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WeldKing COOLTIG220 Owner's Manual

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COOLTIG220
PULSED TIG (P-GTAW)
STICK (SMAW)
Arc Welding Power Source
Serial Number:
Where Purchase:
Date of purchased:
_________________________________
_________________________________
_________________________________

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Summary of Contents for WeldKing COOLTIG220

  • Page 1 COOLTIG220 PULSED TIG (P-GTAW) STICK (SMAW) Arc Welding Power Source Serial Number: _________________________________ Where Purchase: _________________________________ Date of purchased: _________________________________...
  • 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: Serial Number: Where Purchase:...

  • Page 3: Table Of Contents

    Table of Contents SECTION 1   SAFETY PRECAUTIONS .................... 1   SECTION 1 CONSIGNES DE SÉCURITÉ ................... 1   1-1.   Symbol Usage Symboles utilisés ..............1   1-2.   Arc welding Hazards Dangers relatifs au soudage à l’arc ....... 1   1-3.   Safety Standards Normes de sécurité ............6   1-4.

  • Page 4: Section 1 Safety Precautions

    CoolTig - 220 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...
  • Page 5 CoolTig - 220 wiring − replace cord immediately if damaged − bare Couper l’alimentation ou arrêter le moteur avant de  wiring can kill. procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme ...
  • Page 6 CoolTig - 220 manipuler des cartes ou des pièces. MAGNETIC FIELDS can affect Utiliser des pochettes et des boîtes antistatiques pour pacemakers.  stocker, déplacer ou expédier des cartes PC. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.  Pacemaker wearers keep away. FIRE OR EXPLOSION hazard.
  • Page 7 CoolTig - 220 à gaz. enlever les portes, panneaux, recouvrements ou dispositifs de protection pour l’entretien.  Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.  Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et ...
  • Page 8 CoolTig - 220 faire fonctionner l’installation. READ INSTRUCTIONS. LIRE L’utilisateur est tenu de faire corriger rapidement par LES INSTRUCTIONS.  un electrician qualifié les interférences résultant de l’installation.  Si le FCC signale des interférences, arrêter immédiatement l’appareil.  Consult the Owner’s Manual for welding safety ...

  • Page 9: Safety Standards Normes De Sécurité

    CoolTig - 220 1-3. Safety Standards Normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Code for Safety in Welding and Cutting, CSA Standard W117.2, Standard Z49.1, from Global Engineering Documents (phone: from Canadian Standards Association, Standards Sales, 178 1-877-413-5184, website: www.global.ihs.com).

  • Page 10: Section 2 Packing List

    Part no Quantity CoolTig-220 Power source come with 10 ft. (3 M) Power cord and molded NEMA 6-50P 230V AC Plug WeldKing® PRO26 TIG gun 12.5 ft (4M) with on-off WAT31100 switch and 30-70 Dinse Style connection Torch accessories kit 07000510 Argon Regulator / Gauge 6.5 ft.

  • Page 11: Section 3 Basic Information

    CoolTig - 220 SECTION 3 BASIC INFORMATION 3-1. Power source specifications CoolTig220 package (Part No: WMT05000 ) Power supply AC 115V,60Hz,1 phase AC (208)V/230V,60Hz, 1 phase Welding STICK STICK Process Input Amps @ Maximum 23.9 25.4 24.5 24.4 output(A) Rated input (KW) Generator...

  • Page 12: Tig Torch Specifications

    CoolTig - 220 Power source 13(28.7lbs) weight (KG) Packing dimension 63x48x44(24.8x18.9x17.3in) (HxWxD)(CM) Packing 17.9(40lbs) weight(KG) Table 3.1 3-2. TIG torch specifications Model PRO17 (Part no. WAT31100 ) Rated currency(A) 150A DC, 115A AC Rated duty cycle (%) Cooling style Air cooled Air consumption (l/min) 4-15 4(12.5ft)
  • Page 13 CoolTig - 220 3-3. Process/Polarity Table Cable Connections Process Polarity Cable To Cable To Work torch/electrode holder STICK process DCEP – Connect to positive(+) Connect to Reverse output terminal negative(-)output terminal polarity TIG process Connect to negative(-) Connect to DCEN－ both AC and DC output terminal positive(+)output terminal...

  • Page 14: Section 4 Installations

    CoolTig - 220 SECTION 4 INSTALLATIONS 4-1. TIG(AC/DC) welding connection diagram CoolTig220 (115v input) Gauge To gas regulator To main power Cylinder Control cable To 115 volt, 20 ampere individual branch circuit Gas hose TIG torch MUST CONNECTED TO...
  • Page 15 CoolTig - 220 CoolTig220 (208/230v input) Gauge Cylinder Control cable Power cord To gas regulator Gas hose To main power Earth clamp TIG torch MUST CONNECTED TO THE NEGATIVE WHEN USE HF START! Work piece Figure 4.2 Manual no. WDT90100...

  • Page 16: General Installation Procedure For Tig Welding

    CoolTig - 220 4-2. General installation procedure for TIG 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. Avoid transport in invert or side position.

  • Page 17: Stick Welding Connection Diagram

    CoolTig - 220 4-3. STICK welding connection diagram CoolTig220 (115v input) Power Cord Electrode holder To 115 volt, 20 ampere individual branch circuit Earth clamp Figure 4.3 CoolTig220 (208/230v input) Power cord Electrode holder Earth clamp Figure 4.4 4-4. General installation procedure for STICK welding Manual no.
  • Page 18 CoolTig - 220 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.

  • Page 19: Electric Service Guide

    CoolTig - 220 4-5. 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) 208/230...

  • Page 20: Extension Welding Cable Selection Chart

    CoolTig - 220 4-6. Extension Welding Cable Selection Chart CAUTION! Use shortest cable possible. Turn off power before connecting to weld output terminals! Maximum total cable (Copper) length in weld circuit Welding cable size in allowed in Ft(M) AWG (mm Welding Amperes (A) 6(13) 260(80)

  • Page 21: Section 5 Operation

    CoolTig - 220 SECTION 5 OPERATION 5-1. Power source panel layout and description 1. Power indication light 9. AC frequency (60-160Hz) 2. VRD indication light 10. AC balance (60%-90%) 3. Protection indication light 11. Pulse on/off and frequency (0.5-20Hz) 4.
  • Page 22 CoolTig - 220 14.12 pin control port 18. Main switch 15. Negative output connect to torch 19. Power cord 16. Gas outlet to torch 20. Positive output connect 17. Gas inlet Figure 5.2 Manual no. WDT90100 Page 19...

  • Page 23: Operation(Tig)

    CoolTig - 220 5-2. Operation(TIG) USE SINGLE PHASE 115V/208V/230V POWER SUPPLY. 5-2.1.Always use DCEN (electrode connects to negative output) for both DC and AC, using pulse or not using pulse. 5-2.2.Connect up the shielding gas, foot pedal, torch and work lead to power source according to figure 4.1, 4.2, make sure connections are firm and reliable.
  • Page 24 CoolTig - 220 AC balance (60-90%, default is 75%): percentage of time polarity is electrode negative. The electrode positive cycle insures that the aluminum oxide is thoroughly removed, allowing the electrode negative cycle a thorough penetration of the base metal. AC frequency (60Hz-160Hz, default 90Hz): AC frequency controls bead width, lower AC frequency gets wider weld bead/ puddle gets wider.

  • Page 25: Operation(Stick)

    CoolTig - 220 5-3. Operation(STICK) USE SINGLE PHASE 115V/208/230V POWER SUPPLY. 5-3.1.DCEP (electrode connect to positive output) is most common used connection for STICK welding. In some case, DCEN or AC connection is required according to the specification of the electrode used. 5-3.2.Connect up the electrode holder, earth lead to power source according to section 4.3: STICK welding connection diagram, make sure connections are firm and reliable.

  • Page 26: Short Circuit Protection While Welding

    CoolTig - 220 automatically sense and identify the devices when connected. All remote controls work at TIG mode only. The maximum current remote control can adjust is limited to the current setting at machine. If you want to use panel to set the welding current while connecting to a remote current control torch, turn the current potentiometer in torch to max position, then you can adjust welding current by panel control.
  • Page 27 CoolTig - 220 1.0~1.6 0.50 25-50 1.0~1.6 0.75 50-70 1.6~2.4 0.75 65-95 1.6~2.4 1.10 90-120 Table 5.1 5-6.2.STICK welding parameter Electrode diameter (mm) Welding current (A) Welding voltage(V) 20~60 20~23 44~84 22~24 60~100 22~24 80~120 23~25 100~150 24~26 140~180 25~27 Table 5.2 Manual no.

  • Page 28: Torch /Foot Petal Control Connection Receptacle (12 Pins) (Tig)

    CoolTig - 220 5-7. Torch /Foot petal control connection receptacle (12 pins) (TIG) Figure 5.3 Foot pedal Switch torch Remote current Up-down torch torch Short with 2 Short with 1 Potentiometers + Potentiometers + Potentiometer Potentiometer Wiper Wiper Potentiometers - Potentiometers - down Trigger switch...

  • Page 29: Section 6 Trouble Shooting

    CoolTig - 220 SECTION 6 TROUBLE SHOOTING 6-1. General trouble shooting Problem Cause Solution Power Indication Loose contact at input lead Check contact lamp does not on situation after switch on the Lamp malfunction, poor contact Check contact main switch situation.
  • Page 30 CoolTig - 220 protection light on Work excess the rate duty circle Use under rate duty circle Input voltage is too high or too Use under rated input voltage Abnormal current in the main Check and circuit repair the main circuit and drive PCB No AC output while Faulty power supply PCB...
  • Page 31 CoolTig - 220 and Imax for max current No OCV Problem main circuit Check control PCB, Power PCB and IGBT module No gas Contactor Input voltage is too low Use rated input flow out closed voltage after Gas pressure not enough Check gas pull the pressure...
  • Page 32 CoolTig - 220 did not trigger close Control circuit failure Replace circuit board Loose contactor plug Check contactor plug Contactor poor contact Replace contactor Control transformer failure Replace transformer Gas flows all the Foreign object inside the valve Remove time Solenoid valve is damaged replace Wall breaker jump...

  • Page 33: Tig/Stick Welding Trouble Shooting

    CoolTig - 220 Control transformer short circuit Check and replace Solenoid valve short circuit Check and replace Cooling fan short circuit Check and replace The welding current The welding current Repair or cannot be adjusted potentiometer on the front panel change the loose connection or failure potentiometer...
  • Page 34 Check the cable and broken or poor connection contact. Earth cable broken Check the cable and or poor contact connection Weldking cable too Use proper length long welding cable Dirt or oil in the Clean workpiece workpiece surface Tungsten tip too far...
  • Page 35 CoolTig - 220 igniting The distance Adjust distance to board when between the HF about 0.7mm pull the discharger poles is trigger. too close. Fuse melt or poor Check and repair contact Control circuit Check and repair the board failure circuit board AC Contactor Check, repair, replace...
  • Page 36 CoolTig - 220 Control circuit Check, repair, replace failure circuit board Welding cable size See table 2.3 or type is not proper Electrode selection See Table 3.2 is not proper the work piece Clean the workpiece surface surface contaminated by oil Poor contact inside Check, repair, replace the gun...
  • Page 37 CoolTig - 220 Gas pressure Increase gas pressure inadequate Table 6.2 Manual no. WDT90100 Page 34...

  • Page 38: Section 7 Maintenance

    CoolTig - 220 SECTION 7 MAINTENANCE Maintenance 7-1. 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 39: Safety Precaution

    CoolTig - 220 heated. Check if the cable is connected firmly and properly, if it is broken and cause bad insulation. Check the cover grounded properly. Table 7.1 Safety precaution 7-2. Refer to the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING.

  • Page 40: Section 8 Parts List

    CoolTig - 220 SECTION 8 PARTS LIST Item Order No. Description Note 8.253RM.002 Handle Medium size 252*65*56 use with S.006RM.561-E TIG 8.301RM.561 Cover 210EP AC/DC PFC HZ Panel 8.304RM.002-A 1225 fan screen Chamfered inside FLAMA ARC 250 rear penal 8.068RM.945 Rear penal 302.5*190.5*45.enhance nylon 7.232.738 Toggle switch (red)
  • Page 41 CoolTig - 220 HZ-TIG 250 front penal(with large 302.5*191*77,enhanced nylon 8.069RM.990 Amphenol plug） Quick connector CX58 35-70MM hexagon 7.152.313-A female(no sleeve thickness 12MM zhengyuan) '8.462.104 Gas outlet WEIPU SP2112/S12 SERIES 12 pin Amphenol 7.132.012 plug 7.224.300-B1 Key switch cap Omter φ25*15 medium, 7.458.505 Knob black/grey cap no needle...
  • Page 42 CoolTig - 220 7.411.250 rectifier BR6010(32*32) Model:YG2T-2 work solenoid valve 2/2 7.253.013 pressure:0~0.8MPa power:DC24V(gas inletφ6) solenoid valve 8.123RM.923 Enhanced nylon mounting case BLY2-200IOV2L(BYD) 7.321.351 Hull amp sensor W.496RM.501- TIG 200ACDC PFC Base board: B.067RM.501-C primary inverter PCB 8.713.184 insulation block polycarbonate 3 holes 12.5mm single transistor 7.425.670...
  • Page 43 CoolTig - 220 ACDC200E W.496RM.329- Base board B.067RM.329-C. A-10 secondary inverter conductor frame inversed TIG 200E AC/DC A-11 8.422RM.246 heat sink(4) S.006RM.515,section plate 7.800.014 MUR1560 TO-220 (jinquan) A-12 7.401.074 Quick restore diode insulation block(2 A-13 8.713.182 polycarbonate 2 holes 10mm hole) A-14 7.421.695...
  • Page 44 CoolTig - 220 Figure 8.1 Manual no. WDT90100 Page 41...
  • Page 45 CoolTig - 220 TIG torch ® WeldKing PRO17, part no. WAT31100 Figure 8.2 Item Description Order No. Cup gasket 18CG Cup gasket for stubby collet body 18CG20 Gas lens insulator(use with 18CG) 54N01 Insulator large diameter gas lens(use with 18CG)
  • Page 46 CoolTig - 220 Back cap long PRO57Y02 Back cap short PRO57Y04 Momentary switch kit(default) PRO1MS Connector+leadsx4m/12.5ft PROSWL4 Pro-Grip™ Tig Handle Small PROH100 Screw pack PROSP Knuckle joint c/w lock nut PROKJ100 Leather cover x0.8m/2.6ft PROLC100-08 Complete cover assembly x4m/12.5ft PROCO100-40 Neoprene Cover x 3.2m/10.5ft PRONCL-32 Sheath joint repair kit...
  • Page 47 CoolTig - 220 Standard collet body Collet body 1/8”, Φ 3.2mm bore 10N29 Collet body 0.020”,Φ 0.5mm bore 10N30 Collet body 0.040”,Φ 1.0mm bore 10N31 Collet body 1/16”, Φ 1.6mm bore 10N32 Collet body 3/32”, Φ 2.4mm bore 10N28 Standard collet body 5/32’’,Φ 4mm bore 406488 Standard ceramic cup Standard ceramic cup 1/4”, Φ...
  • Page 48 CoolTig - 220 Stubby series collet Stubby Collet 0.020”, Φ 0.5mm bore 10N21S Stubby Collet 0.040”, Φ 1.0mm bore 10N22S Stubby Collet 1/16”, Φ 1.6mm bore 10N23S Stubby Collet 3/32”, Φ 2.4mm bore 10N24S Stubby Collet 1/8”, Φ 3.2mm bore 10N25S Stubby collet body Stubby Collet body 0.020”-1/8”, Φ0.5mm- 3.2 mm bore...
  • Page 49 CoolTig - 220 gas lens body 3/32”, Φ 2.4mm bore 45V26 gas lens body 1/8”, Φ 3.2mm bore 45V27 Standard gas lens cup Standard gas lens cup 1/4”, Φ6mm bore 54N18 Standard gas lens cup 5/16”, Φ8mm bore 54N17 Standard gas lens cup 3/8”, Φ10mm bore 54N16 Standard gas lens cup 7/16”, Φ11mm bore 54N15...
  • Page 50 CoolTig - 220 Large diameter gas lens cup 3/8”, Φ10mm Bore 57N75 Large diameter gas lens cup 3/4”, Φ19mm Bore 57N87 Large Dia Gas Lens Cup 5/89/16mm Bore 53N88 Table 8.3 Manual no. WDT90100 Page 47...
  • Page 51 CoolTig - 220 NOTES WELDKING® CoolTig220 power source Manual no. WDT90100 Page 48...

  • Page 52: Section 9 Electric Diagram

    CoolTig - 220 SECTION 9 ELECTRIC DIAGRAM Figure 9.1 Manual no. WDT90100 Page 49...
  • Page 53 CoolTig - 220 Figure 9.2 Manual no. WDT90100 Page 50...

  • Page 54: Warranty Policy

    (2) All limited warranties are void for, and Malo Welding make it effective within the bounds of law. Products Ltd.(WeldKing® ) does not warrant in any way, any To obtain warranty service you must active your product that evidences misapplication, improper installation, product(s)'s warranty online at weldking.com or mail the...

  • Page 55: Section 11   Authorized Service Center

    AUTHORIZED SERVICE CENTER SECTION 11 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. Find your nearest warranty center at: www.weldking.com/servicelocations.aspx...
  • Page 56 MALO WELDING PRODUCTS LTD. 271, Amber Street, Unit#10,Markham, ON L3R 3J7 Tel: 1 866 686 5088 Fax: 1 866 686 5090 Website: www.weldking.com Printed September 1st, 2016...

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