200AC/DC inverter arc welding machine Operating Manual Revision: AB Operating Features: Issue Date: March 29, 2012 A-11217 Manual No.
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! WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. 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 71 Gower Street Preston, Victoria, Australia, 3072 www.thermadyne.com.
TABLE OF CONTENTS SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS...................................... 1-1 1.01 1.02 1.03 Arc Welding Hazards........................................................................................ 1-1 Principal Safety Standards............................................................................... 1-5 Declaration of Conformity................................................................................ 1-6 SECTION 2: INTRODUCTION ....................
TABLE OF CONTENTS SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS..................... 5-1 5.01 5.02 5.03 5.04 Basic Troubleshooting..................................................................................... 5-1 Power Source Problems.................................................................................. 5-1 Routine Service and Calibration Requirements................................................ 5-2 Cleaning the Welding Power Source.............................
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.
WELDSKILL 200 AC/DC INVERTER 2. Wear approved safety glasses. Side shields recommended. WARNING ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing. 1. Use a Welding Helmet or Welding Faceshield fitted with a proper shade of filter (see ANSI Z49.1 and AS 1674 listed in Safety Standards) to protect your face and eyes when welding or watching.
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 welding can easily go through small cracks and openings to adjacent areas. FUMES AND GASES can be hazardous to your health. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 5. Watch for fire, and keep a fire extinguisher nearby. 6.
WELDSKILL 200 AC/DC INVERTER 5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. 6. Turn face away from valve outlet when opening cylinder valve. 7. Keep protective cap in place over valve except when cylinder is in use or connected for use. 8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in 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. 20402. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.
WELDSKILL 200 AC/DC INVERTER 1.03 Declaration of Conformity Manufacturer and Merchandiser of Quality Consumables and Equipment : CIGWELD Address: 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.
WELDSKILL 200AC/DC INVERTER SECTION 2: INTRODUCTION 2.01 How To Use This Manual 2.02 Equipment Identification To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel.
WELDSKILL 200AC/DC INVERTER 2.04 Symbol Chart Note that only some of these symbols will appear on your model. On Single Phase Wire Feed Function Off Three Phase Wire Feed Towards Workpiece With Output Voltage Off.
WELDSKILL 200AC/DC INVERTER 2.05 Description 2.07 Transporting Methods The CIGWELD WELDSKILL 200AC/DC is a single phase constant current welding inverter capable of performing MMAW (Stick), GTAW (HF TIG) and GTAW (Lift TIG) welding processes. The unit is equipped with digital amperage and voltage meters, and a host of other features in order to fully satisfy the broad operating needs of the modern user. The unit is also fully compliant to Australian Standard AS 60974.1 and IEC 60974.1.
WELDSKILL 200AC/DC INVERTER 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. Suppose a Welding Power Source is designed to operate at a 20% duty cycle, 200 amperes at 18.0 volts.
WELDSKILL 200AC/DC INVERTER 2.10 Specifications Description Plant Part Number Power Source Mass Power Source Dimensions Cooling Welder Type Australian Standards Number of Phases Nominal Supply Voltage Nominal Supply Frequency Welding Current Range (DC STICK Mode) Welding Current Range (DC TIG Mode) Effective Input Current (I1eff) (note1) Maximum Input Current (I1max) Single Phase Generator Requirement (note2) STICK (MMAW) Welding Output, 40ºC, 10 min.
WELDSKILL 200AC/DC INVERTER 2.
WELDSKILL 200AC/DC INVERTER SECTION 3: INSTALLATION, OPERATION AND SETUP 3.01 Environment These units are designed for use in environments with increased hazard of electric shock as outlined in AS60974.1 and AS1674.2 A. Examples of environments with increased hazard of electric shock are: 1. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts. 2.
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 it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work, complete with associated input filters. In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer troublesome.
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.
WELDSKILL 200AC/DC INVERTER 3.08 WELDSKILL 200AC/DC Power Source Controls, Indicators and Features 18 19 5 17 6 MODE 16 200 18.
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. 2.
WELDSKILL 200AC/DC INVERTER 7. Process Selection Button The process selection control is used to select the desired welding mode. Three modes are available, GTAW (LIFT TIG), GTAW (HF TIG) and MMAW (Stick) modes. Note that when the unit is powered off the mode selection control will automatically default to LIFT TIG mode. This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work piece during power up. 8.
WELDSKILL 200AC/DC INVERTER 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). 10. Forward Programming Button Pressing this button will advance to the next step in the programming sequence. 11. Multifunction Control The multifunction control knob is used to adjust welding current. It is also used to adjust parameters when in programming mode. 12.
WELDSKILL 200AC/DC INVERTER 19. Digital Voltmeter / Parameter meter The digital volt meter is used to display the actual output voltage of the power source. It is also used to display Parameters in Programming Mode. Depending on the Programming Parameter selected, the status indictor adjacent to the volt meter will illuminate to show the units of the programming parameter. When welding, the volt meter will display actual welding voltage. 20.
WELDSKILL 200AC/DC INVERTER Programming Parameter Hot Start This parameter operates in all weld modes except LIFT TIG mode 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 BASE (WELD) current. e.g. HOT START current = 130 amps when BASE (WELD) = 100 amps & HOT START = 30 amps Base Current This parameter sets the TIG WELD current when PULSE is OFF. This parameter also sets the STICK weld current.
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. Use the Multi Function Control to adjust the parameter selected. MODE 200 18.
WELDSKILL 200AC/DC INVERTER Up Slope 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 switch has been pressed then released, from INITIAL CUR to PEAK or BASE current. Base Current This parameter sets the TIG WELD current when PULSE is OFF. This parameter also sets the STICK weld current. 15.0 PERCENT (%) FREQ (Hz) Volts 0.0 to 15.
WELDSKILL 200AC/DC INVERTER Post Flow This parameter operates in TIG modes only and is used to adjust the post gas flow time once the arc has extinguished. This control is used to dramatically reduce oxidation of the tungsten electrode. AC Frequency This parameter operates in AC TIG mode only and is used to set the frequency for the AC weld current. Wave Balance This parameter operates in AC TIG mode and is used to set the penetration to cleaning action ratio for the AC weld current.
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. In DC HF TIG mode, if the tungsten electrode touches the work the welding current is reduced to 30 Amps within 1 second.
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. Wipe with a clean lint free cloth. 2. Match regulator to cylinder.
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. NOTE It may be necessary to re-check the shielding gas regulator flow rate following the first weld sequence due to back pressure present within shielding gas hose assembly. 2.
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. The TIG torch will require a trigger switch to operate in Lift TIG or HF TIG Mode. NOTE If the TIG torch has a remote TIG torch current control fitted then it will require to be connected to the 8 pin socket. (Refer to section 3.08.
WELDSKILL 200AC/DC INVERTER 3.14 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. B. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer.
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WELDSKILL 200 AC/DC INVERTER SECTION 4: BASIC WELDING GUIDE 4.01 Stick (MMAW) Basic Welding Technique 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 thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job.
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. Some of the common types of welds are shown in Figures 4-5 through 4-12.
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.
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.
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. A. Butt Welds Set up two plates with their edges parallel, as shown in Figure 4-11, allowing 1.6mm to 2.
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 Art # A-07700_AB 6 3 5 1 2 4 Figure 4-`14: Multi-runs in HV Fillet Weld C. Vertical Welds 1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.
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. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag.
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. The study of distortion is so complex that only a brief outline can be attempted hear. The Cause of Distortion Distortion is caused by: A.
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.
WELDSKILL 200AC/DC INVERTER 3 2 1 Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool.
WELDSKILL 200 AC/DC INVERTER Electrode Selection Chart CIGWELD Electrode Selection Chart Pack Part No. Description Diameter Satincraft 13 2.5mm 2.5mm 3.2mm 3.2mm 4.0mm 1kg 2.5kg 1kg 2.5kg 5kg 322135 612182 322136 612183 611184 Application General purpose electrode suitable for all positional welding and galvanised steel. Ferrocraft 12XP 2.0mm 2.0mm 2.5mm 2.5mm 3.2mm 3.2mm 4.0mm 1kg 2.5kg 1kg 2.5kg 1kg 2.
WELDSKILL 200AC/DC INVERTER 4.02 Stick (MMAW) Welding Troubleshooting FAULT CAUSE 1 Welding current varying REMEDY ARC FORCE control knob is set at a value that causes the welding current to vary excessively with the arc length. 2 A gap is left by A Welding current too low failure of the weld B Electrode too large for metal to fill the joint. root of the weld. C Insufficient gap.
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 Adjust angle so the welding arc is directed more edge of the joint. C Wrong electrode angle. into the base metal. D Travel speed of electrode is too high. D Reduce travel speed of electrode. E Scale or dirt on joint surface. E Clean surface before welding.
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 (nonconsumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based.
WELDSKILL 200 AC/DC INVERTER Tungsten Electrode Types Electrode Type (Ground Finish) Welding Application Features Colour Code Thoriated 2% DC welding of mild steel, stainless steel and copper Excellent arc starting, Long life, High current carrying capacity Red Zirconated 1% High quality AC welding of aluminium, magnesium and their alloys. Self cleaning, Long life, Maintains balled end, High current carrying capacity.
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. thermadyne.com.au or contact CIGWELD. 4.
WELDSKILL 200 AC/DC INVERTER 7 Dirty weld pool A Electrode contaminated A Clean the electrode by grinding off the by contact with work contaminates. piece or filler rod material. B Work piece surface has B Clean surface. foreign material on it. C Gas contaminated with C Check gas lines for cuts and loose fitting air. or change gas cylinder. 8 Poor weld finish 9 Arc start is not smooth. Inadequate shielding gas. Increase gas flow or check gas line for gas flow problems.
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WELDSKILL 200AC/DC INVERTER SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Basic Troubleshooting ! WARNING There are extremely dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson and you have had training in power measurements and troubleshooting techniques.
WELDSKILL 200AC/DC INVERTER 5.03 Routine Service and Calibration Requirements ! WARNING There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do not attempt to open or repair unless you are an accredited CIGWELD Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.
WELDSKILL 200AC/DC INVERTER 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 accordance with the requirements below 1. For outlets/wiring and associated accessories supplying transportable equipment - at least once every 3 months; and 2. For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12 months. D.
WELDSKILL 200AC/DC INVERTER C. Calibration Equipment All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question. Only test equipment with valid calibration certificates (NATA certified laboratories) shall be utilized. 5.04 Cleaning the Welding Power Source ! WARNING There are dangerous voltage and power levels present inside this product.
WELDSKILL 200AC/DC INVERTER SECTION 6: KEY SPARE PARTS 6.
WELDSKILL 200AC/DC INVERTER Item 1 2 3 4 5 6 7 8 9 10 11 13 Part Number W7005500 W7005502 W7005503 W7005504 W7005505 W7005506 W7005507 W7005508 W7005509 W7005512 W7003033 W7005513 W7003036 14 15 16 17 W7005514 W7005515 W7003076 704461 12 KEY SPARE PARTS WeldSkill 200AC/DC Spare Parts Description PCB display PCB HF PCB aux power supply PCB primary inverter PCB AC output drive PCB control PCB secondary rectifier PCB EMC filter Coil coupling Fan assembly Gas solenoid assembly Dinse Socket 50mm² Control
WELDSKILL 200AC/DC INVERTER A-11227 APPENDIX: CIRCUIT DIAGRAM Manual 0-5207 A-1 APPENDIX
CIGWELD - LIMITED WARRANTY TERMS LIMITED WARRANTY: CIGWELD Pty Ltd, A Thermadyne Company, hereafter, “CIGWELD” warrants to customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material.
TERMS OF WARRANTY – January 2012 1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply of goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including warranties as to merchantability and fitness for purpose) associated with the supply of goods and services.
WARRANTY SCHEDULE – January 2012 These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of sale from the 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.
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION CIGWELD, Australia 71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7391 Email: enquiries@thermadyne.com.au Thermadyne USA 2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.
Asia Pacific Regional Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 +61 3 9474 7391 FAX: Email: enquiries@thermadyne.com.au www.thermadyne.com.
