Aluminum pulse question

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I have an Esab MultiMaster 260 system and use the spoolgun with .035" 4034 wire. I just installed the Esab pulse control and cannot get a weld to even come close to working properly when using pulse. I have tried every combination of adjustments, but can't get a good clean bead. Is anyone using the MM260 with pulse? Should I try thinner wire?MIG beads that I've seen from other machines using pulse look almost like they were tigged.I am welding 1/8" aluminum treadplate to the same and also to 1/8" angle and 3/16" angle. Yes- it's clean.
Reply:With pulse mig, you will want to run HIGH pulse..probably 150+ pulses per second.
Reply:I dont know if this helps you any but with my PowCon I have the pulser set around 60 pulses per second and about 20% pulse width.   I can usually use the same pulse settings on different thicknesses and just adjust the voltage and wire speed to match the thickness.  I've pulse-mig'd aluminum on a few different machines and the weld beads are usually very smooth with a very finely (closely) rippled surface, far from the look of the individual wire dips of a TIG weld.   When you use the pulse, you can set the voltage higher and wire speed lower than what you would normally use for the same weld without pulse.   On the machines at work, on 1/16" aluminum with .035 4043, I can set it to 14-16 volts and 275-300 ipm without the pulse whereas with the pulse the voltage is up around 18-20 and wire speed is down around 150 and the amps come out around 40 for the same weld.   The machines at work (Millermatic 350P's) use a computerized pulse program so the pulse settings probably wont be of any help to you on your machine.  I dont even know how to correlate those computer settings to compare them to the PowCon and MK pulsers I have here at home which are analog.  The PowCons use pulses-per-second and pulse-width as the controls and the MK's use on-time and off-time as the controls and it's hard to compare those too.    On the MK's I i generally use about 2 times the on-time for the off-time setting which puts them both at about 50% on the dials.   I had to just spend ALOT of time playing with them till I figured out what worked and what I liked.  Keep experimenting and I'm sure you'll find out what works for you . Also with pulse I've found that gas coverage is even more critical than straight mig to keep soot off the weld.  I think it has to do with a constant wire feed rate into a pulsed arc creating a higher potential for unclean burning of the wire.   I've found a slower wire feed rate works better with pulse for cleaner welds.Hope that helps you some...
Reply:Oh, on your wire size, the .035 should be fine for that thickness.   If I was going to change the wire size, I would go up not down.   You can only go down to .030 with 4043 aluminum wire anyways, as far as I know, and there's not much difference between that and .035.   If anything I would go to a thicker wire if 1/8" and thicker material is what you're welding most, maybe try some .045 or 3/64.
Reply:You're using 100% argon sheilding gas right?
Reply:yes- 100% argon from a reputable dealer.
Reply:You might want to try posting on the Hobart weld forum. There is a guy there with  MM260 with the pulse (and every other option). His user name is Brand X. He is registered on this board as well, but doesn't look like he is here very much.www.hobartwelders.com/mboardJohn