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

PP/OM

550

0580

115

2/99 rev. A

158-001

OWNERS MANUAL

16882 ARMSTRONG AVE., IRVINE, CALIFORNIA 92606 TEL [phone] FAX [phone]

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