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CIGWELD WELDSKILL 180 Service Manual Download Page 30

SERVICE MANUAL

180

OPERATION 5-2 0-5461

5.02 Arc Welding Electrodes

Metal arc welding electrodes consist of a core wire surrounded by a flux coating. The flux coating is applied

to the core wire by an extrusion process.
The coating on arc welding electrodes serves a number of purposes:
A. To provide a gaseous shield for the weld metal, and preserve it from contamination by the atmosphere

whilst in a molten state.

B.  To give a steady arc by having ‘arc stabilisers’ present, which provide a bridge for current to flow across.
C.  To remove oxygen from the weld metal with ‘deoxidisers’.
D.  To provide a cleansing action on the work piece and a protective slag cover over the weld metal to prevent

the formation of oxides while the metal is solidifying. The slag also helps to produce a bead of the desired

contour.

E. To introduce alloys into the weld deposits in special type electrodes.

5.03 Types of Electrodes

Arc Welding electrodes are classified into a number of groups depending on their applications. There are a

great number of electrodes used for specialised industrial purposes which are not of particular interest for

everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for

welding large diameter pipes, etc.
The range of electrodes dealt 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 Selection Chart

Description

Diameter

Pack

Part No.

Application

Satincraft 13

2.5mm

2.5mm

3.2mm

3.2mm

4.0mm

1kg

2.5kg

1kg

2.5kg

5kg

322135

612182

322136

612183

611184

General purpose electrode suitable for all positional

welding and galvanised steel.

Ferrocraft

12XP

2.0mm

2.0mm

2.5mm

2.5mm

3.2mm

3.2mm

4.0mm

1kg

2.5kg

1kg

2.5kg

1kg

2.5kg

5kg

322128

612231

322129

612232
322138
612233

611234

General purpose, extra performance electrode

recommended for all positional (inc. Vertical down)

welding of mild and galvanised steel.

WeldSkill GP

2.0mm

2.0mm

2.5mm

2.5mm

2.5mm

3.2mm

3.2mm

3.2mm

4.0mm

1 kg

2.5 kg

1 kg

2.5 kg

5 kg

1 kg

2.5 kg

5 kg

5 kg

WEG1020

WEG2520

WEG1025

WEG2525

WEG5025
WEG1032
WEG2532

WEG5032

WEG5040

User-friendly GP electrode for welding thin section

mild and galvanised steels. Excellent for vertical

down fillet welding applications.

Ferrocraft 16

Twincoat

2.5mm
3.2mm
4.0mm

5 kg

5 kg

5 kg

611752

611753

611754

Hydrogen Controlled type offering exceptional AC/DC

performance in all welding positions.

Satincrome

308L-17

2.5mm
3.2mm
4.0mm

2.5 kg
2.5 kg
2.5 kg

611602
611603
611604

Stainless Steel type for 19Cr/10Ni stainless grades

including 201, 202, 301, 302, 303, 304, 304L, 305,

308, etc

Cigweld Electrode Selection Chart continued over page

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Summary of Contents for WELDSKILL 180

Page 1: ...SERVICE MANUAL Version No AA Issue Date February 24 2016 Manual No 0 5461 180 Art A 13053 180 Inverter INPUT SUPPLY OUTPUT CURRENT DC STICK ELECTRODE 4 0mm MAX WARRANTY 2 WARRANTY 3 ...

Page 2: ...e 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...

Page 3: ...00 61 3 9474 7391 www cigweld com au Copyright 2014 2015 2016 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 acciden...

Page 4: ...thereof 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 periodically Malfunctioning or poorly maintained equipment should not be used Parts that are broken missing worn distorted or contaminated should be replaced immediately Should such repair or replacement ...

Page 5: ...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 STICK MMAW WELDING 5 1 5 01 Setup For STICK MMAW Welding 5 1 5 02 Arc Welding Electrodes 5 2 5 03 Types of Electro...

Page 6: ...1 10 02 How to Remove Cover 10 1 10 03 Visually Inspect 10 1 10 04 DC Bus Preliminary Measurement in Inverter PCB 10 2 10 05 IGBTs Preliminary Check in Inverter PCB 10 3 10 06 DC Bus Voltage Measurement in Inverter PCB 10 5 SECTION 11 ADVANCED TROUBLESHOOTING POWER SOURCE 11 1 11 01 Recommendations when Replacing Primary Bridge Rectifier IGBT Secondary Diode 11 1 11 02 Power Source Issues High OCV...

Page 7: ... 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 work ing above floor lev...

Page 8: ...mate 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 ...

Page 9: ...rks can strike 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 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 bulk head or p...

Page 10: ...Welding AndThe 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 Gov ernment Printing Office May 1989 there is now a very large volume of scientific findings based on e...

Page 11: ...mpressed 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 Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard Z87 1 from Ameri can National Standards Institute 1430 Broadway New ...

Page 12: ... 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 ro...

Page 13: ...To Use This Manual This Service 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 at tention to the information provided under these head ings These special annotations are easily recognized as follows N...

Page 14: ...ase 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 Auxiliary Power Receptacle Rating Auxiliary Power Art A 04937 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 S...

Page 15: ...s that are broken missing 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 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 al tered fro...

Page 16: ...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 d...

Page 17: ... Recommendation refer Note 4 7 6 kW 9 5 kVA 0 8 PF STICK MMAW Welding Output 40ºC 10 min 180 A 20 27 2 V 147 A 30 25 9V 110 A 60 24 4 V 90 A 100 23 6 V TIG GTAW Welding Output 40ºC 10 min 180 A 40 17 2 V 150 A 60 16 V 115 A 100 14 6 V Protection Class IP21S Table 2 1 Specifications NOTE 1 Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities ...

Page 18: ...n 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 reco...

Page 19: ...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 ...

Page 20: ...SERVICE MANUAL 180 INTRODUCTION 2 8 0 5461 This Page Intentionally Blank ...

Page 21: ... 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 e...

Page 22: ...l 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 measure ment 7 The time of day that welding or other activities are to be carried out 8 The immunity of other equipment in the en vironment the user shall ensure that other equipment being used in the environment is compatible this may requi...

Page 23: ...e g ship s 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 risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by direct connec tion to the workpiece but in some co...

Page 24: ...SERVICE MANUAL 180 INSTALLATION 3 4 0 5461 This Page Intentionally Blank ...

Page 25: ...ting would vary according to the type of electrode in use The operator should use the welding current range values as a guide then finally adjust the current setting to suit the application 4 02 Power Source Controls Indicators and Features 1 2 3 4 6 5 7 Front Panel Rear Panel Art A 12796 8 Figure 4 1 1 Process Selection Control The process selection control is used to select the desired welding m...

Page 26: ...the electrode manufacturer s information for the correct polarity Welding current flows from the workpiece via this Dinse type terminal to the power source It is essential however that the male dinse type plug is inserted and turned securely to achieve a sound electrical connec tion Do not over tighten CAUTION 1 Loose welding terminal connections can cause overheating and result in the male plug b...

Page 27: ...can be particularly beneficial in helping to overcome this by automatically increasing current when the machine senses a decrease in voltage levels This is a preset feature and is not adjustable 11 Anti Stick Feature Not Shown This feature operates in Stick Manual Arc mode The anti stick feature senses when the electrode sticks and automatically reduces the current to prevent the Stick Electrode f...

Page 28: ...SERVICE MANUAL 180 OPERATION 4 4 0 5461 This Page Intentionally Blank ...

Page 29: ...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 electrical connection WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Mains power supply is switched off CAUTION Remove any packaging mate...

Page 30: ...of electrodes dealt 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 Selection Chart Description Diameter Pack Part No Application Satincraft 13 2 5mm 2 5mm 3 2mm 3 2mm 4 0mm 1kg 2 5kg 1kg 2 5kg 5kg 322135 612182 322136 612183 611184 General purpose elect...

Page 31: ...m Blisterpack 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 action than Castcraft 55 Table 5 1 Types of Electrodes 5 04 Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of weldin...

Page 32: ...so be 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 making preheating of heavy sections necessary to give proper fusion of weld and base metal 5 08 Arc Welding Practice The techniques used for arc welding are almost identical regardless of what ...

Page 33: ...nd to 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 5 10 Gap varies from 1 6mm 1 16 to 4 8mm 3 16 depending on plate thickness Joint Open Square Butt 1 6mm 1 16 max 1 6mm 1 16 Single Vee Butt Joint Not less than 70 Double Vee Butt Joint 1 6mm 1 16 La...

Page 34: ...e arc 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 after the arc is struck to withdraw the electrode so far that the arc is broken again A little practice will soon remedy both of these faults Art A 07696_AC 20 1 6 mm 1 16 Figure 5 11 Striking an a...

Page 35: ...ngle beads laid down in the sequence shown in Figure 5 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 either machined ground or gouged out to remove slag which may be trapped in the root and to prepare a suitable joint for depositing the backing run If a backing bar is used it is not usually necessar...

Page 36: ...l fillet weld Art A 07703 Figure 5 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 of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag The electrode should point up...

Page 37: ...vol ume 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 weld but when it attempts to expand across the weld or along the weld it meets considerable resistance and to fulfil the desire for continued expansion it has to deform plastically that is the m...

Page 38: ...take place in a given welded structure By correct presetting 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 5 22 E Preheating Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion Figure 5 23 shows a simple applica tion By removing the...

Page 39: ... to relieve weld joint of severe stresses or use crack resistance electrodes B Insufficient throat thickness B Travel slightly slower to alloy greater build up in throat C Cooling rate is too high C Preheat plate and cool slowly 3 A gap is 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 sma...

Page 40: ...e welding current C Wrong electrode angle C Adjust angle so the welding arc is directed more into the base metal D Travel speed of electrode is too high D Reduce travel speed of electrode E Scale or dirt on joint surface E Clean surface before welding Art A 05867_AC Lack of inter run fusion Lack of side fusion scale dirt small electrode amperage too low Lack of root fusion Lack of fusion caused by...

Page 41: ...B Reduce the length of the welding arc C Angle of the electrode is incorrect C Electrode should not be inclined less than 45 to the vertical face D Joint preparation does not allow correct electrode angle D Allow more room in joint for manipulation of the electrode E Electrode too large for joint E Use smaller gauge electrode F Insufficient deposit time at edge of weave F Pause for a moment at edg...

Page 42: ...to be 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 suitable tools to remove all slag from corners E Rust or mill scale is preventing full fusion E Clean joint before welding F Wrong electrode for position in which welding is done F Use electrodes desi...

Page 43: ...as can 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 chambers 4 DO NOT use the regulator flowmeter as a control valve When downstream equipment is not in use for extended periods of time shut off the gas at the cylinder valve and release the gas from...

Page 44: ...ly and attach down stream equipment 5 To protect sensitive down stream equipment a separate safety device may be necessary if the regulator flowmeter is not fitted with a pressure relief device Operation With the regulator flowmeter connected to cylinder or pipeline and the adjustment screw knob fully disen gaged pressurize as follows 1 Stand to one side of regulator flowmeter and slowly open the ...

Page 45: ... flowmeter by opening the downstream valve Bleed welding grade shielding gas into a well ventilated area and away from any ignition source Turn adjusting screw counter clockwise until the required flow rate is indicated on the gauge Close downstream valve Shutdown Close cylinder valve whenever the regulator flowmeter is not in use To shut down for extended periods more than 30 minutes 1 Close cyli...

Page 46: ...t all fittings are tight and the gas valve on the TIG torch is turned off Before commencing to TIG weld open TIG torch gas valve to allow sufficient shielding gas flow when welding Refer to Section 6 03 for recommended Shielding Gas flow rates and other TIG Welding information WARNING Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary sup...

Page 47: ...ork Piece 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 6 4 TIG Welding Application Shot Tungsten Electrode Current Ranges Electrode Diameter DC Current Amps 0 040 1 0mm 30 60 1 16 1 6mm 60 115 3 32 2 4mm 100 165 1 8 3 2mm 135 200 5 32 4 0mm 190 280 3 16 4 8mm ...

Page 48: ...tc Table 6 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 45 40 50 20 30 25 35 0 040 1 0mm 1 16 1 6mm 5 7 Butt Corner Lap Fillet 0 045 1 2mm 45 55 50 60 30 45 35 50 0 040 1 0mm 1 16 1 6mm 5 7 Butt Corner Lap Fillet 1 16 1 6mm 60 70 70 90 40 60 50 70 ...

Page 49: ... terminal 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 clogged with dust or dirt C Clean torch D Shielding gas hose is damaged D Replace shielding gas hose E Shielding gas regulator turned off E Turn On Shielding Gas and adjust Shielding Gas flow rate...

Page 50: ...ble 6 3 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 6 5 on page 6 7 D Incorrect shielding gas is being used D Select the correct shielding gas E Poor work clamp connection to work piece E Improve connection to work piece 10 Arc flutters during TIG welding Tungsten electrode is too lar...

Page 51: ... Testing Maintenance The inspection and testing of the power source and associated accessories shall be carried out in accord ance with Section 5 of AS 1674 2 2007 Safety in Welding and Allied Processes Part 2 Electrical This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Cigweld s original specifications If equipment is to be used...

Page 52: ...d wiring supplying Cigweld welding power sources should be inspected by a licensed electrical worker in ac cordance with the requirements below 1 For outlets wiring and associated accessories supplying transportable equipment at least once every 3 months and 2 For outlets wiring and associated accessories supplying fixed equipment at least once every 12 months D General Maintenance Checks Welding ...

Page 53: ...n then check Current Transformer M1 on the primary tap of the main transformer D16 D17 D18 D19 R59 R60 R61 and ribbon cable between PCBs If all components test OK then replace the Control PCB 7 02 Cleaning the Welding Power Source WARNING There are extremely dangerous voltage and power levels present inside this product Do not attempt to open or repair unless you are a qualified electrical tradesp...

Page 54: ...SERVICE MANUAL 180 ROUTINE SERVICE REQUIREMENTS 7 4 0 5461 This Page Intentionally Blank ...

Page 55: ...er supply The AC is then rectified to extremely smooth DC The diagram to the below shows the basic electrical wiring of a DC output inverter power supply Inverter Technology Summary Rectifier Filter IGBT Transformer Rectifier Inductor AC 50 60Hz DC Rippled DC Smooth AC 23KHz AC 23KHz DC Rippled DC Smooth High Voltage High Voltage High voltage High Voltage Low Voltage Low Voltage Low Voltage Low Am...

Page 56: ...THEORY OF OPERATION 8 2 0 5461 SERVICE MANUAL 180 This Page Intentionally Blank ...

Page 57: ...m mains supply voltage Art A 13056 The 240VAC mains supply voltage is connected via a double pole switch to the input rectifiers on the Main Inverter Board through an EMC Filter Circuit on the EMC Board Overvoltage protection is provided by a varistor 20D511K rated at 320VAC 220J in the EMC Board Rectifier B1 output charges the main capacitor bank C4 C5 C6 C8 to a high DC voltage 340VDC once J1 J2...

Page 58: ...stors The auxiliary inductor T2 provides the inductance to the weld current Two thermal overload devices are mounted in this inverter a thermostat fixed to the IGBT heatsink and a NTC Thermistor mounted in transformer T1 When an over temperature occurs the control circuit inhibits the trig gering of the IGBTs which results in zero welding output The yellow thermal overload indicator LED on the fro...

Page 59: ...nel Art A 13057 Remove the three screws that hold the rear panel to the machine two on the top and two at the bottom of the rear panel Move the rear panel approx 10mm away from the machine Slide the cover approx 10mm towards the rear panel then lift up the cover to clear the front panel Be careful when lifting up the cover as an earth is connected between the cover the main earth stud 10 03 Visual...

Page 60: ...an 5VDC before servicing Ensure the mains supply plug is disconnected from 240VAC receptacle Art A 13058 Testpoint No DC Bus Capacitor Test Multimeter Lead Placement Voltage with Supply voltage OFF Multimeter set for DC volts 1 2 C4 C5 C6 C8 Positive red meter lead to testpoint 1 Negative black meter lead to testpoint 2 0 VDC Table 10 1 DC BUS Multimeter set to measure DC volts ...

Page 61: ... IGBT Q2 Negative black meter lead to testpoint 9 Positive red meter lead to testpoint 10 Q2 CE Diode 0 2 0 8 VDC Table 10 2 IGBT s Multimeter set to measure Diode Voltage Testpoint No IGBT Testing Multimeter Lead Placement Testing Diode Voltage VDC Acceptable Results 4 3 IGBT Q4 Negative black meter lead to testpoint 4 Positive red meter lead to testpoint 3 Q4 CE Resistance 150 Ω 6 5 IGBT Q1 Nega...

Page 62: ...e black meter lead to testpoint 15 Positive red meter lead to testpoint 16 D4 anode cathode 0 2 0 8 VDC 17 18 DIODE D14 Negative black meter lead to testpoint 17 Positive red meter lead to testpoint 18 D14 anode cathode 0 2 0 8 VDC 19 20 DIODE D2 Negative black meter lead to testpoint 19 Positive red meter lead to testpoint 20 D2 anode cathode 0 2 0 8 VDC 21 22 DIODE D1 Negative black meter lead t...

Page 63: ...measurement and troubleshooting techniques DO NOTTOUCH ANY LIVE PARTS Once power is applied to the Power Source there are extremely hazardous voltage and power levels present Do not touch any live parts Art A 13058 Testpoint No DC Bus Capacitor Test Multimeter Lead Placement DC Bus Voltage Multimeter set for DC volts 1 2 C5 C6 C8 Positive red meter lead to testpoint 1 Negative black meter lead to ...

Page 64: ...PRELIMINARY TROUBLESHOOTING POWER SOURCE 10 6 0 5461 SERVICE MANUAL 180 This Page Intentionally Blank ...

Page 65: ...ndations B1 DIODE Recommendations D5 D4 D14 D2 D1 If one IGBT fails then all IGBTs should be replaced The Control PCB normally does not need to be replaced if the IGBTs fail If bridge rectifier fails then the Inverter PCB should be replaced If one diode fails then the all diodes should be replaced The Inverter PCB should operate after the diodes are replaced Type IKW50N65H5 Vce 650V Ic 50A Type BR...

Page 66: ...k filter circuit components across the output terminals on Inverter PCB have failed open circuit C13 R14 R15 R16 V3 Component failure in Control PCB Ribbon cable has bad electrical connections A B C D E Disconnect the machine from the Mains Supply Voltage because input voltages greater than 276VAC will cause component failures with this machine Replace defective components Replace defective compon...

Page 67: ...ts Disconnect the machine from the Mains Supply Voltage because input voltages greater than 276VAC will cause component failures with this machine 8 Excessive welding current is supplied to the welding arc i e welding current can t be controlled by the Amperage Control on front panel A No DC current feedback signal on JP1 pins 14 7 from the Control PCB If no signal then check Current Transformer M...

Page 68: ...OOTING POWER SOURCE 11 4 0 5461 SERVICE MANUAL 180 11 03 Power Indicator Not ON or No Output Power from Machine Art A 13047 Does fan operate constantly after power on or CN1 has 24VDC Is LED1 in Inverter PCB on flashing ...

Page 69: ...0 5461 11 5 ADVANCED TROUBLESHOOTING POWER SOURCE SERVICE MANUAL 180 11 04 IGBT Control IC Voltage Checks in Control PCB Art A 13048 Control PCB must have a fault not covered by the above tests ...

Page 70: ...ICE MANUAL 180 11 05 Over Temperature Indicator ON No Output from Machine Art A 13049 Is the IGBT heatsink thermostat contacts open circuit at 25C contacts should be normally closed Replace IGBT heatsink thermostat with normally closed contacts 50 5 KΩ 25C ...

Page 71: ... the Ther mostat mounted to the IGBT heatsink 0 VDC 2 Lead 2 from the normally closed contacts of the Ther mostat mounted to the IGBT heatsink 0 VDC closed contacts 5 VDC open contacts Table 12 2 CN2 Header pin function connects Thermostat on IGBT heatsink to Inverter PCB CN3 Header Pin Pin function Signal 1 Lead 1 from the NTC thermistor mounted in the main transformer 0 VDC Tr 1 closed 5 VDC Tr ...

Page 72: ...unction connects to MB header on control PCB Power Terminal Name Pin function Signal P1 Active 240 VAC connection 6 35mm QC tab to soft start circuit 240 VAC P8 Active 240 VAC connection 6 35mm QC tab from soft start circuit 240 VAC DC Rectified DC Mains voltage from EMC Rectifier PCB 340VDC DC Rectified DC Mains voltage from EMC Rectifier PCB 0VDC EARTH tab Mains Earth connection to Mains Earth s...

Page 73: ...ermostat signal from Inverter PCB 2 5 VDC Tr 1 closed 5 VDC Tr 1 open 9 OUTA IGBT 1 2 3 4 PWM drive signal 15V p p square wave signal 15 VDC pk 10 OUTB IGBT 1 2 3 4 PWM drive signal 15V p p square wave signal 15 VDC pk 11 Vcc A 15V supply 15 VDC 12 5V supply to Inverter PCB 5 VDC 13 PEAK IFB Primary current feedback signal from Inverter PCB 14 PEAK IFB Primary current feedback signal from Inverter...

Page 74: ...0VDC P7 DC voltage out of the bridge rectifier 0VDC Table 12 8 Power Terminal function connects to EMC PCB Input Bridge Rectifier Check in EMC PCB Testpoint No Input Rectifier Testing Multimeter Lead Placement Testing Diode Voltage P5 P1 DC to AC Negative black meter lead to P5 Positive red meter lead to testpoint P1 cathode anode 0 2 0 8 VDC P5 AC4 1 DC to AC Negative black meter lead to P5 Posit...

Page 75: ...S 13 01 WeldSkill 180 Key Spare Parts 1 3 4 2 Art A 12800_AB Figure 13 1 WELDSKILL 180 POWER SOURCE KEY SPARE PARTS ITEM PART NUMBER DESCRIPTION 1 W7006824 PCB Power Inverter 2 W7006825 PCB Front Panel 3 W7006826 PCB Primary Rectifier EMC Filter 4 W7006809 Fan Assembly Table 13 1 ...

Page 76: ...KEY SPARE PARTS 13 2 Manual 0 5461 SERVICE MANUAL 180 This Page Intentionally Blank ...

Page 77: ... WARRANTY 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 THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to t...

Page 78: ...f CIGWELD is authorized to change this warranty in any way or grant any other warranty and CIGWELD shall not be bound by any such attempt Correction of non conformities in the manner and time provided herein constitutes fulfilment of CIGWELD s obligations to purchaser with respect to the product This warranty is void and seller bears no liability hereunder if purchaser used replacement parts or ac...

Page 79: ...SERVICE MANUAL 180 This Page Intentionally Blank ...

Page 80: ...s 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 6092 2988 Fax 60 3 6092 1085 Indonesia JL Akasia II Blok A 05 No 10A Delta Silicon Lippo Cikarang Bekasi 17550 Indonesia Toll Free 0 800 1842 867 Tel 62 21 8990 6095 Fax 62 21 8990 6096 ...

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