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ESAB CIGWELD WeldSkill 205AC/DC, Operating Manual

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ESAB CIGWELD WeldSkill 205AC/DC Operating Manual Download Page 6

TABLE OF CONTENTS

SECTION 1: 

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ..................................... 1-1

1.01 

Arc Welding Hazards ....................................................................................... 1-1

1.02 

PRINCIPAL SAFETY STANDARDS ................................................................... 1-5

SECTION 2: 

INTRODUCTION  ..................................................................................... 2-1

2.01 

How To Use This Manual ................................................................................ 2-1

2.02 

Equipment Identification ................................................................................. 2-1

2.03 

Receipt Of Equipment ..................................................................................... 2-1

2.04 

Symbol Chart .................................................................................................. 2-2

2.05 Description ..................................................................................................... 2-3
2.06 

User Responsibility ......................................................................................... 2-3

2.07 

Packaged Item ................................................................................................ 2-3

2.08 

Transporting Methods ..................................................................................... 2-3

2.09 

Duty Cycle ....................................................................................................... 2-4

2.10 Specifications ................................................................................................. 2-5
2.11 

Optional Accessories ...................................................................................... 2-6

SECTION 3: 

INSTALLATION ....................................................................................... 3-1

3.01 Environment ................................................................................................... 3-1
3.02 Location .......................................................................................................... 3-1
3.03 Ventilation ....................................................................................................... 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 Generators ...................................................................................................... 3-2
3.08 

Extension Leads .............................................................................................. 3-2

3.09 

Short Circuit Protection While Welding ........................................................... 3-2

3.10 

Electromagnetic Compatibility ........................................................................ 3-2

3.11 

Foot Control, Part No. W4015800 (Optional Accessory)  ................................ 3-4

SECTION 4: 

OPERATION ........................................................................................... 4-1

4.01 Overview ......................................................................................................... 4-1
4.02 

WeldSkill 205AC/DC Power Source Controls 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 ...................................................................... 5-3

5.03 

TIG Programming Modes  .............................................................................. 5-4

5.04 

Factory Reset .................................................................................................. 5-8

5.05 

TIG (GTAW) Basic Welding Technique ............................................................ 5-9

5.06 

TIG (GTAW) Welding Problems ..................................................................... 5-11

Summary of Contents for CIGWELD WeldSkill 205AC/DC

Page 1: ...Version No AA Issue Date 15 04 2019 Manual No 0 5555 P N W1008205 OUTPUT CURRENT AC DC STICK ELECTRODE 4 0mm MAX WARRANTY 2 WARRANTY 3 205A HF...

Page 2: ...ffort 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 receiv...

Page 3: ...www cigweld com au Copyright 2019 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 ass...

Page 4: ...hereof contained in this manual and accompanying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked perio...

Page 5: ...EEA has been used in the design AS 60974 1 2006 Arc Welding Equipment Welding Power Sources IEC 60974 1 2000 MOD IEC 60974 10 2014 Arc Welding Equipment Part 10 Electromagnetic Compatibility EMC Requ...

Page 6: ...02 Location 3 1 3 03 Ventilation 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 Generators 3 2 3 08 Extension Leads 3 2 3...

Page 7: ...6 8 6 15 Arc Length 6 8 6 16 Rate of Travel 6 8 6 17 Making Welded Joints 6 8 6 18 Distortion 6 10 6 19 The Cause of Distortion 6 11 6 20 Overcoming Distortion Effects 6 12 6 21 Welding Problems 6 14...

Page 8: ...This Page Intentionally Blank...

Page 9: ...rical 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 l...

Page 10: ...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...

Page 11: ...rike flam mable 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...

Page 12: ...g AndThe 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...

Page 13: ...as 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 Sales 178 Rexdale Bou...

Page 14: ...GENERAL INFORMATION 1 6 0 5555 This Page Intentionally Blank...

Page 15: ...s 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...

Page 16: ...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 Ar...

Page 17: ...ommended that such repairs be carried out by appropriately qualified persons approved by CIGWELD Advice in this regard can be obtained by contacting accredited CIGWELD Distributor This equipment or an...

Page 18: ...cycle 90 amperes at 23 6 volts This means that it has been designed and built to provide the rated amperage 90A for 6 minutes i e arc welding time out of every 10 minute period 60 of 10 minutes is 6 m...

Page 19: ...factor 8kW at 1 0 power factor Output Terminal Type Dinse Style 50 TIG GTAW Welding Output 40 C 10 min 205A 20 18 2V 120A 60 14 8V 95A 100 13 8V Open Circuit Voltage 63V STICK MMAW Welding Output 40...

Page 20: ...s NOTE 4 CIGWELD reserves the right to change product performance and specifications without notice NOTE 5 If an extension lead is required to be used it is recommended to use a minimum size of 2 5mm2...

Page 21: ...Torches pkt of 5 BG10N25 R Collet 3 2mm for 17 26 18 TIG Torches pkt of 5 BG10N30 R Collet Body 1 0mm for 17 26 18 TIG Torches pkt of 5 BG10N31 R Collet Body 1 6mm for 17 26 18 TIG Torches pkt of 5 BG...

Page 22: ...4 WeldSkill Auto Darkening Welding Helmet Variable Shade 9 13 Oz Flag 454335 WeldSkill Auto Darkening Welding Helmet Variable Shade 9 13 Flaming Skull 454336 WeldSkill Auto Darkening Welding Helmet Va...

Page 23: ...cy section of this machine has an output similar to a radio transmitter The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing 3 01 Environment The...

Page 24: ...m Heavy Duty Extension Lead Longer extension leads may impact welding performance and operation 3 09 Short Circuit Protection While Welding To prolong the useful life of a TIG tungsten elec trode the...

Page 25: ...equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is...

Page 26: ...iometer Wiper 8 Not Used Table 3 1 Description The CIGWELD Foot Control is a foot operated switch and potentiometer which starts and stops the welding process and controls welding current through oper...

Page 27: ...he respective front panel control irrespective of the remote control device setting As an example if the output current on the power source front panel is set to 50 of the available current and the re...

Page 28: ...INSTALLATION 3 6 0 5555 This page is left blank intentionally...

Page 29: ...would vary according to the type of electrode in use The operator should use the welding current range values as a guide then finally adjust the current setting to suit the application 4 02 WeldSkill...

Page 30: ...ote Control 5k ohm Potentiometers Maximum 6 Remote Control 5k ohm Potentiometers Minimum 7 Remote Control 5k ohm Potentiometer Wiper 8 Not used Table 4 1 8 Pin Interconnection Control Plug Configurati...

Page 31: ...g the power source should remain ON such that the fan continues to operate allowing the unit to cool sufficiently If after 30 minutes with the fan running the Fault Indicator has not gone OFF then hav...

Page 32: ...e To select and set Spot time first select Spot Mode on the Trigger and Spot Mode Control Button then either using the Multifunction Control Knob 11 or Back button increment until the Spot Time indica...

Page 33: ...be able to control between 0 100 output 16 VRD ON OFF Indicator A VRD voltage reduction device is a hazard reducing device designed to reduce electric shock hazards present on the output of welding po...

Page 34: ...ng Gas Inlet The Gas Inlet connection is used to supply the appropriate TIG welding gas to the unit Refer to Section 5 02 for TIG setup details Ensure that the shielding gas hose connection is suffici...

Page 35: ...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 th...

Page 36: ...amage internal regulator parts 2 Since the regulator is a preset type no adjustments to the regulator are necessary Before opening the cylinder valve be sure that the flow adjusting valve is in a fing...

Page 37: ...rrent control if applicable via the 8 pin socket located on the front of the Power Source The TIG torch will require a trigger switch to weld in TIG Mode D Connect the work lead to the positive weldin...

Page 38: ...rgon Regulator Gas Hose Figure 5 3 Setup For TIG GTAW Welding 5 03 TIG Programming Modes CAUTION HF is present in allTIG modes This may cause damage to measuring equipment connected to the output of t...

Page 39: ...sed to weld two thin plates together at a desired location by melting the top and bottom plates together to form a nugget between them The weld time is set by the Spot Time In TIG Welding modes once t...

Page 40: ...ode 100 Amps AC TIG mode 50 Amps DC Pulse and AC Pulse TIG modes Peak Current This parameter sets the PEAK weld current when in DC or AC Pulse TIG mode Range 10 to 205 Amps 100 Amps DC Pulse and AC Pu...

Page 41: ...and AC Pulse TIG modes AC Frequency This parameter operates in AC TIG mode or AC Pulse TIG mode and is used to set the frequency for the AC weld current Range 20 to 250 Hz 100 Hz Wave Balance This pa...

Page 42: ...Balance 65 A 11223 Table 5 2 AC TIG Wave Balance 5 04 Factory Reset CAUTION AllWelding Parameters will be restored to the factory setting To restore to factory settings Press and hold the Multifunctio...

Page 43: ...ce 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 6 TIG Weld...

Page 44: ...le 5 6 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 3...

Page 45: ...al 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 clo...

Page 46: ...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 Refer to Table 5 7 on page 5 10 D Incorrect shielding g...

Page 47: ...l If in doubt consult the electrode manufac turer Welding current flows from the power source via Dinse type terminals It is essential however that the male plug is inserted and turned securely to ach...

Page 48: ...s the Process Selection button to select STICK mode Use the Multi Function Control to adjust the Parameter selected While welding the Multi Function Control directly controls the BASE CURRENT Adjust p...

Page 49: ...nt fit up in certain situations with particular electrodes In general increasing the Arc Force control toward 100 maximum Arc Force allows greater penetration control to be achieved Range 0 to 100 30...

Page 50: ...anised steels Excellent for vertical down fillet welding applications OK 53 16 Spezial 2 5mm 3 2mm 4 0mm 1 8 kg 1 6 kg 2 2 kg 53162534G1 53163234G0 53164044G0 Hydrogen Controlled type offering excepti...

Page 51: ...d by using the correct electrodes pre heating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tempering in a furnace B Austenitic manganese stee...

Page 52: ...rhead position butt weld Art A 07694 Figure 6 10 Overhead position fillet weld 6 11 Joint Preparations In many cases it will be possible to weld steel sections without any special preparation For heav...

Page 53: ...the work either directly or through the work table For light gauge material always clamp the work lead directly to the job otherwise a poor circuit will probably result 6 13 The Welder Place yourself...

Page 54: ...plate to form a bead The electrode is directed at the weld pool at about 20 from the vertical The rate of travel has to be adjusted so that a well formed bead is produced If the travel is too fast the...

Page 55: ...the line of the fillet and about 45 from the vertical Some electrodes require to be sloped about 20 away from the perpendicular position to prevent slag from running ahead of the weld Refer to Figure...

Page 56: ...gth of waste pipe Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch The electrode is held at 45 to the horizontal an...

Page 57: ...te 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 but when it atte...

Page 58: ...C Restraint of Parts Forcible restraint of the components being welded is often used to prevent distortion Jigs positions and tack welds are methods employed with this in view D Presetting It is poss...

Page 59: ...710_AB 1 Block Sequence The spaces between the welds are filled in when the welds are cool 2 3 Figure 6 26 Welding sequence Art A 07711_AB 4 3 2 1 Figure 6 27 Step back sequence Art A 07712 Figure 6 2...

Page 60: ...left by failure of the weld metal to fill the root of the weld A Welding current is too low A Increase welding current B Electrode too large for joint B Use smaller diameter electrode C Insufficient g...

Page 61: ...filled by the weld metal undercut A Welding current is too high A Reduce welding current B Welding arc is too long B Reduce the length of the welding arc C Angle of the electrode is incorrect C Electr...

Page 62: ...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 adequate penetration Use suitab...

Page 63: ...ended 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 elec...

Page 64: ...a good connection to the work piece 3 Fault Indicator is illuminated and unit will not commence welding when the torch trigger switch is depressed Duty cycle of power source has been exceeded Leave t...

Page 65: ...006914 Gas Solenoid Assembly 6 W7006925 Front Panel 7 W7006915 Gas Outlet 8 W7006852 Socket Dinse 50mm2 9 W7006917 8 Pin Control Socket socket and pins only 10 W7006916 PCBA Display 11 W7006927 Displa...

Page 66: ...O DESCRIPTION 1 W7005900 Trigger assembly for 26F torch 2 W7005901 Handle assembly for 26F torch 3 W7005902 Dinse 50mm for 26F torch 4 W7005903 Flex head for 26F torch 5 BGSAK2 Tig accessory Kit 6 UOA...

Page 67: ...1 LED1 LED34 Absorption Circuit CN1 1 2 CN7 1 2 1 2 CN8 CN4 1 2 CN2 1 2 3 1 2 CN5 1 2 3 CN5 Absorption PCB CN2 1 2 CN3 1 2 CN6 1 2 3 CN4 3 2 1 CN6 3 2 1 CN1 1 2 CN3 3 2 1 1 2 H1 VR1 1 2 3 4 P2 M 0 Red...

Page 68: ...APPENDIX A 2 0 5555 This Page Intentionally Blank...

Page 69: ...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 T...

Page 70: ...cutting and Oxy fuel torches 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...

Page 71: ...This Page Intentionally Blank...

Page 72: ...08 Fax 61 3 9474 7488 cigweld com au Malaysia No 14 Jalan Teknologi 3 1 Selangor Science Park 1 Kota Damansara 47810 Petaling Jaya Malaysia Tel 60 3 6145 0995 Fax 60 3 6145 0585 Indonesia JI Pulogadun...

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