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ESAB CIGWELD WeldSkill 205AC/DC User Manual

ESAB CIGWELD WeldSkill 205AC/DC
72 pages
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Version No: AA Issue Date: 15-04-2019 Manual No: 0-5555
P/N: W1008205
OUTPUT CURRENT
AC/DC
STICK
ELECTRODE
4.0mm MAX
WARRANTY*
2
WARRANTY*
3
205A
HF

Table of Contents

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ESAB CIGWELD WeldSkill 205AC/DC Specifications

General IconGeneral
BrandESAB
ModelCIGWELD WeldSkill 205AC/DC
CategoryWelding System
LanguageEnglish

Summary

Declaration of Conformity

SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

1.01 Arc Welding Hazards

Essential safety precautions related to electric shock, fire, and personal protection during arc welding.

1.02 Principal Safety Standards

Lists key safety standards and regulations relevant to welding and cutting operations.

SECTION 2: INTRODUCTION

2.01 How To Use This Manual

Guidance on navigating the manual and understanding safety symbols and annotations.

2.02 Equipment Identification

How to locate and record the unit's identification numbers for reference.

2.03 Receipt Of Equipment

Procedures for checking received equipment for completeness and shipping damage.

2.04 Symbol Chart

Explanation of various symbols used on the equipment and in the manual.

2.05 Description

Overview of the WeldSkill 205AC/DC inverter and its capabilities.

2.06 User Responsibility

Outlines the user's role in maintaining and operating the equipment safely and correctly.

2.07 Packaged Item

Lists all components included in the product package.

2.08 Transporting Methods

Safe procedures for moving and transporting the welding power source.

2.09 Duty Cycle

Explanation and graphical representation of the welding power source's duty cycle.

2.10 Specifications

Detailed technical specifications and ratings for the welding power source.

2.11 Optional Accessories

Recommended genuine CIGWELD accessories for enhanced functionality.

SECTION 3: INSTALLATION

3.01 Environment

Guidelines for suitable operating environments, considering electrical shock hazards.

3.02 Location

Recommendations for placing the welder to ensure safe and effective operation.

3.03 Ventilation

Importance of adequate ventilation for removing harmful welding fumes.

3.04 Mains Supply Voltage Requirements

Critical voltage requirements for the mains supply to ensure proper operation.

3.05 High Frequency Introduction

Importance of correct installation to prevent interference from high frequency arcs.

3.06 High Frequency Interference

How high frequency interference can be transmitted and methods to minimize it.

3.07 Generators

Reference for recommendations when using the welder with a generator.

3.08 Extension Leads

Guidance on using extension leads, including recommended size and impact.

3.09 Short Circuit Protection While Welding

Explanation of the built-in circuitry to protect the TIG tungsten electrode.

3.10 Electromagnetic Compatibility

Precautions and user responsibilities for managing electromagnetic compatibility.

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

Description and installation of the optional foot control for welding.

SECTION 4: OPERATION

4.01 Overview

General operating procedures and guidelines for using the welding power source.

4.02 WeldSkill 205AC/DC Power Source Controls and Features

Detailed explanation of all controls, indicators, and features on the power source front panel.

SECTION 5: TIG (GTAW) WELDING

5.01 Shielding Gas Regulator/Flowmeter Operating Instructions

Safety and operating procedures for using shielding gas regulators and flowmeters.

5.02 Setup For TIG (GTAW) Welding

Step-by-step guide for connecting and setting up the TIG torch and gas supply.

5.03 TIG Programming Modes

Explanation of various programming modes and parameters for TIG welding.

5.04 Factory Reset

Procedure to restore all welding parameters to their factory default settings.

5.05 TIG (GTAW) Basic Welding Technique

Fundamental techniques and guidelines for performing TIG welding.

5.06 TIG (GTAW) Welding Problems

Common welding problems encountered in TIG welding and their solutions.

SECTION 6: STICK (MMAW) WELDING

6.01 Setup For STICK (MMAW) Welding

Instructions for connecting the electrode holder and work lead for stick welding.

6.02 STICK Programming Mode

Overview of the programming mode for stick welding and parameter adjustment.

6.03 Arc Welding Electrodes

Explanation of the purpose and composition of arc welding electrode coatings.

6.04 Types of Electrodes

Classification and application guide for various CIGWELD welding electrodes.

6.05 Size of Electrode

Factors influencing electrode size selection for welding.

6.06 Storage of Electrodes

Proper storage guidelines for welding electrodes to maintain quality.

6.07 Electrode Polarity

Guidance on connecting electrodes and work leads for correct polarity.

6.08 Effects of Arc Welding Various Materials

How different metals are affected by arc welding processes.

6.09 Arc Welding Practice

General techniques applicable to arc welding regardless of metal type.

6.10 Welding Position

Information on performing welds in various positions (flat, horizontal, vertical, overhead).

6.11 Joint Preparations

Importance of surface cleaning and joint preparation for sound welds.

6.12 Arc Welding Technique

Basic techniques for beginners learning arc welding.

6.13 The Welder

Advice on posture and comfort for the welder during operation.

6.14 Striking the Arc

Methods for initiating the arc and maintaining proper electrode distance.

6.15 Arc Length

Understanding the impact of arc length on weld quality and heat.

6.16 Rate of Travel

How travel speed affects bead formation and weld quality.

6.17 Making Welded Joints

Techniques for creating butt welds and fillet welds.

6.18 Distortion

Introduction to distortion in welding and factors causing it.

6.19 The Cause of Distortion

Detailed explanation of contraction stresses and metal expansion causing distortion.

6.20 Overcoming Distortion Effects

Methods to minimize or prevent distortion during welding operations.

6.21 Welding Problems

Troubleshooting common issues encountered during stick (MMAW) welding.

SECTION 7: ROUTINE SERVICE REQUIREMENTS AND POWER SOURCE PROBLEMS

7.01 Routine Maintenance & Inspection

Essential checks and maintenance procedures for ensuring equipment safety and performance.

7.02 Cleaning the Welding Power Source

Procedures for cleaning the welding power source to maintain optimal output.

7.03 Basic Troubleshooting

Basic troubleshooting steps that can be performed without specialized equipment.

7.04 Welding Power Source Problems

A table listing common power source faults, their causes, and remedies.

SECTION 8: KEY SPARE PARTS

8.01 WeldSkill 205AC/DC Key Spare Parts

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

8.02 TIG Torch 8m (P/N W4014605) Key Spare Parts

Identification and part numbers for spare parts of the 8m TIG torch.

APPENDIX: WELDSKILL 205AC/DC CIRCUIT DIAGRAM

CIGWELD - LIMITED WARRANTY TERMS

WARRANTY SCHEDULE – WELDSKILL 205AC/DC INVERTERS

Details the warranty periods for the power source and its accessories.

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