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Ultra-Pulse 350MPi
MIG Pulse Pendant Control
Instruction Manual
This manual provides installation and operation instructions for
the following Ultra-Pulse 350MPi MIG Pulse Pendant Control:
P/N 36988
F15-606-A 10 / 2003
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BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
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.
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TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH
SECTION 1 DESCRIPTION ................................................................................................. 10
1.1 General ............................................................................................................. 10
SECTION 2 INSTALLATION ................................................................................................ 10
2.1 General ............................................................................................................. 10
2.2 Cable Connections............................................................................................ 10
2.3 Power Source Set-Up ....................................................................................... 11
SECTION 3 PULSE OPERATION ........................................................................................ 11
3.1 Pulsed MIG Operation ...................................................................................... 11
SECTION 4 PULSE TECHNICAL DATA ............................................................................. 12
4.1 Standard CV Operation ..................................................................................... 12
4.2 Pulse MIG Arc Stability .................................................................................... 13
4.3 Shielding Gases ................................................................................................ 13
4.4 Pulse Parameters ............................................................................................. 13
SECTION 5 ULTRAPULSE MOUNTING OPTIONS ............................................................ 16
SECTION 6 WIRING DIAGRAMS & REPLACEMENT PARTS ........................................... 17
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TABLE OF CONTENTS
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SAFETY 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 non-flammable 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.
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 Pro-
--
cesses", 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
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from your body as possible.
10/98
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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.
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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:
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
tension 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
assu-rer 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
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PRÉCAUTIONS DE SÉCURITÉ
levage, 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.
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WIRE SPEED RANGE
&
"NO PROGRAM"
INDICATOR
PROCESS SELECTION
SWITCH
WIRE MATERIAL
SELECTOR
WIRE DIAMETER
SELECTOR
ARC LENGTH
TRIM
ULTRAPULSE 350 PULSE CONTROL PENDANT
(FOR 350MPi POWER SOURCE ONLY)
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SECTION 1 DESCRIPTION
1.1 General
The Ultra-Pulse 350 pendant is designed to provide
simple to use, high quality, synergic pulsed Mig welding
when used with a 350MPi inverter power source and a
Mig 4HD, 4HD Dual or Mig 5XL "Mongoose" wire feeder.
Synergic pulsed Mig welding means that pulse parameters (such as pulse height, pulse width, background
current and pulse frequency) are automatically adjusted
by the Ultra-Pulse 300i pendant as you change wire feed
speed.
The Ultra-Pulse 350 pendant also provides a PULSE
ARC TRIM that allows the operator to fine tune the pulse
arc length. The operator can change to standard welding
by simply moving the PULSE /STANDARD switch to the
STANDARD position. The system can then be used for
non-pulsed Mig (GMAW), Tig (GTAW) or stick electrode
welding (SMAW) by changing the 350MPi PROCESS
SELECTOR switch to the desired welding process and
connecting the appropriate welding torch or electrode
holder.
SECTION 2 INSTALLATION
2.1 General
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.
The following instructions are intended to supplement
the manuals supplied with the wire feeder and power
source. Be sure to follow all installation, operation and
safety information provided by these manuals.
2.2 Cable Connections
Refer to Figure 1.
The Ultra-Pulse 350 pendant is supplied with a 8-ft (2.4
m) control cable with a 19 pin male amphenol style
connector and a 19 pin female amphenol receptacle.
1. Connect the 19 pin plug to the mating receptacle
on the 350MPi power source.
2. Connect the UltraPulse 19 pin female amphenol
receptacle to the wire feeder control cable male
amphenol plug.
Ultra-Pulse
350
Pendant
FIGURE 1. Connection to Feeder & Power Supply
From Ultra-Pulse
350 MPi Pendant
19-Pin Female Connector to:
Mig 4HD
Mig 4HD Dual
Mig 5XL "Mongoose"
10
19-Pin Male
Connector
to 350 MPi
Page 11
SECTION 2 INSTALLATION
3. Be sure that the secondary output connections
(welding cables) are connected so the positive
cable goes to the wire feeder and the negative
cable goes to the work piece.
2.3 Power Source Set-Up
2. Use output cables that are as short as possible.
Do not loop or coil the work cables. Excessive
cable lengths and coiled cables could result in
less than optimum performance.
3. Proper connection of the work cables to the
work is essential for high quality results. Under-
1. The 350MPi power source is "Pulse Mig Ready"
and requires no additional configuration or adjustments. Place the 350MPi power source
PROCESS SELECTOR switch in the Mig posi-
sized ground clamps, poor connects, frayed
cables, cable splices or clamps attached to
rusting or dirty surfaces will result in unstable
conditions.
tion and the MIG SELECTOR switch to the type
of Mig wire to be used. The position of the
REMOTE/PANEL switch is dependant on the
4. Turn the power source "ON" and initiate the
welding process by closing the torch trigger.
wire feeder and process (STANDARD or
PULSE) being used. Refer to TABLE 1.
SECTION 3 PULSE OPERATION
3.1 Pulsed Mig Operation
A. UltraPulse 350 pendant Set-Up.
1. Set the MATERIAL SELECTOR dial to the wire
type and wire diameter that is being used on the
wire feeder.
NOTE: See Table 2 for the recommended shield-
ing gasses for each wire alloy type.
2. Set Panel Remote Switch to (Remote).
NOTE:The RED light on the UltraPulse pendant will
"Blink" when the wire feed speed is out of
range. A "Steady" light "On" indicates there
is no program for the material and wire
diameter selected.
3. Place the PULSE/STANDARD toggle switch to
the PULSE position.
TABLE 1 - UltraPulse 350 and 350MPi Power Source Set-Up
STANDARD / PULSE SWITCH
REMOTE
CONTROL
PANEL
CONTROL
350 MPi FRONT PANEL
OUTPUT PRESET SWITCH
DIGITAL
AMMETER
DIGITAL
VOLTMETER
VOLTAGE
CONTROL
PANEL/REMOTE
TOGGLE SWITCH
MATERIAL
SELECTOR
SWITCH
Wire UltraPulse Process 350MPi Voltage Control From:
Feeder Switch Power Source
Mig 4HD STANDARD REMOTE Mig 4HD VOLTS POT
PULSE REMOTE UltraPuse 350 TRIM
Mig 4HD DUAL STANDARD REMOTE Mig 4HD VOLTS POT
PULSE REMOTE UltraPuse 350 TRIM
Mig 5XL STANDARD PANEL 350MPi Panel VOLTS
"Mongoose" PULSE REMOTE UltraPuse 350 TRIM
11
PROCESS
SELECTOR
SWITCH
INDUCTANCE (CV)
ARC FORCE (CC)
Page 12
SECTION 3 PULSE OPERATION
4. Set the ARC TRIM knob to the "0" or center
position.
D. Mig 5XL "Mongoose" Wire Feeder
The ARC TRIM is used to fine tune the arc
length performance. Turn the knob clockwise to
increase the arc length or counterclockwise to
decrease the arc length.
Mig 4HD Wire Feeder
B.
1. Set the WIRE FEED SPEED dial to a wire feed
rate that is within the range of the UltraPuse
pendant control.
NOTE-----The RED light on the UltraPulse pendant will "Blink" when the wire feed speed is out
of range.
2. Pull the gun trigger. Begin Welding. Trim the
arc voltage with the UltraPulse pendant TRIM
knob to the desired arc length
Mig 4HD Dual Wire Feeder
C.
1. Pulse operation is the same as the standard Mig
4HD except BOTH guns on the Mig 4HD Dual
will have pulse parameters sent to them based
on the wire type and diameter seletcted on the
UltraPulse Pendant. Each gun CANNOT be
independently controlled for different wire types
or sizes.
1. To pulse with the Mongoose "push/Pull" System, be sure you have the Mig 5XL Pulse
Version wire feeder (PN-37487).
2. Set the 350MPi PANEL/REMOTE switch to the
REMOTE position (See TABLE 1).
3. Set the wire feed speed on the MT-300XL gun.
NOTE-----The RED light on the UltraPulse pendant will "Blink" when the wire feed speed is out
of range.
4. Adjust the UltraPuse Arc Trim to the desired arc
characteristics.
E.
Process control
1. Use a tip-to-work distance of 3/8" to 5/8". This
refers to the distance between the end of the Mig
gun contact tip and the plate or weld puddle.
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. The TRIM knob on the UltraPulse 350 pendant
is used to fine tune the arc length by turning the
dial clockwise to lengthen the arc or counterclockwise to shorten the arc. 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.
SECTION 4 PULSE TECHNICAL DATA
4.1 Standard CV Operation
The Ultra-Pulse 350 pendant provides for both standard
welding and pulsed Mig welding. When the STAN-
DARD/PULSE switch is in the STANDARD position the
wire feeder and power source are ready for standard
non-pulsed CV Mig welding. Follow the basic instructions provided with the power source to change to other
welding processes, such as, Tig or Stick welding .
12
1. For standard CV Mig welding the wire feed
speed and power source output (voltage) are
independent.
2. On a Mig 4HD, set the voltage on the front panel
of the feeder. On a Mig 5XL, set the arc voltage
on the front panel of the power source. Refer to
Table 1.
Page 13
SECTION 4 PULSE TECHNICAL DATA
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
4.2 Pulse MIG Arc Stability
Many variables can affect the arc stability of pulse MIG
welding. Some examples are:
Long welding cables
High resistance cables and connections
Differences in shielding gas compositions
Differences in weld wire chemistry
Water vs. air cooled guns
Base metal surface condition
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 due to higher resistances in the welding
circuit causing changes pulse waveform and average
current levels. The TRIM knob on the UltraPulse pendant 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.
4.3 Shielding Gases
Table 2 lists the range of shielding gases that can be
used with the UltraPuse pendant. The wire burn-off rate
and synergic operation will vary with changes in shielding gas. The UtraPulse TRIM knob is used to compensate for changes in shield gas composition.
4.4 Pulse Parameters
Tables 3 through 7 list the approximate pulse welding
parmeters for each material and diameter. These are
provided for general reference only. Actual pulse parameters can vary with the equipment set-up, welding
application and shielding gases being used. The wire
feed speed ranges shown in the tables are the same as
programmed into the UltraPulse 350 pendant. Attempting to weld outside of the suggested speed ranges will
result in a "blinking" 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.
TABLE 2 - UltraPulse 350 Material, Diameter and Shielding Gases
Material
Type
Carbon
Steel
Stainless
Steel
4000 &
5000
Aluminum
Meta l Core
Carbon
Steel
Meta l Core
Stainless
Steel
Wire
Diameter (In.)
.030, .035,
.040, .045
.030, .035,
.040, .045
.030, .035,
3/64 (.047)
.040, .045,
.052
0.045
Shielding Gas
(AWS Designation)
r - 5% CO2 (SG-AC-5)
r - 8% CO2 (SG-AC-8)
r - 10% CO2 (SG-AC-10)
r - 2% O2 (SG-AO-2)
Ar - 8% CO2 - 2% O2 (SG-ACO-8/2)
r -2% CO2 (SG-AC-2)
r - 8% CO2 (SG-AC-8)
r - 2% O2 (SG-AO-2)
r - 8% CO2 - 2% O2 (SG-ACO-8/2)
Ar - He 50% - 2% CO2 (SG-AHeC-50/2)
r ( SG-A)
r - He 25% (SG-AHe-25)
Ar - He 50% (SG-Ahe-50)
r - 5% CO2 (SG-AC-5)
r - 8% CO2 (SG-AC-8)
r - 10% CO2 (SG-AC-10)
r - 2% O2 (SG-AO-2)
Ar - 8% CO2 - 2% O2 (SG-ACO-8/2)
r - 2% CO2 (SG-AC-2)
r - 8% CO2 (SG-AC-8)
r - 1% O2 (SG-AO-1)
r - He 50% - 2% CO2 (SG-AHeC-50/2)
13
Page 14
SECTION 4 PULSE TECHNICAL DATA - STEEL
TABLE 3 - UltraPulse 350 Carbon Steel Pulse Parameters
.030 Steel .035 Steel
WFS
Pulse
Pulse
Range
Peak
75 273 2.00 11 34 75 257 2.40 0 59
125 279 2.00 15 47 125 272 2.40 18 75
175 285 2.00 19 61 175 287 2.40 36 92
225 292 2.00 23 75 225 302 2.40 54 108
275 298 2.00 27 89 275 317 2.40 72 125
325 304 2.00 31 103 325 332 2.40 90 141
375 311 2.00 35 117 375 347 2.40 1 08 158
425 317 2.00 39 131 425 362 2.40 1 26 174
475 323 2.00 43 145 475 377 2.40 1 44 191
525 330 2.00 47 158 525 392 2.40 1 62 207
575 336 2.00 51 172 575 407 2.40 1 80 224
625 342 2.00 55 186 625 422 2.40 1 98 240
675 349 2.00 59 200
725 355 2.00 63 214
775 361 2.00 67 228
Width
Pulse
Background
.040 Steel .045 Steel
WFS
Pulse
Pulse
Range
Peak
75 367 2.60 13 54 125 348 3.00 32 88
125 370 2.60 30 73 175 363 3.00 55 105
175 374 2.60 46 92 225 378 3.00 77 123
225 378 2.60 63 111 275 393 3.00 1 00 140
275 382 2.60 80 129 325 408 3.00 1 22 158
325 386 2.60 97 148 375 423 3.00 1 45 175
375 389 2.60 113 167 425 438 3.00 1 67 193
425 393 2.60 130 186 475 453 3.00 1 90 210
475 397 2.60 147 205
525 401 2.60 164 223
575 404 2.60 180 242
625 408 2.60 197 261
Width
Pulse
Background
Pulse
Frequency
Pulse
Frequency
WFS
Range
WFS
Range
Pulse
Peak
Pulse
Peak
Pulse
Width
Pulse
Width
Pulse
Background
Pulse
Background
Pulse
Frequency
Pulse
Frequency
TABLE 4 - UltraPulse 350 Stainless Steel Pulse Parameters
.030 Stainless .035 Stainless
WFS
Pulse
Pulse
Range
Peak
200 239 1.90 27 64 75 224 2.30 8 50
250 246 1.90 35 77 125 233 2.30 17 70
300 252 1.90 44 89 175 242 2.30 26 90
350 258 1.90 52 102 225 251 2.30 35 110
400 265 1.90 61 115 275 260 2.30 44 130
450 271 1.90 69 127 325 269 2.30 53 150
500 278 1.90 78 140 375 278 2.30 62 170
550 284 1.90 86 152 425 287 2.30 71 190
600 290 1.90 95 165 475 296 2.30 80 210
650 297 1.90 103 177 525 305 2.30 89 230
700 303 1.90 112 190 575 314 2.30 98 250
750 309 1.90 120 202 625 323 2.30 1 07 270
Width
Pulse
Background
.040 Stainless .045 Stainless
WFS
Pulse
Pulse
Range
Peak
75 214 2.80 24 52 75 285 2.70 39 62
125 234 2.80 41 63 125 306 2.70 50 81
175 254 2.80 57 74 175 326 2.70 60 100
225 275 2.80 74 85 225 347 2.70 71 119
275 295 2.80 90 96 275 367 2.70 81 138
325 316 2.80 107 107 325 388 2.70 92 157
375 336 2.80 124 118 375 409 2.70 1 02 176
425 356 2.80 140 129 425 429 2.70 1 13 195
475 377 2.80 157 140
525 397 2.80 174 151
Width
Pulse
Background
Pulse
Frequency
Pulse
Frequency
WFS
Pulse
Pulse
Range
Peak
675 332 2.30 1 16 290
725 341 2.30 1 25 310
WFS
Pulse
Range
Peak
Width
Pulse
Width
Pulse
Background
Pulse
Background
Frequency
Frequency
Pulse
Pulse
14
Page 15
SECTION 4 PULSE TECHNICAL DATA - ALUMINUM
TABLE 5 - UltraPulse 350 4000 Aluminum Pulse Parameters
.030 4043 AI .035 4043 AI
WFS
Pulse
Pulse
Range
Peak
200 236 1.10 20 109 150 194 1.59 26 60
250 251 1.10 25 131 200 209 1.61 36 80
300 266 1.10 30 152 250 225 1.62 46 101
350 281 1.10 34 174 300 241 1.64 55 121
400 296 1.10 39 196 350 256 1.65 65 142
450 311 1.10 44 218 400 272 1.67 75 162
500 325 1.10 48 240 450 288 1.68 84 183
550 340 1.10 53 262 500 303 1.70 94 203
600 355 1.10 58 284 550 319 1.71 104 224
650 370 1.10 63 306 600 334 1.73 113 244
700 385 1.10 67 328 650 350 1.74 123 265
Width
Pulse
Background
.040 4043 AI .047 4043 AI
WFS
Pulse
Pulse
Range
Peak
Not Programmed 280 340 1.88 87 134
Width
Pulse
Background
Pulse
Frequency
Pulse
Frequency
WFS
Pulse
Pulse
Range
Peak
700 366 1.76 133 286
WFS
Pulse
Range
Peak
80 260 1.50 30 38
130 280 1.60 44 62
180 300 1.69 58 86
230 320 1.79 73 110
330 360 1.98 101 159
380 380 2.07 115 183
430 400 2.17 130 207
480 420 2.26 144 231
530 440 2.36 158 255
Width
Pulse
Width
Pulse
Background
Pulse
Background
Frequency
Frequency
Pulse
Pulse
TABLE 6 - UltraPulse 350 5000 Aluminum Pulse Parameters
030 5356 AI .035 5356 AI
WFS
Pulse
Pulse
Range
Peak
225 310 1.15 25 60 200 256 1.70 28 56
275 318 1.15 31 69 250 261 1.70 33 74
325 326 1.15 38 77 300 266 1.70 38 92
375 335 1.15 44 86 350 271 1.70 43 110
425 343 1.15 51 94 400 276 1.70 48 128
475 351 1.15 57 103 450 280 1.70 53 147
525 359 1.15 64 112 500 285 1.70 58 165
575 368 1.15 70 120 550 290 1.70 63 183
625 376 1.15 77 129 600 295 1.70 68 201
675 384 1.15 83 137 650 300 1.70 73 219
725 392 1.15 90 146 700 305 1.70 78 237
Width
Pulse
Background
.040 5356 AI .047 5356 AI
WFS
Pulse
Pulse
Range
Peak
Not Programmed 300 341 1.50 80 154
Width
Pulse
Background
Pulse
Frequency
Pulse
Frequency
WFS
Pulse
Pulse
Range
Peak
750 310 1.70 83 255
800 315 1.70 88 273
WFS
Pulse
Range
Peak
150 303 1.50 35 74
200 316 1.50 50 101
250 328 1.50 65 127
350 353 1.50 95 181
400 366 1.50 1 10 208
450 379 1.50 1 25 235
500 391 1.50 1 40 262
550 404 1.50 1 55 289
Width
Pulse
Width
Pulse
Background
Pulse
Background
Frequency
Frequency
Pulse
Pulse
12
15
Page 16
SECTION 4 PULSE TECHNICAL DATA - METAL CORE
TABLE 7 - UltraPulse 350 Metal CorePulse Parameters
Steel and Stainless
.040 Metal Core CS .045 Metal Core CS
WFS
Pulse
Pulse
Range
Peak
100 255 2.50 33 80 100 335 2.50 16 101
150 278 2.50 44 100 150 352 2.50 27 122
200 300 2.50 55 120 200 370 2.50 37 144
250 323 2.50 66 140 250 388 2.50 48 166
300 345 2.50 77 160 300 406 2.50 59 187
350 368 2.50 89 180 350 424 2.50 70 209
400 390 2.50 100 200 400 441 2.50 80 231
450 413 2.50 111 220
500 436 2.50 122 240
Width
Pulse
Background
.052 Metal Core CS .045 Metal Core SS
WFS
Pulse
Pulse
Range
Peak
75 358 2.70 16 76 100 407 1.80 35 71
125 385 2.70 45 94 150 418 1.86 44 90
175 412 2.70 74 112 200 429 1.91 53 109
225 438 2.70 103 130 250 440 1.97 62 128
275 465 2.70 132 148 300 451 2.02 70 146
325 492 2.70 160 166 350 462 2.08 79 165
Width
Pulse
Background
Pulse
Frequency
Pulse
Frequency
WFS
Pulse
Pulse
Range
Peak
WFS
Pulse
Range
Peak
400 473 2.13 88 184
450 484 2.19 97 203
500 495 2.24 105 222
550 506 2.30 114 241
Width
Pulse
Width
Pulse
Background
Pulse
Background
Frequency
Frequency
Pulse
Pulse
SECTION 5 ULTRAPULSE MOUNTING OPTIONS
FIGURE 2 - UltraPulse Bracket Assemblies
(Included with Pendant - mount with existing hardware)
PN 0558001590 - Hanger Bracket
Mig 4HD Dual
PN 0558001589 - Hanger Bracket
Mig 4HD
Mounted UltraPulse Assemblies
Mig 4HD
Mig 4HD Dual
Figure 2. UltraPulse 350 Mounting Options
16
Mig 4HD Boom
Page 17
SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS
634515 - SWITCH
(8)951474 - COVER
0558001595 - KNOB
952993 - SWITCH
0558001437 - HANDLE
951032 - LIGHT
(8)2062018 - POTENTIOMETER
0558001019 - KNOB
0558001591 - HANGER
23607860 - BUMPER, RUBBER
0558001587 - BACK PANEL
FIGURE 3 - UltraPulse 350 Replacement Parts (Front and Back View)
17
Page 18
SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS
0558001588 - COVER
(8)38170 - PC BOARD (PCB1)
952988 - TRANSFORMER
0558001022 - CABLE, COMPLETE, 8 FT (P3)
FIGURE 4 - UltraPulse 350 Replacement Parts (Inside View)
0558001586 - STRAIN RELIEF
18
Page 19
SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS
CABLE ASSEMBLY 0558001022
0558001022-C
FIGURE 5 - UltraPulse 350 Cable Wiring Diagram
19
Page 20
SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS
0558001593-B
FIGURE 6 - UltraPulse 350 Wiring Diagram
20
Page 21
SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS
0558001592
21
Page 22
NOTES
22
Page 23
REVISION HISTORY
1. Revision "A" updated wiring/schematic diagrams in Section 6, added Table of Contents, and
included various editorial updates.
23
Page 24
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
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