ESAB Ultra-Pulse 350MPi Mig Pulse Pendant Control User manual

Brand: ESAB

Model: Ultra-Pulse 350MPi Mig Pulse Pendant Control

Category: Welding System

Type: User manual

ESAB Ultra-Pulse 350MPi Mig Pulse Pendant Control offers many capabilities for professional welding. The pendant control enables pulsed MIG operation, providing enhanced arc stability and reduced spatter. It allows for precise control over pulse parameters, including frequency, peak current, and background current. The device is compatible with standard CV power sources and supports various shielding gases. Its mounting options ensure flexibility in different work environments.

Ultra-Pulse 350MPi

MIG Pulse Pendant Control

Instruction Manual

This manual provides installation and operation instructions for

the following Ultra-Pulse 350MPi MIG Pulse Pendant Control:

P/N 36988

F15-606-A 10 / 2003

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles

of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet,

"Precautions and Safe Practices for Arc Welding, Cutting, and Gouging," Form 52-529. Do NOT permit

untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate

this equipment until you have read and fully understand these instructions. If you do not fully understand

these instructions, contact your supplier for further information. Be sure to read the Safety Precautions

before installing or operating this equipment.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and

accompanying labels and/or inserts when installed, operated, maintained and repaired in

accordance with the instructions provided. This equipment must be checked periodically.

Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing,

worn, distorted or contaminated should be replaced immediately. Should such repair or

replacement become necessary, the manufacturer recommends that a telephone or written

request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the

manufacturer. The user of this equipment shall have the sole responsibility for any malfunction

which results from improper use, faulty maintenance, damage, improper repair or alteration by

anyone other than the manufacturer or a service facility designated by the manufacturer.

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SECTION 1 DESCRIPTION ................................................................................................. 10

1.1 General ............................................................................................................. 10

SECTION 2 INSTALLATION ................................................................................................ 10

2.1 General ............................................................................................................. 10

2.2 Cable Connections............................................................................................ 10

2.3 Power Source Set-Up ....................................................................................... 11

SECTION 3 PULSE OPERATION ........................................................................................ 11

3.1 Pulsed MIG Operation ...................................................................................... 11

SECTION 4 PULSE TECHNICAL DATA ............................................................................. 12

4.1 Standard CV Operation ..................................................................................... 12

4.2 Pulse MIG Arc Stability .................................................................................... 13

4.3 Shielding Gases ................................................................................................ 13

4.4 Pulse Parameters ............................................................................................. 13

SECTION 5 ULTRAPULSE MOUNTING OPTIONS ............................................................ 16

SECTION 6 WIRING DIAGRAMS & REPLACEMENT PARTS ........................................... 17

TABLE OF CONTENTS

SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for

your protection. They summarize precaution-

ary information from the references listed in

Additional Safety Information section. Before

performing any installation or operating procedures, be

sure to read and follow the safety precautions listed below

as well as all other manuals, material safety data sheets,

labels, etc. Failure to observe Safety Precautions can result

in injury or death.

PROTECT YOURSELF AND OTHERS

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and

can injure skin and eyes. Hot metal can cause burns.

Training in the proper use of the processes and equip-

ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

area, even if welding helmets, face shields, and goggles

are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from

sparks and rays of the arc when operating or observing

operations. Warn bystanders not to watch the arc and

not to expose themselves to the rays of the electric-arc

or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a weld-

ing helmet or cap for hair protection, to protect against

arc rays and hot sparks or hot metal. A flameproof apron

may also be desirable as protection against radiated

heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuffs, or pockets. Sleeves and collars should be

kept buttoned, and open pockets eliminated from the

front of clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far.

Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

flames and arcs can start fires. Hot slag

or sparks can also cause fires and ex-

plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non-

flammable covering. Combustible materials include wood,

cloth, sawdust, liquid and gas fuels, solvents, paints and

coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden

smoldering fire or fires on the floor below. Make certain

that such openings are protected from hot sparks and

metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece which might pro-

duce flammable or toxic vapors. Do not do hot work on

closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or

portable fire extinguisher. Be sure you are trained in its

use.

10/98

5. Do not use equipment beyond its ratings. For example,

overloaded welding cable can overheat and create a fire

hazard.

6. After completing operations, inspect the work area to

make certain there are no hot sparks or hot metal which

could cause a later fire. Use fire watchers when neces-

sary.

7. For additional information, refer to NFPA Standard 51B,

"Fire Prevention in Use of Cutting and Welding Pro-

cesses", available from the National Fire Protection Asso-

ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live

electrical parts and ground can cause

severe injury or death. DO NOT use AC

welding current in damp areas, if move-

ment is confined, or if there is danger of

falling.

1. Be sure the power source frame (chassis) is connected

to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or

missing connection can expose you or others to a fatal

shock.

4. Use well-maintained equipment. Replace worn or dam-

aged cables.

5. Keep everything dry, including clothing, work area,

cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from

work

and from ground.

7. Do not stand directly on metal or the earth while working

in tight quarters or a damp area; stand on dry boards or

an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)

for specific grounding recommendations. Do not mis-

take the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —

May be dangerous. Electric current flow-

ing through any conductor causes lo-

calized Electric and Magnetic Fields

(EMF). Welding and cutting current cre-

ates EMF around welding cables and

welding machines. Therefore:

1. Welders having pacemakers should consult their physi-

cian before welding. EMF may interfere with some pace-

makers.

2. Exposure to EMF may have other health effects which are

unknown.

3. Welders should use the following procedures to minimize

exposure to EMF:

A. Route the electrode and work cables together. Secure

them with tape when possible.

B. Never coil the torch or work cable around your body.

C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as

possible to the area being welded.

E. Keep welding power source and cables as far away

from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in confined spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area by

natural or mechanical means. Do not weld, cut, or gouge

on materials such as galvanized steel, stainless steel,

copper, zinc, lead, beryllium, or cadmium unless posi-

tive mechanical ventilation is provided. Do not breathe

fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly toxic

gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation

while operating, this is an indication that ventilation is not

adequate. Stop work and take necessary steps to im-

prove ventilation in the work area. Do not continue to

operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specific ventilation recommendations.

5. WARNING: This product, when used for welding or

cutting, produces fumes or gases which

contain chemicals known to the State of

California to cause birth defects and, in

some cases, cancer. (California Health &

Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if

mishandled, can rupture and violently

release gas. Sudden rupture of cylin-

der, valve, or relief device can injure or

kill. Therefore:

1. Use the proper gas for the process and use the proper

pressure reducing regulator designed to operate from

the compressed gas cylinder. Do not use adaptors.

Maintain hoses and fittings in good condition. Follow

manufacturer's operating instructions for mounting regu-

lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain

or strap to suitable hand trucks, undercarriages, benches,

walls, post, or racks. Never secure cylinders to work

tables or fixtures where they may become part of an

electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in

Cylinders", which is available from Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington,

VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualified personnel perform the installa-

tion, troubleshooting, and maintenance work. Do not

perform any electrical work unless you are qualified to

perform such work.

2. Before performing any maintenance work inside a power

source, disconnect the power source from the incoming

electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do not

operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do not

modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for elec-

tric arc welding and cutting equipment, ask

your supplier for a copy of "Precautions and

Safe Practices for Arc Welding, Cutting and

Gouging", Form 52-529.

The following publications, which are available from the

American Welding Society, 550 N.W. LeJuene Road, Mi-

ami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten

Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used through-

out this manual: Means Attention! Be Alert!

Your safety is involved.

Means immediate hazards which, if

not avoided, will result in immediate,

serious personal injury or loss of life.

Means potential hazards which could

result in personal injury or loss of life.

Means hazards which could result in

minor personal injury.

SP98-10

SAFETY PRECAUTIONS

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PROCESS SELECTION

SWITCH

WIRE SPEED RANGE

"NO PROGRAM"

INDICATOR

WIRE MATERIAL

SELECTOR

WIRE DIAMETER

SELECTOR

ARC LENGTH

TRIM

ULTRAPULSE 350 PULSE CONTROL PENDANT

(FOR 350MPi POWER SOURCE ONLY)

SECTION 1 DESCRIPTION

1.1 General

The Ultra-Pulse 350 pendant is designed to provide

simple to use, high quality, synergic pulsed Mig welding

when used with a 350MPi inverter power source and a

Mig 4HD, 4HD Dual or Mig 5XL "Mongoose" wire feeder.

Synergic pulsed Mig welding means that pulse param-

eters (such as pulse height, pulse width, background

current and pulse frequency) are automatically adjusted

by the Ultra-Pulse 300i pendant as you change wire feed

speed.

The Ultra-Pulse 350 pendant also provides a PULSE

ARC TRIM that allows the operator to fine tune the pulse

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 changing the 350MPi PROCESS

SELECTOR switch to the desired welding process and

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) dis-

connect switch or circuit breaker before making the

following connections.

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 1.

The Ultra-Pulse 350 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.

1. Connect the 19 pin plug to the mating receptacle

on the 350MPi power source.

2. Connect the UltraPulse 19 pin female amphenol

receptacle to the wire feeder control cable male

amphenol plug.

FIGURE 1. Connection to Feeder & Power Supply

19-Pin Male

Connector

to 350 MPi

Ultra-Pulse

350

Pendant

19-Pin Female Connector to:

Mig 4HD

Mig 4HD Dual

Mig 5XL "Mongoose"

From Ultra-Pulse

350 MPi Pendant

2. Use output cables that are as short as possible.

Do not loop or coil the work cables. Excessive

cable lengths and coiled cables could result in

less than optimum performance.

3. Proper connection of the work cables to the

work is essential for high quality results. Under-

sized ground clamps, poor connects, frayed

cables, cable splices or clamps attached to

rusting or dirty surfaces will result in unstable

conditions.

4. Turn the power source "ON" and initiate the

welding process by closing the torch trigger.

3. Be sure that the secondary output connections

(welding cables) are connected so the positive

cable goes to the wire feeder and the negative

cable goes to the work piece.

2.3 Power Source Set-Up

1. The 350MPi power source is "Pulse Mig Ready"

and requires no additional configuration or ad-

justments. Place the 350MPi power source

PROCESS SELECTOR switch in the Mig posi-

tion and the MIG SELECTOR switch to the type

of Mig wire to be used. The position of the

REMOTE/PANEL switch is dependant on the

wire feeder and process (STANDARD or

PULSE) being used. Refer to TABLE 1.

SECTION 3 PULSE OPERATION

3.1 Pulsed Mig Operation

A. UltraPulse 350 pendant Set-Up.

1. Set the MATERIAL SELECTOR dial to the wire

type and wire diameter that is being used on the

wire feeder.

NOTE: See Table 2 for the recommended shield-

ing gasses for each wire alloy type.

2. Set Panel Remote Switch to (Remote).

NOTE:The RED light on the UltraPulse pendant will

"Blink" when the wire feed speed is out of

range. A "Steady" light "On" indicates there

is no program for the material and wire

diameter selected.

3. Place the PULSE/STANDARD toggle switch to

the PULSE position.

REMOTE

CONTROL

PANEL

CONTROL

STANDARD / PULSE SWITCH

350 MPi FRONT PANEL

Wire UltraPulse Process 350MPi Voltage Control From:

Feeder Switch Power Source

Mig 4HD STANDARD REMOTE Mig 4HD VOLTS POT

PULSE REMOTE UltraPuse 350 TRIM

Mig 4HD DUAL STANDARD REMOTE Mig 4HD VOLTS POT

PULSE REMOTE UltraPuse 350 TRIM

Mig 5XL STANDARD PANEL 350MPi Panel VOLTS

"Mongoose" PULSE REMOTE UltraPuse 350 TRIM

TABLE 1 - UltraPulse 350 and 350MPi Power Source Set-Up

SECTION 2 INSTALLATION

DIGITAL

AMMETER

DIGITAL

VOLTMETER

VOLTAGE

CONTROL

PANEL/REMOTE

TOGGLE SWITCH

MATERIAL

SELECTOR

SWITCH

INDUCTANCE (CV)

ARC FORCE (CC)

PROCESS

SELECTOR

SWITCH

OUTPUT PRESET SWITCH

SECTION 3 PULSE OPERATION

4. Set the ARC TRIM knob to the "0" or center

position.

The ARC TRIM is used to fine tune the arc

length performance. Turn the knob clockwise to

increase the arc length or counterclockwise to

decrease the arc length.

Mig 4HD Wire Feeder

1. Set the WIRE FEED SPEED dial to a wire feed

rate that is within the range of the UltraPuse

pendant control.

NOTE-----The RED light on the UltraPulse pen-

dant will "Blink" when the wire feed speed is out

of range.

2. Pull the gun trigger. Begin Welding. Trim the

arc voltage with the UltraPulse pendant TRIM

knob to the desired arc length

Mig 4HD Dual Wire Feeder

1. Pulse operation is the same as the standard Mig

4HD except BOTH guns on the Mig 4HD Dual

will have pulse parameters sent to them based

on the wire type and diameter seletcted on the

UltraPulse Pendant. Each gun CANNOT be

independently controlled for different wire types

or sizes.

D. Mig 5XL "Mongoose" Wire Feeder

1. To pulse with the Mongoose "push/Pull" Sys-

tem, be sure you have the Mig 5XL Pulse

Version wire feeder (PN-37487).

2. Set the 350MPi PANEL/REMOTE switch to the

REMOTE position (See TABLE 1).

3. Set the wire feed speed on the MT-300XL gun.

NOTE-----The RED light on the UltraPulse pen-

dant will "Blink" when the wire feed speed is out

of range.

4. Adjust the UltraPuse Arc Trim to the desired arc

characteristics.

Process control

1. Use a tip-to-work distance of 3/8" to 5/8". This

refers to the distance between the end of the Mig

gun 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 and use a 5 to 10

degree gun angle from the vertical.

3. The TRIM knob on the UltraPulse 350 pendant

is used to fine tune the arc length by turning the

dial clockwise to lengthen the arc or counter-

clockwise to shorten the arc. If the arc is "crack-

ling" or if spatter is excessive lengthen the arc.

If the arc is "fluttering" or difficult to control then

shorten the arc length.

SECTION 4 PULSE TECHNICAL DATA

4.1 Standard CV Operation

The Ultra-Pulse 350 pendant provides for both standard

welding and pulsed Mig welding. When the STAN-

DARD/PULSE switch is in the STANDARD position the

wire feeder and power source are ready for standard

non-pulsed CV Mig welding. Follow the basic instruc-

tions provided with the power source to change to other

welding processes, such as, Tig or Stick welding .

1. For standard CV Mig welding the wire feed

speed and power source output (voltage) are

independent.

2. On a Mig 4HD, set the voltage on the front panel

of the feeder. On a Mig 5XL, set the arc voltage

on the front panel of the power source. Refer to

Table 1.

SECTION 4 PULSE TECHNICAL DATA

4.2 Pulse MIG Arc Stability

Many 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 guns

Base metal surface condition

When adverse 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 changes pulse waveform and average

current levels. The TRIM knob on the UltraPulse pen-

dant adjusts the pulse frequency to accommodate small

changes in the welding equipment set-up and base

material variations to achieve a stable pulse welding

condition.

4.3 Shielding Gases

Table 2 lists the range of shielding gases that can be

used with the UltraPuse pendant. The wire burn-off rate

and synergic operation will vary with changes in shield-

ing gas. The UtraPulse TRIM knob is used to compen-

sate for changes in shield gas composition.

4.4 Pulse Parameters

Tables 3 through 7 list the approximate pulse welding

parmeters for each material and diameter. These are

provided for general reference only. Actual pulse pa-

rameters can vary with the equipment set-up, welding

application and shielding gases being used. The wire

feed speed ranges shown in the tables are the same as

programmed into the UltraPulse 350 pendant. Attempt-

ing to weld outside of the suggested speed ranges will

result in a "blinking" indicator light on the UltraPulse front

panel. A "steady" light lite on the panel indicates the wire

material and diameter combination selected does not

have any pulse data programmed.

TABLE 2 - UltraPulse 350 Material, Diameter and Shielding Gases

Material

Type

Wire

Diameter (In.)

Shielding Gas

(AWS Designation)

Carbon

Steel

.030, .035,

.040, .045

r - 5% CO2 (SG-AC-5)

r - 8% CO2 (SG-AC-8)

r - 10% CO2 (SG-AC-10)

r - 2% O2 (SG-AO-2)

Ar - 8% CO2 - 2% O2 (SG-ACO-8/2)

Stainless

Steel

.030, .035,

.040, .045

r -2% CO2 (SG-AC-2)

r - 8% CO2 (SG-AC-8)

r - 2% O2 (SG-AO-2)

r - 8% CO2 - 2% O2 (SG-ACO-8/2)

Ar - He 50% - 2% CO2 (SG-AHeC-50/2)

4000 &

5000

Aluminum

.030, .035,

3/64 (.047)

r ( SG-A)

r - He 25% (SG-AHe-25)

Ar - He 50% (SG-Ahe-50)

Metal Core

Carbon

Steel

.040, .045,

.052

r - 5% CO2 (SG-AC-5)

r - 8% CO2 (SG-AC-8)

r - 10% CO2 (SG-AC-10)

r - 2% O2 (SG-AO-2)

Ar - 8% CO2 - 2% O2 (SG-ACO-8/2)

Metal Core

Stainless

Steel

0.045

r - 2% CO2 (SG-AC-2)

r - 8% CO2 (SG-AC-8)

r - 1% O2 (SG-AO-1)

r - He 50% - 2% CO2 (SG-AHeC-50/2)

SECTION 4 PULSE TECHNICAL DATA - STEEL

.030 Steel .035 Steel

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

75 273 2.00 11 34 75 257 2.40 0 59

125 279 2.00 15 47 125 272 2.40 18 75

175 285 2.00 19 61 175 287 2.40 36 92

225 292 2.00 23 75 225 302 2.40 54 108

275 298 2.00 27 89 275 317 2.40 72 125

325 304 2.00 31 103 325 332 2.40 90 141

375 311 2.00 35 117 375 347 2.40 108 158

425 317 2.00 39 131 425 362 2.40 126 174

475 323 2.00 43 145 475 377 2.40 144 191

525 330 2.00 47 158 525 392 2.40 162 207

575 336 2.00 51 172 575 407 2.40 180 224

625 342 2.00 55 186 625 422 2.40 198 240

675 349 2.00 59 200

725 355 2.00 63 214

775 361 2.00 67 228

.040 Steel .045 Steel

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

75 367 2.60 13 54 125 348 3.00 32 88

125 370 2.60 30 73 175 363 3.00 55 105

175 374 2.60 46 92 225 378 3.00 77 123

225 378 2.60 63 111 275 393 3.00 100 140

275 382 2.60 80 129 325 408 3.00 122 158

325 386 2.60 97 148 375 423 3.00 145 175

375 389 2.60 113 167 425 438 3.00 167 193

425 393 2.60 130 186 475 453 3.00 190 210

475 397 2.60 147 205

525 401 2.60 164 223

575 404 2.60 180 242

625 408 2.60 197 261

.030 Stainless .035 Stainless

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

200 239 1.90 27 64 75 224 2.30 8 50

250 246 1.90 35 77 125 233 2.30 17 70

300 252 1.90 44 89 175 242 2.30 26 90

350 258 1.90 52 102 225 251 2.30 35 110

400 265 1.90 61 115 275 260 2.30 44 130

450 271 1.90 69 127 325 269 2.30 53 150

500 278 1.90 78 140 375 278 2.30 62 170

550 284 1.90 86 152 425 287 2.30 71 190

600 290 1.90 95 165 475 296 2.30 80 210

650 297 1.90 103 177 525 305 2.30 89 230

700 303 1.90 112 190 575 314 2.30 98 250

750 309 1.90 120 202 625 323 2.30 107 270

675 332 2.30 116 290

725 341 2.30 125 310

.040 Stainless .045 Stainless

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

75 214 2.80 24 52 75 285 2.70 39 62

125 234 2.80 41 63 125 306 2.70 50 81

175 254 2.80 57 74 175 326 2.70 60 100

225 275 2.80 74 85 225 347 2.70 71 119

275 295 2.80 90 96 275 367 2.70 81 138

325 316 2.80 107 107 325 388 2.70 92 157

375 336 2.80 124 118 375 409 2.70 102 176

425 356 2.80 140 129 425 429 2.70 113 195

475 377 2.80 157 140

525 397 2.80 174 151

TABLE 3 - UltraPulse 350 Carbon Steel Pulse Parameters

TABLE 4 - UltraPulse 350 Stainless Steel Pulse Parameters

SECTION 4 PULSE TECHNICAL DATA - ALUMINUM

.030 4043 AI .035 4043 AI

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

200 236 1.10 20 109 150 194 1.59 26 60

250 251 1.10 25 131 200 209 1.61 36 80

300 266 1.10 30 152 250 225 1.62 46 101

350 281 1.10 34 174 300 241 1.64 55 121

400 296 1.10 39 196 350 256 1.65 65 142

450 311 1.10 44 218 400 272 1.67 75 162

500 325 1.10 48 240 450 288 1.68 84 183

550 340 1.10 53 262 500 303 1.70 94 203

600 355 1.10 58 284 550 319 1.71 104 224

650 370 1.10 63 306 600 334 1.73 113 244

700 385 1.10 67 328 650 350 1.74 123 265

700 366 1.76 133 286

.040 4043 AI .047 4043 AI

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

80 260 1.50 30 38

130 280 1.60 44 62

180 300 1.69 58 86

230 320 1.79 73 110

Not Programmed 280 340 1.88 87 134

330 360 1.98 101 159

380 380 2.07 115 183

430 400 2.17 130 207

480 420 2.26 144 231

530 440 2.36 158 255

030 5356 AI .035 5356 AI

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

225 310 1.15 25 60 200 256 1.70 28 56

275 318 1.15 31 69 250 261 1.70 33 74

325 326 1.15 38 77 300 266 1.70 38 92

375 335 1.15 44 86 350 271 1.70 43 110

425 343 1.15 51 94 400 276 1.70 48 128

475 351 1.15 57 103 450 280 1.70 53 147

525 359 1.15 64 112 500 285 1.70 58 165

575 368 1.15 70 120 550 290 1.70 63 183

625 376 1.15 77 129 600 295 1.70 68 201

675 384 1.15 83 137 650 300 1.70 73 219

725 392 1.15 90 146 700 305 1.70 78 237

750 310 1.70 83 255

800 315 1.70 88 273

.040 5356 AI .047 5356 AI

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

150 303 1.50 35 74

200 316 1.50 50 101

250 328 1.50 65 127

Not Programmed 300 341 1.50 80 154

350 353 1.50 95 181

400 366 1.50 110 208

450 379 1.50 125 235

500 391 1.50 140 262

550 404 1.50 155 289

TABLE 5 - UltraPulse 350 4000 Aluminum Pulse Parameters

TABLE 6 - UltraPulse 350 5000 Aluminum Pulse Parameters

SECTION 5 ULTRAPULSE MOUNTING OPTIONS

FIGURE 2 - UltraPulse Bracket Assemblies

(Included with Pendant - mount with existing hardware)

Mounted UltraPulse Assemblies

Mig 4HD Boom

Mig 4HD Dual

Mig 4HD

Figure 2. UltraPulse 350 Mounting Options

SECTION 4 PULSE TECHNICAL DATA - METAL CORE

.040 Metal Core CS .045 Metal Core CS

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

100 255 2.50 33 80 100 335 2.50 16 101

150 278 2.50 44 100 150 352 2.50 27 122

200 300 2.50 55 120 200 370 2.50 37 144

250 323 2.50 66 140 250 388 2.50 48 166

300 345 2.50 77 160 300 406 2.50 59 187

350 368 2.50 89 180 350 424 2.50 70 209

400 390 2.50 100 200 400 441 2.50 80 231

450 413 2.50 111 220

500 436 2.50 122 240

.052 Metal Core CS .045 Metal Core SS

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

WFS

Range

Pulse

Peak

Pulse

Width

Pulse

Background

Pulse

Frequency

75 358 2.70 16 76 100 407 1.80 35 71

125 385 2.70 45 94 150 418 1.86 44 90

175 412 2.70 74 112 200 429 1.91 53 109

225 438 2.70 103 130 250 440 1.97 62 128

275 465 2.70 132 148 300 451 2.02 70 146

325 492 2.70 160 166 350 462 2.08 79 165

400 473 2.13 88 184

450 484 2.19 97 203

500 495 2.24 105 222

550 506 2.30 114 241

TABLE 7 - UltraPulse 350 Metal CorePulse Parameters

Steel and Stainless

PN 0558001589 - Hanger Bracket

Mig 4HD

PN 0558001590 - Hanger Bracket

Mig 4HD Dual

0558001437 - HANDLE

(8)2062018 - POTENTIOMETER

0558001019 - KNOB

634515 - SWITCH

(8)951474 - COVER

0558001595 - KNOB

952993 - SWITCH

23607860 - BUMPER, RUBBER

951032 - LIGHT

0558001587 - BACK PANEL

FIGURE 3 - UltraPulse 350 Replacement Parts (Front and Back View)

0558001591 - HANGER

SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS

0558001022 - CABLE, COMPLETE, 8 FT (P3)

0558001586 - STRAIN RELIEF

(8)38170 - PC BOARD (PCB1)

0558001588 - COVER

952988 - TRANSFORMER

FIGURE 4 - UltraPulse 350 Replacement Parts (Inside View)

SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS

CABLE ASSEMBLY 0558001022

FIGURE 5 - UltraPulse 350 Cable Wiring Diagram

0558001022-C

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REVISION HISTORY

1. Revision "A" updated wiring/schematic diagrams in Section 6, added Table of Contents, and

included various editorial updates.

F-15-606-A 10/03 Printed in U.S.A.

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ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

ESAB Ultra-Pulse 350MPi Mig Pulse Pendant Control User manual

Brand: ESAB

Model: Ultra-Pulse 350MPi Mig Pulse Pendant Control

Category: Welding System

Type: User manual

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