Table of Contents
Troubleshooting
Related Manuals for CK WORLDWIDE MT200-AC/DC
Summary of Contents for CK WORLDWIDE MT200-AC/DC
- Page 1 MT200-AC/DC MT200-AC/DC WELDING MACHINE OWNER’S MANUAL THE STANDARD IN TIG WELDING FORM MT200-OM Please read and understand this instruction manual carefully before operating this equipment. CSA E60974-1 www.CKWORLDWIDE.com...
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Page 2: W Arranty Overview
At CK Worldwide, we take pride in the trusted quality, innovation, and support we deliver to our customers and the TIG welding community as a whole. The MT200-AC/DC is the next step in our progression as “The Standard in TIG Welding” marking the continuing evolution of CK Worldwide. This TIG Welding System is the latest development in inverter technology. -
Page 3: Table Of Contents
CONTENTS PAGE arranty Overview ................................Machine Operating Safety 4–5 ............................THE STANDARD MT200-AC/DC Machine Overview ..........................IN TIG WELDING MT200-AC/DC System Components ........................MT200-AC/DC Specifications ............................Machine Layout & Descriptions ..........................Front Panel Selector Switch Function Descriptions REPAIRS ................Front Panel Control Dial Function Descriptions .................. -
Page 4: Machine Operating Safety
SAFETY Welding and cutting equipment can be dangerous to both the operator and people in or near the surrounding working area, if the equipment is not correctly operated. Equipment must only be used under the strict and comprehensive observance of all relevant safety regulations. Read and understand this instruction manual carefully before the installation and operation of this equipment. - Page 5 FIRE HAZARD: Welding on closed containers, such as tanks, drums, or pipes, can cause them to explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
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Page 6: Mt200-Ac/Dc Machine Overview
The MT200-AC/DC has set the benchmark for 220V/115V single phase AC/DC welders and is ideal for multiple applications; aluminum and stainless steel fabrication, light industrial use, repair and maintenance. -
Page 7: Mt200-Ac/Dc System Components
SYSTEM COMPONENTS COMPLETE WELDING SYSTEM INCLUDES: • MT200-AC/DC • CK17 Flex-Head Torch with 12.5' (3.8m) Super-Flex Cable ™ CK17-12-RSF FX CK17 FLEX-HEAD TORCH Flexible torch CK-17-12-RSF FX • Dinse Connector SL2-35MT neck for precise positioning 150 amp ACHF or DCSP @ 100% •... -
Page 8: Mt200-Ac/Dc Specifications
• Adjustable Background Current: 10 – 100% • Adjustable Post Gas: 0.5 – 20 seconds • DC SMAW (stick) • Remote Amperage Control MT200-AC/DC SPECIFICATIONS Input Voltage 115VAC ±15%, 50/60Hz Max. Open Circuit Volts 74 volts 220VAC ±15%, 50/60Hz, Gas Pre-flow 0.5 seconds... -
Page 9: Machine Layout & Descriptions
FRONT VIEW Amperage Display Pulse Selector Remote Control Selector TIG/Stick AC/DC Selector Selector Amperage Selector AC Frequency Background Control Amps Control The blue zones on the control dial indicators are standard starting positions for most TIG welding operations. Pulse AC Balance Frequency Control Control... -
Page 10: Front Panel Selector Switch Function Descriptions
ON/OFF: This switch powers the machine up when switched to the on position and powers the machine down when switched to the off position. NOTE: The On/Off switch is on the back of the MT200-AC/DC. AC/DC: Provides selection of AC or DC current in TIG mode. -
Page 11: Front Panel Control Dial Function Descriptions
CONTROL DIAL FUNCTION DESCRIPTIONS The blue zones on the control dial indicators are standard starting positions for most TIG welding operations. AMPS: Provides adjustment and POST GAS FLOW: Provides adjustment control of the main welding current. and control of gas flow after the Adjustment range 5–... -
Page 12: Cautions / Maintenance / Trouble Shooting
2.3 Over-Voltage Supply: Regarding the power supply voltage range of the machine, please refer to Specifications. The MT200-AC/DC features automatic voltage compensation within the given range. If the input power exceeds the stipulated value, it is possible to cause damage to the components of this equipment. -
Page 13: Machine Installation & Operation
We recommend that you close the cylinder valve when the machine is not in use. CK Worldwide, Inc. authorized representatives or agents of CK Worldwide, Inc. will not be liable or responsible for the loss of any gas. -
Page 14: Set Up & Operation For Dc Tig Welding
INSTALLATION SET-UP FOR DC TIG WELDING INSTALLATION SET UP FOR DC TIG WELDING Turn on the machine using the ON/OFF switch (located Connect the foot pedal remote lead into the on the back of the machine). remote socket. Select the TIG function with the TIG/STICK selector switch. Connect the torch gas connector into the gas receptacle. - Page 15 OPERATION FOR DC TIG WELDING HF (high frequency) ignition allows the arc to be started in TIG welding without touching the tungsten to the work piece. By depressing the foot pedal the machine will activate the gas flow and the HF ignition resulting in the arc igniting across the gap between the tungsten electrode and the work piece.
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Page 16: Dc Tig Welding
DC TIG WELDING The DC power source produces what is known as DC (direct current) in which the main electrical component known as electrons flow in only one direction from the negative pole (terminal) to the positive pole (terminal). In the DC electrical circuit there is an electrical principle at work which should always be taken into account when using any DC circuit. -
Page 17: Pulse Tig Welding, Pulse Dc Tig Welding
Pulsed output allows for controlled heating and cooling periods during welding, providing better The MT200-AC/DC has operator control of heat input, weld penetration and weld appearance. three variables within The MT200-AC/DC has three variables within the pulse cycle: the pulse cycle: Peak Current - Background Current - Pulse Frequency Peak Current... -
Page 18: Example: Pulse Dc Tig Welding
EXAMPLE OF PULSE DC TIG WELDING PULSE DC TIG WELDING — SET UP PARAMETERS: The following steps are a guide for you to set the machine up in Pulse mode. You can experiment by changing any of the variables to see what effect it has over the weld. It is suggested that you change only one variable at a time and then check the results. -
Page 19: Tig Welding Fusion And Filler Wire Technique
TIG WELDING FUSION/FILLER WIRE TECHNIQUES TIG WELDING FUSION TECHNIQUE Manual TIG welding is often considered the most difficult of all the welding processes. Because the welder must maintain a short arc length, great care and skill are required to prevent contact between the electrode and the work piece. -
Page 20: Set Up & Operation For Ac Tig Welding
INSTALLATION SET-UP FOR AC TIG WELDING INSTALLATION SET UP FOR AC TIG WELDING Turn on the machine using the ON/OFF switch (located Connect the foot pedal remote lead into the on the back of the machine). remote socket. Select the TIG function with the TIG/STICK selector switch. Connect the torch gas connector into the gas receptacle. - Page 21 The tungsten electrode requires a sharpened point for AC welding with the MT200-AC/DC. Set the maximum welding current (amps) to be used with the Amps control knob, observing the value set on the digital display.
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Page 22: Traditional Vs. Square Wave Technology Ac Tig Welding
AC TIG WELDING TRADITIONAL AC TIG WELDING EQUIPMENT AC (alternating current) enables you to TIG weld non-ferrous alloys like aluminum, magnesium and aluminum alloys. These materials have an insulating surface oxide layer that melts at a higher AC (alternating current) temperature than the base metal making it difficult to weld the base metal if the oxides are not enables you to TIG weld removed. - Page 23 POLARITY EVEN BALANCE EVEN BALANCE MT200-AC/DC SQUARE WAVE TECHNOLOGY A square wave power supply can change the current from electrode + positive to electrode – negative very quickly. This produces high voltage as the current switches polarities allowing the arc to restart easily. The arc can be maintained without the use of high-frequency or any other arc stabilizing methods.
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Page 24: Example: Pulse Ac Tig Welding
EXAMPLE OF PULSE AC TIG WELDING PULSE AC TIG WELDING — SET UP PARAMETERS: Material = aluminum x 1/8" Tungsten Electrode = 3/32" Zirconiated Gas = Argon The following steps are a guide for you to set the machine up in AC Pulse mode. You can experiment by changing any of the variables to see what effect it has over the weld. -
Page 25: Remote Controls: Installation And Operation
REMOTE AMPERAGE CONTROL INSTALLATION & OPERATIONS CK WORLDWIDE Remote amperage controls allow for the welding current to be adjusted remotely from the welding REMOTE AMPERAGE machine during welding. Generally there are several types of remote amperage control available: CONTROL OPTIONS •... -
Page 26: Set Up & Operation For Smaw (Stick) Welding
INSTALLATION SET-UP FOR SMAW (STICK) WELDING INSTALLATION SET UP FOR SMAW (STICK) WELDING Turn the power source on and select the STICK function with the TIG/STICK selector switch. Connection of Output Cables Two weld output receptacles are available on this welding machine. For Stick welding the electrode holder is connected to the positive receptacle, while the ground lead (work piece) is connected to the negative receptacle, this is known as DC+ polarity. - Page 27 OPERATION FOR SMAW (STICK) WELDING Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer. Place the electrode into the electrode holder and clamp tight. Scratch the electrode against the work piece to create an arc and hold the electrode steady to maintain the arc.
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Page 28: Smaw (Stick) Welding Description / Fundamentals
SMAW (STICK) WELDING GENERAL DESCRIPTION One of the most common types of arc welding is shielded metal arc welding (SMAW) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives off gaseous vapors that serve as a shielding gas and provide a layer of slag, both of which protect the weld area from atmospheric contamination. -
Page 29: Arc Length
SMAW (STICK) WELDING FUNDAMENTALS ELECTRODE SELECTION As a general rule, the selection of an electrode is straight forward, in that it is only a matter of selecting an electrode of similar composition to the parent metal. However, for some metals there is a choice of several electrodes, each of which has particular properties to suit specific classes of work. -
Page 30: Tungsten Electrode Selection & Preparation
TUNGSTEN ELECTRODES Tungsten is a rare metallic element used for manufacturing TIG welding electrodes. The TIG process relies on tungsten’s hardness and high- temperature resistance to carry the welding current to the arc. Tungsten has the highest melting point of any metal at 6,192° F (3,422°C). Tungsten electrodes are nonconsumable and come in a variety of sizes, they are made from pure tungsten or an alloy of tungsten and other rare earth elements. -
Page 31: Tungsten Preparation
TUNGSTEN PREPARATION Always use diamond wheels when grinding and cutting tungsten. While tungsten is a very hard material, the surface of a diamond wheel is harder, and this makes for smooth grinding. Grinding without diamond wheels, such as aluminum oxide wheels, can lead to jagged edges, imperfections, or poor surface finishes not visible to the eye that will contribute to weld inconsistency and weld defects. - Page 32 TUNGSTEN PREPARATION AC / DC TIG WELDING ELECTRODE INCLUDED ANGLE/TAPER FOR SQUARE WAVE TIG WELDING Tungsten electrodes for welding should be ground longitudinally and concentrically with diamond wheels to a specific included angle in conjunction with the tip/flat preparation. Different angles produce different arc shapes and offer different weld penetration capabilities.
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Page 33: Troubleshooting Guide - Smaw (Stick) Welding
SMAW (STICK) WELDING TROUBLESHOOTING The following chart addresses some of the common problems of SMAW (Stick) welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. 1: No arc POSSIBLE REASON SUGGESTED REMEDY Incomplete welding circuit Confirm that the ground clamp is connected. -
Page 34: Troubleshooting Guide - Gtaw (Tig) Welding
GTAW (TIG) WELDING TROUBLESHOOTING The following chart addresses some of the common problems of TIG welding. In all cases of equipment malfunction, the manufacturer’s recommendations should be strictly adhered to and followed. 1: Tungsten burning away quickly POSSIBLE REASON SUGGESTED REMEDY Incorrect Gas Check that pure Argon is being used. - Page 35 GTAW (TIG) WELDING TROUBLESHOOTING 7: HF present but no welding power POSSIBLE REASON SUGGESTED REMEDY Incomplete welding circuit Confirm that the ground clamp is connected. Check all cable connections. Check that the power cable is not separated. No gas Check the gas is connected and cylinder valve open, check hoses, gas valve and torch are not restricted. Set the gas flow between 15–25 CFH (7–12 LMN) flow rate.
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Page 36: Tig Torch Parts
CK17 TIG TORCH PACKAGES • Gas-Cooled INCLUDED WITH THE MT200-AC/DC WELDING MACHINE • 150 amp ACHF or DCSP CK17 FLEX @ 100% HEAD STYLE CABLE CABLE LENGTH STANDARD # SUPER-FLEX # • 8-1/8" (20.6cm) 12½ ft. (3.8m) CK17-12-R FX CK17-12-RSF FX... - Page 37 CK17 TIG TORCH CABLES & CONNECTORS POWER CABLES/HOSES STANDARD SUPER-FLEX 1 PIECE SUPER-FLEX POWER CABLE (INCLUDED WITH MT200-AC/DC) LENGTH 1 PIECE CABLE 1 PIECE CABLE 12-1/2 ft. (3.8m) 57Y01R 57Y01RSF 57Y03R 57Y03RSF 25 ft. (7.6m) 3/8"-24 RH 3/8"-24 RH 1 PIECE STANDARD POWER CABLE 3/8"-24 RH...
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Page 38: Warranty Terms
This Warranty covers material and faulty workmanship defects CK Worldwide, Inc. warrants products manufactured only. This Warranty does not cover damage caused by: by CK Worldwide to be free of defects in materials • Normal wear and tear due to usage and workmanship. -
Page 39: Additional Tig Products
ADDITIONAL PRODUCTS Tungsten Electrode Grinder • Enclosed electrode grinder minimizes grinding dust exposure to both the user and the environment • Standard head for diameters: .040" (1.0mm) 1/16" (1.6mm), 3/32" (2.4mm), and 1/8" (3.2mm) • Angles adjustable from 20°– 60° •... - Page 40 , and LaYZr ™ are trademarks of CK Worldwide Inc. Phone: 1.800.426.0877 Fax: 1.800.327.5038 CK Worldwide, Inc. PO Box 1636, Auburn, WA 98071 USA www.CKWORLDWIDE.com CONNECT WITH US ON: © 2016 CK Worldwide, Inc. All rights reserved. S/WD #108921 4/2016...
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