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CIGWELD WELDSKILL 200HF Operating Manual
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CIGWELD WELDSKILL 200HF Operating Manual

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Art # A-12966
200HF
OPERATING MANUAL
OUTPUT CURRENT
INPUT SUPPLY
WARRANTY*
200HF Inverter
Version No: AA |
Issue Date: October, 2015 | Manual No: 0-5406

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Summary of Contents for CIGWELD WELDSKILL 200HF

  • Page 1 Art # A-12966 200HF OPERATING MANUAL OUTPUT CURRENT INPUT SUPPLY WARRANTY* 200HF Inverter Version No: AA | Issue Date: October, 2015 | Manual No: 0-5406...
  • Page 2 200HF OPERATING MANUAL REGISTER YOUR WARRANTY ONLINE FOR YOUR CHANCE TO GREAT PRIZES http://warranties.cigweld.com.au Check out our online registration for the most up to date competitions and promotions PROTECT YOUR INVESTMENT Please register your warranty online immediately after purchase for complete warranty coverage and to guarantee your proof of purchase.
  • Page 3 YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. CIGWELD is a Market Leading Brand of Arc Welding Products for ESAB. We are a mainline supplier to major welding industry sectors in the Asia Pacific and emerging global markets including; Manufacturing, Construction, Mining, Automotive, Engineering, Rural and DIY.
  • Page 4 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. CIGWELD WeldSkill 200HF Welding Inverter Instruction Manual Number 0-5406 for: Part Number W1008200 Published by:...

  • Page 5: Table Of Contents

    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 1.03 DECLARATION OF CONFORMITY ..............1-6 SECTION 2: INTRODUCTION ..................2-1 2.01 How To Use This Manual ................2-1 2.02 Equipment Identification .................
  • Page 6 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 WARRANTY SCHEDULE – WELDSKILL 200HF INVERTER...

  • Page 7: Arc Welding Safety Instructions And Warnings

    200HF OPERATING MANUAL SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
  • Page 8 200HF OPERATING MANUAL 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and ARC RAYS can burn eyes and skin; NOISE foot protection.
  • Page 9 200HF OPERATING MANUAL 3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. WARNING 4. Be alert that welding sparks and hot materials from FUMES AND GASES can be hazardous to welding can easily go through small cracks and your health.
  • Page 10 200HF OPERATING MANUAL 4. Never allow a welding electrode to touch any Frequency Electric & Magnetic Fields - Background cylinder. Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May 1989): “...there is 5. Use only correct shielding gas cylinders, now a very large volume of scientific findings based regulators, hoses, and fittings designed for the on experiments at the cellular level and from studies specific application;...

  • Page 11: Principal Safety Standards

    200HF OPERATING MANUAL 1.02 PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 12: Declaration Of Conformity

    71 Gower St, Preston Victoria 3072 Australia Description of equipment: Welding Equipment (MMAW, GTAW) including, but not limited to CIGWELD WeldSkill 200HF inverter and associated accessories. Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

  • Page 13: Introduction

    Include the Owner’s Manual number and equipment identification numbers. Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the CIGWELD web site listed below and clicking on the Literature Library link: http://www.cigweld.com.au Manual 0-5406...

  • Page 14: Symbol Chart

    200HF OPERATING MANUAL 2.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier Purging Of Gas...

  • Page 15: Description

    200HF OPERATING MANUAL 2.05 Description 2.06 User Responsibility The WeldSkill 200HF is a single phase 15 Amp constant This equipment will perform as per the information current welding inverter capable of performing 180 contained herein when installed, operated, maintained Amps in MMAW (Stick) with a maximum electrode and repaired in accordance with the instructions size of 4.0mm and 200Amps in GTAW (non-contact...

  • Page 16: Transporting Methods

    During the other 8.5 minutes of the 10 minute period the Welding Power Source must idle Lift unit with handle on top of case. and allowed to cool. 2.10 Specifications WeldSkill 200HF Descriptio Plant Part No W1008200 Power Source Dimensions H245mm ×...

  • Page 17: Optional Accessories

    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.

  • Page 18: Optional Accessories (Cont'd)

    WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Tribal 454323 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 White Carbon 454324 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Oz Flag Note: CIGWELD Electrodes see page 6-2 and 6-3 Table 2-5 INTRODUCTION Manual 0-5406...

  • Page 19: Installation

    200HF OPERATING MANUAL SECTION 3: INSTALLATION 3.04 Mains Supply Voltage 3.01 Environment Requirements These units are designed for use in environments with increased hazard of electric shock. The Mains supply voltage should be within ± 10% of the rated Mains supply voltage. If actual Mains Supply A.

  • Page 20: Electromagnetic Compatibility

    200HF OPERATING MANUAL 3.06 Electromagnetic Compatibility 6. Equipment used for calibration and measurement. 7. The time of day that welding or other activities are to be carried out. WARNING Extra precautions for Electromagnetic 8. The immunity of other equipment in the Compatibility may be required when environment: the user shall ensure that other this Welding Power Source is used in a...
  • Page 21 200HF OPERATING MANUAL 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 shock by touching the metallic components and the electrode at the same time.
  • Page 22 200HF OPERATING MANUAL This Page Intentionally Blank INSTALLATION Manual 0-5406...

  • Page 23: Operation

    200HF OPERATING MANUAL SECTION 4: OPERATION 4.01 Overview Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to workpiece and electrode lead is used to hold electrode (Consult the electrode manufacturers information for the correct polarity). The welding current range values should be used as a guide only. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between different classes of electrode, welding current at any one setting would vary according to the type of electrode in use.
  • Page 24 200HF OPERATING MANUAL 3. Over Temp Indicator This welding power source is protected by a self resetting thermostat. The Over Temp indicator will illuminate if the machine has over heated which normally occurs if the duty cycle of the power source has been exceeded. Should the Over Temp indicator illuminate the output of the power source will be disabled.
  • Page 25 200HF OPERATING MANUAL 4T (Latch Mode) This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the opera- tor can press and release the torch trigger and the output will remain active. To deactivate the power source, the trigger switch must again be depressed and realised, thus eliminating the need for the operator to hold the torch trigger.
  • Page 26 200HF OPERATING MANUAL Down Slope in 4T (Latch Mode) To activate the Downslope function in 4T (Latch Mode) whilst welding, the TIG Torch Trigger Switch must be depressed and held which will ramp the Welding Current down to zero over a defined period of time. The time period is determined by the Downslope Control Knob.
  • Page 27 200HF OPERATING MANUAL 9. Positive Welding Output Terminal The positive welding terminal is used to connect the welding output of the power source to the electrode holder lead. Most General Purpose electrodes are connected with electrode to positive. Consult the electrode manufacturer’s information for the correct polarity.
  • Page 28 200HF OPERATING MANUAL This Page Intentionally Blank OPERATION Manual 0-5406...

  • Page 29: Tig (Gtaw) Welding

    200HF OPERATING MANUAL SECTION 5: TIG (GTAW) WELDING 5.01 Shielding Gas Regulator/Flowmeter Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Regulator/Flowmeter Safety This regulator/flowmeter is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.
  • Page 30 200HF OPERATING MANUAL Art: A-05087 Figure 5-1: Fit Regulator/flowmeter to Cylinder Installation 1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices and damage seats before connecting the regulator/flowmeter. Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition.
  • Page 31 200HF OPERATING MANUAL Adjusting Flow Rate Art: A-05088_AB Figure 5-2: Adjust Flow Rate With the regulator/flowmeter ready for operation, adjust working flow rate as follows: 1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate.

  • Page 32: Setup For Tig (Gtaw) Welding

    5.01) then connect the shielding gas hose from the shielding gas regulator/flowmeter outlet to the quick connect Shielding Gas Inlet fitting gas on the rear of the WeldSkill 200HF Power Source. Ensure that the shielding gas hose connection is sufficiently tight at the regulator connection and the quick connect fitting "locks"...
  • Page 33 200HF OPERATING MANUAL Set Process 240VAC, 15A Mains Supply Selection Switch to HF TIG or LIFT TIG mode Shielding Gas Cylinder (Argon Gas) NEGATIVE OUTPUT TERMINAL TIG Torch See WARNING below Trigger Switch regarding securing the TIG Torch gas cylinder. 8 Pin Control Plug Shielding Gas Hose POSITIVE...

  • Page 34: Tig (Gtaw) Basic Welding Technique

    200HF OPERATING MANUAL 5.03 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non- consumable) electrode and the work piece.
  • Page 35 Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www. cigweld.com.au or contact Cigweld. Manual 0-5406...

  • Page 36: Tig (Gtaw) Welding Problems

    200HF OPERATING MANUAL 5.04 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive bead build up or Welding current is too Increase weld current and/or faulty joint poor penetration or poor preparation. fusion at edges of weld. 2 Weld bead too wide and Welding current is too Decrease weld current.
  • Page 37 Electrode Selection Chart. B The wrong electrode B Select the right size tungsten electrode is being used for the type. Refer to Table 5-5 Cigweld Tungsten welding job. Electrode Selection Chart. C Shielding gas flow rate C Select the right shielding gas flow rate is too high.
  • Page 38 200HF OPERATING MANUAL This Page Intentionally Blank SERVICE 5-10 Manual 0-5406...

  • Page 39: Stick (Mmaw) Welding

    200HF OPERATING MANUAL SECTION 6: STICK (MMAW) WELDING 6.01 Setup For STICK (MMAW) Welding A. Select Stick mode with the process selection control (refer to Section 4.02.4 for further information). B. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer.

  • Page 40: Arc Welding Electrodes

    2.5 kg 611602 Stainless Steel type for 19Cr/10Ni stainless grades Satincrome 3.2mm 2.5 kg 611603 including 201, 202, 301, 302, 303, 304, 304L, 305, 308L-17 308, etc 4.0mm 2.5 kg 611604 Cigweld Electrode Selection Chart continued over page OPERATION Manual 0-5406...

  • Page 41: Size Of Electrode

    200HF OPERATING MANUAL CIGWELD Electrode Selection Chart cont'd Description Diameter Pack Part No. Application 2.5mm 2.5 kg 611692 Stainless Steel type for 309 and 309L grades. It is Satincrome 3.2mm 2.5 kg 611693 also suitable for welding of dissimilar welding of 309Mo-17 other 300 series stainless steels.

  • Page 42: Effects Of Arc Welding Various Materials

    200HF OPERATING MANUAL 6.07 Effects of Arc Welding Various Materials A. High tensile and alloy steels The two most prominent effects of welding these Art # A-07687 steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, Figure 6-2: Flat position, down hand butt weld the occurrence in this zone of under-bead cracks may result.

  • Page 43: Joint Preparations

    200HF OPERATING MANUAL Art # A-07694 Art# A-07693 Figure 6-8: Overhead position, butt weld Figure 6-9: Overhead position fillet, weld 6.10 Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.

  • Page 44: Arc Welding Technique

    200HF OPERATING MANUAL 6.11 Arc Welding Technique 20° Art # A-07696_AC A Word to Beginners For those who have not yet done any welding, the simplest way to commence is to run beads on a piece 1.6 mm (1/16”) of scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode.
  • Page 45 200HF OPERATING MANUAL finally adjust the current setting to suit necessary to remove this, since it serves a similar the application. purpose to the backing run in securing proper fusion at the root of the weld. A. Butt Welds B. Fillet Welds Set up two plates with their edges parallel, as shown in Figure 6-12, allowing 1.6mm to 2.4mm gap between These are welds of approximately triangular cross-...
  • Page 46 200HF OPERATING MANUAL C. Vertical Welds 1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm Ferrocraft 21 electrode and set the current at 100 amps. Make yourself comfortable on a seat in front of the job Art # A-07703 and strike the arc in the corner of the fillet.

  • Page 47: Distortion

    200HF OPERATING MANUAL 6.17 Distortion “locked-up” stresses in the job. Figures 6-20 and 6-21 illustrate how distortion is created. Distortion in some degree is present in all forms of Upsetting Weld Art # A-07705_AB welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be Expansion with compression...
  • Page 48 200HF OPERATING MANUAL E. Preheating Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure 6-23 shows a simple application. By removing the heating source from b and c as soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.

  • Page 49: Welding Problems

    200HF OPERATING MANUAL 6.20 Welding Problems Description Possible Cause Remedy 1 Gas pockets or voids in weld metal Electrodes are damp A Dry electrodes before use (Porosity) Welding current is too high B Reduce welding current 　 　 Surface impurities such as C Clean joint before welding 　...
  • Page 50 200HF OPERATING MANUAL Description Possible Cause Remedy 5 A groove has been formed in the A Welding current is too high. A Reduce welding current base metal adjacent to the toe of a weld and has not been filled by the weld metal (undercut).

  • Page 51: Routine Service Requirements And Power Source Problems

    If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited CIGWELD Service Provider for repair. The basic level of troubleshooting is that which can be performed without special equipment or knowledge. Manual 0-5406...

  • Page 52: Power Source Problems

    Control Plug not plug securely and correctly to connected correctly the 8 Pin control socket of the or loose/faulty front of the WeldSkill 200HF connection in plug. Power Source. Repair or replace if faulty. Faulty TIG Torch Repair or replace TIG Torch Trigger.
  • Page 53 Switch or 8 Pin Control Plug or Switch, 8 Pin Control Lead. Plug or Lead is faulty. Shielding Gas Valve in Have an Accredited Cigweld Power Source is not service provider repair or replace operating correctly. the Shielding Gas Valve.
  • Page 54 Check Tungsten type and size and change if necessary. 10 Arc flutters during TIG Tungsten electrode Select the correct size of tungsten welding is too large for the electrode refer to Table 5-1 Cigweld welding current Tungsten Electrode Selection Chart. Table 7-1 SERVICE Manual 0-5406...

  • Page 55: Section 8: Key Spare Parts

    200HF OPERATING MANUAL SECTION 8: KEY SPARE PARTS 8.01 WeldSkill 200HF Key Spare Parts Art # A-12972 Figure 8-1 WELDSKILL 200HF KEY SPARE PARTS ITEM PART NUMBER DESCRIPTION W7006844 PCB Power Inverter W7006845 PCB Front Panel W7006846 PCB HF W7006829...
  • Page 56 200HF OPERATING MANUAL This Page Intentionally Blank KEY SPARE PARTS Manual 0-5406...

  • Page 57: Cigweld - Limited Warranty Terms

    Any claim under this warranty must be made within the warranty period which commences on the date of purchase of the product. To make a claim under the warranty, take the product (with proof of purchase from a Cigweld Ac- credited Seller) to the store where you purchased the product or contact Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider.
  • Page 58 * 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 the product.
  • Page 59 200HF OPERATING MANUAL This Page Intentionally Blank...
  • Page 60 CIGWELD Pty Ltd Malaysia - Indonesia - CIGWELD An ESAB Brand Lot 151, Jalan Industri 3/5A JL Akasia II Blok A-05 No. 10A 71 Gower Street, Preston VIC 3072 Australia Rawang Integrated Industrial Park, Delta Silicon - Lippo Cikarang Customer Care:...

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