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Arc-Zone MT200-AC/DC Owner's Manual

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Summary of Contents for Arc-Zone MT200-AC/DC

  • Page 2: Warranty

    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 4 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

    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.
  • Page 6 MT200-AC/DC WELDING MACHINE “As a welder of critical aircraft hardware, this machine is extremely easy to use and runs as smooth as our more expensive machines at work. ” – R. Harper, AIRCRAFT WELDER, 38 YEARS EXPERIENCE OVERVIEW www.CKWORLDWIDE.com...

  • Page 7: System Components

    SYSTEM COMPONENTS COMPLETE WELDING SYSTEM INCLUDES: M INCLUDES: MT200-AC/DC CK17 Flex-Head Torch with 12.5' (3.8m) Super-Flex ™ Cable CK17 FLEX-HEAD TORCH CK17 FLEX-HEAD Dinse Connector 150 amp ACHF or DCSP @ 100% 150 amp ACHF or D AK-3 Accessories/Consumables Kit...
  • Page 8 WELDS: Aluminum, Zinc Alloy, Carbon Steels, Alloy Steels, Stainless, Cast Iron, Bronze, Copper GTAW (TIG)/SMAW (Stick) 200 Amp AC/DC Inverter Welder Square Wave AC High Frequency (HF), Pulse, Post Gas, Remote, MT200-AC/DC SPECIFICATIONS 115VAC ±15%, 50/60Hz 74 volts 220VAC ±15%, 50/60Hz, 0.5 seconds...

  • Page 9: Front View

    FRONT VIEW The blue zones on the control dial indicators are standard starting positions for most TIG welding operations. BACK VIEW (Located on the back of the machine) www.CKWORLDWIDE.com...
  • Page 10 SELECTOR SWITCH FUNCTION DESCRIPTIONS ON/OFF: NOTE: The On/Off switch is on the back of the MT200-AC/DC. AC/DC: PANEL/REMOTE: REMOTE PULSE SELECTOR: PULSE ON PULSE OFF TIG/STICK: STICK www.CKWORLDWIDE.com...
  • Page 11 CONTROL DIAL FUNCTION DESCRIPTIONS The blue zones on the control dial indicators are standard starting positions for most TIG welding operations. AMPS: POST GAS FLOW: AC FREQUENCY: PULSE FREQUENCY: AC BALANCE: BACKGROUND AMPS:...

  • Page 12: Working Environment

    CAUTION 1. WORKING ENVIRONMENT Good ventilation is of 2. SAFETY TIPS critical importance 2.1 Ventilation: for the normal performance and service life of this equipment 2.2 Thermal Overload Protection: 2.3 Over-Voltage Supply: MAINTENANCE Exposure to extremely dusty, damp, or corrosive air is damaging to the welding machine For your safety and...
  • Page 13 INSTALLATION & OPERATION Please install the machine strictly according to the following steps. Avoid using this machine in the rain The protection class of this machine is IP21S, so avoid using it in rain. CONNECTION OF INPUT CABLES ATTENTION! CHECK FOR GAS LEAKS RECOMMENDED PROCEDURE IS AS FOLLOWS: At initial set up and at regular intervals we...
  • Page 14 INSTALLATION SET-UP FOR DC TIG WELDING INSTALLATION SET UP FOR DC TIG WELDING (located on the back of the machine). Valve located underneath the safety cover. (located on the back of the machine).
  • Page 15 OPERATION FOR DC TIG WELDING Having trouble? Please see GTAW (TIG) troubleshooting information on pages 34 & 35...

  • Page 16: Dc Tig Welding

    DC TIG WELDING Argon Power source Nozzle current HF ARC IGNITION FOR TIG WELDING High current Gas flow Plasma molecules ..stream www.CKWORLDWIDE.com...
  • Page 17 PULSE TIG WELDING The MT200-AC/DC has 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 Background Current Pulse Frequency PEAK CURRENT BACKGROUND CURRENT PULSE FREQUENCY...
  • Page 18 EXAMPLE OF PULSE DC TIG WELDING PULSE DC TIG WELDING — SET UP PARAMETERS: TIME = 1 SECOND PULSE WIDTH PEAK CURRENT BACKGROUND AMPS www.CKWORLDWIDE.com...

  • Page 19: Tig Welding Fusion Technique

    TIG WELDING FUSION/FILLER WIRE TECHNIQUES TIG WELDING FUSION TECHNIQUE TIG FUSION TECHNIQUE 75° Form a weld pool Angle torch Move the torch slowly and evenly forward TIG WELDING WITH FILLER WIRE TECHNIQUE TIG FILLER WIRE TECHNIQUE 75° Travel direction 15° Form a weld pool Angle torch Add TIG filler wire...
  • Page 20 INSTALLATION SET-UP FOR AC TIG WELDING INSTALLATION SET UP FOR AC TIG WELDING (located on the back of the machine). Valve located underneath the safety cover. (located on the back of the machine).
  • Page 21 OPERATION FOR AC TIG WELDING Having trouble? Please see GTAW (TIG) troubleshooting information on pages 34 & 35 www.CKWORLDWIDE.com...

  • Page 22: 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. REVERSE POLARITY direct polarity current CURRENT reverse polarity STRAIGHT POLARITY REVERSE POLARITY CURRENT STRAIGHT POLARITY HIGH-FREQUENCY VOLTAGE UNBALANCED WAVE FORM IN THE WELDING CIRCUIT REVERSE...
  • Page 23 AC TIG WELDING REVERSE POLARITY CURRENT STRAIGHT POLARITY EVEN BALANCE MT200-AC/DC SQUARE WAVE TECHNOLOGY BALANCED SQUARE WAVE FORM REVERSE POLARITY CURRENT Even penetration, stable arc STRAIGHT POLARITY LESS POSITIVE BALANCE BALANCE ADJUSTED FOR MORE PENETRATION / COOLER TUNGSTEN REVERSE POLARITY...

  • Page 24: Pulse Width

    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 TIME = 1 SECOND PULSE WIDTH PEAK CURRENT BACKGROUND AMPS www.CKWORLDWIDE.com...
  • Page 25 REMOTE AMPERAGE CONTROL INSTALLATION & OPERATIONS CK WORLDWIDE REMOTE AMPERAGE CONTROL OPTIONS HAND AMPERAGE CONTROL FOOT AMPERAGE CONTROL ™ Steady-Grip SLIDING POTENTIOMETER (torch not included) CONNECTION AND OPERATION OF THE REMOTE FOOT CONTROL Rotary Amperage Control Rotary Amperage Control ROTATING BELT POTENTIOMETER ROTATING BELT POTENTIOMETER ROTATING BELT POTENTIOMETER ROTATING BELT POTENTIOMETER...
  • Page 26 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 DC+ Electrode connected to output receptacle. DC- Electrode connected to output receptacle.
  • Page 27 OPERATION FOR SMAW (STICK) WELDING Having trouble? Please see SMAW (Stick) troubleshooting information on pages 33 www.CKWORLDWIDE.com...
  • Page 28 SMAW (STICK) WELDING GENERAL DESCRIPTION Metal core Flux coating Gas shield from flux melt Arc with core wire melt Flux residue forms slag cover Weld metal Metal core Flux coating Base metal Protective > producing a protective gas around the weld area >...
  • Page 29 SMAW (STICK) WELDING FUNDAMENTALS ELECTRODE SELECTION ELECTRODE SIZE ELECTRODE SIZE Maximum Recommended Average Thickness of Material Electrode Diameter 0.03 – 0.07 inches 0.75 – 2mm 3/32 inch 2.4mm 0.07 – 0.19 inches 2 – 4.8 mm 1/8 inch 3.2mm 0.19 – 0.31 inches 4.8 –...

  • Page 30: Tungsten Electrode Current Ranges

    TUNGSTEN ELECTRODES TUNGSTEN ELECTRODE CHARACTERISTICS Tungsten Color Code Characteristics Provides good arc stability for AC welding. Reasonably good resistance to contamination. Lowest Pure current carrying capacity. Least expensive. Maintains a balled end. Used on transformer based Green machines only. Similar performance to thoriated tungsten. Easy arc starting, good arc stability, long life. 2% Ceriated Possible replacement for thoriated.

  • Page 31: Tungsten Preparation

    TUNGSTEN PREPARATION TUNGSTEN GRINDING Use a medium (60 grit or finer) The included angle determines weld bead shape and size. Generally, as the included angle increases, penetration increases and bead width decreases. TUNGSTEN TIP PREPARATION TUNGSTEN EXTENSION DC TIG WELDING STANDARD PARTS Flat: 1/4 TO 1/2 X Diameter General Purpose 3 X Diameter...
  • Page 32 TUNGSTEN PREPARATION AC / DC TIG WELDING ELECTRODE INCLUDED ANGLE/TAPER FOR SQUARE WAVE TIG WELDING In general, blunter electrodes that have a larger included angle provide the following benefits: Flat spot diameter Included angle Sharper electrodes with smaller included angle provide: SAFETY WITH TUNGSTEN ELECTRODES The risk of injury when hand (manually)
  • Page 33 SMAW (STICK) WELDING TROUBLESHOOTING 1: No arc Incomplete welding circuit Wrong mode selected No power supply 2: Porosity − small cavities or holes resulting from gas pockets in weld metal. Arc length too long Work piece dirty, contaminated or moisture Damp electrodes 3: Excessive Spatter Amperage too high...
  • Page 34 GTAW (TIG) WELDING TROUBLESHOOTING 1: Tungsten burning away quickly Incorrect Gas No gas Inadequate gas flow Back cap not fitted correctly Torch connected to DC + Incorrect tungsten being used Tungsten being oxidized after weld is finished Tungsten melting back into the nozzle on AC welding 2: Contaminated tungsten Touching tungsten into the weld pool...
  • Page 35 GTAW (TIG) WELDING TROUBLESHOOTING 7: HF present but no welding power Incomplete welding circuit No gas Tungsten melting into the weld pool 8: Arc wanders during DC welding Poor gas flow Incorrect arc length Tungsten incorrect or in poor condition Poorly prepared tungsten Contaminated base metal Contaminated filler wire...
  • Page 36 CK17 TIG TORCH PACKAGES Gas-Cooled 150 amp ACHF or DCSP @ 100% HEAD STYLE CABLE CABLE LENGTH STANDARD # SUPER-FLEX # 8-1/8" (20.6cm) CK17-12-R FX CK17-12-RSF FX CK17 FX CK17 FX 5 oz (141gm) CK17-25-R FX CK17-25-RSF FX 3 Series Head Accessories HEAD STYLE CABLE...
  • Page 37 CK17 TIG TORCH CABLES & CONNECTORS POWER CABLES/HOSES STANDARD SUPER-FLEX (INCLUDED WITH MT200-AC/DC) LENGTH 1 PIECE CABLE 1 PIECE CABLE 57Y01R 57Y01RSF 57Y03R 57Y03RSF DINSE CONNECTOR TORCH BODIES / HANDLES PART # STYLE CK17 RG RIGID DINSE 35 CK17 FX FLEX (1/2"...

  • Page 38: Warranty Information

    WARRANTY INFORMATION WARRANTY EXCLUSIONS WARRANTY This Warranty covers material and faulty workmanship defects only. This Warranty does not cover damage caused by: WARRANTY PERIOD We offer the following warranty periods from date of purchase. This Warranty does not cover products purchased: Inverter TIG (Power Source Only) 3 Years 3 year warranty on transformers, inductor and rectifier.

  • Page 39: Additional Products

    ADDITIONAL PRODUCTS ADDITIONAL PRODUCTS Tungsten Electrode Grinder Enclosed electrode grinder minimizes grinding grinding dust exposure to both the user and the environment environment Standard head for diameters: .040" (1.0mm) 0mm) 1/16" (1.6mm), 3/32" (2.4mm), and 1/8" (3.2mm) " (3.2mm) Angles adjustable from 20°– 60° Consistent tip geometry Eliminate grinding wheel contamination Both sides of grinding disks are coated...

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