Transcript
F-15-202 July, 1996
INSTALLATION AND OPERATING INSTRUCTIONS
Ultra Pulse 450i MIG Pulse Pendant Control P/N 34946
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 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.
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.
SECTION 2
INSTALLATION
2.1 General
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:
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.
a. Wire feeder without a digital meter kit. b. Wire feeder with a digital meter kit. c. Older wire feeder without installed connectors. Follow the procedure below (a,b or c) that best describes your wire feeder.
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.
a. Procedure for Wire Feeder Without Digital Meter Kit Installed
2.2 Cable Connections
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.
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. Procedure for Wire Feeder With Digital Meter Kit Installed
b. Connect the 19 pin male amphenol plug from the wire feeder to the mating receptacle on the Ultra Pulse pendant. c.
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.
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 2
Multi-conductor Cable
Violet Wire
Wire Harness supplied with Ultra Pulse 450i Kit P3 Receptacle
Main P/C Board
Wire Feeder Without Digital Meter Kit
Multi-conductor Cable
Wire Harness supplied with Digital Meter Kit Violet Wire
P1 Receptacle
P3 Receptacle
Main P/C Board
Wire Feeder With Digital Meter Kit Figure 1. Wire feeder Jumper Connections tor cable to P1-3 of Digital Meter wire harness using a crimp cap as shown in figure 1.
c. Procedure for Older Wire Feeders Without Factory Installed Connector.
2.4 Power Source SetUp
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.
Modify the power source according to the following steps. a. Change hardware jumpers on the main PC board as shown below. J1 & J3 closed FROM: J2 open
J1 J2 J3
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-
J1 open TO: J2 & J3 closed
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. 3
Interconnect Cable
Ultra Pulse 450i Pendant
Jumper (J1) Position FROM: J1 & J3 closed J2 open
TO:
J1 open J2 & J3 closed
19-Pin Connector
J1 J2 J3
J1 J2 J3
Control Board 450i Power Source with Top Cover Removed Figure 2. Interconnection and Jumper Configuration
SECTION 3
OPERATION Selection Table. (see Table 1 or front of Ultra Pulse 450i pendant.)
3.1 Pulsed Mig Operation For synergic pulsed Mig welding, carefully follow the steps below:
C. SVI 450i or MTS 450i power source set-up. 1. Set up 450i power source for Mig welding as described in instruction manual.
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. Set the SLOPE switch to the STEEP position. 3. Set the CONTROL switch to the REMOTE position.
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.
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.
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.
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 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.
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.
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.
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 causing lower than normal pulse peak currents. The power source SLOPE setting can help overcome these types of situations.
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:
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.
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
Table 1. Material Selection WIRE DIAMETER
APPROXIMATE WIRE SPEED RANGE
STEEL
.035 .045
85-600 55-450
95 AR - 5 CO2 98 AR - 2 CO2 AR - CO2 - 02
STAINLESS STEEL
.035 .045
100-600 60-400
98 AR - 2 O2 HE - AR - C02
ALUMINUM 5XXX
3/64 1/16
120-500 100-300
ARGON ARGON-HELIUM
ALUMINUM 4XXX
3/64 1/16
120-500 100-300
ARGON ARGON-HELIUM
MATERIAL
5
SHIELDING GAS
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
1006733 - BOX RECEPTACLE (J1)
32164 - COVER 951086 - HANDLE (QTY. 2) 950282 - KNOB 950291 - WASHER
13732477 - POTENTIOMETER 13730611 - KNOB
950696 - SWITCH
34994 - BASE
38006 - PC BOARD (PCB1)
182W12 - BUMPER, RUBBER (QTY. 4)
Figure 5. Ultra Pulse 450i Replacement Parts
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F-15-202
7/96
2C
Printed in U.S.A.
