HTP Pro Pulse 200 User manual

180 Joey Drive
Elk Grove Village, IL 60007
Ph: 847-357-0700 ·Fax: [phone]
Web: www.usaweld.com
Pro Pulse 200
Owner’s Manual

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Manufacturer’s Warranty
It is expressly agreed that there are no warranties, expressed or implied, made by either the Salesman,
Dealer, or HTP America, Inc. on products or parts furnished hereunder, except the Manufacturer’s
Warranty against defective materials or workmanship as follows:
HTP America, Inc. warrants each new welding machine to be free from defects in material and
workmanship under normal use and service for three years after delivery to the original purchaser. HTP
America, Inc. will repair and replace, at its factory, any part or parts thereof. Products should be returned
to HTP America, Inc., with transportation charges prepaid, and which its examination shall disclose to its
satisfaction to have been thus defective. This warranty being in lieu of all other warranties, expressed or
implied, and all other obligations or liabilities on its part and it neither assumes nor authorizes any other
person to assume for it any other liability in connection with the sale of its machines.
This warranty shall not apply to any welding machine which has been repaired or altered by unauthorized
service departments in any way 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.
HTP America, Inc. shall not be liable in any event, unless HTP America, Inc. receives notice of alleged
breach of warranty within not more than 30 days after the discovery, actual or construction alleged breach
of warranty specifying the claimed defect.
HTP America, Inc. has reserved the right to make change in design or add any improvements to its
products at any time without incurring any obligation to install same on equipment.
This warranty is void unless warranty card is sent to HTP America, Inc. within 15 days from date of
purchase.
Exclusions to Warranty:
1. The MIG Welding Torch is warranted for a period of Ninety (90) Days against defects in material
and workmanship.
2. The contact tips, tip holders, gas diffusers, gas nozzles, and liner are consumable items, WHICH
CARRY NO WARRANTY.
Safety Suggestions
It is forbidden for people with PACEMAKERS to use or come near the machine.
Electric arc welding produces ultra-violet rays, which are harmful to skin and eyes. Ultra-violet
radiation can penetrate lightweight clothing, reflect from light colored surfaces, and burn the skin and
eyes.
Wear non-oily/non-greasy flameproof welding gloves; the oil or grease on the gloves may ignite.
Wear a heavy, pocket-less, long-sleeved shirt, cuff-less trousers, and high-topped work shoes.
Wear a full-faced welding helmet with a number ten or darker lens and a cap.

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Electric arc welding produces flying sparks and hot material, which can cause fire.
To avoid fire, do not weld on wood, plastic tile, or carpeted floors. Concrete or masonry floors
are safest.
Do not weld on pressurized containers.
Do not weld on drums, barrels, tanks or other containers until they have been cleared and cleaned
as described in AWS Standard A6.01.
Do not weld near flammable materials.
Avoid having any type of fuel, such as cigarette lighters or matches, on your person as you weld.
Ensure that there is a fire extinguisher in the welding area.
Electric arc welding produces toxic fumes.
Provide adequate ventilation in the welding area at all times.
Do not weld on galvanized zinc, cadmium, or lead beryllium materials unless you are POSITIVE
that sufficient ventilation is provided. These materials produce toxic fumes.
Do not weld in areas close to degreasing or spraying operations. Chlorinated hydrocarbon vapors
may react with the ultra-violet rays and form highly toxic phosphine gas.
If you develop momentary eye, nose, or throat irritation during welding, stop welding
immediately. This is an indication that ventilation is not adequate. Do not continue to weld until
ventilation is improved.
Noise can damage your hearing. Protect yourself suitably to avoid hearing damage.
The welding arc can cause burns. Keep the tip of the welding gun/torch far from your body and from
other persons.
ELECTRIC SHOCK CAN KILL.
Exposed, electrically hot conductors, other bare metal in the welding circuit, or 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.
Disconnect the power supply before working on the welding machine.
Do not work with deteriorated or damaged cables.
Frequently inspect cables for wear, cracks, and damage. Replace those with excessively worn
insulation to avoid a possible lethal shock from bared cable.
Do not touch bare electrical parts.
Ensure that all the panels covering the welding machine are firmly secured in place when the
machine is connected to the power supply.
Insulate yourself from the workbench and from the floor (ground); use insulating footwear and
gloves.
Keep gloves, footwear, clothes, the work area, and the welding equipment clean and dry.
Check the machine power cable frequently; the power cable must be free from damage to the
insulation. BARE CABLES ARE DANGEROUS. Do not use the machine if the power cable is
damaged; it must be replaced immediately.
If it is necessary to open the machine, first disconnect the power supply. Wait 5 minutes to allow
the capacitors to discharge. Failure to take this precaution may expose the operator to the
dangerous risk of electric shock.

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Fig. 1

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For more information, refer to the following standards and comply as applicable.
1. ANSI Standard Z49.1 SAFETY IN WELDING AND CUTTING, obtainable from the American
Welding Society, 2051 NW 7th St., Miami, FL 33125.
2. ANSI Standard Z87.1 SAFE PRACTICE FOR OCCUPATION AND EDUCATIONAL EYE
AND FACE PROTECTION, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018.
3. America Welding Society Standard A6.0 WELDING AND CUTTING CONTAINERS WHICH
HAVE HELD COMBUSTIBLES, obtainable from same as item 1.
4. NFPA STANDARD 51. OXYGEN-FUEL GAS SYSTEMS FOR WELDING AND CUTTING,
obtainable from the National Fire Protection Assoc., 470 Atlantic Avenue, Boston, MA 02210.
5. NFPA Standard 51B. CUTTING AND WELDING PROCESSES, obtainable from same as item
4.
6. CGA PAMPHLET P-1. SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS,
obtainable from the Compressed Gas Association, 500 Fifth Avenue, New York, NY 10036.
7. OSHA Standard 29 CFR, Part 1910, Subpart Q WELDING, CUTTING AND BRAZING.
Electrical Connection
Your Pro Pulse 200 operates on single-phase, 230 volt power (208-240 volt). The machine will draw 35
amps out of the wall when operating at a welding output of 200 amps. If the machine is operated on a
generator, it needs to be a clean power generator with a minimum of 8500 watts.
General Characteristics
Our new pulsed process welding machine, which features electronic adjustments controlled through a
microprocessor, allows the operator to achieve excellent welding quality, thanks to the advanced
technologies applied. The microprocessor circuit controls optimize the transfer of the arc, irrespective of
the load variation and of the impedance of the welding cables.
This machine is a synergic welding machine.
The key feature of a synergic welding machine is the ease of set up. In the past, charts from the wire
manufacturers were needed to determine wire speed and voltage, as well as CTWD (contact tip to work
distance) of different welding applications, which ultimately determined the arc length and also indicated
which shielding gas to use. With the Pro Pulse 200, this information is preprogrammed, readily available,
and displayed to the operator. The Pro Pulse 200 features an LCD display that allows the operator to select
a synergic program for a specific wire, such as steel, aluminum, stainless steel, silicon bronze, etc. Once
the operator selects a program, the machine tells the operator which gas to use and then allows the operator
to select the thickness of the material being welded. After selecting the synergic program and the material
thickness, the machine will automatically set the correct wire feed speed (IPM) and the matching voltage
to achieve the best welding results. Of course, since a lot of operators encounter different situations,
especially during repairs on used or dirty metal, the Pro Pulse 200 also gives the operator the option to
adjust the weld colder or hotter by increasing or reducing the voltage.
The Pro Pulse 200 also offers, as the first in its class, ST-arc. The ST-arc function reads welding
parameters back to the welding machine live (while welding). The function monitors the arc length and
keeps the arc length constant, while allowing the stick-out (contact tip to work distance) to vary. ST-arc,
essentially, allows the new welder to focus on the location of the weld, as well as the travel speed, and
also allows the experienced welder to keep a perfectly uniform weld bead and uniform heat input, which

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enables the welder to achieve good welds in tight corners—a feat that couldn’t be reached previously with
conventional welding equipment.
What is pulsed process MIG welding?
Pulsed process welding is a form of welding that happens in spray arc transfer. Classic MIG welding is
done in short arc transfer and sounds somewhat like frying bacon. Spray arc welding is a lot hotter, has
excellent penetration, and is typically very quiet (mostly a quiet hissing with an occasional crackle). This
form of welding is so hot that it typically can only be used in flat position, though sometimes in horizontal
position, as well. Pulse gives the operator the option to run the process out of position while retaining the
same desirable characteristics of deep penetration—a virtually spatter free weld with excellent bead
appearance—but does so while enabling the operator to join materials of different thicknesses at increased
travel speed, all while lowering the heat input and distortion.
Pulsed process MIG welding is different than pulse TIG welding. In the MIG process, filler material has to
be added constantly to maintain the welding arc, and this sets the ground rules for the pulse function. When
pulsing with TIG, the operator has the ability to adjust peak current, background current, pulse on time, and
pulse frequency. The operator using pulsed process MIG, on the other hand, typically only has the choice
of pulse on or pulse off. However, the Pro Pulse 200 offers peak pulse (in some programs, under certain
conditions, and up to 300 amps), pulse on time, as well as background current—all preprogrammed,
according to scientific studies for best results, at the factory. The pulse frequency will adjust with the wire
speed; slower wire speeds have a lower frequency, while higher wire speeds have a higher frequency.
Because of the pulse frequency, electronic interferences may occur. For this reason, it is forbidden for
people with PACEMAKERS to use or come near the machine. During the research and development
process here at HTP, we found that some brands/models of auto-darkening welding helmets experience
interference issues with the Pro Pulse 200. Since the frequency changes according to wire speed, we noticed
that a wire speed adjustment of +/-20 IPM typically alleviates the interference issues. We also noticed that
video cameras or security cameras within close proximity to the Pro Pulse 200, when welding in a pulse
program, show the interference in the recorded picture.
Although the spray arc itself is almost silent (just a slight hiss), the sound of the pulse is well noticeable. It
sounds, at times, much like an AC TIG welder. If the operator is used to the classic MIG frying bacon
sound, the sounds the Pro Pulse 200 makes will take a little adjustment time to get used to.
Welding guns compatible with the Pro Pulse 200 include:
HTP 15AK
HTP 24AK
HTP 26AK
Below, we discuss the capabilities and limitations of each of these guns.
15AK—The smallest of the guns. Excellent for reaching into tight spaces (e.g., work on cars). Also,
lightweight for less operator fatigue. Available in 10’, 12’, and 15’ lengths. Best for use on steel (non-
pulse).
24AK—Slightly larger than the 15AK. Still lightweight and fits into most small spaces. Available in 10’,
12’, and 15’ lengths. For pulse welding, a maximum torch length of 10’ is recommended. For any kind of
pulse welding, CuCrZr tips should be used. Failure to do so will result in premature tip wear, poor weld
quality, burn backs, birds nesting, and other problems. The 24AK can be used for:

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Steel (all diameters and thicknesses; both pulse and non-pulse)
Flux-cored (all thicknesses; with or without gas)
Stainless and Silicon Bronze (all thicknesses)
Aluminum (up to ¼” material thickness; ONLY 5356 wire in .035”wire diameter can be used,
and ONLY if the gun length does not exceed 10’)
26AK—Noticeably larger than the 24AK with a thicker torch cable (the thicker torch cable helps the
operator keep the gun straight which is especially important for aluminum welding). Comes in an 8’
length with M8 size CuCrZr tips. The 26AK can be used for:
Steel (all diameters and thicknesses; pulse and non-pulse)
Flux-cored (all thicknesses; with and without gas)
Stainless and Silicon Bronze (all thicknesses)
Aluminum (EVERY wire diameter from .030” to .047” (3/64”); every alloy (5356 and 4043
namely))
Front Panel Controls
A (Mode Selector)—Allows the operator to access different welding modes by repeatedly pressing.
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.
Fig. 2

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F (Upper Encoder)—When you turn the upper encoder in manual mode, the wire feed speed will be
adjusted. When you turn the upper encoder in all synergic and pulse programs, the material thickness is
adjusted along with the wire feed speed, the amperage, and the voltage. (This can also be done while
welding).
G (Lower Encoder)—When you turn the lower encoder in manual mode, the voltage can be set. Turning
the lower encoder in all synergic and pulse programs makes a voltage adjustment to the synergic curve,
though it does not set an absolute arc voltage like in the manual mode. (This can also be done while
welding). If the machine is in a setup menu screen, the lower encoder may be used to scroll or make
adjustments.
How to Weld (Express)
1. Press and release button A (mode selector) as often as required to set the desired mode (MIG 2T is
probably the most popular).
2. Press and release button Bonce to enter program selection. Use encoder Gto scroll through the
program list and find the program you need. Push and release button Cto select the program, and
use encoder Fto set the desired material thickness. Note: If button Bis pressed twice within a short
time, the machine will go into manual mode. In the manual mode, simply use encoder Fto set the
wire feed speed and encoder Gto set the arc voltage.
3. Pull trigger and weld.
The Programs—Overview
The Pro Pulse 200 offers 21 synergic programs, both with and without pulse, as well as a manual mode.
The manual mode operates just like a classic MIG machine with wire speed adjustment in IPM (from 55 to
629) and voltage adjustment (from 13.0 to 35.0). Manual mode can be used for wires that are not in the
synergic program (e.g., cast iron wire). Please obtain the correct settings from your wire distributor or
manufacturer.
The synergic, non-pulse programs sound very similar to classic MIG welding. These programs offer
inductance adjustments, which makes the arc crisp or soft. On inverter-based machines, changing the arc
characteristics is a desired feature, while on classic transformer machines, adjustments like this are not
offered.
The pulse programs are also synergic, but they sound different than classic MIG welding; the sound when
pulse welding changes with the material thickness (wire feed speed). These programs offer a slope down
function, which can be used to fill craters at the end of aluminum welds.
Both pulse and non-pulse programs offer adjustments in start speed (wire run in), speed and duration, and
they also offer burn back and pinch. Burn back determines how long the wire sticks out of the contact tip
when the weld is completed and the machine has stopped welding. Pinch refers to the shape of the wire;
when MIG welding (classic), a ball usually forms at the end of the wire upon completion of the weld. The
operator, then, typically trims the ball off with a pair of pliers. However, the Pro Pulse 200 can do that for
the operator electrically by setting the pinch. The lower the number on burn back, the longer the stick out
(ATTENTION: High numbers can cause the wire to burn back into the contact tip and destroy it).
The higher the pinch number, the more the wire gets trimmed electrically (ATTENTION: the number
required will change by type and diameter of wire. Also, numbers higher than 75 can cause burn
back when welding with aluminum wire).

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Regardless of whether you are running a synergic or a pulsed program, the pre- and post- gas flow can also
be adjusted. Pre-flow ensures shielding gas is alreadyin place when the welding arc starts, which minimizes
or eliminates porosity, discoloration, and/or peppering. Post-flow shields the hot, glowing wire from
contamination through ambient air, and also protects the weld (as long as the torch is kept in place for the
duration of the post-flow after the weld is completed). This function is extremely helpful when welding
stainless and aluminum.
Welding Aluminum with the Pro Pulse 200
The Pro Pulse 200 offers several different programs for welding aluminum. All of the programs are
designed to get the best results using 100% Argon gas. For aluminum welding, the use of a U-shaped drive
roll is required, and the tension on the wire feed unit has to be properly adjusted. Aluminum wire requires
very little tension. A setting just less than 1 will be absolutely sufficient. If higher settings are chosen, wire
feed issues, such as deformation of the wire, wire getting stuck in the contact tip, burn backs, and birds
nesting, will arise. Aluminum shavings will also be deposited in the liner, which will clog up the liner.
The use of CuCrZr contact tips is strongly recommended. Regular contact tips can be used, but need to be
.005”bigger than normal (e.g., .040”tips for .035”wire). Nevertheless, regular tips are not designed to
withstand the extreme heat of pulsed spray arc MIG aluminum welding. The result will be a limited range
of operation; the Pro Pulse 200 cannot run to its full potential and the life span of the contact tips will be
severely limited.
Aluminum wire should be fed through a designated gun if cross contamination is a concern. While 5356
alloy aluminum wire may be fed though a 10’ torch cable (providing the liner is in good condition and the
cable is held as straight as possible), 4043 wire needs to be fed through an 8’ torch cable. In most cases,
aluminum wire can be fed, successfully, through a steel liner. However, Teflon and Graphite liners are
available for critical applications.
Flush tips or slightly recessed tips (tip holders) can be used for aluminum welding or stainless steel welding.
To improve shielding gas coverage, we suggest the use of a cylindrical nozzle.
Please see the instructions that came with your aluminum wire for shielding gas flow rates and CTWD
(contact tip to work distance). A good gas flow rate starting point for welding aluminum is about 35-50
CFH, but depends on wire diameter, nozzle shape and size, etc., and a good CTWD starting point for
welding aluminum is about ¾”. The pinch function needs to be set to 75 or lower to prevent burn backs,
and, to fill the crater at the end of the weld, the slope down (t2) may be set—about 2.5-4 seconds should
suffice, but again, this number depends on material thickness and type of filler wire.
Everybody knows that aluminum is supposed to be preheated before welding. There are a few situations in
which preheating the material is not possible, practical, or safe. If an operator chooses not to preheat the
part(s) that he is welding, for whatever reason, there is a hot start function built into the Pro Pulse 200 that
will reduce the effects of starting an aluminum MIG weld on a cold part.
The hot start function will boost the welding current by about 35% above the selected settings. As the
chosen settings reach 200 amps, that boost will be reduced because the machine is only capable of putting
out 220 amps for a very short period of time. There are 2 ways to access the hot start:

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1. Through time (0.2-4 seconds) that can be pre-selected in the MIG 2T mode Start Menu.
a. Set the start speed between 80-100% and the start time to 0.1 seconds for no hot start. This
will still give you 0.2 seconds of hot start time, but, in reality, that is the time it takes to
ignite the arc so the operator will not notice any hot start.
b. Set the time to 2 seconds to get 4 seconds of hot start time. During the first 2 seconds you
will get 35% hot start, the following 2 seconds (seconds 3 and 4) you will get hot start
tapering down from +35% to the selected welding current).
2. Fully controlled by the operator with no time limit (as needed) through trigger motion in MIG 4T
mode. Note: the 4T trigger was reprogrammed in the aluminum programs.
a. Pull and hold the trigger; 35% added hot start in addition to the selected welding settings.
b. Let go of the trigger; the selected settings are being run, the arc stays lit, and welding is in
progress.
c. Pull and hold the trigger; the machine initiates the slope down sequence and fills the crater
at the end of the weld. Once the slope down timer runs out, the welding current stops
automatically.
d. Let go of the trigger; welding completed, gas flow stopped.
The material thickness settings in the display are approximate, especially when welding aluminum. When
welding aluminum, the values change with the temperature or with the material welded. If the material is
cold, the chosen material thickness in the display may have to be a little higher than the actual material
thickness. When the material is preheated properly or has been welded on for a while, then the thickness in
the display needs to be lower or a lot lower than the actual material thickness. Therefore, the operator has
the ability to adjust the material thickness (which will adjust the wire speed and the voltage at the same
time) while welding by turning the upper encoder counter-clockwise.
Because this is not always practical while welding, there is a second way to control the heat input. For
instance, if the machine is in MIG 2T and the slope down time is set, for example, anywhere between 3 and
6 seconds, the operator has the option, if he notices that the weld is getting too hot, to let go of the trigger.
Laying off the trigger lets the machine go into slope down, causing the welding current to taper gradually.
Just before the machine turns off, the operator depresses the trigger again, though just for a very short time
and then lays off the trigger again, allowing the process to repeat. Doing this allows the operator to fill gaps
and/or manually compensate for a too hot setting or the material heating up.