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WeldKing STICK 200 Owner's Manual

Arc welding power source
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Process: Stick (SMAW)
TIG (GTAW)
Arc Welding Power Source
Date of purchase:
Machine Number:
Where purchased
STICK 200
OWNER'S MANUAL
ISO9001
________________
________________
________________
www.weldking.com

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Summary of Contents for WeldKing STICK 200

  • Page 1 ISO9001 Process: Stick (SMAW) TIG (GTAW) Arc Welding Power Source Date of purchase: ________________ Machine Number: ________________ Where purchased ________________ STICK 200 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 ................6 1-4.

  • Page 3: 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: Installations

    SECTION 2 INSTALLATIONS 2-1. Welding power source and specifications STICK WELDING POWER SOUCE STICK 200 STICK 200 Type 208/230V/60Hz Power supply Phase Rated input(KVA) Open circuit voltage(V) 20-200 Amperage range(A) 20-28 Welding Voltage(V) Rated Duty cycle (%) Rated welding current(A)

  • Page 10: Connection Diagram

    2-2. Connection diagram Power cord To main power Power cord Earth clamp Work piece Electrode holder Foot pad or remote controller Figure 2.1 Arc welding connection diagram Page...

  • Page 11: Install Procedure

    Gauge Power cord Cylinder Ar gas Foot pad or remote controller Tig torch Earth clamp Work piece 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) Input Amperes at rated output(A) Max recommended standard fuse Rating in Amperes...

  • Page 13: Operation

    SECTION 3 OPERATION Front panel Layout POWER OVER HEAT REMOTE Figure 3.1 Page...
  • Page 14 Figure 3.2 1. Power indicator 5. Earth lead terminal 2. Over-heat protection indicator (Turn 6. Welding current adjustment knob red when line voltage exceed limit; Turn 7. Circuit breaker yell when internal temperature too high) 8. Fan 3. Remote control receptacle 9.

  • Page 15: Overheat/Malfunction Light

    Overheat/Malfunction light: When Overheat light change color, power source shut off Green to yellow: work excess the rate duty circle, internal temperature too high. Shut off power source until cool down Green to red and flashing slow: Input voltage is too low. Use rated input voltage. Shut off power source and restart.

  • Page 16: Welding Parameter Selection Chart

    3-4.2 Switch on the power source. 3-4.3 Set Welding Current to desired value (refer to 3-4. Welding Parameter selection chart). Set Arc force to desired value. Increases SMAW short-circuit amperage at low arc voltage. This allows the operator to use a very short arc length without sticking the electrode.
  • Page 17 Plate Tungsten Taper of Tungsten Welding Max argon Weld thickness electrode tungsten electrode current flow rate layer (mm) diameter electrode end diameter (L/min) (mm) (°) (mm) 1.0~1.6 10-15 1.0~1.6 0.12 15-20 1.0~1.6 0.25 15-30 1.0~1.6 0.50 25-50 1.0~1.6 0.75 50-70 1.6~2.4 0.75 65-95...

  • Page 18: 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 19 agency. Cooling fan Power Fan blade blocked Check and stops to rotate indication clear the after machine lamp on blocked blade has worked a Cooling fan circuit malfunction Check fan period circuit Cool fan failure Check fan, replace if necessary Power See No.
  • Page 20 AC Contactor failure Check, repair, replace Welding cable broken or poor Check the contact connection Gun cable broken Replace cable Control transformer failure Check, repair, replace Main transformer failure or Check, repair, poor contact replace Unstable or wandering arc Gas not pure Changes gas Gas pressure too high Reduce...
  • Page 21 connections for remote Amperage control potentiometer Tungsten electrode Gas shield inadequate Increase post oxidizing( not bright) after flowime, check welding nozzle Gas not pure Check if there is water in torch repair.Check and tight all gas fitting Increase gas Gas pressure inadequate pressure Line disconnect switch jump Rectifier short circuit...

  • Page 22: 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 23 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 24 SECTION 6 ELECTRICAL DIAGRAM IGBT 1 1 2 3 4 5 MOTOR AC CN13 CN11 220V REMOTE REC Figure 6.1 Page...
  • Page 25 ABSORBER IGBT2 SHORT ARC LONG ARC THERMOST AT 1 2 3 4 1 2 3 4 5 6 CN10 CN12 CONTROL PCB 红 PRO TECTION 绿 WORK POWER REMOTE PCB ARC FORCE CEPTACLE WELDING CURRENT Title STICK-200Schm atick diagram Size Number Revision Tabloid...

  • Page 26: Parts List

    SECTION 7 PARTS LIST Item Order No. Description Quantity 0811006 Power light 0811007 Work/O.C light 0901031 Welding current knob 0901031 Auxiliary current knob 0601010 Output terminal‘+’ 0601006 Remote receptacle（6P） 0601010 Output terminal ‘-’ 1599144 Front panel 1080079 Main transformer 0208002 Capacitance 0303056 Reactance...
  • Page 27 Figure 7.1 Page...
  • Page 28 Figure 7.2 Page...
  • Page 29 NOTES WELDKING™ TIG 200P Page...

  • Page 30: Warranty Policy

    SECTION 8 WARRANTY POLICY Malo Welding Products Ltd., Warranty Policy Effective August 1 , 2004 LIMITED WARRANTY - Subject to the terms and PERSONS TRAINED AND EXPERIENCED IN THE conditions below, Malo Welding Products Ltd., MAINTENANCE WELDING warrants to its original retail purchaser that new EQUIPMENT.

  • Page 31: 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 32 MALO WELDING PRODUCTS LTD. Bay 6, 5710, Barlow Trail, SE, Calgary, Alberta, Canada, T2C 1Z9 Tel: 1 (403) 203 9118 Fax: 1 (403) 203 3666 www.malowelding.com Printed August 2, 2006...

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