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WELDSKILL 200AC/DC INVERTER

INSTALLATION, OPERATION AND SETUP

3-4

Manual 0-5207

3.08 WELDSKILL 200AC/DC Power Source Controls, Indicators and Features

FAULT

POWER

Amps

Volts

FORWARD

BACK

VOLTS
SECONDS

PERCENT (%)
FREQ (Hz)

AC FREQUENCY

WAVE BALANCE

(ARC FORCE)

MODE

PULSE

PURGE

PROCESS

TRIGGER

2T NORMAL

4T LATCH

HF TIG

LIFT TIG

STICK

Pre

Flow

Hot

Start

Initial

Current

Slope

Base

Current

Peak

Current

Width

Trough

Current

Frequency

Down

Slope

Crater

Current

Post

Flow

WeldSkill

PORTABLE WELDING MACHINE

200

AC/DC

Inverter

2 0 0

1 8 . 0

A-11219

Figure 3-1: Controls on Front Panel

A-11232

OFF

Figure 3-2: Rear Panel

Summary of Contents for 200AC

Page 1: ...A 11217 200AC DC Operating Manual Revision AC Issue Date August 15 2012 Manual No 0 5207 Operating Features inverter arc welding machine...

Page 2: ...ey will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide CIGWELD is the Market Le...

Page 3: ...w cigweld com au Copyright 2012 by CIGWELD All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and...

Page 4: ...ation 3 1 3 04 Mains Supply Voltage Requirements 3 1 3 05 High Frequency Introduction 3 1 3 06 High Frequency Interference 3 2 3 07 Electromagnetic Compatibility 3 2 3 08 WELDSKILL 200AC DC Power Sour...

Page 5: ...rce Problems 5 1 5 03 Routine Service and Calibration Requirements 5 2 5 04 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 CIGWE...

Page 6: ......

Page 7: ...to a good electrical earth ground 11 Do not touch electrode while in contact with the work ground circuit 12 Use only well maintained equipment Repair or replace damaged parts at once 13 In confined...

Page 8: ...Approximate Range of Welding Current in Amps Minimum Shade Number of Filter s Manual Metal Arc Welding covered electrodes MMAW Less than or equal to 100 8 100 to 200 10 200 to 300 11 300 to 400 12 Gr...

Page 9: ...otect yourself and others from flying sparks and hot metal 2 Do not weld where flying sparks can strike flam mable material 3 Remove all flammables within 35 ft 10 7 m of the welding arc If this is no...

Page 10: ...cancer California Health Safety code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General C...

Page 11: ...from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Stan dards Sal...

Page 12: ...chnical Specifications The product is designed and manufactured to a number of standards and technical requirements among them are AS 60974 10 IEC 60974 10 EMC Directive applicable to arc welding equi...

Page 13: ...isted in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation...

Page 14: ...e Decrease Circuit Breaker AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line Connection...

Page 15: ...eplaced immediately Should such repairs or replacements become necessary it is recommended that such re pairs be carried out by appropriately qualified persons approved by CIGWELD Advice in this regar...

Page 16: ...s at 18 0 volts This means that it has been designed and built to provide the rated amperage 200A for 2 minutes i e arc welding time out of every 10 minute period 20 of 10 minutes is 2 minutes During...

Page 17: ...170A 15 26 8V 100A 60 24 0V 80A 100 23 2V TIG GTAW Welding Output 40 C 10 min 200A 20 18 0V 116A 60 14 6V 90A 100 13 6V Open circuit voltage 72V Protection Class IP23S Table 2 1 WELDSKILL 200AC DC Spe...

Page 18: ...RODUCTION 2 6 Manual 0 5207 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 Ta...

Page 19: ...f blasting operations due to the danger of premature firing 3 01 Environment These units are designed for use in environments with increased hazard of electric shock as outlined in AS60974 1 and AS167...

Page 20: ...isturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial...

Page 21: ...Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level 4 Equipotential Bonding Bonding of all metallic com...

Page 22: ...ALANCE ARC FORCE MODE AC DC PULSE PURGE PROCESS TRIGGER 2T NORMAL 4T LATCH HF TIG LIFT TIG STICK Pre Flow Hot Start Initial Current Up Slope Base Current Peak Current Width Trough Current Frequency Do...

Page 23: ...ohm Potentiometers Minimum 7 Remote Control 5k ohm Potentiometer Wiper 8 Not used Table 3 1 8 Pin Interconnection Control Plug Configuration 3 Negative Welding Terminal Negative Welding Terminal Weld...

Page 24: ...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 auto...

Page 25: ...ramming sequence 13 AC frequency Indicator This indicator light will illuminate when programming AC Frequency AC HF TIG mode only 14 Purge Button Press and hold the PURGE button to purge the gas line...

Page 26: ...ode 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 displ...

Page 27: ...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...

Page 28: ...ABLE WELDING MACHINE 200AC DC Inverter 200 18 0 Press to go forward go back between programming status LED s Adjust programming parameter A 11222 Figure 3 6 LIFT TIG and HF TIG Programming Mode Progra...

Page 29: ...e Pulse Width This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current when the PULSE is ON Volts 0 VOLTS SECONDS PERCENT FREQ Hz 8 15 to 80 Pulse Frequency This paramet...

Page 30: ...ntrol changes the ratio of penetration to cleaning action of the AC TIG welding arc Maximum weld penetration is achieved when the WAVE BALANCE control is set to 10 Maximum cleaning of heavily oxidised...

Page 31: ...ressure greater than its rated inlet pressure 2 NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition NEVER loosen a connection or attempt to remove any part o...

Page 32: ...panner 4 Connect and tighten the outlet hose firmly and attach down stream equipment 5 To protect sensitive down stream equipment a separate safety device may be necessary if the regulator is not fitt...

Page 33: ...t in use To shut down for extended periods more than 30 minutes 1 Close cylinder or upstream valve tightly 2 Open downstream equipment valves to drain the lines Bleed gas into a well ventilated area a...

Page 34: ...or flowmeter outlet gas INLET on the rear of the WeldSkill 200 AC DC Power Source Connect the gas hose from the TIG torch to the gas OUTLET on on the front of the WeldSkill 200 AC DC Power Source WARN...

Page 35: ...otentiometer Minimum 7 Potentiometer Wiper 8 Not Used Table 3 4 Description The CIGWELD Foot Control is a foot operated switch and potentiometer which starts and stops the welding process and controls...

Page 36: ...uire the remote local switch set to remote the maximum setting of the power source will be determined by the respective front panel control irrespective of the remote control device setting As an exam...

Page 37: ...control refer to Section 3 08 7 for further information WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the mains power supply is swi...

Page 38: ...WELDSKILL 200AC DC INVERTER INSTALLATION OPERATION AND SETUP 3 20 Manual 0 5207 This page is left blank intentionally...

Page 39: ...e reduced by using the correct electrodes preheating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tempering in a furnace Hydrogen controlled...

Page 40: ...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 Art A 07687 Figure 4 1 Flat Position Down Hand Butt Weld Art...

Page 41: ...eld metal and to produce sound joints In general surfaces being welded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are sho...

Page 42: ...You may at first experience difficulty due to the tip of the electrode sticking to the work piece This is caused by making too heavy a contact with the work and failing to withdraw the electrode quick...

Page 43: ...Figure 4 12 Weld Build up Sequence Heavy plate will require several runs to complete the joint After completing the first run chip the slag out and clean the weld with a wire brush It is important to...

Page 44: ...nd strike the arc in the corner of the fillet The electrode needs to be about 10 from the horizontal to enable a good bead to be deposited Refer Figure 4 15 Use a short arc and do not attempt to weave...

Page 45: ...lt that downhand welding Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe Then tack this to the w...

Page 46: ...e adjacent plate material is heated to a very high temperature and attempts to expand in all directions It is able to do this freely at right angles to the surface of the plate i e through the weld bu...

Page 47: ...D Presetting It is possible in some cases to tell from past experience or to find by trial and error or less frequently to calculate how much distortion will take place in a given welded structure By...

Page 48: ...1 Block Sequence The spaces between the welds are filled in when the welds are cool 2 3 Figure 4 24 Welding Sequence Art A 07711_AB 4 3 2 1 Figure 4 25 Step back Sequence Art A 07428_AB Figure 4 26 Ch...

Page 49: ...4 0mm 2 5 kg 2 5 kg 2 5 kg 611602 611603 611604 Stainless Steel type for 19Cr 10Ni stainless grades including 201 202 301 302 303 304 304L 305 308 etc Satincrome 309Mo 17 2 5mm 3 2mm 4 0mm 2 5 kg 2 5...

Page 50: ...eposits allow slag to be trapped C If very bad chip or grind out irregularities D Lack of penetration with slag trapped beneath weld bead D Use smaller electrode with sufficient current to give adequa...

Page 51: ...teel A Use an electrode that is designed for high sul phur steels B Electrodes are damp B Dry electrodes before use C Welding current is too high C Reduce welding current D Surface impurities such as...

Page 52: ...ding on the welding application Welds Made With or Without Addition of Filler Metal Work Piece Can Be Any Commercial Metal Gas Cup Either Ceramic High lmpact or Water Cooled Metal Inert Gas Shields El...

Page 53: ...ium strength steels Pipes tubing roll cages etc CrMo1 CrMo2 RB2 RB3 ER80S B2 ER90S B3 321379 321383 For welding of high strength Cr Mo steels used at elevated tempera tures 308L 309L 316L R308L R309L...

Page 54: ...r ripples in bead are widely spaced apart Travel speed too fast Reduce travel speed 4 Weld bead too wide or excessive bead build up or excessive penetration in butt joint Travel speed too slow Increas...

Page 55: ...arge for the weld ing current A Select the right size tungsten electrode Refer to Table 4 3 CIGWELD Tungsten Electrode Selection Chart B The wrong electrode is being used for the welding job B Select...

Page 56: ...WELDSKILL 200AC DC INVERTER BASIC WELDING GUIDE 4 18 Manual 0 5207 This page is left blank intentionally...

Page 57: ...not lit and welding arc cannot be established A B Primary control fuse is blown Broken connection in primary circuit A B Replace primary control fuse Have an Accredited CIGWELD Service Provider check...

Page 58: ...ndicator illuminates when the power source is switched back ON turn the power source OFF and have an Accredited CIGWELD Service Provider check the power source Table 5 1 Power Source Problem 5 03 Rout...

Page 59: ...ts to any auxiliary circuit which operates at a voltage not exceeding extra low voltage 1 Separate welding circuit to separate welding circuit 1 Table 5 2 Minimum Insulation Resistance Requirements CI...

Page 60: ...ucted by an accredited CIGWELD service provider Testing Requirements Output current A to be checked to ensure it falls within applicable CIGWELD power source specifications Output Voltage V to be chec...

Page 61: ...WELDSKILL 200AC DC INVERTER Manual 0 5207 6 1 KEY SPARE PARTS SECTION 6 KEY SPARE PARTS 6 01 Power Source 1 2 3 4 5 6 7 8 10 13 14 16 9 11 A 11226 15 12 12 Figure 6 1...

Page 62: ...PCB AC output drive 6 W7005506 PCB control 7 W7005507 PCB secondary rectifier 8 W7005508 PCB EMC filter 9 W7005509 Coil coupling 10 W7005512 Fan assembly 11 W7003033 Gas solenoid assembly 12 W7005513...

Page 63: ...TERMINALS DC BOARD SW1 C1 R2 C4 C2 D2 D4 R4 C6 Q3 G3 Q4 G4 C7 C8 L1 T2 SOFT START WA AC DC DRIVE DRIVER SS POWER SOU HF BOARD HFOUT HF SOUIN AC DRIVE BOARD JB ACPOUT ACOUT GD1 GD2 QF HF DISPLAY BOARD...

Page 64: ......

Page 65: ...R CONSEQUENTIAL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSINESS INTERRUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELD with respect to any...

Page 66: ...our Accredited Distributor in writing of its claim within seven 7 days of becoming aware of the basis thereof and at its own expense returning the goods which are the subject of the claim to CIGWELD...

Page 67: ...CE WARRANTY PERIOD PARTS LABOUR Original main power magnetics 1 Year 1 Year Original main power rectifiers printed circuit boards and power switch semiconductors 1 Year 1 Year All other circuits and c...

Page 68: ...omer 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...

Page 69: ...1257 224800 PT Victor Technologies Utama Indonesia Jl Angsana II Blok AE No 28 Delta Silicon I Cikarang Sukaresmi Bekasi 17550 Indonesia Tel 62 21 8990 6095 Fax 62 21 8990 6096 1867 http www Victortec...

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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Summary of Contents for 200AC

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CIGWELD 200AC, Operating Manual, Page: 22 / 70

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Summary of Contents for 200AC

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