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weldskill 100, 135, 150 MiG

5-1

Service

SECTION 5: 

SERVICE

5.01  Routine Maintenance & 

Inspection

!

 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 tradesperson. 

Disconnect the Welding Power Source 

from the Mains Supply Voltage before 

disassembling.

Welding equipment should be regularly checked by a 

qualified electrical tradesperson to ensure that:

•  The main earth wire of the electrical installation 

is intact.

•  Power  point  for  the  Welding  Power  Source 

is effectively earthed and of adequate current 

rating.

•  Plugs and cord extension sockets are correctly 

wired.

•  Flexible  cord  is  of  the  3-core  tough  rubber 

or plastic sheathed type of adequate rating, 

correctly connected and in good condition.

•  Welding  terminals  are  shrouded  to  prevent 

inadvertent contact or short circuit.

•  The  frame  of  the  Welding  Power  Source  is 

effectively earthed.

•  Welding leads and electrode holder are in good 

condition.

•  The Welding Power Source is clean internally, 

especially from metal filing, slag, and loose 

material. If any parts are damaged for any 

reason, replacement is recommended.

5.02  Cleaning 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 

material. Keep the shunt and lead screw surfaces 

clean as accumulated foreign material may reduce 

the welders output welding current.

5.03  Cleaning the Feed Rolls

Clean the grooves in the drive rolls frequently. This 

can be done by using a small wire brush. Also wipe 

off, or clean the grooves on the upper feed roll. After 

cleaning, tighten the feed roll retaining knobs.

 CAUTION 

Do not use compressed air to clean the 

Welding Power Source. Compressed air 

can force metal particles to lodge between 

live electrical parts and earthed metal parts 

within the Welding Power Source. This 

may result in arcing between this parts 

and their eventual failure.

5.04  Basic Troubleshooting

!

 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 

tradesperson and you have had training in 

power measurements and troubleshooting 

techniques.

If major complex subassemblies are faulty, then 

the Welding Power Source must be returned to an 

Accredited CIGWELD Service Provider for repair.
The basic level of troubleshooting is that which 

can be performed without special equipment or 

knowledge.

Содержание weldskill 100

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 58: ......

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

Страница 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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