CIGWELD weldskill 100 Operating Manual Download Page 7

weldskill 100, 135, 150 MiG

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 when-

ever the output is on. The input power cir-

cuit 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.

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: ......

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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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