ESAB CIGWELD WeldSkill 185LCD Operating Manual
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ESAB CIGWELD WeldSkill 185LCD Operating Manual

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WeldSkill 185LCD
WARRANTY*
WARRANTY*
SAFETY DEVICE
MULTI PROCESS
LCD SCREEN
SPOOL GUN
PLUG & PLAY
2
2
.
3 1
^
2.8"
IN
COMPATIBLE
O
MIG STICK TIG
WITH SGT250
*
185LCD Inverter W1008193
Version No: AB
Issue Date: 19-01-2021
Manual No: 0-5605

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Summary of Contents for ESAB CIGWELD WeldSkill 185LCD

  • Page 1 WeldSkill 185LCD WARRANTY* WARRANTY* SAFETY DEVICE MULTI PROCESS LCD SCREEN SPOOL GUN PLUG & PLAY 2.8” COMPATIBLE MIG STICK TIG WITH SGT250 185LCD Inverter W1008193 Version No: AB Issue Date: 19-01-2021 Manual No: 0-5605...
  • 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 185LCD Welding Inverters Instruction Manual Number 0-5605 for: Part Number W1008193 Published by:...
  • Page 4 WeldSkill 185LCD 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 DECLARATION OF CONFORMITY According to AS/NZS 3820:2020, Essential Safety Requirements for Electrical Equipment Radiocommunications Labelling (Electromagnetic Compatibility) Notice 2017 Type of equipment Arc welding power source Type designation WeldSkill 185LCD with serial number from: KC049-xxxx-xxxx Brand name or trademark CIGWELD Manufacturer or his authorized representative established within the EEA Name, address, and telephone No: Cigweld Pty Ltd...

  • Page 6: 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 SECTION 2: INTRODUCTION ..................2-1 2.01 How To Use This Manual ................2-1 2.02 Equipment Identification ................. 2-1 2.03 Receipt Of Equipment ..................
  • Page 7 TABLE OF CONTENTS SECTION 6: STICK (MMAW) WELDING ................6-1 6.01 Setup for STICK (MMAW) Welding ..............6-1 6.02 Arc Welding Electrodes ................... 6-2 6.03 Types of Electrodes ..................6-3 6.04 Size of Electrode ..................... 6-4 6.05 Storage of Electrodes ..................6-4 6.06 Electrode Polarity ....................
  • Page 8 This Page Intentionally Blank.

  • Page 9: Arc Welding Safety Instructions And Warnings

    WeldSkill 185LCD 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 10 WeldSkill 185LCD 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 11 WeldSkill 185LCD 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 12 WeldSkill 185LCD 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 13: Principal Safety Standards

    WeldSkill 185LCD 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 14 WeldSkill 185LCD This Page Intentionally Blank. GENERAL INFORMATION 0-5605...

  • Page 15: Introduction

    WeldSkill 185LCD SECTION 2: INTRODUCTION 2.02 Equipment Identification 2.01 How To Use This Manual The unit’s identification number (specification or This Owners Manual only applies to the Part Numbers part number), model, and serial number usually ap- listed on page i. pear on a nameplate attached to the control panel.

  • Page 16: Symbol Chart

    WeldSkill 185LCD 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 Increase/Decrease Remote...

  • Page 17: Description

    This equipment or any of its parts should not be al- 2.05 Description tered from standard specification without prior written This CIGWELD WeldSkill 185LCD offers the many approval of CIGWELD. The user of this equipment benefits of a professional welding machine in a...

  • Page 18: Duty Cycle

    WeldSkill 185LCD 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.
  • Page 19 WeldSkill 185LCD NOTE 1 Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service. NOTE 2 The Effective Input Current should be used for the determination of cable size &...

  • Page 20: Optional Accessories

    WeldSkill 185LCD 2.11 Optional Accessories We recommend genuine CIGWELD products. The biggest range and best quality with guaranteed performance. Part Number Description W4018800 E-180 Mig Torch 3m, Euro W6000600 Nozzle OTW11/23/R Contact Tip 0.6mm OTW11/30/R Contact Tip 0.8mm OTW11/35/R Contact Tip 0.9mm OTW11/40/R Contact Tip 1.0mm OTW11/45/R...
  • Page 21 WeldSkill 185LCD TIG Torch Consumables Part Number Description BG10N49/R Nozzle Alumina 8mm, for 17, 26 & 18 TIG Torches (pkt of 5) BG10N48/R Nozzle Alumina 10mm, for 17, 26 & 18 TIG Torches (pkt of 5) BG10N47/R Nozzle Alumina 11mm, for 17, 26 & 18 TIG Torches (pkt of 5) BG10N46/R Nozzle Alumina 12.5mm, for 17, 26 &...
  • Page 22 WeldSkill 185LCD W4018001 Cigweld Heavy Duty Backpack 454337 WeldSkill Essential Auto Darkening Welding Helmet Variable Shade 9-13 454304 WeldSkill Auto Darkening Welding Helmet Fixed Shade 11 Black 454305 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 - Blue 454314 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 - Carbon Fibre 454321 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 - Racer 454322...

  • Page 23: Installation

    WeldSkill 185LCD 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 ± 15% of the rated Mains Supply Voltage. If actual Mains A.

  • Page 24: Electromagnetic Compatibility

    WeldSkill 185LCD 7. The time of day that welding or other activities 3.07 Electromagnetic Compatibility 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 25 WeldSkill 185LCD 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 26 WeldSkill 185LCD This Page Intentionally Blank. INSTALLATION 0-5605...

  • Page 27: Operation

    WeldSkill 185LCD 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 the electrode wire is fed via the MIG Torch (Consult the electrode wire manufaturers 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 wire, welding current at any one setting would vary accordingly to the type of electrode wire in use.
  • Page 28 WeldSkill 185LCD 1. Control Knob Turn or press the Control Knob to select from the menu or change values. To select an option from the displayed menu: • Options will be highlighted in sequence at every turn; • Turn clockwise or anti-clockwise to change selection; •...
  • Page 29 WeldSkill 185LCD 5. LCD Screen A 2.8 inch LCD screen on the front panel displays welding modes menu (Home Screen) and information. Figure 4-2: Home Screen Welding modes can be selected on the Home Screen. Detailed operation method is introduced in Section 5, 6 and 7 for MIG (GMAW / FCAW), TIG (GTAW) and STICK (MMAW) processes.
  • Page 30 WeldSkill 185LCD 9. Remote Control Socket The 8 pin Remote Control Socket is used to connect remote control devices (i.e. Spool Gun or Tig Torch) to the welding power source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
  • Page 31 WeldSkill 185LCD 11. Negative Welding Output Terminal The negative welding terminal 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.
  • Page 32 WeldSkill 185LCD VRD is a hazard reducing device designed to reduce electric shock hazards present on the output of welding power source when operating in STICK (MMAW) mode. Note that the presence of VRD should not be used as a substitute for the use of appropriate safety practices as indicated in Section One of this manual. The green VRD ON wording is displayed on the screen when the VRD is active.
  • Page 33 WeldSkill 185LCD 2T Normal Mode In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold the torch trigger to activate the power source (weld). Release the torch trigger switch to cease welding.
  • Page 34 WeldSkill 185LCD 21. SPOT Settings (MIG mode only) Spot Weld can only be selected in MIG (GMAW / FCAW) 2T Trigger Mode. Spot Weld Time in MIG (GMAW / FCAW) Mode can be selected and adjusted as shown in figures 4-13 and 4-14. To select Spot Mode select the Spot option by rotating the Control Knob to highlight Spot then press the Control Knob to select.
  • Page 35 WeldSkill 185LCD 23. Factory Reset To restore to factory settings, press Back Button and Control Knob at the same time and hold for 3 seconds until model name screen is displayed. This will reset it to the factory settings. Figure 4-17 24.
  • Page 36 WeldSkill 185LCD This Page Intentionally Blank. OPERATION 4-10 0-5605...

  • Page 37: Mig (Gmaw) Welding

    WeldSkill 185LCD SECTION 5: MIG (GMAW) WELDING 5.01 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 38 WeldSkill 185LCD 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 39 WeldSkill 185LCD Adjusting Flow Rate Preset Argon Regulator Open / Increase Desrease / Close Flow Rate Adjusting Valve Gas Hose Cylinder A-13922_AB Figure 5-2: Adjust Flow Rate With the regulator/flowmeter ready for operation, adjust working flow rate as follows: 1. Slowly turn adjusting valve in anti-clockwise direction to open and increase until the bobbin in the flow tube indicates the required flow rate.

  • Page 40: Attaching The Mig Torch (Euro)

    WeldSkill 185LCD 5.02 Attaching the MIG Torch (Euro) Fit the MIG Torch to the power source by pushing the MIG torch connector into the MIG torch adaptor and screwing the plastic torch nut clockwise to secure the MIG torch to the MIG torch adaptor. Art # A-14736 Figure 5-3: Attaching MIG Torch 5.03 Installing Minispool (100mm diameter)

  • Page 41: Installing Handispool (200Mm Diameter)

    WeldSkill 185LCD 5.04 Installing Handispool (200mm diameter) As delivered from the factory, the unit is set for a Handispool (200mm diameter). In order to re-fit a 200mm spool assemble parts in the sequence shown below in Figure 5-5. Adjustment of the nut will control the Mig 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 Torch trigger is released.

  • Page 42: Feed Roller Pressure Adjustment

    WeldSkill 185LCD Wire Drive Tension Screw Pressure Roller Arm Outlet Guide Art # A-14724 Figure 5-6: Wire Drive Assembly Components Outlet Guide MIG Welding Wire Art # A-14725 Inlet Guide Figure 5-7: Mig Welding Wire - Installation 5.06 Feed Roller Pressure Adjustment The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw.

  • Page 43: Changing The Feed Roll

    WeldSkill 185LCD 5.07 Changing the Feed Roll To change feed roll remove the feed roll retaining screw by turning in an anticlockwise direction. Once the feed roll is removed then to replace feed roll simply reverse these directions. A dual groove feed roller is fitted as standard. It can accommodate 0.8/0.9mm Gasless Flux Cored Wires. Select the roller required with the chosen wire size marking facing outward.

  • Page 44: Setup For Mig (Gmaw) Welding With Gas Shielded Mig Wire

    WeldSkill 185LCD 5.09 Setup for MIG (GMAW) Welding with Gas Shielded Mig Wire A. Fit the MIG Torch to the Power Source. (Refer to Section 5.02 Attaching the MIG Torch). B. Connect the Mig torch polarity lead to the positive welding terminal (+). If in doubt, consult the wire manufacturer.
  • Page 45 WeldSkill 185LCD F. Fit the correct Feed Roll for the Gas Shielded MIG wire being used. Refer to Section 2.11 Options and Accessories for Feed Roll types and Part Numbers. 240VAC Gas Hose Mains Supply Supply Input Lead Shielding Gas Cylinder Negative Welding Terminal Shielding Gas Hose Fitted with Quick...

  • Page 46: Setup For Mig (Gmaw) Welding With Gasless Mig Wire (Flux Cored)

    WeldSkill 185LCD 5.10 Setup for MIG (GMAW) Welding with Gasless MIG Wire (Flux Cored) A. Fit the MIG Torch to the Power Source. (Refer to Section 5.02 Attaching the MIG Torch). B. Connect the Mig Torch polarity lead to the negative welding terminal (-). If in doubt, consult the wire manufacturer.

  • Page 47: Setup For Spool Gun Mig (Gmaw) Welding With Gas Shielded Mig Wire

    WeldSkill 185LCD 5.11 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded Mig Wire A. Select MIG mode with the process selection control (refer to Section 4.02.1 for further information). B. Connect the Mig torch polarity lead to the positive welding terminal (+). If in doubt, consult the wire manufacturer.

  • Page 48: Mig (Gmaw/Fcaw) Basic Welding Technique

    WeldSkill 185LCD 5.12 MIG (GMAW/FCAW) Basic Welding Technique Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the very basic concepts in using the Mig mode of welding, where a welding gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
  • Page 49 WeldSkill 185LCD The welding gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below) Hold the gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper filter lenses and use the proper safety equipment.
  • Page 50 WeldSkill 185LCD Distance from the MIG Torch Nozzle to the Work Piece The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20.0mm. This distance may vary depending on the type of joint that is being welded. Travel Speed The speed at which the molten pool travels influences the width of the weld and penetration of the welding run.
  • Page 51 WeldSkill 185LCD 3. Nozzle Angle. This refers to the position of the welding gun in relation to the joint. The transverse angle is usually one half the included angle between plates forming the joint. The longitudinal angle is the angle between the centre line of the welding gun and a line perpendicular to the axis of the weld. The longitudinal angle is generally called the Nozzle Angle and can be either trailing (pulling) or leading (pushing).
  • Page 52 WeldSkill 185LCD Setting of the Power Source 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 (refer to Section 4.02.2) and the welding Voltage Control (refer to Section 4.02.3).

  • Page 53: Cigweld Mig Wire Selection Chart

    WeldSkill 185LCD 5.13 CIGWELD MIG Wire Selection Chart WeldSkill 185LCD DESCRIPTION DIAMETER PACK PART NUMBER APPLICATION 0.6mm Minispool 0.9kg WS0906 0.6mm Handispool 5kg WS5006 General purpose welding wire suitable for the WELDSKILL 0.8mm Minispool 0.9kg WS0908 all positional Gas Metal Arc Welding (GWAW) SOLID of mild and low alloy steels, used in general fabrication and for welding of light to medium...

  • Page 54: Mig (Gmaw/Fcaw) Welding Troubleshooting

    WeldSkill 185LCD 5.14 MIG (GMAW/FCAW) Welding Troubleshooting 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 and Inconsistent wire feed Solving Problems Beyond the Welding Terminals - Porosity When there is a gas problem the result is usually porosity within the weld metal.
  • Page 55 WeldSkill 185LCD Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1 Feed roller driven by motor in the A Wire spool brake is too tight. (Refer 5.08). wirefeed compartment slipping.
  • Page 56 WeldSkill 185LCD Basic MIG (GMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Undercut A Welding arc voltage too A Decrease voltage or increase the wire feed speed. high. B Incorrect torch angle B Adjust angle. C Excessive heat input C Increase the torch travel speed and/or decrease welding current by decreasing the voltage or decreasing the wire feed speed.

  • Page 57: Stick (Mmaw) Welding

    WeldSkill 185LCD SECTION 6: STICK (MMAW) WELDING 6.01 Setup for STICK (MMAW) Welding A. Switch the Power Source On/Off switch located on the rear of the Power Source to the OFF position. B. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer.

  • Page 58: Arc Welding Electrodes

    WeldSkill 185LCD Figure 6-2: STICK Mode Amps Setting screen Figure 6-3: STICK Welding Screen 240VAC Mains Supply MIG Torch Polarity Lead not connected Electrode Holder Lead Negative Welding Terminal Positive Welding Terminal Art # A-A-14731 Work Lead Figure 6-4: Setup For STICK (MMAW) Welding 6.02 Arc Welding Electrodes Metal arc welding electrodes consist of a core wire surrounded by a flux coating.

  • Page 59: Types Of Electrodes

    WeldSkill 185LCD 6.03 Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications. There are a great number of electrodes used for specialised industrial purposes which are not of particular interest for everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for welding large diameter pipes, etc.

  • Page 60: Size Of Electrode

    WeldSkill 185LCD 6.04 Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufficient current (amperage) to run the smaller size electrodes.

  • Page 61: Effects Of Arc Welding Various Materials

    WeldSkill 185LCD 6.07 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 6-5: Flat position, down hand butt weld the occurrence in this zone of under-bead cracks may result.

  • Page 62: Joint Preparations

    WeldSkill 185LCD Art # A-07694 Art# A-07693 Figure 6-11: Overhead position, butt weld Figure 6-12: Overhead position fillet, weld 6.10 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 63: Arc Welding Technique

    WeldSkill 185LCD 6.11 Arc Welding Technique 20° Art # A-07696_AB 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 64 WeldSkill 185LCD 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 6-12, allowing 1.6mm to 2.4mm gap between B. Fillet Welds them and tack weld at both ends.
  • Page 65 WeldSkill 185LCD 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 66: Distortion

    WeldSkill 185LCD 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 67 WeldSkill 185LCD 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 6-28 through 6-31 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 68: Welding Problems

    WeldSkill 185LCD 6.20 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 grease, paint, etc...
  • Page 69 WeldSkill 185LCD Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high Lack of Art # A-05867_AC inter-run fusion Lack of side fusion, scale dirt, small electrode, Lack of root fusion amperage too low Figure 6-33: Example of Lack of Fusion Description Possible Cause Remedy...
  • Page 70 WeldSkill 185LCD 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 　...

  • Page 71: Tig (Gtaw) Welding

    WeldSkill 185LCD SECTION 7: TIG (GTAW) WELDING 7.01 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 72 WeldSkill 185LCD 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 73: Setup For Lift Tig (Gtaw) Welding

    WeldSkill 185LCD Shutdown Close cylinder valve whenever the regulator/flowmeter is not in use. To shut down for extended periods (more than 30 minutes). 1. Close cylinder or upstream valve tightly. 2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from any ignition source.
  • Page 74 WeldSkill 185LCD G. In the Home Screen shown in figure 7-3 select LIFT TIG mode by rotating the Control Knob and pressing to select. For Control Knob operation, refer to page 4-2 item 1. Refer to Section 4.02 for control settings. Figure 7-3: Home Screen Figure 7-4 Figure 7-5...
  • Page 75 WeldSkill 185LCD Gas Hose 240VAC Shielding Gas Cylinder Mains Supply Mig Torch Polarity Lead not connected Work Lead Negative Welding Terminal (-) 8 Pin Socket Positive Welding Terminal (+) Art # A-14732 TIG Torch Figure 7-10: Setup For Lift TIG (GTAW) Welding 0-5605 TIG (GTAW) Welding...

  • Page 76: Tig (Gtaw) Basic Welding Technique

    WeldSkill 185LCD 7.03 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 77 WeldSkill 185LCD Tungsten Electrode Types Electrode Type Welding Application Features Colour Code (Ground Finish) AC & DC welding of mild Longer life, More stable steel, stainless steel, copper, arc, Easier starting, Wider Ceriated 2% Grey aluminium, magnesium and their current range, Narrower more alloys concentrated arc.

  • Page 78: Tig (Gtaw) Welding Problems

    WeldSkill 185LCD 7.04 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 79 WeldSkill 185LCD FAULT CAUSE REMEDY 9 Arc start is not smooth. A Tungsten electrode A Select the right size tungsten electrode. is too large for the Refer to Table 7-1 Cigweld Tungsten welding current. Electrode Selection Chart. B The wrong electrode B Select the right size tungsten electrode is being used for the type.
  • Page 80 WeldSkill 185LCD This Page Intentionally Blank. TIG (GTAW) Welding 7-10 0-5605...

  • Page 81: Routine Service Requirements And Power Source Problems

    WeldSkill 185LCD SECTION 8: ROUTINE SERVICE REQUIREMENTS AND POWER SOURCE PROBLEMS 8.02 Cleaning the Welding Power 8.01 Routine Maintenance & Source Inspection WARNING WARNING There are extremely dangerous voltage and There are extremely dangerous voltage and power levels present inside this product. Do power levels present inside this product.

  • Page 82: Welding Power Source Problems

    WeldSkill 185LCD 8.05 Welding Power Source Problems PROBLEM CAUSE REMEDY Mains Supply Voltage A Power source is not in the Set the power source to MIG is On, the On/Off switch correct mode of operation. mode. Refer to Section 4.02.1. on the rear panel is in the On position and the B MIG Torch Polarity Lead is...
  • Page 83 WeldSkill 185LCD PROBLEM CAUSE REMEDY Mains Supply Voltage is This may occur due to If this occurs leave the Power On, the On/Off switch in the activation of an in- Source On/Off switch in the Off the rear panel is in the On built protective device position for several minutes to position but the Screen...
  • Page 84 WeldSkill 185LCD PROBLEM CAUSE REMEDY Inconsistent wire feed. A Worn or dirty contact tip. Replace if necessary. B Worn feed roll. Replace. C Excessive brake tension on Reduce brake tension on spool wire reel hub. D Worn, kinked or dirty D Clean or replace conduit liner conduit liner No gas flow in MIG mode.

  • Page 85: Section 9: Key Spare Parts

    WeldSkill 185LCD SECTION 9: KEY SPARE PARTS 9.01 WeldSkill 185LCD Key Spare Parts Art # A-14733 Figure 9-1 WELDSKILL 185LCD POWER SOURCE KEY SPARE PARTS ITEM PART NUMBER DESCRIPTION W7006931 PCBA Power Inverter W7006933 PCBA Front Panel W7006806 PCBA EMC Filter W7006867 Fan Assembly W7006868...

  • Page 86: E-180 Mig Torch 3M (P/N W4018800) Key Spare Parts

    WeldSkill 185LCD 9.02 E-180 MIG Torch 3m (P/N W4018800) Key Spare Parts Art # A-13453 Figure 9-2 MIG TORCH KEY SPARE PARTS ITEM PART NUMBER DESCRIPTION W6000600 Nozzle OTW11/23/R Contact Tip 0.6mm OTW11/30/R Contact Tip 0.8mm OTW11/35/R Contact Tip 0.9mm OTW11/40/R Contact Tip 1.0mm OTW11/45/R...

  • Page 87: Appendix 1: Weldskill 185Lcd Circuit Diagram

    WeldSkill 185LCD APPENDIX 1: WELDSKILL 185LCD CIRCUIT DIAGRAM 0-5605 APPENDIX...
  • Page 88 WeldSkill 185LCD This Page Intentionally Blank. APPENDIX 0-5605...

  • Page 89: Cigweld - Limited Warranty Terms

    WeldSkill 185LCD CIGWELD - LIMITED WARRANTY TERMS LIMITED WARRANTY: CIGWELD Pty Ltd, An ESAB Brand, hereafter, “CIGWELD” warrants to customers of its autho- rized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should...
  • Page 90 WeldSkill 185LCD WARRANTY SCHEDULE – WELDSKILL 185LCD INVERTER WARRANTY WARRANTY PERIOD – (Parts and Labour) WeldSkill 185LCD Inverter Power Source 2 Years ACCESSORIES WARRANTY PERIOD MIG torch, TIG torch, electrode holder lead and 3 Months work lead MIG torch / TIG torch consumable items Gas regulator/flowmeter (excluding seat assem- bly, pressure gauges, elastomer seals and "O"...
  • Page 91 WeldSkill 185LCD This Page Intentionally Blank.
  • Page 92 CIGWELD Pty Ltd Malaysia - Indonesia - CIGWELD An ESAB Brand No 14 Jalan Teknologi 3/1 JI. Pulogadung No. 45 71 Gower Street, Preston VIC 3072 Australia Selangor Science Park 1 Kawasan Industri Pulogadung Customer Care: Kota Damansara, 47810 Petaling Jaya...

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