Miller Optima Pulsed Mig

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I was looking for some feedback on the Miller Optima pulse controller.  If you have had experience with this controller, I would really like to hear from you.  I have an XMT 304 and I would like to add pulsed mig capabilities.  Local Miller dealer has none available for trial or for rent, nor do they have any direct experience with it.  With a price of $1200, I want to be sure it is worth the money, before plunking down that much cash!  Thanks for your help!"I am convinced that the "life-blood" of all electronic hardware is not electrons, but "smoke".  I know this because no piece of electronic hardware has ever been revived after it has "lost a lot of smoke!!"Acclim8
Reply:Suggestion: do a search over at http://www.millerwelds.com/resources...oard/index.php as there have been a few threads there on the Optima pendant control.  If you don't see what you need, join and ask as there are lots of folks with pulse welding experience.  Here's one thread from over there that I know of that's kinda sorta on your topic. http://www.millerwelds.com/resources...ghlight=optima  ScottMiller XMT 350 CC/CV w/gas solenoid opt.Miller S-22A wirefeederBernard 400A "Q" gunMiller Spoolmatic 30A / WC-24C-K 200A torch/gas lensWeldcraft WC-18 watercooled torchHypertherm Powermax 30Victor O/A
Reply:Thanks for your reply Dmaxer.  I actually started my quest on the Miller site, so I thought I would try here for a more unbiased point of view.  I followed the thread you suggested and found it was a thread you started over there.  In your case, the Miller rep favored the XMT 350 MPa over the use of the Optima.  So, did you ever buy or try the MPa or the Optima?  Could you or anyone else out there comment on pulsed mig capabilities?  I have never used a pulse controller."I am convinced that the "life-blood" of all electronic hardware is not electrons, but "smoke".  I know this because no piece of electronic hardware has ever been revived after it has "lost a lot of smoke!!"Acclim8
Reply:PULSED SPRAY MIG IS THE BALLS!I have it on a lincoln and use it all the time.  Its the way to go.   Control of MIG, fluid puddle like tig.  It takes a lot of getting used to, but its an all position process.Do a search for pulsed spray and you will see some of the jobs I have done with it.I don't know anything about miller, everything I have is red except my elite helmet.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:David,Do you have a Power MIG 350MP?I've been looking at that model, a very cool unit.Rex
Reply:Rex, I have a V350 Pro with advanced panel.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I like pulsed spray mig as well.  I used it in manufacturing aluminum parts with very old MK pulsers and PowCon pulsers, then we got new Millermatic 350P's.  I liked the 350P so much, I bought one for myself and I ended up with the MK and PowCon units after the company did the upgrade.   The company has since gone out of business but I am still pulsing (as well as all other processses of welding), on my own customers' projects.  If I were to buy a new pulse mig welder today, it would no doubt be the XMT 350 MPa, with a Suitcase feeder (since I already have an XR and a few Cobramatics).MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:I currently have a MK sytems pulsed setup setting above my office.  I tried to get that damn thing running right for two weeks.   Finally got fed the fark up and hooked the cobramatic to a VI-400 and never looked back.Im really likeing the new Miller XMT's with the pulsed built in but i dont know anyone around here that has one that i can fiddle with.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Come play with my lincoln.  David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Dualie, it just takes alot of time spent adjusting the on-time and off-time, assuming it's in working condition.   First get the volts and wire speed set so it's welding fine without the pulse, then add in the pulser and once you figure out the on and off times you like, you can adjust the voltage and wire feed speed for other applications and only make small adjustments to the pulser. On the pulse adjustments, I liked them both toward the middle, where some of the other welders at work liked the on time low and the off time very high or maxed.Don't feel bad if you can't get it running, out of the four I had, one we couldn't set at all, musta had some problem inside.  The other 3 worked fine,  but all differently from eachother.  This stuff is well over 20 years old.The new Miller pulsers are alot easier to set up and run than the old on-time/off-time or frequency/peak% pulsers, like the ones for the PowCon.Buying a used XMT 304 CC/CV and a new Optima would be alot cheaper than buying a new XMT 350 MPa and accomplish about the same thing, minus some max output power and maybe some pulse features.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:The Lincoln makes life easy for me. It has me set the size wire first, .030, .035, or ,045. The gas has to be  98/2 (argon/Oxygen) or argon and up to 20% Co2 will work.  I use 92 argon, 8% Co2 for lots of reasons. Then I set wire speed on the feeder and match that on the machine all in inches per minute.  From there its close or right on.  Fine tune by changing the wire speed a LITTLE to get the proper arc length.  There is a "wave" adjustment.  Higher is faster pulse and lower back ground current.  Lower is the opposite.  Start in the middle.  That is it.  Kinda simple like me.It also has choices for aluminum 4043, 5456 , Metal core,  stainless and nickel.  Then wire size has to be selected.  After that, set like above.For aluminum it also has pulse on pulse which makes the dimes.  In this case, the wave control sets the size or speed of the dimes.  I think it welds aluminum better on regular pulse.I don't need no stinkin dimes.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Their were entirely to many damned dials on that MK systems inverter pulse unit.    I still have it, wonder what the damn thing is worth without the feeder?  Cuz im sure as heck never going to use it again.I need another XMT To run NR-232 .072" anyway so maybe I will just bite the big bullet and get the Pulsed XMT and use it for multiple operations.IF the XMT MPa works as well as the pulse on their pipe pro system then It should be a sweet running some beach.    Besides I get some pretty decent results from just running the cobramatic off of the VI-400 with the adjustable inductance runs the wire good enough.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Oh you have a different MK pulser than the ones I have.  Mine are the Pulse + units, about the size of a home stereo reciever, completely seperate units that connect on the hot and work leads with Tweco connectors, no amphenols.   These were hooked up to old CP250TS power supplies between the power supply and the Cobramtic feeder.  They had only 3 controls- power on/off switch, pulse on-time and pulse off-time, that's it.The PowCon pulsers I have hook up on the 14-pin amphenol connector like a Miller Optima pulser.  I think they only work with PowCon power supplies though.  I used to use one of them on the 300SM untill the contactor went out.   Worked fine before that.The 350 MPa pulser appears to operate very similar to the pulse programming in my Millermatic 350P, going on comparing operator instructions for the XMT to how I use the 350P.  The difference is with the 350P, it's synergic, you don't set the voltage, just the wire speed.   With the XMT, you set the voltage like a regular mig welder.  They both have similar programming for 4043 & 5356 aluminum, mild steel, metal core and stainless.   The XMT adds programming for copper-nickel, silicon-bronze and HSLA that the 350P doesn't have.   I've never welded any of those metals so that wasn't important to me.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Originally Posted by DesertRider33Oh you have a different MK pulser than the ones I have.  Mine are the Pulse + units, about the size of a home stereo reciever, completely seperate units that connect on the hot and work leads with Tweco connectors, no amphenols.   These were hooked up to old CP250TS power supplies between the power supply and the Cobramtic feeder.  They had only 3 controls- power on/off switch, pulse on-time and pulse off-time, that's it.
Reply:No extra access doors on mine.  Just the switch and two pots on the front panel, that's it.   Mine are from the 1980's.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:heres the power unit i was talking about.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:HOLY CRAP!   Its even got a key so you can start it up!David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:That is way different from the ones I have, not even remotely similar.   Mine are MK Pulse +.   Your's has ALOT more controls to play with.  I don't think we would have ever been able to set that one up to weld, way too many variables to control.  It does look fancy though... MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Here is the owner's manual location for your MK 2000Ahttp://www.mkproducts.com/support/Ma...%20MK2000A.zipAnd for my MK Pulse +http://www.mkproducts.com/support/Ma...0Pulse%20+.zipMM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Yea I have the manuals and I even talked to the MK systems guy in Irvine for like 3 hours one day trying to get the damn thing to run right I was VERY VERY close to just smashing the damn thing with my 20 lb sledge.And turns out I couldn't set that thing up to weld either.  But the cobra matic feeder runs sweeeeeet off of a VI-400.   25 volts 370 IPM 0.035" 5356 superglaze she will lay sweet stacks of dimes on 1/4" aluminum all day long.I'm sure if you knew what the hell all of those settings did to the weld arc then you could set the machine to do some damn impressive welding.   But at the end of the day im JUST a welder so all those settings were a bit much for my brain.Oh and that key is to LOCK the cover over the small knobs.   Im sure once you get that thing dialed you want to post an armed guard in front of it to keep someone from bumping your settingsVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:LOL.  No doubt about the armed gaurd!I wouldn't mind giving that thing a try.  Not that I'm going to have any more luck with it than you did, but the experiment might be worth the effort just for fun.   If you're interested in trying a Pulse +, I'd be interested to trade with you.   I'm near San Diego.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:I love pulsed MIG.  The MM350P welders are so easy to set up.  Basically, you set the arc length for the material thickness and the wire feed depending on how fast you want to move the torch.  Run a fast wire feed for production welding and a slow wire feed for complicated shapes when you need time to manipulate the torch.The best part about the process, no spatter.If you do a lot of welding, pulsed mig can save you money on wire (spatter is wasted wire) and it will save you money on time because you wont have to do any post weld grinding.Last edited by 76GMC1500; 02-25-2009 at 10:19 PM.
Reply:I have friends and family in Huntington beach im down their a couple of times a month.    Might have to take you up on your offer.Plus its  a cheep reason to go all the way down to San Diego.  Then I can have dinner at the old town Mexican restaurant...I think "some" of my original problems with the pulse unit was the prince gun had a bad liner.     but like I said the prince still runs fine on the VI-400Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Dualie, sounds good.  Once I get the XR or the Spoolmatic set up to run from the XMT, you can come try out the pulsers and, if still interested in trading, pick whichever pulser you like best to take home with you.   I have 3 or 4 of them here to pick from.  There are a few good taco shops around here too.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:cool keep me informedVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.Will do.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Hey guys do you know of a way to get pulser for thermal arc 252i