CIGWELD WeldSkill 200AC/DC Service Manual Download Page 5

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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 ................................................. 6-4

6.07

Check main input rectifier ............................................................................... 6-4

6.08

DC Bus voltage measurement ......................................................................... 6-4

6.09

PCB Connectors .............................................................................................. 6-5

6.10

DIP switch settings, Control PCB .................................................................. 6-14

6.11 Calibration .................................................................................................... 6-15
6.12

Main Circuit Description ............................................................................... 6-16

6.13

Circuit Diagram ............................................................................................. 6-17

SECTION 7:

DISASSEMBLY PROCEDURE ....................................................................... 7-1

7.01

Safety Precautions for Disassembly ............................................................... 7-1

7.02

Case Removal ................................................................................................. 7-1

7.03

Control Board Removal ................................................................................... 7-2

7.04

Auxiliary Power Supply PCB2 Removal .......................................................... 7-3

7.05

PCB3 Removal ................................................................................................ 7-4

7.06

PCB4 Removal ................................................................................................ 7-5

7.07

PCB5 Removal ................................................................................................ 7-5

7.08

Front Panel assembly Removal ...................................................................... 7-6

7.09

Front Panel (operator Interface) Circuit Board PCB Removal .......................... 7-7

7.10

Back Panel Removal ....................................................................................... 7-8

7.12

Main Power PCB2 Removal .......................................................................... 7-10

7.13

Power Switch S1, Fan and Power Cord Removal .......................................... 7-11

SECTION 8:

ASSEMBLY PROCEDURES .......................................................................... 8-1

8.01

Installing Main Power PCB1 ........................................................................... 8-1

8.02

Installing Main Power PCB2 ........................................................................... 8-2

8.03

Installing Front Panel ...................................................................................... 8-3

8.04

Installing Rear Panel ....................................................................................... 8-4

8.05

Installing PCB5 ............................................................................................... 8-5

8.06

Installing PCB4 ............................................................................................... 8-5

8.07

Installing PCB3 ............................................................................................... 8-6

8.08

Installing Auxiliary Power Supply PCB2 .......................................................... 8-6

8.09

Installing Control Board .................................................................................. 8-7

8.10

Installing Case ................................................................................................ 8-8

SECTION 9:

KEY SPARE PARTS ................................................................................... 9-1

9.01

Power Source ................................................................................................. 9-1

Summary of Contents for WeldSkill 200AC/DC

Page 1: ...A 11419 Service Manual Revision AC Issue Date April 23 2015 Manual No 0 5206 Operating Features 200AC DC INVERTER ARC WELDING MACHINE ...

Page 2: ...l 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 Leading Brand of Arc Welding Products for Victor Technologies Inc We are a mainline supplier to major welding industry sectors in the Asia Pacific and emerging global markets including Manufacturing Construct...

Page 3: ...alia 3072 www cigweld com au Copyright 2012 2013 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 hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cau...

Page 4: ... 2 3 03 Environment 3 3 3 04 Location 3 3 3 05 High Frequency Introduction 3 3 3 06 High Frequency Interference 3 4 3 07 Electromagnetic Compatibility 3 4 3 07 Volt Ampere Curves 3 6 SECTION 4 OPERATION 4 1 4 01 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 0...

Page 5: ...Disassembly 7 1 7 02 Case Removal 7 1 7 03 Control Board Removal 7 2 7 04 Auxiliary Power Supply PCB2 Removal 7 3 7 05 PCB3 Removal 7 4 7 06 PCB4 Removal 7 5 7 07 PCB5 Removal 7 5 7 08 Front Panel assembly Removal 7 6 7 09 Front Panel operator Interface Circuit Board PCB Removal 7 7 7 10 Back Panel Removal 7 8 7 12 Main Power PCB2 Removal 7 10 7 13 Power Switch S1 Fan and Power Cord Removal 7 11 S...

Page 6: ...WARRANTY TERMS INSIDE REAR COVER GLOBAL CUSTOMER SERVICE CONTACT INFORMATION REAR COVER ...

Page 7: ...YS can burn eyes and skin NOISE can dam age 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 2...

Page 8: ...ding can easily go through small cracks and openings to adjacent areas 5 Watch for fire and keep a fire extinguisher nearby 6 Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side 7 Do not weld on closed containers such as tanks or drums 8 Connect work cable to the work as close to the welding area as practical to prevent welding current from travelling l...

Page 9: ...an 400 14 Gas Metal Arc Welding GMAW MIG Aluminium and Stainless Steel Less than or equal to 250 12 250 to 350 13 Gas Tungsten Arc Welding GTAW TIG Less than or equal to 100 10 100 to 200 11 200 to 250 12 250 to 350 13 Greater than 350 14 Flux cored Arc Welding FCAW with or without shielding gas Less than or equal to 300 11 300 to 400 12 400 to 500 13 Greater than 500 14 Air Arc Gouging Less than ...

Page 10: ...s to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cable around the body 4 Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also...

Page 11: ...National Standard and Technical 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 equipment generic emissions and regulations AS 60974 1 IEC 60974 1 2006 applicable to welding equipment and associated accessories AS1674 Safety in welding and allied processes Ext...

Page 12: ...ec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130_AB 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Preflow Time Postflow Time Spot Time Spot Weld Mode Continuous Weld Mode Press to initiate wirefeed and welding release to stop Purgin...

Page 13: ...boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards WARNING FIRE OR EXPLOSION hazard Do not place unit on over or near combustible surfaces Do not service unit near flammables WARNING FLYING METAL or DIRT can injure eyes Wear safety glasses with side shields or face shield during servicing Be careful not to short...

Page 14: ...he Owner s Manual for welding safety precau tions Use only genuine replacement parts from the manufac turer 1 06 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electromagnetic fields There has been and still is some concern about such fields However after examining more than 50...

Page 15: ... you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual Include all equipment identificatio...

Page 16: ...WELDSKILL 200AC DC INVERTER INTRODUCTION Introduction 2 2 Manual 0 5206 Notes ...

Page 17: ...es 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 the other 8 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool The thermal cut out will operate if the duty cycle is exceeded 10 20 30 40 50 60 70 80 90 100 110...

Page 18: ... 8V 100A 60 24 0V 80A 100 23 2V TIG GTAW Welding Output 40ºC 10 min 200A 20 18 0V 116A 60 14 6V 90A 100 13 6V Open circuit voltage VRD inactive 72V 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 Note 3 Motor...

Page 19: ... between 10 C to 40 C 14 F to 104 F In areas free from oil steam and corrosive gases In areas not subjected to abnormal vibration or shock In areas not exposed to direct sunlight or rain Place at a distance of 300mm 12 or more from walls or similar that could restrict natural air flow for cooling The enclosure design of this power source meets the requirements of IP23S as outlined in AS60529 This ...

Page 20: ...netic disturbances 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 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 co...

Page 21: ...endation 3 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 components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a sho...

Page 22: ...hows maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown A 11420 0 10 20 30 40 50 60 70 80 90 100 0 20 40 60 80 100 120 140 160 180 200 220 240 Welding Current AMPS Output Voltage Volts WELDSKILL 200AC DC MMAW STICK GTAW TIG Figure 3 2 WELDSKILL 200AC DC Volt Ampere Curves ...

Page 23: ... 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 Down Slope Crater Current Post Flow WeldSkill PORTABLE WELDING MACHINE 200AC DC Inverter 200 18 0 5 6 8 1 2 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 A 11219 Figure 4 1 WELDSKILL 200AC DC Controls Indicators and Fe...

Page 24: ...entiometers Minimum 7 Remote Control 5k ohm Potentiometer Wiper 8 Not used Table 4 1 8 Pin Interconnection Control Plug Configuration 3 Negative Welding Terminal Negative 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 CAUTION Loose ...

Page 25: ... MMAW Stick modes Note if the unit is in HF TIG mode and it is turned to Off it still remains in HF TIG mode when turned back On If it is in LIFT TIG mode and it is turned Off it still remains in LIFT TIG mode when turned back on If it is STICK mode and is turned to Off it will default to LIFT TIG mode when turned back On This is necessary so as to prevent inadvertent arcing should an electrode ho...

Page 26: ...essing this button will go back to the previous step in the programming 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 in LIFT TIG and HF TIG modes To PURGE the shielding gas line in LIFT TIG and HF TIG modes press the PURGE button and release The indicat...

Page 27: ... displayed on this meter Refer to section 3 08 6 Fault Indicator for further detail 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 t...

Page 28: ...ameter While welding the Multi Function Control directly controls the BASE CURRENT FAULT POWER Amps Volts FORWARD BACK VOLTS SECONDS PERCENT FREQ Hz AC FREQUENCY WAVE BALANCE 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 Current Width Trough Current Frequency Down Slope Crater Current Post Flow Wel...

Page 29: ...Mode only Arc Force is effective when in Manual Arc Mode only Arc Force control provides and adjustable amount of Arc Force or dig control This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit up in certain situations with particular electrodes In general increasing the Arc Force control toward 100 maximum Arc Force allows grea...

Page 30: ... dramatically reduce weld porosity at the start of a weld Volts VOLTS SECONDS PERCENT FREQ Hz 0 0 to 1 0 second Initial Current This parameter operates in 4T TIG modes only and is used to set the start current for TIG The Start Current remains on until the torch trigger switch is released after it has been depressed Note The maximum initial current available will be limited to the set value of the...

Page 31: ...ent This control is used to eliminate the crater that can form at the completion of a weld Volts VOLTS SECONDS PERCENT FREQ Hz 0 0 to 25 0 seconds Crater Current This parameter operates in 4T TIG modes only and is used to set the finish current for TIG The CRATER Current remains ON until the torch trigger switch is released after it has been depressed Note The maximum crater current available will...

Page 32: ...ing action for the AC TIG welding arc Maximum weld penetration is achieved when the WAVE BALANCE is set to 10 Maximum cleaning of heavily oxidised aluminium or magnesium alloys is achieved when the WAVE BALANCE is set to 65 Maximum Penetration and reduced cleaning Balanced with 50 penetration and 50 cleaning Maximum Cleaning and reduced penetration 10 50 65 90 50 35 Wave Balance 50 Wave Balance 10...

Page 33: ... dangerously propel a loose part 3 DO NOT remove the regulator from a cylinder without first closing the cylinder valve and releasing gas in the regulator high and low pressure chambers 4 DO NOT use the regulator as a control valve When downstream equipment is not in use for extended periods of time shut off the gas at the cylinder valve and release the gas from the equipment 5 OPEN the cylinder v...

Page 34: ... With the regulator connected to cylinder or pipeline and the adjustment screw knob fully disengaged pressurize as follows 1 Stand to one side of regulator and slowly open the cylinder valve If opened quickly a sudden pressure surge may damage internal regulator parts 2 With valves on downstream equipment closed adjust regulator to approximate working pressure It is recommended that testing for le...

Page 35: ... turned securely to achieve a sound electrical connection C Connect the work lead to the 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 CAUTION Loose welding terminal connections can cause overheating and result in the male...

Page 36: ...ial Current Up Slope Base Current Peak Current Width Trough Current Frequency Down Slope Crater Current Post Flow WeldSkill PORTABLE WELDING MACHINE 200AC DC Inverter 200 18 0 8 Negative Welding Terminal Work Lead Positive Welding Terminal 8 Pin Control Socket Tig Torch A 11224 Figure 4 9 Setup for TIG Welding 4 07 Foot Control Part No W4015800 Optional Accessory Art A 11338 Figure 4 10 Foot Contr...

Page 37: ...ressed then it displays actual welding current when welding Pressing the pedal to increases the welding current letting up on the pedal decreases the welding current Releasing the pedal completely extinguishes the arc and initiates the post flow shielding gas timer where fitted Note that some power sources may require the remote local switch set to remote the maximum setting of the power source wi...

Page 38: ...ol refer to Section 4 01 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 switched off CAUTION Remove any packaging material prior to use Do not block the air vents at the front or rear of the Welding Power Source CAUTION Loose welding terminal connections can cause overheating and...

Page 39: ...aller main transformer than in a conventional power supply The AC is then rectified to extremely smooth DC The diagram to the below shows the basic electrical wiring of a DC output inverter power supply Inverter Technology Summary Rectifier Filter IGBT Transformer Rectifier Inductor AC 50 60Hz DC Rippled DC Smooth AC 23KHz AC 23KHz DC Rippled DC Smooth High Voltage High Voltage High voltage High V...

Page 40: ...Theory of Operation 5 2 Manual 0 5206 WELDSKILL 200AC DC INVERTER THEORY OF OPERATION Notes ...

Page 41: ...ource to a supply voltage 274VAC 3 There is no weld output and the yellow over temperature light is on A B C Unit has overheated Airflow inlet or outlet ducts are blocked Fan does not operate A B C Allow unit to cool with fan running until over temperature light extinguishes Remove blockages from airflow ducts Replace fan Check fan wiring is not damaged 4 Mode switch does not change welding mode A...

Page 42: ...ge according to Section 6 07 after removing case Before troubleshooting or applying power to unit complete the following checks to avoid causing further damage 6 03 Test Equipment and Tools Digital Multimeter DC clip on ammeter Screwdriver and spanner CRO 20 Mhz bandwidth isolating transformer 6 04 Visually Inspect Visually inspect the inside of the Power Source The levels of current present in th...

Page 43: ... to less than 5VDC before servicing Ensure the mains supply plug is disconnected from receptacle 1 2 3 4 5 6 7 8 9 10 11 A 11421 DC Bus Testing Multimeter Lead Placement Voltage with Supply voltage OFF Upper capacitor bank Positive meter lead to testpoint 1 Negative meter lead to testpoint 2 0 VDC Lower capacitor bank Positive meter lead to testpoint 2 Negative meter lead to testpoint 3 0 VDC Tabl...

Page 44: ... meter lead to testpoint 7 0 to 100 Ω Table 6 5 Inrush PTC Multimeter set to measure ohms Ω 6 07 Check main input rectifier Input Rectifier Testing Multimeter Lead Placement Diode Voltage AC1 to DC Positive meter lead to testpoint 8 Negative meter lead to testpoint 9 0 2 0 8 VDC AC2 to DC Positive meter lead to testpoint 10 Negative meter lead to testpoint 9 0 2 0 8 VDC AC1 to DC Positive meter le...

Page 45: ...tive meter lead to testpoint 3 168 VDC 10 Overall capacitor bank Positive meter lead to testpoint 1 Negative meter lead to testpoint 3 336 VDC 10 Table 6 7 DC BUS Multimeter set to measure DC volts Note These DC voltages are at nominal mains supply voltage of 240VAC 6 09 PCB Connectors 1 EMC filter PCB A 11422 Header Pin Pin function signal ACIN1 Supply side ACTIVE 240 VAC ACIN2 Supply side NEUTRA...

Page 46: ... 0 VDC Table 6 10 DY1 Header pin function connects to souin header on HF PCB DY2 Header Pin Pin function signal 1 24 VDC 24 VDC 2 0 VDC 0 VDC Table 6 11 DY2 Header pin function connects to SOU header on main control PCB POWER FJ Header Pin Pin function signal 1 24 VDC 24 VDC 2 0 VDC 0 VDC 3 24 VDC 24 VDC 4 24 VDC 24 VDC 5 0 VDC 0 VDC Table 6 12 POWER FJ Header pin function connects to POWER header...

Page 47: ...ader pin function connects to QY1 header on Power Supply PCB HF Header Pin Pin function signal 1 HF on off 2 0 VDC 0 VDC Table 6 16 HF Header pin function connects to QF HF header on main control PCB 220V Header Pin Pin function signal 1 240 VAC 2 240 VAC 0 VDC Table 6 17 220V Header pin function HFOUT Header Pin Pin function signal 1 HF transformer primary warning high voltage Do not measure with...

Page 48: ...R1 A 11425 Header Pin Pin function signal TR1 Output 1 of main welding inverter transformer VAC TR2 Output 2 of main welding inverter transformer VAC DC Positive of welding current rectifier VDC DC Negative of welding current rectifier VDC Table 6 19 Header pin function connects to main Inverter transformer ...

Page 49: ... A 11426 J1 Header Pin Pin function signal 1 5 VDC 5 VDC 2 Serial interface 3 Serial interface 4 Serial interface 5 Serial interface 6 Serial interface 7 Serial interface 8 Serial interface 9 Serial interface 10 0 VDC 0 VDC Table 6 20 J1 Header pin function connects to J2 JB header on main control PCB ...

Page 50: ...tion connects to DRIVE header on control PCB OC Header Pin Pin function signal 1 Current transformer secondary 2 Current transformer secondary Table 6 22 OC Header pin function connects to transformer primary current transformer SD Header Pin Pin function signal 1 24 VDC 24 VDC 2 Soft Start Relay drive signal 0V relay on Table 6 23 SD Header pin function connects to SS header on control PCB DCOUT ...

Page 51: ... 1 1 Header Pin Pin function signal TR1 Output 1 of main welding inverter transformer VAC TR2 Output 2 of main welding inverter transformer VAC OUT1 Positive welding output VDC Table 6 25 Header pin function connects to main inverter transformer ACOUT Header Pin Pin function signal 1 enable 2 control signal 1 3 control signal 2 4 No connection 5 15 VDC 15 VDC 6 0 VDC 0 VDC Table 6 26 ACOUT Header ...

Page 52: ...rol PCB 1 1 1 1 1 1 ACPOUT WA DRIVE SS POWER GUN LED SF SOU OT QF HF JB WV JB A 11429_AC 1 1 1 1 1 1 TEST POINTS GUN Header Pin Pin function signal 1 0 VDC 0 VDC 2 trigger 3 Remote pot maximum 4 Remote pot wiper 5 0 VDC 0 VDC Table 6 27 GUN Header pin function connects to 8 pin remote socket ...

Page 53: ...DC Table 6 31 QF HF Header pin function connects to solenoid and HF PCB WV Header Pin Pin function signal 1 Negative welding terminal 0VDC 2 Positive welding terminal 67 VDC Table 6 32 WV Header pin function connects to welding DINSE terminals J2 Header Pin Pin function signal 1 5 VDC 5 VDC 2 Serial interface 3 Serial interface 4 Serial interface 5 Serial interface 6 Serial interface 7 Serial inte...

Page 54: ...l 1 15 VDC 15 VDC 2 0 VDC 0 VDC Table 6 38 DR Header pin function connects to ACOUT header on AC DC output PCB POWER Header Pin Pin function signal 1 24 VDC 24 VDC 2 0 VDC 0 VDC 3 24 VDC 24 VDC Table 6 39 POWER Header pin function connects to POWER fJ header on power supply PCB SS Header Pin Pin function signal 1 24 VDC 24 VDC 2 Soft Start Relay drive signal 0V relay on Table 6 40 SS Header pin fu...

Page 55: ...DSKILL 200AC DC INVERTER Manual 0 5206 6 15 Troubleshooting 6 11 Calibration 1 Calibration 0V A IMAX WVF R68 A 11430 Set SW0 position 4 to OFF while the power source is turned off to allow calibration of output volts amps ...

Page 56: ...s provided by varistor CY1 The rectifier output charges the main capacitor bank C5 C6 C7 C8 C9 and C10 to high voltage Inrush current limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds The primary igbt transistors T3 T4 T5 and T6 switch the transformer primary at high frequency and varying duty cycle The transformer return wire is taken from the terminal ZBQY1 the...

Page 57: ...G 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 J2 10 JB 10 SOLENOID POWER SUPPLY BOARD POWER FJ DC IN DY3 DY1 8 PIN REMOTE GUN OT TH1 TH2 NTCS WV WELD POSITIVE WELD NEGATIVE WELD POSITIVE CT1 OC MOD DY2 240VAC 240VAC 0VAC 0VAC 220VAC WELD NEGATI...

Page 58: ...Troubleshooting 6 18 Manual 0 5206 WELDSKILL 200AC DC INVERTER TROUBLESHOOTING Notes ...

Page 59: ...ormation 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 Remove Screws on front panel 2 Remove Screws on rear panel 3 Remove Screws on side panel 4 Remove ground screw 1 2 3 4 A 11431 SECTION 7 DISASSEMBLY PROCEDURE ...

Page 60: ... from J8 connector 4 Disconnect SOURCE harness from SOURCE connector 5 Disconnect SS harness from SS connector 6 Disconnect GUN harness from GUN connector 7 Disconnect SOU harness from Sou connector 8 Disconnect IGBT OT harness from IGBT OT connector 9 Disconnect QF HF harness from QF HF connector 10 Disconnect WVIN harness from WVIN connector 11 Disconnect JB harness from JB connector 12 Disconne...

Page 61: ...al 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 Disconnect SOURCE FJ harness from SOURCE FJ connector 5 Remove glue then pull out board 5 2 3 4 1 A 11433 ...

Page 62: ...w 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 Disconnect HF harness from HF connector 6 Remove glue then pull out board 6 3 2 1 5 4 A 11434 ...

Page 63: ...6 PCB4 Removal Read and follow safety information in Section 6 02 before proceeding with disassembly 1 Remove 6 screws 2 Disconnect wire from terminals 1 2 A 11435 7 07 PCB5 Removal Read and follow safety information in Section 6 02 before proceeding with disassembly 1 Remove 5 screws 1 A 11436 ...

Page 64: ... 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 5 Disconnect hose from outlet 1 2 4 3 5 A 11437 ...

Page 65: ... 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 1 2 3 A 11438 ...

Page 66: ... 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 4 Back of rear panel 5 Note that fuse may not be fitted in all units 1 3 2 4 A 11439_AC 5 ...

Page 67: ...BLY 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 1 2 2 3 1 A 11440 ...

Page 68: ...sembly Procedure 7 10 Manual 0 5206 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 1 3 4 2 2 2 ...

Page 69: ...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 4 Remove magnetic from ground wire 5 Remove fan 6 Pull out power cord 1 6 2 5 3 4 A 11442 ...

Page 70: ...WELDSKILL 200AC DC INVERTER DISASSEMBLY PROCEDURE Disassembly Procedure 7 12 Manual 0 5206 Notes ...

Page 71: ...LL 200AC DC INVERTER Manual 0 5206 8 1 Assembly Procedures 8 01 Installing Main Power PCB1 1 Install main PCB1 assembly screws 2 Install wire screws 3 Plug harness into connectors 1 2 2 3 1 A 11440 SECTION 8 ASSEMBLY PROCEDURES ...

Page 72: ...Procedures 8 2 Manual 5206 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 1 3 4 2 2 1 ...

Page 73: ... Procedures 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 5 Reinstall 6 screws 1 2 4 3 5 A 11444 ...

Page 74: ...EDURES 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 6 Reinstall gas inlet 7 Reinstall screws 1 3 4 2 7 5 1 6 A 11445 ...

Page 75: ...NVERTER Manual 0 5206 8 5 Assembly Procedures 8 05 Installing PCB5 1 Install wire to terminals tighten screws 1 A 11436 8 06 Installing PCB4 1 Install 4 screws 2 install wire to terminals and tighten 3 Reconnect 2 yellow wires 1 2 3 A 11446 ...

Page 76: ...ctor 4 Plug harness into SOU connector 5 Plug harness into INPUT connector 6 Plug harness into OUTPUT connector 6 3 2 1 5 4 8 08 Installing Auxiliary Power Supply PCB2 1 Install four studs to PCB2 2 Plug harness into the DY2 connector 3 Plug harness into the DY1 connector 4 Plug harness into the Power FJ connector 5 Plug harness into the DCIN connector 6 Put glue on four Stud 5 2 3 4 1 ...

Page 77: ... connector 4 Plug harness into POWER connector 5 Plug harness into SS connector 6 Plug harness into GUN connector 7 Plug harness into SOU connector 8 Plug harness into OT connector 9 Plug harness into QF HF connector 10 Plug harness into WV connector 11 Plug harness into JB connector 12 Plug harness into ACPOUT connector 13 Plug harness into WA connector 10 11 1 2 3 4 5 6 7 8 9 13 12 A 11432 ...

Page 78: ...edures 8 8 Manual 5206 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 1 2 3 4 A 11449 ...

Page 79: ...KEY SPARE PARTS WELDSKILL 200AC DC INVERTER Manual 0 5206 9 1 KEY SPARE PARTS SECTION 9 KEY SPARE PARTS 9 01 Power Source A 11226_AB Figure 9 1 ...

Page 80: ...W7005505 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 Dinse Socket 50mm 13 W7003036 Control socket 8 pin Note that 8 pin control plug part number is UOA706900 14 W7005514 Gas outlet front panel 15 W7005515 Switch On Off 16 W7003076 CT output 17 ...

Page 81: ...OR 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 contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by CIG WELD whethe...

Page 82: ......

Page 83: ...r 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 or nominated Accredited Distributor Accredited Service Provider The goods being used in accordance with the Manufacturer s Operating Manuals and under competent supervision Does not apply to Obsolete...

Page 84: ......

Page 85: ...RCE 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 components including but not limited to relays switches contactors solenoids fans and electric motors 1 Year 1 Year ACCESSORIES WARRANTY PERIOD TIG torch electrode holder lead and work lead 3 Months T...

Page 86: ...act 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 This warranty is given Cigweld Pty Ltd A B N 56007226815 71 Gower Street Preston Victoria Australia 3072 Phone 1300 ...

Page 87: ...4 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 Victor Technologies com Victor Technologies China No 100 Lao Hongjing Rd Minhang District Shanghai PR 200235 Telephone 86 21 64072626 Fax 86 21 64483032 Victor Technologies Asia Sdn Bhd Lot 151 Jalan Industr...

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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CIGWELD WeldSkill 200AC/DC, Service Manual

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