MK Products Weld Control User Manual
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. 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 art, a careful study of
the information provided with the equipment,
and the use of common sense. Rules for
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
H I G H I N T E NS I T Y H E AT AN D
ULTR AV I O L E T RADIAN T EN E R G Y
WHICH MAY CAUSE SERIOUS AND
PERM A N E N T EY E DAMA G E AN D
WHICH MAY DAMAGE ANY EXPOSED
SKIN AREAS.
Wear helmet with safety 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 facilities and a qualied rst 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 cutting) may produce. Prevent
them with adequate ventilation. NEVER
ventilate with oxygen.
Lead-, cadmium-, zinc-, mercury-, berylliumbearing 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 conned space, shut OFF gas supply
at source to prevent possible accumulation of
gases in the space if downstream valves
have been accidentally 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
perchloroethylene vapors to form phosgene.
DO NOT WELD or cut where solvent vapors
can be drawn into 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 re and explosion are: combustibles
reached by the arc, ame, 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 electrical 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).
Walls, ceilings, and oor near work should
be protected by heat-resistant covers or
shields.
Fire watcher must be standing by with
suit able fi re exti nguis hing eq uipme nt
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
than 35 feet, but can be ignited by sparks.
3. Openings (conce aled 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 hea ted, must n ever be
welded on or cut, unless container has rst
been cleaned in accordance with industry
standards.
This includes: a thorough steam or caustic
cleaning (or a solvent of water washing,
depending on the combustible’s solubility),
followed by p urging and inerting with
nitrogen or carbon dioxide, and using
protective equipment.
Water-lling just below working level may
substitute for inerting.
Weld Control Selector Guide - Page i
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 ammable dust,
gas, or liquid vapors (such as gasoline).
D. Compressed Gas Equipment
The safe handling of compressed gas
equipment is detailed in numerous industry
pu bli cat ions . Th e fo llo win g gener al
rules cover many of the most common
situations.
1. Pressure Regulators
Regulator relief valve is designed 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.
Rem ove faulty regulator f rom 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:
Avoid electrical circuit contact with 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 on color to identify 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.
Re p l a c e c aps secu r e l y w h en movin g
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
Prohibited 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.
Coil ex ce ss h ose 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 regulator to cylinder. 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
seats whe re n ec es sa ry. Ti gh te n. If
connection leaks, disassemble, clean, and
retighten, using properly tting 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 pressurization.
Leave adjusting 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
pre ssurized (gauge reaches regu lator
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 (available from your
supplier) for safe and efcient recommended
pressure settings on regulators.
Check for leaks on rst pressurization
and regularly thereafter. Brush 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
Rope staging-support 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
Weld Control Selector Guide - Page ii
SAFETY CONSIDERATIONS
- Continued -
very bright and hot. Sparks y, 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, reect 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 damaged by radiant 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 lter plate with a clear cover plate.
Cracked or broken helmet or shield should
NOT be worn; radiation can be passed
through to cause burns.
Cracked, broken, or loose filter plates
must be replaced IMMEDIATELY. 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 struck. Looking at an arc momentarily
with unprotected 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
Expo sed elec trica lly hot co ndu ctors or
other bare metal in the welding circuit, or in
ungrounded, electrically-HOT equipment can
fatally shock a person 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 ow 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.
Three-ph ase conn ect ion . C hec k p has e
requirement of equipment before installing. If
only three-phase power is available, connect
single-phase equipment to only two wires of
the three-phase line. Do NOT connect the
equipment ground 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 cord with a ground lead 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 grounded mating receptacle.
Never remove the ground prong from a plug,
or use a plug with a broken ground prong.
2. Connectors
Fully insulated lock-type connectors should
be used to join welding cable lengths.
3. Cables
Frequently inspect cables 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 parts 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.
Weld Control Selector Guide - Page iii
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. There are two types of "synergic" units. If the
controls for the power supply are on the power supply, then a Cobramatic II feeder may be adaptable. If
the controls for the power supply are incorporated into that manufacturers wire feeder, then it becomes
difcult to hook up a different type of feeder.
When working with voltages present in this product and
CAUTION :
At the time of its printing the information in this guide was accurate according to the information provided
by the various manufacturers. Due to model variations, modications and other unknowns, this information
may not be accurate in all cases. Refer to the power supply owner's manual if there are any questions
or doubts about proper hook-up. Upon using this guide the user accepts full responsibility of the
consequences that may occur during hook-up. All work should only be attempted by a qualied service
technician with the proper tools and knowledge of electronics.
others, always obser ve warning and caution signs. Ser vice
must only be perfor med by qualied service personnel.
DISCLAIMER
WHY DO I NEED A WELD CONTROL?
The weld control provides the electronics needed to operate the spool gun, as well as, provide the contactor
signal to activate the power supply. In a GMAW (MIG) system the wire is not electrically hot until the weldor
activates the trigger. The weld control then sends the contactor signal to energize the power supply.
There are two types of contactor signals that various power supply manufacturers use. The rst is a "Closing
Contact" signal. With this type of signal the weld control simply touches the two contactor leads together
(providing continuity to the power supply). The second type of signal is the "115VAC" signal. With this
type of signal the weld control sends 115 volts AC to the power supply. If you were to touch the contactor
leads in this position, you would get a SHOCK when the trigger is activated. All GTAW (TIG) machines use
a closing contact signal because it would be unsafe to put a 115VAC contactor signal in a foot control.
WHICH WELD CONTROL?
The WC-1 can be used on all power supplies, although it may not be the most economical or most feasible
approach. Where possible, a dedicated weld control has been developed to simplify installation and lower
cost. These controls interface to a particular power supply or a group of power supplies from a certain
manufacturer.
HOW TO USE THIS GUIDE
1. Using the charts on pages 1 thru 5, locate the power supply you wish to connect to.
2. The next column over will indicate which control is needed for the Prince XL Spool-gun. Sometimes, an
optional control is available. This will be indicated in the third column. The fourth column will list any
special notes. Note: For Cobramatic feeders a weld control is not needed, however, if a contactor
box is listed it should be used.
3. Check the notes column for important information.
4. Check the hook-up instructions column for the section, then go to that section.
5. The Posa Start on the Cobramatic feeders can be used with all CV/CC power supplies by simply
connecting the single black lead extending from the back of the unit to work ground (-).
6. Reference the Appendix for connection information to many utility type welders.
Weld Control Selector Guide - Page iv
Table of Contents
Power Supply Listing 1
Airco 7
Esab 9
Hobart 12
Lincoln 14
Miller 18
Powcon 21
Panasonic 23
Thermal Dynamics 24
Appendix 25
Warranty
Weld Control Selector Guide - Page v
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Weld Control Selector Guide - Page vi
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 1, 6, 7 M-1, 3, 5
Millermatic 250, Vintage C 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 M-1, 3
XMT-300CC & CC/TIG I 2, 7, 8 M-4
Maxtron 300, 400 A 6, 7, 8 M-1, 3
All Maxstars (except 140 & 200) I 2 M-4
Dimension 400 A 1, 6, 7 M-1, 2, 3
MP30E, MP45E, MP65E, 300MT I M-2
All Gold Star SS, 320/330 A/BP
All Syncro Waves, 300ST Aircrafter
Dialarc HF I J (Rec.) 2 M-8
Legend AEAD-200LE I J (Rec.) 2, 3, 5 M-8
Bobcat 225G, 225NT I J (Rec.) M-8
Trailblazer 250, 251, Air Pak A 1, 6, 7 M-1, 3
Big 30A, 40G/D, 50D
with CV-3 installed
Big Blue 251D, 400D I J (Rec.) 2 M-8
Trailblazer 44G/D I 2 M-8
Trailblazer 55G/D A 1, 6, 7 M-1, 3
Invision 354, 456MP A 8 M-1, 3
I 2 M-4, 7
I
A
J (Rec.)
---
2
6, 7
M-4, 8
M-1, 3
WELD CONTROLS AVAILABLE
A P/N 005-0261 PA-M1 Spool Gun Control F P/N 005-0624 MigMaster 251 Kit
B P/N 005-0264 PA-G1 Spool Gun Control I P/N 001-3062 WC-1 Control
C P/N 005-0205 MillerMatic Module J P/N 001-3066 MK200 Contactor
D P/N 005-0629 MillerMatic 250/250-X Intfc Cbl K P/N 005-0617 Gunslinger 260 Intfc Cbl
E P/N 005-0206 MigMaster 250 Module L P/N 005-0676 PA-L1 Spool Gun Control
Weld Control Selector Guide - Page 1
Weld Control Selector Guide
Power Supply Control Required Optional Notes* Section
Lincoln Electric
SP-150, 200 I L-1
SP-250 I B L-2
Wirematic 250, 255 I B L-3
PowerMig 255, 455 I 9 L-7
DC-250, 400, 600, Pulse Power 500 I L-4
R3S-250, 325, 400 I L-4, 5
CV-200, 250, 300, 400 I, L 7 L-6
Invertec V300-PRO, V350-PRO (Fac. & Adv.)
Invertec V350-PRO (Contractor)
TIG 250/300, Squarewave 300/350 I 2 L-8
Weldanpower 225/250 I J (Rec.) 2 L-9
G7, G8000, Ranger 8 (Red-D-Arc ZR-8 & ZR-10) I J (Rec.) L-9
G9, D-10 PRO, Classic w/CV Tap I L-4
Ranger 9, 10, 10-XL, 250, 275, 305 I, L 7, 10 L-6
Commander 300, 500, Vantage 500 I, L 7, 10 L-6
PowerWave 450, 450-ONE --- 8 L-10
L
I
I
J (Rec.)
7, 8
8
L-6
L-9
ESAB (Includes L-Tec & Linde)
L-Tec 225 I E-1
MigMaster 250 E E-2
MigMaster 251 F 8 E-3
MigMaster 300 I 8 E-4
ESAB 352CV, 452CV I 8 E-6
ESAB 251CV 8 E-7
MultiMaster 260 8, 12 E-7
Most V, VI, SVI Units I 8 E-5, 6
L-Tec 300, 400, 450, 650 I E-5, 6
UCC-301, 305, 306 I 2 E-8
HeliArc 250, 306, 301, 401 I 2, 8 E-8
L-Tec 250 Stick I J (Rec.) 2 M-8
ESAB Pulse Arc II-400, 500 I A-3
WELD CONTROLS AVAILABLE
A P/N 005-0261 PA-M1 Spool Gun Control F P/N 005-0624 MigMaster 251 Kit
B P/N 005-0264 PA-G1 Spool Gun Control I P/N 001-3062 WC-1 Control
C P/N 005-0205 MillerMatic Module J P/N 001-3066 MK200 Contactor
D P/N 005-0629 MillerMatic 250/250-X Intfc Cbl K P/N 005-0617 Gunslinger 260 Intfc Cbl
E P/N 005-0206 MigMaster 250 Module L P/N 005-0676 PA-L1 Spool Gun Control
Weld Control Selector Guide - Page 2
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
Mega Mig RC/RBS, Fabstar I
Hobart Excel Arc CV, CV/CC I
Fabricator 210, 300LF I 11
Fabricator 250 I T-2
Mega Flex RCC/RVS I
CyberTig, CyberWave I 2 H-4
Porta-Tig/Stick I 2 H-4
TR-250 I J (Rec.) 2 M-8
TR-250HF I 2 H-4
TigWave 250, 350 I 2 H-4
Champion/Titan Combo I H-4
Champion Fabshop I 2 H-4
Champion 16, 16D, 18 I J (Rec.) 2 H-4
Mega Arc Engine Driven I J (Rec.) 2, 5 M-8
Hobart DCC 353P I H-3
Titan 7000, 8000 AC/DC I J (Rec.) 2 M-8
H-2
M-6
H-3
HT-1,2
H-3
HT-1,2
T-2
M-1
H-3
HT-1
Thermal Dynamics (Includes ThermalArc)
300GMS, 400SMT, 400SMT-W A 6
Fabricator 210, 250 P/N 005-0689 11
Fabricator 310LF I
Fabricator 2620, 4030 I HT-1, 2
Viking 210, 250GM I P/N 003-1623 T-1
Excel Arc CV, CV/CC; Arc Master 351, 501 I HT-1, 2
PowerMaster I
Predator, Explorer (w/o Contactor) I J (Rec.) T-3
Exciter, Hog I J (Rec.) T-3
Predator, Explorer, Hercules, T-Bird (w/contactor) A, I
WELD CONTROLS AVAILABLE
A P/N 005-0261 PA-M1 Spool Gun Control F P/N 005-0624 MigMaster 251 Kit
B P/N 005-0264 PA-G1 Spool Gun Control I P/N 001-3062 WC-1 Control
C P/N 005-0205 MillerMatic Module J P/N 001-3066 MK200 Contactor
D P/N 005-0629 MillerMatic 250/250-X Intfc Cbl K P/N 005-0617 Gunslinger 260 Intfc Cbl
E P/N 005-0206 MigMaster 250 Module L P/N 005-0676 PA-L1 Spool Gun Control
T-2
M-3
T-2
M-1
HT-1, 2
M-3
HT-1
M-1
Weld Control Selector Guide - Page 3
Weld Control Selector Guide
Power Supply Control Required Optional Notes* Section
Powcon
200SM B 6 P-2
300SM I P-1
300T, 300SS I 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 P-1
Plasma +, 225SMC (Single Phase) B 6 P-2
Plasma +, 225SMC (Three Phase) I P-1
Panasonic
Gunslinger 260 K PA-1
Airco
Dip-Pak 200, 225, 250 B 6 A-1
Dip-Cor 300 I A-2
CV-200, 250, 300, 450, 600 I A-3
PA-3A, PulseArc 350, 400, 500 I 4 A-3
Pulse Arc II400, 500 I A-3
Phase Arc 350, 550, 650 I A-3
AC/DC Heli-Welders I 2 A-4
AC/DC Square Waves I 2 A-4
WELD CONTROLS AVAILABLE
A P/N 005-0261 PA-M1 Spool Gun Control F P/N 005-0624 MigMaster 251 Kit
B P/N 005-0264 PA-G1 Spool Gun Control I P/N 001-3062 WC-1 Control
C P/N 005-0205 MillerMatic Module J P/N 001-3066 MK200 Contactor
D P/N 005-0629 MillerMatic 250/250-X Intfc Cbl K P/N 005-0617 Gunslinger 260 Intfc Cbl
E P/N 005-0206 MigMaster 250 Module L P/N 005-0676 PA-L1 Spool Gun Control
Weld Control Selector Guide - Page 4
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. Contactor box not needed if power supply has optional remote control facilities (panel).
6. WC-1 Weld Control can also be used.
7. An adapter cable with Amphenol already attached can be used with the power supply and
WC–1 or Cobramatic combination.
8. Many of the newer power supplies, especially the inverter style units now use a Dinse style
connector for the weld power out. This means the lug on the power cable of the Spool-gun
must be cut-off and replaced by a male Dinse connector (MK P/N: 153-0755).
9. MK does not make a weld control for the Lincoln PowerMig 255. Since Lincoln makes their
own control for a Prince XL Spool-gun, they furnish the control module with the Spool-gun.
However the WC-1 or the MK Cobramatic Cabinet may be used with that unit (See L-7 ).
10. At this time, the Lincoln Commander 300 and 500 does not have 42VAC volts at the 14-Pin
connector. An optional kit (P/N: K1597-1) must be obtained from Lincoln in order to use the
Prince® XL spool gun with the PA-L1. Units with a date code of November 2001 have 42VAC.
11. If the Fabricator 210 has a 4 digit specication number (xxxx), then the 14-Pin Control will
work. If the 4 digit specication has an "A" at the end (xxxxA), then a WC-1 Control must be
used. (See H-2)
12. To use an MK 003-1341 Adapter, the Multimaster 260 requires the optional ESAB spool gun
control module. Units after S/N 0558001793 come standard with the Spool Gun Module.
13. The Classic Series engine driven welder is a CC type power supply. To properly operate this
unit while welding aluminum, the CV tap is required. However, because 42VAC is unavailable
a WC-1 Weld Control must be used.
WELD CONTROLS AVAILABLE
A P/N 005-0261 PA-M1 Spool Gun Control F P/N 005-0624 MigMaster 251 Kit
B P/N 005-0264 PA-G1 Spool Gun Control I P/N 001-3062 WC-1 Control
C P/N 005-0205 MillerMatic Module J P/N 001-3066 MK200 Contactor
D P/N 005-0629 MillerMatic 250/250-X Intfc Cbl K P/N 005-0617 Gunslinger 260 Intfc Cbl
E P/N 005-0206 MigMaster 250 Module L P/N 005-0676 PA-L1 Spool Gun Control
Weld Control Selector Guide - Page 5
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Weld Control Selector Guide - Page 6
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. Set the unit on "MANUAL" and adjust the voltage using the "UP
& DOWN" push-button.
4. Place Wire Feed/Midget Switch to "MIDGET" position.
Note: The feeder inside this unit will also be turned on, so disengage
the spring tension on drive roll.
The PA-G1 Control (P/N 005-0264) is connected to the Dip-Pak 225 as follows:
1. Remove the left panel and locate pin 1 of terminal strip
(where all blue wires converse). Add a wire from pin 1
and route it through the access hole on the center panel
into the left side. Connect the added wire to terminal strip
TB 2 #16 located above the wire feed motor.
2. Connect the green contactor lead extending from the
Control to TB2 #22 and the red contactor lead to TB2
#21.
3. Connect the black wire extending from the Control to TB2
#21 and the white wire to TB2 #16.
Note: The feeder inside this unit will also be turned on, so
disengage the spring tension on drive roll.
A-1
The PA-G1 Control (P/N 005-0264) is connected to the Dip-Pak 250 as follows:
1. Remove the left panel. Splice the red and green
contactor leads extending from the Control to the brown
and blue wires extending from the front panel amphenol;
red to wire to blue and green wire to brown.
2. Locate TB-1 (an 8 position terminal strip inside unit).
Connect the black wire extending from the Control to
TB1 #1 and white wire to #3.
3. Set the switch inside the Dip-Pak wire feed compartment
to "Spoolgun"
4. Connect the spoolgun power lug to the front connector or
to the bolt next to the wire feed motor.
Note: Splice and fork connectors are included in Control kit.
THE WC-1 OR COBRAMATIC CAN ALSO BE CONNECTED TO THESE UNITS BY SIMPLY
CONNECTING THE CONTACTOR AND PLUGGING THE UNIT INTO A STANDARD WALL OUTLET.
(Both the WC-1 or Cobramatic Contactor will be in CLOSING CONTACTS position, see Appendix for
contactor information.)
Weld Control Selector Guide - Page 7
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