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CIGWELD WeldSkill 155 Operating Manual Download Page 1

Version No: 

AB  

Issue Date: 

07-09-2017   

Manual No: 

0-5492

Art # A-13435_AB

155 Inverter W1008155

185 Inverter W1008185

OUTPUT CURRENT

DC

OUTPUT CURRENT

DC

STICK

ELECTRODE

3.2mm MAX

STICK

ELECTRODE

4.0mm MAX

WARRANTY*

2

WARRANTY*

2

155A

185A

MIG

Summary of Contents for WeldSkill 155

Page 1: ...e Date 07 09 2017 Manual No 0 5492 Art A 13435_AB 155 Inverter W1008155 185 Inverter W1008185 OUTPUT CURRENT DC OUTPUT CURRENT DC STICK ELECTRODE 3 2mm MAX STICK ELECTRODE 4 0mm MAX WARRANTY 2 WARRANT...

Page 2: ...ffort 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 receiv...

Page 3: ...91 www cigweld com au Copyright 2017 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...

Page 4: ...hereof contained in this manual and accompanying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked perio...

Page 5: ...g harmonised standard in force within the EEA has been used in the design AS 60974 1 2006 Arc Welding Equipment Welding Power Sources IEC 60974 1 2000 MOD IEC 60974 10 2014 Arc Welding Equipment Part...

Page 6: ...c 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 MIG GMAW WELDING 5 1 5 01 Shielding Gas Regulator Flowmeter Operating Ins...

Page 7: ...ding Problems 6 11 SECTION 7 TIG GTAW WELDING 7 1 7 01 Shielding Gas Regulator Flowmeter Operating Instructions 7 1 7 02 Setup For Lift TIG GTAW Welding 7 3 7 03 TIG GTAW Basic Welding Technique 7 5 7...

Page 8: ...This Page Intentionally Blank...

Page 9: ...rical 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 l...

Page 10: ...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...

Page 11: ...rike flam mable 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...

Page 12: ...dThe 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 P...

Page 13: ...as 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 Stan dards Sales 178 Rexdale Bou...

Page 14: ...GENERAL INFORMATION 1 6 0 5492 This Page Intentionally Blank...

Page 15: ...is 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...

Page 16: ...er AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptac...

Page 17: ...issing plainly worn distorted or contaminated should be replaced immediately Should such repairs or replace ments become necessary it is recommended that such repairs be carried out by appropriately q...

Page 18: ...ustralian Standard AS 60974 1 2006 IEC 60974 1 AS 60974 1 2006 IEC 60974 1 Number of Phases Single Phase Single Phase Nominal Supply Voltage 240V AC 15 240V AC 15 Nominal Supply Frequency 50 60 Hz 50...

Page 19: ...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...

Page 20: ...2 1 6mm V groove knurled flux cored 7977036 Feed Roll 0 6 0 8mm V groove hard wires 7977660 Feed Roll 0 9 1 2mm V groove hard wires 7977731 Feed Roll 0 8 0 9mm U groove soft wires 7977264 Feed Roll 1...

Page 21: ...g 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 o...

Page 22: ...INTRODUCTION 2 8 0 5492 This Page Intentionally Blank...

Page 23: ...ads may impact welding performance and operation 3 01 Environment These units are designed for use in environments with increased hazard of electric shock A Examples of environments with increased haz...

Page 24: ...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 measure ment 7 The time of day that welding or other...

Page 25: ...hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the work piece increasing the...

Page 26: ...INSTALLATION 3 4 0 5492 This Page Intentionally Blank...

Page 27: ...sed as a guide only Current delivered to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrode wire welding current at any one settin...

Page 28: ...AC mains power is applied to the power source and the ON OFF switch located on the rear panel is in the ON position 4 Over Temp Indicator This welding power source is protected by a self resetting th...

Page 29: ...lding At times of non welding the digital meter will display a pre set preview value of Wirefeed Speed MPM This value can be adjusted by varying the Wirespeed Control Knob 6 STICK and LIFT TIG Modes T...

Page 30: ...rved between preview values and actual welding values due to factors including the mode of welding differences in consumables gas mixtures individual welding techniques and the transfer mode of the we...

Page 31: ...erative 13 Positive Welding Output Terminal The positive welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the MIG torch via the M...

Page 32: ...gly When in the Local Mode the unit will not detect the remote device and will operate from the power source controls only Note that the trigger will operate at all times on the remote control socket...

Page 33: ...an dangerously propel a loose part 3 DO NOT remove the regulator flowmeter from a cylinder without first closing the cylinder valve and releasing gas in the regulator flowmeter high and low pressure c...

Page 34: ...wmeter connected to cylinder or pipeline and the adjustment screw knob fully disengaged pressurize as follows 1 Stand to one side of regulator flowmeter and slowly open the cylinder valve If opened qu...

Page 35: ...iods more than 30 minutes 1 Close cylinder or upstream valve tightly 2 Open downstream equipment valves to drain the lines Bleed gas into a well ventilated area and away from any ignition source 3 Aft...

Page 36: ...nd spring tighten the brake The brake is correctly adjusted when the spool stops within 10 to 20mm measured at the outer edge of the spool after Mig Torch trigger is released Wire should be slack with...

Page 37: ...outer edge of the spool after Mig Torch trigger is released Wire should be slack without becoming dislodged from the spool CAUTION Overtension of brake will cause rapid wear of mechanicalWIREFEED part...

Page 38: ...secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Figure 5 6 Remove the contact tip from the MIG torch With the MIG Torch lead reasonably straight feed th...

Page 39: ...clockwise WARNING Before changing the feed roller ensure that the mains supply to the power source is switched off CAUTION The use of excessive pressure may cause rapid wear of the feed rollers shaft...

Page 40: ...e Mig torch polarity lead to the positive welding terminal If in doubt consult the wire manufacturer Welding current flows from the Power Source via Dinse terminals It is essential however that the ma...

Page 41: ...of the WeldSkill 155 or WeldSkill 185 Power Source Ensure that the shielding gas hose connection is sufficiently tight at the regulator connection and the quick connect fitting locks into place correc...

Page 42: ...he MIG wire spool onto the spool holder Refer to sections 5 03 for 100mm diameter spools or 5 04 for 200mm diameter spools G Feed wire through the wire drive mechanism Refer to section 5 05 Art A 1344...

Page 43: ...refer to Section 5 01 then connect the shielding gas hose from the shielding gas regulator flowmeter outlet to the quick connect Shielding Gas Inlet fitting gas on the rear of the WeldSkill 185 Power...

Page 44: ...weld thin and fairly thick steels and some non ferrous metals in all positions Art A 8991_AB Shielding Gas Molten Weld Metal Solidified Weld Metal Nozzle Electrode Arc Base Metal GMAW Process Figure...

Page 45: ...e is not energized until the gun trigger switch is depressed The wire may therefore be placed on the seam or joint prior to lowering the helmet Butt Horizontal Welds Direction of Travel 5 to 15 Longit...

Page 46: ...e and the mechanical properties These variables are Type of electrode wire Size of electrode wire Type of gas not applicable to self shielding wires FCAW Gas flow rate not applicable to self shielding...

Page 47: ...ozzle Axes Art A 08998_AB Longitudinal Angle Axis of Weld Transverse Angle Figure 5 22 Art A 08999_AC Nozzle Angle Right Handed Operator Direction of Gun Travel Leading or Pushing Angle Forward Pointi...

Page 48: ...t level A satisfactory weld cannot be obtained if the Wirespeed and Voltage settings are not adjusted to suit the electrode wire diameter and the dimensions of the work piece If the Wirespeed is too h...

Page 49: ...8mm Handispool 4 5kg WG4508 0 9mm Minispool 0 9kg WG0909 0 9mm Handispool 4 5kg WG4509 AUTOCRAFT 316LSI SOLID STAINLESS STEEL MIG WIRE 0 8mm Minispool 1kg 721285 General purpose all positional stainl...

Page 50: ...y 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 gas hose...

Page 51: ...the wire passing through the feed roller when excessive pressure is applied to the pressure roller adjuster B Swarf can also be produced by the wire passing through an incorrect feed roller groove sh...

Page 52: ...t tip C Incorrect shielding gas C Check shielding gas D Insufficient or excessive heat input D Adjust the wirespeed control or the voltage control 6 Weld cracking A Weld beads too small A Decrease tra...

Page 53: ...lt the electrode manufac turer Welding current flows from the power source via Dinse type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electr...

Page 54: ...alt with in this publication will cover the vast majority of applications likely to be encountered are all easy to use and all will work on even the most basic of welding machines CIGWELD Electrode Se...

Page 55: ...terpack 4 0mm 2 5 kg 2 5 kg Blisterpack 2 5 kg 611732 611733 322217 611734 Soft Ductile Nickel type electrode for repair and maintenance welding of a wide range of cast irons It has better wetting act...

Page 56: ...experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron D Copper and alloys The most important factor is the high rate of heat conductivity of copper...

Page 57: ...produce sound joints In general surfaces being welded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 6 10...

Page 58: ...is established maintain a 1 6mm to 3 2mm gap between the burning electrode end and the parent metal Draw the electrode slowly along as it melts down Another difficulty you may meet is the tendency aft...

Page 59: ...eads laid down in the sequence shown in Figure 6 13 The width of weave should not be more than three times the core wire diameter of the electrode When the joint is completely filled the back is eithe...

Page 60: ...et weld Art A 07703 Figure 6 18 Examples of vertical fillet welds 2 Vertical Down The Ferrocraft 21 electrode makes welding in this position particularly easy Use a 3 2mm electrode at 100 amps The tip...

Page 61: ...e of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions It is able to do this freely at right angles to the surface of the plate i e through the...

Page 62: ...lace in a given welded structure By correct pre setting of the components to be welded constructional stresses can be made to pull the parts into correct alignment A simple example is shown in Figure...

Page 63: ...left by failure of the weld metal to fill the root of the weld A Welding current is too low A Increase welding current B Electrode too large for joint B Use smaller diameter electrode C Insufficient g...

Page 64: ...filled by the weld metal undercut A Welding current is too high A Reduce welding current B Welding arc is too long B Reduce the length of the welding arc C Angle of the electrode is incorrect C Electr...

Page 65: ...trapped C If very bad chip or grind out irregularities D Lack of penetration with slag trapped beneath weld bead D Use smaller electrode with sufficient current to give adequate penetration Use suitab...

Page 66: ...STICK MMAW Welding 6 14 0 5492 This Page Intentionally Blank...

Page 67: ...dangerously propel a loose part 3 DO NOT remove the regulator flowmeter from a cylinder without first closing the cylinder valve and releasing gas in the regulator flowmeter high and low pressure cham...

Page 68: ...ollows 1 Stand to one side of regulator flowmeter and slowly open the cylinder valve If opened quickly a sudden pressure surge may damage internal regulator flowmeter parts 2 With valves on downstream...

Page 69: ...connect the TIG torch trigger switch and remote current control if applicable via the 8 pin socket located on the front of the Power Source The TIG torch will require a trigger switch to weld in LIFT...

Page 70: ...ing Terminal TIG Torch Positive Welding Terminal Mig Torch Polarity Lead not connected Work Lead Shielding Gas Cylinder Shielding Gas Regulator Flowmeter Figure 7 3 Setup For Lift TIG GTAW Welding for...

Page 71: ...ce Can Be Any Commercial Metal Gas Cup Either Ceramic High lmpact or Water Cooled Metal Inert Gas Shields Electrode and Weld Puddle Tungsten Electrode Non Consumable Art A 09658_AC Figure 7 5 TIG Weld...

Page 72: ...e 7 4 Base Metal Thickness DC Current for Mild Steel DC Current for Stainless Steel Tungsten Electrode Diameter Filler Rod Diameter if required Argon Gas Flow Rate Litres min Joint Type 0 040 1 0mm 35...

Page 73: ...al A Connect torch lead to negative welding terminal B No shielding gas flowing to welding region B Check the shielding gas lines for kinks or breaks and shielding gas cylinder contents C Torch is clo...

Page 74: ...Cigweld Tungsten Electrode Selection Chart C Shielding gas flow rate is too high C Select the right shielding gas flow rate for the welding job Refer to Table 7 5 on page 7 7 D Incorrect shielding ga...

Page 75: ...inside this product Do not attempt to open or repair unless you are a qualified electrical tradesperson Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling To clean...

Page 76: ...icator on the front panel is illuminated however the power source will not STICK weld A Power source is not in the correct mode of operation A Set the power source to STICK mode Refer to Section 4 02...

Page 77: ...ct feed roll for MIG wire type being used Refer to section 2 11 for optional feed rolls available and Section 5 07 for feed roll fitting details WeldSkill 185 only B Pressure Roller Arm is not secured...

Page 78: ...nder D Replace gas cylinder 11 Gas flow continues after the torch trigger switch has been released MIG mode Gas valve has jammed open due to impurities in the gas or the gas line Have an accredited CI...

Page 79: ...1 WELDSKILL 155 POWER SOURCE KEY SPARE PARTS ITEM PART NUMBER DESCRIPTION 1 W7006865 PCBA Power Inverter 2 W7006866 PCBA Front Panel 3 W7006806 PCBA EMC Filter 4 W7006867 Fan Assembly 5 W7006868 Wire...

Page 80: ...185 POWER SOURCE KEY SPARE PARTS ITEM PART NUMBER DESCRIPTION 1 W7006880 PCBA Power Inverter 2 W7006881 PCBA Front Panel 3 W7006806 PCBA EMC Filter 4 W7006867 Fan Assembly 5 W7006868 Wire Drive Assemb...

Page 81: ...35 R Contact Tip 0 9mm OTW11 40 R Contact Tip 1 0mm OTW11 45 R Contact Tip 1 2mm 3 W6000606 Diffuser 4 W6000607 Conductor Tube 5 W6000608 Trigger Assembly 6 W6000609 Handle Mouldings includes handle m...

Page 82: ...KEY SPARE PARTS 9 4 0 5492 This page is intentionally blank...

Page 83: ...MIG LED2 TIG LED3 STICK LED4 VR1 VR2 VR3 K2 1 2 H1 CN11 1 2 1 2 CN7 1 2 3 CN3 Q5 1 2 CN6 T r1 24V 1 2 CN10 VR4 CN12 1 2 3 CN13 1 2 3 CN4 1 2 3 1 2 3 4 CN8 Hall Connect to CN8 Hall Red Yellow Blue Bla...

Page 84: ...2 VR3 K1 K2 1 2 H1 CN11 1 2 1 2 3 4 5 6 7 8 H2 1 2 CN7 1 2 3 CN3 Q5 1 2 CN6 T r1 24V 1 2 CN10 VR4 1 2 3 CN1 Filter Circuit S2 3 4 1 2 5 6 WF CN12 1 2 3 CN13 1 2 3 1 2 CN2 CN4 1 2 3 Filter Board 1 2 3...

Page 85: ...ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN CIGWELD S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY CIGWELD PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF T...

Page 86: ...cutting and Oxy fuel torches O rings fuses filters or other parts that fail due to normal wear Note No employee agent or representative of CIGWELD is authorized to change this warranty in any way or...

Page 87: ...This Page Intentionally Blank...

Page 88: ...Tel 61 3 9474 7508 Fax 61 3 9474 7488 cigweld com au Malaysia Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Tel 60 3 609...

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