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
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