CIGWELD WELDSKILL 180 Service Manual
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CIGWELD WELDSKILL 180 Service Manual

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Art # A-13053
180

SERVICE MANUAL

OUTPUT CURRENT
INPUT SUPPLY
STICK
WARRANTY*
WARRANTY*
3
2
DC
ELECTRODE
4.0mm MAX
180 Inverter
Version No: AA |
Issue Date: February 24, 2016 |
Manual No: 0-5461

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Summary of Contents for CIGWELD WELDSKILL 180

  • Page 1: Service Manual

    Art # A-13053 SERVICE MANUAL OUTPUT CURRENT INPUT SUPPLY STICK WARRANTY* WARRANTY* ELECTRODE 4.0mm MAX 180 Inverter Version No: AA | Issue Date: February 24, 2016 | Manual No: 0-5461...
  • Page 2 YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. CIGWELD is a Market Leading Brand of Arc Welding Products for ESAB. We are a mainline supplier to major welding industry sectors in the Asia Pacific and emerging global markets including; Manufacturing, Construc- tion, Mining, Automotive, Engineering, Rural and DIY.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. CIGWELD WeldSkill 180 Welding Inverters Service Manual Number 0-5461 for: Part Numbers W1008180 and W1008181...
  • Page 4 Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Goug- ing,”...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ........1-1 1.01 Arc Welding Hazards ..................1-1 1.02 PRINCIPAL SAFETY STANDARDS ..............1-5 1.03 DECLARATION OF CONFORMITY ..............1-6 SECTION 2: INTRODUCTION ..................2-1 2.01 How To Use This Manual ................2-1 2.02 Equipment Identification .................
  • Page 6 12.01 Inverter PCB ....................12-1 12.02 Control PCB ....................12-3 12.03 EMC PCB ...................... 12-4 SECTION 13: KEY SPARE PARTS ................13-1 13.01 WeldSkill 180 Key Spare Parts ..............13-1 CIGWELD - LIMITED WARRANTY TERMS WARRANTY SCHEDULE – WELDSKILL 180 INVERTERS...

  • Page 7: Arc Welding Safety Instructions And Warnings

    SERVICE MANUAL SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACE- MAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT. Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.
  • Page 8 SERVICE MANUAL 2. Wear approved safety glasses. Side shields WARNING recommended. ARC RAYS can burn eyes and skin; NOISE can damage hearing. 3. Use protective screens or barriers to protect others from flash and glare; warn others not to Arc rays from the welding process produce in- watch the arc.
  • Page 9 SERVICE MANUAL 4. Be alert that welding sparks and hot materials WARNING from welding can easily go through small cracks FUMES AND GASES can be hazardous to your and openings to adjacent areas. health. 5. Watch for fire, and keep a fire extinguisher Welding produces fumes and gases.
  • Page 10 SERVICE MANUAL 6. Turn face away from valve outlet when opening The following is a quotation from the General cylinder valve. Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of 7. Keep protective cap in place over valve except Power when cylinder is in use or connected for use.

  • Page 11: Principal Safety Standards

    SERVICE MANUAL 1.02 PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 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.

  • Page 12: Declaration Of Conformity

    71 Gower St, Preston Victoria 3072 Australia Description of equipment: Welding Equipment (MMAW, GTAW) including, but not limited to CIGWELD Weldskill 140, 180 inverters and associated accessories. Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

  • Page 13: Introduction

    Include the Owner’s Manual number and equipment identification numbers. Electronic copies of this manual can also be down- loaded at no charge in Acrobat PDF format by going to the CIGWELD web site listed below and clicking on the Literature Library link: http://www.cigweld.com.au 0-5461...

  • Page 14: Symbol Chart

    SERVICE MANUAL 2.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier Purging Of Gas Increase/Decrease...

  • Page 15: Description

    SERVICE MANUAL 2.05 Description 2.07 Packaged Item WeldSkill 180 Inverter WeldSkill 180 Inverter with Toolbox (Part No. W1008180) This compact heavy duty, inverter welding machine has infinitely adjustable welding current from 10 to • WeldSkill 180 Inverter Power Source 180 amps. It runs standard general purpose 2.5mm •...

  • Page 16: Transporting Methods

    SERVICE MANUAL 2.08 Transporting Methods These units are equipped with a handle for carrying purposes. WARNING ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source. WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage.

  • Page 17: Specifications

    SERVICE MANUAL 2.10 Specifications WeldSkill 180 Descriptio Toolbox Plant Part No W1008180 Power Source Dimensions H220mmxW130mmxD340mm Power Source Mass 5.8 KG Cooling Fan Cooled Welder Type Stick and Lift TIG Multi Process Inverter Power Source Australian Standard AS 60974.1-2006 / IEC 60974-1...

  • Page 18: Optional Accessories

    Minimum Generator Recommendation at the Maximum Output Duty Cycle. Due to large variations in performance and specifications of different brands and types of generators, CIGWELD cannot guarantee full welding output power or duty cycle on every brand or type of generator.

  • Page 19: Optional Accessories (Cont'd)

    WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Tribal 454323 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 White Carbon 454324 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Oz Flag Note: CIGWELD Electrodes see pages 5-2 and 5-3 Table 2-5 0-5461 INTRODUCTION...
  • Page 20 SERVICE MANUAL This Page Intentionally Blank INTRODUCTION 0-5461...

  • Page 21: Installation

    SERVICE MANUAL SECTION 3: INSTALLATION 3.04 Mains Supply Voltage 3.01 Environment Requirements These units are designed for use in environments with increased hazard of electric shock. The Mains supply voltage should be within ± 10% of the rated Mains supply voltage. If actual Mains Supply A.

  • Page 22: Electromagnetic Compatibility

    SERVICE MANUAL 3.06 Electromagnetic Compatibility 7. The time of day that welding or other activities are to be carried out. WARNING 8. The immunity of other equipment in the en- Extra precautions for Electromagnetic Compat- vironment: the user shall ensure that other ibility may be required when this Welding Power equipment being used in the environment Source is used in a domestic situation.
  • Page 23 SERVICE MANUAL 4. Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However. Metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time.
  • Page 24 SERVICE MANUAL This Page Intentionally Blank INSTALLATION 0-5461...

  • Page 25: Operation

    SERVICE MANUAL SECTION 4: OPERATION 4.01 Overview Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to workpiece and electrode lead is used to hold electrode (Consult the electrode manufacturers information for the correct polarity). The welding current range values should be used 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, welding current at any one setting would vary according to the type of electrode in use.
  • Page 26 SERVICE MANUAL 3. Over Temp Indicator This welding power source is protected by a self resetting thermostat. The Over Temp indicator will illuminate if the machine has over heated which normally occurs if the duty cycle of the power source has been exceeded. Should the Over Temp indicator illuminate the output of the power source will be disabled.
  • Page 27 SERVICE MANUAL 10. Arc Force Feature (Not Shown) This feature operates in Stick (Manual Arc) mode. Stick electrodes can sometimes ‘stick’ to the work piece when pushed into a tight corner or joint fit-up with particular stick electrodes. The Arc force feature can be particularly beneficial in helping to overcome this by automatically increasing current when the machine senses a decrease in voltage levels.
  • Page 28 SERVICE MANUAL This Page Intentionally Blank OPERATION 0-5461...

  • Page 29: Stick (Mmaw) Welding

    SERVICE MANUAL SECTION 5: STICK (MMAW) WELDING 5.01 Setup For STICK (MMAW) Welding A. Select Stick mode with the process selection control (refer to Section 4.02.1 for further information). B. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer.

  • Page 30: Arc Welding Electrodes

    2.5 kg 611602 Stainless Steel type for 19Cr/10Ni stainless grades Satincrome 3.2mm 2.5 kg 611603 including 201, 202, 301, 302, 303, 304, 304L, 305, 308L-17 308, etc 4.0mm 2.5 kg 611604 Cigweld Electrode Selection Chart continued over page OPERATION 0-5461...

  • Page 31: Size Of Electrode

    SERVICE MANUAL CIGWELD Electrode Selection Chart cont'd Description Diameter Pack Part No. Application 2.5mm 2.5 kg 611692 Stainless Steel type for 309 and 309L grades. It is Satincrome 3.2mm 2.5 kg 611693 also suitable for welding of dissimilar welding of 309Mo-17 other 300 series stainless steels.

  • Page 32: Effects Of Arc Welding Various Materials

    SERVICE MANUAL 5.07 Effects of Arc Welding Various Materials A. High tensile and alloy steels The two most prominent effects of welding these Art # A-07687 steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, Figure 5-2: Flat position, down hand butt weld the occurrence in this zone of under-bead cracks may result.

  • Page 33: Joint Preparations

    SERVICE MANUAL Art # A-07694 Art# A-07693 Figure 5-8: Overhead position, butt weld Figure 5-9: Overhead position fillet, weld 5.10 Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.

  • Page 34: Arc Welding Technique

    SERVICE MANUAL 5.11 Arc Welding Technique 20° Art # A-07696_AC A Word to Beginners For those who have not yet done any welding, the simplest way to commence is to run beads on a piece 1.6 mm (1/16”) of scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode.
  • Page 35 SERVICE MANUAL A. Butt Welds purpose to the backing run in securing proper fusion at the root of the weld. Set up two plates with their edges parallel, as shown in Figure 5-12, allowing 1.6mm to 2.4mm gap between B. Fillet Welds them and tack weld at both ends.
  • Page 36 SERVICE MANUAL C. Vertical Welds 1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm Ferrocraft 21 electrode and set the cur- rent at 100 amps. Make yourself comfortable on a seat in front of the job and strike the arc Art # A-07703 in the corner of the fillet.

  • Page 37: Distortion

    SERVICE MANUAL B. Expansion and Contraction of Parent Metal in the Art # A-07704 Fusion Zone: While welding is proceeding, a relatively small vol- ume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions.
  • Page 38 SERVICE MANUAL B. Distribution of Stresses Art # A-07709 Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 5-25 through 5-28 for various weld sequences. Choice of a suitable weld sequence is probably the most ef- fective method of overcoming distortion, although an unsuitable sequence may exaggerate it.

  • Page 39: Welding Problems

    SERVICE MANUAL 5.20 Welding Problems Description Possible Cause Remedy 1 Gas pockets or voids in weld metal A Electrodes are damp A Dry electrodes before use (Porosity) B Welding current is too high B Reduce welding current 　 　 C Surface impurities such as oil, C Clean joint before welding 　...
  • Page 40 SERVICE MANUAL Description Possible Cause Remedy 4 Portions of the weld run do not fuse A Small electrodes used on A Use larger electrodes and to the surface of the metal or edge of heavy cold plate preheat the plate the joint B Welding current is too low B Increase welding current...
  • Page 41 SERVICE MANUAL Description Possible Cause Remedy 5 A groove has been formed in the base A Welding current is too high. A Reduce welding current metal adjacent to the toe of a weld and has not been filled by the weld metal (undercut).
  • Page 42 SERVICE MANUAL Description Possible Cause Remedy 6 Non-metallic particles are trapped in A Non-metallic particles may A If bad undercut is present, the weld metal (slag inclusion) be trapped in undercut from clean slag out and cover previous run with a run from a smaller diameter electrode B Joint preparation too B Allow for adequate...

  • Page 43: Tig (Gtaw) Welding

    SERVICE MANUAL SECTION 6: TIG (GTAW) WELDING 6.01 Shielding Gas Regulator/Flowmeter Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Regulator/Flowmeter Safety This regulator/flowmeter is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.
  • Page 44 SERVICE MANUAL 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.
  • Page 45 SERVICE MANUAL Adjusting Flow Rate Art: A-05088_AB Figure 6-2: Adjust Flow Rate With the regulator/flowmeter ready for operation, adjust working flow rate as follows: 1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate. NOTE! 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.

  • Page 46: Setup For Lift Tig (Gtaw) Welding

    SERVICE MANUAL 6.02 Setup For Lift TIG (GTAW) Welding A. Select Lift TIG mode with the process selection control (refer to Section 4.02.1 for further information). B. Connect the TIG Torch to the negative welding terminal (-). Refer to Note below for Optional TIG Torch information.

  • Page 47: Tig (Gtaw) Basic Welding Technique

    SERVICE MANUAL 6.03 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a weld- ing process in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable) electrode and the work piece.
  • Page 48 Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www. cigweld.com.au or contact Cigweld. OPERATION 0-5461...

  • Page 49: Tig (Gtaw) Welding Problems

    SERVICE MANUAL 6.04 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive bead build up or Welding current is too Increase weld current and/or faulty joint poor penetration or poor preparation. fusion at edges of weld. 2 Weld bead too wide and Welding current is too Decrease weld current.
  • Page 50 Electrode Selection Chart. B The wrong electrode B Select the right size tungsten electrode is being used for the type. Refer to Table 6-3 Cigweld Tungsten welding job. Electrode Selection Chart. C Shielding gas flow rate C Select the right shielding gas flow rate is too high.

  • Page 51: Routine Service Requirements

    B. Insulation Resistance Minimum insulation resistance for in-service Cigweld Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 7-1 below. Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.
  • Page 52 2. The earth terminal of the associated plug of a transportable power source Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying Cigweld welding power sources should be inspected by a licensed electrical worker in ac- cordance with the requirements below: 1.

  • Page 53: Cleaning The Welding Power Source

    SERVICE MANUAL G. Calibrate Power Source This Power Source has no calibration potentiometers on the Control or Inverter PCBs. The firmware within the Control PCB set the maximum output current for the power source. If the welding current can’t be controlled by the Amperage Control (Welding Current) knob on the front panel then: •...
  • Page 54 SERVICE MANUAL This Page Intentionally Blank ROUTINE SERVICE REQUIREMENTS 0-5461...

  • Page 55: Theory Of Operation

    SERVICE MANUAL SECTION 8: THEORY OF OPERATION Inverter Design What does the word inverter mean? The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the incoming AC to DC, and then the transistors create a higher frequency AC. The higher frequency AC then goes on to a much smaller main transformer than in a conventional power supply.
  • Page 56 SERVICE MANUAL This Page Intentionally Blank THEORY OF OPERATION 0-5461...

  • Page 57: Main Circuit Description

    SERVICE MANUAL SECTION 9: MAIN CIRCUIT DESCRIPTION WARNING Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two minutes for capacitors to discharge and check that the DC bus voltage has discharged to less than 5VDC, refer to Section 10.04, after disconnection from mains supply voltage.
  • Page 58 SERVICE MANUAL The primary IGBT transistors (Q1, Q2, Q3, Q4) are configured as an H-bridge circuit and switch the transformer primary at high frequency and varying duty cycle. Secondary output voltage from the transformer is rectified by the fast recovery diodes (D1, D2, D4, D5, D14-1, D14-2) to DC then the DC voltage is connected to the welding output terminals.

  • Page 59: Preliminary Troubleshooting - Power Source

    SERVICE MANUAL SECTION 10: PRELIMINARY TROUBLESHOOTING – POWER SOURCE If the problem cannot be solved by the basic (external) troubleshooting guide, the Power Source covers will have to be removed to allow the technician to analyse failures with a few common tools. WARNING Turn off power and disconnect mains supply plug from receptacle before working on the unit.

  • Page 60: Dc Bus Preliminary Measurement In Inverter Pcb

    SERVICE MANUAL 10.04 DC Bus Preliminary Measurement in Inverter PCB WARNING Check DC bus voltage has discharged to less than 5VDC before servicing. Ensure the mains supply plug is disconnected from 240VAC receptacle. Art # A-13058 Voltage with Supply voltage DC Bus Testpoint No.

  • Page 61: Igbts Preliminary Check In Inverter Pcb

    SERVICE MANUAL 10.05 IGBTs Preliminary Check in Inverter PCB Art # A-13059 Diode Voltage VDC Testpoint IGBT Multimeter Lead Placement Testing Testing Acceptable Results IGBT Q4 Negative (black) meter lead to testpoint 3 Q4 CE Diode 0.2 – 0.8 VDC Positive (red) meter lead to testpoint 4 IGBT Q1 Negative (black) meter lead to testpoint 5...
  • Page 62 SERVICE MANUAL Ohms (Ω) Testpoint Inrush Resistor Multimeter Lead Placement Acceptable Results PTC Resistor Negative (black) meter lead to testpoint 11 36+/-20% Ω MZ71 Positive (red) meter lead to testpoint 12 18RM270 Table 10-4 Inrush PTC, Multimeter set to measure ohms (Ω) Diode Voltage VDC Testpoint DIODE...

  • Page 63: Dc Bus Voltage Measurement In Inverter Pcb

    SERVICE MANUAL 10.06 DC Bus Voltage Measurement in Inverter PCB Apply voltage to the Power Source. WARNING There are extremely dangerous voltage and power levels present inside these Power Sources. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. DO NOT TOUCH ANY LIVE PARTS. Once power is applied to the Power Source, there are extremely hazardous voltage and power levels present.
  • Page 64 SERVICE MANUAL This Page Intentionally Blank PRELIMINARY TROUBLESHOOTING-POWER SOURCE 10-6 0-5461...

  • Page 65: Advanced Troubleshooting - Power Source

    SERVICE MANUAL SECTION 11: ADVANCED TROUBLESHOOTING – POWER SOURCE The following tables are guides for analysing problems and making repairs to the Power Source. 11.01 Recommendations when Replacing Primary Bridge Rectifier / IGBT / Secondary Diode IGBT Recommendations Bridge Rectifier DIODE Recommendations Recommendations (B1) (Q4, Q1, Q3, Q2)

  • Page 66: Power Source Issues, High Ocv, No Fan Or Abnormal Inverter Frequency

    SERVICE MANUAL 11.02 Power Source Issues, High OCV, No Fan or Abnormal Inverter Frequency Fault Possible Cause Remedy The Power Indicator A Frequent switching input switch in Switch off machine for 10 is FLASHING when power source over 6 times may cause minutes then switch on power primary lead is plugged power indicator to flash.
  • Page 67 SERVICE MANUAL Inverter frequency is Control PCB is malfunctioning and Replace Control PCB and abnormal snubber circuit components for replace defective components. secondary diodes on Inverter PCB have failed open circuit, Check components: C1, R74, R1, R2, R3, R83 C15, R75, R20, R21, R23, R30 Check that Mains Supply Voltage is Disconnect the machine from greater than 276VAC.

  • Page 68: Power Indicator Not On Or No Output Power From Machine

    SERVICE MANUAL 11.03 Power Indicator Not ON or No Output Power from Machine Does fan operate constantly after power on or CN1 has 24VDC? Is LED1 in Inverter PCB on/flashing? Art # A-13047 ADVANCED TROUBLESHOOTING-POWER SOURCE 11-4 0-5461...

  • Page 69: Igbt Control Ic Voltage Checks In Control Pcb

    SERVICE MANUAL 11.04 IGBT Control IC Voltage Checks in Control PCB Control PCB must have a fault not covered by the above tests. Art # A-13048 0-5461 11-5 ADVANCED TROUBLESHOOTING-POWER SOURCE...

  • Page 70: Over Temperature Indicator On & No Output From Machine

    SERVICE MANUAL 11.05 Over Temperature Indicator ON & No Output from Machine Is the IGBT heatsink thermostat Replace IGBT heatsink thermostat with normally contacts open circuit at 25C closed contacts (contacts should be normally closed) ? 50±5%K @ 25C ? Art # A-13049 ADVANCED TROUBLESHOOTING-POWER SOURCE 11-6...

  • Page 71: Pcb Connectors

    SERVICE MANUAL SECTION 12: PCB CONNECTORS 12.01 Inverter PCB Art # A-13060 CN1 Header Pin Pin function Signal +24V supply for cooling fan, 24V = Fan ON (also used 24 VDC to supply J1/ J2 relay) 0V supply for cooling fan 0 VDC Table 12-1 CN1 Header pin function (connects fan to Inverter PCB) CN2 Header Pin...
  • Page 72 SERVICE MANUAL JP1 Header Pin Pin function Signal PDA signal which is used to detect a short circuit at the welding terminals 5 VDC 5V = No short at welding terminals; 0.2V = Short at welding terminals OUTA IGBT 1/2/3/4 PWM drive signal, 15V p-p square 15 VDC pk wave signal OUTB IGBT 1/2/3/4 PWM drive signal, 15V p-p square...

  • Page 73: Control Pcb

    SERVICE MANUAL 12.02 Control PCB Art # A-13051 JP1 Header Pin Pin function Signal PDA-SHORT signal which is used to detect a short cir- cuit at the welding terminals 5V = No short at welding 5 VDC terminals; 0.2V = Short at welding terminals OUTA IGBT 1/2/3/4 PWM drive signal, 15V p-p square 15 VDC pk wave signal...

  • Page 74: Emc Pcb

    SERVICE MANUAL 12.03 EMC PCB AC4-1 Art # A-13061 Power Terminal Name Terminal function Signal Neutral 240 VAC connection into EMC filter 240 VAC Between Terminal P1 & P2 Active 240 VAC connection into EMC filter Mains Earth connection to EMC PCB 0 VAC EARTH 3 Active 240 VAC out of EMC filter to P1 (pre-charge...

  • Page 75: Section 13: Key Spare Parts

    SERVICE MANUAL SECTION 13: KEY SPARE PARTS 13.01 WeldSkill 180 Key Spare Parts Art # A-12800_AB Figure 13-1 WELDSKILL 180 POWER SOURCE KEY SPARE PARTS ITEM PART NUMBER DESCRIPTION W7006824 PCB Power Inverter W7006825 PCB Front Panel W7006826 PCB Primary Rectifier/EMC Filter...
  • Page 76 SERVICE MANUAL This Page Intentionally Blank KEY SPARE PARTS 13-2 Manual 0-5461...

  • Page 77: Cigweld - Limited Warranty Terms

    Any claim under this warranty must be made within the warranty period which commences on the date of purchase of the product. To make a claim under the warranty, take the product (with proof of purchase from a Cigweld Ac- credited Seller) to the store where you purchased the product or contact Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider.
  • Page 78 * 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.
  • Page 79 SERVICE MANUAL This Page Intentionally Blank...
  • Page 80 CIGWELD Pty Ltd Malaysia - Indonesia - CIGWELD An ESAB Brand Lot 151, Jalan Industri 3/5A JL Akasia II Blok A-05 No. 10A 71 Gower Street, Preston VIC 3072 Australia Rawang Integrated Industrial Park, Delta Silicon - Lippo Cikarang Customer Care:...

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