MK Products Pulse+ User Manual

Product Description
Pulse +
MK Ma n ual P a rt Numb er
MK Form Number
NWSA Form Number
Effective wi th Serial
Voltage Ratings
Printing/Rev. Date
This manual applies to
the follow ing Model
Pulse+ Add-on Pulse system
Number
Numbers
091 - 0217
550
0580
115
2/99 rev. A
158-001
OWNERS MANUAL
16882 ARMSTRONG AVE., IRVINE, CALIFORNIA 92606 TEL (949) 863-1234 FAX (949) 474-1428

SAFETY CONSIDERATIONS

ELECTRIC ARC WELDING EQUIPMENT
CAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATION
OR MAINTENANCE OF THIS EQUIPMENT
1-1 INTRODUCTION
This equipment is intended for ultimate application by commercial/industrial users and for operation by persons trained and experienced in the use and maintenance of welding equipment. Operation should not be undertaken without adequate training in the use of such equipment. Training is available from many public and private schools or similar facilities.
Safe practices in the installation, operation and maintenance of this equipment requires proper training in the art, a careful study of the information provided with the equipment, and the use of common sense. Rules for safe use are generally provided by suppliers of welding power sources, compressed gas suppliers, and electrode suppliers. Careful compliance with these rules will promote safe use of this equipment.
The following Safety Rules cover some of the more generally found situations. READ THEM CAREFULLY. In case of any doubt, obtain qualified help before proceeding.
1-2 GENERAL PRECAUTIONS
A. Burn Prevention
ELECTRIC ARC WELDING PRODUCES HIGH INTENSITY HEAT AND ULTRAVIOLET RADIANT ENERGY WHICH MAY CAUSE SERIOUS AND PERMANENT EYE DAMAGE AND WHICH MAY DAMAGE ANY EXPOSED SKIN AREAS.
Wear helmet with safety goggles or glasses with side shields underneath, appropriate filter lenses or plates (protected by clear cover glass). This is a must for welding or cutting (and chipping) to protect the eyes from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered.
Medical first aid and eye treatment. First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of flash burns of the eyes and skin burns.
Wear protective clothing - leather (or asbestos) gauntlet gloves, hat, and high safety-toe shoes. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag.
Avoid oily or greasy clothing. A spark may ignite them.
Flammable hair preparations should not be used by persons intending to weld or cut.
Hot metal such as electrode stubs and
work pieces should never be handled without gloves.
Ear plugs should be worn when working on overhead or in a confined space. A hard hat should be worn when others work overhead.
B. T oxic Fume Prevention
WARNING: The use of this product may result in exposure to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
Adequate ventilation. Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen enrichment or depletion that welding (or cutting) may produce. Prevent them with adequate ventilation. NEVER ventilate with oxygen.
Lead-, cadmium-, zinc-, mercury-, beryllium-bearing and similar materials, when welded or cut, may produce harmful concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area, as well as the operator, must wear an air-supplied respirator. For beryllium, both must be used.
Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed form the work surface, the area is well ventilated, or the operator wears an air-supplied respirator.
Work in a confined space only while it is being ventilated and, if necessary, while wearing an air-supplied respirator.
Gas leaks in a confined space should be avoided. Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders into a confined space.
Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left open. Check to be sure that the space is safe before reentering it.
Vapors from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and perchloroethylene vapors to form phosgene. DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene.
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached by the arc, flame,
flying sparks, hot slag, or heated material, misuse of compressed gases and cylinders, and short circuits.
BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of the goggled operator. Sparks can fly many feet.
To prevent fires and explosion: Keep equipment clean and operable, free
of oil, grease, and (in electrical parts) of metallic particles that can cause short circuits.
If combustibles are in area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work cannot be moved, move combustibles at least 35 feet away, out of reach of sparks and heat; or protect against ignition with suitable and snug-fitting, fire-resistant covers or shields.
Walls touching combustibles on opposite sides should not be welded on (or cut). Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields.
Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if:
1. Appreciable combustibles (including building construction) are within 35 feet.
2. Appreciable combustibles are further than 35 feet, but can be ignited by sparks.
3. Openings (concealed or visible) in floors or walls within 35 feet may expose combustibles to sparks.
4. Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat.
Hot work permit should be obtained before operation to ensure supervisor’s approval that adequate precautions have been taken.
After work is done, check that area is free of sparks, glowing embers, and flames.
An empty container that held combustibles, or that can produce flammable or toxic vapors when heated, must never be welded on or cut, unless container has first been cleaned in accordance with industry standards.
This includes: a thorough steam or caustic cleaning (or a solvent of water washing, depending on the combustible’s solubility), followed by
Pulse+ Owner's Manual
purging and inerting with nitrogen or carbon dioxide, and using protective equipment.
Water-filling just below working level may substitute for inerting.
A container with unknown contents should be cleaned (see paragraph above). Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before welding or cutting. They can explode.
Explosive atmospheres. NEVER weld or cut where the air may contain flammable dust, gas, or liquid vapors (such as gasoline).
D. Compressed Gas Equipment
The safe handling of compressed gas equipment is detailed in numerous industry publications. The following general rules cover many of the most common situations.
1. Pressure Regulators
Regulator relief valve is designed to protect only the regulator from overpressure; it is not intended to protect any downstream equipment. Provide such protection with one or more relief devices.
Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed.
Remove faulty regulator from service immediately for repair (first close cylinder valve). The following symptoms indicate a faulty regulator:
Leaks - if gas leaks externally. Excessive Creep - if delivery pressure
continues to rise with downstream valve closed.
Faulty Gauge - if gauge pointer does not move off stop pin when pressurized, nor returns to stop pin after pressure release.
Repair. Do NOT attempt repair. Send faulty regulators for repair to manufacturer’s designated repair center, where special techniques and tools are used by trained personnel.
2. Cylinders
Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including third rails, electrical wires, or welding circuits. They can produced short circuit arcs that may lead to a serious accident. (See 1-3C)
ICC or DOT marking must be on each cylinder. It is an assurance of safety when the cylinder is properly handled.
Identifying gas content. Use only cylinders with name of gas marked on them; do not rely on color to identify gas content. Notify supplier if unmarked. NEVER DEFACE or alter name, number ,
or other markings on a cylinder . It is illegal and hazardous.
Empties: Keep valves closed, replace caps securely; mark MT; keep them separate from FULLS, and return promptly.
Prohibited use. Never use a cylinder or its contents for other than its intended use, NEVER as a support or roller.
Locate or secure cylinders so they cannot be knocked over.
Passageways and work areas. Keep cylinders clear of areas where they may be stuck.
Transporting cylinders. With a crane, use a secure support such as a platform or cradle. Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc. that may cause rupture. Do not allow contents to exceed 55 degrees C (130 degrees F .) Cool with water spray where such exposure exists.
Protect cylinders, particularly valves from bumps, falls, falling objects, and weather. Replace caps securely when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to open a cylinder valve that cannot be opened by hand. Notify your supplier.
Mixing gases. NEVER try to mix any gases in a cylinder.
NEVER refill any cylinder . Cylinder fittings should never be modified
or exchanged.
3. Hose
Prohibited use. Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel gas, green for oxygen, and black for inert gases.
Use ferrules or clamps designed for the hose (not ordinary wire or other substitute) as a binding to connect hoses to fittings.
No copper tubing splices. Use only standard brass fittings to splice hose.
Avoid long runs to prevent kinks and abuse. Suspend hose off ground to keep it from being run over, stepped on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose connections. Immerse pressured hose in water; bubbles indicate leaks
Repair leaky or worn hose by cutting area out and splicing. Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting regulator. Except for hydrogen,
crack valve momentarily, pointing outlet away from people and sources of ignition. Wipe with a clean, lintless cloth.
Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking agree, and that the regulator inlet and cylinder outlet match. NEVER Connect a regulator designed for a particular gas or gases to a cylinder containing any other gas.
Tighten connections. When assembling threaded connections, clean and smooth seats where necessary. Tighten. If connection leaks, disassemble, clean, and retighten, using properly fitting wrench.
Adapters. Use a CGA adapter (available from your supplier) between cylinder and regulator, if one is required. Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads.
Regulator outlet (or hose) connections may be identified by right hand threads for oxygen and left hand threads (with grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through suitable vent before opening cylinder (or manifold valve) by turning adjusting screw in (clockwise). Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization. Leave adjusting screw engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure increases slowly. When gauge is pressurized (gauge reaches regulator maximum) leave cylinder valve in following position: for oxygen and inert gases, open fully to seal stem against possible leak; for fuel gas, open to less than one turn to permit quick emergency shut-off.
Use pressure charts (available from your supplier) for safe and efficient recommended pressure settings on regulators.
Check for leaks on first pressurization and regularly thereafter. Brush with soap solution. Bubbles indicate leaks. Clean off soapy water after test; dried soap is combustible.
E. User Responsibilities
Follow all Safety Rules. Remove leaky or defective equipment
from service immediately for repair. Read and follow user manual instructions.
F . Leaving Equipment Unattended
Close gas supply at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be used for welding or cutting operation; rope may burn.
Pulse+ Owner's Manual
1-3 ARC WELDING
Comply with precautions in 1-1, 1-2, and this section. Arc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot, and compressed gases may be used. The wise operator avoids unnecessary risks and protects himself and others from accidents.
A. Burn Protection
Comply with precautions in 1-2. The welding arc is intense and visibly
bright. Its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn; those from gas-shielded arcs are more severe and painful. DON’T GET BURNED; COMPLY WITH PRECAUTIONS.
1. Protective Clothing
Wear long-sleeve clothing in addition to gloves, hat, and shoes. As necessary, use additional protective clothing such as leather jacket or sleeves, flameproof apron, and fire-resistant leggings. Avoid outer garments of untreated cotton.
Bare skin protection. Wear dark, substantial clothing. Button collar to protect chest and neck, and button pockets to prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. Eyes may be damaged by radiant energy when exposed to the electric arc, even when not looking in the direction of the arc. Never look at an electric arc without protection.
Welding helmet or shield containing a filter plate shade no. 12 or denser must be used when welding. Place over face before striking arc.
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield should NOT be worn; radiation can be passed through to cause burns.
Cracked, broken, or loose filter plates must be replaced IMMEDIA TELY . Replace clear cover plate when broken, pitted, or spattered.
Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck. Looking at an arc momentarily with unprotected eyes (particularly a high intensity gas-shielded arc) can cause a retinal burn that may leave a permanent dark area in the field of vision.
3. Protection of Nearby Personnel
Enclose the welding area. For production welding, a separate room or enclosed
bay is best. In open areas, surround the operation with low-reflective, noncombustible screens or panels. Allow for free air circulation, particularly at floor level.
Viewing the weld. Provide face shields for all persons who will be looking directly at the weld.
Others working in area. See that all persons are wearing flash goggles.
Before starting to weld, make sure that screen flaps or bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B. Generator engine exhaust must be vented
to the outside air. Carbon monoxide can kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C. Equipment’s rated capacity . Do not overload
arc welding equipment. It may overheat cables and cause a fire.
Loose cable connections may overheat or flash and cause afire.
Never strike an arc on a cylinder or other pressure vessel. It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed electrically hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when welding without suitable protection.
To protect against shock: Keep body and clothing dry . Never work in
damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when dampness or sweat cannot be avoided. Sweat, sea water, or moisture between body and an electrically HOT part - or grounded metal ­reduces the body surface electrical resistance, enabling dangerous and possibly lethal currents to flow through the body.
1. Grounding the Equipment
When installing, connect the frames of each unit such as welding power source, control, work table, and water circulator to the building ground. Conductors must be adequate to carry ground currents safely. Equipment made electrically HOT by stray currents may shock, possibly fatally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel.
Three-phase connection. Check phase requirement of equipment before installing. If only three-phase power is available, connect single-phase equipment to only two wires of the three-phase line. Do NOT
connect the equipment ground lead to the third (live) wire, or the equipment will become electrically HOT - a dangerous condition that can shock, possibly fatally.
Before welding, check ground for continuity. Be sure conductors are touching bare metal of equipment frames at connections.
If a line cord with a ground lead is provided with the equipment for connection to a switch box, connect the ground lead to the grounded switch box. If a three-prong plug is added for connection to a grounded mating receptacle, the ground lead must be connected to the ground prong only. If the line cord comes with a three-prong plug, connect to a grounded mating receptacle. Never remove the ground prong from a plug, or use a plug with a broken ground prong.
2. Connectors
Fully insulated lock-type connectors should be used to join welding cable lengths.
3. Cables
Frequently inspect cables for wear, cracks, and damage. IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable. Cables with damaged areas may be taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected from hot metal and sparks.
4. Terminals & Other Exposed Parts
Terminals and other exposed parts of electrical units should have insulating covers secured before operation.
5. Electrode Wire
Electrode wire becomes electrically HOT when the power switch of gas metal­arc welding equipment is ON and welding gun trigger is pressed. Keep hands and body clear of wire and other HOT parts.
6. Safety Devices
Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out.
Before installation, inspection, or service of equipment, shut OFF all power, and remove line fuses (or lock or red-tag switches) to prevent accidental turning ON of power. Disconnect all cables from welding power source, and pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while welding. If, in an emergency, it must be disconnected, guard against shock burns or flash from switch arcing.
Leaving equipment unattended. Always shut OFF, and disconnect all power to equipment.
Power disconnect switch must be available near the welding power source.
Pulse+ Owner's Manual
MK Products, Inc.
Printed in the U.S.A.

Table of Contents

INTRODUCTION....................................................................... 2
Section 1 SPECIFICATIONS .................................................. 9
Section 2 INSTALLATION INSTRUCTIONS ........................... 10
2.1 LOCATION .....................................................................10
2.2 AUXILIARY POWER REQUIREMENTS ................................ 10
2.3 WELD CABLE CONNECTIONS ........................................... 10
Section 3 CABLE CONNECTIONS......................................... 11
Section 4 OPERATION ........................................................ 12
4.1 POWER SWITCH..............................................................1 2
4.2 VOLTMETER.................................................................... 12
4.3 PULSE OPERATION ......................................................... 12
Section 5 PARAMETER SET-UP ........................................... 15
5.1 Peak Level .......................................................................15
5.2 “ON” Time ...................................................................... 15
5.3 "OFF” Time ..................................................................... 15
Section 6 TROUBLE SHOOTING .......................................... 17
6.1 TESTING THE CURRENT SWITCH .................................... 18
6.2 TESTING THE PC BOARD ................................................ 18
6.3 TESTING THE THERMOSTAT ........................................... 18
6.4 TESTING CR1 AND R1..................................................... 18
Section 7 PARTS LIST - PULSE+ WITH METER .................... 19
Pulse+ Owner's Manual Page 6
THIS P AGE INTENTIONALLY BLANK
Pulse+ Owner's Manual Page 7

INTRODUCTION

MK Products’ patented Pulse+ is a transistorized pulse-generating attachment which converts a conventional constant voltage (CV) D.C. power supply into a variable pulsed arc welding machine.
The Pulse+ is exceptionally simple to operate and may be used with any conventional constant voltage (CV) machine, up to 60 open circuit volts and 300 amperes continuous current output. It provides pulse rates continuously variable from 500 pulse per second, down to approximately 30 pulses per second. This of course, includes the frequencies of 60 and 120 pulse per second, available from thyristor supplies operating at line frequencies.
The power supply voltage control set the peak voltage, and the background level is a fixed value by design. The “On time” control is used to adjust the length of the pulse during metal transfer and can be used to apply more heat to the weld. The “Off time” control regulates how close the “on” pulses are together, which can reduce the amount of heat into the weld.
The Pulsed-arc process is a transfer process wherein spray transfer occurs at regular intervals rather than at random intervals. The welding current rapidly switches from high pulsed current to low background current level.
The background current sustains the arc, while each pulse supplies just enough power to free one droplet from the wire tip. In the time between pulses, the welding current is reduced, and no metal transfer occurs.
Pulsed spray uses a lower average current than in regular spray transfer. This lower average current makes it possible to weld out of position. By using a lower average, less heat is put into the metal, causing less distor­tion of the material being welded. Thin metal sections may also be welded more easily with pulsed spray, and it creates very little metal spatter. In addition, the pulse agitation aids in cleaning action and outgasing, which reduces porosity.
The pulsed spray transfer method can use larger diameter electrode wire and still produce a small weld. This is a great advantage, because larger diameter electrode are less expensive than smaller ones. Also, nonferrous wire of a larger diameter can be fed through the wire feeder much easier without risk of bending or jamming. This also allows using one size wire for a variety of jobs using many different thicknesses of metal and joint designs with just one setup in the wire feeder!
At MK Products, we stand behind every product manufactured and ensure that it is free from defects and will perform to the specification con­tained in this manual. If for ANY reason you are not completely satisfied with your purchase, we will make every effort to repair, replace, or refund your purchase.
That is my guarantee.
Douglas M Kensrue
President MK Products
Pulse+ Owner's Manual Page 8

Section 1 SPECIFICATIONS

PRIMARY POWER INPUT - 1 15V AC 50-60 Hz 1 Ampere WELDING POWER INPUT - D.C. 10-60 Volts 0 to 300 Amperes WELDING POWER OUTPUT - D.C. 10-58 Volts 0 to 300 Amperes PULSE CAP ACITY - Pulsed “On” Period - 1 to 10 milliseconds
SI Z E - 18”W x &-3/4”H x 14”L WE IGHT - 31 lbs. ENVIRONMENT - 20 to 105 degrees F , 90% humidity without
AREA REQUIRED - Access required both front and back for
- Pulse “Off” Period - 1 to 20 milliseconds
- Pulse Frequency V ariable from 30 - 500 pps
condensation 0 - 10,000 feet elevation. Units may be stacked vertically up to four high.
connectors and four inches on sides for air circulation.
PULSE OUTPUT VOL T AGE - Equals connected power supply output
voltage, minus approximately a two volt drop.
BACKGROUND LEVEL - Is automatically adjusted depending on
connected power supply output voltage, wire characteristics, wire feed rate, and other welding characteristics. It will typically be 30 to 130 amperes.
CONTROLS -
On/Off Switch Pulse “On” Time - Controls high current
density pulse duration which should be adjusted to achieve welding metal droplet formation, detachment, and axial transfer
to work.
- Pulse “Off” Time - Controls the average welding heat (energy) and should be ad justed to be consistent with wire feed speed used.
- Voltmeter - Reads average voltage while welding.
Pulse+ Owner's Manual Page 9

Section 2 INSTALLATION INSTRUCTIONS

2.1 LOCATION

The Pulse+ should be located to provide adequate ventilation for cooling. There should be a minimum of four inches on each side.
CAUTION: Overheating of unit can cause possible damage
to internal components.
There should be access to both the front and rear of the unit to allow quick disconnection of welding cables for applications not requiring pulse capabili­ties. For standard welding, the connectors can be locked together , thus removing the Pulse+ from the circuit.
CAUTION: DO NOT operate the Pulse+ in the OFF position.
Doing so will cause damage to internal parts.

2.2 AUXILIARY POWER REQUIREMENTS

The Pulse+ is designed to operate on 220 volt 1 Ampere 50-60 Hz circuit. This circuit could be a wall outlet or from an outlet on the power supply , if one is provided.

2.3 WELD CABLE CONNECTIONS

Provided with the Pulse+ are two Dinse 400 Amp male weld cable connectors (P/N 153-0755) and two Dinse 400 Amp female weld cable connectors (P/N 153-0813).
Select adequate size welding cable for the anticipated maximum weld current. Keep the cables as short as possible and as close together as possible. Excessive cable length adds resistance which may reduce the output.
To install the connectors, use Fig. 1 for proper part orientation.
NOTE: Place the connector boot over the cable before cutting back the insulation.
This will keep the copper strands from becoming frayed.
CONNECTOR P ART ORIENTA TION - Fig. 1
Pulse+ Owner's Manual Page 10

Section 3 CABLE CONNECTIONS

Connect the Pulse+ in series with the power source as show in Figure 2.
Connect between any conventional D.C. constant voltage power source (with a maximum output voltage of 60 volts) and the wire feeder. Plug Pulse+ into a 115 V . AC outlet.
Pulse+ Owner's Manual Page 11

Section 4 OPERATION

CAUTION: DO NOT ATTEMPT TO WELD WITH THE PULSE+ TURNED OFF
For non-pulsed operation, the connectors can be locked together, thus removing

4.1 POWER SWITCH

Placing the power switch in the On position energizes the fan and control circuitry . The red indicator lamp should be on at this time.
CAUTION: If the fan does not operate when the power switch is in the On position,
DO NOT attempt to weld. Without proper air flow, unit can overheat and cause

4.2 VOLTMETER

The voltmeter on the front of the Pulse+ will read average voltage during welding. Average amperage can be read off of the power supply amp meter .

4.3 PULSE OPERATION

In pulsed spray welding, the current is varied from the background level to a peak level. The background level is well below the transition current, while the peak level is well into the spray arc region, Figure 3. During the peak level, one droplet is transferred to the work. The current then drops to the back­ground level, which allows the puddle to cool, at which time no metal is transferred.
the Pulse+ from the circuit.
damage to internal parts.
Pulse+ Owner's Manual Page 12
4.3.1. Peak Level
The peak level is set by the voltage control at the power supply . Because the peak level must be well into the spray arc region, it must be set substantially higher than non-pulsed operation (typically 30-40 volts).
4.3.2. Background Level
The background level (typically 30 to 130 amps) is the result of the fixed design values in the Pulse+, together with the power supply input voltage, wire feed rate, and other parameters.
4.3.3. “On Time”
T o obtain the one drop transfer during the peak level, the “On” time must be varied, depending on the wire diameter . As the wire size is increased, so must the “On” time be increased to burn off the larger size wire, Figure 4.
The “On” time is variable from 1 to 10 Ms.
4.3.4. “Off Time”
With the “On” time set to provide a smooth transfer, the “Of f” time is used to control the amount of heat. Decreasing the “Off” time moves the pulses closer together (more heat), while increasing the “Off” time moves the pulses further apart (less heat), Figure 5.
The “Off” time is variable from 1 to 20 ms.
Pulse+ Owner's Manual Page 13
4.3.5. Pulse Frequency
The pulse frequency is determined by adding the “On” time and the “Off” time and dividing it into 1000. Pulse frequency is measured in pulses per second (PPS). For example:
3 ms on and 5 ms off equals 1000/3+5 = 1000/8 = 125 pps
Pulse+ Owner's Manual Page 14

Section 5 PARAMETER SET-UP

5.1 Peak Level

The voltage control on the power supply is used to set the peak level. The melting temperature of the filler wire used determines at what point the voltage should be set. For example, 4043 aluminum may require as little as 30 peak welding volts, whereas steel and stainless may require 35-38 peak welding volts, Figure 7. When trying to weld thin material the peak voltage should be kept as low as possible without losing the spray transfer.

5.2 “ON” Time

The “On” time dial is used to obtain a smooth transfer . Start with an “On” time of 2 ms, and adjust until the correct transfer is achieved.

5.3 “OFF” Time

Start with an “Off” time of 6 ms. If the weld is too cold, decrease the “Off” time. If the weld is too hot, increase the “Off” time. Remember that the wire feed speed must also be increased and decreased accordingly
NOTE: The required open circuit voltage (OCV) may vary from one power supply to
another, depending on the slope of the power supply. Sample parameters can be
found on the nest page.
Pulse+ Owner's Manual Page 15

SAMPLE WELDING PARAMETERS

WIRE
SIZE
WIRE TYPE
WIRE
IPM
WELDING
VOLTS
AVERAGE
VOLTS
WELD AMPS
.030 4043 228 29.5 16.8 52
.035 4043 200 29.5 17.9 67
.035 4043 220 31 18.7 89
3/64 4043 180 33 19.1 108
3/64 4043 214 33 20.3 117
1/16 4043 15 36 22.5 187
.030 5356 308 30 20 59
.035 5356 360 30 18 80
.035 5356 390 30 17.5 88
3/64 5356 250 34 19.5 110
3/64 5356 300 35 20 125
PULSEONPULSE
OFF
1 10
2 11
2 8
3 8
3 5
4 2
1 6
2 10
2 8
3 8
3 5
PLATE
THICKNESS
BASE
METAL
.060 6061 Argon
.090 6061 Argon
1/8 6061 Argon
1/8 6061 Argon
1/4 6061 Argon
3/8 6061 Argon
.060 6061 Argon
.090 6061 Argon
1/8 6061 Argon
1/8 6061 Argon
1/4 6061 Argon
GAS
USED
1/16 5356 260 36 23.5 190
.030 E70S-3 190 33 18.5 65
.035 E70S-3 211 34 19.8 99
.045 E70S-3 150 36 21.8 133
.030 308L 279 34 20.3 78
.035 308L 268 34 20.3 105
.045 308L 145 34 20.9 123
4 2
1.5 15
2 9
3 5
2 8
2.75 6
3 5
3/8 6061 Argon
.050 Steel 98-2
.060 Steel 98-2
3/16 Steel 98-2
.060 S/S 98-2
.080 S/S 98-2
1/8 S/S 98-2
Pulse+ Owner's Manual Page 16

Section 6 TROUBLE SHOOTING

SOME F ACTORS TO CONSIDER: The Pulse+ can only
be sure the CV power supply is operating properly without the Pulse+. The power supply sets the peak level and, therefore, must be set substantially
higher than non-pulsed operation. When an arc is initiated, the Pulse+ is always in the pulse “on” mode to
provide maximum current to initiate the arc. After welding current is flowing, a current switch is utilized to start the pulse timer.
If there appears to be too little output to weld with, be sure the pulse on is at the proper value (or increase it) and that the pulse “off” is not excessive.
Be sure there is a good ground connection to the work and a good cable connection to the Wire Feeder .
reduce the power supply output voltage and current, so
TROUBLE SHOOTING PROCEDURE
Trouble Cause Remedy/Explanati on
Have weld ing output but no pulse
Pilot lamp works , Fan
works , No we ld o utput
Completely Inoperative Open line fuse (F1) Replace fuse 2A 250V
Current switch failure or bad PC board
J2 connector disconnected from PC board
Thermostat open Check Thermostat for continuity
Po we r S upp ly voltag e to o low Increas e sup p ly voltag e
Open CR1 or R1, Bad PC board
The current switch, connected to J4, is located on the negati ve buss bar next to the capactitor bank. Disconnect J4 and short between pins. If the unit now pulses, replace the current switch. If it does not pulse, check PC board.
Replace J2 on board
Disconnect 115 vac. With a ohm-meter check resistance between input + and output + terminals. Should read 5 ohms. If open, check CR1 and R1 separate. If OK, check PC board.
Defective power swi tch (S1) Replace switch
Improp e r li ne vo lta ge Che ck li ne vo lta g e for 115 vac
Pulse+ Owner's Manual Page 17

6.1 TESTING THE CURRENT SWITCH

When current flows through the buss bar, it creates a magnetic field. This magnetic field causes the current switch, which is normally open, to close and turn on the pulse timer circuit. To test, remove the current switch from the unit. Using an ohm meter on Rx1 scale, check to see that the switch is open, indicating no continuity . Using a common magnet, move it to within one to one-half inch from the current switch while watching the ohm meter . As the magnet nears the current switch, it should close, and continuity should be read on the meter .

6.2 TESTING THE PC BOARD

An oscilloscope is required to test the PC board. Set the oscilloscope sec­ond/div to 2 ms and the volts/div to 5V . Place the negative lead on pin 7 of the transformer and the positive lead to connector J2 pin 3. The current switch must be closed so jumper between pins 1 and 2 on the J4 connector, or place a magnet next to the current switch, if you know it works correctly. Turn the Pulse+ on. A square wave should appear on the oscilloscope. The on and off time controls should vary the wave form on the oscilloscope. A bad thermostat will also prevent the PC board from operating.

6.3 TESTING THE THERMOSTAT

The thermostat is located on the back of the heat sink and is connected to J5. It is normally closed and, if the fan malfunctions or if the duty cycle is ex­ceeded, the thermostat will open at 180 degrees F and shut down the unit. To test, use an ohm meter to check for continuity across the thermostat leads.

6.4 TESTING CR1 AND R1

CR1 is the main diode coming off the + input and mounts to the heat sink. R1 is the power resistor inside the heat sink. If either is open, the Pulse+ will not operate. To test, place an ohm meter on DC+ in the Rx1 scale. Attach the positive lead to the + input and the negative lead to the + output. The meter should read from 4 to 5 ohms. If open, check CR1 and R1 separately .
NOTE: The following conditions were used through-out the above test.
WELDING GAS: Aluminum (Argon), Steel & Stainless (98% Argon -
2% Oxygen) POWER SUPPLY: Flat Slope C.V. WELD PO SITION: Flat
WELD TYPE: Fillet
Pulse+ Owner's Manual Page 18

Section 7 PARTS LIST - PULSE+ WITH METER

ITEM PART NO. DESCRIPTION 1 003-0661 Assy. - Top & Bottom Heat Sinks
2 003-0666 Assy. - Cover 3 003-0481 PCB Ctrl Mod. 4 325-0225 10-32 x 3/8 Pan. HD. Scr 5 333-0007 #10 Lock Washer 6 341-0008 #10-32 Hex Nut 7 328-0229 10-32 x 1/2 Soc. Hd. Scr. 8 331-0044 #10 Flat Washer 9 333-0045 #10 Lock Washer 10 435-0821 Connector Strip 11 104-0051 Capacitor - 25,000 mf 12 151-0001 Fuse 2 Amp. 13 152-0058 Fuse Holder 14 153-0809 Connector - Male 15 315-0696 Strain Relief 16 844-0019 A.C. Power Cable 6ft bare leads 17 328-0236 8 - 32 x 3/8 Sosc. HD. cr. 18 333-0006 #8 Lock Washer 19 843-0272 Cable Assy 20 003-0780 Sensor Assembly 21 333-0024 #8 Lock Washer 22 327-0073 8 - 32 x 1/4 Self Tapping Scr. 23 435-0830 Bus Bar 24 325-0167 8 - 32 x 3/8 Pan. Hd. Scr. 25 333-0024 #8 Lock Washer 26 153-0754 Connector - Female 27 329-0221 M-10 Hx. Hd. Scr. (Metric) 28 185-0082 Ring Lug #8 Hole, 12 Ga. Wire 29 845-0100 12 Ga. Wire (Black) 10 Lg. 30 124-0062 Diode - VHE804 31 447-0006 1/4 - 20 x 1/2 Hex Hd. Scr. Brass 32 333-0072 1/4 Lock Washer (Silicon Bronze) 33 435-0827 Diode Plate 34 435-0005 Base 35 003-0561 Assy. - Front Panel 36 325-0167 8 - 32 x 3/8 Pan Hd. Scr. 37 333-0044 #8 Lock Washer 38 301-0104 Rubber Feet 39 325-0230 10 - 32 x 3/4 Pan Hd. Scr. 40 333-0025 #10 Lock Washer 41 201-0005 Fan - 220 volts A.C. 42 324-0135 6 - 32 x 1/2 Flt. Hd. Scr. 43 341-0005 6 - 32 Hex Nut 44 333-0023 #6 Lock Washer 45 327-0112 #10 x 1/2 Self T apping Scr . 46 333-0045 #10 Lock Washer 47 435-0831 Fan Mounting Bracket 48 327-0110 6 - 32 x 3/8 Selft Tappin Scr. 49 333-0023 #6 Lock Washer 50 342-0372 Standoff 7/8 Lg. 51 325-0229 10 - 32 x 5/8 Pan Hd. Scr. 52 332-0004 #10 Flat Washer 53 332-0018 Shoulder Washer
Pulse+ Owner's Manual Page 19
54 003-0494 S/A Diode 55 124-0022 Diode Rectifier - R610 56 003-0662 Assy. Diode Heatsink 57 333-0072 1/4 Lock Washer (Silicon Bronze) 58 449-0001 1/4 - 20 Hex Nut (Brass) 59 843-0256 Cable Assy. 60 003-0660 As sy. - Heat Sink 61 113-0045 Resistor .3 ohm 62 435-0828 Resistor Mounting Bracket 63 435-0836 Contactor Bar 64 113-0042 Resistor 50 ohm 65 327-0109 #4 x 1/4 Self T apping Screw 66 333-0041 #4 Lock Washer 67 843-0254 Cable Assy. 68 327-011 1 #8 x 1/4 Self T apping Screw 69 333-0044 #8 Lcok Washer 70 170-0003 T emperature Sensor 71 843-0255 Cable Assy . - Temp. Sensor 72 327-0108 #2 1/4 Self Tapping Scr. 73 333-0039 #2 Lock Washer 74 186-0164 T erminal Strip 75 325-0137 6 - 32 x 5/8 PN Hd. Scr. 76 333-0043 #6 Lock Washer 77 341-0005 6 -32 Hex Nut 78 159-0051 “ON - “OFF” Switch 79 333-0154 Lock Washer 80 117-0060 200K Potentiometer 81 401-0012 Knob 82 333-0156 Lock Washer 83 341-0050 Nut 84 117-0002 100K Potentiometer 85 431-1251 Back-up Plate 86 169-0043 Volt Meter 87 003-0547 220v pilot lamp 88 327-0022 #8 x 3/8 Self T apping Screw
Pulse+ Owner's Manual Page 20
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Pulse+ Owner's Manual Page 21
Pulse+ Owner's Manual Page 23
Effective April 1, 1998
This warranty supersedes all previous MK Products warranties and is
exclusive, with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY - MK Products,Inc.,Irvine,California

warrants that all new and unused equipment furnished by MK Products is free from defect in workmanship and material as of the time and place of delivery by MK Products. No warranty is made by MK Products with respect to trade accessories or other items manufactured by others. Such trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any.
MK Products warranty does not apply to components having normal useful life of less than one (1) year, such as relay points, wire conduit, tungsten, and welding torch parts that come in contact with the welding wire, including nozzles, nozzle insulators, and contact tips where failure does not result from defect in workmanship or material.
In the case of MK Products breach of warranty or any other duty with respect to the quality of any goods, the exclusive remedies therefore shall be at MK Products option: (1) repair; (2) replacement; (3) where authorized in writing by MK Products, the reasonable cost of repair or replacement at our Irvine, California plant; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. Upon receipt of notice of apparent defect or failure, MK Products shall instruct the claimant on the warranty claim procedures to be followed.
As a matter of general policy only, MK Products may honor an original users warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods from the date of delivery of equipment to the original user:
1. Torches and Weldheads ........................ 1 year
2. All Other Equipment .............................. 3 years
3. Repairs ................................................. 90 days
Classification of any item into the foregoing categories shall be at the sole discretion of MK Products. Notification of any failure must be made in writing within 30 days of such failure.
A copy of the invoice showing the date of sale must accompany products returned for warranty repair or replacement.
All equipment returned to MK Products for service must be properly packaged to guard against damage from shipping. MK Products will not be responsible for any damages resulting from shipping.
Normal surface transportation charges (both ways) for products returned for warranty repair or replacement will be borne by MK Products, except for products sold to foreign markets.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE, OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MK PRODUCTS, IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS.
EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING, MK PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE. MK PRODUCTS WARRANTIES DO NOT EXTEND TO, AND NO RE-SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS WARRANTIES TO ANY CONSUMER.
MK PRODUCTS, INC.
16882 ARMSTRONG AVE. IRVINE, CA 92606 TEL (949) 863-1234 FAX (949) 474-1428
FORM : LW-8 DATE : April 1, 1998
MK Products, Inc.
16882 Armstrong Ave.
Irvine, CA 92606
tel 949/863-1234
fax 949/474-1428
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