Page 1
WELDSKILL MIG WELDING MACHINE Art # A-09201 Operating Manual Version No: AC Issue Date: December 1, 2008 Manual No.: 0-5072 Operating Features:...
Page 2
WE APPRECIATE YOUR BUSINESS! Congratulations on your new CIGWELD product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network.
Page 3
CIGWELD Pty Ltd 71 Gower Street Preston, Victoria, Australia, 3072 www.cigweld.com.au Copyright 2008, 2009 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.
SAFE PRACTICES FOR THE USE OF WELDING EQUIPMENT ........4-1 4.01 Precautions To Be Taken By Operators ................ 4-1 4.02 Personal Protection ..................... 4-1 4.03 Resuscitation For Electric Shock Victims ..............4-3 SECTION 5: SET UP FOR THE WELDSKILL 250, 350 MIG POWER SOURCE ....... 5-1 5.01 Power Source Connections ..................5-1 5.02 Wirefeeder Connections ..................... 5-1 5.03 Common Connections ....................5-1 5.04 Drive Roller Pressure Adjustment ................5-1 5.05 Wire Reel Brake .
Page 5
8.05 Solving Problems Beyond The Welding Terminals - Porosity ........8-2 8.06 Solving Problems Beyond The Welding Terminals - Inconsistent Wire Feed ....8-2 8.07 Welding Problems ....................... 8-3 8.08 Power Source/Wirefeeder Problems ................8-4 APPENDIX 1: KEY SPARE PARTS ................... A-1 APPENDIX 2: VOLT/AMP CURVES .................. A-2 CIGWELD LIMITED WARRANTY Terms of Warranty -2008 Warranty Schedule -2008 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ..........inside Rear Cover...
250, 350 SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING ARC WELDING CAN BE HAZARDOUS. 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. 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. Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study connected to power lines; other prac- and training before using this equipment. Some of these practices apply to equipment tices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Page 8
250, 350 safety instructions WARNING WARNING WELDING can cause fire or explosion. FUMES AND GASES can be hazardous to your health. Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot Welding produces fumes and gases. Breathing workpiece, and hot equipment can cause fires and these fumes and gases can be hazardous to your burns. Accidental contact of electrode or welding health. wire to metal objects can cause sparks, overheat- ing, or fire. 1. Keep your head out of the fumes. Do not breath the fumes.
Page 9
250, 350 WARNING WARNING FLYING SPARKS AND HOT METAL can cause ENGINE FUEL can cause fire or explosion. injury. Engine fuel is highly flammable. Chipping and grinding cause flying metal. As welds 1. Stop engine before checking or adding fuel. cool, they can throw off slag. 2. Do not add fuel while smoking or if unit is near any sparks 1. Wear approved face shield or safety goggles. Side shields or open flames. recommended. 3. Allow engine to cool before fuelling. If possible, check and 2. Wear proper body protection to protect skin. add fuel to cold engine before beginning job. 4. Do not overfill tank — allow room for fuel to expand. WARNING 5. Do not spill fuel. If fuel is spilled, clean up before starting engine. CYLINDERS can explode if damaged. Shielding gas cylinders contain gas under high pres- sure. If damaged, a cylinder can explode. Since gas...
250, 350 safety instructions ABOUT PACEMAKERS: The above procedures are among those also normally recommended for pacemaker wearers. LEAD WARNING Consult your doctor for complete information. This product contains chemicals, including lead, or otherwise produces chemicals known to the 1.02 Principal Safety Standards State of California to cause cancer, birth defects and other reproductive harm. Wash hands after...
250, 350 1.03 Declaration of Conformity Manufacturer: CIGWELD Address: 71 Gower St, Preston Victoria 3072 Australia Description of equipment: Welding Equipment (GMAW). WeldSkill 250, 350 MIG Power Source 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. The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive 73/23/EU, as recently changed in Directive 93/68/EU and to the National legislation for the enforcement of the Directive. National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements among them are: * AS/NZS 3652-(EMC Directive EN50199) applicable to arc welding equipment - generic emissions and regulations. * AS 60974.1- 2006 applicable to welding equipment and associated accessories. * IEC 60974-1 applicable to welding equipment and associated accessories. * UL-94V0 flammability rating for all Printed Circuit Boards used. * 92/31/EEC – EMC Directive EN50199 applicable to Arc Welding Equipment – generic emissions and regulations. Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is in-...
Page 12
250, 350 This page left intentionally blank. Manual No 0-5072 1-6 December 1, 2008...
INTRODUCTION welDskIll 250, 350 SECTION 2: INTRODUCTION 2.01 How to Use This Manual 2.02 Equipment Identification This Owner’s Manual usually applies to just the un- The unit’s identification number (specification or part derlined specification or part numbers listed on the number), model, and serial number usually appear on page 3. If none are underlined, they are all covered a nameplate attached to the machine. by this manual. Equipment which does not have a nameplate attached To ensure safe operation, read the entire manual, to the machine is identified only by the specification including the chapter on safety instructions and or part number printed on the shipping container.
250, 350 INTRODUCTION 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 Remote Continuous Weld...
INTRODUCTION welDskIll 250, 350 2.05 Description 2.06 User Responsibility The WeldSkill 250 and 350 MIG Power Sources are This equipment will perform as per the information Gas Metal Arc Welders (GMAW – commonly known contained herein when installed, operated, maintained as MIG) with integrated wire feeder units. The Power and repaired in accordance with the instructions pro- Sources are designed to meet the broad operating vided. This equipment must be checked periodically. needs of the metal fabrication industry where produc- Defective equipment (including welding leads) should tion efficiency is vital. They are designed to meet the not be used. Parts that are broken, missing, plainly requirements of international standard IEC 60974- worn, distorted or contaminated, should be replaced and Australian Standard AS 60974.. immediately. Should such repairs or replacements become necessary, it is recommended that such...
250, 350 INTRODUCTION 2.07 Duty Cycle 30A plug for 250 20A plug for 250 WeldSkill 250 Welding Current (amps) Art # A-08725_AB Duty Cycle for 350 WeldSkill 350 Welding Current (amps) Art # A-08724 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 0 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 30% duty cycle, 350 amperes at 3.5 volts. This means that it has been designed and built to provide the rated amperage (350A) for 3 minutes, i.e. arc welding time, out of every 0 minute period (30% of 0 minutes is 3 minutes). During the other 7 minutes of the 0 minute period the Welding Power...
INTRODUCTION welDskIll 250, 350 2.08 WeldSkill 250 MIG Power Source Specifications Identification, Weights & Measures WeldSkill 250 Plant Assembly W003400 Plant Dimensions H 980mm x W 440mm x D 988mm (including cylinder carrier & wheels) Power Source Part Number W00340 Power Source Mass 00 kg Energy Input (Refer NOTE Below) This Column Applies to the This Column Applies to a Factory Fitted 2.5mm...
250, 350 INTRODUCTION 2.09 WeldSkill 350 MIG Power Source Specifications Identification, Weights & Measures WeldSkill 350 Plant Assembly W003500 Plant Dimensions H 980mm x W 440mm x D 988mm (including cylinder carrier & wheels) Power Source Part Number W00350 Power Source Mass 2 kg Energy Input (Refer NOTE Below) WeldSkill 350 Input Cable Requirements .5mm 3 core + earth heavy duty R90 insulation type Supply Input Voltage 45 VAC Number of Phases & Frequency...
INTRODUCTION welDskIll 250, 350 2.10 Optional Accessories Part Number Description W403200 Feed Roll 0.6 / 0.8 HARD W40320 Feed Roll 0.8 / .0 HARD W403202 Feed Roll .0 / .2 HARD W403204 Feed Roll .2 / .6 HARD W403205 Feed Roll .0 / .2 SOFT W403207 Feed Roll .2 / .6 SOFT W403208 Feed Roll 0.8 / .0 CORED W403209 Feed Roll .0 / .2 CORED W4032 Feed Roll .2 / .6 CORED W40322 Feed Roll .6 / 2.0 CORED W40324 Geared Adaptor W40325 Feed Roll Adaptor W40326 Plain Pressure Roll (top) Table 2-3 Optional Accessories for 250 Part Number Description W403200 Feed Roll 0.6 / 0.8 HARD...
Page 20
250, 350 This page left intentionally blank. Manual No 0-5072 December , 2008...
INstallatIoN weldskIll 250, 350 SECTION 3: INSTALLATION 3.01 Environment may cause poor welding performance. Too high a supply voltage will cause components to overheat These units are not designed for use in environments and possibly fail. with increased hazard of electric shock. The Welding Power Source must be: A. Examples of environments with increased hazard • Correctly installed, if necessary, by a qualified of electric shock are: electrician. . In locations in which freedom of movement • Correctly earthed (electrically) in accordance is restricted, so that the operator is forced to with local regulations.
250, 350 INstallatIoN 3.07 Methods of Reducing detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with Electromagnetic Emissions the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earth- A. Mains Supply ing the welding circuit, see NOTE. In other cases it Welding equipment should be connected to the mains could involve constructing an electromagnetic screen supply according to the manufacturer’s recommen- enclosing the Welding Power Source and the work, dations. If interference occurs, it may be necessary complete with associated input filters. In all cases, to take additional precautions such as filtering of electromagnetic disturbances shall be reduced to the the mains supply. Consideration should be given to point where they are no longer troublesome. shielding the supply cable of permanently installed NOTE welding equipment in metallic conduit or equivalent.
Page 23
INstallatIoN weldskIll 250, 350 bonding should be achieved by suitable capacitance, selected according to national regulations. F. Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may allevi- ate problems of interference. Screening the entire welding installation may be considered for special applications. December , 2008 Manual No 0-5072...
Page 24
250, 350 This page left intentionally blank. Manual No 0-5072 December , 2008...
250, 350 SECTION 4: SAFE PRACTICES FOR THE USE OF WELDING EQUIPMENT In many situations the “striking” voltage can be hazardous. Any person touching simultaneously the electrode lead/terminal and the work lead/terminal may receive a serious electrical shock. Additional precautions must be exercised where two Welding Power Sources are being used close to each other because, under certain conditions, the voltages between the welding terminals of the two Welding Power Sources could be two times the specified open circuit voltage. It is essential that the Welding Power Source is correctly installed, if necessary, by a qualified electrician and maintained in sound mechanical and electrical condition. It is also important that the Welding Power Source be switched off when not in use. 4.01 Precautions to be Taken by • During pauses between welding runs, electrode holders, TIG torches and MIG torches should Operators be so placed that they cannot make electrical contact with persons or conductive objects. • Whenever practicable, all parts of the welding circuit should be isolated from earth and other • The welding leads, both the electrode lead, TIG...
Page 26
250, 350 safe practices Welding Welding Suggested Process current range Filter Lens GMAW 40 – 50A Shade 0 GMAW 50 – 250A Shade GMAW 250 – 300A Shade 2 GMAW 300 – 400A Shade 3 GMAW Over 400A Shade 4 Table 4- Filter lens size Protective filter lenses are provided to reduce the intensity of radiation entering the eye thus filtering out harmful infrared, ultraviolet radiation and a percentage of the visible light. Such filter lenses are incorporated within welding handshields. To prevent damage to the...
250, 350 4.03 Resuscitation For Electric Shock Victims Electric shock may kill immediately. Early • Cause contraction of the muscles of the body; resuscitation is required if a life is to be saved. • Paralyse breathing due to paralysis of the Every Second Counts! Electrical currents may: centre of respiration in the brain;...
Page 28
250, 350 This page left intentionally blank. Manual No 0-5072 December , 2008...
250, 350 SECTION 5: SET UP FOR THE WELDSKILL 250, 350 POWER SOURCE 5.01 Power Source Connections 5.03 Common Connections A. Remove all packaging materials. A. Lift up the wire feeder pressure levers and pass the electrode wire through the inlet guide, B. Connect the work lead to the negative welding between the rollers, through the centre guide, terminal (-) [positive welding terminal (+) for between the rollers, through the outlet guide flux cored electrode wire]. If in doubt, consult...
250, 350 set up 5.05 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. Correct adjustment will result in the wire reel circumference continuing 5.06 Wire Reel Hub Assembly Art # 0-08734 5-2 December , 2008 Manual No 0-5072...
250, 350 SECTION 6: OPERATION 6.01 Front Panel Art # 0-08735 Art # 0-08733 Figure 6- WeldSkill 250 and 350 Front Panel 1. POWER ON INDICATOR The Power ON Indicator illuminates when the ON/OFF knob is in the ON position and the correct mains voltage is present. WARNING When the light is lit, the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential. 2. WIRESPEED CONTROL The Wirespeed Control knob controls the welding current via the electrode wirefeed rate. ie the speed of the wirefeed motor. 3. FINE VOLTAGE CONTROL SWITCH (WELDSKILL 350 ONLY) The Fine Voltage Control switch increases the voltage (in smaller increments than the Coarse switch) as it is rotated in the clockwise direction.
Page 32
8. TORCH CONNECTOR The MIG torch connects to this outlet. 9. OVERHEAT INDICATOR The critical component for thermal protection is the rectifier stack, which is fitted with a thermal overload cut out device. If the overload operates then the machine should be left to cool for approximately 5 minutes before resuming welding. The thermal overload will not operate and there will be no danger of transformer damage if the Power Source is operated within its duty cycle. The WeldSkill 250 and 350 Compact Power Source has a front panel indication of Overheat (Thermal Overload). 10. VOLTAGE CONTROL SWITCH MODE SWITCH (WELDSKILL 250 ONLY) The Voltage Control Switch increases the voltage as it is rotated in the clockwise direction. And do not switch it while welding is going on. December , 2008 Manual No 0-5072...
250, 350 6.02 Internal Welding Controls GAS PURGE Art # A-08738 Figure 6-2 Internal welding controls A. MODE SWITCH The Weld Mode Selector switch selects the method of welding mode. Art # A-08726 Mode Functional Description This mode of welding is used to weld two or more components together with CONTINUOUS (2T) a continuous weld. This mode of welding is used to weld two plates together at a desired location SPOT by melting the top & bottom plates together to form a nugget between them. The spot time period is set by the SPOT TIME control shaft located in the electrode wire compartment. This mode of welding is mainly used for long weld runs, as the operator need LATCH (4T) only press the trigger to activate the weld, then press the trigger again to stop. This obviates the need for the operator to depress the trigger for the complete length of the weld run. Table 6- Mode Switch Functional Description...
Page 34
250, 350 operation B. SPOT TIMER Art # 0-08730 When the MODE SELECTOR switch is switched to the SPOT position, the SPOT TIME shaft controls the duration of a single spot weld. When the MODE SELECTOR switch is switched to the STITCH position, the SPOT TIME shaft controls the welding or 'ON' time whilst stitch welding. C. BURNBACK Art # A-08727 Burnback time is the difference between the wirefeed motor stopping and switching off of the welding cur- rent. The Burnback time allows the electrode wire to burn out of the molten metal weld pool. The Burnback time is factory set for optimum performance. Clockwise adjustment increases Burnback time. D. WIRE INCH SWITCH Art # 0-08729 When the push button switch is pressed down, the electrode wire is fed through the Wirefeed system & MIG torch. No gas flows or welding voltage is not present when the Wire Inch Switch is pressed down. December , 2008 Manual No 0-5072...
Page 35
250, 350 E. GAS PURGE GAS PURGE Art # A-08728 When the push button switch is pressed, the shielding gas flows through the Wirefeed system & out of the MIG torch nozzle. The Wirefeed motor does not operate and welding voltage is not present when the Gas Purge Switch is pressed down. December , 2008 Manual No 0-5072...
Page 36
250, 350 This page left intentionally blank. December , 2008 Manual No 0-5072...
250, 350 SECTION 7: BASIC WELDING TECHNIQUE 7.01 Setting of the Power Source & 7.03 Distance from the MIG Torch Wirefeeder Nozzle to the Work Piece Power source setting requires some practice by the The electrode wire stick out from the MIG Torch nozzle operator, as the welding plant has two control settings should be between 0mm to 20.0mm. This distance that have to balance. These are the Wirespeed control may vary depending on the type of joint that is being and the welding Voltage Control. The welding current welded. is determined by the Wirespeed control, the current 7.04 Travel Speed will increase with increased Wirespeed, resulting in a shorter arc. Less wire speed will reduce the current...
Page 38
250, 350 basic welding technique This demonstrates that where the upper limit of cur- rent is limited by machine capacity and duty cycle, higher deposition rates and therefore greater pro- ductivity will be achieved by using smaller electrode wire. This product is a particularly efficient MIG welder with the 0.9mm steel wire in spray transfer mode. The savings from decreased welding time will more than cover the small cost penalty of the smaller electrode wire sizes. (0.9mm wire cost approximately 0% more than .2mm, but is deposited approximately 5% faster). Higher current density (or smaller diameter wire) also gives deeper penetration 1.2 mm (.045") 0.9 mm (.035")
250, 350 SECTION 8: SERVICE 8.01 Routine Maintenance & Inspection The only routine maintenance required for the WeldSkill 250, 350 MIG Power Source is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment. WARNING There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Wirefeeder from the Welding Power Source and the Welding Power Source from the Mains Supply Voltage before disassembling. Special maintenance is not necessary for the control unit parts in the Power Source. If these parts are dam- aged for any reason, replacement is recommended. CAUTION Do not blow air into the Power Source during cleaning. Blowing air into the Power Source can cause metal particles to interfere with sensitive electronic components and cause damage to the Power Source..
250, 350 service 8.05 Solving Problems Beyond the Welding Terminals - Porosity When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal. Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be reduced by checking the following points. FAULT CAUSE Gas cylinder contents and flow Ensure that the gas cylinder is not empty and the flow meter is meter. correctly adjusted to 5 litres per minute. Gas leaks. Check for gas leaks between the regulator/cylinder connection and in the gas hose to the Power Source. Internal gas hose in the Power Ensure the hose from the solenoid valve to the torch adaptor Source. has not fractured and that it is connected to the torch adaptor. Welding in a windy environment.
250, 350 Incorrect or worn contact tip The contact tip transfers the weld current to the electrode wire. If the hole in the contact tip is too large then arcing may occur inside the contact tip resulting in the wire jamming in the contact tip. When using soft wire such as aluminium it may become jammed in the contact tip due to expansion of the wire when heated. A contact tip designed for soft wires should be used. Poor work lead contact to work If the work lead has a poor electrical contact to the work piece piece then the connection point will heat up and result in a reduction of power at the arc. Bent liner This will cause friction between the wire and the liner thus reducing wire feedability 8.07 Welding Problems FAULT CAUSE...
250, 350 service 5 Irregular weld shape Incorrect voltage and current Adjust voltage and current by settings. Convex, Arc voltage adjusting the Voltage Control too low switch positions and the Concave, voltage too high Wirespeed control knob. Wire is wandering Replace contact tip Incorrect shielding gas Check gas selection Insufficient or excessive heat Adjust the Wirespeed control knob input or the Voltage Control switch. 6 Arc does not have The MIG torch has been Connect the MIG torch to the a crisp sound that connected to the wrong voltage positive welding terminal (+) for short arc exhibits polarity on the front panel solid wires and gas shielded flux when the wirefeed cored wires. speed and voltage are adjusted correctly 7 Weld cracking Weld beads too small Decrease torch travel speed...
Page 43
250, 350 4 Mains supply voltage Electrode wire stuck in conduit Check for clogged / kinked MIG is ON, no wire feed liner or contact tip (burn-back Torch conduit liner or worn but gas flows from jam). contract tip. Replace faulty the MIG Torch when components. the torch trigger Faulty control PCB Have an Accredited CIGWELD switch is depressed. Service Provider investigate the fault. 5 Wire feeds when the Poor or no work lead contact. Clean work clamp area and ensure torch trigger switch is good electrical contact. depressed but arc can not be established. 6 Jerky wire feed Worn or dirty contact tip Replace Worn feed roll. Replace Excessive back tension from wire Reduce brake tension on spool reel hub. hub...
Page 44
250, 350 This page left intentionally blank. Manual No 0-5072 December , 2008...
250, 350 APPENDIX 1: KEY SPARE PARTS Part No Description Part No Description W7004526 Main Transformer W7004513 Control Transformer W7004501 Contactor W7004532 Thermostat 150°C,WS250 W7004502 PCB Control W7004515 Inch switch W7004503 Solenoid Valve,36VAC W7004538 Thermostat 105°C,WS250 W7004504 Wire Reel Hub W7004517 Resistor 0.5 ohm 30W...
“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,...
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 49
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.
Need help?
Do you have a question about the weldskill 250 and is the answer not in the manual?
Questions and answers