WeldKing Pulsewave200 Owner'S Manual Download

Page: 2 / 51

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.

EMF Information EMF Information

.............................................................. 6

SECTION 2

PACKING LIST ............................................................................................................... 7

SECTION 3

INSTALLATIONS........................................................................................................... 8

3-1.

Welding power source specifications

........................................................... 8

3-2.

TIG torch specifications

.................................................................................... 9

3-3.

Process/Polarity Table

....................................................................................... 9

3-4.

TIG(AC/DC) welding connection diagram

.................................................. 10

3-5.

General installation procedure for TIG welding

........................................ 11

3-6.

STICK welding connection diagram

............................................................ 12

3-7.

General installation procedure for STICK welding

.................................. 13

3-8.

Electric service guide

...................................................................................... 13

3-9.

Extension Welding Cable Selection Chart

................................................. 14

SECTION 4 OPERATION .................................................................................................................... 15

4-1.

Panel layout and description

......................................................................... 15

4-2.

Parameter memory setting

............................................................................. 22

4-3.

Parameter lockout

............................................................................................ 22

4-4.

Short circuit protection while welding

........................................................ 22

4-5.

Operate with remote current control device connected

......................... 22

4-6.

Operation(TIG)

................................................................................................... 23

4-7.

Operation(STICK)

.............................................................................................. 23

4-8.

Welding Parameter selection chart

.............................................................. 24

SECTION 5 TROUBLE SHOOTING ................................................................................................... 26

5-1.

General trouble shooting

................................................................................ 26

5-2.

TIG/STICK welding trouble shooting

........................................................... 29

SECTION 6

MAINTENANCE ............................................................................................................ 33

6-1.

Maintenance

....................................................................................................... 33

6-2.

Safety precaution

.............................................................................................. 33

SECTION 7

PARTS LIST ................................................................................................................. 36

7-1.

Power Source

..................................................................................................... 36

7-2.

TIG torch

............................................................................................................. 40

SECTION 8

ELECTRIC DIAGRAM ................................................................................................ 45

SECTION 9

WARRANTY POLICY ................................................................................................ 47

SECTION 10

AUTHORIZED SERVICE CENTER .......................................................................... 48

All manuals and user guides at all-guides.com

Summary of Contents for Pulsewave200

Page 1: ...Power Sour ne Numbe Purchase f purchase SEWAVE GTAW rce r _ e _ ed _ E200 _________ _________ _________ _________ _________ _________ _________ _________ _________ _________ _________ _________ _ _ _ All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 2: ...re for STICK welding 13 3 8 Electric service guide 13 3 9 Extension Welding Cable Selection Chart 14 SECTION 4 OPERATION 15 4 1 Panel layout and description 15 4 2 Parameter memory setting 22 4 3 Parameter lockout 22 4 4 Short circuit protection while welding 22 4 5 Operate with remote current control device connected 22 4 6 Operation TIG 23 4 7 Operation STICK 23 4 8 Welding Parameter selection c...

Page 3: ...E SÉ This group of Out possible PARTS and symbols and necessary ac Ce groupe d Attention ORGANES M Consulter le afferents ci d prendre pour s au souda Do not use movement is falling Use AC outp process If AC outpu control if pre Additional sa any of the conditions a while wearin such as floo cramped po lying or whe or accidenta ground For equipment semiautoma 2 a DC m welder with r situations u we...

Page 4: ...or tal he to tal ork r ON de pe nd to ore us de ant fin à ant es r ant de ant la est res es si es ou me un tel es ts C à der der es y y y y y y y y y y y y y y y y y y anual no W situations l u fil à tension outre ne pas Couper l alim de procéder l entretien l alimentation 1910 147 vo Installer le p terre conven manuel de l provinciales Toujours d alimentatio terre du cord à la borne de du cordon ...

Page 5: ...Porteurs de distance Les porteurs doivent d ab de s approch l arc de gou ielding gas c essure If dama s cylinders are n sure to treat the Protect compre heat mechanic open flames sp Install cylinders a stationary s falling or tipping Keep cylinders electrical circui Never drape a Never allow a cylinder Never weld on will result Use only correc hoses and f application ma good condition Turn face aw...

Page 6: ...o lift and be sure forks a d opposite side uniquement po les chariots l accessoire vage de capac de levage po les fourches so dépasser du cô RTS can y NES euvent des uch as fans and guards close ove doors pane ce as necessary or guards whe fore reconnecti anes mobiles te Ma un es r de ne en ur our ue eur en ou es our de ant on té e er ar d are of our es ité our ont ôté ed els y en ng ells y y y y ...

Page 7: ...il ulièrement le nstallation eusement fermé es sources de h lateurs à une di MANUAL ence HF peu es avec les gation et de e sécurité et les des personnes es équipements ner l installation faire corrige an qualifié les allation érences arrête contrôle e és les portes e aute fréquence istance correcte Ma t s e s s s r s r t t e anual no W et utiliser un les interféren Consult th precaution Use only g...

Page 8: ... h power frequen an health hazar rth and eviden final conclusio y wish to minimi elds when weldi kplace use the effets de basse es et électrique passage dans amps encore un certa endant après av été faites penda un comité spéc uncil a conclu e jugement du sition aux cham à haute fréquen aine Toutefois les preuves ndant que les soient établies i otre exposition a t le soudage ou es sur le poste d a...

Page 9: ... Gauge hose with Ma d clamp with MANUAL TION 2 eWave200 p ce come wi Plug 26 ft 8M w ale 5 8 18 ga h 16 ft 5 M Ma PAC Table 2 1 package Par th 10 ft 3 with on off sw as connecto lead anual no W CKING L rt No 070025 M Power c witch 26ft or on both e M070301 LIST 500 Part cord n 07002 n 07000 end n 07000 07000 Page7 t no Qua a 1 2610 1 a 1 0510 1 a 1 0462 1 0417 1 7 ntity 1 1 1 1 1 1 1 All manuals a...

Page 10: ...60 100 s sion ion KG MANUAL TION 3 ource spe Pu AC TIG 00 18V 20A 4 5 5 2 200A 18V 165A 16 6V 0 120A 14 8V Ma INST ecifications ulseWave20 AC STIC 160 200 28 31 5A 7 200 35 20 28V 60 16 26 6V 100 1 24 8V 20 to 40 to 48 x14 1 56 x27 Table 3 1 anual no W TALLAT s 00 CK D 0V 275V 60 1 8V 17 A 66 00A 40 65A V 60 20A V 100 0 68 IP23 H 40 4 F to 85 40 F to 4 x24 19x51 2 10 5 22 5lbs x28 22x101 18 40lbs ...

Page 11: ...mm Thoria e red band Table arity to EP verse arity C EN aight arity C Ma TY CYCLE C n please see Back Cap 1 x 1 6mm 1 ozzle Alumina ode 1 8 3 2 ated Type re Table 3 2 Cable orch electro Connect to p output ter Connect to n output ter Table 3 3 anual no W CAN DAMAG PRO26 Pa 200A A 0 5 4 0 e separate to x Collet Body x Collet 1 8 a No5 1 x N 2mm Thoriat ed band and Cable Co To ode holder positive rm...

Page 12: ... M DC weldi 208 230v i G UST CONNE NEGTIVE EQUENCY S ork piece as hose MANUAL ing conne nput Gauge ECTED WHEN START Ma ection diag Figure 3 1 anual no W gram M070301 Cyl T T Page1 linder Earth cla To main pow To gas regul Control ca 10 mp wer ator able All manuals and user guides at all guides com ...

Page 13: ...tch located cable to the torch must Refer to n 90º clockw ose to the pro Cylinder Valv clamp to you Ma dure for TI d in a stable in invert or s on the rear p positive outp connected Figure 2 6 ise oper shieldin ve to the fully ur work piece anual no W IG welding e position and side position panel to OF put terminal d to negat Insert torch g gas source y open positi e M070301 g d with good v FF and...

Page 14: ... Wo OWNER S M welding co 208 230v i th clamp ork piece MANUAL onnection nput Powe Cord Ma diagram Figure 3 2 er To pow anual no W main wer Do not gas ga M070301 t connect auge Page1 12 Electrode holder All manuals and user guides at all guides com ...

Page 15: ...on proced d be installe oid transport itch located er earth cab holder earth guide MACHINE M LICABLE EL CORDEMEN RE CONFOR put A d fuse Ratin AWG Conductor Size in AWG Ma dure for ST d in a stable in invert or s on the rear p ble accordin clamp quick MUST BE CO LECTRICAL NT DE CETT RME AUX C 230 60 20 AC TIG ng 25 30 12 70 21M 12 Table 3 4 anual no W TICK weld e position and side position panel to...

Page 16: ... C MANUAL ng Cable S USE SHO A gth t Ft Circuit is total Ma Selection C RTEST CAB 100 4 20mm2 4 20 mm2 3 30 mm2 l of both weld Table 3 5 anual no W Chart BLE POSSIB 1 Cable S 2 3 30 2 2 35 2 1 50 d cables and M070301 BLE 150 Size AWG 0 mm2 5 mm2 0 mm2 d earth cable Page1 200 3 30 mm2 1 50 mm2 1 0 60 mm s 14 2 2 m2 All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 17: ...6 SEWAVE200 Panel la 7 16 15 13 14 OWNER S M SE ayout and 2 MANUAL ECTION d descripti 8 Ma 4 OP ion Figure 4 1 9 anual no W ERATIO 10 M070301 ON 11 Page1 3 12 1 17 19 18 15 All manuals and user guides at all guides com ...

Page 18: ...se the knob ht yellow TIG nate indicatin ply power at t s the yellow wer source o d TIG STICK e is within ac TICK t DC Apply tput AC Ap on TIG STIC ess both AC with HF arc ns according with lift arc s ns according Ma parameter v ring welding they are act the same tim the meter w ny time the f STICK uring welding isplay O e G STICK elect the par active to be a eter The par b to choose th G STICK ng...

Page 19: ...ng slope dow When curre is turned off ectrode and 5s ose the shiel Ma when TIG w rol is connec nd finish cur If you want t o 0 Figure 4 2 enoid valve w 0 1 10s Afte arted The de put current s up time is 0 ain the weldin he output will wn period cu ent slope dow the gas valv work piece a d gas stops anual no W welding Defa cted to the we rent are cont to control the will open to s er purge air f ef...

Page 20: ...ode and 5s ose the shie TIG ave These s p t3 se trigger Ma ong welding r Figure 4 3 ding power s witch only an power sourc ding enoid valve 0 1 10s Aft rted The def t start curren The output c t slope up tim his period th the welding orch trigger w eset finish cu pe down tim t finish curre will turn off bu the gas valv work piece a eld gas stops settings can b Gas on Welding current P anual no W r...

Page 21: ...ted to the m for AC TIG default 40 900Hz defau ff ed in real tim default is 75 insures that Ma n used wave ol ditional AC po oise level in thin materia sion of squar ction meanwh ult 0 2s purg 170 for DC T ure a soft arc amount of tim 0 s amount of le set to 0 5 170 for DC 5s protect t be changed i 5 170 for DC ing current W machine this 5 170 for DC percenta ult off turn k me during we percentag ...

Page 22: ...A defaul time When achine this c fault 30 a setting kic ce the tenden tion TIG ST ion TIG ST Ma penetration o ult 110Hz A gets wider A arc becomes me during we rcent above w en arc is initia total current lt 100A Us a remote cu control is the Percent abo cks in when y ncy of electro TICK ICK anual no W of the base m C frequency As AC freque s more focus lding welding curre ated It helps ses this s...

Page 23: ... connec cable conne switch nlet TIG 5 MANUAL ol connectio On off to per Trigge Trigge ction TIG ection 8 18 right ha Ma on receptacl Figure 4 4 f switch orch R er switch er switch Table 4 1 and threads f anual no W e 12 pins Remote curr Potentiom Potentiomet Potentiom Trigger s Trigger s Short wi Short wi female conn M070301 TIG rent torch meters ter Wiper meters switch switch ith 11 ith 10 ection...

Page 24: ...n Ma g ent paramete wn and releas r left will di 0 dial the rizing up to 1 procedures a n is active the current m ockwise from e lockout func without param WORD TH SET AND IT The voltage m o any operati h or foot ped again the cur ob until the v out function machine will r right will d hile weldin ablished if th 20A at with li e contaminat he work for m ent contro art no 0700 l receptacle a ces wh...

Page 25: ... make urce Select Ma 30V POWE cts to negativ edal torch a rm and reliab TIG mode H value refer to nd descriptio eel welding um and its a broken Duri elts and pene plate TIG we e seam Pul t input in eac ncy need hi arge and de meter left w meters And d the voltage m adjust gas vo orch and kee direction Aim ctrode to wo slowly lift el ing seam along seam e as valve At th 230V POWE e output is m nect...

Page 26: ... AND STA PPROVED R Taper of tungsten electrode 10 20 20 25 30 35 45 ter m Ma value refer to nd descriptio e striking a m too high If el ource and wa ion chart ommission of DE PRODUC ART FIRES U RESPIRATOR e Tungste electrod diamete mm 0 1 0 12 0 25 0 50 0 75 0 75 1 10 Table 4 2 Welding cu 20 6 44 8 60 10 anual no W o section 4 8 on Select us match lift ele lectrode stick all switch f the machin CE...

Page 27: ...PULS SEWAVE200 2 3 4 OWNER S M 2 5 3 2 4 0 MANUAL Ma 80 12 100 1 140 1 Table 4 3 anual no W 20 50 80 M070301 Page2 23 25 24 26 25 27 25 All manuals and user guides at all guides com ...

Page 28: ...w malfunc Cooling circu malfunc Cool fan f The st capacitor damag See No Work exce rate duty Input volta too high o low anual no W LE SHOO se ntact at ead p tion ntact witch ction fan it ction failure art of fan ged o 1 ess the circle age is r too U M070301 OTING So Check con Check con Replace Check swit nec Check Check fa nec Change Use under r Use under rat Page2 lution ntact situation ntact sit...

Page 29: ...CB is accura Problem circu Input volta too lo Gas pres not eno anual no W mal n the rcuit ower PCB ty dary drive B ty y IGBT le D is en ting at not ate A th main it age is w ssure ugh M070301 Check and r circuit and d Check repa Check repa Check an Change Adjust potent he control PC and Imax fo Check contr PCB and I Use rated i Check ga Page2 repair the ma drive PCB P air or replace air or replace...

Page 30: ...hort cir anual no W hose tion valve e C sage em s hose em C gger e circuit e ntactor g r poor ct rol rmer e short it n rmer rcuit M070301 Check gas Check and re va Check and r pas heck and rep Check g Replace c Check con Replace Replace t Check a Check a Page2 s connection place Soleno alve repair the ga ssage pair torch ca un trigger circuit board ntactor plug contactor transformer and replace an...

Page 31: ...e and recep mach Poor conn between elec and weldin anual no W rol rmer rcuit valve rcuit fan rcuit 5 1 g se ble size rode holder e ct between arth cable ptacle at hine nection ctrode hold ng cable M070301 Check a Check a Check a S Choose the Choose electr Clean and con Clean Page2 and replace and replace and replace olution e right cable e the right siz rode holder d tighten all w nnections and ti...

Page 32: ...nual no W ot installed leaking gas route d by air ble broken ontact broken or ontact ble too long l in the iece ip too far workpiece CB broken e between arger poles close t or poor act cuit board re tor failure M070301 Connect th and check in g Check t co Check t co Use prope Clean wo Reduce t abo Change H Adjust dis 0 Check Check and Check r Page3 e gas hose f possible lea gas route the cable and...

Page 33: ... too high cuit failure ble size or t proper election is oper ce surface ted by oil t inside the n failure ctor failure citor failure trol failure M070301 Check r Check r Check r Cha Reduc Check r circ See See Clean t s Check r Chec Chec Chec Check re connectio Ampe pote Page3 repair replac repair replac repair replac anges gas ce pressure repair replac cuit board e table 2 3 Table 3 2 he workpiece...

Page 34: ...de after G Ma Gas shield in Gas not Gas pre inadeq Table anual no W nadequate t pure essure uate 5 2 M070301 che Check if t torch and re tight a Increase Page3 ck nozzle there is wate epair Check all gas fitting e gas pressu 32 r in k and re All manuals and user guides at all guides com ...

Page 35: ... ion zzle when ne parts in the to and machine witches perly and if t the machine mal vibration ng operation are over hea ons are over cted firmly an cause bad properly n pped with w to choose p rds There sh mable explos cated at a sa othing away t be grounde light is enlig r heat and a ntil welder co d not work in Ma MAI eping the ma WITCH OFF 6 M orch to here is e noise ated nd B v tr C b ru Tabl...

Page 36: ...ANUAL expose to s elder during w e machine an ode Size mm n 3 32 2 5 32 2 5 4 4 4 6 4 n 1 4 6 4 dapted with p M Ma un welding nd clean the Arc Curre Amperes Less than 60 160 160 250 250 550 Less than 50 150 150 500 permission o Miami Florida Table 6 2 anual no W dust inside ent s Min Prot Sh 60 0 0 50 0 of the Americ a M070301 nimum tective hade 7 8 10 11 8 8 10 can Welding Page3 Suggeste Shade No...

Page 37: ...PULS SEWAVE200 0 OWNER S M MANUAL WELDKI M NOTES NG PulseW Manual no W S Wave200 WM070301 Page e35 All manuals and user guides at all guides com ...

Page 38: ...ve module thermistor Rectifier brid Rectifier brid positioning c AC DC TIG2 invertor PCB POWER SU WITH HF P M 7 PA cription ch ame te DC full ntrol PCB ert IGBT dge dge cap 200 primary B AND UPPLY PCB CB Manual no W PARTS LI TIG 200A S 006RM WS 160 LIGHT C 25A 250 GT 2000 milling c AG1202 AC DC m Enhance base boa TIG 200A 7 800 01 STGW60 CWF4B1 length15 BR6010 φ13 5 7 Base board B WM070301 IST Not...

Page 39: ...sink 6 heat sink 7 M display PCB utlet lar ection out plastic engyuan small high sensor insulation me separation w e re diode Manual no W B Base bo 25 15 m body gre needle TIG 200A S 006RM M12 1 5 WEIPU S SERIES CX58 35 thicknes 20 small BLY2 20 plastic i PCB with TIG 250 inductan 3 006RM TIG 200A cycle TIG 200A S 006RM HTS 419 PF 408 b TIG 200A S 006RM 60APU0 TIG 200A bar7 800 TIG 200A bar7 800 W...

Page 40: ...module solenoid val solenoid val Power plug M 200 nvertor PCB nvert IGBT lve box lve Table 7 1 Manual no W TIG 200A bar7 800 Base board B TIG 200A bar7 800 TIG 200A bar7 800 FGA180 enhance model Y pressure input DC US XN6 WM070301 AC DC secti 0 014 067RM 285 AC DC secti 0 014 AC DC secti 0 014 0N33ATD ed nylon YG2T 2 work e 0 0 8MPa C24V gas inl 50P Page on D on on letφ6 e38 1 1 1 1 8 1 1 1 All ma...

Page 41: ...PULS SEWAVE200 0 OWNER S M MANUAL M Figure 7 1 Manual no W WM070301 Page e39 All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 42: ... ns insulator u or large diam head flexible head include ap O ring ap long ap short ntary switch k MANUAL o 07002610 DESCRIPT bby collet bod use with 18C meter gas len cup gasket kit default M Figure 7 2 TION dy CG ns use with 1 Manual no W 8CG WM070301 O 18CG 18CG20 54N01 54N63 PRO26 PRO26 98W18 PRO57Y PRO57Y PRO1M Page ORDER NO 0 FX Y02 Y04 MS e40 All manuals and user guides at all guides com ...

Page 43: ...32 ndard collet ndard ceram MANUAL 8m 26ft e large ck nut m 2 6ft sembly x8m 2m 23 6ft kit DE S 0 5mm bore 1 0mm bore 6mm bore 2 4mm bore 2mm bore 4 0mm bore Sta Φ 3 2mm b 20 Φ 0 5mm 40 Φ 1 0mm 6 Φ 1 6mm 2 Φ 2 4mm body 5 32 Φ Stan mic cup 1 4 M 26ft Table 7 2 ESCRIPTION Standard col e e ndard collet bore m bore m bore bore bore Φ 4mm bore ndard cerami Φ 6mm bore Manual no W N let body ic cup e WM0...

Page 44: ... 0m 16 Φ 1 6m 32 Φ 2 4m 8 Φ 3 2mm Stu ody 0 020 1 Stubby s mic cup 1 4 mic cup 5 16 mic cup 3 8 mic cup 7 16 mic cup 1 2 mic cup 5 8 G 0 020 Φ 0 5 M Φ 8mm bor Φ 10mm bor Φ 13mm bor Φ 16mm bor Φ 19mm bor Φ 6mm bore ard long cera 8mm bore 0mm bore 11mm bore ubby series c mm bore mm bore mm bore mm bore m bore ubby collet b 8 Φ0 5mm standard cer Φ 6mm bore Φ 8mm bor Φ 10mm bor Φ 11mm bo Φ 13mm bor Φ ...

Page 45: ...m 3 32 Φ 2 4m 8 Φ 3 2mm ens cup 1 4 ens cup 5 16 ens cup 3 8 ens cup 7 16 ens cup 1 2 ens cup 11 16 cup 5 16 Φ cup 3 8 Φ 1 cup 7 16 Φ dy ens body 1 1 ens body 3 3 ens body 1 8 gas lens cup gas lens cup gas lens cup gas lens cup M 0mm bore mm bore mm bore m bore Φ6mm bore Φ8mm bor Φ10mm bor Φ11mm bo Φ13mm bor 6 Φ17mm b 8mm bore 0mm bore 11mm bore 6 Φ1 6mm 32 Φ2 4mm 8 Φ3 2mm b p 1 2 Φ15m p 3 8 Φ10m ...

Page 46: ...PULS SEWAVE200 0 OWNER S M MANUAL N WELDKI M NOTES ING PulseW Manual no W S Wave200 WM070301 Page e44 All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 47: ...PULS SEWAVE200 0 OWNER S M SECTIO MANUAL ON 8 M ELECT Figure 8 1 Manual no W TRIC DIA WM070301 AGRAM Page e45 All manuals and user guides at all guides com ...

Page 48: ...PULS SEWAVE200 0 OWNER S M MANUAL M Figure 8 2 Manual no W WM070301 Page e46 All manuals and user guides at all guides com ...

Page 49: ... P IN P A A R R O P O C W PA AL P D LT If fo an pr be co To pr pr W pu de al Au ne se pl w fro Manual no RANTY P d Warran ision at Ap ND PERSONS SE AND M UTTING EQUI n the event of a he exclusive re td WELDKING r where autho td WELDKING easonable cost ervice station o rice less reaso pon return of t o compensatio f any kind will b IMITATION O EPLACEMENT OODS SHALL NY WARRA RODUCTS LT R IMPLIED I R...

Page 50: ...weldki ANUAL 10 AU te www we Ltd will n d party and anty cente ing com UTHORI eldking co not distrib d will not er at m servic Manual IZED SE om to fill th bute of dis sent prom celocati no WM070 RVICE C he warran sclose cus motion ma ons asp 0301 CENTER ty registra stomer s p terial to th px Page48 ation form private he m All manuals and user guides at all guides com ...

Page 51: ...te OWNER S MA O WELDIN Amber Street 1 866 686 1 866 686 weldking co d July 16 2 ANUAL NG PRODU t Unit 10 M 5088 5090 om 014 UCTS LTD Markham ON D N L3R 3J7 Manu ual no WM0 070301 All manuals and user guides at all guides com a l l g u i d e s c o m ...

Search results

Summary of Contents for Pulsewave200

Reviews:

Related manuals for Pulsewave200

Brands by name

Popular brands

WeldKing Pulsewave200, Owner'S Manual

Search results

Summary of Contents for Pulsewave200

Reviews:

Related manuals for Pulsewave200

Brands by name

Popular brands