MK Products MK 2000A User Manual
MK2000A Inverter Power Supply
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16882 Armstrong Ave., Irvine, CA 92606 TEL (949) 863-1234 FAX (949) 474-1428 www.mkproducts.com
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
app lication by com mercial/industrial
users and for operation by persons
trained and experienced in the use and
maintenanc e of welding equipment.
Operation should not be under taken
without adequate training in the use of
such equipment. Training is available
from many public and private schools or
similar facilities.
Safe practices in the installation, operation and maintenance of this equipment
requires proper training in the ar t, a
careful study of the information provided
with the equipme nt, and the use of
common sense. Rule s fo r safe use
are generally provided by suppliers of
welding power sources, compressed
gas suppliers, and electrode suppliers.
Careful compliance with these rules will
promote safe use of this equipment.
The following Safety Rules cover some
of the more generally found situations.
READ THEM CAREFULLY. In case of
any doubt, obtain qualied help before
proceeding.
1-2 GENERAL PRECAUTIONS
A. Burn Prevention
ELECTRIC ARC WELDING PRODUCES
HIGH INTENSITY HEAT AND ULTRAVIOLET RADIANT ENERGY WHICH
MAY CAUSE SERIOUS AND PERMANENT EYE DAMAGE AND WHICH
MAY DAMAGE ANY EXPOSED SKIN
AREAS.
Wear helm et with safet y goggles or
glasses with side shields underneath,
appropriate lter lenses or plates (protected by clear cover glass). This is a
must for welding or cutting (and chipping)
to protect the eyes from radiant energy
and ying metal. Replace cover glass
when broken, pitted, or spattered.
Medical rst aid and eye treatment. First
aid fac ilities and a qualified first aid
person should be available for each shift
unless medical facilities are close by for
immediate treatment of ash burns of
the eyes and skin burns.
Wear protective clothing - leather (or
asbestos) gauntlet gloves, hat, and high
safety-toe shoes. Button shirt collar and
pocket aps, and wear cufess trousers
to avoid entry of sparks and slag.
Avoid oily or greasy clothing. A spark
may ignite them.
Flammable hair preparations should not
be used by persons intending to weld
or cut.
Hot metal such as electrode stubs and work
pieces should never be handled without
gloves.
Ear plugs should be worn when working
on overhead or in a conned space. A
hard hat should be worn when others work
overhead.
B. Toxic Fume Prevention
WARNING: The use of this product may
result in exposure to chemicals known
to the State of California to cause cancer
and birth defects or other reproductive
harm.
Adequate ventilation. Severe discomfort,
illness or death can result from fumes,
vapors, heat, or oxygen enrichment or
depletion that welding (or cu tting) may
pro duc e. Prevent them with adequate
ventilation. NEVER ventilate with oxygen.
Lead-, cadmium-, zinc-, mercury-, beryllium-bearing and similar materials, when
welded or cut, may produce harmful concentrations of toxic fumes. Adequate local
exhaust ventilation must be used, or each
person in the area, as well as the operator,
must wear an air-supplied respirator. For
beryllium, both must be used.
Metals coated with or containing materials
that emit toxic fumes should not be heated
unless coating is removed form the work
surface, the area is well ventilated, or the
operator wears an air-supplied respirator.
Work in a conned space only while it is
being ventilated and, if necessary, while
wearing an air-supplied respirator.
Gas leaks in a conned space should be
avoided. Leaked gas in large quantities can
change oxygen concentration dangerously.
Do not bring gas cylinders into a conned
space.
Leaving confined space, shut OFF gas
supply at source to prevent possible accumulation of gases in the space if downstream valves have bee n accide ntally
opened or left open. Check to be sure that
the space is safe before reentering it.
Vapors from chlorinated solvents can be
decomposed by the heat of the arc (or
ame) to form PHOSGENE, a highly toxic
gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the
arc can also decompose trichloroethylene
and perchl oroethylene vapo rs to form
phosgene. DO NOT WELD or cut where
so lvent vapors can be drawn int o the
welding or cutting atmosphere or where
the radiant energy can penetrate to atmospheres containing even minute amounts of
trichloroethylene or perchloroethylene.
C. Fire and Explosion Prevention
Causes of fire and explosion are: com-
bustibles reac hed by the arc, flame,
ying sparks, hot slag, or heated material, misuse of compressed gases and
cylinders, and short circuits.
BE AWARE THAT ying sparks or falling
slag can pass through cracks, along
pipes, through windows or doors, and
through wall or oor openings, out of
sight of the goggled operator. Sparks
can y many feet.
To prevent res and explosion:
Keep equipment clean and operable,
free of oil, grease, and (in el ectrical
parts) of metallic particles that can cause
short circuits.
If combustibles are in area, do NOT weld
or cut. Move the work if practicable,
to an area free of combustibles. Avoid
paint spray rooms, dip tanks, storage
areas, ventilators. If the work cannot
be moved, move combustibles at least
35 feet away, out of reach of sparks and
heat; or protect against ignition with
suitable and snug-tting, re-resistant
covers or shields.
Walls touching combustibles on opposite
sides should not be welded on (or cut).
Wal ls, ce ilings, and floor nea r work
should be protected by heat-resistant
covers or shields.
Fire watcher must be standing by with
suitable fire extinguishing equipment
during and for some time after welding
or cutting if:
1. Appreciable combustibles (including
building construction) are within 35 feet.
2. Appreciable combustibles are further
th an 35 fee t, but ca n be i gnited by
sparks.
3. Openings (concealed or visible) in
oors or walls within 35 feet may expose
combustibles to sparks.
4. Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be
ignited by radiant or conducted heat.
Hot work permit should be obtained
before operation to ensure supervisor’s
approval that adequate precautions have
been taken.
After work is done, check that area is
free of sparks, glowing embers, and
ames.
An empty container that held combustibles, or that can produce ammable or
toxic vapors when heated, must never
be welded on or cut, unless container
has rst been cleaned in accordance
with industry standards.
This inclu de s: a th orough ste am or
caustic cleaning (or a solvent of water
washing, depending on the combustible’s
solubility), followed by purging and inerting with nitrogen or carbon dioxide, and
using protective equipment.
Water-lling just below working level may
substitute for inerting.
A containe r with unknow n 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 ammable
dust, gas, or liquid vapors (suc h as
gasoline).
D. Compressed Gas Equipment
The safe handling of compressed gas
eq ui pm ent is det ailed in num er ous
industry publications. The foll owing
general rules cover many of the most
common situations.
1. Pressure Regulators
Regulator relief valve is des igned to
protect only the regulator from overpressure; it is not intended to protect
any downstream equipment. Provide
such protection with one or more relief
devices.
Never connect a regulator to a cylinder
containing gas other than that for which
the regulator was designed.
Remove faulty regulator from service
immediately for repair (rst close cylinder
valve). The following symptoms indicate
a faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure
continues to rise with downstream valve
closed.
Faulty Gauge - if gauge pointer does
not move off stop pin when pressurized,
nor returns to stop pin after pressure
release.
Repair. Do NOT attempt repair. Send
faulty regulators for repair to manufacturer’s designated repair center, where
special techniques and tools are used
by trained personnel.
2. Cylinders
Cylinders must be handled carefully to
prevent leaks and damage to their walls,
valves, or safety devices:
Avo id electrical cir cu it contact w ith
cylinders including third rails, electrical
wires, or welding circuits. They can
produced short circuit arcs that may lead
to a serious accident. (See 1-3C)
ICC or DOT marking must be on each
cylinder. It is an assurance of safety
when the cylinder is properly handled.
Identifying gas content. Use only cylinders with name of gas marked on them;
do not rely o n c ol or to ident if y gas
content. Notify supplier if unmarked.
NEVER DEFACE or alter name, number,
or other markings on a cylinder. It is illegal
and hazardous.
Empties: Keep valves closed, replace caps
securely; mark MT; keep them separate
from FULLS, and return promptly.
Prohibited use. Never use a cylinder or its
contents for other than its intended use,
NEVER as a support or roller.
Locate or secure cylinders so they cannot
be knocked over.
Passageways and work areas. Keep cylinders clear of areas where they may be
stuck.
Transporting cylinders. With a crane, use
a secure support such as a platform or
cradle. Do NOT lift cylinders off the ground
by their valves or caps, or by chains, slings,
or magnets.
Do NOT expose cylinders to excessive
heat, sparks, slag, and ame, etc. that may
cause rupture. Do not allow contents to
exceed 55 degrees C (130 degrees F.)
Cool with water spray where such exposure
exists.
Protect cylinders, particularly valves from
bumps, falls, falling objects, and weather.
Replace caps securely when moving cylinders.
Stuck valve. Do NOT use a hammer or
wrench to open a cylinder valve that cannot
be opened by hand. Notify your supplier.
Mixing gases. NEVER try to mix any gases
in a cylinder.
NEVER rell any cylinder.
Cylinder ttings should never be modied
or exchanged.
3. Hose
Pro hib ited use. Never use hose other
than that designed for the specied gas.
A general hose identication rule is: red
for fuel gas, green for oxygen, and black
for inert gases.
Use ferrules or clamps designed for the
hose (not ordinary wire or other substitute)
as a binding to connect hoses to ttings.
No copper tubing splices. Use only standard brass ttings to splice hose.
Avoid long runs to prevent kinks and abuse.
Suspend hose off ground to keep it from
being run over, stepped on, or otherwise
damaged.
Coi l excess hose to prevent kinks and
tangles.
Protect hose from damage by sharp edges,
and by sparks, slag, and open ame.
Examine hose regularly for leaks, wear, and
loose connections. Immerse pressured
hose in water; bubbles indicate leaks
Repair leaky or worn hose by cutting area
out and splicing. Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that
may clog orices and damage seats before
connecting regulator. Except for hydrogen,
crack valve momentarily, pointing outlet
away from people and sources of ignition.
Wipe with a clean, lintless cloth.
Match reg ulator to cylinde r. Before
connecting, check that the regulator label
and cylinder marking agree, and that the
regulator inlet and cylinder outlet match.
NEVER Connect a regulator designed
for a particular gas or gases to a cylinder
containing any other gas.
Tighten connections. When assembling
threaded connections, clean and smooth
sea ts where necessar y. Tighten. If
connection leaks, disassemble, clean,
and retigh te n, usi ng prope rl y fitting
wrench.
Adapters. Use a CGA adapter (available
from your supplier) between cylinder
and regulator, if one is required. Use
two wrenches to tighten adapter marked
RIGHT and LEFT HAND threads.
Regulator outlet (or hose) connections
may be identied by right hand threads
for oxygen and left hand threads (with
grooved hex on nut or shank) for fuel
gas.
5. Pressurizing Steps:
Drain regulator of residual gas through
suitable vent before opening cylinder
(or manifold valve) by turning adjusting
screw in (clockwise). Draining prevents
excessive compression heat at high
pressure seat by allowing seat to open
on pre ss ur ization . Leave adjust ing
screw engaged slightly on single-stage
regulators.
Stand to side of regulator while opening
cylinder valve.
Open cylinder valve slowly so that regulator pressure increases slowly. When
gauge is pressurized (gauge reaches
regulator maximum) leave cylinder valve
in following position: for oxygen and inert
gases, open fully to seal stem against
possible leak; for fuel gas, open to less
than one turn to permit quick emergency
shut-off.
Use pressure charts (availabl e from
your supplier ) for safe and ef ficie nt
recomme nded pre ssure sett ings on
regulators.
Check for leaks on rst pressurization
and regularly thereafter. Br ush with
soap solution. Bubbles indicate leaks.
Clean off soapy water after test; dried
soap is combustible.
E. User Responsibilities
Follow all Safety Rules.
Remove leaky or defective equipment
from service immediately for repair. Read
and follow user manual instructions.
F. Leaving Equipment Unattended
Close gas supply at source and drain
gas.
G. Rope Staging-Support
Rop e staging-suppor t should not be
used for welding or cutting operation;
rope may burn.
1-3 ARC WELDING
Comply with precautions in 1-1, 1-2,
and this section. Arc Welding, properly
done, is a safe process, but a careless
operator invites trouble. The equipment
carries high currents at signicant voltages. The arc is very bright and hot.
Sparks y, fumes rise, ultraviolet and
infrared ener gy radiate s, weldments
are hot, and compressed gases may
be used. The wise op erator avoid s
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. Skin burns resemble
acute sunburn; those from gas-shielded
arcs are more severe and painful. DON’T
GET BURNED; COMPLY WITH PRECAUTIONS.
1. Protective Clothing
Wear long-sleeve clothing in addition to
gloves, hat, and shoes. As necessary,
use additional protective clothing such
as leather jacket or sleeves, ameproof
apron, and re-resistant leggings. Avoid
outer garments of untreated cotton.
Bare skin protection. Wear dark, substantial clothing. Button collar to protect
chest and neck, and button pockets to
prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. Eyes
may be dama ged by radian t energy
when exposed to the electric arc, even
when not looking in the direction of the
arc. Never look at an electric arc without
protection.
Welding helmet or shield containing a
lter plate shade no. 12 or denser must
be used when welding. Place over face
before striking arc.
Protect filter plate with a clear cover
plate.
Cracke d or broken helmet or shield
should NOT be worn; radiation can be
passed through to cause burns.
Cracked, broken, or loose lter plates
must b e repl aced I MM EDIATELY.
Replace clear cover plate when broken,
pitted, or spattered.
Flash goggles with side shields MUST
be worn under the helmet to give some
protection to the eyes should the helmet
not be lowered over the face before
an arc is stru ck. Looking at an ar c
mo me nt ar il y with u np rotected eyes
(particularly a high intensity gas-shielded
arc) can cause a retinal burn that may
leave a permanent dark area in the eld
of vision.
3. Protection of Nearby Personnel
Enclose the welding area. For production
welding, a separate room or enclosed
bay is best. In open areas, surround the
operation with low-reective, noncombustible screens or panels. Allow for free
air circulation, particularly at oor level.
Viewing the weld. Provide face shields for
all persons who will be looking directly
at the weld.
Others working in area. See that all persons
are wearing ash goggles.
Before starting to weld, make sure that
screen aps or bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented
to the outside air. Carbon monoxide can
kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment’s rated capacity. Do not overload
arc welding equipment. It may overheat
cables and cause a re.
Loose cable connections may overheat or
ash and cause are.
Never strike an arc on a cylinder or other
pressure vessel. It creates a brittle area that
can cause a violent rupture or lead to such
a rupture later under rough handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed electrically hot conductors or
other bare metal in the welding circuit, or in
ungrounded, electrically-HOT
equipme nt can fatally shock a perso n
whose body becomes a conductor. DO
NOT STAND, SIT, LIE, LEAN ON, OR
TOUCH a wet surface when welding without
suitable protection.
To protect against shock:
Keep body and clothing dry. Never work
in damp area without adequate insulation
against electrical shock. Stay on a dry
duckboard, or rubber mat when dampness
or sweat cannot be avoided. Sweat, sea
water, or moisture between body and
an electrically HOT part - or grounded
metal - reduces the body surface electrical resistance, enabling dangerous and
possibly lethal currents to flow through
the body.
1. Grounding the Equipment
When installing, connect the frames of
each unit such as welding power source,
control, work table, and water circulator to
the building ground. Conductors must be
adequate to carry ground currents safely.
Equipment made electrically HOT by stray
currents may shock, possibly fatally. Do
NOT GROUND to electrical conduit, or to
a pipe carrying ANY gas or a ammable
liquid such as oil or fuel.
Thr ee-phase conne cti on. Check phase
requirement of equipment before installing.
If only three-phase power is avail able,
connect single-phase equipment to only
two wires of the three-phase line. Do NOT
connect the equipment groun d lead to
the third (live) wire, or the equipment will
become electrically HOT - a dangerous
condition that can shock, possibly fatally.
Before welding, check ground for continuity.
Be sure conductors are touching bare
metal of equipment frames at connections.
If a line c ord w it h a ground lea d is
provided with the equipment for connection to a switch box, connect the ground
lead to the grounded switch box. If a
three-prong plug is added for connection
to a grounded mating receptacle, the
ground lead must be connected to the
ground prong only. If the line cord comes
with a three-prong plug, connect to a
gro unded mati ng rece ptacle. Never
remove the ground prong from a plug, or
use a plug with a broken ground prong.
2. Connectors
Fully insu lated lock-type connectors
should be used to join welding cable
lengths.
3. Cables
Fre quently inspec t cabl es for wear,
cracks, and damage. IMMEDIATELY
REPLACE those with excessively worn
or damaged insulation to avoid possibly
lethal shock from bared cable. Cables
with damaged areas may be taped to
give resistance equivalent to original
cable.
Keep cable dry, free of oil and grease,
and protected from hot metal and
sparks.
4. Terminals and Other Exposed Parts
Terminals and other exposed par ts of
electrical units should have insulating
covers secured before operation.
5. Electrode Wire
Electrode wire becomes electrically HOT
when the power switch of gas metal-arc
welding equipment is ON and welding
gun trigger is pressed. Keep hands
and body clear of wire and other HOT
parts.
6. Safety Devices
Safety devices such as interlocks and
circuit breakers should not be disconnected or shunted out.
Before installation, inspection, or service
of equipment, shut OFF all power, and
remove line fuses (or lock or red-tag
switches) to prevent accidental turning
ON of power. Disconnect all cables from
welding power source, and pull all 115
volts line-cord plugs.
Do not open power circuit or change
polarity while welding. If, in an emergency, it must be disconnected, guard
against shock burns or ash from switch
arcing.
Leaving equipment unattended. Always
shut OFF, and disconnect all power to
equipment.
Power disconnect switch must be available near the welding power source.
Thank You
For selecting a quality product. We want you to take
pride in operating this product...as much pride as we
have in bringing the product to you!
When this equipment is shipped, title passes to the purchaser upon receipt by the
carrier. Consequently, claims for material damaged in shipment must be made by the
purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below for future reference. This
information can be found on your machine nameplate.
Model Name & Number _____________________
Code & Serial Number _____________________
Date of Purchase _____________________
Whenever you request replacements parts for, or information on this equipment always
supply the information you have recorded above.
Please Examine Carton and Equipment For Damage Immediately
Read this Owner’s Manual completely before attempting to use this equipment. Save this manual
and keep it handy for quick reference. Pay particular attention to the safety instructions we
have provided for your protection.
TABLE OF CONTENTS
Section 1 Specications ................................................ 8
Section 2 System Controls & Front Panel ............................ 9
Section 3 General.......................................................10
Section 4 Design ........................................................10
Electrical ..........................................................10
Mechanical ........................................................ 11
Section 5 Control Panel
Section 6 Operating Characteristics .................................12
Non-Pulsed Operation ........................................... 12
Remote Connector Pin Assignments ...........................20
Frequency Calculation Procedures.............................24
Section 7 Input Power Connections ..................................25
This page intentionally blank
Section 1 SPECIFICATIONS
Primary Input Power
50/60 Hz 3 phase 208-277 Volts 36 Amps source must have 15
KVA rating.
3 phase 380-460 Volts 4 wire wye 36 Amps source must
have 15 KVA rating.
1 Phase 208-240 Volts 50 Amps 50% duty cycle on 12 KVA
source 100% duty cycle on 25 KVA source.
Output
DC 6-50 volts
30-300 amperes 100% duty cycle at 10 KVA out (eg. 33 @300a)
Slope Control Flat to Vertical, Provides constant (potential) to
constant current operation.
Inductance Electronically provided 0-3 millihenries
Dual Slope
Capability (eg. CV during normal use - CC during Short circuit
transfer)
Idle Power Unit "On" contactor open - 80 watts (22w with fan off)
Unit "On", contactor closed no arc - 100 watts
Efciency 92% at Full rated power
Pulse Output
Pulse adds to background level setting providing 0 to 100% output during
pulse.
Pulse "On Time" may be 0% to 100% of total pulse interva. Pulse repetition
rate variable from 20 pulse per second to 2000 pulse per second.
Pulse rise time - variable (external only) - 100usec min. - sym rise and fall.
Controls
All functions are calibrated in 0-100% of full scale and may be controlled
remotely with 0-10 volts signals. For use with Robot Control Computers,
desired functions may be commanded from the control computer with
remaining function locally controlled at the power supply.
Size
16-1/4" x 8-1/2" x 24" (41.3 cm x 21.6 cm x 61 cm)
Weight
78 lbs. (35.4 KG)
Maximum Heat Dissipation
900 watts
Environment
-20°F to +110°F (-30°C to + 44°C) 90% humidity without condensation. 0 10,000 ft. elevation. Normal handling for electrical equipment, units may be
stacked or mounted side-by-side. Access required to rear of unit to connect
primary power cable. Cooling air inlet in rear - needs at least 4" clearance
from wall. Auto Over-temp shut down.
MK 2000A - Owner's Manual - Page 8
Section 2 SYSTEM CONTROLS AND FRONT PANEL
HEAT
(PULSE WIDTH)
MODE
HEAT
REMOTE
LOCAL
BKGND
LEVEL
PULSE
LEVEL
PULSE
WIDTH
BKGND
SLOPE
PULSE
SLOPE
PULSE
HEIGHT
INDUC-
TANCE
RISE
TIME
FREQ.
HEAT
INDUCTANCE
(NORMAL MIN:CCW)
PULSE HEIGHT
(NORMAL MAX:CW)
(4)
1 2 3 4
7
98 10
5
6
(1)(7)
(6)
(5)
PULSE
LEVEL
BACKGROUND
SLOPE
BACKGROUND
LEVEL
PULSE
SLOPE
WIRE
DIAMETER
(FREQUENCY)
(FREQ-WIDTH)
(9)
(2)
(10)
(3)
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Set Mode switch to "HEAT". Set Wire Diameter, Pulse Level (process) and background level per chart.
Control weld heat with "HEAT" control. Trim arc length with wire feeder rate control.
MK 2000A - Owner's Manual - Page 9
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