You are on page 1of 88

200AC/DC

INVERTER
ARC WELDING MACHINE

A-11419

Service Manual
Revision: AC Issue Date: April 23, 2015 Manual No.: 0-5206
Operating Features:
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Cigweld product. We are proud
to have you as our customer and will strive to provide you with
the best service and reliability in the industry. This product
is backed by our extensive warranty and world-wide service
network. To locate your nearest distributor or service provider call
+1300 654 674, or visit us on the web at www.cigweld.com.cn

This Service Manual has been designed to instruct you on the correct
use and operation of your CIGWELD product. Your satisfaction with
this product and its safe operation is our ultimate concern. Therefore
please take the time to read the entire manual, especially the Safety
Precautions. They will help you to avoid potential hazards that may
exist when working with this product.

YOU ARE IN GOOD COMPANY!


The Brand of Choice for Contractors and Fabricators Worldwide.
CIGWELD is the Market 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, Construction, Mining, Automotive,
Engineering, Rural and DIY.

We distinguish ourselves from our competition through market-


leading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced


products to achieve a safer working environment for industry
operators.
! WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgement,
the Manufacturer assumes no liability for its use.

Welding Power Supply


Service Manual Number 0-5206 for:

WeldSkill 200AC/DC Plant Part Number W1006200

Published by:
CIGWELD Pty Ltd
71 Gower Street
Preston, Victoria, Australia, 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 cause.

Publication Date: January 15, 2013

Record the following information for Warranty purposes:

Where Purchased: _____________________________________

Purchase Date: _____________________________________

Equipment Serial #: _____________________________________


TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS........................................................ 1-1
1.01 Arc Welding Hazards........................................................................................ 1-1
1.02 Principal Safety Standards............................................................................... 1-4
1.03 Declaration of Conformity................................................................................ 1-5
1.04 Symbol Chart................................................................................................... 1-6
1.05 Servicing Hazards............................................................................................ 1-7
1.06 EMF Information.............................................................................................. 1-8
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 Description...................................................................................................... 2-1
2.05 Transportation Methods................................................................................... 2-1
SECTION 3:
SAFETY AND INSTALLATION........................................................................ 3-1
3.01 Duty Cycle........................................................................................................ 3-1
3.02 Specifications.................................................................................................. 3-2
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
4.04 Short Circuit Protection While Welding.......................................................... 4-10
4.05 Shielding Gas Regulator Operating Instructions............................................ 4-11
4.06 Setup for TIG (GTAW) Welding...................................................................... 4-13
4.07 Foot Control, Part No. W4015800 (Optional Accessory)................................ 4-14
4.08 Setup for STICK (MMAW) Welding .............................................................. 4-16
SECTION 5:
THEORY OF OPERATION............................................................................. 5-1
5.01 Inverter Design................................................................................................ 5-1
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
WARRANTY TERMS.................................................................... INSIDE REAR COVER

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION.................................. REAR COVER


SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 200AC/DC INVERTER
SECTION 1:
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.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator
does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study
and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices ap-
ply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the European Standard EN60974-1 entitled: Safety in welding and allied processes Part 2: Electrical.
This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety
precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

12. Use only well-maintained equipment. Repair or replace


1.01 Arc Welding Hazards 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.
WARNING Use equipment with DC output.

ELECTRIC SHOCK can kill. 14. Wear a safety harness to prevent falling if working above floor
level.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is 15. Keep all panels and covers securely in place.
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live
when power is on. In semiautomatic or automatic wire
welding, the wire, wire reel, drive roll housing, and all WARNING
metal parts touching the welding wire are electrically
live. Incorrectly installed or improperly grounded ARC RAYS can burn eyes and skin; NOISE can dam-
equipment is a hazard age hearing.
1. Do not touch live electrical parts. Arc rays from the welding process produce intense
2. Wear dry, hole-free insulating gloves and body protection. heat and strong ultraviolet rays that can burn eyes and
skin. Noise from some processes can damage hearing.
3. Insulate yourself from work and ground using dry insulating
mats or covers. 1. Use a Welding Helmet or Welding Faceshield fitted with a
proper shade of filter (see ANSI Z49.1 and AS 1674 listed in
4. Disconnect input power or stop engine before installing or Safety Standards) to protect your face and eyes when welding
servicing this equipment. Lock input power disconnect switch or watching.
open, or remove line fuses so power cannot be turned on 2. Wear approved safety glasses. Side shields recommended.
accidentally.
5. Properly install and ground this equipment according to its 3. Use protective screens or barriers to protect others from flash
Owner’s Manual and national, state, and local codes. and glare; warn others not to watch the arc.

6. Turn off all equipment when not in use. Disconnect power to 4. Wear protective clothing made from durable, flame-resistant
equipment if it will be left unattended or out of service. material (wool and leather) and foot protection.

7. Use fully insulated electrode holders. Never dip holder in 5. Use approved ear plugs or ear muffs if noise level is high.
water to cool it or lay it down on the ground or the work 6. Never wear contact lenses while welding.
surface. Do not touch holders connected to two welding
machines at the same time or touch other people with the
holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced WARNING
cables.
FUMES AND GASES can be hazardous to your health.
9. Do not wrap cables around your body. Welding produces fumes and gases. Breathing these
10. Ground the workpiece to a good electrical (earth) ground. fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
11. Do not touch electrode while in contact with the work (ground)
circuit.
Manual 0-5206 1-1 Safety Instructions and Warnings
WELDSKILL 200AC/DC INVERTER SAFETY INSTRUCTIONS AND WARNINGS
2. If inside, ventilate the area and/or use exhaust at the arc to 9. Do not use welder to thaw frozen pipes.
remove welding fumes and gases.
10. Remove stick electrode from holder or cut off welding wire at
3. If ventilation is poor, use an approved air-supplied respirator. contact tip when not in use.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
and cleaners.
WARNING
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for FLYING SPARKS AND HOT METAL can cause injury.
welding can displace air causing injury or death. Be sure the
breathing air is safe. Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
6. Do not weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc can react 1. Wear approved face shield or safety goggles. Side shields
with vapours to form highly toxic and irritating gases. recommended.

7. Do not weld on coated metals, such as galvanized, lead, or 2. Wear proper body protection to protect skin.
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded. WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
WARNING pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding process,
WELDING can cause fire or explosion. be sure to treat them carefully.
Sparks and spatter fly off from the welding arc.
The flying sparks and hot metal, weld spatter, hot 1. Protect compressed gas cylinders from excessive heat,
workpiece, and hot equipment can cause fires and mechanical shocks, and arcs.
burns. Accidental contact of electrode or welding wire 2. Install and secure cylinders in an upright position by chaining
to metal objects can cause sparks, overheating, or fire. them to a stationary support or equipment cylinder rack to
1. Protect yourself and others from flying sparks and hot metal. prevent falling or tipping.
2. Do not weld where flying sparks can strike flammable 3. Keep cylinders away from any welding or other electrical
material. circuits.
3. Remove all flammables within 35 ft (10.7 m) of the welding 4. Never allow a welding electrode to touch any cylinder.
arc. If this is not possible, tightly cover them with approved
covers. 5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
4. Be alert that welding sparks and hot materials from welding associated parts in good condition.
can easily go through small cracks and openings to adjacent
areas. 6. Turn face away from valve outlet when opening cylinder
valve.
5. Watch for fire, and keep a fire extinguisher nearby.
7. Keep protective cap in place over valve except when cylinder is
6. Be aware that welding on a ceiling, floor, bulkhead, or in use or connected for use.
partition can cause fire on the hidden side.
8. Read and follow instructions on compressed gas cylinders,
7. Do not weld on closed containers such as tanks or drums. associated equipment, and CGA publication P-1 listed in Safety
Standards.
8. Connect work cable to the work as close to the welding area
as practical to prevent welding current from travelling long,
possibly unknown paths and causing electric shock and fire
hazards.

Safety Instructions and Warnings 1-2 Manual 0-5206


SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 200AC/DC INVERTER
Recommended Protective Filters for Electric Welding
Approximate range of Welding Minimum Shade Number of
Description of Process
Current in Amps Filter(s)
Less than or equal to 100 8
100 to 200 10
Manual Metal Arc Welding covered
200 to 300 11
electrodes (MMAW)
300 to 400 12
Greater than 400 13
Less than or equal to 150 10
Gas Metal Arc Welding (GWAW) 150 to 250 11
(MIG) other than Aluminium and 250 to 300 12
Stainless Steel 300 to 400 13
Greater than 400 14
Gas Metal Arc Welding (GMAW) Less than or equal to 250 12
(MIG) Aluminium and Stainless Steel 250 to 350 13
Less than or equal to 100 10
100 to 200 11
Gas Tungsten Arc Welding (GTAW) 200 to 250 12
(TIG) 250 to 350 13
Greater than 350 14
Less than or equal to 300 11
Flux-cored Arc Welding (FCAW) 300 to 400 12
-with or without shielding gas. 400 to 500 13
Greater than 500 14
Air – Arc Gouging Less than or equal to 400 12
50 to 100 10
Plasma-Arc Cutting 100 to 400 12
400 to 800 14
Plasma-Arc Spraying — 15
Less than or equal to 20 8
20 to 100 10
Plasma-Arc Welding
100 to 400 12
400 to 800 14
Submerged Arc Welding — 2(5)
Resistance Welding — Safety Spectacles or eye shield
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.

Manual 0-5206 1-3 Safety Instructions and Warnings


WELDSKILL 200AC/DC INVERTER SAFETY INSTRUCTIONS AND WARNINGS
1.02 Principal Safety Standards
WARNING Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
MOVING PARTS can cause injury.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
Moving parts, such as fans, rotors, and belts can cut fingers and dent of Documents, U.S. Government Printing Office, Washington,
hands and catch loose clothing. D.C. 20402.

1. Keep all doors, panels, covers, and guards closed and Recommended Safe Practices for the Preparation for Welding and
securely in place. Cutting of Containers That Have Held Hazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, from American Welding
2. Stop engine before installing or connecting unit. Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
3. Have only qualified people remove guards or covers for National Electrical Code, NFPA Standard 70, from National Fire
maintenance and troubleshooting as necessary. Protection Association, Batterymarch Park, Quincy, MA 02269.
4. To prevent accidental starting during servicing, disconnect Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
negative (-) battery cable from battery. from Compressed Gas Association, 1235 Jefferson Davis Highway,
5. Keep hands, hair, loose clothing, and tools away from Suite 501, Arlington, VA 22202.
moving parts. Code for Safety in Welding and Cutting, CSA Standard W117.2, from
6. Reinstall panels or guards and close doors when servicing Canadian Standards Association, Standards Sales, 178 Rexdale
is finished and before starting engine. Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Pro-

! WARNING
tection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from Na-
This product, when used for welding or cutting, pro-
tional Fire Protection Association, Batterymarch Park, Quincy, MA
duces fumes or gases which contain chemicals know
02269.
to the State of California to cause birth defects and, in
some cases, cancer. (California Health & Safety code Safety in welding and allied processes Part 1: Fire Precautions, AS
Sec. 25249.5 et seq.) 1674.1-1997 from SAI Global Limited, www.saiglobal.com.
NOTE Safety in welding and allied processes Part 2: Electrical, AS 1674.2-
2007 from SAI Global Limited, www.saiglobal.com.
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields Filters for eye protectors - Filters for protection against radiation
generated in welding and allied operations AS/NZS 1338.1:1992
The following is a quotation from the General Conclusions Section
from SAI Global Limited, www.saiglobal.com.
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields - Background
Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing
Office, May 1989): “...there is now a very large volume of scientific
findings based on experiments at the cellular level and from studies
with animals and people which clearly establish that low frequency
magnetic fields and interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the results
are complex. Current scientific understanding does not yet allow
us to interpret the evidence in a single coherent framework. Even
more frustrating, it does not yet allow us to draw definite conclu-
sions about questions of possible risk or to offer clear science-based
advice on strategies 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 normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
Safety Instructions and Warnings 1-4 Manual 0-5206
SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 200AC/DC INVERTER
1.03 Declaration of Conformity
Manufacturer and Merchandiser of Quality Consumables and Equipment : CIGWELD
Address: 71 Gower St, Preston
Victoria 3072
Australia

Description of equipment: CIGWELD WeldSkill 200AC/DC INVERTER Power Source 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.
* The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive 73/23/EU, as recently changed
in Directive 93/68/EU and to the National legislation for the enforcement of the Directive.
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
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process,
to ensure the product is safe and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the
manufactured product meets or exceeds all design specifications.

CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance, ultra safe operation and
world class quality for more than 30 years and will continue to achieve excellence.

Manual 0-5206 1-5 Safety Instructions and Warnings


WELDSKILL 200AC/DC INVERTER SAFETY INSTRUCTIONS AND WARNINGS
1.04 Symbol Chart
Note that only some of these symbols will appear on your model.

On Single Phase Wire Feed Function

Wire Feed Towards


Off Three Phase Workpiece With
Output Voltage Off.
Three Phase Static
Dangerous Voltage Frequency Converter- Welding Gun
Transformer-Rectifier

Increase/Decrease Remote Purging Of Gas

X
Continuous Weld
Circuit Breaker Duty Cycle
Mode

AC Auxiliary Power % Percentage Spot Weld Mode

Fuse Panel/Local Spot Time


t

Shielded Metal
Amperage t1 Preflow Time
Arc Welding (SMAW)

Gas Metal Arc


Voltage t2
Postflow Time
Welding (GMAW)

Gas Tungsten Arc 2 Step Trigger


Hertz (cycles/sec) Welding (GTAW) Operation
Press to initiate wirefeed and
Air Carbon Arc welding, release to stop.
Frequency
Cutting (CAC-A)

Negative Constant Current 4 Step Trigger


Operation
Press and hold for preflow, release
Constant Voltage to start arc. Press to stop arc, and
Positive
Or Constant Potential hold for preflow.

Direct Current (DC) High Temperature


t Burnback Time

Protective Earth
Fault Indication
(Ground) IPM Inches Per Minute

Line Arc Force


MPM Meters Per Minute

Line Connection Touch Start (GTAW)


S See Note

Auxiliary Power Variable Inductance See Note

115V 15A Receptacle Rating-


V Voltage Input
Auxiliary Power
Art # A-04130_AB

Note: For environments with increased hazard of electrical shock, Power Supplier bearing the S mark conform to EN50192
when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
Cannot be disposed with household garbage.

Safety Instructions and Warnings 1-6 Manual 0-5206


SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 200AC/DC INVERTER
1.05 Servicing Hazards

! WARNING
WARNING
FLYING METAL or DIRT can injure eyes.
The symbols shown below are used throughout this • Wear safety glasses with side shields or face shield during
manual to call attention to and identify possible haz- servicing.
ards. When you see the symbol, watch out, and follow
• Be careful not to short metal tools, parts, or wires together
the related instructions to avoid the hazard.
during testing and servicing.
Only qualified persons should test, maintain, and
repair this unit.
Only qualified persons should test, maintain, and WARNING
repair this unit.
HOT PARTS can cause sever burns.

• Do not touch hot parts bare handed.


WARNING • Allow cooling period before working on equipment.
• To handle not parts, use proper tools and/or wear heavy,
ELECTRIC SHOCK can kill.
insulated welding gloves and clothing to prevent burns.
• Do not touch live electrical parts.
• Turn Off welding power source and wire feeder and disconnect
and lockout input power using line disconnect switch, circuit WARNING
breakers, or by removing plug from receptacle, or stop engine
before servicing unless the procedure specifically requires an EXPLODING PARTS can cause injury.
energized unit. • Failed parts can explode or cause other parts to explode when
• Insulate yourself from ground by standing or working on power is applied to inverters.
dry insulating mats big enough to prevent contact with the • Always wear a face shield and long sleeves when servicing
ground. inverters.
• Do not leave live unit unattended.
• If this procedure requires and energized unit, have only per-
sonnel familiar with and following standard safety practices
WARNING
do the job.
• When testing a live unit, use the one-hand method. Do not SHOCK HAZARD from testing.
put both hands inside unit. Keep one hand free.
• Turn Off welding power source and wire feeder or stop engine
• Disconnect input power conductors from de-energized supply before making or changing meter lead connections.
line BEFORE moving a welding power source.
• Use at least one meter lead that has a self-retaining spring
SIGNIFICANT DC VOLTAGE exists after removal of input clip such as an alligator clip.
power on inverters.
• Read instructions for test equipment.
• Turn Off inverters, disconnect input power, and discharge
input capacitors according to instructions in Troubleshooting
Section before touching any parts.
WARNING
FALLING UNIT can cause injury.
WARNING
• Use lifting eye to lift unit only, NOT running gear, gas cylinders,
STATIC (ESD) can damage PC boards. or any other accessories.

• Put on grounded wrist strap BEFORE handling boards or parts. • Use equipment of adequate capacity to lift and support unit.

• Use proper static-proof bags and boxes to store, move, or • If using lift forks to move unit, be sure forks are long enough
ship PC boards. to extend beyond opposite side of unit.

WARNING
WARNING
MOVING PARTS can cause injury,
FIRE OR EXPLOSION hazard.
• Keep away from moving parts such as fans.
• Do not place unit on, over, or near combustible surfaces.
• Keep away from pinch points such as drive rolls.
• Do not service unit near flammables.
• Have only qualified persons remove doors, panels, covers, or
guards for maintenance as necessary.
• Keep hands, hair, loose clothing, and tools away from moving
parts.

Manual 0-5206 1-7 Safety Instructions and Warnings


WELDSKILL 200AC/DC INVERTER SAFETY INSTRUCTIONS AND WARNINGS
• Reinstall doors, panels, covers, or guards when maintenance
is finished and before reconnecting input power. 1.06 EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
WARNING Welding current, as it flows through welding cables, will cause
electromagnetic fields. There has been and still is some concern
MAGNETIC FIELDS can affect Implanted Medical
about such fields. However, after examining more than 500 studies
Devices.
spanning 17 years of research, a special blue ribbon committee
• Wearers of Pacemakers and other Implanted Medical Devices of the National Research Council concluded that: “The body of
should keep away from servicing areas until consulting their evidence, in the committee’s judgment, has not demonstrated
doctor and the device manufacturer. that exposure to power-frequency electric and magnetic fields is
a human-health hazard.” However, studies are still going forth and
evidence continues to be examined. Until the final conclusions of
the research are reached, you may wish to minimize your exposure
WARNING to electromagnetic fields when welding or cutting.

OVERUSE can cause OVERHEATING. To reduce magnetic fields in the workplace, use the following
procedures:
• Allow cooling period; follow rated duty cycle.
1. Keep cables close together by twisting or taping them, or using
• Reduce current or reduce duty cycle before starting to weld a cable cover.
again.
2. Arrange cables to one side and away from the operator.
• Do not block or filter airflow to unit.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator
WARNING as practical.

H.F. RADIATION can cause interference. 5. Connect work clamp to workpiece as close to the weld as pos-
sible.
• High-frequency (H.F.) can interfere with radio navigation,
About Implanted Medical Devices:
safety services, computers, and communications equipment.
• Have only qualified persons familiar with electronic equipment Implanted Medical Device wearers should consult their doctor
install, test, and service H.F. producing units. and the device manufacturer before performing or going near arc
welding, spot welding, gouging, plasma arc cutting, or induction
• The user is responsible for having a qualified electrician
heating operations. If cleared by your doctor, then following the
promptly correct any interference problem resulting from
above procedures is recommended.
the installation.
• If notified by the FCC about interference, stop using the
equipment at once.
• Have the installation regularly checked and maintained.
• Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.

! WARNING
READ INSTRUCTIONS.

• Use Testing Booklet (Part No. 150 853) when servicing this
unit.
• Consult the Owner’s Manual for welding safety precau-
tions.
• Use only genuine replacement parts from the manufac-
turer.

Safety Instructions and Warnings 1-8 Manual 0-5206


INTRODUCTION WELDSKILL 200AC/DC INVERTER
SECTION 2:
INTRODUCTION
2.01 How to Use This Manual 2.03 Receipt of Equipment
To ensure safe operation, read the entire manual, includ- When you receive the equipment, check it against the
ing the chapter on safety instructions and warnings. invoice to make sure it is complete and inspect the
Throughout this manual, the word WARNING, CAU- equipment for possible damage due to shipping. If there
TION and NOTE may appear. Pay particular attention to is any damage, notify the carrier immediately to file a
the information provided under these headings. These claim. Furnish complete information concerning damage
special annotations are easily recognized as follows: claims or shipping errors to the location in your area
listed in the inside back cover of this manual. Include

! WARNING
all equipment identification numbers as described above
along with a full description of the parts in error.

Gives information regarding possible per- 2.04 Description


sonal injury. Warnings will be enclosed in a
box such as this. The CIGWELD WELDSKILL 200AC/DC is a single phase
constant current welding inverter capable of performing
MMAW (Stick), GTAW (HF TIG) and GTAW (Lift TIG)
CAUTION welding processes. The unit is equipped with digital
Refers to possible equipment damage. Cau- amperage and voltage meters, and a host of other fea-
tions will be shown in bold type. tures in order to fully satisfy the broad operating needs
of the modern user. The unit is also fully compliant to
NOTE Australian Standard AS 60974.1 and IEC 60974.1.
Offers helpful information concerning certain
The WELDSKILL 200AC/DC provides excellent welding
operating procedures. Notes will be shown
performance across a broad range of applications when
in italics
used with the correct welding consumables and proce-
You will also notice icons from the safety section ap- dures. The following instructions detail how to correctly
pearing throughout the manual. These are to advise you and safely set up the machine and give guidelines on
of specific types of hazards or cautions related to the gaining the best efficiency and quality from the Power
portion of information that follows. Some may have Source. Please read these instructions thoroughly be-
multiple hazards that apply and would look something fore using the unit.
like this:
2.05 Transportation Methods

! Disconnect input power


2.02 Equipment Identification
conductors from de-energized supply line before
The unit’s identification number (specification or part moving the welding power source.
number), model, and serial number usually appear
Lift unit with handle on top of case. Use handcart or
on a nameplate attached to the machine. Equipment
similar device of adequate capacity. If using a fork
which does not have a nameplate attached to the
lift vehicle, secure the unit on a proper skid before
machine is identified only by the specification or part
transporting.
number printed on the shipping container. Record these
numbers for future reference.

Manual 0-5206 2-1 Introduction


WELDSKILL 200AC/DC INVERTER INTRODUCTION
Notes

Introduction 2-2 Manual 0-5206


SAFETY AND INSTALLATION WELDSKILL 200AC/DC INVERTER
SECTION 3:
SAFETY AND INSTALLATION
3.01 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding
current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10
minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate
at a 20% duty cycle, 200 amperes 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.

100

90
Duty Cycle (PERCENTAGE)

80
WELDSKILL
200 AC/DC
70

60
MMAW (STICK)
50
GTAW (TIG)
40

30 SAFE OPERATING REGION


20
(TIG & STICK)

10

0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220

Welding Current (AMPS) A-11218

Figure 3-1: WELDSKILL 200AC/DC Duty Cycle

Manual 0-5206 3-1 Safety and Installation


WELDSKILL 200AC/DC INVERTER SAFETY AND INSTALLATION
3.02 Specifications
Description WELDSKILL 200 AC/DC
Plant Part Number W1006200
Power Source Mass 22 kg
Power Source Dimensions H 400mm x W 240mm x D 475mm
Cooling Fan Cooled
Welder Type Inverter Power Source
Australian Standards AS 60974.1-2006 / IEC 60974-1
Number of Phases 1
Nominal Supply Voltage 240V +/- 15%
Nominal Supply Frequency 50/60Hz
Welding Current Range (STICK Mode) 5 – 200A
Effective Input Current (I1eff) (note1) 15A
Maximum Input Current (I1max) 38.8A
Single Phase Generator Requirement 10kVA
(note2)
STICK (MMAW) 170A @ 15%, 26.8V
Welding Output, 40ºC, 10 min. 100A @ 60%, 24.0V
80A @ 100%, 23.2V
TIG (GTAW) 200A @ 20%, 18.0V
Welding Output, 40ºC, 10 min. 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 start fuses or thermal circuit breakers are recommended for this application. Check local
requirements for your situation in this regard.

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.

Safety and Installation 3-2 Manual 0-5206


SAFETY AND INSTALLATION WELDSKILL 200AC/DC INVERTER
3.03 Environment
These units are designed for use in environments with increased hazard of electric shock as outlined in AS 60974.1
and AS 1674.2. Additional safety precautions may be required when using unit in an environment with increased
hazard of electric shock. Please refer to relevant local standards for further information prior to using in such areas.
A. 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.
B. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of
unavoidable or accidental contact by the operator.
C. In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the
human body and the insulation properties of accessories.
Environments with increased hazard of electric shock do not include places where electrically conductive parts in
the near vicinity of the operator, which can cause increased hazard, have been insulated.

3.04 Location
Be sure to locate the welder according to the following guidelines:
• In areas, free from moisture and dust.
• Ambient temperature 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
provides adequate protection against solid objects (greater than 12mm), and direct protection from vertical
drops. Under no circumstances should the unit be operated or connected in a micro environment that will
exceed the stated conditions. For further information please refer to AS 60529.
• Precautions must be taken against the power source toppling over. The power source must be located on
a suitable horizontal surface in the upright position when in use.

! WARNING
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.

3.05 High Frequency Introduction


The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference
due to high frequency initiated or stabilised arc is almost invariably traced to improper installation. The following
information is intended as a guide for personnel installing high frequency welding machines.

! WARNING EXPLOSIVES
The high frequency 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

Manual 0-5206 3-3 Safety and Installation


WELDSKILL 200AC/DC INVERTER SAFETY AND INSTALLATION
cases this remedial action may be as simple as earthing

! WARNING COMPUTER
the welding circuit, see NOTE below. In other cases it
could involve constructing an electromagnetic screen
enclosing the Welding Power Source and the work,
It is also possible that operation close to complete with associated input filters. In all cases,
computer installations may cause computer electromagnetic disturbances shall be reduced to the
malfunction. point where they are no longer Trouble-some.
NOTE
3.06 High Frequency Interference The welding circuit may or may not be
Interference may be transmitted by a high frequency earthed for safety reasons. Changing the
initiated or stabilised arc welding machine in the earthing arrangements should only be
following ways. authorised by a person who is competent to
assess whether the changes will increase the
1. Direct Radiation: Radiation from the machine can risk of injury, e.g. by allowing parallel welding
occur if the case is metal and is not properly grounded. current return paths which may damage the
It can occur through apertures such as open access earth circuits of other equipment. Further
panels. The shielding of the high frequency unit in guidance is given in IEC 974-13 Arc Welding
the Power Source will prevent direct radiation if the Equipment - Installation and use (under
equipment is properly grounded. preparation).
2. Transmission via the Supply Lead: Without
adequate shielding and filtering, high frequency energy B. Assessment of Area
may be fed to the wiring within the installation (mains) Before installing welding equipment, the user shall make
by direct coupling. The energy is then transmitted by an assessment of potential electromagnetic problems
both radiation and conduction. Adequate shielding and in the surrounding area. The following shall be taken
filtering is provided in the Power Source. into account.
3. Radiation from Welding Leads: Radiated interference 1. Other supply cables, control cables, signaling and
from welding leads, although pronounced in the vicinity telephone cables; above, below and adjacent to the
of the leads, diminishes rapidly with distance. Keeping welding equipment.
leads as short as possible will minimise this type of
interference. Looping and suspending of leads should 2. Radio and television transmitters and receivers.
be avoided wherever possible.
3. Computer and other control equipment.
4. Re-Radiation from Unearthed Metallic Objects: A
4. Safety critical equipment, e.g. guarding of industrial
major factor contributing to interference is re-radiation
equipment.
from unearthed metallic objects close to the welding
leads. Effective grounding of such objects will prevent 5. The health of people around, e.g. the use of pace-
re-radiation in most cases. makers and hearing aids.
6. Equipment used for calibration and measurement.
3.07 Electromagnetic Compatibility
7. The time of day that welding or other activities are
to be carried out.
WARNING 8. The immunity of other equipment in the environment:
Extra precautions for Electromagnetic the user shall ensure that other equipment being
Compatibility may be required when this used in the environment is compatible: this may
Welding Power Source is used in a domestic require additional protection measures.
situation. The size of the surrounding area to be considered
will depend on the structure of the building and other
A. Installation and Use - Users Responsibility activities that are taking place. The surrounding area
may extend beyond the boundaries of the premises.
The user is responsible for installing and using the
welding equipment according to the manufacturer’s
instructions. If electromagnetic 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
Safety and Installation 3-4 Manual 0-5206
SAFETY AND INSTALLATION WELDSKILL 200AC/DC INVERTER
C. Methods of Reducing Electromagnetic Emissions
1. Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations.
If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply.
Consideration should be given to shielding the supply cable of permanently installed welding equipment in
metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding
should be connected to the Welding Power Source so that good electrical contact is maintained between the
conduit and the Welding Power Source enclosure.
2. Maintenance of Welding Equipment
The welding 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 equipment is in
operation. The welding equipment should not be modified in any way except for those changes and adjustments
covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilizing devices
should be adjusted and maintained according to the manufacturer’s recommendation
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 shock by
touching the metallic components and the electrode at the same time. The operator should be insulated from
all such bonded metallic components.
5. Earthing of the Work Piece
Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size
and position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection
of the work piece to earth should be made by direct connection to the work piece, but in some countries where
direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according
to national regulations.
6. Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems
of interference. Screening the entire welding installation may be considered for special applications.

Manual 0-5206 3-5 Safety and Installation


WELDSKILL 200AC/DC INVERTER SAFETY AND INSTALLATION
3.07 Volt-Ampere Curves
Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source.
Curves of other settings fall between curves shown.

100
90
80 WELDSKILL 200AC/DC
70
GTAW(TIG )
Output Voltage (Volts)

60
50
40
30 MMAW ( STICK)
20
10
0
0 20 40 60 80 100 120 140 160 180 200 220 240

Welding Current (AMPS) A-11420

Figure 3-2: WELDSKILL 200AC/DC Volt-Ampere Curves

Safety and Installation 3-6 Manual 0-5206


OPERATION WELDSKILL 200AC/DC INVERTER
SECTION 4:
OPERATION
4.01 WELDSKILL 200AC/DC Power Source Controls, Indicators and Features
18 19 5

17
6

MODE

200 18.0
VOLTS
AC
SECONDS

16 PERCENT (%) POWER

7
DC
FREQ (Hz) FAULT
Peak
Amps Current Volts
PULSE PROCESS
Hot LIFT TIG
Start Trough
Base Current
Width
HF TIG
Current
Up Down
Slope Slope STICK
Initial Frequency Crater
Current Current
Post
PURGE Pre
Flow Flow TRIGGER

15
AC FREQUENCY
WAVE BALANCE
(ARC FORCE)
2T NORMAL
8
4T LATCH

9
BACK FORWARD
14
200 AC/DC Inverter
PORTABLE WELDING MACHINE WeldSkill
10
13

12

11

1 2 3 4 A-11219

Figure 4-1: WELDSKILL 200AC/DC Controls, Indicators and Features

20

ON

OFF

21
22

A-11232

Figure 4-2: Rear Panel

Manual 0-5206 4-1 Operation


WELDSKILL 200AC/DC INVERTER OPERATION
1. Positive Welding Terminal
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.
2. 8 Pin Control Socket
The 8 pin receptacle is used to connect a trigger switch or remote control to the welding Power Source
circuitry:
To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. The socket
information is included in the event the supplied cable is not suitable and it is necessary to wire a plug or
cable to interface with the 8 pin receptacle.

Socket Pin Part Number / Description


1 Not used
2 Trigger Switch Input
3 Trigger Switch Input 2 1
4 Not used 5 4 3
5 Remote Control 5k ohm Potentiometers Maximum 8 7 6
6 Remote Control 5k ohm Potentiometers Minimum
7 Remote Control 5k ohm Potentiometer Wiper
8 Not used A-11228

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 welding terminal connections can cause overheating and result in the male plug being fused in the
terminal.
4. Shielding Gas Outlet
The Shield Gas Outlet located on the front panel is a 5/8-18 UNF female gas fitting and is utilised for the
connection of a suitable TIG Torch.
5. Power ON Indicator
The POWER ON indicator illuminates when the ON/OFF switch (20) is in the ON position and the correct
mains voltage is present.
6. Fault Indicator (Thermal Overload or Primary Circuit Overcurrent)
The Fault Indicator will illuminate in conjunction with an “Err 001” displayed on the ammeter and voltmeter
digital displays if either of the following two conditions exists.

A-11476

Operation 4-2 Manual 0-5206


OPERATION WELDSKILL 200AC/DC INVERTER
1. Thermal Overload
This is due to the duty cycle of the power source being exceeded. Once the power source cools sufficiently
it will automatically reset and the Fault Indicator and Err 001 will go off and the power source is then
able to continue welding. During the time of cooling 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 have an Accredited CIGWELD Service Provider check the
power source.
2. Primary Circuit Overcurrent
This is due to primary circuit component(s) malfunctioning which results in excessive primary circuit
current. Switch OFF the power source immediately to allow all components to cool down for at least
30 minutes. If after 30 minutes “Err 001” is displayed and Fault Indicator illuminates when the power
source is switched back ON turn the power source OFF and have an Accredited CIGWELD Service
Provider check the power source.
7. Process Selection Button
The process selection control is used to select the desired welding mode. Three modes are available,
GTAW/ (LIFT TIG), GTAW (HF TIG) and 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 holder be connected to the unit
and mistakenly be in contact with the work piece during power up.
8. Trigger Mode Control Button (HF TIG and LIFT TIG Mode only)
The trigger mode control is used to switch the functionality of the of the torch trigger between 2T (normal),
and 4T (latch mode).
2T Normal Mode
In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold
the torch trigger to activate the power source (weld). Release the torch trigger switch to cease welding.

A-11220_AB

Figure 4-3
4T Latch Mode
This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the
operator 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.
Note that when operating in GTAW (HF and LIFT TIG modes), the power source will remain activated until
the selected down slope time has elapsed

Manual 0-5206 4-3 Operation


WELDSKILL 200AC/DC INVERTER OPERATION
AMPS
Peak
Current

Base
Current
Down
Arc Ignited Slope Arc Terminated
Up
Initial Slope
Current Crater
Current
TIME
Post
Pre Flow
Flow

Press & hold Release Press & hold Release


Trigger Trigger Trigger Trigger A-11221

Figure 4-4
9. Wave Balance / Arc Force Indicator
This indicator light will illuminate when programming Wave Balance (AC HF TIG mode only) or Arc Force
(STICK mode only).
10. Forward Programming Button
Pressing this button will advance to the next step in the programming sequence.
11. Multifunction Control
The multifunction control knob is used to adjust welding current.
It is also used to adjust parameters when in programming mode.

12. Forward Programming Button


Pressing 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 indicator will
illuminated and shielding gas will purge for a preset period of 15 seconds. (This cannot be adjusted).
To stop shielding gas from purging within this time press the PURGE button and release and the purge
indicator will extinguish and shielding gas will cease.
15 Pulse Button
Press the PULSE button to toggle Pulse On and OFF in LIFT TIG and HF TIG modes
16. Programming Parameter Indicators
These indicator lights will illuminate when programming.
17. Mode Button
Press the MODE button to toggle AC and DC output in all Process modes

Operation 4-4 Manual 0-5206


OPERATION WELDSKILL 200AC/DC INVERTER
18. Digital Ammeter
The digital amperage meter is used to display both the pre-set current and actual output current of the
power source.
At times of non-welding, the amperage meter will display a pre-set (preview) amperage value. This value
can be adjusted by varying the multifunction control when the Programming Parameter Indicator light
shows BASE CURRENT.
When welding, the amperage meter will display actual welding current.
Should a remote device be connected the maximum setting of the power source will be determined by the
respective front panel control, irrespective of the remote control device setting. As an example, if the output
current on the power source front panel is set to 50% and the remote control device is set to 100%, the
maximum achievable output from the unit will be 50%. Should 100% output be required, the respective
power source front panel control must be set to 100%, in which case the remote device will then be able
to control between 0-100% output.
NOTE
If a fault condition occurs for either Thermal Overload or Primary Circuit Overload then “Err” is
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 the programming parameter.
When welding, the volt meter will display actual welding voltage.
NOTE
If a fault condition occurs for either Thermal Overload or Primary Circuit Overload then an “001” is
displayed on this meter. (Refer to section 3.08.6 Fault Indicator for further detail)
20. On / Off Switch (not shown)
This Switch is located on the rear of the Power Source and turns mains power off and on.

! WARNING
When the front digital displays are lit, the machine is connected to the Mains supply voltage and
the internal electrical components are at Mains voltage potential.
21. Shielding Gas Inlet
The Shield Gas Inlet is a 5mm nipple suitable for connection of a gas hose to a regulated Shielding Gas
Supply. The Shielding Gas inlet is located on the rear of the Power Source.
21. Cooling Fan
The WeldSkill 200AC/DC is fitted with a cooling fan that will operate continuously when the On/Off switch
on the rear panel is switched to the On position.

Manual 0-5206 4-5 Operation


WELDSKILL 200AC/DC INVERTER OPERATION
4.02 WELDSKILL 200AC/DC - STICK Programming Mode
Press the PROCESS button to select STICK mode.
Press the MODE switch to toggle between AC and DC welding output.
The Programming LED’s are always active. Press FORWARD or BACK to cycle through available programming
functions.
Use the Multi Function Control to adjust the Parameter.
While welding the Multi Function Control directly controls the BASE CURRENT

MODE
VOLTS
AC
SECONDS
PERCENT (%) POWER
DC
FREQ (Hz) FAULT
Amps Current Volts
PULSE PROCESS
Hot LIFT TIG
Start Trough
Base Current
Width
HF TIG
Current
Up Down
Slope Slope STICK
Initial Frequency Crater
Current Current
Post
PURGE Pre
Flow Flow TRIGGER
WAVE BALANCE 2T NORMAL
AC FREQUENCY (ARC FORCE)
4T LATCH

BACK FORWARD

200 AC/DC
PORTABLE WELDING MACHINE
Inverter
WeldSkill

Press to go forward / go back


Adjust programming parameter between programming status
A-11222_AB
LED’s
Figure 4-5: Stick Programming Mode

Operation 4-6 Manual 0-5206


OPERATION WELDSKILL 200AC/DC INVERTER
Programming Parameter Adjustment Device Display

70
Hot Start
This parameter operates in all weld modes
except LIFT TIG mode and is used to heat up
Amps
the weld zone in TIG modes or improve the
start characteristics for stick electrodes the 0 to 70A (max 170A weld current)
peak start current on top of the BASE (WELD)
current.
e.g. HOT START current = 130 amps when
BASE (WELD) = 100 amps & HOT START = 30
amps

170
Base Current
This parameter sets the TIG WELD current
when PULSE is OFF. This parameter also sets
Amps
the STICK weld current.
5 to 170A (DC STICK mode)
10 to 170A (AC STICK mode)

100
Arc Force (STICK Mode only) VOLTS
SECONDS
Arc Force is effective when in Manual Arc PERCENT (%)

Mode only. Arc Force control provides and Volts


FREQ (Hz)

adjustable amount of Arc Force (or "dig") 0 to 100%


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 greater
penetration control to be achieved.
Table 4-2

4.03 WELDSKILL 200AC/DC – LIFT TIG and HF TIG Programming Mode


Press the PROCESS button to select LIFT TIG or HF TIG mode.
Press the MODE switch to goggle between AC and DC welding output.
The Programming LED's are always active. Press FORWARD or BACK to cycle through available programming
functions.
Use the Multi Function Control to adjust the parameter selected.

Manual 0-5206 4-7 Operation


WELDSKILL 200AC/DC INVERTER OPERATION

MODE
VOLTS
AC
SECONDS
PERCENT (%) POWER
DC
FREQ (Hz) FAULT
Amps Current Volts
PULSE PROCESS
Hot LIFT TIG
Start Trough
Base Current
Width
HF TIG
Current
Up Down
Slope Slope STICK
Initial Frequency Crater
Current Current
Post
PURGE Pre
Flow Flow TRIGGER
WAVE BALANCE 2T NORMAL
AC FREQUENCY (ARC FORCE)
4T LATCH

BACK FORWARD

200 AC/DC
PORTABLE WELDING MACHINE
Inverter
WeldSkill

Press to go forward / go back


Adjust programming parameter between programming status
A-11222_AB
LED’s
Figure 4-6: LIFT TIG and HF TIG Programming Mode

Programming Parameter Adjustment Device Display

1.0
Pre-Flow VOLTS
SECONDS
This parameter operates in PERCENT (%)

TIG modes only and is used to Volts


FREQ (Hz)

provide gas to the weld zone 0.0 to 1.0 second


prior to striking the arc, once
the torch trigger switch has been
pressed. This control is used to
dramatically reduce weld porosity
at the start of a weld.

200
Initial Current VOLTS
SECONDS
This parameter operates in (4T) PERCENT (%)

TIG modes only and is used to Amps


FREQ (Hz)

set the start current for TIG. The 5 to 200 Amps (DC TIG mode)
Start Current remains on until the 30 to 200 Amps (AC LIFT TIG mode)
torch trigger switch is released 10 to 200A (AC HF TIG mode)
after it has been depressed.
Note: The maximum initial current
available will be limited to the set
value of the base current.

15.0
Up Slope VOLTS
SECONDS
This parameter operates in (4T) PERCENT (%)

TIG modes only and is used to Volts


FREQ (Hz)

set the time for the weld current 0.0 to 15.0 seconds
to ramp up, after the torch trigger
switch has been pressed then
released, from INITIAL CUR to
PEAK or BASE current.

200
Base Current
This parameter sets the TIG
WELD current when PULSE is Amps
OFF. This parameter also sets the 5 to 200A (DC TIG mode)
STICK weld current. 30 to 200A (AC LIFT TIG mode)
10 to 200A (AC HF TIG mode)
Operation 4-8 Manual 0-5206
OPERATION WELDSKILL 200AC/DC INVERTER

200
Peak Current
This parameter sets the PEAK
weld current when in PULSE Amps
mode. 10 to 200A (DC TIG mode)
30 to 200A (AC TIG mode)

200
Trough Current
The lowest point in the pulse is
called the Trough. Amps

5 to 200A (DC HF TIG mode)


30 to 200A (AC LIFT TIG mode)
10 to 200A (AC HF TIG mode)

80
Pulse Width VOLTS
SECONDS
This parameter sets the PERCENT (%)

percentage on time of the PULSE Volts


FREQ (Hz)

FREQUENCY for PEAK weld 15 to 80%


current when the PULSE is ON.

200
Pulse Frequency VOLTS
SECONDS
This parameter sets the PULSE PERCENT (%)

FREQUENCY when the PULSE is Volts


FREQ (Hz)

ON.. 0.5 to 200 Hz

25.0
Down Slope VOLTS
SECONDS
This parameter operates in TIG PERCENT (%)

modes only and is used to set Volts


FREQ (Hz)

the time for the weld current 0.0 to 25.0 seconds


to ramp down, after the torch
trigger switch has been pressed,
to crater current. This control is
used to eliminate the crater that
can form at the completion of a
weld.

200
Crater Current VOLTS
SECONDS
This parameter operates in (4T) PERCENT (%)

TIG modes only and is used to Amps


FREQ (Hz)

set the finish current for TIG. 5 to 200A (DC TIG mode)
The CRATER Current remains 30 to 200A (AC TIG mode)
ON until the torch trigger switch 10 to 200A (AC HF TIG mode)
is released after it has been
depressed.
Note: The maximum crater
current available will be limited to
the set value of the base current.

60.0
Post Flow VOLTS
SECONDS
This parameter operates in TIG PERCENT (%)

modes only and is used to adjust Volts


FREQ (Hz)

the post gas flow time once 0.0 to 60.0 seconds


the arc has extinguished. This
control is used to dramatically
reduce oxidation of the tungsten
electrode.

150
AC Frequency VOLTS
SECONDS
This parameter operates in AC PERCENT (%)

TIG mode only and is used to Volts


FREQ (Hz)

set the frequency for the AC weld 15 to 150 Hz


current.

Manual 0-5206 4-9 Operation


WELDSKILL 200AC/DC INVERTER OPERATION

65
Wave Balance VOLTS
SECONDS
This parameter operates in AC PERCENT (%)

TIG mode and is used to set the


FREQ (Hz)

Volts
penetration to cleaning action 10 to 65%
ratio for the AC weld current.
Generally WAVE BALANCE is set
to 50% for AC STICK welding.
The WAVE BALANCE control
changes the ratio of penetration
to cleaning action of the AC TIG
welding arc. Maximum weld
penetration is achieved when
the WAVE BALANCE control is
set to 10%. Maximum cleaning
of heavily oxidised aluminium or
magnesium alloys is achieved
when the WAVE BALANCE control
is set to 65%.
Table 4-2
WAVE BALANCE is used for aluminium welding in AC HF TIG or AC LIFT TIG mode
It is used to set the ratio of penetration to cleaning 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%.

Wave Balance = 50% Wave Balance = 10% Wave Balance = 65%

50% 10% 65%


(+) (+) (+)

(-) (-) (-)


50% 90% 35%
Balanced with 50% penetration Maximum Penetration and Maximum Cleaning and
and 50% cleaning reduced cleaning reduced penetration

A-11223

Table 4-3: AC TIG Wave Balance

4.04 Short Circuit Protection While Welding


To prolong the useful life of a TIG tungsten electrode, the Weldskill 200 AC/DC incorporates special circuitry.
In DC LIFT TIG mode, if the tungsten electrode touches the work the welding current is reduced to 20 Amps.
In DC HF TIG mode, if the tungsten electrode touches the work the welding current is reduced to 0 Amps
within 1 second.
In STICK mode, if the electrode touches the work for more than two seconds the welding current is reduced
to 0 Amps.

Operation 4-10 Manual 0-5206


OPERATION WELDSKILL 200AC/DC INVERTER
4.05 Shielding Gas Regulator Operating Instructions

! WARNING
This equipment is designed for use with welding grade (Inert) shielding gases only.
Shielding Gas Regulator Safety
This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working
pressure required for the equipment using it.
If the equipment is improperly used, hazardous conditions are created that may cause accidents. It is the
users responsibility to prevent such conditions. Before handing or using the equipment, understand and
comply at all times with the safe practices prescribed in this instruction.

SPECIFIC PROCEDURES for the use of regulators are listed below.


1. NEVER subject the regulator to inlet pressure greater than its rated inlet pressure.
2. NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition. NEVER
loosen a connection or attempt to remove any part of a regulator until the gas pressure has been
relieved. Under pressure, gas can 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 valve SLOWLY. Close after use.
User Responsibilities

This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in
accordance with the instructions provided. Equipment must be checked periodically and repaired, replaced,
or reset as necessary for continued safe and reliable performance. Defective equipment should not be used.
Parts that are broken, missing, obviously worn, distorted, or contaminated should be replaced immediately.
The user of this equipment will generally have the sole responsibility for any malfunction, which results from
improper use, faulty maintenance, or by repair by anyone other than an accredited repairer.

CAUTION
Match regulator to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to
a cylinder containing any other gas.

Art: A-05087

Figure 4-7: Fit Regulator to Cylinder

Manual 0-5206 4-11 Operation


WELDSKILL 200AC/DC INVERTER OPERATION
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.
Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of
ignition. Wipe with a clean lint free cloth.
2. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking
agree and that the regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed
for a particular gas or gases to a cylinder containing any other gas.
3. Connect the regulator inlet connection to cylinder or pipeline and tighten it firmly but not excessively,
with a suitable spanner.
4. Connect and tighten the outlet hose firmly and attach down-stream equipment.
5. To protect sensitive down-stream equipment a separate safety device may be necessary if the regulator
is not fitted with a pressure relief device.
Operation

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 leaks at the regulator connection points be carried out using a suitable
leak detection solution or soapy water.
3. Purge air or other unwanted welding grade shielding gas from equipment connected to the regulator
by individually opening then closing the equipment control valves. Complete purging may take up to
ten seconds or more, depending upon the length and size of the hose being purged.
Adjusting Flow Rate

Art: A-05088_AB

Figure 4-8: Adjust Flow Rate

With the regulator 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.
NOTE
It may be necessary to re-check the shielding gas regulator flow rate following the first weld
sequence due to back pressure present within shielding gas hose assembly.

Operation 4-12 Manual 0-5206


OPERATION WELDSKILL 200AC/DC INVERTER
2. To reduce flow rate, allow the welding grade shielding gas to discharge from regulator 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 is not in use. To shut down for extended periods (more than 30
minutes).
1. Close cylinder or upstream valve tightly.
2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away
from any ignition source.
3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.
4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove
regulators.

4.06 Setup for TIG (GTAW) Welding


A. Select Lift TIG or HF TIG mode with the process selection control (refer to Section 4.01.7 for further
information).
B. Connect the TIG Torch to the 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.
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 plug being fused
in the bayonet terminal.
D. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown
below. The TIG torch will require a trigger switch to operate in Lift TIG or HF TIG Mode.
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 3.08.2 Remote Control Socket for further information).
E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section
4.05) then connect the shielding gas hose from the regulator/flowmeter outlet gas INLET on the rear of
the WeldSkill 200 AC/DC Power Source. Connect the gas hose from the TIG torch to the gas OUTLET on
on the front of the WeldSkill 200 AC/DC Power Source.

! WARNING
Before connecting the work clamp to the work make sure the mains power supply is switched off.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable
stationary support to prevent falling or tipping.

Manual 0-5206 4-13 Operation


WELDSKILL 200AC/DC INVERTER OPERATION

MODE

200 18.0
VOLTS
AC
SECONDS
PERCENT (%) POWER
DC
FREQ (Hz) FAULT
Peak
Amps Current Volts
PULSE PROCESS
Hot LIFT TIG
Start Trough
Base Current
Width
HF TIG
Current
Up Down
Slope Slope STICK
Initial Frequency Crater
Current Current
Post
PURGE Pre
Flow Flow TRIGGER
WAVE BALANCE 2T NORMAL
AC FREQUENCY (ARC FORCE)
4T LATCH

BACK FORWARD

200 AC/DC
PORTABLE WELDING MACHINE
Inverter
WeldSkill

Negative Welding
Positive Welding Terminal (-)
Terminal (+)

Work Lead

A-11224
8 Pin Control Socket
Tig Torch

Figure 4-9: Setup for TIG Welding

4.07 Foot Control, Part No. W4015800 (Optional Accessory)

Art # A-11338

Figure 4-10: Foot Control

1 2

3 4 5

6 7 8

Art # A-11339
Art # A-11340

Figure 4-11: 8 Pin Control Plug


Operation 4-14 Manual 0-5206
OPERATION WELDSKILL 200AC/DC INVERTER
Pin Description
1 Not Used
2 Trigger Switch
3 Trigger Switch
4 Not Used
5 Potentiometer Maximum
6 Potentiometer Minimum
7 Potentiometer Wiper
8 Not Used
Table 4-4
Description
The CIGWELD Foot Control is a foot operated switch and potentiometer which starts and stops the welding
process and controls welding current through operation of the foot pedal. Refer to list below for compatible
Cigweld power sources.
Installation
Attach the 8-pin connector on the end of the cable to the 8-pin receptacle on the front of the welding machine.
To complete the connection, align the keyway, insert the plug, and rotate the threaded collar fully clockwise
Foot Control Operation
Press the foot pedal to start the machine output functions. The foot control potentiometer controls the welding
current up to the level set on the welding power source. Note that the maximum current must be set on the
power source by the operator prior to the foot control being connected. With the foot control connected, the
power source will only display minimum preview Amps until the foot control is depressed 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 will be determined by the 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 remote control device is set to 100% output or maximum, the maximum achievable output
from the unit will be 50%. Should 100% output be required, the respective front panel control must be set
to 100% or maximum, in which case the remote device will then be able to control between 1-100% output.
This foot control is compatible with the following Cigweld power sources:
WeldSkill 200AC/DC Part No: W1006202
Transmig 175i Part No: W1005176
Transmig 200i Part No: W1005202
Transmig 250i Part No: W1003251
Transtig 200AC/DC Part No: 700719
Note 1: Some power sources other than specified as above may not function with the foot control.
Note 2: The foot control will only work correctly when power source trigger mode 2T (Normal) is selected.

Manual 0-5206 4-15 Operation


WELDSKILL 200AC/DC INVERTER OPERATION
4.08 Setup for STICK (MMAW) Welding
A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode
manufacturer. 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.
B. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer.
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.
C. Select STICK mode with the process selection control (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 result in the male plug being fused
in the bayonet terminal.

MODE

200 18.0
VOLTS
AC
SECONDS
PERCENT (%) POWER
DC
FREQ (Hz) FAULT
Peak
Amps Current Volts
PULSE PROCESS
Hot LIFT TIG
Start Trough
Base Current
Width
HF TIG
Current
Up Down
Slope Slope STICK
Initial Frequency Crater
Current Current
Post
PURGE Pre
Flow Flow TRIGGER
WAVE BALANCE 2T NORMAL
AC FREQUENCY (ARC FORCE)
4T LATCH

BACK FORWARD

200 AC/DC Inverter


PORTABLE WELDING MACHINE WeldSkill

Negative Welding
Positive Welding Terminal (-)
Terminal (+)

A-11225

Electrode Holder
Work Lead

Figure 4-12: Setup for Manual Arc Welding

Operation 4-16 Manual 0-5206


THEORY OF OPERATION WELDSKILL 200AC/DC INVERTER
SECTION 5:
THEORY OF OPERATION
5.01 Inverter Design
What does the word inverter mean?
The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the
incoming AC to DC, and then the transistors create a higher frequency AC. The higher frequency AC then goes on
to a much smaller 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 -23K Hz AC -23K Hz DC - Rippled DC -Smooth


High Voltage High Voltage High voltage High Voltage Low Voltage Low Voltage Low Voltage
Low Amperage Low Amperage Low Amperage Low Amperage High Amperage High Amperage High Amperage

Art # A-09846

Manual 0-5206 5-1 Theory of Operation


WELDSKILL 200AC/DC INVERTER THEORY OF OPERATION

Notes

Theory of Operation 5-2 Manual 0-5206


TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER
SECTION 6:
TROUBLESHOOTING
6.01 Basic Troubleshooting-Power Source Faults
The following table is a guide for analyzing problems and making repairs to the Power Source.
Fault Possible Cause Remedy
1 There is no weld A The main Power Switch is set to OFF A Set main Power Switch to ON
output and all front B Control fuse is blown B Replace Line fuse
panel displays are off C The main Power Switch is faulty C Replace main Power Switch
D Loose connection to EMC board D Tighten connections
E Faulty Power Inverter board E Replace Power Inverter board
F Faulty Control board F Replace Control board
G Faulty Display board G Replace Display board
2 There is no weld A The internal protection circuit to shut A Check to see if mains supply
output and all front the unit down if the mains supply voltage is >274VAC. A
panel displays are off voltage is too high has operated generator with poor voltage
or flickering on & off regulation may cause a supply
voltage in excess of 274VAC.
Connect Power Source to a
supply voltage <274VAC.
3 There is no weld A Unit has overheated A Allow unit to cool with
output and the yellow fan running until over
over temperature light temperature light extinguishes
is on B Airflow inlet or outlet ducts are B Remove blockages from
blocked airflow ducts
C Fan does not operate C Replace fan. Check fan wiring
is not damaged
4 Mode switch does not A Faulty Display board A Replace Display board
change welding mode
5 No HF output when A Points gap too large A Use Feeler gauge to set points
HF mode is selected gap
B Faulty HF board B Replace HF board
6 A welding arc can A Work Lead cable too small A Use correct weld cable size
be established but B Loose welding connections B Tighten welding connections
the weld is erratic or C Loose earth clamp C Tighten earth clamp
inconsistent D Incorrect weld polarity selected D Correct weld polarity.
E No shielding gas E Refer to weld consumable
manufacturers recommended
polarity
F Wind blows shielding gas away F Connect shielding gas
G Incorrect TIG tungsten electrode G Shield welding area from
draughts
H Poorly prepared or worn TIG H Use correct tungsten type
tungsten Regrind tungsten to correct
shape
Table 6-1: Power Source Faults

Manual 0-5206 6-1 Troubleshooting


WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING
6.02 Advanced Troubleshooting
If the problem cannot be solved by the basic (external) troubleshooting guide, the Power Source cover will have
to be removed to allow the technician to analyze failures with a few common tools.

! WARNING
Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow
two minutes for capacitors to discharge after disconnection from mains supply voltage.

Checking Unit Before Applying Power

! Turn SW1 to OFF position, and disconnect unit from primary line voltage before working on unit.

! Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are off
before removing case.

! Check DC bus voltage 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 these units can cause burning or
arcing of PCB, transformers, switches, or rectifier when a failure occurs. Carefully inspect all components within
these units.
Look in particular for the following:
a) Loose or broken wires or connectors.
b) Burned or scorched parts or wires or evidence of arcing.
c) Any accumulation of metal dust or filings that may have caused shorting or arcing.
If any parts are damaged, they must be replaced. Refer to the Spare Parts section for a complete list of components
used in the Power Source.
Locate the faulty component(s) then replace where necessary.

Troubleshooting 6-2 Manual 0-5206


TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER
6.05 Preliminary DC Bus measurement of the main inverter board

! Read and follow safety information in Section 6.02 before proceeding.

! Check DC bus voltage has discharged to less than 5VDC before servicing. Ensure the mains supply plug
is disconnected from receptacle
1 4 6

10

11

A-11421
3 5 2 8

DC Bus Testing Multimeter Lead Placement Voltage with Supply voltage OFF
Upper capacitor bank Positive meter lead to testpoint 1 0 VDC
Negative meter lead to testpoint 2
Lower capacitor bank Positive meter lead to testpoint 2 0 VDC
Negative meter lead to testpoint 3
Table 6-2: DC BUS, Multimeter set to measure DC volts

Manual 0-5206 6-3 Troubleshooting


WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING
6.06 Preliminary check of the main inverter board

! Read and follow safety information in Section 6.02 before proceeding.


IGBT Testing Multimeter Lead Placement Diode Voltage
Positive meter lead to testpoint 4
IGBT T3 &T4 0.2 – 0.8 VDC
Negative meter lead to testpoint 1
Positive meter lead to testpoint 3
IGBT T5 & T6 0.2 – 0.8 VDC
Negative meter lead to testpoint 5
Table 6-3: IGBT’s, Multimeter set to measure Diode Voltage
IGBT Testing Multimeter Lead Placement Ohms
IGBT T3 & T4 Positive meter lead to testpoint 1 >150 Ω
Negative meter lead to testpoint 4
IGBT T5 & T6 Positive meter lead to testpoint 5 >150 Ω
Negative meter lead to testpoint 3
Table 6-4: IGBT’s, Multimeter set to measure ohms (Ω)
Inrush PTC Multimeter Lead Placement Ohms
PTC Positive meter lead to testpoint 6 0 to 100 Ω
Negative meter lead to testpoint 7
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 0.2 – 0.8 VDC
Negative meter lead to testpoint 9
AC2 to DC+ Positive meter lead to testpoint 10 0.2 – 0.8 VDC
Negative meter lead to testpoint 9
AC1 to DC- Positive meter lead to testpoint 11 0.2 – 0.8 VDC
Negative meter lead to testpoint 8
AC2 to DC- Positive meter lead to testpoint 11 0.2 – 0.8 VDC
Negative meter lead to testpoint 10
Table 6-6: Input Rectifier, Multimeter set to measure Diode Voltage
6.08 DC Bus voltage measurement

Apply voltage to the Power Source.

! WARNING
There are extremely dangerous voltage and power levels present inside these Power Sources. Do not
attempt to diagnose or repair unless you have had training in power electronics measurement and
troubleshooting techniques.

Once power is applied to the Power Source, there are extremely hazardous voltage and power levels present.
Do not touch any live parts.

Troubleshooting 6-4 Manual 0-5206


TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER
DC Bus Testing Multimeter Lead Placement Voltage with
Supply voltage
OFF
Upper capacitor bank Positive meter lead to testpoint 1 168 VDC +/-10%
Negative meter lead to testpoint 2
Lower capacitor bank Positive meter lead to testpoint 2 168 VDC +/-10%
Negative meter lead to testpoint 3
Overall capacitor bank Positive meter lead to testpoint 1 336 VDC +/-10%
Negative meter lead to testpoint 3
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 NEUTRAL 0 VAC
ACOUT1 Load side ACTIVE 240 VAC
ACOUT2 Load side NEUTRAL 0 VAC
GND Earth
Table 6-8: EMC Header pin function

Manual 0-5206 6-5 Troubleshooting


WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING
2 Power Supply PCB
DCIN DY2 DY1

C41

1
R41
1 1
DY3
DY3
POWER/FJ
1

8.066.526--G
R28

A-11423_AB

DCIN Header Pin Pin function signal


1 DC Bus positive 336 VDC ±10%
2 DC Bus negative 0 VAC
Table 6-9: DCIN Header pin function (connects to mains supply)

DY1 Header Pin Pin function signal


1 +24 VDC 24 VDC
2 0 VDC 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 on main control PCB)
3 HF filter PCB

Header Pin Pin function signal


WELD+ Positive Welding Terminal
WELD- Negative Welding Terminal
GND Earth Earth
Table 6-13: EMC Header pin function

Troubleshooting 6-6 Manual 0-5206


TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER
4 HF PCB

R6

HF 1

1 R2
SOU V1
R3

R1

1
4

A-11424_AB
220V COIL

COIL Header Pin Pin function signal


1 +24 VDC 700VAC +/-10%
2 GND (ARC starter primary input) 700VAC +/-10%
Table 6-14: ARC starter primary input

HOU Header Pin Pin function signal


1 +24 VDC +24VDC
2 GND 0VDC
Table 6-15: HOU Header 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 multimeter
2 HF transformer primary (warning high voltage) Do not measure
with multimeter
Table 6-18: HFOUT Header pin function (connects to HF transformer)

Manual 0-5206 6-7 Troubleshooting


WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING
5 AC/DC Drive PCB
DC-

DC+

A-11425

TR2 TR1

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)

Troubleshooting 6-8 Manual 0-5206


TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER
6 Display PCB

A-11426
J1 (10 pin)

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)

Manual 0-5206 6-9 Troubleshooting


WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING
7 Primary Side Inverter PCB
OC DCOUT SD

1
1
1

IN
1

A-11427_AB

DRIVE Header Pin Pin function signal


1 +15 VDC 15 VDC
2 PWM signal 1
3 PWM signal 2
4 PWM signal 2
5 PWM signal 1
6 Current Transformer Signal
7 0 VDC 0 VDC
Table 6-21: DRIVE Header pin function (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 Header Pin Pin function signal
1 +336V 336VDC
2 0V 0 VDC
Table 6-24: DC OUT Header pin function (connects to DCIN header on control PCB)
Troubleshooting 6-10 Manual 0-5206
TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER
8 AC/DC Output PCB
TR1

POSITIVE OUTPUT
OF WELDING
RECTIFIER

TR2

1 NEGATIVE OUTPUT
1
OF WELDING
RECTIFIER

JP3

A-11428_AC

POSITIVE SIDE IGBT’S POSITIVE OUTPUT NEGATIVE SIDE IGBT’S

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 pin function (connects to DR & ACPOUT header on control PCB)

Manual 0-5206 6-11 Troubleshooting


WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING
9 Main Control PCB
GUN LED/SF SOU OT QF/HF
1 1 1

WV
1

TEST
POINTS
1
SS
1 JB
1
POWER

1
JB
1

DRIVE

1 1

WA ACPOUT A-11429_AC

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)

Troubleshooting 6-12 Manual 0-5206


TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER
LED/SF Header Pin Pin function signal
1 +24 VDC 24 VDC
2 No connection
3 No connection
4 No connection
Table 6-28: LED/SF Header pin function
SOU Header Pin Pin function signal
1 +24 VDC 24 VDC
2 0 VDC 0 VDC
Table 6-29: SOU Header pin function(connects to DY2 header on power supply PCB)
OT Header Pin Pin function signal
1 +24 VDC 24 VDC
2 Thermal switch input (switch closed = 0VDC) 0 VDC
3 0 VDC 0 VDC
Table 6-30: OT Header pin function (connects to DY2 thermostats)
QF/HF Header Pin Pin function signal
1 +24 VDC 24 VDC
2 Solenoid coil, 0V = solenoid ON 0 VDC
3 HF on / off
4 0 VDC 0 VDC
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 interface
8 Serial interface
9 Serial interface
10 0 VDC 0 VDC
Table 6-33: J2 Header pin function (connects to J1 header on display PCB))
DCIN Header Pin Pin function signal
1 +336 VDC +336 VDC
2 0 VDC 0 VDC
Table 6-34: DCIN Header pin function (connects to DCOUT header on primary inverter PCB)
ACPOUT Header Pin Pin function signal
1 enable
2 control signal 1
3 control signal 2
Table 6-35: ACPOUT Header pin function (connects to ACOUT header on AC/DC output PCB)

Manual 0-5206 6-13 Troubleshooting


WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING
WA Header Pin Pin function signal
1 +15 VDC +15 VDC
2 -15 VDC -15 VDC
3 Current signal +/- 4 VDC
4 0 VDC 0 VDC
Table 6-36: WA Header pin function (connects to Hall Eddwxr Currebt Trabsfirner)
DRIVE Header Pin Pin function signal
1 +15 VDC 15 VDC
2 PWM signal 1
3 PWM signal 2
4 PWM signal 2
5 PWM signal 1
6 Current Transformer Signal
6 0 VDC 0 VDC
7 +15 VDC 15 VDC
Table 6-37: DRIVE Header pin function (connects to DRIVE header on primary inverter PCB)
DR Header Pin Pin function signal
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 function (connects to SD header on primary inverter PCB)

6.10 DIP switch settings, Control PCB


1 DIP Switch SW0, control PCB
SW1 position Function
1 Set to ON for Weldskill 200AC/DC
2 Set to OFF for Weldskill 200AC/DC
3 Set to ON for Weldskill 200AC/DC
4 Set to ON for Weldskill 200AC/DC
5 Set to ON for Weldskill 200AC/DC
Table 6-41: SW0 Dip Switch functions

Troubleshooting 6-14 Manual 0-5206


TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER
6.11 Calibration

1 Calibration
R68

WVF

0V

IMAX

A-11430

Set SW0 position 4 to OFF while the power source is turned off, to allow calibration of output volts & amps.

Manual 0-5206 6-15 Troubleshooting


WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING
2 Output Current Calibration
Select STICK process and DC mode on the front panel.
Measure no load output welding voltage and adjust WVF potentiometer so Volts display reads within 0.1V of the
measured value.
Select TIG process and DC mode on the front panel.
Connect a load to the output terminals. The load should be of a resistance to give 18V at 200A.
Set front panel AMPS potentiometer to maximum.
Adjust Imax trimpot until output amps is 200A +/-0 2A
Set front panel AMPS potentiometer to minimum.
Adjust 0V (SW100) trimpot until output amps is 5A +/- 0.2A
Repeat the minimum & maximum calibration until both are within tolerance
Set front panel AMPS potentiometer to maximum.
Adjust A potentiometer so Amps display reads within 0.5A of the measured value.

6.12 Main Circuit Description

! WARNING
Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow
two minutes for capacitors to discharge after disconnection from mains supply voltage.

The mains supply voltage is connected via a double pole switch to the input rectifiers on the main inverter board
through an EMC filter. Overvoltage protection is 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 voltage at this point is approximately
half the DC bus voltage).

Secondary output voltage from the transformer is rectified by the output diodes (D1, and D2) to DC. This DC is
controlled by the PWM of the primary side igbt transistors, and is filtered by an inductor before connecting to
the welding output terminals. IGBT1 to IGBT8 control whether AC or DC output is sent to the welding terminals.

A thermal overload device (thermal switch) is fixed to the rectifier heatsink. When an over temperature occurs,
the control circuit inhibits the trigger, gas solenoid, and the welding output. The thermal overload indicator LED
on the front panel is illuminated.

The current transformer CT1 provides a signal to the control circuit to indicate both transformer primary current,
and also detect transformer saturation. The Hall effect current sensor CT2 is powered from regulated + & - 15VDC
supplies and provides a voltage signal proportional to the output welding current to allow the control circuit to
regulate welding current.

Troubleshooting 6-16 Manual 0-5206


Manual 0-5206
POSITIVE
SOFT
START
R1 Q1
C1 D1 D2
C3 G1
240VAC R3 Q3
G3 C7
SW1
A T1 HALL EFFECT WELD POSITIVE
INPUT
RECTIFIER CT2 POSITIVE
C5
R1
6.13 Circuit Diagram

N R4
CT1
Q2
R2 G2
E C2 Q4
0VAC C4
D3 D4 C6 G4 C8

OC
WELDING TERMINALS

NEGATIVE
DRIVER
WELD NEGATIVE
AC
SS DRIVE

DC
L1
DC BOARD
T2 NEGATIVE

DC-IN
POWER

POWER/FJ
WA
HFOUT

6-17
GD1

MAIN CONTROL BOARD HF BOARD


240VAC

ACOUT
WELD POSITIVE

ACPOUT
AC DRIVE BOARD
220VAC

SOLENOID
GD2

POWER SUPPLY BOARD


0VAC
ACOUT

JB
WELD NEGATIVE

DY2
DY3
SOU
FAN 24VDC HF SOUIN
NTCS DY1

QF/HF

MOD
WELD POSITIVE

WV
WELD NEGATIVE
TH1 TH2

OT
DISPLAY BOARD

J2 (10)

JB (10)
8 PIN REMOTE
GUN

A-11227_AC

Troubleshooting
TROUBLESHOOTING WELDSKILL 200AC/DC INVERTER
WELDSKILL 200AC/DC INVERTER TROUBLESHOOTING
Notes

Troubleshooting 6-18 Manual 0-5206


DISASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER
SECTION 7:
DISASSEMBLY PROCEDURE
7.01 Safety Precautions for Disassembly

! Read and follow safety information 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.
2 1

A-11431

Manual 0-5206 7-1 Disassembly Procedure


WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE
7.03 Control Board Removal

! Read and follow safety information in Section 6.02 before proceeding with disassembly
Remove case (refer to 6.04) before remove control board.
1. M4 Screw. Remove 4 screws from control panel.
2 Disconnect DRIVE harness from DRIVE connector.
3. Disconnect J8 harness 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. Disconnect ACP OUT harness from ACPOUT connector.
13. Disconnect WA harness from WA connector.
Ensure to unplug all harness from the main control PCB.
2 3 4 5

1 6

8
13

12
9

A-11432
11 10

Disassembly Procedure 7-2 Manual 0-5206


DISASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER
7.04 Auxiliary Power Supply PCB2 Removal

! 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

A-11433

Manual 0-5206 7-3 Disassembly Procedure


WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE
7.05 PCB3 Removal

! Read and follow 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 A-11434
1

Disassembly Procedure 7-4 Manual 0-5206


DISASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER
7.06 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

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

Manual 0-5206 7-5 Disassembly Procedure


WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE
7.08 Front 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.

A-11437

2 4 3 5

Disassembly Procedure 7-6 Manual 0-5206


DISASSEMBLY PROCEDURE WELDSKILL 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.

A-11438

2 3

Manual 0-5206 7-7 Disassembly Procedure


WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE
7.10 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.
4

1 3

A-11439_AC

Disassembly Procedure 7-8 Manual 0-5206


DISASSEMBLY 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
3

A-11440
1

Manual 0-5206 7-9 Disassembly Procedure


WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE
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
2

3
2

Disassembly Procedure 7-10 Manual 0-5206


DISASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER
7.13 Power 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.

3 5

A-11442

Manual 0-5206 7-11 Disassembly Procedure


WELDSKILL 200AC/DC INVERTER DISASSEMBLY PROCEDURE

Notes

Disassembly Procedure 7-12 Manual 0-5206


ASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER
SECTION 8:
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
3

A-11440
1

Manual 0-5206 8-1 Assembly Procedures


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

2
2

Assembly Procedures 8-2 Manual -5206


ASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER
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 3 2 4

A-11444

Manual 0-5206 8-3 Assembly Procedures


WELDSKILL 200AC/DC INVERTER ASSEMBLY PROCEDURES
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

2 4

A-11445

Assembly Procedures 8-4 Manual -5206


ASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER
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.

A-11446
2
3

Manual 0-5206 8-5 Assembly Procedures


WELDSKILL 200AC/DC INVERTER ASSEMBLY PROCEDURES
8.07 Installing PCB3
1. Insert plastic stud onto PCB3 board.
2. install screw.
3. Plug harness into HF connector.
4. Plug harness into SOU connector.
5. Plug harness into INPUT connector.
6. Plug harness into OUTPUT connector.
1

5 6 2

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
4

Assembly Procedures 8-6 Manual -5206


ASSEMBLY PROCEDURE WELDSKILL 200AC/DC INVERTER
8.09 Installing Control Board
1. Install 4 screws.
2. Plug harness into DRIVE connector.
3. Plug harness into J8 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.
2 3 4 5

1 6

8
13

12
9

A-11432
11 10

Manual 0-5206 8-7 Assembly Procedures


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.
4 3

A-11449

Assembly Procedures 8-8 Manual -5206


KEY SPARE PARTS WELDSKILL 200AC/DC INVERTER
SECTION 9:
KEY SPARE PARTS
9.01 Power Source

A-11226_AB

Figure 9-1

Manual 0-5206 9-1 KEY SPARE PARTS


WELDSKILL 200AC/DC INVERTER KEY SPARE PARTS
WeldSkill 200AC/DC Spare Parts
Item Part Number Description
1 W7005500 PCB display
2 W7005503 PCB aux power supply
3 W7005502 PCB HF
4 W7005504 PCB primary inverter
5 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 50mm²
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 704461 Dinse plug male 50mm² (not shown)
Table 9-1

KEY SPARE PARTS 9-2 Manual 0-5206


CIGWELD - LIMITED WARRANTY TERMS
LIMITED WARRANTY: CIGWELD Pty Ltd, A Victor Technologies Company, hereafter, “CIGWELD” warrants to
customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in work-
manship or material. Should any failure to conform to this warranty appear within the time period applicable to
the CIGWELD products as stated below, CIGWELD shall, upon notification thereof and substantiation that the
product has been stored, installed, operated, and maintained in accordance with CIGWELD’s specifications,
instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair,
neglect, alteration, or accident, correct such defects by suitable repair or replacement, at CIGWELD’s sole
option, of any components or parts of the product determined by CIGWELD to be defective.
CIGWELD MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND
IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: CIGWELD SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL,
INDIRECT 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 whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not,
except as expressly provided herein, exceed the price of the goods upon which such liability is based. No
employee, agent, or representative of CIGWELD is authorized to change this warranty in any way or grant any
other warranty.
PURCHASER’S RIGHTS UNDER THIS 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 the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend
more than the time stated plus one year from the date CIGWELD delivered the product to the authorized
distributor.
TERMS OF WARRANTY – JANUARY 2011
1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply
of goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain
situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including war-
ranties as to merchantability and fitness for purpose) associated with the supply of goods and services.
A consumer should seek legal advice as to the nature and extent of these protected interests. In some
circumstances, the supplier of goods and services may legally stipulate that the said conditions, warran-
ties, guarantees, rights and remedies are limited or entirely excluded. The warranties set out in Clause 2
shall be additional to any nonexcludable warranties to which the Customer may be entitled pursuant to any
statute.
2. Subject to Clause 3. CIGWELD gives the following warranties to the Customer:
Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantable
quality and reasonably fit for the purpose for which they are supplied by CIGWELD.
CIGWELD will repair or, at its option, replace those of the goods which, upon examination, are found by
CIGWELD to be defective in workmanship and/or materials.
CIGWELD reserves the right to request documented evidence of date of purchase.
3. The Warranty in Clause 2;
Is conditional upon:
The Customer notifying CIGWELD or 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 goods sold at auction, second-hand goods and prototype goods.
Breakdown or malfunction caused by accident, misuse or normal wear and tear.
Repairs or replacement made other than by CIGWELD or Accredited Service Providers, unless by prior
arrangement with CIGWELD.
Replacement parts or accessories which may affect product safety or performance and which are not
manufactured, distributed or approved by CIGWELD.
4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supply of
goods which are not of a kind ordinarily acquired for personal, domestic or household use or consumption
to any one or more of the following (the choice of which shall be at the option of CIGWELD).
The replacement of the goods or the supply of equivalent goods.
The repair of goods.
The payment of cost of replacing the goods or acquiring equivalent goods.
The payment of the cost of having goods repaired.
5. Except as provided in Clauses 2 to 4 above, to the extent permitted by statute, CIGWELD hereby excludes
all liability for any loss, damage, death or injury of any kind whatsoever occasioned to the Customer in
respect of the supply of goods including direct, indirect, consequential or incidental loss, damage or injury
of any kind.
WARRANTY SCHEDULE – JANUARY 2011
These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of
sale from the Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the
warranty period extend more than the time stated plus one year from the date CIGWELD delivered the product
to the Accredited Distributor. Unless otherwise stated the warranty period includes parts and labour. CIGWELD
reserves the right to request documented evidence of date of purchase.

WARRANTY PERIOD
WELDSKILL 200AC/DC POWER SOURCE
PARTS LABOUR
Original main power magnetics. 1 Year 1 Year
Original main power rectifiers, printed circuit boards and power switch 1 Year 1 Year
semiconductors.
All other circuits and components including, but not limited to, relays, switches, 1 Year 1 Year
contactors, solenoids, fans and electric motors.
ACCESSORIES WARRANTY PERIOD
TIG torch, electrode holder lead and work lead. 3 Months
TIG torch consumable items. NIL
Gas regulator/flowmeter (excluding seat assembly, pressure gauges, elastomer 1 Year
seals and “O” rings).
Regulator seat assemblies and pressure gauges. 6 Months
Elastomer seals and “O” rings used in the equipment. 3 Months
Please note that the information detailed in this statement supersedes any prior published data produced by
CIGWELD.
INNOVATION TO SHAPE THE WORLD™ CIGWELD Pty Ltd
ABN: 56 007 226 815
A Victor Technologies Company
71 Gower Street
Preston VIC 3072 Australia

T: +61 3 9474 7400


F: +61 3 9474 7391
enquiries@cigweld.com.au
www.cigweld.com.au

CIGWELD Terms of Warranty - 2012

Effective 1st January 2012, all warranties against defects (also known as a manufacturer’s warranty)
supplied with goods or services must comply with the mandatory requirements in the new Australian
Consumer Law and the Trade Practices (Australian Consumer Law) Amendment Regulations (2010)
(No.1).

This Warranty Statement should be read in conjunction with the Warranty Schedule contained in the
operating instructions of the product. This schedule contains the warranty period applicable to the
product

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 Accredited Seller) to the store where you purchased the product or contact
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 654 674
Email: enquiries@cigweld.com.au
Website: www.cigweld.com.au

This warranty is provided in addition to other rights and remedies you have under law:
Our goods come with guarantees which cannot be excluded under the Australian Consumer Law. You
are entitled to replacement or refund for a major failure and to compensation for other reasonably
foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail
to be of acceptable quality and the failure does not amount to a major failure.

Failures due to incorrect use are not covered by this warranty and consumers are reminded to only use
the product in accordance with the Operating Instruction supplied with the product. Additional copies of
Operating Instructions are available from Cigweld Customer Care
1300 654 674 or the Website.
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Cigweld, Australia Victor Technologies, China


71 Gower Street No 100 Lao Hongjing Rd
Preston, Victoria Minhang District
Australia, 3072 Shanghai, PR, 200235
Telephone: 61-3-9474-7400 Telephone: 86-21-64072626
Fax: 61-3-9474-7391 Fax: 86-21-64483032
Email: cigweldsales@cigweld.com.au
Victor Technologies Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Victor Technologies USA
Rawang Integrated Industrial Park - Jln Batu Arang
2800 Airport Road
48000 Rawang Selangor Darul Ehsan
Denton, Tx 76207 USA
West Malaysia
Telephone: (940) 566-2000
Telephone: 603+ 6092 2988
800-426-1888
Fax : 603+ 6092 1085
Fax: 800-535-0557
Email: sales@thermalarc.com
Victor Technologies Italy
OCIM, S.r.L.
Victor Technologies Canada
Via Benaco, 3
2070 Wyecroft Road
20098 S. Giuliano
Oakville, Ontario
Milan, Italy
Canada, L6L5V6
Tel: (39) 02-98 80320
Telephone: (905)-827-1111
Fax: (39) 02-98 281773
Fax: 905-827-3648

Victor Technologies International


Victor Technologies Europe
2070 Wyecroft Road
Europe Building
Oakville, Ontario
Chorley North Industrial Park
Canada, L6L5V6
Chorley, Lancashire
Telephone: (905)-827-9777
England, PR6 7Bx
Fax: 905-827-9797
Telephone: 44-1257-261755
Fax: 44-1257-224800

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
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