CIGWELD weldskill 100 Operating Manual Download Page 13

weldskill 100, 135, 150 MiG

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 Operating Manual applies to just specification or 

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

A WARNING gives information regarding 

possible personal injury. 

 CAUTION

A CAUTION refers to possible equipment 

damage.

NOTE 

 A NOTE offers helpful information 

c o n c e r n i n g   c e r t a i n   o p e r a t i n g 

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.
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

Summary of Contents for weldskill 100

Page 1: ...240 V 100 AMP AC 135 AMP DC 150 AMP DC Art A 09010 100 Operating Manual Revision AB Issue Date November 13 2013 Manual No 0 5129 Operating Features weldskill MIG welding machine 135 150...

Page 2: ...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 Br...

Page 3: ...ston Victoria Australia 3072 61 3 9474 7400 61 3 9474 7391 www cigweld com au Copyright 2009 2010 2011 2012 2013 by CIGWELD Pty Ltd All rights reserved Reproduction of this work in whole or in part wi...

Page 4: ...Style Connection WeldSkill 150 MIG Torch 3 5 3 10 Polarity Changeover 3 6 3 11 Installing Minispool 100mm diameter WeldSkill 100 MIG 3 8 3 12 Installing Minispool 100mm diameter WeldSkill 135 and 150...

Page 5: ...c Troubleshooting 5 1 5 05 Welding Problems 5 2 5 06 Power Source Problems 5 5 5 07 Key Spare Parts 5 6 APPENDIX 1 100 MIG CIRCUIT DIAGRAM A 1 APPENDIX 2 135 MIG CIRCUIT DIAGRAM A 2 APPENDIX 3 150 MIG...

Page 6: ......

Page 7: ...lectrical 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 da...

Page 8: ...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 Ar...

Page 9: ...rheating 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 weldi...

Page 10: ...e fueling If possible check and add fuel to cold engine before beginning job 4 Do not overfill tank allow room for fuel to expand 5 Do not spill fuel If fuel is spilled clean up before starting engine...

Page 11: ...sks 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 coi...

Page 12: ...ications The product is designed and manufactured to a number of standards and technical requirements among them are AS NZS CISPR 11 2004 applicable to Industrial Equipment generic emissions and regul...

Page 13: ...ve 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 Operatin...

Page 14: ...se 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 Auxiliar...

Page 15: ...0 Mig gives excellent performance on mild steel stainless steel and aluminium wires with Argon based shielding gases The WeldSkill 150 Mig is supplied ready to weld including a spool of 0 8mm Cigweld...

Page 16: ...act Tip 1 2mm Spare Nozzle Spare Operating Manual 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 witho...

Page 17: ...Amps 41 130 Amps Factory Fitted Supply Plug Rating 10 Amps 10 Amps 15 Amps Effective Input Current I1eff 4 6 Amps 9 7 Amps 11 6 Amps Maximum Input Current I1max 13 Amps 24 3 Amps 27 2 Amps Single Phas...

Page 18: ...Weldskill 100 135 150 MIG 2 6 Introduction This page left blank intentionally...

Page 19: ...on page 2 4 WARNING Any electrical work must be carried out by a qualified Electrical Tradesperson 3 01 Environment These units are designed for use in environments with increased hazard of electric...

Page 20: ...he Faceshield and Lens should be cleaned after use with a soft cloth 3 07 Electromagnetic Compatibility WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Po...

Page 21: ...he 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 equi...

Page 22: ...ontaining any other gas Art A 05087 Figure 3 3 Fit Regulator to Cylinder Regulators fitting to welder Blow out the hose before connecting to the regulator and rear of welding power source to remove du...

Page 23: ...ig torch adaptor and screwing the plastic torch collar clockwise to secure the Mig torch to the Mig torch adaptor To remove the Mig Torch simply reverse these directions 50 Portable Welding Machine MI...

Page 24: ...l 2 FCAW Self shielding Wire no Shielding Gas 2 Reverse Polarity 2 Connected to Neg output terminal 2 Connected to Pos output terminal Exception Check with the MIG Wire Manufacturer for recommended po...

Page 25: ...ng the leads from the terminals and reversing them if necessary Refer to Figure 3 7 4 Replace the polarity terminal knobs Polarity Terminal Knobs Cable to MIG Torch Red Cable Cable to Work Lead Black...

Page 26: ...ence shown below in figure Figure 3 8 1 Minispool 2 Spacer 3 Spring 4 Locking Pin Align and Push in and turn clockwise 90 degrees to secure in place Note Only Minispools of 100mm diameter are suitable...

Page 27: ...sher 2 Minispool 3 Spacer 4 Wingnut Adjustment of this wingnut will control the Mig Wire Spool Brake Clockwise rotation of the wingnut tightens the brake The Brake is correctly adjusted when the spool...

Page 28: ...n place 4 Handispool Ensure that pin on Wire spool hub aligns with hole allocated in Handispool 5 Spacer 6 Wingnut Adjustment of this wingnut will control the Mig Wire Spool Brake Clockwise rotation o...

Page 29: ...ol Power switch to ON With the Mig Torch lead reasonably straight feed the wire through the torch by depressing the trigger switch Fit the appropriate contact tip for the electrode wire size being use...

Page 30: ...lakes and swarf If it is not the cause of slipping the feedroll pressure can be increased by rotating the pressure screw clockwise The use of excessive pressure may cause rapid wear of the feed roller...

Page 31: ...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 NOTE Suitable for Gasless Mi...

Page 32: ...d 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 NOTE Refer to the set up guide located on the inside of the wirefee...

Page 33: ...d 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 NOTE Refer to the set up guide located on the inside of the wirefee...

Page 34: ...d 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 NOTE Refer to the set up guide located on the inside of the wirefee...

Page 35: ...d 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 NOTE Refer to the set up guide located on the inside of the wirefee...

Page 36: ...Weldskill 100 135 150 MIG 3 18 Installation This Page Left Intentionally Blank...

Page 37: ...inates when the Control On Off switch is in the On position and the correct mains voltage is present D Output Voltage Control Switch The Output Voltage Control Switch sets the voltage range of the wel...

Page 38: ...the OFF position C MIG Torch Cable End Port The MIG Torch cable and MIG Torch switch leads are routed through this opening D Work Cable and Clamp Port The work cable and clamp are routed through this...

Page 39: ...orch to the Power Source by pushing the torch connector into the torch adaptor and screwing the plastic torch nut clockwise to secure the torch to the torch adaptor D Work CableandClampPortDinseConnec...

Page 40: ...iding excellent results when used with correct shielding gas Applications include steel gates trailers and general maintenance WS5008 0 8mm Handispool 5kg WS0906 0 6mm Handispool 5kg WS5006 0 8mm Mini...

Page 41: ...k Shielding is obtained through decomposition of the flux within the tubular wire Additional shielding may or may not be obtained from an externally supplied gas or gas mixture The process is normally...

Page 42: ...are controlled by these variables Preselected Variables Preselected variables depend upon the type of material being welded the thickness of the material the weld ing position the deposition rate and...

Page 43: ...e Power source and Wirefeeder setting requires some practice by the operator as the welding plant has two control settings that have to balance These are the Wirespeed control and the welding Voltage...

Page 44: ...Weldskill 100 135 150 MIG 4 8 Operation This Page Intentionally Left Blank...

Page 45: ...the Welding Power Source WARNING Refer to WARNING on page 3 2 To clean the Welding Power Source open the enclosure and use a vacuum cleaner to remove any accumulated dirt metal filings slag and loose...

Page 46: ...not empty and the flow meter is correctly adjusted to 15 litres per minute 2 Gas leaks Check for gas leaks between the regulator cylinder connection and in the gas hose to the Power Source 3 Internal...

Page 47: ...pressure roller adjuster B Swarf can also be produced by the wire passing through an incorrect feed roller groove shape or size C Swarf is fed into the conduit liner where it accumulates thus reducin...

Page 48: ...voltage too low Concave voltage too high A Adjust voltage and current by adjusting the Output Voltage Control Switch positions and the Wirespeed control knob B Wire is wandering B Replace contact tip...

Page 49: ...rd Faulty C Have an Accredited CIGWELD Service Provider investigate the fault 5 Mains supply voltage is ON no wire feed but gas flows from the MIG Torch 135 and 150 Mig when the torch trigger switch i...

Page 50: ...B Printed Circuit Board Faulty B Have an Accredited CIGWELD Service Provider investigate the fault 12 OVERHEAT Indicator is illuminated Power Source Over Heat Protection circuit has operated Cease wel...

Page 51: ...weldskill 100 135 150 MIG Appendix A 1 Art A 09011 WeldSkill 100 MIG Circuit Diagram Appendix 1 100 MIG circuit diagram...

Page 52: ...weldskill 100 135 150 MIG A 2 Appendix Art A 09012_AB WeldSkill 135 MIG Circuit Diagram Trigger Switch Appendix 2 135 MIG circuit diagram...

Page 53: ...weldskill 100 135 150 MIG Appendix A 3 Art A 09013_AB WeldSkill 150 MIG Circuit Diagram Trigger Switch Appendix 3 150 MIG circuit diagram...

Page 54: ...weldskill 100 135 150 MIG A 4 Appendix This page left blank intentionally...

Page 55: ...TIAL 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...

Page 56: ...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 o...

Page 57: ...eserves the right to request documented evidence of date of purchase WARRANTY PERIOD WELDSKILL MIG WELDING POWER SOURCE WeldSkill 100 Mig WeldSkill 135 Mig and WeldSkill 150 Mig 1 year Control P C Boa...

Page 58: ......

Page 59: ...7 261755 Fax 44 1257 224800 Thermadyne Utama Indonesia Kawasan Industri Jababeka JI Jababeka VI Blok P No 3 Cikarang Bekasi 17550 Indonesia Tel 62 21 893 6071 Fax 62 21 893 6067 6068 http www thermady...

Page 60: ...Corporate Headquarters 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 FAX 61 3 9474 7488 Email cigweldsales cigweld com au www cigweld com au...

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