CIGWELD weldskill 100 Operating Manual
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CIGWELD weldskill 100 Operating Manual

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100
135
150
Operating Manual
weldskill
MiG weldinG Machine
Art # A-09010
Revision: AB
Issue Date: November 13, 2013
Operating Features:
100
135
150
AMP
AMP
AMP
AC
DC
®
240
V
DC
Manual No.: 0-5129

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Summary of Contents for CIGWELD weldskill 100

  • Page 1 weldskill ® MiG weldinG Machine Art # A-09010 Operating Manual Revision: AB Issue Date: November 13, 2013 Manual No.: 0-5129 Operating Features:...
  • Page 2 To locate your nearest distributor or service agency call +1300 654 674, or visit us on the web at www.cigweld.com.au. This Operating Manual has been designed to instruct you on the correct use and operation of your CIGWELD product.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. Operating Manual Number 0-5129 for: Cigweld WeldSkill 100 Mig Welding Machine Part Number W1004100 Cigweld WeldSkill 135 Mig Welding Machine...

  • Page 4: Table Of Contents

    Attaching the Euro 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 MIG ... 3-9 3.13 Installing Handispool (200mm diameter) –...
  • Page 5 APPENDIX 1:100 MIG CIRCUIT DIAGRAM .............. A-1 APPENDIX 2:135 MIG CIRCUIT DIAGRAM .............. A-2 APPENDIX 3:150 MIG CIRCUIT DIAGRAM .............. A-3 CIGWELD LIMITED WARRANTY Terms of Warranty – MARCH 2008 Warranty Schedule – MARCH 2008 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......Inside Rear Cover...

  • Page 7: Section 1:Arc Welding Safety Instructions And Warnings

    100, 135, 150 MiG SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
  • Page 8 100, 135, 150 MiG 2. Wear approved safety glasses. Side shields recommended. 3. Use protective screens or barriers to protect others WARNING from flash and glare; warn others not to watch the arc. ARC RAYS can burn eyes and skin; NOISE can damage hearing.
  • Page 9 100, 135, 150 MiG 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. WARNING 4. Be alert that welding sparks and hot materials from...
  • Page 10 100, 135, 150 MiG 4. Never allow a welding electrode to touch any cylinder. WARNING 5. Use only correct shielding gas cylinders, MOVING PARTS can cause injury. regulators, hoses, and fittings designed for the specific application; maintain them and associated Moving parts, such as fans, rotors, and belts can cut parts in good condition.

  • Page 11: Principal Safety Standards

    100, 135, 150 MiG To reduce magnetic fields in the workplace, use the following procedures. 1. Keep cables close together by twisting or taping them. WARNING 2. Arrange cables to one side and away from the STEAM AND PRESSURIZED HOT COOLANT operator.

  • Page 12: Declaration Of Conformity

    Victoria 3072 Australia Description of equipment: Welding Equipment (GMAW, FCAW) including, but not limited to CIGWELD Weldskill 100 MIG, 135 Mig and 150 Mig 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: Section 2:Introduction

    Include the Owner’s Manual number and equipment identification numbers. Electronic copies of this manual can also be downloaded 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 Introduction...

  • Page 14: Symbol Chart

    100, 135, 150 MiG 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-...

  • Page 15: Description

    Weldskill 100 Mig This equipment will perform as per the information contained herein when installed, operated, maintained The WeldSkill 100 Mig is a semi-automatic Flux Cored and repaired in accordance with the instructions Arc Welder (FCAW) with an integrated wire feed unit.

  • Page 16: Packaged Items

    100, 135, 150 MiG 2.08 Packaged Items WeldSkill WeldSkill WeldSkill 100 Mig 135 Mig 150 Mig Power Source Mig Torch (fitted to 100 &135) Mig Torch (Euro Torch Connector) Work Lead (fitted to 100 &135) Work Lead (25mm Dinse Connector) Mini Spool 0.8mm Gasless Mild Steel Mig Wire...

  • Page 17: Specifications

    100, 135, 150 MiG 2.10 Specifications Description WeldSkill 100 Mig WeldSkill 135 Mig WeldSkill 150 Mig Power Source Part Number W1004100 W1004135 W1004150 Cooling Fan Cooled Fan Cooled Fan Cooled Welder Type Conventional Conventional Conventional Transformer Transformer Transformer Welding Power Source Mass...
  • Page 18 100, 135, 150 MiG This page left blank intentionally. Introduction...

  • Page 19: Section 3:Installation

    100, 135, 150 MiG SECTION 3: INSTALLATION 3.01 Environment G. The enclosure design of this power source meets the requirements of IP21S as outlined in AS 60529 These units are designed for use in environments with . This provides adequate protection against solid increased hazard of electric shock.

  • Page 20: Welding Face Shield Assembly

    CIGWELD. Advice in this regard can equipment. Further guidance is given be obtained by contacting an accredited CIGWELD in IEC 974-13 Arc Welding Equipment - Distributor.
  • Page 21 100, 135, 150 MiG B. Assessment of Area 2. Maintenance of Welding Equipment Before installing welding equipment, the user shall The welding equipment should be routinely make an assessment of potential electromagnetic maintained according to the manufacturer’s problems in the surrounding area. The following shall recommendations.

  • Page 22: Using A Shielding Gas For (Gmaw) Process

    100, 135, 150 MiG 3.08 Using a Shielding Gas for Adjusting Regulator (GMAW) Process Adjust the control knob on the regulator to the required flow rate, indicated on the gauge dial (approximately NOTE: 10 - 15 LPM). Refer to Figure 3-5.

  • Page 23: Attaching The Euro Style Connection Weldskill 150 Mig Torch

    100, 135, 150 MiG 3.09 Attaching the Euro Style Connection WeldSkill 150 MIG Torch. Fit the MIG Torch to the Power Source by pushing the torch connector into the (A) Mig 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.

  • Page 24: Polarity Changeover

    100, 135, 150 MiG 3.10 Polarity Changeover WARNING ELECTRIC SHOCK CAN KILL! Make certain the machine is unplugged from the power receptacle. Do not plug machine in until told to do so in these instructions As delivered from the factory, the output polarity is connected as (reverse polarity). The output terminals are located on the interior panel of the welding power source.
  • Page 25 100, 135, 150 MiG Connection for FCAw (reverse polarity) 1. Open the door to the machine. 2. Remove the polarity terminal knobs. 3. Set up the polarity (as per Table 3-1 above) by removing the leads from the terminals and reversing them if necessary.

  • Page 26: Installing Minispool (100Mm Diameter) - Weldskill 100 Mig

    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 for use with the WeldSkill 100 Mig. Locking Pin Spring Spacer Minispool...

  • Page 27: Installing Minispool (100Mm Diameter) - Weldskill 135 And 150 Mig

    100, 135, 150 MiG 3.12 Installing Minispool (100mm diameter) – WeldSkill 135 and 150 MIG As delivered from the factory, the unit is set for a Minispool (100mm diameter). Assemble parts in sequence shown below in figure 3-9. 1. Friction Washer 2.

  • Page 28: Installing Handispool (200Mm Diameter) - Weldskill 135 And 150 Mig

    100, 135, 150 MiG 3.13 Installing Handispool (200mm diameter) – WeldSkill 135 and 150 MIG As delivered from the factory, the unit is set for a Minispool (100mm diameter). Assemble parts in sequence shown below in figure 3-10. 1. Remove Minispool (if already in place).

  • Page 29: Inserting Wire Into The Wire Feed Mechanism

    100, 135, 150 MiG 3.14 Inserting Wire into the Wire Feed Mechanism Lift up the pressure arm and pass the electrode wire through the inlet guide, between the rollers, through the outlet guide and into the MIG torch. Lower the pressure arm and adjust the pressure accordingly. Plug the mains supply lead into a suitable 240VAC outlet and turn the front panel Control Power switch to ON.

  • Page 30: Drive Roller Pressure Adjustment

    100, 135, 150 MiG 3.15 Drive Roller Pressure Adjustment The pressure roller applies pressure to the grooved feed roller via an adjustable pressure screw. These devices should be adjusted to a minimum pressure that will provide satisfactory wirefeed without slippage. If slip- ping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit liner should be checked for kinks and clogging by metal flakes and swarf.

  • Page 31: Setup For Weldskill 100 Mig

    Suitable for Gasless Mig Wire only. Refer to the set up guide located on the inside of the wirefeed compartment door. 240V AC POWER SOURCE WORK CLAMP WORK Art # A-09017 Figure 3-13: Set-up for WeldSkill 100 Mig Installation 3-13...

  • Page 32: Setup For Weldskill 135 Mig With Gasless Mig Wire

    100, 135, 150 MiG 3.18 Setup for WeldSkill 135 Mig with Gasless MIG Wire WARNING Before connecting the work clamp to the work and inserting the electrode wire in the Mig Torch make sure the Mains power supply is switched off.

  • Page 33: Setup For Weldskill 135 Mig With Gas Shielded Mig Wire

    100, 135, 150 MiG 3.19 Setup for WeldSkill 135 MIG with Gas Shielded Mig Wire WARNING Before connecting the work clamp to the work and inserting the electrode wire in the Mig Torch make sure the Mains power supply is switched off.

  • Page 34: Setup For Weldskill 150 Mig With Gasless Mig Wire

    100, 135, 150 MiG 3.20 Setup for WeldSkill 150 Mig with Gasless MIG Wire WARNING Before connecting the work clamp to the work and inserting the electrode wire in the Mig Torch make sure the Mains power supply is switched off.

  • Page 35: Setup For Weldskill 150 Mig With Gas Shielded Mig Wire

    100, 135, 150 MiG 3.21 Setup for WeldSkill 150 Mig with Gas Shielded MIG Wire WARNING Before connecting the work clamp to the work and inserting the electrode wire in the Mig Torch make sure the Mains power supply is switched off.
  • Page 36 100, 135, 150 MiG This Page Left Intentionally Blank 3-18 Installation...

  • Page 37: Section 4:Operation

    100, 135, 150 MiG SECTION 4: OPERATION 4.01 WeldSkill 100 Mig Power Source Controls, Indicators and Features A. MIG Gun Cable End Port The MIG Torch cable and MIG Torch switch leads CAUTION are routed through this opening. The Output Voltage Control Switch MUST B.

  • Page 38: Weldskill 135 Mig Power Source Controls, Indicators And Features

    100, 135, 150 MiG 4.02 WeldSkill 135 Mig Power Source Controls, Indicators and Features A. Wirespeed Control C. MIG Torch Cable End Port The Wirespeed Control knob controls the weld- The MIG Torch cable and MIG Torch switch leads ing current via the electrode wire feed rate which are routed through this opening.

  • Page 39: Weldskill 150 Mig Power Source Controls, Indicators And Features

    100, 135, 150 MiG 4.03 WeldSkill 150 Mig Power Source Controls, Indicators and Features A. Wirespeed Control C. MIG Torch Connection (Euro) Fit the MIG Torch to the Power Source by pushing The Wirespeed Control knob controls the weld-...

  • Page 40: Cigweld Mig Wire Selection Chart

    Aluminium alloys containing Magnesium. Note that a suitable shielding gas is required. Note Minispool = 100mm diameter, Handispool = 200mm diameter. Figure 4-4 Cigweld MIG Wire Selection Chart Operation...

  • Page 41: Basic Welding Technique

    100, 135, 150 MiG 4.05 Basic Welding Technique Shielding Gas Nozzle (Optional) (Optional) Two different welding processes are covered in this Molten Metal section, with the intention of providing the very basic Flux Cored Molten Electrode concepts in using the Mig mode of welding, where a...
  • Page 42 100, 135, 150 MiG Preselected Variables Preselected variables depend upon the type of material 5° to 15° Longitudinal Angle being welded, the thickness of the material, the weld- 30° to 60° ing position, the deposition rate and the mechanical Transverse Angle properties.
  • Page 43 100, 135, 150 MiG 3. Nozzle Angle. This refers to the position of setting of the Power source the welding gun in relation to the joint. The Power source and Wirefeeder setting requires some transverse angle is usually one half the in- practice by the operator, as the welding plant has two cluded angle between plates forming the joint.
  • Page 44 100, 135, 150 MiG This Page Intentionally Left Blank Operation...

  • Page 45: Section 5:Service

    100, 135, 150 MiG SECTION 5: SERVICE 5.02 Cleaning the Welding Power 5.01 Routine Maintenance & Source Inspection WARNING WARNING Refer to WARNING on page 3-2. There are extremely dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless To clean the Welding Power Source, open the you are a qualified electrical tradesperson.

  • Page 46: Welding Problems

    100, 135, 150 MiG 5.05 Welding Problems solving Problems Beyond the welding Terminals. The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG torch. There are two main areas where problems occur with GMAW, Porosity...
  • Page 47 100, 135, 150 MiG solving Problems Beyond the welding Terminals - inconsistent wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1 Wire spool brake is too tight Feed roller driven by motor in the cabinet will slip.
  • Page 48 E Slow the cooling rate by preheating part to be welded or cool slowly. Cold weld puddle A Faulty rectifier unit A Have an Accredited CIGWELD Service Provider test then replace the faulty component. B Loss of a phase in the Mains B Check mains power supply voltage.

  • Page 49: Power Source Problems

    100, 135, 150 MiG 5.06 Power Source Problems FAULT CAUSE REMEDY Control On/Off Power Source Output Set the Power Source Output Voltage Switch Indicator light Voltage Selector Switch Control Switch to either position 1, 2, 3 or is ON but welding...

  • Page 50: Key Spare Parts

    100, 135, 150 MiG Gas flow continues Gas Solenoid Valve has Have an Accredited CIGWELD Service after the torch trigger jammed open due to Agent repair or replace Gas Solenoid Valve. switch has been impurities in the gas or released.

  • Page 51: Appendix 1:100 Mig Circuit Diagram

    100, 135, 150 MiG APPENDIX 1: 100 MIG CIRCUIT DIAGRAM Appendix...

  • Page 52: Appendix 2:135 Mig Circuit Diagram

    100, 135, 150 MiG APPENDIX 2: 135 MIG CIRCUIT DIAGRAM Trigger Switch Appendix...

  • Page 53: Appendix 3:150 Mig Circuit Diagram

    100, 135, 150 MiG APPENDIX 3: 150 MIG CIRCUIT DIAGRAM Appendix...
  • Page 54 100, 135, 150 MiG This page left blank intentionally. Appendix...

  • Page 55: Cigweld Limited Warranty

    “Purchaser” that its products will be free of defects in workmanship or mate- rial. Should any failure to conform to this warranty appear within the time period applicable to the CIGWELD products as stated below, CIGWELD shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with CIGWELD’s specifications, instructions,...
  • Page 56 CIGWELD. 4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supply of goods which are not of a kind ordinarily acquired for personal, domestic or household use or consumption to any one or more of the following (the choice of which shall be at the option of CIGWELD).
  • Page 57 Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date CIGWELD delivered the product to the Accredited Distributor. Unless otherwise stated the warranty period includes parts and labour. CIGWELD reserves the right to request documented evidence of date of purchase.

  • Page 59: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne, China Cigweld, Australia 71 Gower Street RM 102A Preston, Victoria 685 Ding Xi Rd Chang Ning District Australia, 3072 Telephone: 61-3-9474-7400 Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 61-3-9474-7510 Email: cigweldsales@cigweld.com.au Fax: 86-21-69171139 Thermadyne Asia Sdn Bhd...
  • Page 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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Weldskill 150Weldskill 135

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