CIGWELD 200AC Operating Manual
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CIGWELD 200AC Operating Manual

200ac/dc inverter arc welding machine
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200AC/DC
Operating Manual
inverter
ArC welDing MAChine
Revision: AC
Operating Features:
Issue Date: August 15, 2012
A-11217
Manual No: 0-5207

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  • Page 1 200AC/DC inverter ArC welDing MAChine Operating Manual A-11217 Revision: AC Issue Date: August 15, 2012 Manual No: 0-5207 Operating Features:...
  • Page 2 To locate your nearest distributor or Accredited Service Provider call +1300 654 674, or visit us on the web at www.cigweld.com.au This Operating 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 Operating Manual Number 0-5207 for: WeldSkill 200AC/DC Plant Part Number W1006200 Published by: CIGWELD Pty Ltd...

  • Page 4: Table Of Contents

    WELDSKILL 200AC/DC Power Source Controls, Indicators and Features ..3-4 3.09 WELDSKILL 200AC/DC - STICK Programming Mode ........3-8 3.10 WELDSKILL 200AC/DC – LIFT TIG and HF TIG Programming Mode ... 3-10 3.11 Short Circuit Protection While Welding ............3-13 3.12 Shielding Gas Regulator Operating Instructions ...........
  • Page 5 Cleaning the Welding Power Source ............... 5-4 SECTION 6: KEY SPARE PARTS ................... 6-1 6.01 Power Source ....................6-1 APPENDIX: CIRCUIT DIAGRAM ................A-1 CIGWELD - LIMITED WARRANTY TERMS TERMS OF WARRANTY – January 2012 WARRANTY SCHEDULE – January 2012 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION...

  • Page 7: Arc Welding Safety Instructions And Warnings

    WELDSKILL 200AC/DC INVERTER SECTION 1: ARC WELDING 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 200 AC/DC INVERTER 2. Wear approved safety glasses. Side shields recom- mended. WARNING 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the ARC RAYS can burn eyes and skin; NOISE arc.
  • Page 9 WELDSKILL 200AC/DC INVERTER 3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. WARNING 4. Be alert that welding sparks and hot materials from FUMES AND GASES can be hazardous to welding can easily go through small cracks and your health.
  • Page 10 WELDSKILL 200 AC/DC INVERTER 5. Use only correct shielding gas cylinders, The following is a quotation from the General Con- regulators, hoses, and fittings designed for the clusions Section of the U.S. Congress, Office of specific application; maintain them and associated Technology Assessment, Biological Effects of Power parts in good condition.

  • Page 11: Principal Safety Standards

    WELDSKILL 200AC/DC INVERTER 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.

  • Page 12: Declaration Of Conformity

    71 Gower St, Preston Victoria 3072 Australia Description of equipment: CIGWELD WeldSkill 200AC/DC INVERTER Power Source and associated accessories. * Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

  • Page 13: Introduction

    Use care to avoid damaging the Additional copies of this manual may be purchased equipment when using bars, hammers, etc., to un- by contacting CIGWELD at the address and phone crate the unit. number for your location listed in the inside back cover of this manual.

  • Page 14: Symbol Chart

    WELDSKILL 200AC/DC INVERTER 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...

  • Page 15: Description

    WELDSKILL 200AC/DC INVERTER 2.05 Description 2.07 Transporting Methods The CIGWELD WELDSKILL 200AC/DC is a single This unit is equipped with a handle for carrying phase constant current welding inverter capable of purposes. performing MMAW (Stick), GTAW (HF TIG) and GTAW (Lift TIG) welding processes.

  • Page 16: Duty Cycle

    Power Source must idle and be allowed to cool. The thermal cut out will operate if the duty cycle is exceeded. WELDSKILL 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 2-1: WELDSKILL 200AC/DC Duty Cycle INTRODUCTION Manual 0-5207...

  • Page 17: Specifications

    90A @ 100%, 13.6V Open circuit voltage Protection Class IP23S Table 2-1: 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 18: Options And Accessories

    WELDSKILL 200AC/DC INVERTER 2.11 Options and Accessories Part Number Description W4013602 Tig Torch with 4m lead and remote control W4015800 Foot Control with 8m lead BGSAK2 TIG Torch accessory kit Table 2-2: Options and Accessories INTRODUCTION Manual 0-5207...

  • Page 19: Installation, Operation And Setup

    WELDSKILL 200AC/DC INVERTER SECTION 3: INSTALLATION, OPERATION AND SETUP 3.01 Environment conditions. For further information please refer to AS 60529. These units are designed for use in environments H. Precautions must be taken against the power with increased hazard of electric shock as outlined in source toppling over.

  • Page 20: High Frequency Interference

    WELDSKILL 200AC/DC INVERTER assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see NOTE below. In other cases WARNING COMPUTER it could involve constructing an electromagnetic It is also possible that operation close...
  • Page 21 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. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent.

  • Page 22: Weldskill 200Ac/Dc Power Source Controls, Indicators And Features

    WELDSKILL 200AC/DC INVERTER 3.08 WELDSKILL 200AC/DC Power Source Controls, Indicators and Features MODE VOLTS 200 18.0 SECONDS POWER PERCENT (%) FAULT FREQ (Hz) Peak Amps Volts Current PULSE PROCESS LIFT TIG Trough Start Current Base HF TIG Width Current Down...
  • Page 23 WELDSKILL 200AC/DC INVERTER 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 24 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 25 WELDSKILL 200AC/DC INVERTER 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 3-4 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 26: Weldskill 200Ac/Dc - Stick Programming Mode

    Supply. The Shielding Gas inlet is located on the rear of the Power Source. 22. 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 27 WELDSKILL 200AC/DC INVERTER MODE VOLTS 200 18.0 SECONDS POWER PERCENT (%) FAULT FREQ (Hz) Peak Amps Volts Current PULSE PROCESS LIFT TIG Trough Start Current Base HF TIG Width Current Down STICK Slope Slope Crater Initial Frequency Current Current Post...

  • Page 28: Weldskill 200Ac/Dc - Lift Tig And Hf Tig Programming Mode

    WELDSKILL 200AC/DC INVERTER 3.10 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. The Programming LED's are always active. Press FORWARD or BACK to cycle through available programming functions.
  • Page 29 WELDSKILL 200AC/DC INVERTER Up Slope VOLTS 15.0 SECONDS This parameter operates in (4T) PERCENT (%) TIG modes only and is used to FREQ (Hz) Volts set the time for the weld current 0.0 to 15.0 seconds to ramp up, after the torch trigger...
  • Page 30 WELDSKILL 200AC/DC INVERTER Post Flow VOLTS 60.0 SECONDS This parameter operates in TIG PERCENT (%) modes only and is used to adjust FREQ (Hz) Volts the post gas flow time once 0.0 to 60.0 seconds the arc has extinguished. This...

  • Page 31: Short Circuit Protection While Welding

    WELDSKILL 200AC/DC INVERTER 3.11 Short Circuit Protection While Welding To prolong the useful life of a TIG tungsten electrode, the WeldSkill 200 AC/DC incorporates special circuitry. In DC LIFT TIG mode, if the tungsten electrode touches the work the welding current is reduced to 40 Amps.
  • Page 32 WELDSKILL 200AC/DC INVERTER Art: A-05087 Figure 3-7: Fit Regulator to Cylinder 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 33: Setup For Tig (Gtaw) Welding

    WELDSKILL 200AC/DC INVERTER Adjusting Flow Rate Art: A-05088_AB Figure 3-8: Adjust Flow Rate With the regulator ready for operation, adjust working flow rate as follows: 1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate.
  • Page 34 WELDSKILL 200AC/DC INVERTER CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal. D. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below.

  • Page 35: Foot Control, Part No. W4015800 (Optional Accessory)

    Table 3-4 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 36 50%. Should 100% output be required, the respective front panel control must be set to 100% or maximum, in which case the remote device will then be able to control between 1-100% output. This foot control is compatible with the following Cigweld power sources: WeldSkill 200AC/DC Part No: W1006202...

  • Page 37: Setup For Stick (Mmaw) Welding

    WELDSKILL 200AC/DC INVERTER 3.15 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 38 WELDSKILL 200AC/DC INVERTER This page is left blank intentionally. INSTALLATION, OPERATION AND SETUP 3-20 Manual 0-5207...

  • Page 39: Basic Welding Guide

    Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited CIGWELD Distributor. Effects of Arc Welding Various Materials A.
  • Page 40 WELDSKILL 200AC/DC INVERTER Welding Position The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these.
  • Page 41 WELDSKILL 200 AC/DC INVERTER Art# A-07693 Figure 4-7: Overhead Position, Butt Weld Art # A-07694 Figure 4-8: Overhead Position, Fillet Weld Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.
  • Page 42 WELDSKILL 200AC/DC INVERTER Arc Welding Technique - A Word to Beginners For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position.
  • Page 43 WELDSKILL 200 AC/DC INVERTER 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 up and the bead will be too large. Making Welded Joints Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.
  • Page 44 WELDSKILL 200AC/DC INVERTER and undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 4-14. Weaving in HV fillet welds is undesirable. 45° from vertical 60° - 70° from line of weld Art # A-07699_AB Figure 4-13: Electrode Position for HV Fillet Weld...
  • Page 45 WELDSKILL 200 AC/DC INVERTER Art # A-07702 Figure 4-16: Multi Run Vertical Fillet Weld Art # A-07703 Figure 4-17: Examples of Vertical Fillet Welds 2. Vertical Down The Ferrocraft 21 electrode makes welding in this position particularly easy. Use a 3.2mm electrode at 100 amps.
  • Page 46 WELDSKILL 200AC/DC INVERTER Distortion Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur.
  • Page 47 WELDSKILL 200 AC/DC INVERTER B. Distribution of Stresses Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 4-20 through 4-23 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it.
  • Page 48 WELDSKILL 200AC/DC INVERTER Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool. Figure 4-24: Welding Sequence Art # A-07711_AB Figure 4-25: Step back Sequence Art # A-07428_AB Figure 4-26: Chain Intermittent Welding...
  • Page 49 It 2.5/3.2mm Blisterpack 322217 has better “wetting” action than Castcraft 55. 4.0mm 2.5 kg 611734 Table 4-1: CIGWELD Electrode Selection Chart Further information on CIGWELD electrodes can be found at the website www.cigweld.com.au Manual 0-5207 4-11 BASIC WELDING GUIDE...

  • Page 50: Stick (Mmaw) Welding Troubleshooting

    WELDSKILL 200AC/DC INVERTER 4.02 Stick (MMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE control knob Reduce the ARC FORCE control knob until weld- varying is set at a value that ing current is reasonably constant while prohibit-...
  • Page 51 WELDSKILL 200 AC/DC INVERTER 5 Portions of the A Small electrodes used on A Use larger electrodes and preheat the plate. weld run do not heavy cold plate. fuse to the surface B Welding current is too low. B Increase welding current. of the metal or C Wrong electrode angle.

  • Page 52: Tig (Gtaw) Basic Welding Technique

    WELDSKILL 200AC/DC INVERTER 4.03 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding 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 53 WELDSKILL 200 AC/DC INVERTER Tungsten Electrode Types Electrode Type Welding Application Features Colour Code (Ground Finish) DC welding of mild Excellent arc starting, Thoriated 2% steel, stainless steel Long life, High current and copper carrying capacity High quality AC weld- Self cleaning, Long ing of aluminium, life, Maintains balled...

  • Page 54: Tig (Gtaw) Welding Problems

    WELDSKILL 200AC/DC INVERTER TIG Welding is generally regarded as a specialised process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www.
  • Page 55 9 Arc start is not smooth. A Tungsten electrode is A Select the right size tungsten electrode. too large for the weld- Refer to Table 4-3 CIGWELD Tungsten ing current. Electrode Selection Chart. B The wrong electrode B Select the right tungsten electrode type.
  • Page 56 WELDSKILL 200AC/DC INVERTER This page is left blank intentionally. BASIC WELDING GUIDE 4-18 Manual 0-5207...

  • Page 57: Power Source Problems And Routine Service Requirements

    If major complex subassemblies are faulty, then the Welding Power Source must be returned to an ac- credited CIGWELD Service Provider for repair. The basic level of troubleshooting is that which can be performed without special equipment or knowledge. Refer also to section 4 for solving welding problems.

  • Page 58: Routine Service And Calibration Requirements

    The inspection and testing of the power source and associated accessories shall be carried out in accordance with Section 5 of AS 1674.2 - 2007: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with CIGWELD original specifications.
  • Page 59 2. The earth terminal of the associated plug of a transportable power source Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying CIGWELD welding power sources should be inspected by a licensed electrical worker in ac- cordance with the requirements below - 1.

  • Page 60: Cleaning The Welding Power Source

    Output current (A) to be checked to ensure it falls within applicable CIGWELD power source specifications Output Voltage (V) to be checked to ensure it falls within applicable CIGWELD power source specifications Accuracy of digital meters to be checked to ensure it falls within applicable CIGWELD power source specifi- cations...

  • Page 61: Key Spare Parts

    WELDSKILL 200AC/DC INVERTER SECTION 6: KEY SPARE PARTS 6.01 Power Source A-11226 Figure 6-1 Manual 0-5207 KEY SPARE PARTS...
  • Page 62 WELDSKILL 200AC/DC INVERTER WeldSkill 200AC/DC Spare Parts Item Part Number Description W7005500 PCB display W7005502 PCB HF W7005503 PCB aux power supply W7005504 PCB primary inverter W7005505 PCB AC output drive W7005506 PCB control W7005507 PCB secondary rectifier W7005508 PCB EMC filter...

  • Page 63: Appendix: Circuit Diagram

    WELDSKILL 200AC/DC INVERTER APPENDIX: CIRCUIT DIAGRAM ACOUT ACPOUT QF/HF POWER J2 (10) POWER/FJ POWER SUPPLY BOARD DC-IN JB (10) A-11227_AB Manual 0-5207 APPENDIX...

  • Page 65: Cigweld - Limited Warranty Terms

    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 66 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 67 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 68 To make a claim under the warranty, take the product (with proof of purchase from a Cigweld Accredited Seller) to the store where you purchased the product or contact Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider.
  • Page 69 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Victor Technologies, China CIGWELD, Australia 71 Gower Street No 100 Lao Hongjing Rd Preston, Victoria Minhang District Shanghai, PR, 200235 Australia, 3072 Telephone: 61-3-9474-7400 Telephone: 86-21-64072626 Fax: 86-21-64483032 Fax: 61-3-9474-7391 Email: enquiries@cigweld.com.au Victor Technologies Asia Sdn Bhd...
  • Page 70 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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