091-0510A Mini Micro.indd
Contents
1. DO NOT WELD At this point however the weldhead may have sustained considerable damage Therefore it is important to monitor the Gain error and Zero error and provide maintenance as necessary Mini Micro Owner s Manual Page 8 Section i B Cont Motor Calibration Data 08 07 01 15 45 04 08 07 01 15 45 04 Gain Error 3 5 Zero error 0 05 RPM Cal Actual Cal Actual Measured Update RPM RPM Sec Sec Sec Sec Sec 6 00 0 00 10 00 0 00 0 00 0 00 0 00 2 00 1 98 30 00 30 36 30 60 30 05 Tachometer Gain error 4 1 Zero error 0 13 RPM Actual Read Measured Update RPM RPM RPM RPM Sec 0 00 0 00 0 00 0 00 0 00 1 98 1 93 1 91 1 94 Cal Time Error DO NOT WELD CobraTig 150 The report generated by this unit is not as elaborate as the report from the ACL however it does show some very important information It shows both the MOTOR and TACH gain values The calibration and adjustment is still the same The Zero Offset for both the MOTOR and TACH is also shown MOTOR Calibration report MOTOR gain 4 6 Zero offset 0 30 RPM TACH gain 1 9 Zero offset 0 02 RPM Should these MOTOR amp TACH gain values return with number of 0 00 and 0 00 RPM the calibration was invalid and should be re run Results containing all zeros are an indication that the weldhead is in need of service MOTOR Calibration report MOTOR gain 0 0 Zero offset 0 00 RPM TACH gain 0 0 Zero offset 0 00 RPM NOTE If2. Safety Guidelines Installation Technical Specifications Electrical Mechanical Weldhead Connections Collet Selection Tungsten Electrode Gas Flow Rates Weldhead Coolant Operations Weldhead Calibration Accessories Benchmount Extension Cable Collets Maintenance Preventative Maintenance Rotor Accuracy Cable Assembly Troubleshooting Arc Start Troubleshooting Operational Troubleshooting Figures Figure 1 Dimensions Figure 2 Extension Cable Assembly Parts Lists Appendix A Collets Appendix B Locating Mandrels Appendix C Pre Ground Tungsten Electrodes Warranty Mini Micro Owner s Manual Page 1 THIS PAGE INTENTIONALLY BLANK Mini Micro Owner s Manual Page 2 Section A Installation Technical Specifications The MiniMicroTM weldhead was designed for precision welding of small diameter tubes and fittings The MiniMicro weldhead is capable of welding 1 8 to 1 2 inch OD tubes and associated fittings Electrical The MiniMicro uses a 24VDC motor with TACH feedback It is controlled by an orbital power supply motor control circuit to turn the rotor at the precise speed to create a near perfect weld Mechanical Power Cable Size 6 75A 600V Twist lock cable end connectors Gas Water Hose Size Nylon Tube Y4 OD x 0 17 ID Double end shut off coupler Control Cable Specification 20AWG 12 conductor Weldhead Connections The MiniMicro come
3. ground mirror finish is best P WT ai I FFJ 1 j ica Mem k d Incorrect Crosswise grind marks restrict welding current cause arc wander risk inclusions Figure 3 Mini Micro Owner s Manual Page 5 Section A Cont All tungsten supplied by MK Products Inc is prepared using the latest manufacturing techniques in order to meet the geometry specifications as described above Installing the Tungsten Electrode The electrode is mounted in the rotor and held in place with a setscrew To insert the electrode jog the rotor around until both the tungsten hole and the tungsten set screw are visible in the top of the rotor Loosen the tungsten setscrew Insert a properly prepared electrode from the top of the rotor and tighten the setscrew Be sure to set the appropriate arc gap prior to welding Setting the Arc Gap 1 Placethe partto be weldedon the lower Collets with the clamps in the upright open position 2 Place the appropriate thickness gauge between the tungsten electrode and the part to be welded so that the tungsten electrode is at the correct gap Be certain the thickness gauge is perpendicular to the tungsten electrode 3 Tighten the setscrew to secure the tungsten electrode in the rotor Recommended Arc Gap The proper arc gap is an important part of the proper use of your orbital welding equipment Improper arc gap can cause arc strikes to occur to your Collets or to the Side
4. n toque partes el tricas e elec trodos com a pele ou roupa molha da e Isoie se da pe a e terra OSRPORMBA LIBRE IPLALAKTMNEWLIE CU ke K t ET vZCTE n w 3 HEKU TT FS ERRAZEI NENSETER SUL OARAENMAMMI 4688 ord SYSE IL SU FE mas SU Saz op AR 24 HE Ha DAS ii W ya ell sl ail ua O Ji puapli slay JIN d il w l lall AU Ga tall anl DA dasa le VIE ada Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos e RAPT ENOATOBERFER SMBH CEN EGA ll AE CEET kk og esi si Sc AMIX GHZ Amt lS SUSU ALU Agli ma Wear eye ear and body protection Prot jase los ojos los oidos y ei cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und Kir perschutz e Use prote o para a vista ouvido e corpo eb HRUSHCABRELTF Wo CARR HASRIRRBAR er HA Fi RSR Ap SA day Hie de Adi gala ga cil gl ae Baan g READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ
5. 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 where necessary Tighten If connection leaks disassemble clean and retighten using properly 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 identified 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 regula tor 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 o
6. LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Mini Micro Owner s Manual Page 20 Keep your head out of fumes Turn power off before servicing Do not operate with panel open or e Use ventilation or exhaust to guards off remove fumes from breathing zone Los humos fuera de la zona de res Desconectar el cable de ali No operar con panel abierto o pens n Spal salaria mentaci n de poder de la m quina guardas quitadas AVISO D E antes de iniciar cualquier servicio humos Utilice ventilaci n o i P R E C AU C IO N aspiraci n para gases e Gardez la t te F cart des tum es e D branchez le courant avant l entre N op rez pas avec les panneaux French e Utilisez un ventilateur ou un aspira tien ouverts au avec les dispositifs de teur pour ter les fum es des zones protection enlev s A l l E N TI O N de travail e Vermeiden Sie das Einatmen von e Strom vor Wartungsarbeiten e Anlage nie ohne Schutzgehause German Schweibrauch abschalten Netzstrom v llig ff oder Innenschutzverkleidung in Sorgen Sie fiir gute Be und nen Maschine anhalten Betrieb setzen WA N U N G Entl ftung des Arbeitsplatzes amp Mantenha s
7. March 1 2001 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 defect in workmanship and material as of the time and place of delivery by MK Products No warranty is made by MK Products with respect to trade accessories or other items manufactured by others Such trade accessories and other items are sold subject to the warranties of their respective manufacturers if any MK Products warranty does not apply to components having normal useful life of less than one 1 year such as relay points wire conduit tungsten and welding torch parts that come in contact with the welding wire including gas cups gas cup insulators and contact tips where failure does not result from defect in workmanship or material In the case of MK Products breach of warranty or any other duty with respect to the quality of any goods the exclusive remedies therefore shall be at MK Products option 1 repair 2 replacement 3 where authorized in writing by MK Products the reasonable cost of repair or replacement at our Irvine California plant or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer srisk and expense Upon receipt of noti
8. 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 electri cal 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 flammable liquid such as oil or fuel Three phase connection Check phase 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 danger Safety Page iii ous condition that can shock possibly fatally Before welding check ground for continu ity Be sure conductors are touching bare metal of equipment frames at co
9. 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 refill any cylinder Cylinder fittings should never be modified or exchanged 3 Hose Prohibited use Never use hose other than that designed for the specified gas A general hose identification 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 fittings No copper tubing splices Use only stan dard brass fittings 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 excess hose to prevent kinks and tangles Protect hose from damage by sharp edges and by sparks slag and open flame 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 orifices and damage seats before connecting regulator Except for hydrogen Safety Page ii crack valve momentarily pointing outlet away from people and sources of ignition Wipe with a clean lintless cloth Match regulator to cylinder
10. Welding functions of the weldhead transfer through this connector The operator controls are on the weldhead handle They include JOG GAS NEXT LEVEL FINAL SLOPE and START STOP Gas Hose The gas connector is a double end shut off type valve that prevents flow or leakage out of either the unit or the gas hose if the connection is broken The gas hose connector from the weldhead plugs into the GAS OUT receptacle Water Hoses The water connectors are a quick release type that prevent flow or leakage out of either the CobraCooler or the water hose if the connection is broken The water hose connectors from the weldhead plug into the WATER IN amp WATER OUT receptacles on the rear panel of the CobraCooler Collets The three piece collet assembly mounts to both the jaws and the bottom face plate of the weldhead and maintain the weld joint alignment of the parts to be welded The collets are manufactured to correspond with the outside diameter of the material to be welded Each set of collets has three pieces two sides and one bottom Two sets of collets are needed to weld two tubes together Collet Adjustment Extended Collets Only The parts to be welded are held in place by the Collets The tolerance of the outside diameter of tubes and pipes vary so these variations are handled through the use of brass tipped setscrews referred to as plungers in the top Collet halves These plungers not only make up
11. all values for MOTOR or WELDER calibration are zeros it means that he calibration did not complete successfully and is not valid Section C Accessories Benchmount The MiniMicro weldhead can be used while held in the operator s hand However at times it may be necessary for the operator to use both hands to manipulate parts within the weldhead which requires the use of a Benchmount This Benchmount P N 005 0634 can be affixed to any table or counter edge and can hold the MiniMicro Model 4000 orbital weldhead Mini Micro Owner s Manual Page 9 Section C Cont Section D Extension Cable When longer weldhead cables are needed a weldhead extension cable is also available in a 25 length The extension cable P N 005 0635 has all the necessary connections needed to connect the MiniMicro to the CobraTig 150 welding leads gas coolant supply and return and control interface or to an ACL using the Pig Tail Kit P N 005 0619 Collets A set of Collets is defined as 3 each 120 segments for each side of the weldhead Typically 2 sets are required per each weldhead See Appendix A for Part Numbers Maintenance Due to the complexity of the MiniMicro M there is no maintenance permitted for the MiniMicro with the exception of preventive maintenance adjustments and replacement of consumables Preventative Maintenance Prior to performing any maintenance the weldhead should be tested to benchmark
12. 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 beryl lium bearing and similar materials when welded or cut may produce harmful con centrations 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 confined space only while it is being ventilated and if necessary while wearing an air supplied respirator Gas leaks in a confined space should be avoided Leaked gas in large quantities can change oxygen concentration dangerously Do not bring gas cylinders into a confined space Leaving confined space shut OFF gas supply at source to prevent possible accu mulation of gases in the space if down stream 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 flame to form PHOSGENE a highly toxic gas and other lung and eye irritating prod ucts The ultraviolet radiant ener
13. its performance A normal calibration should be run and the required correction noted If the weldhead is running slowly this usually indicates that there is an excessive load on the drive motor and that maintenance is required Rotor Accuracy Weld uniformity depends on the accuracy of the position of the rotor during welding Rotor rotation should be circular in motion in a plane at right angles to the tube and concentric with the center of the tube to be welded Any deviation from the proper tracking or discontinuity in the rotor will appear in the weld Problems in the plane of rotation are usually associated with Collets and can be corrected by Collet modification Discontinuities with rotor motion are more serious and may require replacement of the rotor the race or both Proper replacement requires factory tooling and is not a field repair Cable Assembly An electrical measurement should be made to determine continuity from the positive cable connector to the rotor and from the negative cable connector to the jaws on the weldhead Resistance measurements should be less than 0 1 ohms A measurement should also be made to verify that no conductivity exists between the positive and negative power cables Any measurable conductivity through the weldhead will severely reduce arc start reliability The resistance measurement must be greater than 20 M 2 when measured between the tungsten and the jaws A visual inspection shou
14. the pre purge settings should be determined by the size of the tube and weldhead size the smaller the tube in a given size weldhead the longer the pre purge time If an arc strike occurs to the Collet or Side Plate Clamp the resulting arc spot may induce future arc strikes Be sure to smooth out any arc spots with a fine abrasive pad or cover it with appropriate insulating tape Be sure that there is a tube in the weldhead before trying to make a weld Operational Troubleshooting If the weldhead does not return to the Home position but continues to rotate when the Home switch is pressed the Reed Switch is most likely defective The MiniMicro weldhead must be returned to the factory for any and all repairs Mini Micro Owner s Manual Page 11 THIS PAGE INTENTIONALLY BLANK Mini Micro Owner s Manual Page 12 Section F Figures Figure 1 DIMENSIONS yc NE SE EN Figure 2 Extension Cable Assembly ani Mini Micro Owner s Manual Page 13 Figure 1 Dimensions 71 05mm 2 797in 50 35mm 1 982in 11 98mm 0 472in 9 60mm 0 378in 14 36mm 0 565in 240 23mm 9 458in 22 18mm 0 873in Mini Micro Owner s Manual Page 14 Figure 2 005 0635 Extension Cable Assembly The Maximum length between the weldhead and the power suppply is 37 5 feet One Extension Cable Weldhead Side 25 ft Power Supply Side Connectio
15. ICH MAY CAUSE SERIOUS AND PER MANENT EYE DAMAGE AND WHICH MAY DAMAGE ANY EXPOSED SKIN AREAS Wear helmet with safety goggles or glasses with side shields underneath appropriate filter lenses or plates pro tected by clear cover glass This is a must for welding or cutting and chipping to protect the eyes from radiant energy and flying metal Replace cover glass when broken pitted or spattered Medical first aid and eye treatment First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of flash 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 flaps and wear cuffless 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 confined 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
16. M L PRODUCTS IN ICRO Orbital Weldhead Owner s Manual Product Manual Serial Voltage Rating Revision Model Number A Mini Micro 091 0510 02020001 N A May 2002 Rev A 4000 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 opera tion 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 qualified help before proceeding 1 2 GENERAL PRECAUTIONS A Burn Prevention ELECTRICARC WELDING PRODUCES HIGH INTENSITY HEAT AND ULTRA VIOLET RADIANT ENERGY WH
17. PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVI SION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANT ABILITY OR OF FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TOANYANDALL EQUIPMENT FURNISHED BY MK PRODUCTS IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING MK PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERI ENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE MK PRODUCTS WARRANTIES DO NOT EXTEND TO AND NO RE SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS WARRANTIES TO ANY CONSUMER DATE March 1 2001 PRODUCTS WWW MKPRODUCTS COM 16882 ARMSTRONG AVE IRVINE CALIFORNIA 92606 TEL 949 863 1234 FAX 949 474 1428
18. Plate Clamp Be sure the arc gap is as short as possible consistent with the process and weld current level but not so short as to crash or touch the weld being made If no arc gap is known when designing a weld procedure a good rule of thumb is as follows Arc Gap Wall Thickness x 0 5 010 CAUTION Do not over tighten the tungsten set screw Over tightening the setscrew can crack and splinter the tungsten causing errant starts and arc wander Be sure that the tungsten does not extend into the rotor teeth and that both setscrews are flush with the rotors surface Any length of tungsten that is protruding out the back of the rotor will jam with the meshing gears inside the weldhead This will push the tungsten into the weld being made and inevitably cause an ARC FAULT If the weldhead becomes jammed a Motor Stall will result Usually some foreign matter or a piece of tungsten electrode has fallen within the gear mechanism of the weldhead hindering the rotation of the gears Clearing a Jammed Weldhead In order to clear the jam turn the weldhead upside down and vigorously shake the weldhead Before turning the weldhead right side up attempt to locate the foreign object If the jam cannot be cleared in this manner the weldhead must be returned to MK for disassembly to have the objects removed Mini Micro Owner s Manual Page 6 Section A Cont Section B Gas Flow Rates Recommended arc gas flo
19. ce of apparent defect or failure MK Products shall instruct the claimant on the warranty claim procedures to be followed As a matter of general policy only MK Products may honor an original user s warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods from the date of delivery of equipment to the original user 1 Torches Weldheads and Water RecIrculators ui 1 year 2 All Other Equipmen t UUUUULjLU 3 years di ROPA iii ii aiaa 90 davs 16882 Armstrong Ave Irvine CA 92606 Tel 949 863 1234 Fax 949 474 1428 p RO D U CTS www mkproducts com Classification of any item into the foregoing categories shall be at the sole discretion of MK Products Notification of any failure must be made in writing within 30 days of such failure A copy ofthe invoice showing the date of sale must accompany products returned for warranty repair or replacement All equipment returned to MK Products for service must be properly packaged to guard against damage from shipping MK Products will not be responsible for any damages resulting from shipping Normal surface transportation charges both ways for products returned for warranty repair or replacement will be borne by MK Products except for products sold to foreign markets ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTA TION AS TO
20. ction 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 emer gency it must be disconnected guard against shock burns or flash from switch arcing Leaving equipment unattended Always shut OFF and disconnect all power to equipment Power disconnect switch must be avail able near the welding power source Please Examine Carton and Equipment For Damage Immediately 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 amp Number Code amp Serial Number Date of Purchase Whenever requesting replacement parts or information on this equipment always supply the information you have recorded above 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
21. eat 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 than 35 feet but can be ignited by sparks 3 Openings concealed or visible in floors 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 flames An empty container that held combus tibles or that can produce flammable or toxic vapors when heated must never be welded on or cut unless container has first 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 purging and inert ing with nitrogen or carbon dioxide and using protective equipment Water filling just below working level may substitute for inerting 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 H
22. eu rosto da fumaga e N n opere com as tampas removidas e Mantenha se afastado das partes Portuguese e Use ventilag o e exhaust o para e Desligue a corrente antes de fazer moventes A remover fumo da zona respirat ria servi o N o opere com os paineis abertos ATE N AO N o toque as partes el tricas nuas ou guardas removidas Otl1I1 ARS5MERMITISKLT ILFI TA H E ZEMH AX ONANPAMN ERYNALAKE PE PSM EFREAX17F T RNE E L ELE O amp f 7 HC T44 4B R U CT u AFT F ossee ottima ERT BA J 22 amp ETE E O TFR IE FE JB GLER J Bi GERE it e da 75 SR Has YA 2 e HST AAS Hoste Ho Gel 4942 ER e Sye 2371 38 oHM AIS HAS AH 7274 22718 HRGA GSM e lyn dal ai Ana Al d i Jk AMD JAN alle Ala jl cals 13 jlgall Lia Judi YO EAM gaal bia la Ji Ay sill Jiul dele angi All ll Aak a Ap Aka GN At oe glad saj LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR fl gt RR PH DA p Dir TIRA EFRBMLTF SY CLTRHORAEREC BHD TR AU GGTIE SE HE JAZ BIE JE HB BE RO RN BA DI RR RE EE RAT EM Ki JL O MA B8 D5 RI OR HEME o ol AlSo SS AAAS Salon FAN ZAL COMMAS Salz HR CI asl aa lal Ali gli ciluziai gig landet dii ol Uy G andi p gd SU quali Glace ag l g cy 1 A Mini Micro Owner s Manual Page 21 THIS PAGE INTENTIONALLY BLANK Mini Micro Owner s Manual Page 22 LIMITED WARRANTY Effective
23. gy 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 atmo spheres containing even minute amounts of trichloroethylene or perchloroethylene Safety Page i C Fire and Explosion Prevention Causes of fire and explosion are com bustibles reached by the arc flame flying sparks hot slag or heated mate rial misuse of compressed gases and cylinders and short circuits BE AWARE THAT flying sparks or falling slag can pass through cracks along pipes through windows or doors and through wall or floor openings out of sight of the goggled operator Sparks can fly many feet To prevent fires 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 fitting fire resistant covers or shields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceilings and floor near work should be protected by h
24. hose from gas shielded arcs are more severe and painful DON T GET BURNED COMPLY WITH PRE CAUTIONS 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 flameproof apron and fire resistant leggings Avoid outer garments of untreated cotton Bare skin protection Wear dark sub stantial 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 filter 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 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 cau
25. ld be made to determine the condition of the weldhead and the cable assembly If there are damaged or worn items the weldhead should be returned for factory service Mini Micro Owner s Manual Page 10 Section E Troubleshooting Arc Start Troubleshooting If you experience intermittent arc start problems or strikes to the Collet or Side Plate Clamp instead of the part to be welded check for the following 1 9 The proper arc gap is an important part of the proper use of your MK Orbital equipment Improper arc gap can cause arc strikes to occur to vour Side Plate Clamp or Collets Be sure that the tungsten is ground properly 18 included angle and a 015 017 flat at the end of the tip Sharpening should be accomplished with the grind marks parallel to the longitudinal axis of the tungsten not around the tungsten reference Figure 3 Parts must be clean with no oxidation oils or other insulating surface contaminant If the tungsten is contaminated at any time it should be replaced Dirty tungsten can cause poor arc starts and tungsten inclusions Make sure that the part to be welded is tight in the Collets or a loose ground will result If the part to be welded can be turned in a latched Collet tighten the Collet plungers Avoid any tooling that might have sharp edges or points or this will cause an arc strike to the Collets or the Side Plate Clamp To insure reliable arc starting and extended tungsten life
26. n nections If a line cord with a ground lead is provided with the equipment for connec tion 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 discon nected or shunted out Before installation inspe
27. ns Coolant Gas Weld Power Control Mini Micro Owner s Manual Page 15 THIS PAGE INTENTIONALLY BLANK Mini Micro Owner s Manual Page 16 Section G Parts Lists Appendix A GOES Appendix B Locating Mandrels ii Appendix C Pre Ground Tungsten Electrodes EUU EU Mini Micro Owner s Manual Page 17 THIS PAGE INTENTIONALLY BLANK Mini Micro Owner s Manual Page 18 Appendix A Collets and Jaws Description Part Number Description Part Number Flush Micro Fit Collets Extended Collets Appendix B Locating Mandrels Description Part Number LOCATING MANDREL 1 8 LOCATING MANDREL 1 4 LOCATING MANDREL 3 8 LOCATING MANDREL 1 2 18 Deg included b 015 Flat Tungsten Sold in Packages of 10 Mini Micro Owner s Manual Page 19 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself fram work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aisiese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouili s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre e Ber hren Sie keine stromfilhrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e isolieren Sie sich von den Elektroden und dem Erdboden e N
28. ollow 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 Compressed Gas Equipment The safe handling of compressed gas equipment is detailed in numerous industry publications The following general rules cover many of the most common situations 1 Pressure Regulators Regulator relief valve is designed to protect only the regulator from over pressure 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 first 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 manufac turer 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 elect
29. passage of the reed switch or home sensor in the weldhead The rotation is clocked by the computer and by process of adjusting and recalculating provides very accurate and consistent speeds NOTE IT IS RECOMMENDED THAT THE WELDHEAD BE CALIBRATED EACH TIME THE SYSTEM IS TURNED ONT FAILURE TO CALIBRATE THE WELDHEAD MAY RESULT IN THE WELDHEAD OPERATING AT A ROUGH ADJUSTMENT THAT MAY NOT PROVIDE CORRECT ROTOR SPEED AGAINST THE CONTROLLERS DEMAND SPEED The following paragraphs describe the weldhead calibration results when being used on the MK Orbital ACL 200 Amp welding power supply and the CobraTig 150 welding power supply Mini Micro Owner s Manual Page 7 Section B Cont AGL A report is generated showing the measured time for each revolution of the weldhead The two readings are averaged together to give the actual time in seconds This value divided into 60 seconds provides the actual rpm From these results a Gain error and a Zero error is calculated These are printed as percentages on the report and are used by the computer to convert the speed demanded by the procedure into a speed which will result in the proper actual value by the motor control The report also shows the data for the tachometer and computes a corresponding Gain and Zero error value The computer corrects the motor speed values shown by the display bar graph to represent true values The far right column of the repo
30. pen to less than one turn to permit quick emergency shut off Use pressure charts available from your supplier for safe and efficient recommended pressure settings on regulators Check for leaks on first 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 significant volt ages The arc is 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 Skin burns resemble acute sunburn t
31. rical 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 cylin ders 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 cylin ders 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 flame etc that may cause rupture Do not allow contents to exceed 55 C 130 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 cyl inders
32. rt shows an Update value for the motor and tachometer This update column is only present when using a weld procedure with the Pre Weld Home option Prior to beginning a weld a procedure with this option will cause the rotor to complete one revolution at the high speed used in the initial calibration The computer times this revolution and a gain correction is derived The purpose of this procedure is to calibrate the weldhead before each weld where environmental changes may affect the weldhead speed Motor Calibration Data 08 07 01 15 45 04 08 07 01 15 45 04 Gain Error 3 5 Zero error 0 05 RPM Cal Actual Cal Actual Measured Update RPM RPM Sec Sec Sec Sec Sec 6 00 5 84 10 00 10 27 10 27 10 26 0 00 2 00 1 98 30 00 30 36 30 60 30 05 Tachometer Gain error 4 1 Zero error 0 13 RPM Actual Read Measured Update RPM RPM RPM RPM Sec 5 84 5 96 5 96 5 96 0 00 1 98 1 93 1 91 1 94 When a new or repaired weldhead is received a calibration should be run to benchmark its performance This initial benchmark calibration check can then be used to compare prior calibration reports to determine the condition of the weldhead If the Gain error is more than 10 and Zero error more than 5 rpm off of the benchmark calibration then the weldhead should be disassembled and cleaned If the Gain error reaches 50 or the Zero error reaches 2 rpm during a calibration check the computer will state
33. s equipped with an integrated 12 foot cable which can connect with the CobraCooler installed to either the CobraTig 150 or the Advanced Color Logic ACL orbital power supply The cable assembly provides a path for weld power operator control and motor signals inert gas flow and recirculating coolant flow see Figure 1 Zin Ham TT Fr ti SECH n I WEB _ a e ui ch Figure 1 MK Orbital Power Supplies The MiniMicro connects directly to either the CobraTig 150 or the ACL orbital power supply with the addition of Pig Tails and the CobraCooler M Connecting to the CobraTig 150 The MiniMicro connects directly to the CobraTig 150 orbital power supply with a CobraCooler installed with its integrated 12 foot cable Connecting to the ACL The MiniMicro connects to the ACL orbital power supply with a Pig Tail Kit P N 005 0619 and a CobraCooler Model 250 150 Mini Micro Owner s Manual Page 3 Section A Cont Welding Leads The two welding Power Leads use a twist lock type of power connector These are designed to attach directly to the rear panel of the CobraTig 150 The male connector connects to the receptacle labeled ELECTRODE The female connector connects to the receptacle labeled GROUND Control Cable The 24 MS type pin connector attaches to the mating receptacle on the rear panel of the orbital welding power supply All of the Control Feedback and
34. se a retinal burn that may leave a permanent dark area in the field 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 reflective noncombus tible screens or panels Allow for free air circulation particularly at floor 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 flash goggles Before starting to weld make sure that screen flaps 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 lt may overheat cables and cause a fire Loose cable connections may overheat or flash and cause afire Never strike an arc on a cylinder or other pressure vessel lt 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 equipment can fatally shock a person whose body becomes a conductor DO NOT
35. the diameter difference between the Collet and the part to be welded but they also act as an aid in the grounding path between the weldhead and the tube or pipe to be welded The tube or pipe is forced down into the bottom halves of the Collets which are screwed to a line bored concentric face in the weldhead side plates The plungers are adjusted as follows 1 Backthe plungers out until the brass tip is flush or below the surface of the bored Collet surface 2 Place the parts to be welded into the Collets and clamp down the latches Adjust the latching mechanism of the weldhead to ensure a tight but not overly tight clamping of the Side Plate Jaws 3 Alternately adjust the plungers on one side of the weldhead until contact is made and then add about 1 4 turn more 4 Atthis point the tube should be firmly held in place The tube should not turn if attempting to rotate it by hand Mini Micro Owner s Manual Page 4 Section A Cont 5 Repeatthe process for the opposite side of the weldhead 6 Once completed check the alignment of the parts A misalignment may be corrected by moving the left or right plunger in or out by a fraction of a turn and then repeating the opposite action to the opposing plunger on the same Collet Tungsten Electrode The recommended tungsten type to be used in the MiniMicro and the MK orbital welding system is 2 Ceriated 1 16 inch diameter Appendix C gives the MK part numbers for pre gro
36. und tungsten electrodes required for a specified tube diameter These lengths of tungsten are long enough to allow the setscrew to securely hold the tungsten while maintaining a relatively close arc gap and keep the tungsten from sticking out the back of the rotor while using a large arc gap Tungsten Geometry The recommended grind angle and shape for tungsten is 18 included angle and a 015 inch flat Figure 2 Regardless of the electrode tip geometry selected it is important that consistent electrode geometry be used once a welding procedure is established Kaz E 18 Deg Included aci n T Wes 015 Flat Figure 2 Changes in electrode geometry can significantly influence the weld bead shape and size therefore electrode tip configuration is a welding variable that should be defined during procedure development Tungsten Preparation Tungsten electrodes should be properly ground for consistent results If the electrode is to be hand ground use a dedicated diamond wheel The grinding marks should be perpendicular to the tungsten electrode or poor arc starts arc wander and inclusions may occur See Figure 3 No other parts should be ground with these wheels since contamination of the electrode could result and create problems with arc initiation arc wander during the weld and tungsten inclusions in the weld bead i Correct Lengthwise grind marks don t restrict current Diamond
37. w rate is 15 to 20 CFH at 50 PSI with the ACL and 20 CFH with the CobraTig 150 Flow rates higher than 25 CFH can create turbulence within the weldhead chamber and blow the arc about Back up gas flow rates are typically between 5 and 20 CFH depending on internal volume and component configuration Typically when welding components with relatively large internal volumes a separate source for backup purge gas is recommended Weldhead Coolant Only coolant solutions that are recommended by MK Products Inc and or its distributors for use in its products are suitable for use in the MiniMicroTM weldhead Use a name brand additive which does not contain reactive sulphur or chlorine and does not react with copper brass or aluminum or create a custom mix using this formula A solution of 3 Quarts 2 85 Liters Distilled water 1 Quart 95 Liters ethylene glycol 1 tsp 5 ml liquid glycerin Tap water should not be used since it may hinder arc starting DO NOT USE AUTOMOTIVE ANTI FREEZE This may contain additives that are not compatible with this equipment And will Void the Warranty Operation Weldhead Calibration The software program in the orbital welding power supply provides for weldhead rotor speed and motor controller calibration This calibration program consists of driving the rotor at two predetermined speeds set by the operator for one revolution at each speed The start and end of each rotation are detected by the
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