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CIGWELD WELDSKILL 200HF, Operating Manual

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CIGWELD WELDSKILL 200HF Operating Manual Download Page 17

OPERATING MANUAL

200HF

Manual 0-5406                                                                              2-5 INTRODUCTION

NOTE 1

Due to variations that can occur in manufactured products, claimed performance, voltages, 

ratings, all capacities, measurements, dimensions and weights quoted are approximate only. 

Achievable capacities and ratings in use and operation will depend upon correct installation, use, 

applications, maintenance and service. 

NOTE 2

The Effective Input Current should be used for the determination of cable size & supply 

requirements.

NOTE 3

Motor start fuses or thermal circuit breakers are recommended for this application. Check local 

requirements for your situation in this regard.

NOTE 4

Minimum Generator Recommendation at the Maximum Output Duty Cycle. 

Due to large variations in performance and specifications of different brands and types of 

generators, CIGWELD cannot guarantee full welding output power or duty cycle on every brand 

or type of generator. 

Some small generators incorporate low cost circuit breakers on their outputs. These circuit 

breakers usually will have a small reset button, and will trip much faster than a switchboard 

type circuit breaker. This may result in not being able to achieve full output or duty cycle from 

the power source / generator combination. For this reason we recommend a generator that 

incorporates switchboard type circuit breakers.

CIGWELD recommends that when selecting a generator, that the particular power source / 

generator combination be adequately trialled to ensure the combination performs to the users 

expectations.

NOTE 5

CIGWELD reserves the right to change product performance and specifications without notice.

2.11  Optional Accessories

We recommend genuine CIGWELD products.
The biggest range and best quality with guaranteed performance.

Part Number

Description

W4014604 TIG Torch 26F with Flex Head, 4m lead, 50mm Dinse Plug, Trigger Switch and Remote Control 

BGSAK2 

TIG Torch Accessory Kit for 17, 26 & 18 TIG Torches

210254

WeldSkill Argon Regulator/Flowmeter, 55LPM, 2 Gauge 

OTD10/4016  Foot Control with 7.6m lead with 8 pin plug

WS42550

WeldSkill Welding Leadset 4m, 25mm

2 

cable, 50mm

2

 dinse, 250A Twistlock Electrode Holder 

WS53550

WeldSkill Welding Leadset 5m, 35mm

2 

cable, 50mm

2

 dinse, 400A Twistlock Electrode Holder 

Table 2-2

Summary of Contents for WELDSKILL 200HF

Page 1: ...OPERATING MANUAL Version No AA Issue Date October 2015 Manual No 0 5406 INPUT SUPPLY OUTPUT CURRENT 200HF WARRANTY Art A 12966 200HF Inverter ...

Page 2: ... Customers 61 3 9474 7508 Please register your warranty online immediately after purchase for complete warranty coverage and to guarantee your proof of purchase http warranties cigweld com au FOR YOUR CHANCE TO WIN REGISTER YOUR WARRANTY ONLINE GREAT PRIZES R R RE E EG G G GI I IS S S ST T TE E ER R R Y Y YO O O OU U UR R R OPERATING MANUAL 200HF ...

Page 3: ...wever errors do occur and we apologize if there are any contained in this manual Due to our constant effort to bring you the best products we may make an improvement that does not get reflected in the manual If you are ever in doubt about what you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer support for...

Page 4: ...w cigweld com au Copyright 2015 CIGWELD Pty Ltd 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 cause For Print...

Page 5: ...nt 3 1 3 02 Location 3 1 3 03 Ventilation 3 1 3 04 Mains Supply Voltage Requirements 3 1 3 05 Generators 3 1 3 06 Electromagnetic Compatibility 3 2 SECTION 4 OPERATION 4 1 4 01 Overview 4 1 4 02 Power Source Controls Indicators and Features 4 1 SECTION 5 TIG GTAW WELDING 5 1 5 01 Shielding Gas Regulator Flowmeter Operating Instructions 5 1 5 02 Setup For TIG GTAW Welding 5 4 5 03 TIG GTAW Basic We...

Page 6: ...istortion 6 9 6 19 Overcoming Distortion Effects 6 9 6 20 Welding Problems 6 11 SECTION 7 ROUTINE SERVICE REQUIREMENTS AND POWER SOURCE PROBLEMS 7 1 7 01 Routine Maintenance Inspection 7 1 7 02 Cleaning the Welding Power Source 7 1 7 03 Basic Troubleshooting 7 1 7 04 Power Source Problems 7 2 SECTION 8 KEY SPARE PARTS 8 1 8 01 WeldSkill 200HF Key Spare Parts 8 1 CIGWELD LIMITED WARRANTY TERMS WARR...

Page 7: ...ood 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 spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output 14 Wear a safety harness to prevent falling if working above floor level ...

Page 8: ...proximate 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 Greater than 400 13 Gas Metal Arc Welding GWAW MIG other than Aluminium and Stainless Steel Less than or equal to 150 10 150 to 250 11 250 to 300 12 300 to 400 13 Greater than 400 14 Gas Metal Arc Welding ...

Page 9: ...ks overheating or fire 1 Protect yourself and others from flying sparks and hot metal 2 Do not weld where flying sparks can strike flammable material 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 4 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent a...

Page 10: ...th defects and in some cases 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 Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric Magnetic Fields Background Paper OTA BP E 63 Washingto...

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 Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway...

Page 12: ...dard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements among them are IEC 60974 10 applicable to Industrial Equipment generic emissions and regulations AS 60974 1 IEC 60974 1 applicable to welding equipment and associated accessories Extensive product design verification is conducted at the manufacturing facility as part of th...

Page 13: ...o the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 01 How To Use This Manual This Owners Manual only applies to the Part Numbers listed on page i To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOT...

Page 14: ...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 Auxiliary Power Receptacle Rating Auxiliary Power 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 Wel...

Page 15: ...ms with Australian Standard AS 60974 1 and IEC 60974 1 and is complimented with a 3 year warranty that has been tested through rigorous 40 temperature testing drop testing life cycle testing and IP21S water ingress testing Simply plug it into any standard 15 Amp power point and get welding right away 2 06 User Responsibility This equipment will perform as per the information contained herein when ...

Page 16: ...uilt to provide the rated amperage 90A for 1 5 minutes i e arc welding time out of every 10 minute period 15 of 10 minutes is 1 5 minutes During the other 8 5 minutes of the 10 minute period the Welding Power Source must idle and allowed to cool 2 10 Specifications Description WeldSkill 200HF Plant Part No W1008200 Power Source Dimensions excludes handle gas nipple H245mm W145mm D420mm Power Sourc...

Page 17: ...ly will have a small reset button and will trip much faster than a switchboard type circuit breaker This may result in not being able to achieve full output or duty cycle from the power source generator combination For this reason we recommend a generator that incorporates switchboard type circuit breakers CIGWELD recommends that when selecting a generator that the particular power source generato...

Page 18: ... of 5 BG57Y02 R Back Cap Long for 17 26 18 TIG Torches pkt of 2 BG57Y04 R Back Cap Short for 17 26 18 TIG Torches pkt of 2 Table 2 3 TIG Electrodes Part Number Description 699846 Ceriated Electrode 1 6mm x 175mm AC DC Grey Pkt of 10 699847 Ceriated Electrode 2 4mm x 175mm AC DC Grey Pkt of 10 699848 Ceriated Electrode 3 2mm x 175mm AC DC Grey Pkt of 10 Table 2 4 Related Products Part Number Descri...

Page 19: ...ed for use in environments with increased hazard of electric shock 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 In locations which are fully or partially limited by conduc...

Page 20: ...critical equipment e g guarding of industrial equipment 5 The health of people around e g the use of pacemakers and hearing aids 6 Equipment used for calibration and measurement 7 The time of day that welding or other activities are to be carried out 8 The immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may ...

Page 21: ...ition e g ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by direct connection to the workpiece but in som...

Page 22: ...OPERATING MANUAL 200HF INSTALLATION 3 4 Manual 0 5406 This Page Intentionally Blank ...

Page 23: ...welding current range values as a guide then finally adjust the current setting to suit the application 4 02 Power Source Controls Indicators and Features 1 2 3 4 5 6 7 8 9 10 11 12 13 Front Panel Rear Panel Art A 12967 Figure 4 1 Front and Rear Panel 1 Amperage Control Welding Current The amperage control knob adjusts the amount of welding current delivered by the power source The am perage is in...

Page 24: ... desired welding mode Three modes are available HF TIG Stick and Lift TIG modes Refer to section 5 02 for TIG GTAW set up details or section 6 01 for Stick MMAW set up details 5 Trigger Mode Control Lift TIG and HF TIG Modes only The trigger mode control is used to switch the functionality of the torch trigger between 2T normal and 4T latch mode 2T Normal Mode In this mode the torch trigger must r...

Page 25: ...erating in GTAW LIFT TIG HF TIG modes the power source will remain activated until the selected down slope time has elapsed At any time whilst in 4T Mode if the TIG Torch Trigger Switch is depressed and released welding will cease immediately 6 Arc Force Down Slope Control Arc Force Feature Not Shown This feature operates in Stick Manual Arc mode Stick electrodes can sometimes stick to the work pi...

Page 26: ...at the male dinse type plug is inserted and turned securely to achieve a sound electrical connec tion Do not over tighten CAUTION 1 Loose welding terminal connections can cause overheating and result in the male plug being fused in the Dinse terminal 8 Control Socket 8 Pin The 8 pin socket on the power source is used to connect a trigger switch or remote control device i e foot control to the weld...

Page 27: ... Shielding Gas Inlet The Shielding Gas Inlet connection is a quick connect type and is used to supply the appropriate shielding gas to the unit Refer to section 5 02 for TIG GTAW set up details 14 Hot Start Feature Not Shown This feature operates in Stick Manual Arc mode The Hot Start feature improves the arc start characteristics by momentarily increasing the welding current to a level above the ...

Page 28: ...OPERATING MANUAL 200HF OPERATION 4 6 Manual 0 5406 This Page Intentionally Blank ...

Page 29: ...has been relieved Under pressure gas can dangerously propel a loose part 3 DO NOT remove the regulator flowmeter from a cylinder without first closing the cylinder valve and releasing gas in the regulator flowmeter high and low pressure chambers 4 DO NOT use the regulator flowmeter as a control valve When downstream equipment is not in use for extended periods of time shut off the gas at the cylin...

Page 30: ...ct 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 flowmeter is not fitted with a pressure relief device Operation With the regulator flowmeter connected to cylinder or pipeline and the adjustment screw knob fully disengaged pressurize as follows 1 Stand to one side of regula...

Page 31: ...lator flowmeter by opening the downstream valve Bleed welding grade shielding gas into a well ventilated area and away from any ignition source Turn adjusting screw counterclockwise until the required flow rate is indicated on the gauge Close downstream valve Shutdown Close cylinder valve whenever the regulator flowmeter is not in use To shut down for extended periods more than 30 minutes 1 Close ...

Page 32: ... it does not leak 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 4 02 8 Remote Control Socket for further information F Fit the welding grade shielding gas regulator flowmeter to the shielding gas cylinder refer to Section 5 01 then connect the shielding gas hose from the shielding gas regulator flowmete...

Page 33: ...G Torch 8 Pin Control Plug TIG Torch Gas Hose connection TIG Torch Trigger Switch TIG Torch Remote Current Control Shielding Gas Hose Shielding Gas Cylinder Argon Gas See WARNING below regarding securing the gas cylinder Figure 5 3 Setup for TIG GTAW Welding WARNING Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent fal...

Page 34: ...al Work Piece Can Be Any Commercial Metal Gas Cup Either Ceramic High lmpact or Water Cooled Metal Inert Gas Shields Electrode and Weld Puddle Tungsten Electrode Non Consumable Art A 09658_AC Figure 5 4 TIG Welding Application Shot Tungsten Electrode Current Ranges Electrode Diameter DC Current Amps 0 040 1 0mm 30 60 1 16 1 6mm 60 115 3 32 2 4mm 100 165 1 8 3 2mm 135 200 5 32 4 0mm 190 280 3 16 4 ...

Page 35: ...ses etc Table 5 4 Base Metal Thickness DC Current for Mild Steel DC Current for Stainless Steel Tungsten Electrode Diameter Filler Rod Diameter if required Argon Gas Flow Rate Litres min Joint Type 0 040 1 0mm 35 45 40 50 20 30 25 35 0 040 1 0mm 1 16 1 6mm 5 7 Butt Corner Lap Fillet 0 045 1 2mm 45 55 50 60 30 45 35 50 0 040 1 0mm 1 16 1 6mm 5 7 Butt Corner Lap Fillet 1 16 1 6mm 60 70 70 90 40 60 5...

Page 36: ...filler rod 6 Electrode melts or oxidises when an arc is struck A Torch lead connected to positive welding terminal A Connect torch lead to negative welding terminal B No shielding gas flowing to welding region B Check the shielding gas lines for kinks or breaks and shielding gas cylinder contents C Torch is clogged with dust or dirt C Clean torch D Shielding gas hose is damaged D Replace shielding...

Page 37: ...for the welding current A Select the right size tungsten electrode Refer to Table 5 1 Cigweld Tungsten Electrode Selection Chart B The wrong electrode is being used for the welding job B Select the right size tungsten electrode type Refer to Table 5 5 Cigweld Tungsten Electrode Selection Chart C Shielding gas flow rate is too high C Select the right shielding gas flow rate for the welding job Refe...

Page 38: ...OPERATING MANUAL 200HF SERVICE 5 10 Manual 0 5406 This Page Intentionally Blank ...

Page 39: ...rom the power source via Dinse terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection 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 fron...

Page 40: ...ange of electrodes dealt with in this publication will cover the vast majority of applications likely to be encountered are all easy to use and all will work on even the most basic of welding machines CIGWELD Electrode Selection Chart Description Diameter Pack Part No Application Satincraft 13 2 5mm 2 5mm 3 2mm 3 2mm 4 0mm 1kg 2 5kg 1kg 2 5kg 5kg 322135 612182 322136 612183 611184 General purpose ...

Page 41: ... 3 2mm Blisterpack 4 0mm 2 5 kg 2 5 kg Blisterpack 2 5 kg 611732 611733 322217 611734 Soft Ductile Nickel type electrode for repair and maintenance welding of a wide range of cast irons It has better wetting action than Castcraft 55 Table 6 1 Types of Electrodes 6 04 Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of w...

Page 42: ...ay also be experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron D Copper and alloys The most important factor is the high rate of heat conductivity of copper making preheating of heavy sections necessary to give proper fusion of weld and base metal 6 08 Arc Welding Practice The techniques used for arc welding are almost identical regardless of ...

Page 43: ...etal 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 shown in Figure 6 10 Gap varies from 1 6mm 1 16 to 4 8mm 3 16 depending on plate thickness Joint Open Square Butt 1 6mm 1 16 max 1 6mm 1 16 Single Vee Butt Joint Not less than 70 Double Vee Butt Joint 1 6mm 1...

Page 44: ...s a match is struck As soon as the arc is established maintain a 1 6mm to 3 2mm gap between the burning electrode end and the parent metal Draw the electrode slowly along as it melts down Another difficulty you may meet is the tendency after the arc is struck to withdraw the electrode so far that the arc is broken again A little practice will soon remedy both of these faults Art A 07696_AC 20 1 6 ...

Page 45: ...sing either a weave technique or single beads laid down in the sequence shown in Figure 6 13 The width of weave should not be more than three times the core wire diameter of the electrode When the joint is completely filled the back is either machined ground or gouged out to remove slag which may be trapped in the root and to prepare a suitable joint for depositing the backing run If a backing bar...

Page 46: ... A 07703 Figure 6 18 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 The electrode should point upwards at an angle...

Page 47: ...ther away and tends to bulge or is upset When the weld area begins to cool the upset metal attempts to contract as much as it expanded but because it has been upset it does not resume its former shape and the contraction of the new shape exerts a strong pull on adjacent metal Several things can then happen The metal in the weld area is stretched plastic deformation the job may be pulled out of sha...

Page 48: ...ate thus reducing distortion Art A 07707 Figure 6 22 Principle of presetting Art A 07708 B Preheat Preheat Dotted lines show effect if no preheat is used Weld C Figure 6 23 Reduction of distortion by preheating Art A 07709 Figure 6 24 Examples of distortion Art A 07710_AB 1 Block Sequence The spaces between the welds are filled in when the welds are cool 2 3 Figure 6 25 Welding sequence Art A 0771...

Page 49: ...g current B Electrode too large for joint B Use smaller diameter electrode C Insufficient gap C Allow wider gap D Incorrect sequence D Use correct build up sequence Insufficient Gap Incorrect Sequence Art A 05866_AC Figure 6 29 Example of Insufficient Gap or Incorrect Sequence 4 Portions of the weld run do not fuse to the surface of the metal or edge of the joint A Small electrodes used on heavy c...

Page 50: ...es are trapped in the weld metal slag inclusion A Non metallic particles may be trapped in undercut from previous run A If bad undercut is present clean slag out and cover with a run from a smaller diameter electrode B Joint preparation too restricted B Allow for adequate penetration and room for cleaning out the slag C Irregular deposits allow slag to be trapped C If very bad chip or grind out ir...

Page 51: ...ment is recommended 7 02 Cleaning the Welding Power Source 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 Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling To clean the Welding Power Source open the enclosure and use a vacuum cleaner t...

Page 52: ...rk piece C TIG Torch 8 Pin Control Plug not connected correctly or loose faulty connection in plug C Connect 8 Pin TIG Torch control plug securely and correctly to the 8 Pin control socket of the front of the WeldSkill 200HF Power Source Repair or replace if faulty D Faulty TIG Torch Trigger D Repair or replace TIG Torch Trigger switch lead 3 Over Temp Indicator is illuminated and unit will not co...

Page 53: ...rch Trigger Switch 8 Pin Control Plug or Lead is faulty E Ensure that the 8 Pin Control Plug is correctly connected or repair or replace the Tig Torch Trigger Switch or 8 Pin Control Plug or Lead F Shielding Gas Valve in Power Source is not operating correctly F Have an Accredited Cigweld service provider repair or replace the Shielding Gas Valve 8 Gas flow continues after the torch trigger switch...

Page 54: ... Welding Grade Argon is being used C Inadequate shielding gas flow or shielding gas not turned on C Turn on shielding gas and set shielding gas flow rate for the welding job Refer to Table 5 5 on Page 5 7 D Incorrect Tungsten D Check Tungsten type and size and change if necessary 10 Arc flutters during TIG welding Tungsten electrode is too large for the welding current Select the correct size of t...

Page 55: ...72 7 Figure 8 1 WELDSKILL 200HF KEY SPARE PARTS ITEM PART NUMBER DESCRIPTION 1 W7006844 PCB Power Inverter 2 W7006845 PCB Front Panel 3 W7006846 PCB HF 4 W7006829 Primary Rectifier 5 W7006849 Solenoid Valve 24VDC 6 W7006809 Fan 24VDC 7 W7006847 Control Socket 8 Pin c w wiring harness Note 8 Pin control plug is part number UOA706900 Table 8 1 ...

Page 56: ...KEY SPARE PARTS 8 2 Manual 0 5406 OPERATING MANUAL 200HF This Page Intentionally Blank ...

Page 57: ...IS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN CIGWELD S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY CIGWELD PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to...

Page 58: ...orches O rings fuses filters or other parts that fail due to normal wear Note No employee agent or representative of CIGWELD is authorized to change this warranty in any way or grant any other warranty and CIGWELD shall not be bound by any such attempt Correction of non conformities in the manner and time provided herein constitutes fulfilment of CIGWELD s obligations to purchaser with respect to ...

Page 59: ...OPERATING MANUAL 200HF This Page Intentionally Blank ...

Page 60: ...s Tel 61 3 9474 7508 Fax 61 3 9474 7488 cigweld com au Malaysia Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Tel 60 3 6092 2988 Fax 60 3 6092 1085 Indonesia JL Akasia II Blok A 05 No 10A Delta Silicon Lippo Cikarang Bekasi 17550 Indonesia Toll Free 0 800 1842 867 Tel 62 21 8990 6095 Fax 62 21 8990 6096 ...

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