Tweco 200DC User Manual

200AC/DC

INVERTER

ARC WELDING MACHINE

Operating Manual

Revision: AB Issue Date: March 29, 2012 Manual No.: 0-5207
Operating Features:

A-11217

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 agency call
[phone], or visit us on the web at www.thermadyne.com.au

This Operating 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 Thermadyne Industries 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 market­leading, 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
Operating Manual Number 0-5207 for:

WeldSkill 200AC/DC Plant Part Number W1006200

Published by:
CIGWELD Pty Ltd
71 Gower Street
Preston, Victoria, Australia, 3072

www.thermadyne.com.au

Copyright 2012 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: March 15, 2012
Revision AB Date: March 29, 2012

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

TABLE OF CONTENTS

SECTION 1:

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

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

1.02 Principal Safety Standards .............................................................................. 1-5

1.03 Declaration of Conformity ............................................................................... 1-6

SECTION 2:

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

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

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

2.03 Receipt of Equipment ...................................................................................... 2-1

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

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

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

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

2.08 Packaged Items .............................................................................................. 2-3

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

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

2.11 Options and Accessories ................................................................................ 2-6

SECTION 3:

INSTALLATION, OPERATION AND SETUP ........................................................ 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location .......................................................................................................... 3-1

3.03 Ventilation ....................................................................................................... 3-1

3.04 Mains Supply Voltage Requirements .............................................................. 3-1

3.05 High Frequency Introduction .......................................................................... 3-1

3.06 High Frequency Interference ........................................................................... 3-2

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

3.08 WELDSKILL 200AC/DC Power Source Controls, Indicators and Features ....... 3-4

3.09 WELDSKILL 200AC/DC - STICK Programming Mode ..................................... 3-8

3.10 WELDSKILL 200AC/DC – LIFT TIG and HF TIG Programming Mode ........... 3-10

3.11 Short Circuit Protection While Welding ......................................................... 3-12

3.12 Shielding Gas Regulator Operating Instructions ........................................... 3-12

3.13 Setup for TIG (GTAW) Welding ..................................................................... 3-15

3.14 Setup for STICK (MMAW) Welding ............................................................. 3-17

SECTION 4:

BASIC WELDING GUIDE ............................................................................ 4-1

4.01 Stick (MMAW) Basic Welding Technique ........................................................ 4-1

4.02 Stick (MMAW) Welding Troubleshooting ...................................................... 4-12

4.03 TIG (GTAW) Basic Welding Technique .......................................................... 4-14

4.04 TIG (GTAW) Welding Problems ..................................................................... 4-16

TABLE OF CONTENTS

SECTION 5:

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS .................... 5-1

5.01 Basic Troubleshooting .................................................................................... 5-1

5.02 Power Source Problems ................................................................................. 5-1

5.03 Routine Service and Calibration Requirements ............................................... 5-2

5.04 Cleaning the Welding Power Source ............................................................... 5-4

SECTION 6:

KEY SPARE PARTS ................................................................................... 6-1

6.01 Power Source ................................................................................................. 6-1

APPENDIX: CIRCUIT DIAGRAM ........................................................................... A-1

CIGWELD - LIMITED WARRANTY TERMS

TERMS OF WARRANTY – January 2012

WARRANTY SCHEDULE – January 2012

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

WELDSKILL 200AC/DC INVERTER

!

SECTION 1:

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE
INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR
SERVICING THIS EQUIPMENT.

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 apply 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 Australian Standard AS1674.2-2007 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.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause
fatal shocks or severe burns. The electrode
and work circuit is 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 metal parts
touching the welding wire are electrically
live. Incorrectly installed or improperly
grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body
protection.

3. Insulate yourself from work and ground using dry
insulating mats or covers.

4. Disconnect input power or stop engine before
installing or servicing this equipment. Lock input
power disconnect switch open, or remove line
fuses so power cannot be turned on acciden­tally.

5. Properly install and ground this equipment accord­ing to its Owner’s Manual and national, state, and
local codes.

6. Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or
out of service.

7. Use fully insulated electrode holders. Never dip
holder in water to cool it or lay it down on the
ground or the work 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 cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth)
ground.

11. Do not touch electrode while in contact with the
work (ground) circuit.

12. Use only well-maintained equipment. Repair or
replace damaged parts at once.

13. In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.

14. Wear a safety harness to prevent falling if working
above floor level.

15. Keep all panels and covers securely in place.

Manual 0-5207 1-1 GENERAL INFORMATION

WELDSKILL 200 AC/DC INVERTER

2. Wear approved safety glasses. Side shields recom­mended.

WARNING

ARC RAYS can burn eyes and skin; NOISE
can damage hearing.

Arc rays from the welding process produce
intense heat and strong ultraviolet rays
that can burn eyes and skin. Noise from
some processes can damage hearing.

1. Use a Welding Helmet or Welding Faceshield fitted
with a proper shade of filter (see ANSI Z49.1 and
AS 1674 listed in Safety Standards) to protect your
face and eyes when welding or watching.

Recommended Protective Filters for Electric Welding

Description of Process

Manual Metal Arc Welding - covered
electrodes (MMAW)

Gas Metal Arc Welding (GWAW)
(MIG) other than Aluminium and
Stainless Steel

Gas Metal Arc Welding (GMAW)
(MIG) Aluminium and Stainless Steel

Gas Tungsten Arc Welding (GTAW)
(TIG)

Flux-cored Arc Welding (FCAW) -with
or without shielding gas.

Air - Arc Gouging Less than or equal to 400 12

Plasma - Arc Cutting

Plasma - Arc Spraying

Plasma - Arc Welding

Submerged - Arc Welding

Resistance Welding

Approximate Range of

Welding Current in Amps

Less than or equal to 100 8

Greater than 400 13

Less than or equal to 150 10

Greater than 400 14

Less than or equal to 250 12

Less than or equal to 100 10

Greater than 350 14

Less than or equal to 300 11

Greater than 500 14

Less than or equal to 20 8

3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the
arc.

4. Wear protective clothing made from durable,
flame-resistant material (wool and leather) and
foot protection.

5. Use approved ear plugs or ear muffs if noise level
is high.

6. Never wear contact lenses while welding.

Minimum Shade Number of

Filter(s)

100 to 200 10
200 to 300 11
300 to 400 12

150 to 250 11
250 to 300 12
300 to 400 13

250 to 350 13

100 to 200 11
200 to 250 12
250 to 350 13

300 to 400 12
400 to 500 13

50 to 100 10
100 to 400 12
400 to 800 14

—

20 to 100 10
100 to 400 12
400 to 800 14

—

—

Safety Spectacles or eye

15

2(5)

shield

Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.

GENERAL INFORMATION 1-2 Manual 0-5207

WARNING

FUMES AND GASES can be hazardous to
your health.

Welding produces fumes and gases.
Breathing these fumes and gases can be
hazardous to your health.

1. Keep your head out of the fumes. Do not breath
the fumes.

2. If inside, ventilate the area and/or use exhaust at
the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied
respirator.

4. Read the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals,
consumables, coatings, and cleaners.

5. Work in a confined space only if it is well venti­lated, or while wearing an air-supplied respirator.
Shielding gases used for welding can displace air
causing injury or death. Be sure the breathing air
is safe.

WELDSKILL 200AC/DC INVERTER

3. Remove all flammables within 35 ft (10.7 m) of the
welding arc. If this is not possible, tightly cover
them with approved covers.

4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher
nearby.

6. Be aware that welding on a ceiling, floor, bulkhead,
or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks
or drums.

8. Connect work cable to the work as close to the
welding area as practical to prevent welding cur­rent from travelling long, possibly unknown paths
and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.

WARNING

6. Do not weld in locations near degreasing, cleaning,
or spraying operations. The heat and rays of the
arc can react with vapours to form highly toxic
and irritating gases.

7. Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating
is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air­supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded.

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding
arc. The flying sparks and hot metal, weld
spatter, hot workpiece, and hot equipment
can cause fires and burns. Accidental con

­tact of electrode or welding wire to metal
objects can cause sparks, overheating,
or fire.

1. Protect yourself and others from flying sparks and
hot metal.

2. Do not weld where flying sparks can strike flam­mable material.

FLYING SPARKS AND HOT METAL can
cause injury.

Chipping and grinding cause flying metal.
As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side
shields recommended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to
treat them carefully.

1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position
by chaining them to a stationary support or equip­ment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other
electrical circuits.

4. Never allow a welding electrode to touch any
cylinder.

Manual 0-5207 1-3 GENERAL INFORMATION

WELDSKILL 200 AC/DC INVERTER

!

5. Use only correct shielding gas cylinders,
regulators, hoses, and fittings designed for the
specific application; maintain them and associated
parts in good condition.

6. Turn face away from valve outlet when opening
cylinder valve.

7. Keep protective cap in place over valve except
when cylinder is in use or connected for use.

8. Read and follow instructions on compressed
gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed
and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.

4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from bat­tery.

The following is a quotation from the General Con­clusions Section of the U.S. Congress, Office of
Technology Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background
Paper, OTA-BP-E-63 (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 conclusions 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.

5. Keep hands, hair, loose clothing, and tools away
from moving parts.

6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.

WARNING

This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals know to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety code Sec. 25249.5 et seq.)

NOTE

Considerations About Welding And The
Effects of Low Frequency Electric and
Magnetic Fields

ABOUT PACEMAKERS:

The above procedures are among those
also normally recommended for pace­maker wearers. Consult your doctor for
complete information.

GENERAL INFORMATION 1-4 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

1.02 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550
N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Stan­dards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.

Safety in welding and allied processes Part 1: Fire Precautions, AS 1674.1-1997 from SAI Global Limited,
www.saiglobal.com.

Safety in welding and allied processes Part 2: Electrical, AS 1674.2-2007 from SAI Global Limited, www.
saiglobal.com.

Filters for eye protectors - Filters for protection against radiation generated in welding and allied operations
AS/NZS 1338.1:1992 from SAI Global Limited, www.saiglobal.com.

Manual 0-5207 1-5 GENERAL INFORMATION

WELDSKILL 200 AC/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 60974.1-2006 /IEC 60974-1 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.

GENERAL INFORMATION 1-6 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

!

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.

Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular at­tention to the information provided under these head­ings. These special annotations are easily recognized
as follows:

WARNING

A WARNING gives information regarding
possible personal injury.

CAUTION

A CAUTION refers to possible equipment
damage.

NOTE

A NOTE offers helpful information con
cerning certain operating procedures.

Additional copies of this manual may be purchased
by contacting CIGWELD at the address and phone
number for your location listed in the inside back cover
of this manual. Include the Owner’s Manual number
and equipment identification numbers.

-

2.02 Equipment Identification

The unit’s identification number (specification or
part number), model, and serial number usually ap­pear on a nameplate attached to the control panel. In
some cases, the nameplate may be attached to the
rear panel. Equipment which does not have a control
panel such as gun and cable assemblies is identified
only by the specification or part number printed on
the shipping container. Record these numbers on the
bottom of page ii for future reference.

2.03 Receipt of Equipment

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

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

Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un­crate the unit.

Manual 0-5207 2-1 INTRODUCTION

WELDSKILL 200AC/DC INVERTER

Gas Tungsten Arc
Welding (GTAW)

Air Carbon Arc
Cutting (CAC-A)

Constant Current

Constant Voltage
Or Constant Potential

High Te mperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static
Frequency Converter­Transformer-Rectifier

Dangerous Voltage

Off

On

Panel/Local

Shielded Metal
Arc Welding (SMAW)

Gas Metal Arc
Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth
(Ground)

Line

Line Connection

Auxiliary Power

Receptacle Rating­Auxiliary Power

Art # A-04937

115V 15A

t

t1

t2

%

X

IPM

MPM

t

V

Fuse

Wire Feed Function

Wire Feed Towards
Workpiece With
Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld
Mode

Press to initiate wirefeed and
welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Disturbance In
Ground System

Welding Gun

Burnback Time

Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.

4 Step Trigger
Operation

2 Step Trigger
Operation

2.04 Symbol Chart

Note that only some of these symbols will appear on your model.

INTRODUCTION 2-2 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

!

2.05 Description

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) welding processes. The unit is equipped
with digital amperage and voltage meters, and a host
of other features in order to fully satisfy the broad
operating needs of the modern user. The unit is also
fully compliant to Australian Standard AS 60974.1
and IEC 60974.1.

The WELDSKILL 200AC/DC provides excellent weld­ing performance across a broad range of applications
when used with the correct welding consumables and
procedures. The following instructions detail how
to correctly and safely set up the machine and give
guidelines on gaining the best efficiency and quality
from the Power Source. Please read these instructions
thoroughly before using the unit.

2.06 User Responsibility

This equipment will perform as per the information
contained herein when installed, operated, maintained
and repaired in accordance with the instructions pro­vided. This equipment must be checked periodically.
Defective equipment (including welding leads) should
not be used. Parts that are broken, missing, plainly
worn, distorted or contaminated, should be replaced
immediately. Should such repairs or replacements
become necessary, it is recommended that such re­pairs be carried out by appropriately qualified persons
approved by CIGWELD. Advice in this regard can
be obtained by contacting an Accredited CIGWELD
Distributor.

2.07 Transporting Methods

This unit is equipped with a handle for carrying
purposes.

WARNING

ELECTRIC SHOCK can kill. DO NOT TOUCH
live electrical parts. Disconnect input
power conductors from de-energized
supply line before moving the welding
power source.

WARNING

FALLING EQUIPMENT can cause serious
personal injury and equipment damage.

Lift unit with handle on top of case.

Use handcart or similar device of adequate capacity.

If using a fork lift vehicle, place and secure unit on a
proper skid before transporting.

2.08 Packaged Items

• WELDSKILL200AC/DCInverterPowerSource

• Electrodeholderwith4mlead

• WorkClampwith4mlead

• TigTorch4mleadwithremotecurrentcontrol

• TigTorchAccessorykit

• Regulator/Flowmeter

• ShieldingGasHose

This equipment or any of its parts should not be al­tered from standard specification without prior written
approval of CIGWELD. The user of this equipment
shall have the sole responsibility for any malfunction
which results from improper use or unauthorized
modification from standard specification, faulty
maintenance, damage or improper repair by anyone
other than appropriately qualified persons approved
by CIGWELD.

• ShoulderStrap

• OperatingManual

Manual 0-5207 2-3 INTRODUCTION

WELDSKILL 200AC/DC INVERTER

2.09 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

80

70

60

50

40

MMAW (STICK)

WELDSKILL

200 AC/DC

GTAW (TIG)

30

20

Duty Cycle (PERCENTAGE)

10

0

0

SAFE OPERATING REGION

(TIG & STICK)

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

Figure 2-1: WELDSKILL 200AC/DC Duty Cycle

Welding Current (AMPS)

A-11218

INTRODUCTION 2-4 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

2.10 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 (DC STICK Mode) 5 – 170A
Welding Current Range (DC TIG Mode) 5 - 200A
Effective Input Current (I
Maximum Input Current (I
Single Phase Generator Requirement

(note2)
STICK (MMAW)
Welding Output, 40ºC, 10 min.

TIG (GTAW)
Welding Output, 40ºC, 10 min.

Open circuit voltage 76V
Protection Class IP23S

1eff) (note1) 15A

1max) 38.8A

10kVA

170A @ 15%, 26.8V
100A @ 60%, 24.0V
80A @ 100%, 23.2V
200A @ 20%, 18.0V
116A @ 60%, 14.6V
90A @ 100%, 13.6V

Table 2-1: 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.

Manual 0-5207 2-5 INTRODUCTION

WELDSKILL 200AC/DC INVERTER

2.11 Options and Accessories

Part Number Description

W4013602 Tig Torch with 4m lead and remote control
W4015800 Foot Control with 4m lead
BGSAK2 TIG Torch accessory kit

Table 2-2: Options and Accessories

INTRODUCTION 2-6 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

!

SECTION 3:

INSTALLATION, OPERATION AND SETUP

3.01 Environment

These units are designed for use in environments
with increased hazard of electric shock as outlined in
AS60974.1 and AS1674.2

A. Examples of environments with increased hazard

of electric shock are:

1. In locations in which freedom of movement
is restricted, so that the operator is forced
to perform the work in a cramped (kneeling,
sitting or lying) position with physical contact
with conductive parts.

2. In locations which are fully or partially limited
by conductive elements, and in which there
is a high risk of unavoidable or accidental
contact by the operator.

3. In wet or damp hot locations where humidity
or perspiration considerable reduces the
skin resistance of the human body and the
insulation properties of accessories.

B. 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.

3.02 Location

conditions. For further information please refer
to AS 60529.

H. 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.

3.03 Ventilation

Since the inhalation of welding fumes can be harmful,
ensure that the welding area is effectively ventilated.

3.04 Mains Supply Voltage Requirements

The Mains supply voltage should be within ± 15%
of the rated mains supply voltage. Too low a voltage
may cause poor welding performance. Too high a
supply voltage will cause components to overheat
and possibly fail.

The Welding Power Source must be:

• Correctlyinstalled,ifnecessary,byaqualied

electrician.

• Correctlyearthed (electrically) in accordance

with local regulations.

• Connectedtothecorrectsizepowerpointand

fuse as per the Specifications on page 2-5.

Be sure to locate the welder according to the following
guidelines:

A. In areas, free from moisture and dust.

B. Ambient temperature between 0° C to 40° C.

C. In areas, free from oil, steam and corrosive

gases.

D. In areas, not subjected to abnormal vibration or

shock.

E. In areas, not exposed to direct sunlight or rain.

F. Place at a distance of 300mm or more from walls

or similar that could restrict natural air flow for
cooling.

G. 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

!

WARNING

Any electrical work must be carried out by
a qualified Electrical Tradesperson.

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 0-5207 3-1 INSTALLATION, OPERATION AND SETUP

WELDSKILL 200AC/DC INVERTER

!

!

WARNING COMPUTER

It is also possible that operation close
to computer installations may cause
computer malfunction.

3.06 High Frequency Interference

assistance of the manufacturer. In some cases this
remedial action may be as simple as earthing the
welding circuit, see NOTE below. In other cases
it could involve constructing an electromagnetic
screen enclosing the Welding Power Source and
the work, complete with associated input filters.
In all cases, electromagnetic disturbances shall
be reduced to the point where they are no longer
troublesome.

Interference may be transmitted by a high frequency
initiated or stabilised arc welding machine in the
following ways.

1. Direct Radiation: Radiation from the machine can
occur if the case is metal and is not properly grounded.
It can occur through apertures such as open access
panels. The shielding of the high frequency unit in
the Power Source will prevent direct radiation if the
equipment is properly grounded.

2. Transmission via the Supply Lead: Without
adequate shielding and filtering, high frequency energy
may be fed to the wiring within the installation (mains)
by direct coupling. The energy is then transmitted by
both radiation and conduction. Adequate shielding
and filtering is provided in the Power Source.

3. Radiation from Welding Leads: Radiated
interference from welding leads, although pronounced
in the vicinity of the leads, diminishes rapidly with
distance. Keeping leads as short as possible will
minimise this type of interference. Looping and
suspending of leads should be avoided wherever
possible.

4. Re-Radiation from Unearthed Metallic Objects:
A major factor contributing to interference is re­radiation from unearthed metallic objects close to the
welding leads. Effective grounding of such objects will
prevent re-radiation in most cases.

NOTE

The welding circuit may or may not be
earthed for safety reasons. Changing the
earthing arrangements should only be
authorised by a person who is competent
to assess whether the changes will
increase the risk of injury, e.g. by allowing
parallel welding current return paths which
may damage the earth circuits of other
equipment. Further guidance is given in
IEC 60974-13 Arc Welding Equipment ­Installation and use (under preparation).

B. Assessment of Area

Before installing welding equipment, the user shall

make an assessment of potential electromagnetic
problems in the surrounding area. The following
shall be taken into account

1. Other supply cables, control cables, signalling
and telephone cables; above, below and
adjacent to the welding equipment.

2. Radio and television transmitters and
receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of
industrial equipment.

3.07 Electromagnetic Compatibility

WARNING

Extra precautions for Electromagnetic
Compatibility may be required when
this Welding Power Source is used in a
domestic situation.

A. Installation and Use - Users Responsibility

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

INSTALLATION, OPERATION AND SETUP 3-2 Manual 0-5207

5. The health of people around, e.g. the use of
pacemakers and hearing aids.

6. Equipment used for calibration and
measurement.

7. The time of day that welding or other activities
are to be carried out.

8. The immunity of other equipment in the
environment: the user shall ensure that other
equipment being used in the environment
is compatible: this may require additional
protection measures.

The size of the surrounding area to be considered

will depend on the structure of the building
and other activities that are taking place. The
surrounding area may extend beyond the
boundaries of the premises.

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 stabilising devices should be adjusted and maintained according to the manufacturer’s
recommendations.

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 Workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of it’s

size and position, e.g. ship’s hull or building steelwork, a connection bonding the workpiece to earth
may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of
the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where
necessary, the connection of the workpiece to earth should be made by direct connection to the
workpiece, but in 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 0-5207 3-3 INSTALLATION, OPERATION AND SETUP

WELDSKILL 200AC/DC INVERTER

200

18.0

5

6

8

1 2 3 4

7

8

9

10

11

12

13

14

15

16

17

18 19

A-11219

3.08 WELDSKILL 200AC/DC Power Source Controls, Indicators and Features

MODE

AC

DC

PULSE

PURGE

200

PORTABLE WELDING MACHINE

Pre

Flow

AC/DC

Hot

Start

Initial

Current

AC FREQUENCY

Inverter

Amps

Up

Slope

Base

Current

Peak

Current

Width

Frequency

Trough
Current

Volts

Down
Slope

WAVE BALANCE
(ARC FORCE)

FORWARDBACK

Crater

Current

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

Post
Flow

PROCESS

TRIGGER

WeldSkill

POWER

FAULT

LIFT TIG

HF TIG

STICK

2T NORMAL

4T LATCH

Figure 3-1: Controls on Front Panel

20

21

OFF

ON

22

A-11232

Figure 3-2: Rear Panel

INSTALLATION, OPERATION AND SETUP 3-4 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

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

2

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

Table 3-1: 8 Pin Interconnection Control Plug Configuration

1

5

4

3

8

7

6

A-11228

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 Shielding 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. Thermal Overload Indicator Light

This welding power source is protected by a self resetting thermostat. The indicator will illuminate if the
duty cycle of the power source has been exceeded. Should the thermal overload indicator illuminate the
output of the power source will be disabled. Once the power source cools down this light will go OFF and
the over temperature condition will automatically reset. Note that the mains power switch should remain
in the on position such that the fan continues to operate thus allowing the unit to cool sufficiently. Do not
switch the unit off should a thermal overload condition be present.

Manual 0-5207 3-5 INSTALLATION, OPERATION AND SETUP

WELDSKILL 200AC/DC INVERTER

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 that when the unit is powered off the mode selection control will automatically default to LIFT TIG mode.

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 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 3-3

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

AMPS

Peak

Current

Base

Current

Initial

Current

Arc Ignited

Pre

Flow

Up

Slope

Crater

Current

Down
Slope

Arc Terminated

Post
Flow

TIME

Press & hold

Trigger

Release

Trigger

Press & hold

Trigger

Release

Trigger

A-11221

Figure 3-4

INSTALLATION, OPERATION AND SETUP 3-6 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

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. Back 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
illuminate 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

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.

Manual 0-5207 3-7 INSTALLATION, OPERATION AND SETUP

WELDSKILL 200AC/DC INVERTER

200

18.0

Press to go forward / go back
between programming status
LED’s

A

djust programming parameter

A-11222

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.

20. On / Off Switch

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 Shielding 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.

22. 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.

3.09 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 selected.

While welding the Multi Function Control directly controls the BASE CURRENT

MODE

AC

DC

PULSE

PURGE

Hot

Start

Initial

Current

Pre

Flow

AC FREQUENCY

Amps

Up

Slope

Base

Current

Peak

Current

Width

Frequency

Trough
Current

Volts

Down
Slope

WAVE BALANCE
(ARC FORCE)

Crater

Current

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

Post
Flow

PROCESS

TRIGGER

POWER

FAULT

LIFT TIG

HF TIG

STICK

2T NORMAL

4T LATCH

200

PORTABLE WELDING MACHINE

INSTALLATION, OPERATION AND SETUP 3-8 Manual 0-5207

AC/DC

FORWARDBACK

Inverter

Figure 3-5: Stick Programming Mode

WeldSkill

Programming Parameter Adjustment Device Display

Amps

70

Amps

170

Hot Start

This parameter operates in all weld modes
except LIFT TIG mode and is used to heat up
the weld zone in TIG modes or improve the
start characteristics for stick electrodes the
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

Base Current

This parameter sets the TIG WELD current
when PULSE is OFF. This parameter also sets
the STICK weld current.

Arc Force (STICK Mode only)

Arc Force is effective when in Manual Arc
Mode only. Arc Force control provides and
adjustable amount of Arc Force (or "dig")
control. This feature can be particularly
beneficial in providing the operator the ability
to compensate for variability in joint fit-up in
certain situations with particular electrodes. In
general increasing the Arc Force control toward
100% (maximum Arc Force) allows greater
penetration control to be achieved.

Table 3-2

WELDSKILL 200AC/DC INVERTER

0 to 70A (max 170A weld current)

5 to 170A (DC STICK mode)

10 to 170A (AC STICK mode)

100

Volts

0 to 100%

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

Manual 0-5207 3-9 INSTALLATION, OPERATION AND SETUP

WELDSKILL 200AC/DC INVERTER

200

18.0

Press to go forward / go back
between programming status
LED’s

A

djust programming parameter

A-11222

3.10 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.

MODE

AC

DC

PULSE

PURGE

200

PORTABLE WELDING MACHINE

Pre

Flow

AC/DC

Hot

Start

AC FREQUENCY

Amps

Slope

Initial

Current

Inverter

Peak

Current

Base

Width

Current

Up

Frequency

Trough
Current

Volts

Down
Slope

WAVE BALANCE
(ARC FORCE)

FORWARDBACK

Crater

Current

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

Post
Flow

PROCESS

TRIGGER

Figure 3-6: LIFT TIG and HF TIG Programming Mode

Programming Parameter Adjustment Device Display

Pre-Flow

This parameter operates in
TIG modes only and is used to
provide gas to the weld zone

1.0

Volts

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.

Initial Current

This parameter operates in (4T)
TIG modes only and is used to
set the start current for TIG. The
Start Current remains on until the
torch trigger switch is released

30 to 200 Amps (AC LIFT TIG mode)

200

Amps

5 to 200 Amps (DC TIG mode)

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.

POWER

FAULT

LIFT TIG

HF TIG

STICK

2T NORMAL

4T LATCH

WeldSkill

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

INSTALLATION, OPERATION AND SETUP 3-10 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

Up Slope

This parameter operates in (4T)
TIG modes only and is used to
set the time for the weld current
to ramp up, after the torch trigger
switch has been pressed then
released, from INITIAL CUR to
PEAK or BASE current.

Base Current

This parameter sets the TIG
WELD current when PULSE is
OFF. This parameter also sets the
STICK weld current.

Peak Current

This parameter sets the PEAK
weld current when in PULSE
mode.

Trough Current

The lowest point in the pulse is
called the Trough.

Pulse Width

This parameter sets the
percentage on time of the PULSE
FREQUENCY for PEAK weld
current when the PULSE is ON.

Pulse Frequency

This parameter sets the PULSE
FREQUENCY when the PULSE is
ON..

Down Slope

This parameter operates in TIG
modes only and is used to set
the time for the weld current
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.

Crater Current

This parameter operates in (4T)
TIG modes only and is used to
set the finish current for TIG.
The CRATER Current remains
ON until the torch trigger switch
is released after it has been
depressed.
Note: The maximum crater
current available will be limited to
the set value of the base current.

VOLTS

SECONDS

15.0

Volts

0.0 to 15.0 seconds

PERCENT (%)

FREQ (Hz)

200

Amps

5 to 200A (DC TIG mode)

30 to 200A (AC LIFT TIG mode)

10 to 200A (AC HF TIG mode)

200

Amps

10 to 200A (DC TIG mode)
30 to 200A (AC TIG mode)

200

Amps

5 to 200A (DC HF TIG mode)

30 to 200A (AC LIFT TIG mode)

10 to 200A (AC HF TIG mode)

8

0

Volts

15 to 80%

200

Volts

0.5 to 200 Hz

25.0

Volts

0.0 to 25.0 seconds

200

Amps

5 to 200A (DC TIG mode)

30 to 200A (AC TIG mode)

10 to 200A (AC HF TIG mode)

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

Manual 0-5207 3-11 INSTALLATION, OPERATION AND SETUP

WELDSKILL 200AC/DC INVERTER

Post Flow

This parameter operates in TIG
modes only and is used to adjust
the post gas flow time once
the arc has extinguished. This
control is used to dramatically
reduce oxidation of the tungsten
electrode.

AC Frequency

This parameter operates in AC
TIG mode only and is used to
set the frequency for the AC weld
current.

Wave Balance

This parameter operates in AC
TIG mode and is used to set the
penetration to cleaning action
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 3-3

60.0

Volts

0.0 to 60.0 seconds

150

Volts

15 to 150 Hz

5

6

Volts

10 to 65%

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

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%

10%50% 65%

(+)(+) (+)

(-)(-) (-)

90%50% 35%

Balanced with 50% penetration

and 50% cleaning

Maximum Penetration and

reduced cleaning

Maximum Cleaning and

reduced penetration

A-11223

Table 3-4: AC TIG Wave Balance

INSTALLATION, OPERATION AND SETUP 3-12 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

3.11 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 40 Amps.

In DC HF TIG mode, if the tungsten electrode touches the work the welding current is reduced to 30 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.

3.12 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.

Manual 0-5207 3-13 INSTALLATION, OPERATION AND SETUP

WELDSKILL 200AC/DC INVERTER

Art: A-05087

Figure 3-7: Fit Regulator to Cylinder

Installation

1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting the regulator.

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.

INSTALLATION, OPERATION AND SETUP 3-14 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

Adjusting Flow Rate

Art: A-05088_AB

Figure 3-8: 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.

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 counter clockwise, 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.

3.13 Setup for TIG (GTAW) Welding

A. Select Lift TIG or HF TIG mode with the process selection control (refer to Section 3.08.7 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.

Manual 0-5207 3-15 INSTALLATION, OPERATION AND SETUP

WELDSKILL 200AC/DC INVERTER

!

200

18.0

8

Negative Welding
Terminal (-)

Work Lead

Positive Welding
Terminal (+)

8 Pin Control Socket

Tig Torch

A-11224

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

3.12) 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.

MODE

AC

DC

PULSE

Hot

Start

Initial

Current

Pre

PURGE

Flow

AC FREQUENCY

AC/DC

200

PORTABLE WELDING MACHINE

Inverter

Amps

Up

Slope

Peak

Current

Trough

Current

Base

Width

Current

Frequency

Volts

Down
Slope

Crater
Current

WAVE BALANCE
(ARC FORCE)

FORWARDBACK

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

Post
Flow

PROCESS

TRIGGER

WeldSkill

POWER

FAULT

LIFT TIG

HF TIG

STICK

2T NORMAL

4T LATCH

INSTALLATION, OPERATION AND SETUP 3-16 Manual 0-5207

Figure 3-9: Setup for TIG Welding

WELDSKILL 200AC/DC INVERTER

200

18.0

8

Negative Welding
Terminal (-)

Work Lead

Positive Welding
Terminal (+)

Electrode Holder

A-11225

3.14 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 3.08.7 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

AC

DC

PULSE

Hot
Start

Initial

Current

Pre

PURGE

Flow

AC FREQUENCY

AC/DC

200

PORTABLE WELDING MACHINE

Inverter

Amps

Up

Slope

Peak

Current

Trough
Current

Base

Width

Current

Frequency

Volts

Down
Slope

Crater

Current

WAVE BALANCE
(ARC FORCE)

FORWARDBACK

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz)

Post
Flow

PROCESS

TRIGGER

WeldSkill

POWER

FAULT

LIFT TIG

HF TIG

STICK

2T NORMAL

4T LATCH

Manual 0-5207 3-17 INSTALLATION, OPERATION AND SETUP

Figure 3-10: Setup for Manual Arc Welding.

WELDSKILL 200AC/DC INVERTER

This page is left blank intentionally.

INSTALLATION, OPERATION AND SETUP 3-18 Manual 0-5207

WELDSKILL 200 AC/DC INVERTER

SECTION 4:

BASIC WELDING GUIDE

4.01 Stick (MMAW) Basic Welding Technique

Size of Electrode

The electrode size is determined by the thickness of metals being joined and can also be governed by the type
of welding machine available. Small welding machines will only provide sufficient current (amperage) to run
the smaller size electrodes.

For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job.
A little practice will soon establish the most suitable electrode for a given application.

Storage of Electrodes

Always store electrodes in a dry place and in their original containers.

Electrode Polarity

Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive
polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult
the electrode data sheet or your nearest Accredited CIGWELD Distributor.

Effects of Arc Welding Various Materials

A. High tensile and alloy steels

The two most prominent effects of welding these steels are the formation of a hardened zone in the weld
area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks may result.
Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes,
preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode
deposits or tempering in a furnace.

Hydrogen controlled Electrodes must be used for this application. Use Ferrocraft 61 or 16TXP for normal
strength (500 MPa) steels, and Alloycraft range for higher strength steels.

B. Austenitic manganese steels

The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason
it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or
skip welding to distribute the heat. Suitable Electrode types are Cobalarc Austex or Cobalarc Mangcraft.

C. Cast Iron

Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness,
generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white­heart malleable, due to the porosity caused by gas held in this type of iron. Suitable Electrode types are
Castcraft 55 or Castcraft 100.

D. Copper and alloys

The most important factor is the high rate of heat conductivity of copper, making preheating of heavy
sections necessary to give proper fusion of weld and base metal. Suitable Electrode types are Bronzecraft
AC-DC electrodes.

Arc Welding Practice

The techniques used for arc welding are almost identical regardless of what types of metals are being joined.
Naturally enough, different types of electrodes would be used for different metals as described in the preceding
section.

Manual 0-5207 4-1 BASIC WELDING GUIDE

WELDSKILL 200AC/DC INVERTER

Art # A-07688

Art # A-07689

Art # A-07690

Welding Position

The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in
flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions
intermediate between these. Some of the common types of welds are shown in Figures 4-5 through 4-12.

Art # A-07687

Figure 4-1: Flat Position, Down Hand Butt Weld

Figure 4-2: Flat Position, Gravity Fillet Weld

Figure 4-3: Horizontal Position, Butt Weld

Figure 4-4: Horizontal-Vertical (HV) Position

Art A-07691

Figure 4-5: Vertical Position, Butt Weld

Art # A-07692

Figure 4-6: Vertical Position, Fillet Weld

BASIC WELDING GUIDE 4-2 Manual 0-5207

WELDSKILL 200 AC/DC INVERTER

Open Square Butt

Single Vee Butt Joint

Not less than

Art# A-07693

Figure 4-7: Overhead Position, Butt Weld

Art # A-07694

Figure 4-8: Overhead Position, Fillet Weld

Joint Preparations

In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections
and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being
joined to ensure proper penetration of the weld metal and to produce sound joints.

In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be
removed from oxy-cut surfaces. Typical joint designs are shown in Figure 4-9.

Joint

Gap varies from

1.6mm (1/16”) to 4.8mm (3/16”)
depending on plate thickness

Single Vee Butt Joint

Lap Joint

Not less than

45°

Double Vee Butt Joint

1.6mm (1/16”)

1.6mm (1/16”)

70°

Not less than

70°

1.6mm (1/16” ) max

1.6mm (1/16”) max

Tee Joints

Fillet Joint

(Fillet both sides of the

joint)

Corner Weld

Edge Joint

Plug Weld Plug Weld

Art # A-07695_AE

Figure 4-9: Typical Joint Designs for Arc Welding

Manual 0-5207 4-3 BASIC WELDING GUIDE

WELDSKILL 200AC/DC INVERTER

20°

Arc Welding Technique - A Word to Beginners

For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of
scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode. Clean any paint, loose scale or
grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand
position. Make sure that the work clamp is making good electrical contact with the work, either directly or
through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a
poor circuit will probably result.

The Welder

Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as
much work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body
will soon make you feel tired. Relax and you will find that the job becomes much easier. You can add much to
your peace of mind by wearing a leather apron and gauntlets. You won't be worrying then about being burnt
or sparks setting alight to your clothes.

Place the work so that the direction of welding is across, rather than to or from, your body. The electrode
holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode
burns down. If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of
weight off your hand. Be sure the insulation on your cable and electrode holder is not faulty, otherwise you
are risking an electric shock.

Striking the Arc

Practice this on a piece of scrap plate before going on to more exacting work. You may at first experience
difficulty due to the tip of the electrode "sticking" to the work piece. This is caused by making too heavy a
contact with the work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it.
This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same
way as a match is struck. As soon as the arc is established, maintain a 1.6mm to 3.2mm gap between the
burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.

Another difficulty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that
the arc is broken again. A little practice will soon remedy both of these faults.

Art # A-07696_AB

1.6 mm (1/16”)

Figure 4-10: Striking an Arc

Arc Length

The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will
find that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the
weld metal comes across in large, irregular blobs. The weld bead is flattened and spatter increases. A short
arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being
blanketed by slag and the electrode tip being solidified in. If this should happen, give the electrode a quick
twist back over the weld to detach it. Contact or "touch-weld" electrodes such as Ferrocraft 21 do not stick in
this way, and make welding much easier.

Rate of Travel

After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards
the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the
plate to form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel
has to be adjusted so that a well-formed bead is produced.

BASIC WELDING GUIDE 4-4 Manual 0-5207

WELDSKILL 200 AC/DC INVERTER

20°-30°

If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual
globules. If the travel is too slow, the weld metal piles up and the bead will be too large.

Making Welded Joints

Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.

A. Butt Welds

Set up two plates with their edges parallel, as shown in Figure 4-11, allowing 1.6mm to 2.4mm gap between
them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal
pulling the plates out of alignment. Plates thicker than 6.0mm should have their mating edges bevelled to
form a 70º to 90º included angle. This allows full penetration of the weld metal to the root. Using a 3.2mm
Ferrocraft 21 electrode at 100 amps, deposit a run of weld metal on the bottom of the joint.

Do not weave the electrode, but maintain a steady rate of travel along the joint sufficient to produce a
well-formed bead. At first you may notice a tendency for undercut to form, but keeping the arc length
short, the angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help
eliminate this. The electrode needs to be moved along fast enough to prevent the slag pool from getting
ahead of the arc. To complete the joint in thin plate, turn the job over, clean the slag out of the back and
deposit a similar weld.

Electrode

Tack Weld

Tack Weld

Art # A-07697_AB

Figure 4-11: Butt Weld

Art # A-07698

Figure 4-12: Weld Build up Sequence

Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag
out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the
second run. Subsequent runs are then deposited using either a weave technique or single beads laid down
in the sequence shown in Figure 4-12. The width of weave should not be more than three times the core
wire diameter of the electrode. When the joint is completely filled, the back is either machined, ground or
gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing
the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar
purpose to the backing run in securing proper fusion at the root of the weld.

B. Fillet Welds

These are welds of approximately triangular cross-section made by depositing metal in the corner of two
faces meeting at right angles. Refer to Figure 4-4.

A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be
tacked together at right angles. Using a 3.2mm Ferrocraft 21 electrode at 100 amps, position angle iron
with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) fillet. Strike the
arc and immediately bring the electrode to a position perpendicular to the line of the fillet and about 45º
from the vertical. Some electrodes require to be sloped about 20º away from the perpendicular position
to prevent slag from running ahead of the weld. Refer to Figure 4-13. Do not attempt to build up much
larger than 6.4mm width with a 3.2mm electrode, otherwise the weld metal tends to sag towards the base,

Manual 0-5207 4-5 BASIC WELDING GUIDE

WELDSKILL 200AC/DC INVERTER

Art # A-07699_AB

and undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 4-14. Weaving in HV
fillet welds is undesirable.

45° from
vertical

60° - 70° from line
of weld

Figure 4-13: Electrode Position for HV Fillet Weld

Art # A-07700_AB

6

3

1

5

2

4

Figure 4-`14: Multi-runs in HV Fillet Weld

C. Vertical Welds

1. Vertical Up

Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm

Ferrocraft 21 electrode and set the current at 100 amps. Make yourself comfortable on a seat in front
of the job and strike the arc in the corner of the fillet. The electrode needs to be about 10º from the
horizontal to enable a good bead to be deposited. Refer Figure 4-15. Use a short arc, and do not attempt
to weave on the first run. When the first run has been completed de-slag the weld deposit and begin
the second run at the bottom. This time a slight weaving motion is necessary to cover the first run and
obtain good fusion at the edges. At the completion of each side motion, pause for a moment to allow
weld metal to build up at the edges, otherwise undercut will form and too much metal will accumulate
in the centre of the weld. Figure 4-16 illustrates multi-run technique and Figure 4-17 shows the effects
of pausing at the edge of weave and of weaving too rapidly.

Art # A-07701

Figure 4-15: Single Run Vertical Fillet Weld

BASIC WELDING GUIDE 4-6 Manual 0-5207

WELDSKILL 200 AC/DC INVERTER

Art # A-07702

Figure 4-16: Multi Run Vertical Fillet Weld

Art # A-07703

Figure 4-17: Examples of Vertical Fillet Welds

2. Vertical Down

The Ferrocraft 21 electrode makes welding in this position particularly easy. Use a 3.2mm electrode at

100 amps. The tip of the electrode is held in light contact with the work and the speed of downward
travel is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should
point upwards at an angle of about 45º.

3. Overhead Welds

Apart from the rather awkward position necessary, overhead welding is not much more difficult that

downhand welding. Set up a specimen for overhead welding by first tacking a length of angle iron at
right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench
or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch.
The electrode is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-18). The tip of
the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique
is not advisable for overhead fillet welds. Use a 3.2mm Ferrocraft 12XP electrode at 100 amps, and
deposit the first run by simply drawing the electrode along at a steady rate. You will notice that the
weld deposit is rather convex, due to the effect of gravity before the metal freezes.

Art # A-07704

Figure 4-18: Overhead Fillet Weld

Manual 0-5207 4-7 BASIC WELDING GUIDE

WELDSKILL 200AC/DC INVERTER

Upsetting

Distortion

Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely
perceptible, but in other cases allowance has to be made before welding commences for the distortion that
will subsequently occur. The study of distortion is so complex that only a brief outline can be attempted hear.

The Cause of Distortion

Distortion is caused by:

A. Contraction of Weld Metal:

Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means
that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In
a welded joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore,
cooling causes the weld metal to flow plastically, that is, the weld itself has to stretch if it is to overcome
the effect of shrinking volume and still be attached to the edge of the joint. If the restraint is very great,
as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld
metal does not crack, there will still remain stresses "Locked-up" in the structure. If the joint material is
relatively weak, for example, a butt joint in 2.0mm sheet, the contracting weld metal may cause the sheet
to become distorted.

B. Expansion and Contraction of Parent Metal in the Fusion Zone:

While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very
high temperature and attempts to expand in all directions. It is able to do this freely at right angles to the
surface of the plate (i.e., "through the weld", but when it attempts to expand "across the weld" or "along the
weld", it meets considerable resistance, and to fulfil the desire for continued expansion, it has to deform
plastically, that is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by
expanding, pushes against the cooler, harder metal further away, and tends to bulge (or is "upset". When
the weld area begins to cool, the "upset" metal attempts to contract as much as it expanded, but, because
it has been "upset" it does not resume its former shape, and the contraction of the new shape exerts a
strong pull on adjacent metal. Several things can then happen.

The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the
powerful contraction stresses (distortion), or the weld may crack, in any case, there will remain "locked­up" stresses in the job. Figures 4-19 and 4- 20 illustrate how distortion is created.

Hot

Weld

Hot

Expansion with
compression

Cool

Art # A-07705_AB

Figure 4-19: Parent Metal Expansion

Art # A-07706_AB

Weld

Permanent Upset

Contraction
with tension

Figure 4-20: Parent Metal Contraction

Overcoming Distortion Effects

There are several methods of minimizing distortion effects.

A. Peening

This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of
this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable
on the last layer.

BASIC WELDING GUIDE 4-8 Manual 0-5207

WELDSKILL 200 AC/DC INVERTER

B. Distribution of Stresses

Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so
that they tend to cancel each other out. See Figures 4-20 through 4-23 for various weld sequences. Choice
of a suitable weld sequence is probably the most effective method of overcoming distortion, although an
unsuitable sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is
often successful in eliminating distortion.

C. Restraint of Parts

Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and
tack welds are methods employed with this in view.

D. Presetting

It is possible in some cases to tell from past experience or to find by trial and error (or less frequently, to
calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the
components to be welded, constructional stresses can be made to pull the parts into correct alignment.
A simple example is shown in Figure 4-21.

E. Preheating

Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to
reduce distortion. Figure 4-22 shows a simple application. By removing the heating source from b and c as
soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.

Art # A-07707

Figure 4-21: Principle of Presetting

Art # A-07708

B

Dotted lines show effect if no preheat is used

Weld

C

PreheatPreheat

Figure 4-22: Reduction of Distortion by Preheating

Art # A-07709

Figure 4-23: Examples of Distortion

Manual 0-5207 4-9 BASIC WELDING GUIDE

WELDSKILL 200AC/DC INVERTER

1

Art # A-07710_AB

2

Block Sequence.
The spaces between the welds are
filled in when the welds are cool.

Figure 4-24: Welding Sequence

2

3

4

Figure 4-25: Step back Sequence

3

1

Art # A-07428_AB

Figure 4-26: Chain Intermittent Welding

Art # A-07713_AB

Figure 4-27: Staggered Intermittent Welding

BASIC WELDING GUIDE 4-10 Manual 0-5207

WELDSKILL 200 AC/DC INVERTER

Electrode Selection Chart

CIGWELD Electrode Selection Chart

Description Diameter Pack Part No. Application

Satincraft 13

Ferrocraft

12XP

2.5mm

2.5mm

3.2mm

3.2mm

4.0mm

2.0mm

2.0mm

2.5mm

2.5mm

3.2mm

3.2mm

4.0mm

1kg

2.5kg
1kg

2.5kg
5kg

1kg

2.5kg
1kg

2.5kg
1kg

2.5kg
5kg

322135
612182
322136
612183
611184

322128
612231
322129
612232
322138
612233
611234

General purpose electrode suitable for all positional
welding and galvanised steel.

General purpose, Xtra performance electrode
recommended for all positional (inc. Vertical down)
welding of mild and galvanised steel.

WeldSkill GP

Ferrocraft 16

Twincoat

Satincrome

308L-17

Satincrome

309Mo-17

Satincrome

316L-17

2.0mm

2.0mm

2.5mm

2.5mm

2.5mm

3.2mm

3.2mm

3.2mm

4.0mm

2.5mm

2.5mm

3.2mm

3.2mm

4.0mm

2.5mm

3.2mm

4.0mm

2.5mm

3.2mm

4.0mm

2.0mm

2.5mm

3.2mm

2.5/3.2mm

4.0mm

1 kg

2.5 kg
1 kg

2.5 kg
5 kg
1 kg

2.5 kg
5 kg
5 kg

2.5 kg
5 kg

2.5 kg
5 kg
5 kg

2.5 kg

2.5 kg

2.5 kg

2.5 kg

2.5 kg

2.5 kg

2,5 kg

2.5 kg

2.5 kg

Blisterpack

2.5 kg

WEG1020
WEG2520
WEG1025
WEG2525
WEG5025
WEG1032
WEG2532
WEG5032
WEG5040

612752
611752
612753
611753
611754

611602
611603
611604

611692
611693
611694

611661
611662
611663
322215
611664

User-friendly GP electrode for welding thin section mild
and galvanised steels. Excellent for vertical down fillet
welding applications.

Hydrogen Controlled type offering exceptional AC/DC
performance in all welding positions.

Stainless Steel type for 19Cr/10Ni stainless grades
including 201, 202, 301, 302, 303, 304, 304L, 305,
308, etc

Stainless Steel type for 309 and 309L grades. It is also
suitable for welding of dissimilar welding of other 300
series stainless steels.

Stainless Steel type for welding of matching Mo bearing
grades, 316 and 316L.

Weldall

Castcraft 55

Castcraft

100

2.5mm

3.2mm

2.5/3.2mm

4.0mm

3.2mm

4.0mm

2.5mm

3.2mm

2.5/3.2mm

4.0mm

2.5 kg

2.5 kg

Blisterpack

2.5 kg

2.5 kg

2.5 kg

2.5 kg

2.5 kg

Blisterpack

2.5 kg

611702
611703
322216
611704

611723
611724

611732
611733
322217
611734

High alloy stainless steel type for welding of unknown
steels, repair of die or tool steels and for joining
dissimilar steels. (Not recommended for cast iron).

For repair and maintenance welding of S.G. cast iron,
meehanites and other cast irons. It produces high
strength weld than Castcraft 100.

Soft, Ductile Nickel type electrode for repair and
maintenance welding of a wide range of cast irons. It
has better “wetting” action than Castcraft 55.

Table 4-1: CIGWELD Electrode Selection Chart

Further information on CIGWELD electrodes can be found at the website www.thermadyne.com

Manual 0-5207 4-11 BASIC WELDING GUIDE

WELDSKILL 200AC/DC INVERTER

Art: A-04971

4.02 Stick (MMAW) Welding Troubleshooting

FAULT CAUSE REMEDY

1 Welding current

varying

2 A gap is left by

failure of the weld
metal to fill the
root of the weld.

3 Non-metallic par-

ticles are trapped
in the weld metal.

ARC FORCE control knob
is set at a value that
causes the welding current
to vary excessively with

Reduce the ARC FORCE control knob until weld­ing current is reasonably constant while prohibit­ing the electrode from sticking to the work piece
when you “dig” the electrode into the workpiece.

the arc length.

A Welding current too low A Increase welding current.

B Electrode too large for

B Use smaller diameter electrode.

joint.

C Insufficient gap. C Allow wider gap.

A Non-metallic particles may

be trapped in undercut

A If a bad undercut is present clean slag bout and

cover with a run from a smaller gauge electrode.

from previous run.

B Joint preparation too

restricted.

C Irregular deposits allow

B Allow for adequate penetration and room for

cleaning out the slag.

C If very bad, chip or grind out irregularities.

slag to be trapped.

D Lack of penetration with

slag trapped beneath weld
bead.

D Use smaller electrode with sufficient current to

give adequate penetration. Use suitable tools to
remove all slag from comers.

4 A groove has been

formed in the base
metal adjacent to
the toe of a weld
and has not been
filled by the weld
metal (undercut).

E Rust or mill scale is pre-

E Clean joint before welding.

venting full fusion.

F Wrong electrode for posi-

tion in which welding is
done.

F Use electrodes designed for position in which

welding is done, otherwise proper control of slag
is difficult.

Figure 1-Example of insufficient gap or incorrect sequence

A Welding current is too

A Reduce welding current.

high.

B Welding arc is too long. B Reduce the length of the welding arc.

C Angle of the electrode is

incorrect.

D Joint preparation does not

allow correct electrode

C Electrode should not be inclined less than 45° to

the vertical face.

D Allow more room in joint for manipulation of the

electrode.

angle.

E Electrode too large for

E Use smaller gauge electrode.

joint.

F Insufficient deposit time at

edge of weave.

BASIC WELDING GUIDE 4-12 Manual 0-5207

F Pause for a moment at edge of weave to allow

weld metal buildup.

WELDSKILL 200 AC/DC INVERTER

5 Portions of the

weld run do not
fuse to the surface
of the metal or
edge of the joint.

6 Gas pockets or

voids in weld
metal (porosity)

A Small electrodes used on

A Use larger electrodes and preheat the plate.

heavy cold plate.

B Welding current is too low. B Increase welding current.

C Wrong electrode angle. C Adjust angle so the welding arc is directed more

into the base metal.

D Travel speed of electrode

D Reduce travel speed of electrode.

is too high.

E Scale or dirt on joint

E Clean surface before welding.

surface.

Art: A-04972

Figure 2: Example of Lack of Fusion

A High levels of sulphur in

steel.

A Use an electrode that is designed for high sul-

phur steels.

B Electrodes are damp. B Dry electrodes before use.

7 Crack occurring in

weld metal soon
after solidification
commences

C Welding current is too

C Reduce welding current.

high.

D Surface impurities such as

D Clean joint before welding.

oil, grease, paint, etc.

E Welding in a windy envi-

E Shield the weld area from the wind.

ronment.

F Electrode damaged ie flux

coating incomplete.

F Discard damaged electrodes and only use elec-

trodes with a complete flux coating.

A Rigidity of joint. A Redesign to relieve weld joint of severe stresses

or use crack resistance electrodes.

B Insufficient throat thick-

ness.

B Travel slightly slower to allow greater build up in

throat.

C Weld current is too high. C Decrease welding current.

Art: A-04973

Figure 3: Example of Slag Inclusion

Table 4-2: Welding Problems MMAW (Stick)

Manual 0-5207 4-13 BASIC WELDING GUIDE

WELDSKILL 200AC/DC INVERTER

4.03 TIG (GTAW) Basic Welding Technique

Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding
process in which fusion is produced by an electric arc that is established between a single tungsten (non­consumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding
grade shielding gas mixture which is generally Argon based. A filler metal may also be added manually in some
circumstances depending on the welding application.

A-09658_AB

Gas Cup

Either Ceramic,

Work Piece

Can Be Any Commercial

Metal

Welds Made With or Without

Addition of Filler Metal

High-lmpact or

Water Cooled

Metal

Tungsten Electrode

Non-Consumable

Inert Gas

Shields Electrode

and Weld Puddle

Figure 4-28: TIG Welding Application Shot

Tungsten Electrode Current Ranges

Electrode Diameter DC Current (Amps)

0.040” (1.0mm) 30-60

1/16” (1.6mm) 60-115

3/32” (2.4mm) 100-165

1/8” (3.2mm) 135-200

5/32” (4.0mm) 190-280

3/16” (4.8mm) 250-340

Table 4-3: Current Ranges for Various Tungsten Electrode Sizes

Guide for Selecting Filler Wire Diameter

Filler Wire Diameter DC Current Range (Amps)

1/16” (1.6mm) 20-90

3/32” (2.4mm) 65-115

1/8” (3.2mm) 100-165

3/16” (4.8mm) 200-350

Table 4-4: Filler Wire Selection Guide

BASIC WELDING GUIDE 4-14 Manual 0-5207

Tungsten Electrode Types

WELDSKILL 200 AC/DC INVERTER

Electrode Type

(Ground Finish)

Thoriated 2%

Zirconated 1%

Ceriated 2%

TIG Welding Filler Rods

Comweld

Rod

Aust Std AWS Std Part No.

Welding Application Features Colour Code

DC welding of mild
steel, stainless steel
and copper

High quality AC weld­ing of aluminium,
magnesium and their
alloys.

AC & DC welding of
mild steel, stainless
steel, copper, alumin­ium, magnesium and
their alloys

Table 4-5 Tungsten Electrode Types

1.6mm

Excellent arc starting,
Long life, High current
carrying capacity

Self cleaning, Long
life, Maintains balled
end, High current car­rying capacity.

Longer life, More
stable arc, Easier
starting, Wider current
range, Narrower more
concentrated arc.

Part No.

2.4mm

Part No.

3.2mm

Red

White

Grey

Type/Application

LW1

LW1-6

Supersteel

CrMo1
CrMo2

308L
309L
316L

Base Metal

Thickness

0.040”

1.0mm

0.045”

1.2mm

1/16”

1.6mm

R4
R6
R2

RB2
RB3

R308L
R309L
R316L

DC Current

for Mild

Steel

35-45
40-50

45-55
50-60

60-70
70-90

ER70S-4
ER70S-6
ER70S-2

ER80S-B2
ER90S-B3

ER308L
ER309L
ER316L

DC Current

for Stainless

20-30
25-35

30-45
35-50

40-60
50-70

321411
321417
321370

—
—

321406
321403
321400

Table 4-6 TIG Welding Filler Rods

Steel

—
—
—

321379
321383

321407
321404
321401

Tungsten
Electrode
Diameter

0.040”

1.0mm

0.040”

1.0mm

1/16”

1.6mm

—
—
—

—
—

—
—
—

Diameter (if

For mild-medium strength steels.
Pipes, tubing, roll cages, etc.

For welding of high strength Cr-Mo
steels used at elevated tempera­tures.

For stainless steels. Stainless pipes,
tubing, architectural uses, etc.

Filler Rod

required)

1/16”

1.6mm

1/16”

1.6mm

1/16”

1.6mm

Argon Gas
Flow Rate
Litres/min

5-7 Butt/Corner

5-7 Butt/Corner

7 Butt/Corner

Joint Type

Lap/Fillet

Lap/Fillet

Lap/Fillet

1/8”

3.2mm

3/16”

4.8mm

1/4”

6.4mm

Manual 0-5207 4-15 BASIC WELDING GUIDE

80-100
90-115

115-135
140-165

160-175
170-200

65-85

90-110

100-125
125-150

135-160
160-180

1/16”

1.6mm

3/32”

2.4mm

1/8”

3.2mm

Table 4-7 Welding Rate

3/32”

2.4mm

1/8”

3.2mm

5/32”

4.0mm

7 Butt/Corner

Lap/Fillet

10 Butt/Corner

Lap/Fillet

10 Butt/Corner

Lap/Fillet

WELDSKILL 200AC/DC INVERTER

TIG Welding is generally regarded as a specialised process that requires operator competency. While many of
the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG
Welding process is outside the scope of this Operating Manual. For further information please refer to www.
thermadyne.com.au or contact CIGWELD.

4.04 TIG (GTAW) Welding Problems

FAULT CAUSE REMEDY

1 Excessive bead build up or

poor penetration or poor
fusion at edges of weld.

2 Weld bead too wide and

flat or undercut at edges
of weld or excessive burn
through.

3 Weld bead too small or

insufficient penetration or
ripples in bead are widely
spaced apart.

4 Weld bead too wide or

excessive bead build up or
excessive penetration in
butt joint.

5 Uneven leg length in fillet

joint

6 Electrode melts or oxidises

when an arc is struck.

Welding current is too
low

Welding current is too
high

Travel speed too fast Reduce travel speed.

Travel speed too slow Increase travel speed.

Wrong placement of
filler rod

A Torch lead connected

to positive welding
terminal.

Increase weld current and/or faulty joint
preparation.

Decrease weld current.

Re-position filler rod.

A Connect torch lead to negative welding

terminal.

B No gas flowing to weld-

ing region.

C Torch is clogged with

dust or dirt.

D Gas hose is cut. D Replace gas hose.

E Gas passage contains

impurities.

F Gas regulator turned

off.

G The electrode is too

small for the welding
current.

H Power source is set for

STICK welding.

B Check the gas lines for kinks or breaks

and gas cylinder contents.

C Clean torch.

E Disconnect gas hose from the rear of

Power Source then raise gas pressure
and blow out impurities.

F Turn on.

G Increase electrode diameter or reduce the

welding current.

H Set Power Source to LIFT TIG or HF TIG

mode.

BASIC WELDING GUIDE 4-16 Manual 0-5207

WELDSKILL 200 AC/DC INVERTER

7 Dirty weld pool A Electrode contaminated

by contact with work
piece or filler rod mate­rial.

B Work piece surface has

foreign material on it.

C Gas contaminated with

air.

8 Poor weld finish Inadequate shielding

gas.

9 Arc start is not smooth. A Tungsten electrode is

too large for the weld­ing current.

B The wrong electrode

is being used for the
welding job.

C Gas flow rate is too

high.

A Clean the electrode by grinding off the

contaminates.

B Clean surface.

C Check gas lines for cuts and loose fitting

or change gas cylinder.

Increase gas flow or check gas line for
gas flow problems.

A Select the right size tungsten electrode.

Refer to Table 4-3 CIGWELD Tungsten
Electrode Selection Chart.

B Select the right tungsten electrode type.

Refer to Table 4-5 CIGWELD Tungsten
Electrode Selection Chart.

C Select the right rate for the welding job.

Refer to Table 4-7.

10 Arc flutters during TIG

welding.

D Incorrect shielding gas

is being used.

E Poor work clamp con-

nection to work piece.

Tungsten electrode is
too large for the weld­ing current.

D Select the right shielding gas.

E Improve connection to work piece.

Select the right size tungsten electrode.
Refer to Table 4-3 CIGWELD Tungsten
Electrode Selection Chart.

Manual 0-5207 4-17 BASIC WELDING GUIDE

WELDSKILL 200AC/DC INVERTER

This page is left blank intentionally.

BASIC WELDING GUIDE 4-18 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

!

SECTION 5:

POWER SOURCE PROBLEMS AND ROUTINE SERVICE

REQUIREMENTS

5.01 Basic Troubleshooting

WARNING

There are extremely dangerous voltage and power levels present inside this product. Do not attempt
to open or repair unless you are a qualified electrical tradesperson and you have had training in
power measurements and troubleshooting techniques.

If major complex subassemblies are faulty, then the Welding Power Source must be returned to an ac­credited CIGWELD Service Provider for repair. The basic level of troubleshooting is that which can be
performed without special equipment or knowledge. Refer also to section 4 for solving welding problems.

5.02 Power Source Problems

FAULT CAUSE REMEDY

1 Mains supply voltage is

ON, power indicator is
illuminated however unit
will not commence welding
when the torch trigger
switch is depressed.

2 Mains supply voltage is

ON. Indicator light is not lit
and welding arc cannot be
established.

3 Fault Indicator is illuminated

and unit will not commence
welding when the torch
trigger switch is depressed.

4 Welding output continues

when torch trigger releasedA

5 Welding output voltage

is present when the
torch trigger switch is
depressed but arc cannot be
established.

6 Welding output voltage is

not present when torch
trigger depressed

7 TIG electrode melts when

arc is struck.

8 Arc flutters during TIG

welding.

9 No HF output in HF mode HF Circuit faulty Have an Accredited CIGWELD

A

Power source is not in the
correct mode of operation.

B

Faulty torch trigger.

A BPrimary control fuse is blown.

Broken connection in primary
circuit.

Duty cycle of power source has
been exceeded.

Trigger mode selection is in 4T
(LATCH) mode

B

Torch trigger leads shorted

Poor or no work lead contact. Clean work clamp area and ensure

Faulty trigger switch / lead Repair or replace Torch / trigger

TIG torch is connected to
the (+) VE terminal.
Tungsten electrode is too
large for the welding current.

Table 5-1: Power Source Problem

A

Set the power source to the
correct mode of operation with
the process selection switch.

B

Repair or replace torch trigger
switch/lead.

A BReplace primary control fuse.

Have an Accredited CIGWELD
Service Provider check primary
circuit.

Leave the power source
switched ON and allow it to
cool. Note that fault indicator
must be extinguished prior to
commencement of welding.

A

Change to 2T (NORMAL) mode

B

Repair or replace Torch / trigger
lead

good electrical contact.

lead

Connect the TIG torch to the (-)
VE terminal.
Select the correct size of tungsten
electrode.

Service Provider check HF circuit.

Manual 0-5207 5-1 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS

WELDSKILL 200AC/DC INVERTER

!

5.03 Routine Service and Calibration Requirements

WARNING

There are extremely dangerous voltage and power levels present inside this Inverter Power Source.
Do not attempt to open or repair unless you are an accredited CIGWELD Service Provider. Discon­nect the Welding Power Source from the Mains Supply Voltage before disassembling.

Routine Inspection, Testing & Maintenance

The inspection and testing of the power source and associated accessories shall be carried out in accordance
with Section 5 of AS 1674.2 - 2007: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an
insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with CIGWELD
original specifications.

If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined
in AS 1674.2 - 2007, then the above tests should be carried out prior to entering this location.

A. Testing Schedule

1. For transportable equipment, at least once every 3 months; and

2. For fixed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging,
including the date of the most recent inspection.

A transportable power source is deemed to be any equipment that is not permanently connected and fixed
in the position in which it is operated.

B. Insulation Resistance

Minimum insulation resistance for in-service CIGWELD Inverter Power Sources shall be measured at a
voltage of 500V between the parts referred to in Table 5-2 below. Power sources that do not meet the
insulation resistance requirements set out below shall be withdrawn from service and not returned until
repairs have been performed such that the requirements outlined below are met.

Components to be Tested

Input circuit (including any connected control circuits) to welding circuit
(including any connected control circuits)

All circuits to exposed conductive parts

Welding circuit (including any connected control circuits) to any auxiliary
circuit which operates at a voltage exceeding extra low voltage

Welding circuit (including any connected control circuits) to any auxiliary
circuit which operates at a voltage not exceeding extra low voltage

Minimum Insulation

Resistance (MΩ)

5

2.5

10

1

Separate welding circuit to separate welding circuit

Table 5-2: Minimum Insulation Resistance Requirements: CIGWELD Inverter Power Sources

C. Earthing

The resistance shall not exceed 1Ω between any metal of a power source where such metal is required
to be earthed, and -

1. The earth terminal of a fixed power source; or

2. The earth terminal of the associated plug of a transportable power source

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-2 Manual 0-5207

1

WELDSKILL 200AC/DC INVERTER

Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring
supplying CIGWELD welding power sources should be inspected by a licensed electrical worker in ac­cordance with the requirements below -

1. For outlets/wiring and associated accessories supplying transportable equipment - at least once
every 3 months; and

2. For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12
months.

D. General Maintenance Checks

Welding equipment should be regularly checked by an accredited CIGWELD Service Provider to ensure that:

1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly
connected and in good condition.

2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short
circuit.

3. The Welding System is clean internally, especially from metal filing, slag, and loose material.

E. Accessories

Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be
inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable
condition. All unsafe accessories shall not be used.

F. Repairs

If any parts are damaged for any reason, it is recommended that replacement be performed by an ac­credited CIGWELD Service Provider.

Power Source Calibration

A. Schedule

Output testing of all CIGWELD Inverter Power Sources and applicable accessories shall be conducted at
regular intervals to ensure they fall within specified levels. Calibration intervals shall be as outlined below -

1. For transportable equipment, at least once every 3 months; and

2. For fixed equipment, at least once every 12 months.

If equipment is to be used in a hazardous location or environments with a high risk of electrocution as
outlined in AS 1674.2 - 2007, then the above tests should be carried out prior to entering this location.

B. Calibration Requirements

Where applicable, the tests outlined in Table 5-3 below shall be conducted by an accredited CIGWELD
service provider.

Testing Requirements

Output current (A) to be checked to ensure it falls within applicable CIGWELD power source specifications

Output Voltage (V) to be checked to ensure it falls within applicable CIGWELD power source specifications

Accuracy of digital meters to be checked to ensure it falls within applicable CIGWELD power source specifi­cations

Table 5-3: Calibration Parameters

Periodic calibration of other parameters such as timing functions are not required unless a specific fault
has been identified.

Manual 0-5207 5-3 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS

WELDSKILL 200AC/DC INVERTER

!

C. Calibration Equipment

All equipment used for Power Source calibration shall be in proper working condition and be suitable for
conducting the measurement in question. Only test equipment with valid calibration certificates (NATA
certified laboratories) shall be utilized.

5.04 Cleaning the Welding Power Source

WARNING

There are dangerous voltage and power levels present inside this product. Do not attempt to open
or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source
from the Mains Supply Voltage before disassembling.

To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated
dirt, metal filings, slag and loose material. Keep the shunt and lead screw surfaces clean as accumulated foreign
material may reduce the welders output welding current.

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-4 Manual 0-5207

6.01 Power Source

WELDSKILL 200AC/DC INVERTER

SECTION 6:

KEY SPARE PARTS

15

12

1

13

12

14

7

6

16

8

5

2

3

4

9

11

10

Figure 6-1

A-11226

Manual 0-5207 6-1 KEY SPARE PARTS

WELDSKILL 200AC/DC INVERTER

WeldSkill 200AC/DC Spare Parts

Item Part Number Description

1 W7005500 PCB display
2 W7005502 PCB HF
3 W7005503 PCB aux power supply
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

13 W7003036 Control socket 8 pin, (Note that 8 pin control plug part number is

14 W7005514 Gas outlet, front panel
15 W7005515 Switch On/Off
16 W7003076 CT, output
17 704461 Dinse plug male 50mm² (not shown)

W7005513 Dinse Socket 50mm²

UOA706900)

Table 6-1

KEY SPARE PARTS 6-2 Manual 0-5207

WELDSKILL 200AC/DC INVERTER

APPENDIX: CIRCUIT DIAGRAM

A-11227

Manual 0-5207 A-1 APPENDIX

CIGWELD - LIMITED WARRANTY TERMS

LIMITED WARRANTY: CIGWELD Pty Ltd, A Thermadyne Company, hereafter, “CIGWELD” warrants to custom­ers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship
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 CIG­WELD 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 2012

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 war­ranties 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, warran­ties, 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 2012

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.

WELDSKILL 200AC/DC POWER SOURCE

Original main power magnetics.

Original main power rectifiers, printed circuit boards and power switch
semiconductors.

All other circuits and components including, but not limited to, relays, switches,
contactors, solenoids, fans and electric motors.

ACCESSORIES WARRANTY PERIOD

TIG torch, electrode holder lead and work lead.

TIG torch consumable items.

Gas regulator/flowmeter (excluding seat assembly, pressure gauges, elastomer
seals and “O” rings).
Regulator seat assemblies and pressure gauges.

Elastomer seals and “O” rings used in the equipment.

Please note that the information detailed in this statement supersedes any prior published data produced by
CIGWELD.

WARRANTY PERIOD

PARTS LABOUR

1 Year 1 Year
1 Year 1 Year

1 Year 1 Year

3 Months

NIL

1 Year

6 Months
3 Months

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

CIGWELD, Australia

71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

Thermadyne USA

2800 Airport Road
Denton, Tx 76207 USA
Telephone: [phone]
800-426-1888
Fax: [phone]
Email: [e-mail]

Thermadyne Canada

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Thermadyne, China

RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: [phone]
Fax: [phone]

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085

Thermadyne Italy

OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: [phone]
Fax: [phone]

Thermadyne Europe

Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: [phone]
Fax: [phone]

PT. Thermadyne Utama Indonesia

Jl. Angsana II Blok AE No. 28
Delta Silicon I, Cikarang - Sukaresmi
Bekasi, 17550
Indonesia
Tel: [phone]
Fax: [phone] / 1867
http://www.thermadyne.com

Thermadyne International

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Asia Pacific Regional Headquarters

71 Gower Street
Preston, Victoria, Australia, 3072
Telephone: [phone]
FAX:
Email: [e-mail]

[phone]

www.thermadyne.com.au