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Art # A-09908_AB

WELDSKILL 

250 

Operating Manual

Version No: 

AE

 

 

Issue Date: 

December 27,2013                

Manual No.:

 0-5182

Operating Features: 

MIG WELDING MACHINE 

350

WIREFEEDER (Optional)

4R

Summary of Contents for W1003400

Page 1: ...Art A 09908_AB WELDSKILL 250 Operating Manual Version No AE Issue Date December 27 2013 Manual No 0 5182 Operating Features MIG WELDING MACHINE 350 WIREFEEDER Optional 4R...

Page 2: ...ey 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 Le...

Page 3: ...Plant Optional All Regions Part Number W3000401 Published by CIGWELD Pty Ltd 71 Gower Street Preston Victoria Australia 3072 www victortechnologies com Copyright 2011 2012 2013 by CIGWELD All rights r...

Page 4: ...ptional Accessories 2 8 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 Installation and Users Responsibility 3 2...

Page 5: ...g Terminals Porosity 7 3 7 06 Solving Problems Beyond the Welding Terminals Inconsistent Wire Feed 7 4 7 07 Welding Problems 7 5 7 08 Power Source Wirefeeder Problems 7 6 APPENDIX 1 KEY SPARE PARTS A...

Page 6: ......

Page 7: ...bove floor level 15 Keep all panels and covers securely in place WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultr...

Page 8: ...ring 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...

Page 9: ...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...

Page 10: ...ctor for complete information 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...

Page 11: ...et 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 Standard...

Page 12: ...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...

Page 13: ...t 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...

Page 14: ...se 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...

Page 15: ...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...

Page 16: ...lding Gas Adaptor Operating Manual WeldSkill 350 MIG Plant Part No W1003500 Asia Version WeldSkill 350 MIG Power Source compact MIG Torch MB 36 style Work lead Cylinder Chain 200mm Spool Adaptor Feed...

Page 17: ...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 30 duty...

Page 18: ...00 18 3V 250A 20 26 5V 144A 60 21 2V 112A 100 19 6V Operating Temperature Range 0 C 40 C 0 C 40 C Number of Output Voltage Switch Settings 12 Protection Class IP21S Table 2 1 WeldSkill 250 Specificati...

Page 19: ...350A 30 31 6V 250A 60 26 3V 205A 100 24 4V Operating Temperature Range 0 C 40 C Number of Output Voltage Switch Settings 24 Protection Class IP21S Table 2 2 WeldSkill 350 Specification Table 2 2 Weld...

Page 20: ...l 4R Wirefeeder Specification 2 12 Optional Accessories Part Number Description 7977729 Feed Roll 0 6 0 8mm V Groove hard wire 7977703 Feed Roll 0 9 1 2mm V Groove hard wire 7977346 Feed Roll 1 2 1 6m...

Page 21: ...s power source meets the requirements of IP21S as outlined in AS 60529 This provides adequate protection against solid objects and direct protection from vertical drops as outlined in the aforemention...

Page 22: ...rent return paths which may damage the earth circuits of other equip ment Further guidance is given in IEC 974 13 Arc Welding Equipment Installa tion and use under preparation 3 06 Assessment of Area...

Page 23: ...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 com...

Page 24: ...3 4 Manual 0 5182 weldskill 250 350 INstallation Installation...

Page 25: ...in the ON posi tion and the correct mains voltage is present WARNING When the light is lit the machine is connected to the Mains supply voltage and the internal electrical components are at Mains vol...

Page 26: ...that the male plug is inserted and turned securely to achieve a sound electrical connection 7 NEGATIVE WELDING TERMINAL Negative Welding Terminal Welding current flows from the Power Source via heavy...

Page 27: ...T 12 PIN 1 trigger 2 Motor Positive 24VDC 3 Motor Negative 4 CW of remote wirespeed pot 5 ACW of remote wirespeed pot 6 wiper of 5k remote wirespeed pot 7 trigger 8 solenoid 9 solenoid 10 no connectio...

Page 28: ...uch time as the desired Spot time has elapsed after which the power source will de activate The spot time period is set by the SPOT TIME control A located in the wiredrive compartment LATCH 4T This mo...

Page 29: ...ge Switch is used to purge gas or impurities such as air out of the gas system When the push button switch is pressed the shielding gas flows through the Wirefeed system out of the MIG torch nozzle Th...

Page 30: ...uctions WARNING This equipment is designed for use with welding grade Inert shielding gases only NOTE WeldSkill Argon Regulator Flowmeter is not included in Asia Versions Part Nos W1003400 and W100350...

Page 31: ...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...

Page 32: ...088_AB Figure 4 5 Adjust Flow Rate With the regulator ready for operation adjust working flow rate as follows 1 Slowly turn adjusting screw knob in clock wise direction until the outlet gauge indicate...

Page 33: ...electrode wire If in doubt consult the electrode wire manufacturer E Fit the gas regulator and flowmeter to the gas cylinder then connect the gas hose from the rear of the Power Source to the Flowmet...

Page 34: ...etup Art 0 09923_AD Setup for MIG GMAW Welding with Gas Shielded Shielded MIG Wire Setup for MIG GMAW Welding with Gas Gasless MIG Wire 300mm Wire spool installation 200mm Wire spool installation Figu...

Page 35: ...e feed rollers shafts and bearing 5 02 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking If it is considered necessary adjustmen...

Page 36: ...upplied when using 200mm diameter wire spools Ensure that the drive dog pin engages the mating hole in the wire spool Push the spool securing clip into place to retain the wire spool securely The elec...

Page 37: ...to a minimum pressure that will provide satisfactory WIREFEED without slippage If slipping occurs and inspection of the wire contact tip reveals no wear distortion or burn back jam the conduit liner s...

Page 38: ...mechanical means The WELD SKILL 4R Wirefeeder may fall from a hook mechanical hoist as the small bracket on the handle is not designed to secure a lifting hook mechanical hoist in the corner of the Ha...

Page 39: ...cally however the process may be operated automatically and can be machine operated The process can be used to weld thin and fairly thick steels and some non ferrous metals in all positions Art A 8991...

Page 40: ...helmet with proper filter lenses and use the proper safety equipment CAUTION Do not pull the welding gun back when the arc is established This will create excessive wire extension stick out and make...

Page 41: ...lbes Most of the welding done by all processes is on carbon steel The items below describe the welding variables in short arc welding of 24gauge 0 024 0 6mm to 6 4mm mild sheet or plate The applied te...

Page 42: ...This refers to the position of the welding gun in relation to the joint The transverse angle is usually one half the included angle between plates forming the joint The longitudinal angle is the angl...

Page 43: ...rdly alters the current level but lengthens the arc By decreasing the voltage a shorter arc is obtained with a little change in current level When changing to a different electrode wire diameter diffe...

Page 44: ...WELDSKILL 250 350 BASIC WELDING GUIDE Basic Welding Guide 6 6 Manual 0 5182...

Page 45: ...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 Insulation Resistance Minimum...

Page 46: ...ited Cigweld Service Provider 2 Power Source Calibration Schedule Output testing of all Cigweld Power Sources and applicable accessories shall be conducted at regular intervals to ensure they fall wit...

Page 47: ...rosity within the weld metal Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal Contaminants range fr...

Page 48: ...ith swarf A B C Increased amounts of swarf are produced by the wire passing through the feed roller when excessive pressure is applied to the pressure roller adjuster Swarf can also be produced by the...

Page 49: ...increasing the Voltage Control switch positions 4 Excessive spatter A B Arc voltage too high Arc voltage too low A B Lower voltage by reducing the Voltage Control switch positions or turn the Wirespe...

Page 50: ...lems FAULT CAUSE REMEDY 1 Mains supply voltage is ON Indicator light is not lit and welding arc can not be established A B Primary fuse is blown Broken connection in primary circuit A B Replace primar...

Page 51: ...epair Disconnect gas hose from the rear of Power Source or wirefeeder then raise gas pressure and blow out impurities Turn on Replace cylinder 8 Gas flow continues after the torch trigger switch has b...

Page 52: ...7 8 Manual 0 5182 weldskill 250 350 service Service...

Page 53: ...itch On Off 415V 5 W7004506 Fan Assembly 220V 6 W7004540 Wire Drive Assembly 7 W7004541 Local Remote Switch 8 W7004513 Control Transformer 9 W7004515 Inch Purge Switch 10 W7004518 Switch 2T 4T Spot 11...

Page 54: ...itch On Off 415V 5 W7004506 Fan Assembly 220V 6 W7004540 Wire Drive Assembly 7 W7004541 Local Remote Switch 8 W7004537 Control Transformer 9 W7004515 Inch Purge Switch 10 W7004518 Switch 2T 4T Spot 11...

Page 55: ...2 Art A 10330_AB 3 4 WELDSKILL 4R WIREFEEDER SPARE PARTS WELDSKILL 4R WIREFEEDER SPARE PARTS Seq Part No Description 1 W7004540 Wire Drive Assembly 2 W7004539 Solenoid Valve 36VAC 3 W7004543 Euro Adap...

Page 56: ...eldSkill 250 VA Curve 0 0 5 0 10 0 15 0 20 0 25 0 30 0 35 0 40 0 45 0 50 0 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 Amps Volts Art 0 08731 WeldSkill 350 VA Curve Weldskill 350 VA Curv...

Page 57: ...2 3 CN9 Over heat LED2 Gun T S 1 2 3 4 CN7 17 18 Motor power 2 8 9 10 11 6 7 20A 21A 2 1 7 2 15 25 24 3 4 5 22D 13 14 22C 22A 22B 21B 21C 21D 20B 20C 20D 16 1 0 Burn back 100K VR3 Spot switch 4T 4T 1...

Page 58: ...Gun T S 1 2 3 4 CN7 17 18 Motor power 2 8 9 10 11 6 7 20A 21A 2 1 7 2 15 25 24 3 4 5 22D 13 14 22C 22A 22B 21B 21C 20B 20C 20D 16 1 0 Burn back 100K VR3 Spot switch 4T 4T 1 2 5 3 6 4 Spot switch 30 4...

Page 59: ...50 Manual 0 5182 A 7 Appendix 1 2 3 4 5 Title max Potentiometer Motor Solenoid Valve 1 2 3 4 5 6 7 8 9 10 11 12 P1 mid min 1 2 5 3 4 6 8 7 9 10 11 12 P1 Wirespeed Torch Art A 09928_AB APPENDIX 5 4R WI...

Page 60: ...weldskill 250 350 Appendix Appendix A 8 Manual 0 5182...

Page 61: ...QUENTIAL 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 contrac...

Page 62: ...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...

Page 63: ...LL 250 AND 350 MIG POWER SOURCES WELDSKILL 4R WIREFEEDER PARTS LABOUR Original main power rectifier main power magnetics and control printed circuit boards 1 Year 1 Year All other circuits and compone...

Page 64: ......

Page 65: ...57 224800 PT Victor Technologies Utama Indonesia Jl Angsana II Blok AE No 28 Delta Silicon I Cikarang Sukaresmi Bekasi 17550 Indonesia Tel 62 21 8990 6095 Fax 62 21 8990 6096 1867 http www victortechn...

Page 66: ...Asia Pacific Regional Headquarters 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 FAX 61 3 9474 7391 Email enquiries cigweld com au www cigweld com au...

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