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WeldKing COOLARC 160 Owner's Manual

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Process: Stick (SMAW)
TIG (GTAW)
Arc Welding Power Source
Date of purchase:
Machine Number:
Where purchased
COOLARC 160
OWNER'S MANUAL
________________
________________
________________
www.weldking.com

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Summary of Contents for WeldKing COOLARC 160

  • Page 1 Process: Stick (SMAW) TIG (GTAW) Arc Welding Power Source Date of purchase: ________________ Machine Number: ________________ Where purchased ________________ COOLARC 160 OWNER’S MANUAL www.weldking.com...

  • Page 2: Table Of Contents

    Table of Contents SECTION 1 SAFETY PRECAUTIONS ................... 1 SECTION 1 CONSIGNES DE SÉCURITÉ ................1 1-1. Symbol Usage ...................... 1 Symboles utilisés ........................1 1-2. Arc welding Hazards ..................1 Dangers relatifs au soudage à l’arc .................. 1 1-3. Safety standard reference ................

  • Page 3: Section 1 Safety Precautions

    SECTION 1 SAFETY PRECAUTIONS SECTION 1 CONSIGNES DE SÉCURITÉ 1-1. Symbol Usage Symboles utilisés Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Symbole graphique This group of symbols means Warning! d’avertissement ! Attention ! Cette Watch Out possible ELECTRIC SHOCK, procedure comporte des risques...
  • Page 4 constant voltage wire welder grands afin d’éviter tout contact physique recommended. And, do not work alone! avec la pièce à couper ou le sol. Disconnect input power or stop engine Ne pas se servir de source électrique à before installing or servicing this equipment. courant électrique dans les zones humides, Lockout/tagout input power according to dans les endroits confinés ou là...
  • Page 5 tension à vide doublée. s’assurer l’alimentation correctement dimensionnée et protégée N’utiliser qu’un matériel en bon état. avant de mettre l’appareil en service. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel. FLYING METAL Porter un harnais de sécurité si l’on doit injure eyes.
  • Page 6 soupape de la bouteille. CYLINDERS can explode Le couvercle du détendeur doit toujours être if damaged. en place, sauf lorsque la bouteille est utilisée BOUTEILLES ou qu’elle est reliée pour usage ultérieur. peuvent exploser si elles Utiliser les équipements corrects, les bonnes sont endommagées.
  • Page 7 interference problem resulting from the MOVING PARTS installation. cause injury. If notified by the FCC about interference, ORGANES stop using the equipment at once. MOBILES peuvent Have the installation regularly checked provoquer and maintained. blessures. Keep high-frequency source doors and panels tightly shut, keep spark gaps at Keep away from moving parts correct setting, and use grounding and...

  • Page 8: Safety Standard Reference

    1-3. Safety standard reference Code for Safety in Welding and Cutting, CSA Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Standard W117.2, from Canadian Standards Documents (phone: 1-877-413-5184, website: Association, Standards Sales, 178 Rexdale www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website:...

  • Page 9: Section 2 Installations

    SECTION 2 INSTALLATIONS 2-1. Welding power source and specifications STICK WELDING POWER SOUCE COOLARC 160 COOLARC 160 Type 115V/60Hz 208/230V/60Hz Power supply Phase Rated input(KVA) Open circuit voltage(V) Amperage range(A) Stick 20-90 20-160 20-90 20-160 20-23.6 20-26.4 Rated welding voltage (V)

  • Page 10: 230V Connection Diagram

    2-2. 230V Connection diagram Power cord Electrode holder Earth clamp Work piece Figure 2.1 Arc welding connection diagram Page...

  • Page 11: Install Procedure

    Gauge Cylinder Ar gas Power cord Earth clamp Work piece Tig torch Figure 2.2 Tig welding connection diagram 2-3. Install procedure 2-3.1. Welding machine should be installed in a stable position and with good ventilation. Avoid direct sun outdoors. Avoid transport in invert or side position. 2-3.2.

  • Page 12: Electric Service Guide

    2-4. Electric service guide CAUTION WARNING: THIS WELDING MACHINE MUST BE CONNECTED TO POWER SOURCE IN ACCORDANCE WITH APPLICABLE ELECTRICAL CODES AVERTISSEMENT: LE RACCORDEMENT DE CETTE MACHINE DE SOUDAGE Á L’ALIMENTATION DOIT ÉTRE CONFORME AUX CODES D’ ÉLECTRICITÉ PERTINENTS Input voltage(V) Frequency(Hz) 21.6 Input Amperes at rated output(A)

  • Page 13: Operation

    SECTION 3 OPERATION Front panel Layout Figure 3.1 Page...
  • Page 14 INPUT AC-115V AC-230V Figure 3.2 1. Over-heat protection indicator 6. Fan 2. Terminal + 7. Power cord 3. Terminal - 8. TIG/STICK selector 4. Welding current adjustment knob 5. Main switch Page...

  • Page 15: Operation

    Operation USE SINGLE PHASE 115/208/230V POWER SUPPLY. 3-2.1 Check the connection of work piece, earth cable, electrode holder (or TIG torch), gas cylinder (when TIG), regulator and hose (When TIG), make sure they are firm and reliable. 3-2.2 Switch on the power source. 3-2.3 Set Welding Current to desired value (refer to 3-4.
  • Page 16 TIG: CAUTION GRINDING THE TUNGSTEN ELECTRODE PRODUCES DUST AND FLYING SPARKS WHICH CAN CAUSE INJURY AND START FIRES.USE LOCAL EXHAUST AT THE GRINDER OR WEAR AN APPROVED RESPIRATOR Plate Tungsten Taper of Tungsten Welding Max argon Weld thickness electrode tungsten electrode current flow rate...

  • Page 17: Section 4 Troubles Shooting

    SECTION 4 TROUBLES SHOOTING Problem Cause Solution Power Indication lamp does Loose contact at input lead Check contact not go on after switching on situation the main switch Lamp malfunction, poor Check contact contact situation. Replace lamp Main switch malfunction Check switch, replace if necessary...
  • Page 18 Poor contact between welding Clean and or earth cable and receptacle tighten all weld at machine connections Poor connection between Clean and electrode hold and welding tighten cable Failure of arc to ignite or Fuse melt or poor contact Check and does not ignite properly repair Main power switch failure...
  • Page 19 not proper Electrode selection is not See Table 3.2 proper the work piece surface Clean the contaminated by oil workpiece surface Poor contact inside the gun Check, repair, replace Rectifier tube failure Check, replace Output reactor failure Check, replace Output capacitor failure Check, replace Remote control failure Check...
  • Page 20 replace Control transformer short Check and circuit replace Solenoid valve short circuit Check and replace Cooling fan short circuit Check and replace Page...

  • Page 21: Section 5 Maintenance

    SECTION 5 MAINTENANCE 5.1. Maintenance Periodic maintenance is necessary for keeping the machine working properly. CAUTION DISCONNECT POWER INPUT AND SWITCH OFF THE MAIN POWER SWITCH BEFORE START OF MAINTENANCE. Regular Check and Inspection 6 Month Routine Maintenance • Replace unreadable lables •...
  • Page 22 5.1.7. Do not switch off the welder during welding! 5.1.8. Welding machine should not work in a flammable and toxic environment, avoid moisture, rain, and do not directly expose to sun. 5.1.9. Periodically maintain the machine and clean the dust inside. Page...

  • Page 23: Electrical Diagram

    SECTION 6 ELECTRICAL DIAGRAM INPUT Power Switch 115V/230V CN102 CN101 RECTIFIER capacitor board CN109 CN103 CN108 DC FAN ARC series Figure 6.1 Page...
  • Page 24 Current knob ARC series inverter board Thermostat XH-1 CN10 TIG/STICK Switch Transformers Port CN301 OUTPUT Port rectifier board Figure 6.2 Page...

  • Page 25: Section 7 Parts List

    SECTION 7 PARTS LIST Item Order No. Description Model Quantity Y01430005 Potential meter WH118/1K/2W B01041017 Control module KM-01 Y05030009 MosFet model FMH23N50E B01011014 Inverter PCB MINI200C-NB B01061001 Drive PCB DRIVE MODULE QD-01 Y22010003 12038 DC24V/0.31A B01031016 Rectifier PCB MINI200C-ZL Y03110001 Reactor T185-26-15:15 B01021002...
  • Page 26 Figure 7.1 Page...
  • Page 27 Figure 7.2 Page...
  • Page 28 NOTES WELDKING™ COOLARC 160 Page...

  • Page 29: Section 8 Warranty Policy

    Malo Welding Products material and workmanship at the time it is shipped. Ltd.(WELDKING™ ), in appropriate cases, (3) the THERE ARE NO WARRANTIES WHICH EXTEND reasonable cost of repair or replacement at an BEYOND THE FACE OF THE MALO WELDING authorized service station;...

  • Page 30: Authorized Service Center

    SECTION 9 AUTHORIZED SERVICE CENTER Please go to our website www.weldking.com to fill the warranty registration form. Malo Welding Products Ltd. will not distribute of disclose customer's private information to any third party and will not sent promotion material to the customer.
  • Page 31 MALO WELDING PRODUCTS LTD. 3275, 14th ave, Unit A, Markham, Ontario, Canada, L3R 0H3 Tel: 1 866 686 5088 Fax: 1 866 686 5090 www.weldking.com Printed at November 28, 2009...

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