CIGWELD WeldSkill 200AC/DC Service Manual
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CIGWELD WeldSkill 200AC/DC Service Manual

Inverter arc welding machine
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200AC/DC
INVERTER
ARC WELDING MACHINE
A-11419

Service Manual

Revision: AC
Issue Date: April 23, 2015
Manual No.: 0-5206
Operating Features:

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Questions and answers

James Alexander McFarlane
January 27, 2025

I **** getting the error message Error 001

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1 comments:
Mr. Anderson
February 10, 2025

Error 001 on the CIGWELD WeldSkill 200AC/DC indicates either a thermal overload or a primary circuit overcurrent issue.

1. Thermal Overload: This occurs when the duty cycle of the power source is exceeded. The unit will reset automatically once it cools down. The fan should remain running during this period. If the Fault Indicator remains on after 30 minutes, the unit should be checked by an Accredited CIGWELD Service Provider.

2. Primary Circuit Overcurrent: This results from a malfunction in primary circuit components, causing excessive current. The unit should be switched off and allowed to cool for at least 30 minutes. If Error 001 and the Fault Indicator persist after restarting, the unit should be inspected by an Accredited CIGWELD Service Provider.

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Summary of Contents for CIGWELD WeldSkill 200AC/DC

  • Page 1: Service Manual

    200AC/DC INVERTER ARC WELDING MACHINE A-11419 Service Manual Revision: AC Issue Date: April 23, 2015 Manual No.: 0-5206 Operating Features:...
  • Page 2 To locate your nearest distributor or service provider call +1300 654 674, or visit us on the web at www.cigweld.com.cn This Service Manual has been designed to instruct you on the correct use and operation of your CIGWELD product.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. Welding Power Supply Service Manual Number 0-5206 for: WeldSkill 200AC/DC Plant Part Number W1006200 Published by: CIGWELD Pty Ltd 71 Gower Street Preston, Victoria, Australia, 3072 www.cigweld.com.au...

  • Page 4: Table Of Contents

    WELDSKILL 200AC/DC Power Source Controls, Indicators and Features ..4-1 4.02 WELDSKILL 200AC/DC - STICK Programming Mode ........4-6 4.03 WELDSKILL 200AC/DC – LIFT TIG and HF TIG Programming Mode ..... 4-7 4.04 Short Circuit Protection While Welding ............4-10 4.05 Shielding Gas Regulator Operating Instructions ...........
  • Page 5 TABLE OF CONTENTS SECTION 6: TROUBLESHOOTING ................6-1 6.01 Basic Troubleshooting-Power Source Faults ........... 6-1 6.02 Advanced Troubleshooting ................6-2 6.03 Test Equipment and Tools ................6-2 6.04 Visually Inspect ....................6-2 6.05 Preliminary DC Bus measurement of the main inverter board ......6-3 6.06 Preliminary check of the main inverter board ..........
  • Page 6 WARRANTY TERMS ..............INSIDE REAR COVER GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......... REAR COVER...

  • Page 7: Safety Instructions And Warnings

    SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 200AC/DC INVERTER SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
  • Page 8 WELDSKILL 200AC/DC INVERTER SAFETY INSTRUCTIONS AND WARNINGS 9. Do not use welder to thaw frozen pipes. 2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. 10. Remove stick electrode from holder or cut off welding wire at 3.
  • Page 9 SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 200AC/DC INVERTER Recommended Protective Filters for Electric Welding Minimum Shade Number of Approximate range of Weldi Description of Process Current in Amps Filter(s) Less than or equal to 100 100 to 200 Manual Metal Arc Welding covered...

  • Page 10: Principal Safety Standards

    WELDSKILL 200AC/DC INVERTER SAFETY INSTRUCTIONS AND WARNINGS 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American WARNING Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. MOVING PARTS can cause injury. Safety and Health Standards, OSHA 29 CFR 1910, from Superinten- Moving parts, such as fans, rotors, and belts can cut fingers and dent of Documents, U.S.

  • Page 11: Declaration Of Conformity

    Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance, ultra safe operation and world class quality for more than 30 years and will continue to achieve excellence.

  • Page 12: Symbol Chart

    WELDSKILL 200AC/DC INVERTER SAFETY INSTRUCTIONS AND WARNINGS 1.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static...

  • Page 13: Servicing Hazards

    SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 200AC/DC INVERTER 1.05 Servicing Hazards WARNING WARNING FLYING METAL or DIRT can injure eyes. The symbols shown below are used throughout this • Wear safety glasses with side shields or face shield during manual to call attention to and identify possible haz- servicing. ards. When you see the symbol, watch out, and follow • Be careful not to short metal tools, parts, or wires together...

  • Page 14: Emf Information

    WELDSKILL 200AC/DC INVERTER SAFETY INSTRUCTIONS AND WARNINGS • Reinstall doors, panels, covers, or guards when maintenance 1.06 EMF Information is finished and before reconnecting input power. Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields WARNING Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern MAGNETIC FIELDS can affect Implanted Medical about such fields. However, after examining more than 500 studies Devices. spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of...

  • Page 15: Introduction

    2.04 Description Gives information regarding possible per- sonal injury. Warnings will be enclosed in a The CIGWELD WELDSKILL 200AC/DC is a single phase box such as this. constant current welding inverter capable of performing MMAW (Stick), GTAW (HF TIG) and GTAW (Lift TIG) welding processes.
  • Page 16 WELDSKILL 200AC/DC INVERTER INTRODUCTION Notes Introduction Manual 0-5206...

  • Page 17: Safety And Installation

    200 AC/DC MMAW (STICK) GTAW (TIG) SAFE OPERATING REGION (TIG & STICK) 100 110 120 130 140 150 160 170 180 190 200 210 220 Welding Current (AMPS) A-11218 Figure 3-1: WELDSKILL 200AC/DC Duty Cycle Manual 0-5206 Safety and Installation...

  • Page 18: Specifications

    90A @ 100%, 13.6V Open circuit voltage (VRD inactive) Protection Class IP23S Table 3-1: WELDSKILL 200AC/DC Specification NOTE Note 1: The Effective Input Current should be used for the determination of cable size & supply requirements. Note 2: Generator Requirements at the Maximum Output Duty Cycle.

  • Page 19: Environment

    SAFETY AND INSTALLATION WELDSKILL 200AC/DC INVERTER 3.03 Environment These units are designed for use in environments with increased hazard of electric shock as outlined in AS 60974.1 and AS 1674.2. Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock.

  • Page 20: High Frequency Interference

    WELDSKILL 200AC/DC INVERTER SAFETY AND INSTALLATION cases this remedial action may be as simple as earthing the welding circuit, see NOTE below. In other cases it could involve constructing an electromagnetic screen WARNING COMPUTER enclosing the Welding Power Source and the work, It is also possible that operation close to complete with associated input filters.
  • Page 21 SAFETY AND INSTALLATION WELDSKILL 200AC/DC INVERTER C. Methods of Reducing Electromagnetic Emissions 1. Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply.

  • Page 22: Volt-Ampere Curves

    Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. WELDSKILL 200AC/DC GTAW(TIG ) MMAW ( STICK) Welding Current (AMPS) A-11420 Figure 3-2: WELDSKILL 200AC/DC Volt-Ampere Curves Safety and Installation Manual 0-5206...

  • Page 23: Operation

    OPERATION WELDSKILL 200AC/DC INVERTER SECTION 4: OPERATION 4.01 WELDSKILL 200AC/DC Power Source Controls, Indicators and Features MODE 200 18.0 VOLTS SECONDS POWER PERCENT (%) FREQ (Hz) FAULT Peak Amps Volts Current PULSE PROCESS LIFT TIG Trough Start Current Base HF TIG...
  • Page 24 WELDSKILL 200AC/DC INVERTER OPERATION 1. Positive Welding Terminal Positive Welding Terminal. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
  • Page 25 During the time of cooling the power source should remain ON such that the fan continues to operate allowing the unit to cool sufficiently. If after 30 minutes with the fan running the Fault Indicator has not gone OFF then have an Accredited CIGWELD Service Provider check the power source.
  • Page 26 WELDSKILL 200AC/DC INVERTER OPERATION AMPS Peak Current Base Current Down Arc Ignited Arc Terminated Slope Slope Initial Crater Current Current TIME Post Flow Flow Press & hold Press & hold Release Release Trigger Trigger Trigger A-11221 Trigger Figure 4-4 9. Wave Balance / Arc Force Indicator This indicator light will illuminate when programming Wave Balance (AC HF TIG mode only) or Arc Force (STICK mode only).
  • Page 27 Supply. The Shielding Gas inlet is located on the rear of the Power Source. 21. Cooling Fan The WeldSkill 200AC/DC is fitted with a cooling fan that will operate continuously when the On/Off switch on the rear panel is switched to the On position.

  • Page 28: Weldskill 200Ac/Dc - Stick Programming Mode

    WELDSKILL 200AC/DC INVERTER OPERATION 4.02 WELDSKILL 200AC/DC - STICK Programming Mode Press the PROCESS button to select STICK mode. Press the MODE switch to toggle between AC and DC welding output. The Programming LED’s are always active. Press FORWARD or BACK to cycle through available programming functions.

  • Page 29: Weldskill 200Ac/Dc - Lift Tig And Hf Tig Programming Mode

    Table 4-2 4.03 WELDSKILL 200AC/DC – LIFT TIG and HF TIG Programming Mode Press the PROCESS button to select LIFT TIG or HF TIG mode. Press the MODE switch to goggle between AC and DC welding output.
  • Page 30 WELDSKILL 200AC/DC INVERTER OPERATION MODE VOLTS SECONDS POWER PERCENT (%) FREQ (Hz) FAULT Amps Volts Current PULSE PROCESS LIFT TIG Trough Start Current Base HF TIG Width Current Down Slope STICK Slope Crater Initial Frequency Current Current Post PURGE TRIGGER...
  • Page 31 OPERATION WELDSKILL 200AC/DC INVERTER Peak Current This parameter sets the PEAK weld current when in PULSE Amps mode. 10 to 200A (DC TIG mode) 30 to 200A (AC TIG mode) Trough Current The lowest point in the pulse is called the Trough.

  • Page 32: Short Circuit Protection While Welding

    WELDSKILL 200AC/DC INVERTER OPERATION Wave Balance VOLTS SECONDS This parameter operates in AC PERCENT (%) TIG mode and is used to set the FREQ (Hz) Volts penetration to cleaning action 10 to 65% ratio for the AC weld current. Generally WAVE BALANCE is set to 50% for AC STICK welding.

  • Page 33: Shielding Gas Regulator Operating Instructions

    OPERATION WELDSKILL 200AC/DC INVERTER 4.05 Shielding Gas Regulator Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Regulator Safety This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.
  • Page 34 WELDSKILL 200AC/DC INVERTER OPERATION Installation 1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices and damage seats before connecting the regulator. Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition.

  • Page 35: Setup For Tig (Gtaw) Welding

    OPERATION WELDSKILL 200AC/DC INVERTER 2. To reduce flow rate, allow the welding grade shielding gas to discharge from regulator by opening the downstream valve. Bleed welding grade shielding gas into a well ventilated area and away from any ignition source. Turn adjusting screw counterclockwise, until the required flow rate is indicated on the gauge.

  • Page 36: Foot Control, Part No. W4015800 (Optional Accessory)

    WELDSKILL 200AC/DC INVERTER OPERATION MODE 200 18.0 VOLTS SECONDS PERCENT (%) POWER FAULT FREQ (Hz) Peak Amps Volts Current PULSE PROCESS LIFT TIG Trough Start Base Current HF TIG Current Width Down Slope STICK Slope Initial Crater Frequency Current Current...
  • Page 37 Table 4-4 Description The CIGWELD Foot Control is a foot operated switch and potentiometer which starts and stops the welding process and controls welding current through operation of the foot pedal. Refer to list below for compatible Cigweld power sources.

  • Page 38: Setup For Stick (Mmaw) Welding

    WELDSKILL 200AC/DC INVERTER OPERATION 4.08 Setup for STICK (MMAW) Welding A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

  • Page 39: Theory Of Operation

    THEORY OF OPERATION WELDSKILL 200AC/DC INVERTER SECTION 5: THEORY OF OPERATION 5.01 Inverter Design What does the word inverter mean? The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the incoming AC to DC, and then the transistors create a higher frequency AC. The higher frequency AC then goes on to a much smaller main transformer than in a conventional power supply.
  • Page 40 WELDSKILL 200AC/DC INVERTER THEORY OF OPERATION Notes Theory of Operation Manual 0-5206...

  • Page 41: Troubleshooting

    TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER SECTION 6: TROUBLESHOOTING 6.01 Basic Troubleshooting-Power Source Faults The following table is a guide for analyzing problems and making repairs to the Power Source. Fault Possible Cause Remedy There is no weld The main Power Switch is set to OFF...

  • Page 42: Advanced Troubleshooting

    WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING 6.02 Advanced Troubleshooting If the problem cannot be solved by the basic (external) troubleshooting guide, the Power Source cover will have to be removed to allow the technician to analyze failures with a few common tools.

  • Page 43: Preliminary Dc Bus Measurement Of The Main Inverter Board

    TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER 6.05 Preliminary DC Bus measurement of the main inverter board Read and follow safety information in Section 6.02 before proceeding. Check DC bus voltage has discharged to less than 5VDC before servicing. Ensure the mains supply plug...

  • Page 44: Preliminary Check Of The Main Inverter Board

    WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING 6.06 Preliminary check of the main inverter board Read and follow safety information in Section 6.02 before proceeding. IGBT Testing Multimeter Lead Placement Diode Voltage Positive meter lead to testpoint 4 IGBT T3 &T4 0.2 – 0.8 VDC...

  • Page 45: Pcb Connectors

    TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER DC Bus Testing Multimeter Lead Placement Voltage with Supply voltage Upper capacitor bank Positive meter lead to testpoint 1 168 VDC +/-10% Negative meter lead to testpoint 2 Lower capacitor bank Positive meter lead to testpoint 2...
  • Page 46 WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING Power Supply PCB DCIN POWER/FJ 8.066.526--G A-11423_AB DCIN Header Pin Pin function signal DC Bus positive 336 VDC ±10% DC Bus negative 0 VAC Table 6-9: DCIN Header pin function (connects to mains supply) DY1 Header Pin...
  • Page 47 TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER HF PCB A-11424_AB COIL 220V COIL Header Pin Pin function signal +24 VDC 700VAC +/-10% GND (ARC starter primary input) 700VAC +/-10% Table 6-14: ARC starter primary input HOU Header Pin Pin function signal +24 VDC...
  • Page 48 WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING AC/DC Drive PCB A-11425 Header Pin Pin function signal Output 1 of main welding inverter transformer Output 2 of main welding inverter transformer Positive of welding current rectifier Negative of welding current rectifier Table 6-19: Header pin function (connects to main Inverter transformer)
  • Page 49 TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER Display PCB A-11426 J1 (10 pin) J1 Header Pin Pin function signal +5 VDC 5 VDC Serial interface Serial interface Serial interface Serial interface Serial interface Serial interface Serial interface Serial interface 0 VDC 0 VDC...
  • Page 50 WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING Primary Side Inverter PCB DCOUT A-11427_AB DRIVE Header Pin Pin function signal +15 VDC 15 VDC PWM signal 1 PWM signal 2 PWM signal 2 PWM signal 1 Current Transformer Signal 0 VDC 0 VDC Table 6-21: DRIVE Header pin function (connects to DRIVE header on control PCB)
  • Page 51 TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER AC/DC Output PCB POSITIVE OUTPUT OF WELDING RECTIFIER NEGATIVE OUTPUT OF WELDING RECTIFIER A-11428_AC POSITIVE SIDE IGBT’S POSITIVE OUTPUT NEGATIVE SIDE IGBT’S Header Pin Pin function signal Output 1 of main welding inverter transformer Output 2 of main welding inverter transformer...
  • Page 52 WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING Main Control PCB LED/SF SOU OT QF/HF TEST POINTS POWER DRIVE ACPOUT A-11429_AC GUN Header Pin Pin function signal 0 VDC 0 VDC trigger Remote pot maximum Remote pot wiper 0 VDC 0 VDC Table 6-27: GUN Header pin function (connects to 8 pin remote socket)
  • Page 53 TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER LED/SF Header Pin Pin function signal +24 VDC 24 VDC No connection No connection No connection Table 6-28: LED/SF Header pin function SOU Header Pin Pin function signal +24 VDC 24 VDC 0 VDC 0 VDC...

  • Page 54: Dip Switch Settings, Control Pcb

    6.10 DIP switch settings, Control PCB DIP Switch SW0, control PCB SW1 position Function Set to ON for Weldskill 200AC/DC Set to OFF for Weldskill 200AC/DC Set to ON for Weldskill 200AC/DC Set to ON for Weldskill 200AC/DC Set to ON for Weldskill 200AC/DC...

  • Page 55: Calibration

    TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER 6.11 Calibration Calibration IMAX A-11430 Set SW0 position 4 to OFF while the power source is turned off, to allow calibration of output volts & amps. Manual 0-5206 6-15 Troubleshooting...

  • Page 56: Main Circuit Description

    WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING 2 Output Current Calibration Select STICK process and DC mode on the front panel. Measure no load output welding voltage and adjust WVF potentiometer so Volts display reads within 0.1V of the measured value. Select TIG process and DC mode on the front panel.

  • Page 57: Circuit Diagram

    TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER 6.13 Circuit Diagram ACOUT ACOUT ACPOUT QF/HF POWER J2 (10) POWER/FJ POWER SUPPLY BOARD DC-IN JB (10) A-11227_AC Manual 0-5206 6-17 Troubleshooting...
  • Page 58 WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING Notes Troubleshooting 6-18 Manual 0-5206...

  • Page 59: Disassembly Procedure

    DISASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER SECTION 7: DISASSEMBLY PROCEDURE 7.01 Safety Precautions for Disassembly Read and follow safety information in Section 6.02 before proceeding. Unplug unit before beginning Disassembly procedure. 7.02 Case Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1.

  • Page 60: Control Board Removal

    WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE 7.03 Control Board Removal Read and follow safety information in Section 6.02 before proceeding with disassembly Remove case (refer to 6.04) before remove control board. 1. M4 Screw. Remove 4 screws from control panel. 2 Disconnect DRIVE harness from DRIVE connector.

  • Page 61: Auxiliary Power Supply Pcb2 Removal

    DISASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER 7.04 Auxiliary Power Supply PCB2 Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Disconnect DCIN harness from DCIN Connector. 2 Disconnect DY2 harness from DY2 connector. 3. Disconnect DY1 harness from DY1 connector 4.

  • Page 62: Pcb3 Removal

    WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE 7.05 PCB3 Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Remove screw. 2. Disconnect output harness from output Connector. 3 Disconnect input harness from input connector. 4. Disconnect SOU harness from SOU connector 5.

  • Page 63: Pcb4 Removal

    DISASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER 7.06 PCB4 Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Remove 6 screws. 2. Disconnect wire from terminals. A-11435 7.07 PCB5 Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1.

  • Page 64: Front Panel Assembly Removal

    WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE 7.08 Front Panel assembly Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Remove front panel screws. 2. Remove Positive Output Terminal Bolt. 3. Remove Negative Output Terminal Bolt. 4. Remove ground wire from front panel.

  • Page 65: Front Panel (Operator Interface) Circuit Board Pcb Removal

    DISASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER 7.09 Front Panel (operator Interface) Circuit Board PCB Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Remove Control Panel Screws. 2. Disconnect JB harness from JB connector. 3. Remove ground wire.

  • Page 66: Back Panel Removal

    WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE 7.10 Back Panel Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Remove 6 screws on rear panel. 2. Remove ground screw and input wire screw. 3. Remove gas inlet.
  • Page 67 DISASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER 7.11 Main Power PCB1 Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Remove 5 screws. 2. Remove wire screws. 3. Disconnect harness from connectors. A-11440 Manual 0-5206 Disassembly Procedure...

  • Page 68: Main Power Pcb2 Removal

    WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE 7.12 Main Power PCB2 Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Remove 4 screws. 2. Remove 5 screws. 3. Remove wire screws 4. Disconnect harness from connectors. Disassembly Procedure...

  • Page 69: Power Switch S1, Fan And Power Cord Removal

    DISASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER 7.13 Power Switch S1, Fan and Power Cord Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Remove 3 switch screws. 2. Remove power cord screw. 3. Disconnect wire from switch terminals.
  • Page 70 WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE Notes Disassembly Procedure 7-12 Manual 0-5206...

  • Page 71: Assembly Procedures

    ASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER SECTION 8: ASSEMBLY PROCEDURES 8.01 Installing Main Power PCB1 1. Install main PCB1 assembly screws 2. Install wire screws. 3. Plug harness into connectors. A-11440 Manual 0-5206 Assembly Procedures...

  • Page 72: Installing Main Power Pcb2

    WELDSKILL 200AC/DC INVERTER ASSEMBLY PROCEDURES 8.02 Installing Main Power PCB2 1. Install 5 screws. 2. Install wire screws. 3. Plug harness into connectors. 4. Install base plate. Assembly Procedures Manual -5206...

  • Page 73: Installing Front Panel

    ASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER 8.03 Installing Front Panel 1. Reinstall positive output terminals on front panel with 17mm wrench. 2. Reinstall negative output terminals on front panel with 17mm wrench. 3. Reinstall ground wire. 4. Reinstall hose for gas outlet.

  • Page 74: Installing Rear Panel

    WELDSKILL 200AC/DC INVERTER ASSEMBLY PROCEDURES 8.04 Installing Rear Panel 1. Reinstall ON/OFF Switch. install 3 screws. 2 Plug power supply cable to swtich connector. 3. Reinstall ferrite core into ground wire. 4. Reinstall fan. 5. Reinstall power cord and screw.

  • Page 75: Installing Pcb5

    ASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER 8.05 Installing PCB5 1. Install wire to terminals , tighten screws. A-11436 8.06 Installing PCB4 1. Install 4 screws. 2. install wire to terminals and tighten. 3. Reconnect 2 yellow wires. A-11446 Manual 0-5206 Assembly Procedures...

  • Page 76: Installing Pcb3

    WELDSKILL 200AC/DC INVERTER ASSEMBLY PROCEDURES 8.07 Installing PCB3 1. Insert plastic stud onto PCB3 board. 2. install screw. 3. Plug harness into HF connector. 4. Plug harness into SOU connector. 5. Plug harness into INPUT connector. 6. Plug harness into OUTPUT connector.

  • Page 77: Installing Control Board

    ASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER 8.09 Installing Control Board 1. Install 4 screws. 2. Plug harness into DRIVE connector. 3. Plug harness into J8 connector. 4. Plug harness into POWER connector. 5. Plug harness into SS connector. 6. Plug harness into GUN connector.

  • Page 78: Installing Case

    WELDSKILL 200AC/DC INVERTER ASSEMBLY PROCEDURES 8.10 Installing Case 1. Install ground screw. 2. Install side panel screws. 3. Install front panel screws. 4. Install rear panel screws. A-11449 Assembly Procedures Manual -5206...

  • Page 79: Key Spare Parts

    KEY SPARE PARTS WELDSKILL 200AC/DC INVERTER SECTION 9: KEY SPARE PARTS 9.01 Power Source A-11226_AB Figure 9-1 Manual 0-5206 KEY SPARE PARTS...
  • Page 80 WELDSKILL 200AC/DC INVERTER KEY SPARE PARTS WeldSkill 200AC/DC Spare Parts Item Part Number Description W7005500 PCB display W7005503 PCB aux power supply W7005502 PCB HF W7005504 PCB primary inverter W7005505 PCB AC output drive W7005506 PCB control W7005507 PCB secondary rectifier...
  • Page 81 WELD whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of CIGWELD is authorized to change this warranty in any way or grant any other warranty.
  • Page 83 CIGWELD. 4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supply of goods which are not of a kind ordinarily acquired for personal, domestic or household use or consumption to any one or more of the following (the choice of which shall be at the option of CIGWELD).
  • Page 85 Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date CIGWELD delivered the product to the Accredited Distributor. Unless otherwise stated the warranty period includes parts and labour. CIGWELD reserves the right to request documented evidence of date of purchase.
  • Page 86 Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider. All costs associated with lodging the warranty claim including the return of goods to Cigweld or our Nominated Accredited Distributor / Accredited Service Provider are the responsibility of the consumer.

  • Page 87: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Victor Technologies, China Cigweld, Australia No 100 Lao Hongjing Rd 71 Gower Street Minhang District Preston, Victoria Shanghai, PR, 200235 Australia, 3072 Telephone: 86-21-64072626 Telephone: 61-3-9474-7400 Fax: 86-21-64483032 Fax: 61-3-9474-7391 Email: cigweldsales@cigweld.com.au Victor Technologies Asia Sdn Bhd...
  • Page 88 Asia Pacific Regional Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX: +61 3 9474 7391 Email: enquiries@cigweld.com.au www.Cigweld.com.au...

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