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CIGWELD WeldSkill 200AC/DC User Manual

CIGWELD WeldSkill 200AC/DC
88 pages
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A-11419
Service Manual
Revision: AC Issue Date: April 23, 2015 Manual No.: 0-5206
Operating Features:
200AC/DC
INVERTER
ARC WELDING MACHINE

Table of Contents

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CIGWELD WeldSkill 200AC/DC Specifications

General IconGeneral
BrandCIGWELD
ModelWeldSkill 200AC/DC
CategoryWelding System
LanguageEnglish

Summary

Safety Instructions and Warnings

Arc Welding Hazards

Details potential hazards associated with arc welding processes, including electric shock and arc ray exposure.

Principal Safety Standards

Lists key safety standards and regulations relevant to welding equipment operation and safety.

Declaration of Conformity

States the equipment's compliance with relevant Australian and international standards and directives.

Symbol Chart

Provides a visual reference for symbols used on the equipment and in the manual.

Servicing Hazards

Highlights safety precautions and hazards specific to testing, maintaining, and repairing the equipment.

EMF Information

Discusses electromagnetic field considerations and precautions for safe operation.

Introduction

How to Use This Manual

Explains how to navigate and interpret the manual's structure, warnings, and notations.

Equipment Identification

Guides users on locating and recording the unit's identification numbers for reference.

Receipt of Equipment

Provides instructions for inspecting the equipment upon receipt and handling potential shipping damage.

Description

Details the CIGWELD WeldSkill 200AC/DC inverter's capabilities and features.

Transportation Methods

Outlines safe procedures for moving the welding power source.

Safety and Installation

Duty Cycle

Explains the concept of duty cycle and its relation to welding current and temperature limits.

Specifications

Lists the technical specifications, part numbers, dimensions, and electrical requirements of the welder.

Environment

Defines suitable operating environments and precautions for increased hazard of electric shock.

Location

Provides guidelines for selecting an appropriate and safe location for the welding machine.

High Frequency Introduction

Emphasizes the importance of correct installation for high frequency welding equipment.

High Frequency Interference

Discusses how interference can be transmitted and how to minimize it.

Electromagnetic Compatibility

Details user responsibilities and methods for reducing electromagnetic emissions.

Volt-Ampere Curves

Illustrates the maximum voltage and amperage output capabilities of the welding power source.

Operation

Power Source Controls, Indicators and Features

Identifies and describes the front and rear panel controls, indicators, and features of the welder.

Stick Programming Mode

Explains how to select and use the STICK welding mode and its programming functions.

Lift TIG and HF TIG Programming Mode

Details the selection and use of LIFT TIG and HF TIG modes and their programming parameters.

Short Circuit Protection While Welding

Describes the circuitry that protects the TIG tungsten electrode from short circuits.

Shielding Gas Regulator Operating Instructions

Provides safety procedures and user responsibilities for operating shielding gas regulators.

Setup for TIG (GTAW) Welding

Guides users on connecting and setting up the welding machine for TIG welding.

Foot Control (Optional Accessory)

Explains the installation and operation of the optional foot control for current adjustment.

Setup for STICK (MMAW) Welding

Guides users on connecting and setting up the welding machine for STICK welding.

Theory of Operation

Inverter Design

Explains the fundamental principles and technology behind inverter power supplies.

Troubleshooting

Basic Troubleshooting - Power Source Faults

Provides a table of common faults, possible causes, and remedies for power source issues.

Advanced Troubleshooting

Guides on using common tools and safety precautions for advanced troubleshooting.

Test Equipment and Tools

Lists essential test equipment and tools required for diagnosing and repairing the unit.

Visual Inspection

Describes how to conduct a visual inspection of internal components for damage or faults.

DC Bus Measurement of Main Inverter Board

Details procedures for measuring DC bus voltage on the main inverter board.

Main Inverter Board Checks

Covers preliminary checks for IGBTs and PTC components on the main inverter board.

Input Rectifier Check

Outlines steps to check the input rectifier using a multimeter.

DC Bus Voltage Measurement

Explains how to measure DC bus voltage after applying power.

PCB Connectors

Provides pin functions for EMC filter PCB connectors.

DIP Switch Settings, Control PCB

Details the function of DIP switch SW0 on the control PCB for various settings.

Calibration

Describes the procedure for calibrating output voltage and amperage.

Main Circuit Description

Provides a technical overview of the main circuit's operation and components.

Circuit Diagram

Presents the overall circuit diagram of the welding power source.

Disassembly Procedure

Safety Precautions for Disassembly

Lists essential safety precautions to follow before disassembling the unit.

Case Removal

Details the steps required to remove the outer casing of the welding machine.

Control Board Removal

Provides step-by-step instructions for disconnecting and removing the main control PCB.

Auxiliary Power Supply PCB2 Removal

Guides on disconnecting and removing the auxiliary power supply PCB2.

PCB3 Removal

Details the process for removing PCB3, including harness disconnections.

PCB4 Removal

Outlines the steps for removing PCB4, including screw and wire disconnections.

PCB5 Removal

Describes the procedure for removing PCB5, involving screw removal.

Front Panel Assembly Removal

Explains how to remove the front panel assembly, including terminals and wires.

Front Panel (Operator Interface) PCB Removal

Details the removal of the operator interface circuit board from the front panel.

Back Panel Removal

Guides on how to remove the back panel, including screws and gas inlet.

Main Power PCB1 Removal

Provides instructions for removing the main power PCB1, including screws and harnesses.

Main Power PCB2 Removal

Details the procedure for removing the main power PCB2, including screws and harnesses.

Power Switch, Fan, and Power Cord Removal

Explains how to remove the power switch, cooling fan, and power cord.

Assembly Procedures

Installing Main Power PCB1

Instructs on installing screws, wires, and harnesses for Main Power PCB1.

Installing Main Power PCB2

Details installing screws, wires, harnesses, and the base plate for Main Power PCB2.

Installing Front Panel

Guides on reinstalling output terminals, ground wire, gas outlet hose, and screws for the front panel.

Installing Rear Panel

Provides instructions for reinstalling the ON/OFF switch, power cable, fan, and power cord.

Installing PCB5

Details the process of installing wires and securing PCB5 with screws.

Installing PCB4

Guides on installing screws, wires, and reconnecting yellow wires for PCB4.

Installing PCB3

Explains how to install PCB3, including studs, screws, and harness connections.

Installing Auxiliary Power Supply PCB2

Details installing studs, harnesses, and glue for the Auxiliary Power Supply PCB2.

Installing Control Board

Guides on installing screws and plugging in all necessary harnesses for the control board.

Installing Case

Provides steps for installing the ground screw, panel screws, and the outer case.

Key Spare Parts

Power Source Spare Parts

Lists part numbers and descriptions for key spare components of the power source.

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