Weld Control Selector Guide Product: Weld Control Selector Guide Manual: 091-0458 Revision: Oct 2003 Rev E The Most Comprehensive Guide to Connecting Prince® XL Spool Guns & Cobramatic® Wire Feed Systems to Welding Power Supplies
Safety Considerations ELECTRIC ARC WELDING EQUIPMENT CAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATION OR MAINTENANCE OF THIS EQUIPMENT 1-1 INTRODUCTION This equipment is intended for ultimate application by commercial/industrial users and for operation by persons trained and experienced in the use and maintenance of welding equipment. Operation should not be undertaken without adequate training in the use of such equipment.
Safety Considerations - Continued - A container with unknown contents should be cleaned (see paragraph above). Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut. Hollow castings or containers must be vented before welding or cutting. They can explode. Explosive atmospheres. NEVER weld or cut where the air may contain flammable dust, gas, or liquid vapors (such as gasoline). D.
Safety Considerations - Continued - very bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot, and compressed gases may be used. The wise operator avoids unnecessary risks and protects himself and others from accidents. A. Burn Protection Comply with precautions in 1-2. The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes.
ABOUT THIS GUIDE This Weld Control Selector Guide is designed to aid in selection and installation of various weld controls and Cobramatic feeders. The most popular power supplies from various manufacturers are covered, however, many others are not. The power supplies not covered in this guide can also be hooked up to Cobramatic feeders by modifying the connections. Spool-guns may also be hooked up by using a WC-1 control box. The exception to this is "synergic" type of power supplies.
Table of Contents Power Supply Listing Airco Esab Hobart Lincoln Miller Powcon Panasonic Thermal Dynamics 1 7 9 12 14 18 21 23 24 Appendix 25 Warranty Weld Control Selector Guide - Page v
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Weld Control Selector Guide Power Supply Control Required Optional Notes* Section Miller Electric Millermatic 35, Spoolmate 200 I M-5 Millermatic 200, Regency 250, 300, 350 A Millermatic 250, Vintage C 1, 6, 7 M-1, 3, 5 M-6 Millermatic 250-X, 251 D M-5, 6 CP-200, 250TS, 300, 302, MC-300VS A 1,6, 7 M-1, 2, 3 Shopmaster 300 A 7 M-1, 3 All Delta Welds, Pulstar 450, IntelliWeld 650 A 1, 6, 7 M-1, 3, 5 Arc Pak 350 A 1, 6, 7 M-1, 3 XMT-200, 300, 304 (Optima Excluded) A 6, 7, 8
Weld Control Selector Guide Power Supply Control Required Optional Notes* Section Lincoln Electric SP-150, 200 I SP-250 I B Wirematic 250, 255 I B PowerMig 255, 455 I DC-250, 400, 600, Pulse Power 500 I R3S-250, 325, 400 L-1 L-2 L-3 9 L-4 I CV-200, 250, 300, 400 L-7 L-4, 5 I, L Invertec V300-PRO, V350-PRO (Fac. & Adv.) Invertec V350-PRO (Contractor) L I I J (Rec.) TIG 250/300, Squarewave 300/350 I Weldanpower 225/250 I J (Rec.
Weld Control Selector Guide Power Supply Control Required Optional Notes* Section Hobart (Includes ThermalArc) BetaMig 200 B H-1 BetaMig 250, 251 I H-2 BetaMig 2510, IronMan 250 C H-2 M-6 Mega Mig RC/RBS, Fabstar I H-3 HT-1,2 Hobart Excel Arc CV, CV/CC I H-3 HT-1,2 Fabricator 210, 300LF I Fabricator 250 I T-2 Mega Flex RCC/RVS I H-3 HT-1 CyberTig, CyberWave I 2 H-4 Porta-Tig/Stick I 2 H-4 TR-250 I 2 M-8 TR-250HF I 2 H-4 TigWave 250, 350 I 2 H-4 2 H-4 11 J (
Weld Control Selector Guide Power Supply Control Required Optional Notes* Section 6 P-2 Powcon 200SM B 300SM I 300T, 300SS I P-1 2 P-4 400SS I 2 P-5 400SM, 400SMT, 630SMP B 1, 6 P-3 500SM, 500SM AC/DC B 6 P-3 500MP I Plasma +, 225SMC (Single Phase) B P-1 Plasma +, 225SMC (Three Phase) I P-1 K PA-1 6 P-2 Panasonic Gunslinger 260 Airco Dip-Pak 200, 225, 250 B 6 Dip-Cor 300 I CV-200, 250, 300, 450, 600 I PA-3A, PulseArc 350, 400, 500 I Pulse Arc II400, 500 I A
Weld Control Selector Guide Notes: 1. Miller power supply must have 14 pin Amphenol or the WC-1 must be used. See WC-1 hookup, section M-2. 2. Constant current (CC) power supplies can only be used in spray transfer mode with ALUMINUM and CORED wire only. 3. These power supplies put out less than 24VAC to the spool gun therefore maximum speed will not be obtained. This means 3/64 diameter wire should be used when welding materials thicker than 1/4. 4. Must be used in the non "synergic" mode. 5.
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Airco The PA-G1 Control (P/N 005-0264) is connected to the Dip-Pak 200 as follows: 1. Connect the red and green contactor leads extending from the Control to the spade connectors located next to the wire feed motor; red to wire to the left spade and green wire to the right spade. 2. Connect the black wire extending from the Control to the left spade along with the red and the white wire to #3 on the terminal strip located above the wire feed motor. 3.
Airco A-2 The WC-1 Weld Control or the Cobramatic Cabinet can be connected to the Dip-Cor 300 as follows: 1. Connect the black and white contactor leads extending from the WC-1 or Cobramatic to the spade connectors located on the center panel below the wire feed motor. Place the contactor in the CLOSING CONTACTS position (see Appendix for contactor information). 2. Plug the 115VAC plug extending from the WC-1 or Cobramatic into a standard wall outlet. 3.
ESAB (Includes L-Tec & Linde) E-1 The older L-Tec 225 is connected as follows: 1. Install 1/4 (.250) wide female spade connectors to the Black and White contactor wires extending from the WC-1 Weld Control or the Cobramatic Cabinet to the male spade connectors located on the inside wall of the welder by the wire feeder. First remove the existing trigger leads from the LTec torch. Place the WC-1 or Cobramatic in the CLOSING CONTACTS position (see Appendix for contactor information). 2.
ESAB (Includes L-Tec & Linde) E-5 The older Linde CV machines are connected as follows: 1. Connect the black and white contactor leads extending from the WC-1 Weld Control or the Cobramatic Cabinet to the 6-Pin metal Pyle-National plug; black to pin 3 and white to pin 5. Place WC-1 or Cobramatic in the 115VAC CONTACTOR position (See Appendix for changing contactor). 2.
ESAB (Includes L-Tec & Linde) E-5 The Prince XL Spool-gun may be hooked up to the ESAB 251cv Power Supply using the welders builtin speed control module. This is accomplished by using a MK adapter pigtail (P/N 003-1341) which will plug directly into the ESAB power supply's 8-Pin amphenol on the front of the machine. The lug on the Prince XL's power cable will have to be cut off and replaced by a male Dinse connector (MK P/N: 153-0755).
Hobart (Includes ThermalArc) H-1 The Prince XL Spool-gun may be hooked up to the BetaMig 200 or the BetaMig LF by using the PA-G1 Control (P/N 005-0264) as follows: 1. Open the left side of BetaMig. 2. Splice the red and green contactor leads extending from the Control to the spade connectors below the wire feed motor on the deck (trigger connection). 3. Remove the right side panel of BetaMig and locate the small control transformer next to the input voltage taps.
Hobart (Includes ThermalArc) H-4 The WC-1 Weld Control or the Cobramatic Cabinet can be connected to Hobart CC power supplies as follows (The contactor is always found on pins "A" and "B" regardless of the type of amphenol): All TIG machines use CLOSING CONTACTS! 5-Pin Amphenol 1. Connect the black and white contactor leads from the WCPlug 3106A18-20P 1 or Cobramatic to pins A & B of the remote amphenol: black to "A" and white to "B".
Lincoln Electric L-1 The SP-150 & 200 are interfaced using the WC-1 Weld Control or the Cobramatic Cabinet as follows: 1. Connect the black and white contactor leads extending from the WC-1 or Cobramatic to the 4-Pin plug located below the wire feed motor. Place the contactor in the CLOSING CONTACTS position (see Appendix for contactor information). 2. Plug the 115VAC plug extending from the WC-1 or Cobramatic into a standard wall outlet (in some cases 115VAC can be found at the fan motor). 3.
Lincoln Electric L-3 The Wirematic 250 and Wirematic 255 are interfaced using the WC-1 Weld Control or the Cobramatic Cabinet as follows: 1. Connect the black and white contactor leads from the WC-1 or Cobramatic to the two solid pins on the 4-Pin Amp plug (trigger plug). Place the contactor in the CLOSING CONTACTS position (see Appendix for contactor information). Back 2. Plug the 115VAC plug from the unit into a standard wall outlet. side of 3.
Lincoln Electric L-4 For all Lincoln CV power supplies except the R3S-325 the following applies. See section L-5 for the R3S-325. 1. Connect the black and white contactor leads from the WC-1 or Cobramatic to the terminal strip on the Lincoln power supply; black to 2 & white to 4. Place WC-1 or Cobramatic in CLOSING CONTACTS position (see Appendix for contactor information). 2.
Lincoln Electric A Cobramatic Cabinet and Torch can be used in conjunction with the Lincoln PowerMig 255: If a user already has a Prince Spool-gun with a WC-1 Control, The WC-1 would be hooked up the same. 1. Since there's no 115VAC easily available on the PowerMig 255, Plug the 115VAC plug from the WC-1 or Cobramatic into a standard wall plug. 2.
Miller Electric M-1 The PA-M1 Control (P/N 005-0261) comes equipped with a 14-Pin amphenol and simply plugs into the Miller power supply. If the unit is a CV/CC power supply operate in the "CV" mode; have the remote voltage selector on "panel" and the contactor selector on "14- Pin". Note - On the XMT series machines, a Dinse style connector (MK P/N 153-0755) would have to replace the lug on the power cable of the spool-gun.
Miller Electric M-4 The WC-1 Control Box or a Cobramatic system can also be connected to Miller CC power supplies with 14-Pin amphenols as follows: 1. Connect the black and white contactor leads from the WC-1 or Cobramatic to pins A & B of the 14-Pin amphenol; black to "A" and white to "B". Place the contactor in CLOSING CONTACTS position (see Appendix for contactor information). 2. Plug the 115VAC plug from the WC-1 or Cobramatic into a standard wall outlet. 3.
Miller Electric M-6 The Vintage/Millermatic 250/Hobart Beta-Mig 2510 kit P/N 005-0205 includes everything needed to attach to these power supplies. 1. The blank panel on the front of the unit is removed and the Spool Gun Control is put in its place. Both the push gun and the spool gun may be hooked-up at the same time. 2. For spool gun operation set the desired voltage on the Millermatic 250 front panel and set the wire speed on the bottom of the spool gun. 3.
Powcon P-1 The WC-1 Weld Control or the Cobramatic Cabinet is connected to Powcon power supplies as follows: 1. Connect the black and white contactor leads extending from the WC-1 or Cobramatic to pins 8 & 9 of the 14-Pin AMP plug; black to 8 and white to 9. Place the contactor in the CLOSING CONTACTS position (see Appendix for contactor information). 2.
Powcon P-4 The WC-1 Weld Control or the Cobramatic Cabinet is connected to Powcon power supplies as follows: 1. Connect the black and white contactor leads extending from the WC-1 or Cobramatic to pins 8 & 9 of the 14-Pin AMP plug; black to 8 and white to 9. Place the contactor in the CLOSING CONTACTS position (see Appendix for contactor information). 2. Plug the 115VAC plug extending from the WC-1 or Cobramatic into a standard wall outlet. 3. Add a jumper between pins 10 and 14. 4.
Panasonic PA-1 The Gunslinger 260 kit (P/N 005-0617) plugs directly into the amphenol on the front of the unit. The lug on the power cable of the Prince XL Spool-gun will be hooked up to the positive (+) terminal of the welder. It is inside the door housing the unit's wire feeder, just under the feeder. A Cobramatic Cabinet may be hooked up to the Gunslinger 260 as follows: 1. Plug the 115VAC plug extending from the Cobramatic Cabinet into a standard wall outlet. 2.
Thermal Dynamics (Includes ThermalArc) T-1 The WC-1 or Cobramatic can be connected to the Thermal Viking 210/250-GM power supplies as follows: 1. Connect the black and white contactor leads from the WC-1 or Cobramatic to the spade style terminal inside the door above the wire feed motor of the Viking unit. The contactor leads will replace the existing wires going to the two spades on the right side. Place the contactor in CLOSING CONTACTS position (see Appendix for contactor information). 2.
Appendix PosaStart Connections Contactor Output Configuration MK200 Contactor Box Connections WC-1 & Spool Gun Connections Spool Gun Controls Utility Style Welders Cobramatic Connectivity Prince XL Spool Gun Connectivity Weld Control Selector Guide - Page 25 27 28 29 30 31 32 33 34
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POSASTART CONNECTIONS The Cobramatic and Cobra II Wire Feeders each have, a single black 14 ga. wire with an alligator clip, extending from the back connected to the main board. This is the voltage sensing lead for the PosaStart circuit. In order for PosaStart to properly work, this lead must be connected to the welding GROUND. Typically, most power supplies will accept the PosaStart lead connected to either the work GROUND lug on their front panel or the GROUND clamp.
CONTACTOR OUTPUT CONFIGURATION Contactor Selection There are two types of contactor signals that various power supply manufacturers use. A "Closing Contact or Contactor" and a “115VAC Contactor” signal. Once the power supply contactor is closed, the welding leads become electrically live and are referred to as being “live” or “hot”. For the Closing Contactor type, the weld control simply touches the two contactor leads together (providing a continuity signal to the power supply) like a light switch.
MK200 CONTACTOR BOX CONNECTIONS 1. Remove the existing black and white contactor cord from WC-1 or Cobramatic. 2. Connect the leads extending from the contactor box to the WC-1/ Cobramatic main board as shown below. 115VAC INPUT WHITE BLACK GREEN COBRAMATIC / WC-1 WC-1MAIN & COBRAMATIC BOARD J5 1 2 3 4 115VAC CONTACTOR OUTPUT GREEN BLACK WHITE working with voltages present in this Product and others, CAUTION: When always observe warning and caution signs.
Weld Control Selector Guide - Page 30 GAS HOSE ELECTRICAL CABLE POWER CABLE POSASTART SENSING LEADS Red NOTE: The Posa Start feature permits the WC-1 to be used in combination with any Constant Current DC power source with an open circuit voltage in excess of 55 volts. Weld Control Box CONTACTOR LEADS GROUND COUPLER - AW-430-RH M.K.
SPOOL GUN CONTROLS FOR POWER SUPPLIES THAT SUPPLY AN AUXILIARY 26 VAC The PA-G1 is designed to hook-up to CV power supplies that supply an auxiliary 26 VAC @ 1.7 amps and uses a closing contact signal. The unit is supplied with bare wires that must be connected to the power supply.
UTILITY STYLE WELDERS There are many other welders made by companies like CK Systematics, Century Manufacturing, and some foreign manufactured machines that are capable of welding aluminum, utilizing the Cobramatic system or Prince XL Spool Guns. These units can usually be broken down into two categories. 1. A utility MIG welder with the wire feeder built into the unit. These units need to be in 200 to 275 amp range and operate from 208/230/460 Volts 2.
Cobramatic COBRAMATIC CONNECTIVITY ® “Show Us Your Colors” Prince® XL Pistol Grip CobraMAX™ Gooseneck Torch Python® Advanced Gooseneck SVI 450i 120VAC Output 19 Pin V350PRO 120VAC Output 14 Pin XMT 304 120VAC Output 14 Pin Ultra Flex™ 350 120VAC Output 19 & 14 Pin Cobra Welding Systems Weld Control Selector Guide - Page 33
Prince XL Spool Gun PRINCE XL®SPOOL GUN CONNECTIVITY PowerMIG 300 MillerMatic 251 Fabricator 250 MultiMaster 260 Gunslinger 260 Direct Connect Interface Cable 005-0629 Interface Cable 005-0689 Interface Cable 005-0617 Interface Cable 005-0206 PA-L1 005-0676 Interface Cable 005-0206 PA-M-1 005-0261 PA-M-1 005-0261 Migmaster 250 V350PRO XMT 304 Ultra Flex™ 350 Cobra Welding Systems Weld Control Selector Guide - Page 34
3 YEAR LIMITED WARRANTY Effective February 1, 2003 This warranty supersedes all previous MK Products warranties and is exclusive, with no other guarantees or warranties expressed or implied. LIMITED WARRANTY - MK Products, Inc., Irvine, California warrants that all new and unused equipment furnished by MK Products is free from defects in workmanship and material as of the time and place of delivery by MK Products.
www.mkproducts.com 16882 Armstrong Ave.
