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WeldKing COOLARC 200 Owner's Manual

Stick smaw, tig gtaw
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COOLARC
200
STICK ( SMAW)
TIG ( GTAW)
Owner's Manual

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Summary of Contents for WeldKing COOLARC 200

  • Page 1 COOLARC STICK ( SMAW) TIG ( GTAW) Owner’s Manual...
  • Page 2 READ INSTRUCTIONS!  Consult the Owner’s Manual for welding safety precautions.  Use only genuine replacement parts  While the information contained in this Manual represents the Manufacturer's best judgment, the Manufacturer assumes no liability for its use. Model Name: _________________________________ Date of purchased: _________________________________...

  • Page 4: Table Of Contents

    Table of Contents SECTION 1 SAFETY PRECAUTIONS ....................5   SECTION 1 CONSIGNES DE SÉCURITÉ ..................5   1-1.   Symbol Usage Symboles utilisés ..............5   1-2.   Arc welding Hazards Dangers relatifs au soudage à l’arc ....5   1-3.

  • Page 5: 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 d’avertissement Attention ! Cette procedure comporte des risques possibles ! Les dangers éventuels This group of symbols means Warning! Watch Out sont...
  • Page 6 CoolArc200 open-circuit voltage will be present. normes de sécurité).  Use only well-maintained equipment. Repair or  Installer le poste correctement et le mettre à la replace damaged parts at once. Maintain unit terre convenablement selon les consignes du according to manual. manuel de l’opérateur et les normes nationales, provinciales et locales.
  • Page 7 de manipuler des cartes ou des pièces. affecter les stimulateurs  Utiliser des pochettes et des boîtes antistatiques cardiaques. pour stocker, déplacer ou expédier des cartes PC.  Pacemaker wearers keep away.  Wearers should consult their doctor before going FIRE OR EXPLOSION near arc welding, gouging, or spot welding operations.
  • Page 8 CoolArc200 bouteille à gaz.  Seules des personnes qualifiées sont autorisées à enlever les portes, panneaux, recouvrements ou  Une électrode de soudage ne doit jamais entrer en dispositifs de protection pour l’entretien. contact avec une bouteille.  Remettre les portes, panneaux, recouvrements ou ...
  • Page 9 utiliser une terre et un blindage pour réduire les interférences éventuelles.  Le rayonnement haute fréquence (HF) peut provoquer interférences avec équipements radio-navigation READ INSTRUCTIONS. LIRE communication, les services de sécurité et les ordinateurs. LES INSTRUCTIONS.  Demander seulement à des personnes qualifiées familiarisées avec équipements...

  • Page 10: Safety Standards Normes De Sécurité

    CoolArc200 1-3. Safety Standards Normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Code for Safety in Welding and Cutting, CSA Standard Standard Z49.1, from Global Engineering Documents W117.2, from Canadian Standards Association, Standards (phone: 1-877-413-5184, website: www.global.ihs.com). Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).

  • Page 11: Packing List

    SECTION 2 PACKING LIST CoolArc200 package (Part No: 07003700 ) Description Part no Quantity CoolArc200 Power source come with 10 ft. (3 M) Power cord and NEMA 6-50P 230V AC Plug 300 Amp electrode holder with 13 ft (4 M) #4 lead and 50mm male 07000463 Dinse plug 300 Amp ground clamp with 10 ft (3 M) lead #4 lead and 50mm...

  • Page 12: Basic Information

    CoolArc200 SECTION 3 BASIC INFORMATION 3-1. Welding power source specifications CoolArc200 package (Part No: 07003700 ) AC 115V,60Hz,1 phase AC (208)V/230V,60Hz, 1 phase Power supply STICK STICK Welding Process Input Amps @ Maximum output(A) Rated input (KW) Generator Requirements(KVA) OCV (V) 10A,10.4V - 110A, 14.4V 10A, 10.4V - 200A, 18V Amperage range(A) 40%@110A,14.4V...

  • Page 13: Duty Cycle & Over Heating

    Table 3.1 3-2. Duty cycle & Over heating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops, over-heat protection lamp (yellow) will illuminate. Wait 15 minutes for unit to cool. Reduce amperage or voltage, or duty cycle before resume welding. Figure 3.1 CAUTION! EXCEEDING DUTY CYCLE CAN DAMAGE UNIT AND VOID...

  • Page 14: Installations

    CoolArc200 SECTION 4 INSTALLATIONS 4-1. STICK welding connection diagram CoolArc200 (115v input) Power Cord Electrode To 115 volt, 20 ampere holder individual branch circuit Earth clamp Figure 4.1 Manual no. WM070401 Page 9...
  • Page 15 CoolArc200 (208/230v input) Power Cord Earth clamp Electrode holder Figure 4.2 Page 10 Manual no. WM070401...

  • Page 16: General Installation Procedure For Stick Welding

    CoolArc200 4-2. General installation procedure for STICK welding 4-2.1.Welding machine should be installed in a stable position and with good ventilation. Avoid direct sun outdoors or rain. Place at a distance of 12” (300mm) or more from walls or similar that could restrict natural air flow for cooling.

  • Page 17: Lift-Tig Welding Connection Diagram

    4-3. LIFT-TIG welding connection diagram CoolArc200 (115v input) Gauge Cylinder Power Cord To 115 volt, 20 ampere individual branch circuit Earth clamp TIG Torch Figure 4.3 Page 12 Manual no. WM070401...
  • Page 18 CoolArc200 CoolArc200 (208/230v input) Gauge Cylinder Power Cord TIG Torch Earth clamp Figure 4.4 Manual no. WM070401 Page 13...

  • Page 19: General Installation Procedure For Lift-Tig Welding

    4-4. General installation procedure for Lift-TIG welding 4-4.1.Welding machine should be installed in a stable position and with good ventilation. Avoid direct sun outdoors or rain. Place at a distance of 12” (300mm) or more from walls or similar that could restrict natural air flow for cooling. Avoid transport in invert or side position. 4-4.2.Switch the ON/OFF Switch (located on the rear panel) to OFF.

  • Page 20: Extension Welding Cable Selection Chart

    CoolArc200 4-6. Extension Welding Cable Selection Chart CAUTION! Use shortest cable possible. Turn off power before connecting to weld output terminals! Welding cable size in Maximum total cable (Copper) length in weld circuit allowed in Ft(M) AWG (mm Welding Amperes (A) 6(13) 260(80) 130(40)

  • Page 21: Section 5 Operation

    SECTION 5 OPERATION 5-1. Power source panel layout and description 1. Welding current meter (digital) 5. STICK/lift TIG selection button 2. Power indication light 6. STICK indication light 3. Protection indication light 7. TIG indication light 4. Current adjustment knob 8.
  • Page 22 CoolArc200 11. Power cord 9. Positive output 12. Main switch 10. Negative output Figure 5.2 Manual no. WM070401 Page 17...

  • Page 23: Operation

    5-2. Operation USE SINGLE PHASE 115V/208V/230V POWER SUPPLY. 5-2.1.Switch on the power source. 5-2.2.Set Welding Current to desired value (refer to 5-3 Welding Parameter selection chart). 5-2.3.The display value of digital voltage meter will change when you turn the current knob to pre-set the welding current.
  • Page 24 CoolArc200 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 25: Section 6 Trouble Shooting

    SECTION 6 TROUBLE SHOOTING 6-1. General trouble shooting Problem Cause Solution Power Indication lamp does Loose contact at input lead Check contact not on after switch on the main situation switch Lamp malfunction, poor contact Check contact situation. Replace lamp Main switch malfunction Check switch, replace if necessary...
  • Page 26 CoolArc200 Low line mains power voltage Use input voltage according to specification Rectifier short circuit Check and replace Main transformer short circuit Check and replace Control transformer short circuit Check and replace Cooling fan short circuit Check and replace The digital meter do not The LED is broken Change the LED display properly...

  • Page 27: Tig/Stick Welding Trouble Shooting

    Table 6.1 6-2. TIG/STICK welding trouble shooting Problem Cause Solution Erratic or improper weld Wrong cable size Choose the right cable size output. Cable or receptacle too Wrong electrode holder size Choose the right size hot. electrode holder Poor contact between welding or Clean and tighten all weld earth cable and receptacle at connections...
  • Page 28 CoolArc200 Remote control failure Check resistance and connections for remote Amperage control potentiometer Tungsten electrode Gas shield inadequate check nozzle oxidizing( not bright) after Gas not pure Check if there is water in welding torch and repair. Check and tight all gas fitting Gas pressure inadequate Increase gas pressure Table 6.2...

  • Page 29: Maintenance

    SECTION 7 MAINTENANCE 7-1. Maintenance Periodic maintenance is necessary for keeping the machine work 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 labels. ...
  • Page 30 CoolArc200 7-2.7.Welding machine should not work in a flammable and toxic environment, avoid moisture, rain, and do not directly expose to sun. 7-2.8.Do not switch off the welder during welding! 7-2.9.Periodically maintain the machine and clean the dust inside. Lens Shade Selector Guide Operation Electrode Size in.

  • Page 31: Parts List

    SECTION 8 PARTS LIST Item Order No. Description Note 8.301RM.386 Cover Curve penal ARC 200PFC/160PFC EMC board(similar to W.496RM.332-A-1 Base board(B.067RM.332-A) GYS) CWF4B103J4250 600mm without pin 7.231.088-B Thermistor shangying 3750V ARC 160 PFC/200 PFC HZ Penal 8.422RM.318 Heat sink I /w:S.021RM.379-E 8.068.011 Rear penal ZX7-160 simple JD03-A1 30A(high end) red 125/250V...
  • Page 32 CoolArc200 ARC 200 PFC HZ penal 8.422RM.321 Heat sink IV /w:S.021RM.379-E 8.123RM.382 Supporting bar HZ penal ARC 160PFC/200PFC ARC 200 PFC /w S.021RM.379-E L.185RM.379-U Transformer CSA certificate ARC160/200E-PFC W.496RM.515 Base board: B.067RM.515 absorb PCB 8.069RM.909-A Front penal With Ф12 hole Quick connector female CX58 35-70MM Hexagon thickness 7.152.313-A...
  • Page 33 8.713.184 Insulation block(4) polycarbonate (3 holes 12mm) Single transistor igbt 7.425.555 STGW60V60DF module Table 8.1 Page 28 Manual no. WM070401...
  • Page 34 CoolArc200 Figure 8.1 Manual no. WM070401 Page 29...
  • Page 35 NOTES WELDKING® CoolArc200 power source Page 30 Manual no. WM070401...

  • Page 36: Electric Diagram

    CoolArc200 SECTION 9 ELECTRIC DIAGRAM Figure 9.1 Manual no. WM070401 Page 31...

  • Page 37: Warranty Policy

    (2) All limited warranties are void for, and Malo Welding warranty online at weldking.com or mail the product Products Ltd.(WeldKing® ) does not warrant in any way, any registration card included in the package to Malo Welding product that evidences misapplication, improper installation, Products Ltd.(WELDKING®...

  • Page 38: Section 11 Authorized Service Center

    CoolArc200 SECTION 11 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.

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