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ESAB Cigweld EasyWeld 160, Operating Manual

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WARNING

Read and understand this entire Manual and your employer’s safety practices before installing, 
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgement, 
the Manufacturer assumes no liability for its use. 

CIGWELD HandyWeld / EasyWeld 160 Welding Inverters
Instruction Manual Number 0-5617 for:
Part Numbers  W1201160 and W1200160

Published by:
CIGWELD Pty Ltd
CIGWELD An ESAB Brand
71 Gower Street,
Preston, Victoria, Australia, 3072
+61 3 9474 7400 

+61 3 9474 7391

www.cigweld.com.au

Copyright 2021
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, accident, or any other cause.

For Printing Material Specification refer to document 47x1915.

Publication Date:  01-10-2021
Revision Date: 09-10-2021           

Record the following information for Warranty purposes:

Where Purchased: 

 ____________________________________

Purchase Date: 

 ____________________________________

Equipment Serial #: 

 ____________________________________

i

EasyWeld / HandyWeld 160

Summary of Contents for Cigweld EasyWeld 160

Page 1: ...al No 0 5617 Art A 14825_AB EasyWeld 160 W1201160 HandyWeld 160 W1200160 OUTPUT CURRENT DC STICK ELECTRODE 3 2mm MAX WARRANTY 2 WARRANTY 1 160A MIG EasyWeld HandyWeld 160 OPERATING MANUAL DIGITAL PRE SETS MIG QUICK SET PLATE THICKNESS CONTROL ...

Page 2: ...ur 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manual If you are ever in doubt about what you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer support for assistance YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators W...

Page 3: ...gweld com au Copyright 2021 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 accident or any other cause For Printing ...

Page 4: ...description 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 ...

Page 5: ...e following has been used in the design AS 1674 2 2007 Safety in welding and allied processes Part 2 Electrical AS 60974 1 2020 Arc Welding Equipment Part 1 Welding Power Sources AS NZS 3760 2010 In service Safety Inspection and Testing of Electrical Equipment EN IEC 60974 1 2018 A1 2019 Arc Welding Equipment Part 1 Welding Power Sources EN 60974 10 2014 A1 2015 Arc Welding Equipment Part 10 EMC r...

Page 6: ...1 3 06 Extension Leads 3 1 3 07 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 MIG GMAW WELDING 5 1 5 01 Shielding Gas Regulator Flowmeter Operating Instructions 5 1 5 02 Attaching the MIG Gun Euro EasyWeld 160 only 5 4 5 03 Installing Minispool 100mm diameter 5 4 5 04 Installing Handispool 200mm diameter...

Page 7: ...g Welded Joints 6 6 6 17 Distortion 6 9 6 18 The Cause of Distortion 6 9 6 19 Overcoming Distortion Effects 6 9 6 20 Welding Problems 6 11 SECTION 7 ROUTINE SERVICE REQUIREMENTS AND POWER SOURCE PROBLEMS 7 1 7 01 Routine Maintenance Inspection 7 1 7 02 Cleaning the Welding Power Source 7 1 7 03 Cleaning the Feed Rolls 7 1 7 04 Basic Troubleshooting 7 1 7 05 Welding Power Source Problems 7 2 SECTIO...

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

Page 9: ...ectrical 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 level 15 Ke...

Page 10: ...ocess Approximate 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 ...

Page 11: ...sparks 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 o...

Page 12: ... AboutWelding 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 base...

Page 13: ...ty 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Natio...

Page 14: ...EasyWeld HandyWeld 160 GENERAL INFORMATION 1 6 0 5617 This Page Intentionally Blank ...

Page 15: ...d its accessories 2 01 How To Use This 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 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 easi...

Page 16: ...tal Arc Welding GMAW Increase 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 Auxiliary Power Receptacle Rating Auxiliary Power Art A 14840 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Pre...

Page 17: ...eace of mind The EasyWeld 160 and HandyWeld 160 provide ex cellent welding performance across a broad range of applications when used with the correct welding con sumables and procedures The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efficiency and quality from the power sources Please read these instructions thoroughly befo...

Page 18: ...t 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...

Page 19: ... VRD On Stick Weld Mode 35V 35V Open Circuit Voltage VRD Off Stick Weld Mode 82V 82V Effective Input Current I1eff refer Note 2 10 Amps 240VAC 9 Amps 230 240VAC Maximum Input Current I1max 27 Amps 240VAC 28 Amps 230VAC 27 Amps 240VAC Minimum Single Phase Gen erator Recommendation refer Note 4 9 0 kVA at 0 8 Power Factor 7 2 kVA at 1 0 Power Factor 9 0 kVA at 0 8 Power Factor 7 2 kVA at 1 0 Power F...

Page 20: ...e right to change product performance and specifications without notice NOTE 6 If an extension lead is required to be used it is recommended to use a minimum size of 1 5mm2 Heavy Duty Extension Lead Longer extension leads may impact welding performance and operation 2 11 Optional Accessories We recommend genuine CIGWELD products The biggest range and best quality with guaranteed performance EasyWe...

Page 21: ...Function Cut Wire Clean Nozzle Remove Hot Nozzle Pick up hold hot welding jobs pieces Remove Contact Tip Cut Trim Spring Steel Liner Long Nose Pliers Mini Hammers to tap out spatter in the nozzle 210254 WeldSkill Argon Regulator Flowmeter 55LPM 2 Gauge W4011501 WeldSkill Welding Equipment Trolley 201030 CutSkill Preset Argon Regulator Flowmeter Vertical Inlet WS41625 WeldSkill Welding Leadset 4m 1...

Page 22: ...elding Helmet Variable Shade 9 13 Tribal 454324 WeldSkill Auto Darkening Welding Helmet Variable Shade 9 13 Oz Flag 454335 WeldSkill Auto Darkening Welding Helmet Variable Shade 9 13 Flaming Skull 454336 WeldSkill Auto Darkening Welding Helmet Variable Shade 9 13 Pink Lady 454332 ProLite Auto Darkening Welding Helmet Variable Shade 9 13 Space 454333 ProLite Auto Darkening Welding Helmet Variable S...

Page 23: ...extension leads 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 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 ...

Page 24: ...cal 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 req...

Page 25: ...n 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 ...

Page 26: ...EasyWeld HandyWeld 160 INSTALLATION 3 4 0 5617 This Page Intentionally Blank ...

Page 27: ... application buy fine tuning the WFS Amps and Volts Trim settings 4 02 Power Source Controls Indicators and Features Art A 14826 1 2 3 4 5 6 7 8 9 10 11 12 13 Figure 4 1 EasyWeld 130 as Pictured 1 Process Selection Control The process selection control is used to select the desired welding mode Three modes are available MIG Gasless FCAW MIG Gas Solid GMAW and STICK MMAW modes Refer to section 5 09...

Page 28: ...otential of serious electric shock such as when changing electrodes The red VRD OFF light illuminates green light is off when the VRD is inactive during welding operation Under this condition the output voltage of the unit will be at welding potential which in most cases may exceed 35V DC 5 Control Knob The EasyWeld HandyWeld models are equipped with a Quick Set Feature This allows the user to sim...

Page 29: ...turn to viewing mode To press the control knob within the 10 seconds digital meter display changes to next item on the menu for adjustment and corresponding LED indicator lights up If there is no operation within the 10 seconds digital meter returns to the last pre set value before welding and corresponding LED indicator lights up STICK Mode In STICK Mode the digital meter is used to display the P...

Page 30: ... is used to connect the welding output of the power source to the work lead Most General Purpose electrodes are connected with work lead to negative Consult 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 that the male dinse type plug is inserted and turned securely to achiev...

Page 31: ...ding machine The strap is designed to be fitted into the sheet metal slot at the rear of the machine and through the plastic horizontal slot at the front panel housing Strap details Overall Length 1 62m 1625mm Width 3 7cm 37mm supplied with a Rubber Shoulder Comforter L 150 x W 50mm and two Plastic Buckles W 45mm x L 31mm Step 1 Being mindful to keep the buckle on the Nylon Strap in the upward fac...

Page 32: ...EasyWeld HandyWeld 160 OPERATION 4 6 0 5617 This Page Intentionally Blank ...

Page 33: ...der 180Amps and a minimum of 18 LPM for welding amperages over 200Amps A lower gas flow will affect the welding quality and cause a porous weld while high gas flow results in bigger consumption of gas The flow rate is measured at the middle of the float ball Art A 14843 Shielding Gas Cylinder Preset Argon Regulator Gas Hose Hose Clamp Gas Inlet Fitting Figure 5 1 Shielding Gas Connection Shielding...

Page 34: ...nder Installation 1 Remove cylinder valve plastic dust seal Clean the cylinder valve outlet of impurities that may clog orifices and damage seats before connecting the regulator flowmeter Crack the valve open then close momentarily pointing the outlet away from people and sources of ignition Wipe with a clean lint free cloth 2 Match regulator flowmeter to cylinder Before connecting check that the ...

Page 35: ...low rate NOTE 5 It may be necessary to re check the shielding gas regulator flowmeter flow rate following the first weld sequence due to back pressure present within shielding gas hose assembly 2 To reduce flow rate allow the welding grade shielding gas to discharge from regulator flowmeter by opening the downstream valve Bleed welding grade shielding gas into a well ventilated area and away from ...

Page 36: ... As delivered from the factory the unit is fitted with a Wire Spool Hub which accepts a Handispool of 200mm diameter In order to fit a Minispool of 100mm diameter assemble parts in the sequence shown below in Figure 5 5 The nut and 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 Gun trigger is release...

Page 37: ...G Wire Spool Brake Clockwise rotation of this nut tightens 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 Gun trigger is released Wire should be slack without becoming dislodged from the spool WARNING Moving Parts can cause injury NOTE This spool hub nut can be removed by unscrewing in an anticlockwise direction an...

Page 38: ...the outlet guide and into the MIG Gun Re secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Figure 5 7 Remove the contact tip from the MIG Gun With the MIG Gun lead reasonably straight feed the wire through the Gun by depressing the trigger switch Fit the appropriate contact tip WARNING Keep hands clear of the contact tip holder while feeding wire throu...

Page 39: ...k for the correct drive tension is to bend the end over of the wire once out the end of the MIG Gun and hold it about 50mm from a piece of wood an insulated object and let it run into the wood The wire should coil up without stopping and slipping at the drive rollers tighten the pressure tension adjustment screw if it slips WOOD Tighten Feed wire to check drive roll pressure Tighten knob enough to...

Page 40: ...d Wires Markings are indicated on the side edge of the feed roll for example 0 8 0 30 0 9 0 35 GROOVE B GROOVE A GROOVE A SIZE GROOVE B SIZE A 09583 Figure 5 10 Dual Groove Feed Roll Art A 14832 Feed Roll Figure 5 11 Changing the Feed Roll 5 08 Wire Reel Brake When fitting the Wire Spool the adjustment of the nut will control the MIG Wire Spool Brake Clockwise rotation of this nut tightens the bra...

Page 41: ...der Refer to sections 5 03 for 100mm diameter spools or 5 04 for 200mm diameter spools F Switch the Power Source On Off switch located on the rear of the Power Source to the On position and ensure the Power indicator on the Front Panel is illuminated G Select MIG Gasless Mode using the Process Selection Control button Refer to section 4 02 1 Page 4 1 H Feed wire through the wire drive mechanism Re...

Page 42: ... Select MIG Gasless Mode Figure 5 15 Select Welding Wire Diameter NOTE Quick Set wire sizes for MIG GASLESS Flux Cored Wire are 0 8mm and 0 9mm diameter Figure 5 16 Select Plate Material Thickness At this point the desired Quick Set settings have been set and the unit is ready for Welding Once the Welding Arc is established the display will show the Welding Current If the user wishes to adjust the...

Page 43: ... selected by first selecting Volts function and then holding the Control Knob depressed for approximately 3 seconds The display will change from the Pre set Volts Value to display the Volts Trim Value The LED Display will show 0 0 when in the factory Quick Set Value for the selected Wire and Plate Thickness If adjustments are made and you are unhappy with the results you can simply return the Volt...

Page 44: ...icator on the Front Panel is illuminated G Select MIG Gas Solid Mode using the Process Selection Control button Refer to section 4 02 1 Page 4 1 H Feed wire through the wire drive mechanism Refer to section 5 05 WARNING Moving Parts can cause injury I Connect the work lead to the negative welding terminal If in doubt consult the wire manufacturer Welding current flows from the Power Source via Din...

Page 45: ...n Control button refer to section 4 02 1 for further information Figure 5 21 Select MIG Gas Mode Figure 5 22 Select Welding Wire Diameter NOTE Quick Set wire sizes for MIG GAS SolidWire are 0 6mm and 0 8mm diameter Figure 5 23 Select Plate Material Thickness At this point the desired Quick Set settings have been set and the unit is ready for Welding Once the Welding Arc is established the display ...

Page 46: ... selected by first selecting Volts function and then holding the Control Knob depressed for approximately 3 seconds The display will change from the Pre set Volts Value to display the Volts Trim Value The LED Display will show 0 0 when in the factory Quick Set Value for the selected Wire and Plate Thickness If adjustments are made and you are unhappy with the results you can simply return the Volt...

Page 47: ...an be used to 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 5 27 FLUX CORED ARC WELDING FCAW This is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a continuous flux filled electrode...

Page 48: ...ery poor weld The electrode wire 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 Longitudinal Angle 90 Transverse Angle Art A 08993 Figure 5 30 Direction of Travel 5 to 15 Longitudinal Angle 30 to 60 Transverse Angle Art A 08994 Figure 5 31 Vertical Fillet...

Page 49: ...sition rate 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 wires FCAW Primary Adjustable Variables These control the process after preselected variables have been found They control the penetration bead width bead height arc stability deposition ra...

Page 50: ... Nozzle Axes Art A 08998_AB Longitudinal Angle Axis of Weld Transverse Angle Figure 5 35 Art A 08999_AC Nozzle Angle Right Handed Operator Direction of Gun Travel Leading or Pushing Angle Forward Pointing Trailing or Pulling Angle Backward Pointing 90 Figure 5 36 Establishing the Arc and Making Weld Beads Before attempting to weld on a finished work piece it is recommended that practice welds be m...

Page 51: ...are required A thinner electrode wire needs more Wire Feed Speed to achieve the same current level A satisfactory weld cannot be obtained if the Wire Feed Speed and Voltage settings are not adjusted to suit the electrode wire diameter and the thickness of the work piece If the Wire Feed Speed is too high for the welding voltage stubbing will occur as the wire dips into the molten pool and does not...

Page 52: ...OLID STAINLESS STEEL MIG WIRE 0 8mm Minispool 1kg 721285 General purpose all positional solid stainless steel wire providing excellent results when used with correct shielding gas Suitable for the general welding of a wide range of stainless steels 300 400 series Please Note A suitable shielding gas is required 0 8mm Handispool 5kg 720288 AUTOCRAFT AL5356 SOLID ALUMINIUM MIG WIRE 0 8mm Minispool 0...

Page 53: ...linder is 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 gas hose in the Power Source Ensure the hose from the solenoid valve to the gun adaptor has not fractured and that it is connected to the gun adaptor 4 Welding in a windy environment Shield ...

Page 54: ...reased amounts of swarf are produced by the wire passing through the feed roll when excessive pressure is applied to the pressure roller adjuster B Swarf can also be produced by the wire passing through an incorrect feed roll groove shape or size C Swarf is fed into the conduit liner where it accumulates thus reducing wire feedability 6 Incorrect or worn contact tip A The contact tip transfers the...

Page 55: ...ing B Replace contact tip C Incorrect shielding gas C Check shielding gas D Insufficient or excessive heat input D Adjust the Wire Feed Speed control or the voltage control 6 Weld cracking A Weld beads too small A Decrease travel speed B Weld penetration narrow and deep B Reduce current and voltage and increase MIG Gun travel speed or select a lower penetration shielding gas C Excessive weld stres...

Page 56: ...MIG GMAW WELDING 5 24 Manual 0 5617 EasyWeld HandyWeld 160 This Page Intentionally Blank ...

Page 57: ...ng current flows from the power source via Dinse type terminals It is essential that the male plug is inserted and turned securely to achieve a sound electrical connection D Select STICK mode with the process selection control refer to section 4 02 01 for further information WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Mains...

Page 58: ...ding except vertical down for use on mild and galvanised steel pipes plates angle iron RHS tubes and grid mesh WeldSkill GP General Purpose Welding 2 0mm 2 0mm 2 0mm 2 5mm 2 5mm 2 5mm 2 5mm 3 2mm 3 2mm 3 2mm 3 2mm 25 Rods 1 0Kg 2 5Kg 20 Rods 1 0Kg 2 5Kg 5 0Kg 15 Rods 1 0Kg 2 5Kg 5 0Kg WEG0220 WEG1020 WEG2520 WEG0225 WEG1025 WEG2525 WEG5025 WEG0232 WEG1032 WEG2532 WEG5032 A user friendly General Pu...

Page 59: ...0 WES316025 WES316125 WES316032 WES316132 WELDSKILL 316L stainless steel electrode has been formulated for the all positional except vertical down fillet and butt welding of stainless steels 316L produces low spatter levels with a smooth running bead Weldskill 316L is suitable for a wide range of Molybdenum bearing stainless steels suitable for the general purpose welding of other Austenitic stain...

Page 60: ...may also 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 6 08 Arc Welding Practice The techniques used for arc welding are almost identical regardless of...

Page 61: ...metal and 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 6 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 ...

Page 62: ... as the 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_AB 20 1 6 mm 1 16 Figure 6 11 Strikin...

Page 63: ... or single beads 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 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 ne...

Page 64: ...ertical fillet 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 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 po...

Page 65: ...small 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...

Page 66: ...n will take place 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 6 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 6 23 shows a simple applica tion By remo...

Page 67: ...y 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 smaller diameter electrode C Insufficient gap C Allow wider gap D Incorrect sequence D Use correct build up sequence Insufficient Gap Incorrect Sequence Art A 05866_AC Figure 6 29 Example of Insufficient Gap or Incorrect Sequence 4...

Page 68: ...as not been 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 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 Elect...

Page 69: ...w slag 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 electrod...

Page 70: ...EasyWeld HandyWeld 160 STICK MMAW Welding 6 14 0 5617 This Page Intentionally Blank ...

Page 71: ...els present 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 the Welding Power Source open the en closure and use a vacuum cleaner to remove any accumulated dirt metal filings slag and loose mate rial Keep the shunt and lead screw surfaces clean as ...

Page 72: ...un is correctly connected to the Euro Style MIG Gun Adaptor Refer to Section 4 02 5 5 02 EasyWeld 160 Only 2 Mains Supply Voltage is On the On Off switch on the rear panel is in the On position and the Power indicator 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 Se...

Page 73: ...he Power Source is repeatedly switched On then Off rapidly or the supply to the Power Source is switched On then Off rapidly If this occurs leave the Power Source On Off switch in the Off position for several minutes to allow the protective device to reset 5 Over Temp Indicator is illuminated in addition to E01 showing on Digital Display and the unit will not commence welding when the gun trigger ...

Page 74: ...down position or not correctly adjusted E Secure Pressure Roller in the down position and ensure that it is correctly adjusted Refer to Section 5 05 and 5 06 9 No gas flow in MIG mode A Gas hose is damaged A Replace or repair B Gas passage contains impurities B Disconnect gas hose from the rear of power source or wirefeeder and blow out impurities C Machine set in MIG Gasless mode C Set Machine to...

Page 75: ...0 POWER SOURCE KEY SPARE PARTS ITEM PART NUMBER DESCRIPTION 1 W7007250 Control Knob 2 W7007251 PCBA Display 3 W7007252 Euro MIG Gun Adaptor EasyWeld 160 only 4 W7007253 Wire Drive Assembly 5 W7007254 Spool Hub Assembly 6 W7007245 Gas Solenoid Valve 24VDC 7 W7007274 Input Supply ON OFF Switch 8 W7007247 PCBA EMC Filter 9 W7007246 PCBA Main 10 W7007244 Fan Assembly 11 W7007249 Dinse Socket 25mm2 Tab...

Page 76: ...of 10 OTW11 35 R Contact Tip 0 9mm Pack of 10 OTW11 40 R Contact Tip 1 0mm Pack of 10 OTW11 45 R Contact Tip 1 2mm Pack of 10 3 W6000602 Gas Diffuser 4 W6000607 Conductor Tube 5 W6000608 Trigger 6 WS1240015 R Conduit Liner Steel 0 6 1 0mm Blue Hard Wires WS1240031 R Conduit Liner Steel 1 0 1 2mm Red Hard Wires WS1260026 R Conduit Liner Teflon 0 8 1 2mm Red Soft Wires WS0010304 R Jump Liner 1 0 1 2...

Page 77: ...UMBER DESCRIPTION 1 W6000600 Gas Nozzle 2 OTW11 23 R Contact Tip 0 6mm Pack of 10 OTW11 30 R Contact Tip 0 8mm Pack of 10 OTW11 35 R Contact Tip 0 9mm Pack of 10 OTW11 40 R Contact Tip 1 0mm Pack of 10 OTW11 45 R Contact Tip 1 2mm Pack of 10 3 W6000602 Gas Diffuser 4 W6000607 Conductor Tube 5 W6000608 Trigger Assembly Table 8 3 Note Liner is not replaceable Replacement MIG Gun CMG16DL for HandyWel...

Page 78: ...KEY SPARE PARTS 8 4 0 5617 EasyWeld HandyWeld 160 This Page Intentionally Blank ...

Page 79: ...CN8 MAIN BOARD IF LG1 LE HE HG1 C7 C8 D3 D4 D10 C13 C12 D5 D7 Q1A Q1B Q2A Q2B HG2 LG2 5 R7 C11 5 6 4 1 T4 1 3 4 2 BR1 C9 3 4 K1B t RT1 R01 R02 C4 R12 R13 D1 D2 4 1 3 2 T1 FLQ1 FLQ2 FLQ1 C3 R0_2 v RY1 L2 AC240V 60HZ 1 2 3 CN9 1 2 3 CN404 GAS IN DIS BOARD Fan 1 2 CN5 Valve 1 2 CN7 C5 D6 1 2 Euro CON 1 2 CN4 1 2 Art A 14838 ...

Page 80: ...EasyWeld HandyWeld 160 APPENDIX A 2 0 5617 This Page Intentionally Blank ...

Page 81: ...IS 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...

Page 82: ...l wear Note No employee agent or representative of 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 he...

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Page 84: ...u International Enquiries Tel 61 3 9474 7508 Fax 61 3 9474 7488 cigweld com au Malaysia No 14 Jalan Teknologi 3 1 Selangor Science Park 1 Kota Damansara 47810 Petaling Jaya Malaysia Tel 60 3 6145 0995 Fax 60 3 6145 0585 Indonesia JI Pulogadung No 45 Kawasan Industri Pulogadung Jakarta 13930 Indonesia Tel 62 21 460 0188 Fax 62 21 461 2929 Selangor Darul Ehsan ...

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