CIGWELD WELDSKILL 200HF User manual

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

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OPERATING MANUAL
200HF

Check out our online registration for the most
up to date competitions and promotions
PROTECT YOUR INVESTMENT
Australia: 1300 654 674 | International Customers: [phone]
Please register your warranty online
immediately after purchase for
complete warranty coverage and to
guarantee your proof of purchase.
http://warranties.cigweld.com.au
FOR YOUR CHANCE TO
WIN
REGISTER YOUR
WARRANTY ONLINE
GREAT PRIZES
R
R
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E
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OPERATING MANUAL 200HF
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 accredited service provider call
Australia: 1300 654 674, International Customers: [phone], or visit
us on the web at www.cigweld.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.
We have made every effort to provide you with accurate instructions,
drawings, and photographs of the product(s) while writing this manual.
However errors do occur and we apologize if there are any contained in
this manual.
Due to our constant effort to bring you the best products, we may make
an improvement that does not get reflected in the manual. If you are ever
in doubt about what you see or read in this manual with the product you
received, then check for a newer version of the manual on our website or
contact our customer support for assistance.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
CIGWELD is a Market Leading Brand of Arc Welding Products for ESAB.
We are a mainline supplier to major welding industry sectors in the Asia
Pacific and emerging global markets including; Manufacturing, Construction,
Mining, Automotive, Engineering, Rural and DIY.
We distinguish ourselves from our competition through market-leading,
dependable products that have stood the test of time. We pride ourselves
on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales
and marketing expertise.
Above all, we are committed to develop technologically advanced products
to achieve a safer working environment for industry operators.
OPERATING MANUAL
200HF

!
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.
CIGWELD WeldSkill 200HF Welding Inverter
Instruction Manual Number 0-5406 for:
Part Number W1008200
Published by:
CIGWELD Pty Ltd
CIGWELD An ESAB Brand
71 Gower Street,
Preston, Victoria, Australia, 3072
Tel: [phone] Fax: [phone]
www.cigweld.com.au
Copyright 2015
CIGWELD Pty Ltd
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.
For Printing Material Specification refer to document 47x1915.
Publication Date: October, 2015
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
i
OPERATING MANUAL
200HF

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 Packaged Item ................................................................................................ 2-3
2.08 Transporting Methods..................................................................................... 2-4
2.09 Duty Cycle....................................................................................................... 2-4
2.10 Specifications ................................................................................................. 2-4
2.11 Optional Accessories ...................................................................................... 2-5
2.11 Optional Accessories (Cont'd) ........................................................................ 2-6
SECTION 3:
INSTALLATION ....................................................................................... 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 Generators ...................................................................................................... 3-1
3.06 Electromagnetic Compatibility ........................................................................ 3-2
SECTION 4:
OPERATION ........................................................................................... 4-1
4.01 Overview......................................................................................................... 4-1
4.02 Power Source Controls, Indicators and Features ............................................ 4-1
SECTION 5:
TIG (GTAW) WELDING............................................................................... 5-1
5.01 Shielding Gas Regulator/Flowmeter Operating Instructions............................ 5-1
5.02 Setup For TIG (GTAW) Welding ...................................................................... 5-4
5.03 TIG (GTAW) Basic Welding Technique ............................................................ 5-6
5.04 TIG (GTAW) Welding Problems....................................................................... 5-8
SECTION 6:
STICK (MMAW) WELDING .......................................................................... 6-1
6.01 Setup For STICK (MMAW) Welding ................................................................ 6-1
6.02 Arc Welding Electrodes................................................................................... 6-2
6.03 Types of Electrodes......................................................................................... 6-2
6.04 Size of Electrode ............................................................................................. 6-3
6.05 Storage of Electrodes...................................................................................... 6-3
6.06 Electrode Polarity............................................................................................ 6-3
6.07 Effects of Arc Welding Various Materials ........................................................ 6-4
6.08 Arc Welding Practice....................................................................................... 6-4
6.09 Welding Position............................................................................................. 6-4

TABLE OF CONTENTS
6.10 Joint Preparations........................................................................................... 6-5
6.11 Arc Welding Technique ................................................................................... 6-6
6.12 The Welder...................................................................................................... 6-6
6.13 Striking the Arc............................................................................................... 6-6
6.14 Arc Length ...................................................................................................... 6-6
6.15 Rate of Travel.................................................................................................. 6-6
6.16 Making Welded Joints..................................................................................... 6-6
6.17 Distortion........................................................................................................ 6-9
6.18 The Cause of Distortion .................................................................................. 6-9
6.19 Overcoming Distortion Effects ........................................................................ 6-9
6.20 Welding Problems ........................................................................................ 6-11
SECTION 7:
ROUTINE SERVICE REQUIREMENTS AND POWER SOURCE PROBLEMS .................... 7-1
7.01 Routine Maintenance & Inspection ................................................................. 7-1
7.02 Cleaning the Welding Power Source ............................................................... 7-1
7.03 Basic Troubleshooting .................................................................................... 7-1
7.04 Power Source Problems ................................................................................. 7-2
SECTION 8: KEY SPARE PARTS .......................................................................... 8-1
8.01 WeldSkill 200HF Key Spare Parts ................................................................... 8-1
CIGWELD - LIMITED WARRANTY TERMS
WARRANTY SCHEDULE – WELDSKILL 200HF INVERTER

OPERATING MANUAL 200HF
Manual 0-5406 1-1 GENERAL INFORMATION
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.
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.

OPERATING MANUAL
200HF
GENERAL INFORMATION 1-2 Manual 0-5406
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.
2. Wear approved safety glasses. Side shields
recommended.
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.
Recommended Protective Filters for Electric Welding
Description of Process Approximate Range of
Welding Current in Amps
Minimum Shade Number of
Filter(s)
Manual Metal Arc Welding - covered
electrodes (MMAW)
Less than or equal to 100 8
100 to 200 10
200 to 300 11
300 to 400 12
Greater than 400 13
Gas Metal Arc Welding (GWAW)
(MIG) other than Aluminium and
Stainless Steel
Less than or equal to 150 10
150 to 250 11
250 to 300 12
300 to 400 13
Greater than 400 14
Gas Metal Arc Welding (GMAW)
(MIG) Aluminium and Stainless Steel
Less than or equal to 250 12
250 to 350 13
Gas Tungsten Arc Welding (GTAW)
(TIG)
Less than or equal to 100 10
100 to 200 11
200 to 250 12
250 to 350 13
Greater than 350 14
Flux-cored Arc Welding (FCAW) -with
or without shielding gas.
Less than or equal to 300 11
300 to 400 12
400 to 500 13
Greater than 500 14
Air - Arc Gouging Less than or equal to 400 12
Plasma - Arc Cutting
50 to 100 10
100 to 400 12
400 to 800 14
Plasma - Arc Spraying — 15
Plasma - Arc Welding
Less than or equal to 20 8
20 to 100 10
100 to 400 12
400 to 800 14
Submerged - Arc Welding — 2(5)
Resistance Welding —Safety Spectacles or eye
shield
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.

OPERATING MANUAL 200HF
Manual 0-5406 1-3 GENERAL INFORMATION
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.
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 air-
supplied 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 contact 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.
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
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.

OPERATING MANUAL
200HF
GENERAL INFORMATION 1-4 Manual 0-5406
4. Never allow a welding electrode to touch any
cylinder.
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.
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 known 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
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.
ABOUT PACEMAKERS:
The above procedures are among
those also normally recommended for
pacemaker wearers. Consult your doctor
for complete information.

OPERATING MANUAL 200HF
Manual 0-5406 1-5 GENERAL INFORMATION
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.

OPERATING MANUAL
200HF
GENERAL INFORMATION 1-6 Manual 0-5406
1.03 DECLARATION OF CONFORMITY
Manufacturer: CIGWELD
Address: 71 Gower St, Preston
Victoria 3072
Australia
Description of equipment: Welding Equipment (MMAW, GTAW) including, but not limited to CIGWELD WeldSkill
200HF inverter and associated accessories.
Serial numbers are unique with each individual piece of equipment and details description, parts
used to manufacture a unit and date of manufacture.
The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive
2006/95/EC) 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:
• IEC 60974-10 applicable to Industrial Equipment - generic emissions and regulations.
• AS 60974.1 / IEC 60974-1 applicable to welding equipment and associated accessories.
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.

OPERATING MANUAL 200HF
Manual 0-5406 2-1 INTRODUCTION
SECTION 2:
INTRODUCTION
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 i 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 un-
crate the unit.
2.01 How To Use This Manual
This Owners Manual only applies to the Part Numbers
listed on page i.
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
Gives information regarding possible
personal injury. Warnings will be
enclosed in a box such as this.
CAUTION
Refers to possible equipment damage.
Cautions will be shown in bold type.
NOTE
Offers helpful information concerning
certain operating procedures. Notes will
be shown in italics
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.
Electronic copies of this manual can also be
downloaded at no charge in Acrobat PDF format by
going to the CIGWELD web site listed below and
clicking on the Literature Library link:
http://www.cigweld.com.au

OPERATING MANUAL
200HF
INTRODUCTION 2-2 Manual 0-5406
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
Single Phase
Three Phase
Three Phase Static
Frequency Converter-
Transformer-Rectifier
Dangerous Voltage
Off
On
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Increase/Decrease
Circuit Breaker
AC AuxiliaryPower
Remote
Duty Cycle
Percentage
Amperage
Voltage
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
AuxiliaryPower
Receptacle Rating-
AuxiliaryPower
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
Metres 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 Tr igger
Operation
2 Step Tr igger
Operation
Art # A-12893

OPERATING MANUAL 200HF
Manual 0-5406 2-3 INTRODUCTION
2.05 Description
The WeldSkill 200HF is a single phase 15 Amp constant
current welding inverter capable of performing 180
Amps in MMAW (Stick) with a maximum electrode
size of 4.0mm and 200Amps in GTAW (non-contact
start HF Tig and touch start Lift Tig).
This welding inverter has a user-friendly control
panel with practical push button operation for mode
selection, clearly visible LED indicators and sturdy
large control knobs that are easy to grip and control
even with your gloves on.
Weighing only 8.2kg and fitted with a convenient
carry strap and robust handle means the 200HF
can easily be thrown over your shoulder and carried
up and down ladders or around awkward areas of
the worksite, making it ideal for remote repair and
maintenance jobs.
This compact, and light-weight unit is a great addition
to the workshop ensuring the ultimate portability in
light TIG fabrication and stainless steel work for the
Tradesman or Maintenance Worker.
The WeldSkill 200HF is supplied standard with
features such as Arc Force, Down Slope Control (2T &
4T), Hot Start, Post Gas Flow and Anti-Stick assisting
you in controlling arc stability and achieving smoother
welding results.
This affordable welding inverter package also comes
with the added convenience of a Tig Torch with remote
current control and a 4 metre twist lock electrode
holder that provides excellent electrode grip and
flexibility as you can weld up to 4m away from the unit.
In addition to its appealing design and functional
features, the 200HF provides the added reassurance
of a high quality welding inverter conforms with
Australian Standard AS 60974.1 and IEC 60974.1 and
is complimented with a 3 year warranty that has been
tested through rigorous 40℃temperature testing,
drop testing, life cycle testing, and IP21S water
ingress testing. Simply plug it into any standard 15
Amp power point and get welding right away!
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 accredited CIGWELD
Distributor.
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 unauthorised
modification from standard specification, faulty
maintenance, damage or improper repair by anyone
other than appropriately qualified persons approved
by CIGWELD.
2.07 Packaged Item
WeldSkill 200HF Inverter (Part No. W1008200)
• WeldSkill 200HF Inverter Power Source
• TIG Torch type 26F with flex head, 4m lead,
trigger switch and remote current control
• TIG Torch Accessory Kit that includes 1.6mm
and 2.4mm tungstens with collets, collet bodies
and No 4, 5 & 6 Alumina Nozzles
• WeldSkill Argon Regulator/Flowmeter
• 4m Lead with Twistlock Electrode Holder
• 4m Lead with Work Clamp
• Shielding Gas Hose Assembly
• Shoulder Strap
• Operating Manual

OPERATING MANUAL
200HF
INTRODUCTION 2-4 Manual 0-5406
2.08 Transporting Methods
These units are 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.
2.09 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 15% duty cycle,
90 amperes at 23.6 volts. This means that it has been
designed and built to provide the rated amperage
(90A) for 1.5 minutes, i.e. arc welding time, out of
every 10 minute period (15% of 10 minutes is 1.5
minutes). During the other 8.5 minutes of the 10
minute period the Welding Power Source must idle
and allowed to cool.
2.10 Specifications
DescriptionWeldSkill 200HF
Plant Part No W1008200
Power Source Dimensions
(excludes handle & gas nipple)
H245mm × W145mm × D420mm
Power Source Mass 8.2 kg
Cooling Fan Cooled
Welder Type HF TIG, Lift TIG and Stick Multi Process Inverter
Power Source
Australian Standard AS 60974.1-2006 / IEC 60974-1
Number of Phases Single Phase
Nominal Supply Voltage 240 VAC ± 10%
Nominal Supply Frequency 50/60 Hz
Welding Current Range - TIG 10 - 200 A
Welding Current Range - Stick 10 - 180 A
Nominal DC Open Circuit Voltage 75 V
Factory Fitted Supply Plug Rating 15 Amps
Effective Input Current (I1eff )
(refer Note 2)
15 Amps
Maximum Input Current (I1max) 33.9 Amps
Minimum Single Phase Generator
Recommendation (refer Note 4)
7.6 kW
(9.5 kVA at 0.8 PF)
STICK (MMAW) Welding Output, 40ºC, 10 min. 180 A @ 20%, 27.2 V
147 A @ 30%, 25.9 V
110 A @ 60%, 24.4 V
90 A @ 100%, 23.6 V
TIG (GTAW) Welding Output, 40ºC, 10 min. 200 A @ 30%, 18.0 V
155 A @ 60%, 16.2 V
130 A @ 100%, 15.2 V
Protection Class IP21S
Table 2-1: Specifications

OPERATING MANUAL 200HF
Manual 0-5406 2-5 INTRODUCTION
NOTE 1
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.
NOTE 2
The Effective Input Current should be used for the determination of cable size & supply
requirements.
NOTE 3
Motor start fuses or thermal circuit breakers are recommended for this application. Check local
requirements for your situation in this regard.
NOTE 4
Minimum Generator Recommendation at the Maximum Output Duty Cycle.
Due to large variations in performance and specifications of different brands and types of
generators, CIGWELD cannot guarantee full welding output power or duty cycle on every brand
or type of generator.
Some small generators incorporate low cost circuit breakers on their outputs. These circuit
breakers usually will have a small reset button, and will trip much faster than a switchboard
type circuit breaker. This may result in not being able to achieve full output or duty cycle from
the power source / generator combination. For this reason we recommend a generator that
incorporates switchboard type circuit breakers.
CIGWELD recommends that when selecting a generator, that the particular power source /
generator combination be adequately trialled to ensure the combination performs to the users
expectations.
NOTE 5
CIGWELD reserves the right to change product performance and specifications without notice.
2.11 Optional Accessories
We recommend genuine CIGWELD products.
The biggest range and best quality with guaranteed performance.
Part Number Description
W4014604 TIG Torch 26F with Flex Head, 4m lead, 50mm Dinse Plug, Trigger Switch and Remote Control
BGSAK2 TIG Torch Accessory Kit for 17, 26 & 18 TIG Torches
210254 WeldSkill Argon Regulator/Flowmeter, 55LPM, 2 Gauge
OTD10/4016 Foot Control with 7.6m lead with 8 pin plug
WS42550 WeldSkill Welding Leadset 4m, 25mm2 cable, 50mm2dinse, 250A Twistlock Electrode Holder
WS53550 WeldSkill Welding Leadset 5m, 35mm2 cable, 50mm2dinse, 400A Twistlock Electrode Holder
Table 2-2

OPERATING MANUAL
200HF
INTRODUCTION 2-6 Manual 0-5406
2.11 Optional Accessories (Cont'd)
TIG Torch Consumables
Part Number Description
BG10N49/R Nozzle Alumina 8mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N48/R Nozzle Alumina 10mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N47/R Nozzle Alumina 11mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N46/R Nozzle Alumina 12.5mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N22/R Collet 1.0mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N23/R Collet 1.6mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N24/R Collet 2.4mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N25/R Collet 3.2mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N30/R Collet Body 1.0mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N31/R Collet Body 1.6mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N32/R Collet Body 2.4mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N28/R Collet Body 3.2mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG57Y02/R Back Cap – Long for 17, 26 & 18 TIG Torches (pkt of 2)
BG57Y04/R Back Cap – Short for 17, 26 & 18 TIG Torches (pkt of 2)
Table 2-3
TIG Electrodes
Part Number Description
699846 Ceriated Electrode 1.6mm x 175mm AC/DC Grey (Pkt of 10)
699847 Ceriated Electrode 2.4mm x 175mm AC/DC Grey (Pkt of 10)
699848 Ceriated Electrode 3.2mm x 175mm AC/DC Grey (Pkt of 10)
Table 2-4
Related Products
Part Number Description
646754 WeldSkill TIG Welding Gloves
646755 WeldSkill Heavy Duty Welding Gloves
454304 WeldSkill Auto Darkening Welding Helmet Fixed Shade 11 Black
454305 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Blue
454314 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Carbon Fibre
454321 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Racer
454322 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Tribal
454323 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 White Carbon
454324 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Oz Flag
Note: CIGWELD Electrodes see page 6-2 and 6-3
Table 2-5

OPERATING MANUAL
200HF
OPERATING MANUAL 200HF
Manual 0-5406 3-1 INSTALLATION
SECTION 3:
INSTALLATION
3.04 Mains Supply Voltage
Requirements
The Mains supply voltage should be within ± 10% of
the rated Mains supply voltage. If actual Mains Supply
Voltage is outside this range Welding Current may
not be available and may cause internal components
to fail.
Refer to Specifications on page 2-4 for Supply Voltage
information.
The Welding Power Source must be:
• Correctly installed, if necessary, by a qualified
electrician.
• Correctly earthed (electrically) in accordance
with local regulations.
• Connected to the correct size power point and
fuse as per the Specifications on page 2-4.
IMPORTANT NOTE
This product has been fitted with a supply
plug as indicated in Section 2.10. Note
that the welding output range applicable
with the fitted supply plug is detailed in
Section 2.10.
!
WARNING
Any electrical work must be carried out by
a qualified Electrical Tradesperson.
3.05 Generators
Refer to Note 4 on page 2-5 for recommendations
when using with a Generator.
3.01 Environment
These units are designed for use in environments with
increased hazard of electric shock.
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.
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
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.
3.03 Ventilation
Since the inhalation of welding fumes can be harmful,
ensure that the welding area is effectively ventilated.

OPERATING MANUAL
200HF
INSTALLATION 3-2 Manual 0-5406
3.06 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 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.
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 974-13 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.
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.
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 it’s 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.