HTP Pro Pulse 300 Owner's Manual
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HTP Pro Pulse 300 Owner's Manual

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Pro Pulse™ 300
Owner's Manual
180 Joey Drive
Elk Grove Village, IL 60007
Ph: (847) 357-0700 · Fax: (847) 357-0744
Web: www.usaweld.com

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  • Page 1 Pro Pulse™ 300 Owner’s Manual 180 Joey Drive Elk Grove Village, IL 60007 Ph: (847) 357-0700 · Fax: (847) 357-0744 Web: www.usaweld.com...
  • Page 2 Carts, flow meters, heavy-duty ground clamps, power plugs, etc. In order for you to get the most out of your Pro Pulse 300, please work with HTP America, Inc. so we can help you customize your Pro Pulse 300 package for your specific welding application(s)—communication is essential for us to understand your needs and wants, as well as the task(s) you expect the Pro Pulse 300 to perform.
  • Page 3 MIG welding guns. Birds nesting is not much of an issue with the Pro Pulse 300. However, burn back may occur and must be addressed immediately—failure to do so will result in EXCESSIVE tip usage! When a burn back occurs, the damaged tip becomes useless and must be replaced.

  • Page 4: Manufacturer's Warranty

    This warranty shall not apply to any welding machine which has been repaired or altered by unauthorized service departments in any was so as, in the judgment of HTP America, Inc., to affect its stability and reliability, nor which has been subjected to misuse, negligence, or accident.
  • Page 5 Noise can damage your hearing. Pr otect your self suitably to avoid hear ing damage. The welding arc can cause burns. Keep the tip of the welding gun/tor ch far fr om your body and far fr om other persons. Electric arc welding produces toxic fumes.
  • Page 6 Fig. 1...
  • Page 7 Pro Pulse 300 Specifications MIG: 320 Maximum Output Amperage TIG/Stick: 300 MIG: 12 Minimum Output Amperage TIG/Stick: 4 Maximum Recommended Thickness *Single pass capacity varies depending on the material Up to 5/8” being welded and the settings of the machine.

  • Page 9: Front Panel Connections

    Front Panel Connections Fig. 2 Pos. Type Description Connects MIG welding guns and push-pull guns to the machine. The Euro Connector includes a trigger connection as well as a gas Euro Connector connection. The wire from the internal wire feed unit also feeds through the Euro Connector.

  • Page 10: Back Panel Connections

    Back Panel Connections Fig. 3 Pos. Description Port for the Smart Water-Cooler Port for TIG and Spool Gun Shielding Gas Port for MIG and Push-Pull Gun Shielding Gas Power Switch Input Power Cable...

  • Page 11: Electrical Connection

    Alternatively, you can run the Pro Pulse 300 on 3-phase power from 200 to 575 volts; the power draw on 240 volt, 3- phase power is 31 amps and 15 amps on 480 volt, 3-phase power. If you are planning to use your Pro Pulse 300 on a generator, you may connect the machine to a single–...

  • Page 12: Front Panel Controls

    Front Panel Controls Fig. 4 A (Select Mode Button)—Allows you to access different welding modes by pressing repeatedly. B, C, D, E (Setup and Selection Buttons)—The function of these buttons differs depending on which mode the machine is in and what setup screen the machine is on. The function of the individual button is shown in the display right above each button.
  • Page 13 Then, you typically trim off the ball with a pair of pliers. However, the Pro Pulse 300 can trim off the ball for you electrically by setting the pinch. The higher the pinch number, the more the wire gets trimmed electrically (ATTENTION: The number required will change based on the type and the diameter of the wire used.
  • Page 14 If you choose to not preheat the part(s) that you are welding, for whatever reason, there is a hot start function built into the Pro Pulse 300 that will reduce the effects of starting an aluminum MIG weld on a cold part.
  • Page 15 HTP recommends using a MIG remote control for maximum control when welding aluminum. If a MIG remote control is not available, MIG 4T is the next best option for performance and control.
  • Page 16 (For more information regarding Hot Start and Arc peak/welding current, refers to the background current. Force, please refer to the Glossary, which starts on Page All other HTP stick welding machines (the Inverarc 200 34.) TLP and the Invertig 221) have the duty-cycle and the Ibase current factory fixed at 50% each.

  • Page 17: Tig Welding

    The TIG welding process requires the use of 100% Argon gas. Install the flowmeter on your tank, and connect the flowmeter to the Pro Pulse 300 with the supplied gas hose. To connect the gas hose, fasten one end of the gas hose to the flowmeter and the other to the back of the welding machine (Fig.
  • Page 18 MIG Welding—General Information MIG welding with the Pro Pulse 300 can be done three different ways: manual, synergic, and pulse. In any case, the following things are critical to making good welds: ...
  • Page 19   Use drive rolls with a groove that matches the wire Use the proper wire tension. When welding with diameter chosen. There are different sizes and mild steel or stainless steel, feed tension is important shapes of drive rolls. For .023”, .024”, and .025” but a little forgiving.
  • Page 20 (the yellow bar that highlights the program will move as you turn right encoder G). There are 32 programs in the Pro Pulse 300. To see a complete list of the programs installed on your Pro Pulse 300, please see Appendix I on Page 33. Each program listed includes a short description.
  • Page 21 a fully manual adjustable double pulse. These options are available regardless of the material (mild steel, stainless steel, silicon bronze, or aluminum) and wire diameter. These pulse features work regardless of which MIG gun you use; air-cooled, water-cooled, spool gun, or push-pull gun all work equally well with these pulse features.
  • Page 22 the wire. Depending on the setting, there might not be a Synergic, non-pulse programs have an option to adjust ball on the end of the wire that needs to be clipped off inductance (Fig. 27). By turning right encoder G (Fig. before re-striking an arc.
  • Page 23 The smart water-cooler Very extreme double pulse settings may necessitate an plugs into the back of the Pro Pulse 300 (Fig. 3, Pos. P), increase in voltage; in some cases, depending on the and into a separate 220/240 volt, single-phase circuit.
  • Page 24 The third line allows you to switch between the spool are certain that is your desired weld procedure. gun and the internal wire feeder. With the Pro Pulse 300, you have the option to run steel wire on the internal wire feeder while running aluminum on a spool gun.

  • Page 25: Job Mode

    JOB is modified from the original. weld and releasing the trigger makes the machine stop welding. To leave the current JOB and return the Pro Pulse 300  Each set of parameters (JOB) saved in slots 1 into the “regular” welding mode, quickly press and...

  • Page 26: Remote Control Option

    Also, set the t2 slope down between 2.5 and 5 seconds to fill the crater at the end of the weld. Remote Control Option The Pro Pulse 300 features a remote control (foot pedal or hand control) option for MIG welding. The unique...
  • Page 27 There is no way to override this function. The Pro Pulse 300 is a machine in the 300 amp class; it is designed for welding operations up to 300 amps in TIG and Stick mode and up to 320 amps in MIG and pulsed MIG mode. Depending on the selected program and the welding material, the peak pulse can be as high as 600 amps (Note: This will not show in the display;...
  • Page 28 HTP 24 Series MIG Welding Gun Relatively lightweight and fits into most small spaces. Available in 10’, 12’, and 15’ lengths. For pulse welding, we recommend a maximum torch length of 10’. For any kind of pulse welding, CuCrZr contact tips should be used.
  • Page 29 HTP 26 Series MIG Welding Gun Noticeably larger than the 24 Series MIG Welding Gun with a thicker torch cable (the thicker torch cable helps the operator keep the gun straight, which is especially important when welding aluminum). Available in 8’, 10’, and 12’...
  • Page 30 HTP 36 Series MIG Welding Gun Air-cooled gun that can handle the full output of the Pro Pulse 300. For pulse and high amperage welding applications, we recommend the use of CRZR contact tips. Available in 10’, 12’, and 15’ lengths, but pulse applications typically produce the best results with 10’...
  • Page 31 Pro Pulse 300 Wiring Diagram...
  • Page 32 Pro Pulse 300 Parts Diagram...
  • Page 33 Pro Pulse 300 Parts List Position Part # Description Position Part # Description 661043 Front Fan Cover 660645 Insulator, H12 664620 Euro Gun Connector 650302 Secondary Power Diode 661062 Knob 613793 Primary Inverter PCB 661385 Front Panel Frame 613792 Driver Inverter PCB...
  • Page 34 Pro Pulse 300 Wire Feed Assembly Parts Diagram & List Position Part# Description Position Part# Description 613933 Wire Drive Front Housing 636550 Pressure Arm, Right, 37mm 613934 Wire Drive Rear Housing 636560 Pressure Adjustment Unit, 2mm 661423 Gear to Motor...
  • Page 35 Appendix I—Pro Pulse 300 Program List Program # Material Wire Diameter Shield Gas Program Name Type Min. IPM Max. IPM Wire Speed (m/m) Wire Speed (m/m) Min. Thickness (mm) Max. Thickness (mm) Mild Steel .023” - .025” AR 8-25%CO2 Ms .023 Ar 8-25%CO2 Synergic 20.0...

  • Page 36: Appendix Ii-Glossary

    Since the frequency changes according to wire speed, we noticed that a wire speed adjustment of +/-20 IPM typically alleviates the issues. We also noticed that video cameras within close proximity to the Pro Pulse 300, when welding in a...
  • Page 37 Stands for Voltage Reduction Device. V.R.D. is a system which reduces the no-load voltage (OCV). When you activate the V.R.D., the Pro Pulse 300 reduces the maximum no-load voltage to a lower and safer voltage—normally less than 18 volts. Used as an additional aid for operator safety and for when safety procedures at work require extra protection.

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