ESAB Ultra Pulse 450i Mig Pulse Pendant Control Installation manual / Instruction manual

INSTALLATION AND OPERATING INSTRUCTIONS

Ultra Pulse 450i

MIG Pulse Pendant Control

P/N 34946

F-15-202

July, 1996

Read and understand the entire contents of this manual, the power source manual, and the wire
feeder manual used with this unit. Special emphasis should be given to the safety material
throughout all manuals, before installation, operation, or maintenance of this equipment. This
unit and these instructions are for use only by persons trained and experienced in the safe
operation of welding equipment. Do not allow untrained persons to install, operate, or maintain
this unit. Contact your distributor if you do not fully understand these instructions.

Be sure this information reaches the operator.
You can get extra copies through your supplier.

SECTION 1 DESCRIPTION

1.1 General

The Ultra Pulse 450i pendant is designed to provide
simple to use, high quality, synergic pulsed Mig welding
when used with an SVI 450i or MTS 450i inverter power
source and a Mig 4HD or MIGhty 4HD 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 450i pendant as you change wire feed
speed.

The Ultra Pulse 450i pendant also provides a PULSE
ARC TRIM dial that enables the operator to fine tune the
pulse arc by adjusting the 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
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.

back to the pendant and power source. Therefore, it is
important that the wire feeder be set-up properly. There
are three possible configurations for the wire feeder:

a. Wire feeder
b. Wire feeder
c. Older wire feeder

without
with

a digital meter kit.

a digital meter kit.

without

installed connectors.

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 2.
The Ultra Pulse 450i 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.

a. Connect the 19 pin plug to the mating receptacle

on the SVI 450i or MTS 450i power source.

b. Connect the 19 pin male amphenol plug from the

wire feeder to the mating receptacle on the Ultra
Pulse pendant.

c. Be sure that the secondary output connections

(welding cables) are connected so that the posi­tive cable goes to the wire feeder and the nega­tive cable goes to the work piece.

2.3 Wire Feeder Set-Up

In order for the synergic pulsed Mig operation to function
properly, the wire feeder must provide the proper signals

Follow the procedure below (a,b or c) that best describes
your wire feeder.

a. Procedure for Wire Feeder Without Digital Meter

Kit Installed
Remove the wire feeder sheet metal cover and

locate the spare violet wire in the multi-conduc­tor cable exiting the rear panel of the Mig 4HD
feeder. The violet wire will have a single in-line
connector. Connect the mating connector of the
supplied single wire harness to the mating violet
wire and the plug end to the P3 receptacle on the
Mig 4HD main P/C board.

b. Procedure for Wire Feeder With Digital Meter

Kit Installed
Remove the wire feeder sheet metal cover and

locate the spare violet wire in the multi-conduc­tor cable exiting the rear panel of the Mig 4HD
feeder. The violet wire will have a single in-line
connector. Connect the spare mating connec­tor (P1-3) of the five wire harness supplied with
the Digital Meter kit to the violet wire of the multi­conductor cable. Connect the Digital Meter wire
harness between P3 of the Main P/C board and
P1 of the Digital Meter board.

2

Multi-conductor
Cable

Multi-conductor
Cable

Violet
Wire

P3

Receptacle

Wire Feeder Without Digital Meter Kit

Violet
Wire

P3

Receptacle

Wire Harness
supplied with
Ultra Pulse 450i Kit

Main P/C Board

Wire Harness
supplied with
Digital Meter Kit

P1
Receptacle

Main P/C Board

Wire Feeder With Digital Meter Kit

Figure 1. Wire feeder Jumper Connections

c. Procedure for Older Wire Feeders Without

Factory Installed Connector.
If the Mig 4HD is an older model, the violet wire

in the multi-conductor cable will have a crimped
insulating cap. A butt splice crimp connector
must be field installed to mate with the wire
harness packaged with the Ultra Pulse control
pendant. Remove the in-line connector on the
single wire harness and connect this wire to the
spare violet wire of the multi-conductor cable
using a butt splice crimp connector. Connect
the plug end of the single wire harness to P3 of
the Mig 4HD main P/C board.

If a Digital Meter kit has already been installed
and does not have the spare mating connector
attached to P1-3 on the Digital Meter board,
remove the plug end of the single wire harness
and connect the violet wire of the multi-conduc-

tor cable to P1-3 of Digital Meter wire harness
using a crimp cap as shown in figure 1.

2.4 Power Source SetUp

Modify the power source according to the following
steps.

a. Change hardware jumpers on the main PC

board as shown below.

FROM: TO:

3

J1 & J3 closed
J2 open

J1 J2 J3

b. Locate and remove one end of the ORANGE

jumper wire between P3-2 and P2-9. Tape ex­posed end of the wire or lug with a blind insulated
lug.

J1 open
J2 & J3 closed

J1 J2 J3

Ultra Pulse

450i

Pendant

Jumper (J1) Position

Interconnect Cable

FROM:

J1 & J3 closed
J2 open

J1 J2 J3

Figure 2. Interconnection and Jumper Configuration

J1 open

TO:

J2 & J3 closed

J1 J2 J3

19-Pin Connector

Control Board

450i Power Source with
Top Cover Removed

SECTION 3 OPERATION

3.1 Pulsed Mig Operation

For synergic pulsed Mig welding, carefully follow the
steps below:

A. Ultra Pulse 450i pendant set-up.

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

2. Be sure to use one of the shielding gases that is
listed on the Material Selection Table. (see
Table 1 or front of Ultra Pulse 450i pendant.)

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

C. SVI 450i or MTS 450i power source set-up.

Selection Table. (see Table 1 or front of Ultra
Pulse 450i pendant.)

1. Set up 450i power source for Mig welding as
described in instruction manual.

2. Set the SLOPE switch to the STEEP position.

3. Set the CONTROL switch to the REMOTE
position.

4. Use output work cables that are as short as
possible. Do not loop or coil the work cables.
Excessive lengths or coiled cables will result in
unstable conditions.

4. Set the ARC TRIM potentiometer to the "0" or
center position.
The ARC TRIM can be used to fine tune the
performance by slowly turning the dial clock­wise to shorten the arc or counterclockwise to
lengthen the arc.

B. Mig 4HD wire feeder set-up.

1. Set the WIRE FEED SPEED dial to a wire feed
rate that is within the range listed on the Material

5. Proper connection of the work cables to the
work is essential for high quality results. Under­sized ground clamps, poor connects, frayed
cables, cable splices or clamps attached to
rusting or dirty surfaces will result in unstable
conditions.

6. Turn the power source "ON" and initiate the
welding process by closing the torch trigger.

4

D. Process control.

3.2 Standard Operation

1. Use a tip-to-work distance of 5/8" to 3/4". This refers
to the distance between the end of the Mig torch
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.

3. The ARC TRIM on the Ultra Pulse 450i pendant can
be used to fine tune the arc performance by slowly
turning the dial clockwise to shorten the arc or
counterclockwise to lengthen the arc. If the arc to
"crackling" or if spatter is excessive lengthen the arc
by turning the dial counterclockwise. If the arc is
"fluttering" or difficult to control then shorten the arc
by turning the dial clockwise.

The Ultra Pulse 450i pendant provides for both standard
welding and pulsed Mig welding. When the STANDARD/
PULSE switch is in the STANDARD position the wire
feeder and power source are ready for standard non­pulsed Mig, Tig or Stick welding. Follow the basic instruc­tions provided with the wire feeder and power source.

For standard Mig welding the wire feed speed and power
source output (voltage) are independent. Set the wire
feed speed on the Mig 4HD or MIGhty 4HD and the
voltage on the front panel of the power source. Voltage
can also be set on the wire feeder VOLTS potentiometer
providing that the power source CONTROL switch is in
the REMOTE position.

SECTION 4 ADVANCED OPERATION

4.1 Effects of SLOPE on Pulse MIG Arc

Stability

Many uncontrollable 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 torches
Base metal surface condition

When these 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 lower than normal pulse peak currents. The
power source SLOPE setting can help overcome these
types of situations.

The initial Ultra Pulse 450i setup should always start with
the STEEP slope setting on the power source front
panel. The synergic relationships designed into the Ultra
Pulse 450i control are dependent on the STEEP slope
setting. But, if low pulse peak currents are suspected,
the MEDIUM slope setting can be used to boost the pulse
peak current and, in most cases, remedy the "crackling"
pulse arc instability. When using the MEDIUM slope, the
synergic relationship of pulse frequency (arc length) to
wire feed speed may not "track" as designed. This
means, when the wire feed speed is changed the ARC
TRIM potentiometer will also have to be adjusted. This
is normal with changes in the programmed slope setting.

MATERIAL

STEEL

STAINLESS

STEEL

ALUMINUM

5XXX

ALUMINUM

4XXX

Table 1. Material Selection

WIRE

DIAMETER

.035
.045

.035
.045

3/64
1/16

3/64
1/16

APPROXIMATE

WIRE SPEED RANGE

85-600
55-450

100-600

60-400

120-500
100-300

120-500
100-300

5

SHIELDING GAS

95 AR - 5 CO2
98 AR - 2 CO2

AR - CO2 - 02

98 AR - 2 O2

HE - AR - C02

ARGON

ARGON-HELIUM

ARGON

ARGON-HELIUM

Figure 3. Ultra Pulse 450i Schematic Diagram

DENOTES SELFLEAD.

DENOTES CONNECTION USING IN-LINE COUPLER.

Figure 4. Ultra Pulse 450i Wiring Diagram

6

951882 - CABLE, COMPLETE, 8 FT (P3)

96W85 - STRAIN RELIEF

32164 - COVER

950282 - KNOB
950291 - WASHER

950696 - SWITCH

1006733 - BOX RECEPTACLE (J1)

951086 - HANDLE (QTY. 2)

13732477 - POTENTIOMETER
13730611 - KNOB

34994 - BASE

38006 - PC BOARD (PCB1)

182W12 - BUMPER, RUBBER (QTY. 4)

Figure 5. Ultra Pulse 450i Replacement Parts

7

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

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