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COOLARC

200

Owner’s Manual

STICK ( SMAW)

TIG ( GTAW)

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Summary of Contents for COOLARC 200

Page 1: ...COOLARC 200 Owner s Manual STICK SMAW TIG GTAW ...

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 ...

Page 3: ......

Page 4: ... General installation procedure for STICK welding 11 4 3 LIFT TIG welding connection diagram 12 4 4 General installation procedure for Lift TIG welding 14 4 5 Electric service guide 14 4 6 Extension Welding Cable Selection Chart 15 SECTION 5 OPERATION 16 5 1 Power source panel layout and description 16 5 2 Operation 18 5 3 Welding Parameter selection chart 18 SECTION 6 TROUBLE SHOOTING 20 6 1 Gene...

Page 5: ...E ÉLECTRIQUE entraîner la mort Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the we...

Page 6: ...er le moteur avant de procéder à l installation à la réparation ou à l entretien de l appareil Déverrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l opérateur et les normes nationales provinciales et locales Toujours vérifier la terre du cordon d alimentation...

Page 7: ...consulter leur médecin avant de s approcher des opérations de soudage à l arc de gougeage ou de soudage par points CYLINDERS can explode if damaged LES BOUTEILLES peuvent exploser si elles sont endommagées Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect com...

Page 8: ... doors panels covers or guards for maintenance as necessary Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power S abstenir de toucher des organes mobiles tells que des ventilateurs Maintenir fermés et verrouillés les portes panneaux recouvrements et dispositifs de protection Seules des personnes qualifiées sont autorisées à enlever les portes pa...

Page 9: ...installation Si le FCC signale des interférences arrêter immédiatement l appareil Effectuer régulièrement le contrôle et l entretien de l installation Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles READ INSTRUCTIONS LIRE LES INSTR...

Page 10: ...2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to work piece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended Considération...

Page 11: ...lArc200 Power source come with 10 ft 3 M Power cord and NEMA 6 50P 230V AC Plug 1 300 Amp electrode holder with 13 ft 4 M 4 lead and 50mm male Dinse plug 07000463 1 300 Amp ground clamp with 10 ft 3 M lead 4 lead and 50mm male Dinse plug 07000462 1 Adapter Cable 5FT NEMA 6 50R 230V 5 20P 120V 07001825 1 Owner manual 07000418 1 ...

Page 12: ... Amperage range A 10A 10 4V 110A 14 4V 10A 10 4V 200A 18V Duty cycle 40 40 110A 14 4V 60 90A 16 3V 100 70A 12 8V 40 110A 24 4V 60 90A 23 6V 100 70A 22 8V 40 200A 18V 60 165A 16 6V 100 130A 15 2V 40 200A 28V 60 165A 26 6V 100 130A 25 2V Power factor 0 99 Protection class IP23 Insulation class H Operating temperature C 20 to 40 4 F to 104 F Storage temperature C 40 to 85 40 F to 185 F Machine dimens...

Page 13: ... 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 WARRANTY ...

Page 14: ...o WM070401 Page 9 CoolArc200 SECTION 4 INSTALLATIONS 4 1 STICK welding connection diagram CoolArc200 115v input Figure 4 1 To 115 volt 20 ampere individual branch circuit Power Cord Earth clamp Electrode holder ...

Page 15: ...Page 10 Manual no WM070401 CoolArc200 208 230v input Figure 4 2 Power Cord Earth clamp Electrode holder ...

Page 16: ...ort in invert or side position 4 2 2 Switch the ON OFF Switch located on the rear panel to OFF 4 2 3 Connect the work lead cable to the positive output terminal and the LIFT TIG Torch cable to the negative output terminal Refer to Figure 2 6 Insert torch earth clamp quick connector into receptacle and turn 90º clockwise 4 2 4 Connect the gas line hose to the proper shielding gas source Refer to Fi...

Page 17: ...Page 12 Manual no WM070401 4 3 LIFT TIG welding connection diagram CoolArc200 115v input Figure 4 3 To 115 volt 20 ampere individual branch circuit Power Cord Cylinder Gauge Earth clamp TIG Torch ...

Page 18: ...Manual no WM070401 Page 13 CoolArc200 CoolArc200 208 230v input Figure 4 4 Power Cord Cylinder Gauge Earth clamp TIG Torch ...

Page 19: ...onnection diagram refer to Figure 4 3 and 4 4 Insert Electrode holder earth clamp quick connector into receptacle and turn 90º clockwise 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 ...

Page 20: ...CAUTION Use shortest cable possible Turn off power before connecting to weld output terminals Welding cable size in AWG mm2 Maximum total cable Copper length in weld circuit allowed in Ft M Welding Amperes A 100 200 6 13 260 80 130 40 4 20 330 100 160 50 3 30 410 125 200 60 Table 4 2 ...

Page 21: ...ayout and description 1 Welding current meter digital 2 Power indication light 3 Protection indication light 4 Current adjustment knob 5 STICK lift TIG selection button 6 STICK indication light 7 TIG indication light 8 STICK VRD indication light Figure 5 1 1 2 3 4 5 6 7 8 ...

Page 22: ...Manual no WM070401 Page 17 CoolArc200 9 Positive output 10 Negative output 11 Power cord 12 Main switch Figure 5 2 12 10 11 9 ...

Page 23: ...alve on the torch adjust gas volume to 3 5L MIN check if there is gas leaking 5 2 6 Touch tungsten electrode to workpiece at weld start point Hold electrode to Workpiece for 1 2 seconds and then slowly lift electrode Arc is formed when electrode is lifted Aim Tungsten electrode to the welding seam 5 2 7 After arc is ignited move the torch along seam evenly Fine tune the welding parameter to obtain...

Page 24: ...RESPIRATOR Plate thickness mm Tungsten electrode diameter mm Taper of tungsten electrode Tungsten electrode end diameter mm Welding current A Max argon flow rate L min Weld layer 0 2 1 0 1 6 10 0 1 10 15 2 1 0 4 1 0 1 6 20 0 12 15 20 2 5 1 0 6 1 0 1 6 20 0 25 15 30 2 5 1 1 0 1 0 1 6 25 0 50 25 50 3 1 1 6 1 0 1 6 30 0 75 50 70 4 1 2 4 1 6 2 4 35 0 75 65 95 6 1 3 0 1 6 2 4 45 1 10 90 120 7 1 2 Table...

Page 25: ...sary 2 Cooling fan stops to rotate after machine has worked a period Power indication lamp on Cooling fan blade blocked by obstacle Clear Cool fan failure Check fan replace if necessary Power indication lamp off See No 1 3 Overheat light on Work excess the rate duty circle Use under rate duty circle Input voltage is too high Use under rate input voltage 4 The mains power circuit breaker or fuse nu...

Page 26: ...n Initial setting at PCB is not accurate Adjust potentiometer Imin on the control PCB for min current and Imax for max current 7 No OCV Problem main circuit Check control PCB Power PCB and IGBT module No arc Welding cable and earth cable is loose or broken Check and repair Difficult to strike the arc or electrode stick to the workpiece Loose connection Check connection and repair Surface of the wo...

Page 27: ...weld connections Poor connection between electrode hold and welding cable Clean and tighten 13 Unstable or wandering arc Gas not pure Changes gas Gas pressure too high Reduce pressure Control circuit failure Check repair replace circuit board Welding cable size or type is not proper See Table 4 1 Electrode selection is not proper See Table 5 1 the work piece surface contaminated by oil Clean the w...

Page 28: ...nections for remote Amperage control potentiometer 14 Tungsten electrode oxidizing not bright after welding Gas shield inadequate check nozzle Gas not pure Check if there is water in torch and repair Check and tight all gas fitting Gas pressure inadequate Increase gas pressure Table 6 2 ...

Page 29: ...ed by loose or rusted screw Check the contactors and relays in the machine or on the PCB work properly Calibrate the current meter Check the resistance between machine case and main circuit if the value is smaller than 1MΩ sent the machine to an authorized warranty depot to inspect and repair immediately Table 7 1 7 2 Safety precaution Refer to the American National Standard Z49 1 entitled SAFETY ...

Page 30: ... inside Lens Shade Selector Guide Operation Process Electrode Size in mm Arc Current Amperes Minimum Protective Shade Suggested Shade No Comfort Shielded metal arc welding SMAW Less than 3 32 2 5 3 32 5 32 2 5 4 5 32 1 4 4 6 4 More than 1 4 6 4 Less than 60 60 160 160 250 250 550 7 8 10 11 10 12 14 Gas tungsten arc welding GTAW Less than 50 50 150 150 500 8 8 10 10 12 14 AWS F2 2 2001 R2010 Adapte...

Page 31: ...ertificate 1 7 8 122RM 386 Fan installation plate ARC 160 200 PFC curve penal 1 8 8 304RM 001 Fan cover Curve penal 1 9 7 720 053 Fan MODEL 3610VL 05W B70 24VDC 0 49A 1 10 8 123RM 919 Middle sport plate Enhanced nylon 1 11 8 423RM 089 MCR heat sink ARC 200 PFC HZ penal w S 021RM 379 E 1 12 8 713RM 200 MCR insulation cap 95 7 31 8 10 for 4 pc MUR dust proof 1 13 7 401 079 Fast recovery diode STTH60...

Page 32: ...386 A Penal installation plate ARC 160 200 PFC curve penal with stud length change 1 26 7 458 505 Knob middle size φ21 15 black body with grey cap 1 27 L 271RM 071 U PFC induction Ferrite ring w S 021RM 071 FU CSA certificate 1 28 WP 496RM 507 1 ARC 200PFC control pcb mini Base board BP 067RM 507 1 29 8 422RM 319 Heat sink II ARC 200 PFC HZ penal w S 021RM 379 E 1 30 7 411 250 A Rectifier bridge S...

Page 33: ...Page 28 Manual no WM070401 36 8 713 184 Insulation block 4 polycarbonate 3 holes 12mm 6 37 7 425 555 Single transistor igbt module STGW60V60DF 6 Table 8 1 ...

Page 34: ...Manual no WM070401 Page 29 CoolArc200 Figure 8 1 ...

Page 35: ...Page 30 Manual no WM070401 NOTES WELDKING CoolArc200 power source ...

Page 36: ...Manual no WM070401 Page 31 CoolArc200 SECTION 9 ELECTRIC DIAGRAM Figure 9 1 ...

Page 37: ...previously sold or manufactured MALO WELDING PRODUCTS LTD WELDKING S PRODUCTS ARE FOR COMMERCIAL INDUSTRIAL USE AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING PLASMA CUTTING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Malo Welding Products Ltd WELDKING s option 1 repair or 2 replacement or where authorized in wri...

Page 38: ...e 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 http www weldking com servicelocations aspx ...

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