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
2
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.
3
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
4
TABLE OF CONTENTS
5
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.
6
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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9
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)
10
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
11
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
12
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.
B.
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
C.
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.
E.
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.
13
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
A
r - 5% CO2 (SG-AC-5)
A
r - 8% CO2 (SG-AC-8)
A
r - 10% CO2 (SG-AC-10)
A
r - 2% O2 (SG-AO-2)
Ar - 8% CO2 - 2% O2 (SG-ACO-8/2)
Stainless
Steel
.030, .035,
.040, .045
A
r -2% CO2 (SG-AC-2)
A
r - 8% CO2 (SG-AC-8)
A
r - 2% O2 (SG-AO-2)
A
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)
A
r ( SG-A)
A
r - He 25% (SG-AHe-25)
Ar - He 50% (SG-Ahe-50)
Metal Core
Carbon
Steel
.040, .045,
.052
A
r - 5% CO2 (SG-AC-5)
A
r - 8% CO2 (SG-AC-8)
A
r - 10% CO2 (SG-AC-10)
A
r - 2% O2 (SG-AO-2)
Ar - 8% CO2 - 2% O2 (SG-ACO-8/2)
Metal Core
Stainless
Steel
0.045
A
r - 2% CO2 (SG-AC-2)
A
r - 8% CO2 (SG-AC-8)
A
r - 1% O2 (SG-AO-1)
A
r - He 50% - 2% CO2 (SG-AHeC-50/2)
14
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
15
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
12
16
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
17
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
18
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
19
SECTION 6 WIRING DIAGRAMS AND REPLACEMEMT PARTS
CABLE ASSEMBLY 0558001022
FIGURE 5 - UltraPulse 350 Cable Wiring Diagram
0558001022-C
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23
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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