ESAB CIGWELD WeldSkill 205AC/DC Operating Manual
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ESAB CIGWELD WeldSkill 205AC/DC Operating Manual

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WARRANTY*
OUTPUT CURRENT
HF
STICK
WARRANTY*
3
2
205A
AC/DC
ELECTRODE
4.0mm MAX
P/N: W1008205
Version No: AA
Issue Date: 15-04-2019
Manual No: 0-5555

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Summary of Contents for ESAB CIGWELD WeldSkill 205AC/DC

  • Page 1 WARRANTY* OUTPUT CURRENT STICK WARRANTY* 205A AC/DC ELECTRODE 4.0mm MAX P/N: W1008205 Version No: AA Issue Date: 15-04-2019 Manual No: 0-5555...
  • Page 2 YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. CIGWELD is a Market Leading Brand of Arc Welding Products for ESAB. We are a mainline supplier to major welding industry sectors in the Asia Pacific and emerging global markets including; Manufacturing, Construc- tion, Mining, Automotive, Engineering, Rural and DIY.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. CIGWELD WeldSkill 205AC/DC Welding Inverters Instruction Manual Number 0-5555 for: Part Numbers W1008205 Published by:...
  • Page 4 Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Goug- ing,”...
  • Page 5 DECLARATION OF CONFORMITY According to The Arc Welding Power Source Directive AS 60974.1-2006 (equivalent to IEC 60974-1 Ed. 2.1) The EMC Directive IEC 60974-10:2014 published on 06 February 2014 Type of equipment Welding Inverter Power Source Type designation etc. Welding Performance Brand name or trade mark Cigweld Manufacturer or his authorised representative established within the EEA...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ........1-1 1.01 Arc Welding Hazards ..................1-1 1.02 PRINCIPAL SAFETY STANDARDS ..............1-5 SECTION 2: INTRODUCTION ..................2-1 2.01 How To Use This Manual ................2-1 2.02 Equipment Identification ................. 2-1 2.03 Receipt Of Equipment ..................
  • Page 7 TABLE OF CONTENTS SECTION 6: STICK (MMAW) WELDING ................6-1 6.01 Setup For STICK (MMAW) Welding ..............6-1 6.02 STICK Programming Mode ................6-2 6.03 Arc Welding Electrodes ................... 6-3 6.04 Types of Electrodes ..................6-4 6.05 Size of Electrode ..................... 6-5 6.06 Storage of Electrodes ..................
  • Page 8 This Page Intentionally Blank...

  • Page 9: Arc Welding Safety Instructions And Warnings

    SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACE- MAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT. Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.
  • Page 10 2. Wear approved safety glasses. Side shields WARNING recommended. ARC RAYS can burn eyes and skin; NOISE can damage hearing. 3. Use protective screens or barriers to protect others from flash and glare; warn others not to Arc rays from the welding process produce in- watch the arc.
  • Page 11 4. Be alert that welding sparks and hot materials WARNING from welding can easily go through small cracks FUMES AND GASES can be hazardous to your and openings to adjacent areas. health. 5. Watch for fire, and keep a fire extinguisher Welding produces fumes and gases.
  • Page 12 6. Turn face away from valve outlet when opening The following is a quotation from the General cylinder valve. Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of 7. Keep protective cap in place over valve except Power when cylinder is in use or connected for use.

  • Page 13: Principal Safety Standards

    1.02 PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W.
  • Page 14 This Page Intentionally Blank GENERAL INFORMATION 0-5555...

  • Page 15: Introduction

    SECTION 2: INTRODUCTION 2.01 How To Use This Manual 2.02 Equipment Identification This Owners Manual only applies to the Part Numbers The unit’s identification number (specification or listed on page i. part number), model, and serial number usually ap- pear on a nameplate attached to the control panel. In To ensure safe operation, read the entire manual, some cases, the nameplate may be attached to the including the chapter on safety instructions and...

  • Page 16: Symbol Chart

    2.04 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 Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier Purging Of Gas Increase/Decrease Remote...

  • Page 17: Description

    2.05 Description 2.07 Packaged Item The CIGWELD WELDSKILL 205AC/DC is a single WeldSkill 205AC/DC Inverter (Part No. W1008205) phase constant current welding inverter capable • WeldSkill 205AC/DC Inverter Power Source of performing MMAW (Stick) and GTAW (HF TIG) welding processes. The unit is equipped with digital •...

  • Page 18: Duty Cycle

    2.09 Duty Cycle The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used.

  • Page 19: Specifications

    2.10 Specifications Description WELDSKILL 205 AC/DC Plant Part Number W1008205 Power Source Mass 12 kg Power Source Dimensions H 324mm x W 176mm x D 430mm Cooling Fan Cooled Welder Type Inverter Power Source Australian Standards AS 60974.1-2006 / IEC 60974-1 Number of Phases Nominal Supply Voltage 240V +/- 15%...

  • Page 20: Optional Accessories

    NOTE 3 Minimum Generator Recommendation at the Maximum Output Duty Cycle. Due to large variations in performance and specifications of different brands and types of generators, CIGWELD cannot guarantee full welding output power or duty cycle on every brand or type of generator. Some small generators incorporate low cost circuit breakers on their outputs.
  • Page 21 TIG Torch Consumables Part Number Description BG10N49/R Nozzle Alumina 8mm, for 17, 26 & 18 TIG Torches (pkt of 5) BG10N48/R Nozzle Alumina 10mm, for 17, 26 & 18 TIG Torches (pkt of 5) BG10N47/R Nozzle Alumina 11mm, for 17, 26 & 18 TIG Torches (pkt of 5) BG10N46/R Nozzle Alumina 12.5mm, for 17, 26 &...
  • Page 22 Related Products Part Number Description 646754 WeldSkill TIG Welding Gloves 646755 WeldSkill Heavy Duty Welding Gloves 454304 WeldSkill Auto Darkening Welding Helmet Fixed Shade 11 Black 454305 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Blue 454314 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Carbon Fibre 454321 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Racer 454322...

  • Page 23: Installation

    SECTION 3: INSTALLATION 3.04 Mains Supply Voltage 3.01 Environment Requirements These units are designed for use in environments with increased hazard of electric shock. The Mains Supply Voltage should be within ± 15% of the rated Mains Supply Voltage. If actual Mains A.

  • Page 24: High Frequency Interference

    3.09 Short Circuit Protection While WARNING It is also possible that operation Welding close to computer installations may To prolong the useful life of a TIG tungsten elec- cause computer malfunction. trode, the WeldSkill 205 AC/DC incorporates special circuitry. 3.06 High Frequency Interference In AC and DC HF TIG mode, if the tungsten elec- Interference may be transmitted by a high frequency trode touches the work the welding current is...
  • Page 25 B. Assessment of Area 2. Maintenance of Welding Equipment Before installing welding equipment, the user shall The welding equipment should be routinely make an assessment of potential electromagnetic maintained according to the manufacturer’s problems in the surrounding area. The following shall recommendations.

  • Page 26: Foot Control, Part No. W4015800 (Optional Accessory)

    3.11 Foot Control, Part No. W4015800 (Optional Accessory) Art # A-11338 Figure 3-1: Foot Control Art # A-11339 Art # A-11340 Figure 3-2: 8 Pin Control Plug Description Not Used Trigger Switch Trigger Switch Not Used Potentiometer Maximum Potentiometer Minimum Potentiometer Wiper Not Used Table 3-1...
  • Page 27 Foot Control Operation Press the foot pedal to start the machine output functions. The foot control potentiometer controls the welding current up to the level set on the welding power source. With the foot control connected, the power source will only display minimum preview Amps until the foot control is depressed then it displays actual welding current when welding.
  • Page 28 This page is left blank intentionally. INSTALLATION 0-5555...

  • Page 29: Operation

    SECTION 4: OPERATION 4.01 Overview Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to workpiece and electrode lead is used to hold electrode (Consult the electrode manufacturers information for the correct polarity). The welding current range values should be used as a guide only. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between different classes of electrode, welding current at any one setting would vary according to the type of electrode in use.
  • Page 30 2. 8 Pin Control Socket The 8 pin receptacle is used to connect a trigger switch or remote control to the welding Power Source circuitry: To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. The socket information is included in the event the supplied cable is not suitable and it is necessary to wire a plug or cable to interface with the 8 pin receptacle.
  • Page 31 5. Power ON Indicator The POWER ON indicator illuminates when the ON/OFF switch is in the ON position and the correct mains voltage is present. NOTE If the Power Source is repeatedly switched On then Off rapidly or the supply to the power source is turned On and Off rapidly it may not turn On due to in-built protective devices acting.
  • Page 32 4T Latch Mode This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator can press and release the torch trigger and the output will remain active. To deactivate the power source, the trigger switch must again be depressed and realised, thus eliminating the need for the operator to hold the torch trigger.
  • Page 33 13 Pulse Hz (Frequency) Indicator (AC and DC TIG Pulse Modes only) Pulse indicator will illuminate when set pulse frequency (AC and DC Pulse TIG modes only). Refer to Section 5.03 in the Programming Mode for further detail. 14. Programming Parameter Indicators These indicator lights will illuminate when programming.
  • Page 34 20. Back Button Press Back Button to return to previous parameter selected.. 21. On / Off Switch This Switch is located on the rear of the Power Source and turns mains power off and on. WARNING When the front digital displays are lit, the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential.

  • Page 35: Tig (Gtaw) Welding

    SECTION 5: TIG (GTAW) WELDING 5.01 Shielding Gas Regulator/Flowmeter Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Regulator/Flowmeter Safety This regulator/flowmeter 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 36 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 37: Setup For Tig (Gtaw) Welding

    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 clockwise, until the required flow rate is indicated on the gauge. Close downstream valve.

  • Page 38: Tig Programming Modes

    Preset Argon Regulator 240VAC Gas Hose Shielding Gas Cylinder Mains Supply Gas Hose Positive Welding Terminal (+) Work Lead 8 Pin Socket Gas Outlet TIG Torch Trigger Switch Negative Welding Terminal (-) TIG Torch TIG Torch Remote Current Art # A-13993 Control Figure 5-3: Setup For TIG (GTAW) Welding 5.03 TIG Programming Modes...
  • Page 39 Programming Parameter Adjustment Display Factory Setting Device Pre-Flow 0.5 second This parameter operates TIG modes only and is used to provide gas to the weld zone prior to striking the arc, once Range: 0.1 to 1.0 second the torch trigger switch has been pressed.
  • Page 40 Programming Parameter Adjustment Display Factory Setting Device Up Slope 1 second This parameter operates in (4T) TIG modes only and is used to set the time for the weld current to ramp up, after the torch trigger Range: 0.0 to 15.0 seconds switch has been depressed then released, from INITIAL CUR to PEAK or BASE current.
  • Page 41 Programming Parameter Adjustment Display Factory Setting Device Crater Current 20 Amps This parameter operates in (4T) TIG modes only and is used to set the finish current for TIG. The CRATER Current remains Range: ON until the torch trigger switch is released after it has been 10 Amps to base current (AC/ depressed.

  • Page 42: Factory Reset

    Wave Balance = 50% Wave Balance = 10% Wave Balance = 65% Balanced with 50% penetration Maximum Penetration and Maximum Cleaning and and 50% cleaning reduced cleaning reduced penetration A-11223 Table 5-2: AC TIG Wave Balance 5.04 Factory Reset CAUTION All Welding Parameters will be restored to the factory setting.

  • Page 43: Tig (Gtaw) Basic Welding Technique

    5.05 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a weld- ing process in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable) electrode and the work piece.
  • Page 44 Tungsten Electrode Types Electrode Type Welding Application Features Colour Code (Ground Finish) AC & DC welding of mild Longer life, More stable steel, stainless steel, copper, arc, Easier starting, Wider Ceriated 2% Grey aluminium, magnesium and their current range, Narrower more alloys concentrated arc.

  • Page 45: Tig (Gtaw) Welding Problems

    5.06 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive bead build up or Welding current is too Increase weld current and/or faulty joint poor penetration or poor preparation. fusion at edges of weld. 2 Weld bead too wide and Welding current is too Decrease weld current.
  • Page 46 FAULT CAUSE REMEDY 9 Arc start is not smooth. A Tungsten electrode A Select the right size tungsten electrode. is too large for the Refer to Table 5-3 Cigweld Tungsten welding current. Electrode Selection Chart. B The wrong electrode B Select the right size tungsten electrode is being used for the type.

  • Page 47: Stick (Mmaw) Welding

    SECTION 6: STICK (MMAW) WELDING 6.01 Setup For STICK (MMAW) Welding A. Select Stick mode with the process selection control (refer to Section 4.02.07 for further information). B. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer.

  • Page 48: Stick Programming Mode

    6.02 STICK Programming Mode Press the Process Selection button to select STICK mode. Use the Multi Function Control to adjust the Parameter selected. While welding the Multi Function Control directly controls the BASE CURRENT Adjust programming parameter A-13997 Figure 6-2: Stick Programming Mode STICK (MMAW) Welding 0-5555...

  • Page 49: Arc Welding Electrodes

    Programming Parameter Adjustment Display Factory Device Setting Hot Start 40 Amps This parameter operates in all weld modes and is used to heat up the weld zone in TIG modes or improve the start characteristics for stick electrodes the peak start current on top of the Range: 0 to 70Amps BASE (WELD) current.

  • Page 50: Types Of Electrodes

    6.04 Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications. There are a great number of electrodes used for specialised industrial purposes which are not of particular interest for everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for welding large diameter pipes, etc.

  • Page 51: Size Of Electrode

    6.05 Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufficient current (amperage) to run the smaller size electrodes. For most work, a 2.5mm electrode will be quite sufficient.

  • Page 52: Joint Preparations

    Art # A-07687 Art# A-07693 Figure 6-3: Flat position, down hand butt weld Figure 6-9: Overhead position, butt weld Art # A-07694 Art # A-07688 Figure 6-4: Flat position, gravity fillet weld Figure 6-10: Overhead position fillet, weld 6.11 Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation.

  • Page 53: Arc Welding Technique

    Single Vee Butt Joint Open Square Butt Not less than 70° Joint 1.6mm (1/16” ) max Gap varies from 1.6mm (1/16”) to 4.8mm (3/16”) depending on plate thickness 1.6mm (1/16”) Not less than Single Vee Butt Joint Double Vee Butt Joint Not less than 45°...

  • Page 54: Striking The Arc

    6.14 Striking the Arc If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. If the travel is too slow, the weld metal piles Practice this on a piece of scrap plate before going on up and the bead will be too large.
  • Page 55 45° from vertical 60° - 70° from line of weld Art # A-07698 Figure 6-14: Weld build up sequence Art # A-07699_AB Heavy plate will require several runs to complete the Figure 6-15: Electrode position for HV fillet weld joint. After completing the first run, chip the slag out and clean the weld with a wire brush.

  • Page 56: Distortion

    a length of angle iron at right angles to another Art # A-07701 piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch.

  • Page 57: The Cause Of Distortion

    6.19 The Cause of Distortion Distortion is cause by: A. Contraction of Weld Metal: Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In a welded joint, the metal becomes attached to the side of the joint and cannot contract freely.

  • Page 58: Overcoming Distortion Effects

    6.20 Overcoming Distortion Effects There are several methods of minimising distortion effects. A. Peening This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer.
  • Page 59 Art # A-07709 Figure 6-25: Examples of distortion Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool. Figure 6-26: Welding sequence Art # A-07711_AB Figure 6-27: Step back sequence Art # A-07712 Figure 6-28: Chain intermittent welding Art # A-07713_AB Figure 6-29: Staggered intermittent welding...

  • Page 60: Welding Problems

    6.21 Welding Problems Description Possible Cause Remedy 1 Gas pockets or voids in weld metal A Electrodes are damp A Dry electrodes before use (Porosity) B Welding current is too high B Reduce welding current 　 　 C Surface impurities such as oil, C Clean joint before welding 　...
  • Page 61 Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high Lack of Art # A-05867_AC inter-run fusion Lack of side fusion, scale dirt, small electrode, Lack of root fusion amperage too low Figure 6-31: Example of Lack of Fusion Description Possible Cause Remedy...
  • Page 62 Description Possible Cause Remedy 6 Non-metallic particles are trapped in A Non-metallic particles may A If bad undercut is present, the weld metal (slag inclusion) be trapped in undercut from clean slag out and cover previous run with a run from a smaller diameter electrode B Joint preparation too B Allow for adequate...

  • Page 63: Routine Service Requirements And Power Source Problems

    SECTION 7: ROUTINE SERVICE REQUIREMENTS AND POWER SOURCE PROBLEMS 7.02 Cleaning the Welding Power 7.01 Routine Maintenance & Source Inspection WARNING WARNING There are extremely dangerous voltage and There are extremely dangerous voltage and power levels present inside this product. Do power levels present inside this product.

  • Page 64: Welding Power Source Problems

    7.04 Welding Power Source Problems FAULT CAUSE REMEDY 1 Mains Supply Voltage is On, Power source is not in the Set the power source to the the On/Off switch on the rear correct mode of operation. correct mode of operation with panel is in the On position the process selection switch.

  • Page 65: Section 8: Key Spare Parts

    SECTION 8: KEY SPARE PARTS 8.01 WeldSkill 205AC/DC Key Spare Parts Art # A-13995 Figure 8-1 WELDSKILL 205AC/DC POWER SOURCE KEY SPARE PARTS ITEM PART NUMBER DESCRIPTION W7006923 Top and Side Panel W7006913 PCBA Primary Inverter W7006929 Fan Assembly W7006924 Base Panel W7006914 Gas Solenoid Assembly...

  • Page 66: Tig Torch 8M (P/N W4014605) Key Spare Parts

    8.02 TIG Torch 8m (P/N W4014605) Key Spare Parts A-11669_AB Figure 8-2 TIG TORCH SPARE PARTS ITEM PART NO. DESCRIPTION W7005900 Trigger assembly for 26F torch W7005901 Handle assembly for 26F torch W7005902 Dinse 50mm for 26F torch W7005903 Flex head for 26F torch BGSAK2 Tig accessory Kit* UOA706900...

  • Page 67: Appendix: Weldskill 205Ac/Dc Circuit Diagram

    APPENDIX: WELDSKILL 205AC/DC CIRCUIT DIAGRAM 0-5555 APPENDIX...
  • Page 68 This Page Intentionally Blank. APPENDIX 0-5555...

  • Page 69: Cigweld - Limited Warranty Terms

    CIGWELD - LIMITED WARRANTY TERMS LIMITED WARRANTY: CIGWELD Pty Ltd, An ESAB Brand, hereafter, “CIGWELD” warrants to customers of its autho- rized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the CIGWELD products as stated below, CIGWELD shall, upon notification thereof and substantiation that the product has been stored, installed, oper- ated, and maintained in accordance with CIGWELD’s specifications, instructions, recommendations and recognized...
  • Page 70 WARRANTY SCHEDULE – WELDSKILL 205AC/DC INVERTERS WARRANTY WARRANTY PERIOD – (Parts and Labour) WeldSkill 205AC/DC Inverter Power Source 3 Years ACCESSORIES WARRANTY PERIOD TIG torch, electrode holder lead and work lead 3 Months TIG torch consumable items Gas regulator/flowmeter (excluding seat assem- bly, pressure gauges, elastomer seals and "O"...
  • Page 71 This Page Intentionally Blank...
  • Page 72 CIGWELD Pty Ltd Singapore - Malaysia - Indonesia - CIGWELD An ESAB Brand ESAB Asia Pacific No 14 Jalan Teknologi 3/1 JI. Pulogadung No. 45 71 Gower Street, Preston VIC 3072 Australia 38 Joo Koon Circle Selangor Science Park 1...

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