20 101 171

475

400 2.50 80 244

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

Table 4-3. Carbon Steel Pulse Weld Data

.045 soft

WFS

Range

(IPM)

75 500 2.00 20 65

125 500 2.00 20 95

175 500 2.00 20 125

225 500 2.00 20 155

275 500 2.00 20 185

325 500 2.00 20 215

375 500 2.00 20 245

425 500 2.00 20 275

475 500 2.00 20 305

525 500 2.00 20 335

Pulse

Peak

(Amps)

Pulse

Width

(ms)

Pulse Back-

ground
(Amps)

Pulse

Frequen-

cy (Hz)

WFS

Range

(IPM)

75 430 2.20 20 65

125 430 2.20 20 95

175 430 2.20 20 125

225 430 2.20 20 155

275 430 2.20 20 185

325 430 2.20 20 215

375 430 2.20 20 245

425 430 2.20 20 275

475 430 2.20 20 305

525 430 2.20 20 335

WFS

Range

(IPM)

29

75 430 1.80 20 75

125 430 1.80 20 110

175 430 1.80 20 145

225 430 1.80 20 180

275 430 1.80 20 215

325 430 1.80 20 250

375 430 1.80 20 285

425 430 1.80 20 320

475 430 1.80 20 355

525 430 1.80 20 390

Pulse

Peak

(Amps)

Pulse

Peak

(Amps)

.045 med

Pulse

Width

(ms)

.045 strong

Pulse

Width

(ms)

Pulse Back-

ground
(Amps)

Pulse Back-

ground
(Amps)

Pulse

Frequen-

cy (Hz)

Pulse

Frequen-

cy (Hz)

SECTION 4 OPERATION

Table 5-4 Stainless Steel Pulse Weld Data

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)

100 300 1.64

20

55 100 234 2.80

19

47

150 300 1.71

24

71 150 244 2.80

45

62

200 300 1.78

27

88 200 255 2.80

71

78

250 300 1.86

31

104 250 265 2.80

97

93

300 300 1.93

35

120 300 275 2.80

123

108

350 300 2.00

39

136 350 285 2.80

148

124

400 300 2.07

42

153 400 296 2.80

174

139

450 300 2.14

46

169 450 306 2.80

200

155

500 300 2.21

50

185 500 316 2.80

226

170

550 300 2.28

53

201 550 327 2.80

252

185

600 300 2.35

57

218 600 337 2.80

277

201

650 300 2.42

61

234 650 347 2.80

303

216

700 300 2.49

65

250 700 358 2.80

329

231

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)

125 305 2.70

58

81

175 325 2.70

65

100

225 345 2.70

71

119

275 365 2.70

77

138

325 385 2.70

84

157

375 405 2.70

90

176

425 426 2.70

97

195

475 446 2.70

103

214

525 466 2.70

110

233

575 486 2.70

116

252

625 506 2.70

122

271

WFS Range

(IPM)

Pulse

Peak

(Amps)

Pulse

Width

(ms)

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

50

428 2.00 47 72

100

453 2.00 84 105

150

478 2.00 122 137

200

503 2.00 160 170

250

528 2.00 197 202

300

553 2.00 235 235

350

578 2.00 272 267

400

603 2.00 310 300

450

627 2.00 347 333

500

652 2.00 385 365

1/16 Stainless

.035 Stainless .040 Stainless

.045 Stainless .052 Stainless

NO PROGRAM

Table 4-4. Stainless Steel Pulse Weld Data

30

SECTION 4 OPERATION

Table 5-5 4000 Aluminum Pulse Weld Data

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)

200 239 1.80

32

89 150 218 1.80

33

70

250 246 1.80

44

105 200 232 1.80

45

89

300 253 1.80

56

121 250 246 1.80

56

108

350 260 1.80

67

137 300 259 1.80

67

127

400 266 1.80

79

152 350 273 1.80

78

146

450 273 1.80

90

168 400 287 1.80

89

165

500 280 1.80

102

184 450 300 1.80

100

184

550 287 1.80

113

200 500 314 1.80

111

203

600 294 1.80

125

216 550 328 1.80

123

222

650 301 1.80

137

231 600 341 1.80

134

242

650 355 1.80

145

261

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)

150 206 2.20

22

138

200 226 2.20

47

156

250 246 2.20

73

174

300 267 2.20

98

192

350 287 2.20

123

210

400 307 2.20

149

228

450 327 2.20

174

245

500 347 2.20

199

263

550 367 2.20

225

281

600 387 2.20

250

299

WFS Range

(IPM)

Pulse Peak

(Amp s)

Pulse
Width

(ms)

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

175

376 2.30 89 117

225

407 2.30 119 142

275

437 2.30 149 167

325

468 2.30 179 191

375

499 2.30 209 216

425

530 2.30 239 240

475

561 2.30 269 265

525

592 2.30 299 289

1/16 4043 Aluminum

.035 4043 AIuminum .040 4043 Aluminum

.052 4043 Aluminum3/64 4043 Aluminum

NO PROGRAM

Table 4-5. 4000 Aluminum Pulse Weld Data

31

SECTION 4 OPERATION

Table 5-6 5000 Aluminum Pulse Weld Data

SECTION 5 OPERATION

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)

200

260 1.70

14

66

150

236 1.70

26

53

250

264 1.70

20

81

200

245 1.70

33

70

300

268 1.70

26

97

250

254 1.70

40

86

350

272 1.70

31

112

300

263 1.70

47

103

400

276 1.70

37

127

350

272 1.70

54

119

450

280 1.70

43

142

400

281 1.70

61

135

500

284 1.70

48

157

450

290 1.70

68

152

550

288 1.70

54

173

500

299 1.70

75

168

600

292 1.70

60

188

550

308 1.70

82

185

650

296 1.70

66

203

600

317 1.70

89

201

650

326 1.70

96

218

700

335 1.70

103

234

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)

150

248 1.90

33

64

200

260 1.90

44

90

250

271 1.90

54

115

300

282 1.90

64

140

350

294 1.90

75

166

400

305 1.90

85

191

450

316 1.90

95

217

500

328 1.90

106

242

WFS Range

(IPM)

Pulse

Peak

(Amps)

Pulse
Width

(ms)

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

175

376 2.30 68 96

225

407 2.30 78 116

275

438 2.30 88 135

325

469 2.30 99 155

375

499 2.30 109 175

425

530 2.30 119 194

475

561 2.30 129 214

525

592 2.30 139 234

1/16 5356 Aluminum

.052 5356 Aluminum3/64 5356 Aluminum

.035 5356 Aluminum .040 5356 Aluminum

NO PROGRAM

Table 4-6. 5000 Aluminum Pulse Weld Data

32

SECTION 4 OPERATION

Table 5-7 Metal Core Carbon Steel Pulse Weld Data

.035 Metal Core CS .040 Metal Core CS

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)

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

326 2.50 77 185

550 333 2.50 86 199
600 340 2.50 96 213

.045 Metal Core CS .052 Metal Core CS

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)

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

522 2.50 193 223

425

545 2.7 0 224 200

700 549 2.50 217 244 475 572 2.70 253 217

525 599 2.70 283 235

1/16 Metal Core CS

WFS

Range

(IPM)

Pulse

Peak

(Amps)

Pulse
Width

(ms)

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

75 388 3.2 0 9 86
125 411 3.2 0 53 106
175 435 3.2 0 97 127
225 459 3.2 0 141 148
275 483 3.2 0 186 168
325 507 3.2 0 230 189
375 531 3.2 0 274 210
425 555 3.2 0 318 230
475 579 3.2 0 363 251
525 603 3.2 0 407 272

NO PROGRAM

Table 4-7. Metal Core Carbon Steel Pulse Weld Data

33

SECTION 4 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)

.045 Metal Core SS .052 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)

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

1/16 Metal Core SS

WFS

Range

(IPM)

Pulse

Peak

(Amps)

Pulse
Width

(ms)

Pulse

Back-
ground
(Amps)

Pulse

Frequency

(Hz)

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

NO PROGRAM

NO PROGRAM

NO PROGRAM

Table 4-8. Metal Core Stainless Steel Pulse Weld Data

34

NOTES

35

NOTES

36

REVISION HISTORY

Original release - 06/2009.1.

37

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