CIGWELD WeldSkill 250 MIG Service Manual
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CIGWELD WeldSkill 250 MIG Service Manual

Mig welding machine and 4r wirefeeder (optional)
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250
350
4R

Service Manual

WELDSKILL
MIG WELDING MACHINE
WIREFEEDER (Optional)
Reversion: AC
Operating Features:
Issue Date: December 27, 2013
Art # A-10132
Manual No.: 0-5186

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Summary of Contents for CIGWELD WeldSkill 250 MIG

  • Page 1: Service Manual

    WELDSKILL MIG WELDING MACHINE WIREFEEDER (Optional) Art # A-10132 Service Manual Reversion: AC Issue Date: December 27, 2013 Manual No.: 0-5186 Operating Features:...
  • Page 2 YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. CIGWELD is the Market Leading Brand of Arc Welding Products for Victor Technologies. We are a mainline supplier to major welding industry sectors in the Asia Pacific and emerging global markets including; Manufacturing, Construction, Mining, Automotive, Engineering, Rural and DIY.
  • Page 3 CIGWELD Pty Ltd 71 Gower Street Preston, Victoria, Australia, 3072 www.victortechnologies.com Copyright 2011, 2012, 2013 by CIGWELD All rights reserved. Reproduction of this work, in whole or in part, without written permission of the pub- lisher is prohibited. The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

  • Page 4: Table Of Contents

    Packaged Items ....................2-2 SECTION 3: SAFETY AND INSTALLATION .............. 3-1 3.01 Duty Cycle ....................... 3-1 3.02 WeldSkill 250 MIG Power Source Specifications ..........3-2 3.03 WeldSkill 350 MIG Power Source Specifications ..........3-3 3.04 WeldSkill 4R Wirefeeder Specifications ............3-4 3.05...
  • Page 5 6.11 Advanced Troubleshooting ................6-14 6.12 Test Specification ..................6-18 6.13 WELDSKILL 250 MIG POWER SOURCE CIRCUIT DIAGRAM ......6-19 6.14 WELDSKILL 350 MIG POWER SOURCE CIRCUIT DIAGRAM ......6-20 SECTION 7: DISASSEMBLY PROCEDURE .............. 7-1 7.01 Safety Precautions for Disassembly ............... 7-1 7.02...

  • Page 7: Section 1: Safety Instructions And Warnings

    SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 250, 350 SECTION 1: 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: Safety Instructions And Warnings

    WELDSKILL 250, 350 SAFETY INSTRUCTIONS AND WARNINGS 2. If inside, ventilate the area and/or use exhaust at the arc to 9. Do not use welder to thaw frozen pipes. remove welding fumes and gases. 10. Remove stick electrode from holder or cut off welding wire at 3.
  • Page 9 SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 250, 350 Recommended Protective Filters for Electric Welding Minimum Shade Number of Approximate range of Weldi Description of Process Current in Amps Filter(s) Less than or equal to 100 100 to 200 Manual Metal Arc Welding covered 200 to 300 electrodes (MMAW) 300 to 400...

  • Page 10: Principal Safety Standards

    WELDSKILL 250, 350 SAFETY INSTRUCTIONS AND WARNINGS WARNING ABOUT PACEMAKERS: MOVING PARTS can cause injury. The above procedures are among those also normally recommended for pacemaker wearers. Consult your Moving parts, such as fans, rotors, and belts can cut fingers and doctor for complete information.

  • Page 11: Declaration Of Conformity

    Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance, ultra safe operation and world class quality for more than 30 years and will continue to achieve excellence.

  • Page 12: Symbol Chart

    WELDSKILL 250, 350 SAFETY INSTRUCTIONS AND WARNINGS 1.04 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...

  • Page 13: Servicing Hazards

    SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 250, 350 1.05 Servicing Hazards WARNING WARNING FLYING METAL or DIRT can injure eyes. The symbols shown below are used throughout this • Wear safety glasses with side shields or face shield during manual to call attention to and identify possible haz- servicing. ards. When you see the symbol, watch out, and follow • Be careful not to short metal tools, parts, or wires together the related instructions to avoid the hazard.

  • Page 14: Emf Information

    WELDSKILL 250, 350 SAFETY INSTRUCTIONS AND WARNINGS • Reinstall doors, panels, covers, or guards when maintenance 1.06 EMF Information is finished and before reconnecting input power. Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields WARNING Welding current, as it flows through welding cables, will cause electromagnetic fields.

  • Page 15: Section 2: Introduction

    INTRODUCTION WELDSKILL 250, 350 SECTION 2: INTRODUCTION 2.01 How to Use This Manual 2.03 Receipt of Equipment This Manual usually applies to the part numbers listed When you receive the equipment, check it against the on page i. To ensure safe operation, read the entire invoice to make sure it is complete and inspect the manual, including the chapter on safety instructions and equipment for possible damage due to shipping.

  • Page 16: User Responsibility

    This equipment or any of its parts should not be altered 1.0/1.2mm U Groove; from standard specification without prior written ap- proval of CIGWELD. The user of this equipment shall 0.8/0.9mm V Knurled, 1.2/1.6mm V Knurled. have the sole responsibility for any malfunction which • C o n t a c t t i p s : 0 .
  • Page 17 INTRODUCTION WELDSKILL 250, 350 WeldSkill 250 MIG Plant (Part No: W1003400) (Asia Version) • WeldSkill 250 MIG Power Source (compact) • Mig Torch MB 26 style • Work lead • Cylinder Chain • 200mm Spool Adaptor • Feed rolls: 0.6/0.8mm V Groove; 0.9/1.2mm V Groove (fitted), 1.0/1.2mm U Groove; 0.8/0.9mm V Knurled, 1.2/1.6mm V Knurled. • Contact tips: 0.6mm; 0.8mm, 0.9mm (fitted);1.0mm, 1.2mm, 1.6mm...
  • Page 18 WELDSKILL 250, 350 INTRODUCTION Notes Introduction Manual 0-5186...

  • Page 19: Section 3: Safety And Installation

    SAFETY AND INSTALLATION WELDSKILL 250, 350 SECTION 3: SAFETY AND INSTALLATION 3.01 Duty Cycle Art# A-09909_AC WeldSkill 250 Welding Current (amps) Duty Cycle for 350 WeldSkill 350 Welding Current (amps) Art # A-08724 WeldSkill 350 Welding Current (amps) Figure 3-1: Weldskill 250 & 350 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.

  • Page 20: Weldskill 250 Mig Power Source Specifications

    WELDSKILL 250, 350 SAFETY AND INSTALLATION 3.02 WeldSkill 250 MIG Power Source Specifications Description WeldSkill 250 MIG Plant Part Numbers W1003400 & W1004500 Plant Dimensions H 1050mm x W 470mm x D 1020mm Power Source Mass 100kg Cooling Fan Cooled...

  • Page 21: Weldskill 350 Mig Power Source Specifications

    SAFETY AND INSTALLATION WELDSKILL 250, 350 3.03 WeldSkill 350 MIG Power Source Specifications Description WeldSkill 350 MIG Plant Part Numbers W1003500 & W1004600 Plant Dimensions H 1050mm x W 470mm x D 1020mm Power Source Mass 112kg Cooling Fan Cooled Input Cable Requirements 1.5mm + 3 core &...

  • Page 22: Weldskill 4R Wirefeeder Specifications

    WELDSKILL 250, 350 SAFETY AND INSTALLATION 3.04 WeldSkill 4R Wirefeeder Specifications Description WeldSkill 4R Wirefeeder Wirefeeder Plant Part Number W3000401 Wirefeeder Plant Dimensions H 490mm x W 420mm x D 670mm Wirefeeder Plant Mass 25kg Wire Feed Motor Voltage 24VDC Gas Solenoid Voltage 36VAC Minimum Wire Speed...

  • Page 23: Environment

    SAFETY AND INSTALLATION WELDSKILL 250, 350 3.05 Environment These units are designed for use in environments with increased hazard of electric shock. A. Examples of environments with increased hazard of electric shock are: 1. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts.

  • Page 24: Mains Supply Voltage Requirements

    • Correctly earthed (electrically) in accordance with local regulations. • Connected to the correct size power point and fuse as per the Specifications on page 3-2, 3-3 and 3-4. The WeldSkill 250 MIG Power Source is supplied with a 20 Amp input lead and is designed for a 240 VAC supply voltage. The following Mains Current Circuit recommendations are required to obtain the maximum welding current and...

  • Page 25: Electrical Input Connections

    SAFETY AND INSTALLATION WELDSKILL 250, 350 3.09 Electrical Input Connections 3.10 Electromagnetic Compatibility WARNING WARNING ELECTRIC SHOCK can kill; SIGNIFICANT Extra precautions for Electromagnetic DC VOLTAGE is present after removal of Compatibility may be required when this input power. Welding Power Source is used in a domestic situation.

  • Page 26: Assessment Of Area

    WELDSKILL 250, 350 SAFETY AND INSTALLATION 2. Maintenance of Welding Equipment 3.12 Assessment of Area The welding equipment should be routinely Before installing welding equipment, the user shall make maintained according to the manufacturer’s an assessment of potential electromagnetic problems recommendations.

  • Page 27: Volt-Ampere Curves

    SAFETY AND INSTALLATION WELDSKILL 250, 350 3.14 Volt-Ampere Curves Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. WeldSkill 250 VA Curve 50.0 45.0 40.0 35.0 30.0 25.0 20.0 15.0 10.0...
  • Page 28 WELDSKILL 250, 350 SAFETY AND INSTALLATION Notes Safety and Installation 3-10 Manual 0-5186...

  • Page 29: Section 4: Operation

    OpERATION WELDSKILL 250, 350 SECTION 4: OPERATION 4.01 Power Source Front Panel Art # 0-09919 Art # 0-09918 TORCH REMOTE REMOTE TORCH Figure 4-1 WeldSkill 250 & 350 MIG Front Panel 1. POWER ON INDICATOR/MAIN POWER CONTROL SWITCH The Power ON Indicator illuminates when the Main Power Control Switch ON/OFF knob is in the ON posi- tion and the correct mains voltage is present.
  • Page 30 WELDSKILL 250, 350 OpERATION 3. VOLTAGE CONTROL SWITCH - FINE (WELDSKILL 350 ONLY) The Fine Voltage Control switch increases the welding voltage (in smaller increments than the Coarse switch) as it is rotated in a clockwise direction. CAUTION The Coarse & Fine Voltage Control switches MUST NOT BE SWITCHED during the welding process.

  • Page 31: Power Source Internal Welding Controls

    OpERATION WELDSKILL 250, 350 10. VOLTAGE CONTROL SWITCH (WELDSKILL 250 ONLY) The Voltage Control Switch is a 12 position that increases the welding voltage as it is rotated in a clockwise direction. CAUTION The Voltage Control switch MUST NOT BE SWITCHED during the welding process. 11.
  • Page 32 WELDSKILL 250, 350 OpERATION A. SPOT TIME SPOT (s) Art # 0-10092 When the TRIGGER MODE SELECTOR switch is switched to the SPOT position, the SPOT TIME control adjusts the duration of a single spot weld. B. TRIGGER MODE SWITCH The Trigger Mode Selector switch selects the desired welding mode.
  • Page 33 OpERATION WELDSKILL 250, 350 D. WIRE INCH SWITCH INCH Art # 0-10094 The Wire Inch Switch is used to feed the MIG wire through the MIG torch. When the push button switch is pressed down, the electrode wire is fed through the Wirefeed system & MIG torch. No gas flows and welding voltage is not present when the Wire Inch Switch is activated.

  • Page 34: Wirefeeder Front Panel

    WELDSKILL 250, 350 OpERATION 4.03 4R Wirefeeder Front Panel WIRESPEED Art # 0-09925_AB 1. WIRESPEED CONTROL The Wirespeed Control Knob controls the welding current via the electrode wirefeed rate, ie the speed of the wirefeed motor. 2. MIG TORCH ADAPTOR (Euro Style) The MIG torch adaptor is the connection point for the MIG welding torch.
  • Page 35 OpERATION WELDSKILL 250, 350 2. NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition. NEVER loosen a connection or attempt to remove any part of a regulator until the gas pressure has been re- lieved.
  • Page 36 WELDSKILL 250, 350 OpERATION Operation 2. To reduce flow rate, allow the welding grade shielding gas to discharge from regulator by With the regulator connected to cylinder or pipeline, opening the downstream valve. Bleed weld- and the adjustment screw/knob fully disengaged, ing grade shielding gas into a well ventilated pressurize as follows: area and away from any ignition source.

  • Page 37: Setup For The Weldskill 250 & 350 Mig Power Source

    OpERATION WELDSKILL 250, 350 4.05 Setup For The WeldSkill 250 & 350 MIG Power Source Power Source Connections A. Remove all packaging materials. B. Connect the work lead to the negative welding terminal (-) [positive welding terminal (+) for flux cored electrode wire].
  • Page 38 WELDSKILL 250, 350 OpERATION Setup for MIG (GMAW) Welding with Setup for MIG (GMAW) Welding Gas Shielded Shielded MIG Wire with Gas Gasless MIG Wire 300mm Wire spool installation 200mm Wire spool installation Art# 0-09923_AD Figure 4-6 WeldSkill 250 & 350 Setup and Spool Hub Operation Manual 0-5186 4-10...

  • Page 39: Wire Reel Brake

    OpERATION WELDSKILL 250, 350 Inserting Wire Into The Wire Feed Mechanism Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide, between the rollers, through the centre guide, between the rollers, through the outlet guide and into the MIG torch. WARNING DO NOT WEAR GLOVES WHILE THREADING THE WIRE OR CHANGING THE WIRE SPOOL.
  • Page 40 WELDSKILL 250, 350 OpERATION Wirefeeder Connections A. Connect the welding power cable from the Wirefeeder’s interconnection cables to the positive welding terminal (+) [negative welding terminal (-) for flux cored electrode wire]. If in doubt, consult the elec- trode wire manufacturer. (Power Source Torch Polarity Lead not required to be connected when using wirefeeder) B.

  • Page 41: Wire Reel Brake

    OpERATION WELDSKILL 250, 350 4.08 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking. If it is considered necessary, adjustment can be made by turning the large nut inside the open end of the hub clockwise to tighten the brake.
  • Page 42 WELDSKILL 250, 350 OpERATION Notes Operation Manual 0-5186 4-14...

  • Page 43: Section 5: Main Circuit Description

    MAIN CIRCUIT DESCRIpTION WELDSKILL 250, 350 SECTION 5: MAIN CIRCUIT DESCRIPTION 5.01 Main Circuit Description Output filter capacitors on the WELDSKILL 250 provide voltage to the arc when the main transformer secondary NOTE voltage drops below the arc voltage. Resistor R3 (15ohm 50W) provides a discharge path for the output This general description should be read in filter capacitors via a normally closed contact on the...
  • Page 44 WELDSKILL 250, 350 MAIN CIRCUIT DESCRIpTION Notes Main Circuit Description Manual 0-5186...

  • Page 45: Section 6: Troubleshooting

    REMEDY 1 Mains supply voltage Primary fuse is blown. Replace primary fuse. is ON. Indicator light Broken connection in primary Have an Accredited CIGWELD is not lit and welding circuit. Service Provider check primary arc can not be circuit. established.

  • Page 46: Checking Unit Before Applying Power

    WELDSKILL 250, 350 TROUBLESHOOTING 8 Gas flow continues Gas valve has jammed open due Have an Accredited CIGWELD after the torch trigger to impurities in the gas or the gas Service Provider repair or replace switch has been line. gas valve.

  • Page 47: Case Removal

    TROUBLESHOOTING WELDSKILL 250, 350 6.04 Case Removal Read and follow safety information in Section 6.02 before proceeding. 1. Cover Remove Screws Art # A-10152 - Remove all the screws from the cover panel 2. Door Panel - Carefully lift the door panel from power source. - Remove screws from the cover panel.

  • Page 48: Visually Inspect

    WELDSKILL 250, 350 TROUBLESHOOTING 6.05 Visually Inspect Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning or arcing of PCB, transformers, switches, or rectifier when a failure occurs. Carefully inspect all components within these units.

  • Page 49: Check Main Output Rectifier

    TROUBLESHOOTING WELDSKILL 250, 350 6.06 Check Main Output Rectifier Read and follow safety information in Section 6.02 before proceeding. Art # A-10154 Output Rectifier Testing Multimeter Lead Placement Diode Voltage AC1 to DC+ Positive meter lead to testpoint 1 0.2-0.8VDC Positive meter lead to testpoint 2 AC2 to DC+ Positive meter lead to testpoint 3...

  • Page 50: Check Main On / Off Switch

    WELDSKILL 250, 350 TROUBLESHOOTING 6.07 Check main On / Off Switch Art # A-10155 Power Switch Testing Multimeter Lead Placement Impedance Positive meter lead to testpoint 2 Switch ON 0 to 0.5 Ω Negative meter lead to testpoint 3 Positive meter lead to testpoint 1 Switch ON 0 to 0.5 Ω...

  • Page 51: Check Main Ac Contractor

    TROUBLESHOOTING WELDSKILL 250, 350 6.08 Check Main AC Contractor AC Contactor Testing Multimeter Lead Placement Impedance 0 to 0.5 Ω Positive meter lead to testpoint 5 Positive meter lead to testpoint 9 Positive meter lead to testpoint 6 0 to 0.5 Ω Positive meter lead to testpoint 10 Positive meter lead to testpoint 7 Contactor ON...

  • Page 52: Control Pcb

    WELDSKILL 250, 350 TROUBLESHOOTING 6.09 Control PCB Art # A-10156 CN1 Header Pin Pin Function Signal AC Contactor control 36VAC Table 6-5 CN1 Header Pin Function(connect to windings of AC contactor) CN2 Header Pin Pin Function Signal Thermostat +15VDC 0VDC Table 6-6 CN2 Header Pin Function(connect to Overheat thermostat) CN3 Header Pin Pin Function...

  • Page 53: Troubleshooting

    TROUBLESHOOTING WELDSKILL 250, 350 CN5 Header Pin Pin Function Signal wiredrive power supply 30VAC wiredrive power supply 30VAC Table 6-9 CN5 Header Pin Function(connect to control transformer) CN6 Header Pin Pin Function Signal Burn back time setpoint Spot Switch Signal Spot Switch Signal Spot time setpoint Spot time setpoint...

  • Page 54: Circuit Diagram For Control Pcb

    WELDSKILL 250, 350 TROUBLESHOOTING 6.10 Circuit Diagram for Control PCB 1. Circuit Diagram for Control PCB MOTOR POWER 17 18 MOTOR 6A10 6A10 510R S8550 100K 180K 1N4007 1N4007 200R BT151 180K 1N4007 R63 1K BT151 BT151 R64 33K 470K R65 6K8 220R 1N4007...
  • Page 55 TROUBLESHOOTING WELDSKILL 250, 350 5. Motor drive To determine wirespeed, a voltage is derived from the +15V rail through R65 to be supplied into the wirespeed potentiometer. Established by the front panel mounted wirespeed potentiometer, R63, R64, a voltage set point is fed to U5 pin 12.
  • Page 56 WELDSKILL 250, 350 TROUBLESHOOTING 10. Inch The INCH button is connected to CN6 terminals 7 & 8. When the INCH button is pressed U5 A pin 3 is pulled high, causing U5 pin 1 to go high, enabling motor drive operation.
  • Page 57 TROUBLESHOOTING WELDSKILL 250, 350 13. Outputs from Control PCB Terminal Output Descriptions Reference DC supply to wire drive motor CN9/3 CN9/1 CN9/3 = 0 to -24 Vdc AC supply to contactor and gas solenoid CN1/1 CN1/3 CN1/1 = 0 Vac (contactor &...

  • Page 58: Advanced Troubleshooting

    WELDSKILL 250, 350 TROUBLESHOOTING 6.11 Advanced Troubleshooting If the problem cannot be solved by the basic (external) troubleshooting guide, the Power Source covers and/or the Wirefeeder covers will have to be removed. The advanced level of troubleshooting allows the technician with a few common tools to remove the covers and analyse failures.
  • Page 59 TROUBLESHOOTING WELDSKILL 250, 350 Once power is applied to the Power Source, there are extremely hazardous voltage and power levels present. Do not touch any live parts. 4 Power Source or Wirefeeder Faults The following table is a guide for analyzing problems and making repairs to the Power Source and/or Wirefeeder. Fault Possible Cause Remedy...
  • Page 60 WELDSKILL 250, 350 TROUBLESHOOTING 5 Power Source Faults The following table is a guide for analysing problems and making repairs to the Power Source. Fault Possible Cause Remedy T h e w i r e f e e d m o t o r Control fuse or circuit breaker is Replace the fuse or repair and the contactor do...
  • Page 61 TROUBLESHOOTING WELDSKILL 250, 350 A welding arc can be Bad electrical connection(s) Repair the termination established but the welding between the secondary side of the point(s) after the fault has c u r r e n t d i m i n i s h e s . main transformer and the rectifier.

  • Page 62: Test Specification

    WELDSKILL 250, 350 TROUBLESHOOTING 6.12 Test Specification 1 Open Circuit Voltage (OCV) Measure open circuit voltage at the output terminals for each of the following settings. Meter used: DC Voltmeter. WELDSKILL 250 Open Circuit Voltage Switch Settings (OCV) Position 1 22.5 V Position 2 23.6 V...

  • Page 63: Weldskill 250 Mig Power Source Circuit Diagram

    TROUBLESHOOTING WELDSKILL 250, 350 6.13 WELDSKILL 250 MIG POWER SOURCE CIRCUIT DIAGRAM Manual 0-5186 6-19 Troubleshooting...

  • Page 64: Weldskill 350 Mig Power Source Circuit Diagram

    WELDSKILL 250, 350 TROUBLESHOOTING 6.14 WELDSKILL 350 MIG POWER SOURCE CIRCUIT DIAGRAM Troubleshooting 6-20 Manual 0-5186...

  • Page 65: Section 7: Disassembly Procedure

    DISASSEMBLY pROCEDURE WELDSKILL 250, 350 SECTION 7: DISASSEMBLY PROCEDURE 7.01 Safety Precautions for Disassembly Read and follow safety information in Section 6.02 before proceeding. Unplug unit before beginning Disassembly procedure. Manual 0-5186 Disassembly Procedure...

  • Page 66: Control Board Removal

    WELDSKILL 250, 350 DISASSEMBLY pROCEDURE 7.02 Control Board Removal Read and follow safety information in Section 6.02 before proceeding with disassembly Remove case (refer to 6.04) before remove control board. Refer to graphics on page 7-3. 1. Disconnect CN1 harness from CN1 connector. 2.

  • Page 67: Disassembly Procedure

    DISASSEMBLY pROCEDURE WELDSKILL 250, 350 Art # A-10201 Art # A-10202 Manual 0-5186 Disassembly Procedure...

  • Page 68: Front Panel Assembly Removal

    WELDSKILL 250, 350 DISASSEMBLY pROCEDURE 7.03 Front Panel Assembly Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Remove wirespeed control knob by loosening the set screw. 2 Remove output voltage select switch by loosening the set screw. 3.
  • Page 69 DISASSEMBLY pROCEDURE WELDSKILL 250, 350 Manual 0-5186 Disassembly Procedure...

  • Page 70: Wirefeeder Assembly Removal

    WELDSKILL 250, 350 DISASSEMBLY pROCEDURE 7.04 Wirefeeder Assembly Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Disconnect the wirefeeder connector. 2. Unscrews the wirefeeder fixed bolts. 3. Unscrew torch polarity lead cable terminal bolts and remove it. Disassembly Procedure Manual 0-5186...

  • Page 71: Back Panel Removal

    DISASSEMBLY pROCEDURE WELDSKILL 250, 350 7.05 Back Panel Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Disconnect input cord from terminals. Ground wire screw. 2. Disconnect power cord form cable anchorage. 3. Disconnect input cord ground wire from rear panel. 4.

  • Page 72: Power Switch S1 And Power Cord Removal

    WELDSKILL 250, 350 DISASSEMBLY pROCEDURE 7.06 Power Switch S1 and Power Cord Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Gas inlet. Remove gas inlet from rear panel. 2. SW1 locking tabs Squeeze the locking tabs and push SW1 out from the rear panel. 3.

  • Page 73: Output Rectifier Removal

    DISASSEMBLY pROCEDURE WELDSKILL 250, 350 7.07 Output Rectifier Removal Read and follow safety information in Section 6.02 before proceeding with disassembly 1. Remove AC input screws. 2. Remove positive output terminal bolts. 3. Remove positive output terminal bolts. 4. Unscrew fixed screws from inductor Manual 0-5186 Disassembly Procedure...
  • Page 74 WELDSKILL 250, 350 DISASSEMBLY pROCEDURE Notes Disassembly Procedure Manual 0-5186...

  • Page 75: Section 8: Assembly Procedures

    ASSEMBLY pROCEDURE WELDSKILL 250, 350 SECTION 8: ASSEMBLY PROCEDURES 8.01 Installing Output Rectifier Assembly 1. Main output rectifier assembly. 2. Install main rectifier assembly to inductor plate. 3. Reconnect secondary of main transformer to rectifier. 4. Reconnect positive dinse to rectifier output positive. 5.

  • Page 76: Installing Back Panel

    WELDSKILL 250, 350 ASSEMBLY pROCEDURES 8.02 Installing Back Panel 1. Install power cord (clockwise rotation until tight). 2. Install gas inlet. 3. Install fan. 4. Reconnect Rear Panel screws. 5. Reconnect power cord to cable anchorage. 6. Reconnect power cord ground wire to rear panel. 7.
  • Page 77 ASSEMBLY pROCEDURE WELDSKILL 250, 350 Manual 0-5186 Assembly Procedures...

  • Page 78: Installing Front Panel

    WELDSKILL 250, 350 ASSEMBLY pROCEDURES 8.03 Installing Front Panel 1. Install potentiometer and knob. Align the knob pointer to line up with maximum correct calibration mark on the panel,then set screw. 2. Install output voltage selection switch. 3. Install power and overheat indicators. 4.
  • Page 79 ASSEMBLY pROCEDURE WELDSKILL 250, 350 BLACK BLACK YELLOW BLUE BLACK ORANGE WHITE Art # A-10278 Manual 0-5186 Assembly Procedures...

  • Page 80: Installing Main Control Panel

    WELDSKILL 250, 350 ASSEMBLY pROCEDURES 8.04 Installing Main Control Panel Refer to diagram page 8-7. 1. Connect CN1 harness from CN1 connector. 2. Connect CN2 harness from CN2 connector. 3. Connect CN3 harness from CN3 connector. 4. Connect CN4 harness from CN4 connector. 5.

  • Page 81: Installing Case

    ASSEMBLY pROCEDURE WELDSKILL 250, 350 8.05 Installing Case 1. Install Case. 2. Install Screws. Tighten screws. Install Screws Tighten Screws Front & Rear Manual 0-5186 Assembly Procedures...
  • Page 82 WELDSKILL 250, 350 ASSEMBLY pROCEDURES Notes Assembly Procedures Manual 0-5186...

  • Page 83: Section 9: Replacement Parts

    REPLACEMENT PARTS WELDSKILL 250, 350 SECTION 9: REPLACEMENT PARTS 9.01 Power Source Art # A-10328_AB WELDSKILL 250 MIG SPARE PARTS WELDSKILL 250 MIG SPARE PARTS Seq. Part No Description W7004501 Contactor W7004502 PCB Control W7004503 Solenoid Valve, 36VAC W7004505 Switch, On/Off, 415V...

  • Page 84: Replacement Parts

    WELDSKILL 250, 350 REPLACEMENT PARTS Art # A-10329_AB WELDSKILL 350 MIG SPARE PARTS WELDSKILL 350 MIG SPARE PARTS Seq. Part No Description W7004501 Contactor W7004502 PCB Control W7004503 Solenoid Valve, 36VAC W7004505 Switch, On/Off, 415V W7004506 Fan Assembly, 220V W7004540 Wire Drive Assembly W7004541 Local Remote Switch...

  • Page 85: Replacement Parts

    REPLACEMENT PARTS WELDSKILL 250, 350 Art # A-10330_AB WELDSKILL 4R WIREFEEDER SPARE PARTS WELDSKILL 4R WIREFEEDER SPARE PARTS Seq. Part No Description W7004540 Wire Drive Assembly W7004539 Solenoid Valve, 36VAC W7004543 Euro Adaptor, (includes rear stem assembly) W7004544 Wire Reel Hub Manual 0-5186 Replacement Parts...
  • Page 86 WELDSKILL 250, 350 REPLACEMENT PARTS Notes Replacement Parts Manual 0-5186...

  • Page 87: Section 10: Options And Accessories

    OpTIONS AND ACCESSORIES WELDSKILL 250, 350 SECTION 10: OPTIONS AND ACCESSORIES 10.01 Options and Accessories Part Number Description 7977729 Feed Roll 0.6/0.8mm V Groove - hard wire 7977703 Feed Roll 0.9/1.2mm V Groove - hard wire 7977346 Feed Roll 1.2/1.6mm V Groove - hard wire 7977733 Feed Roll 0.8/ 0.9mm U Groove - soft wire 7977730...
  • Page 88 WELDSKILL 250, 350 OpTIONS AND ACCESSORIES Notes Options and Accessories 10-2 Manual 0-5186...

  • Page 89: Cigweld Limited Warranty

    WELD whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of CIGWELD is authorized to change this warranty in any way or grant any other warranty.
  • Page 90 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 91 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 93: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Cigweld, Australia Victor Technologies, China 71 Gower Street No.100 Lao Hongjing Rd, Preston, Victoria Minhang District Australia, 3072 Shanghai 200235 Telephone: 61-3-9474-7400 China Fax: 61-3-9474-7391 Telephone: 86-21-64072626 Email: enquiries@cigweld.com.au Fax: 86-21-64483032 Victor Technologies Asia Sdn Bhd...
  • Page 94 Asia Pacific Regional Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX: +61 3 9474 7391 Email: enquiries@cigweld.com.au www.cigweld.com.au...

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