00 ® WELDSKILL INVERTER ARC WELDING MACHINE Operating Manual Revision: AB Operating Features: Issue Date: March 3, 2008 100 AMP DC Manual No.
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. To locate your nearest distributor or service agency call +1300 654 674, or visit us on the web at www.cigweld.com.au.
! WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. Cigweld Weldskill 100 Inverter Arc Welder Instruction Manual Number 0-5062 for: Part Number W1003101 Published by: Thermadyne Industries, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.
TABLE OF CONTENTS TABLE OF CONTENTS (continued) SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS...................................... 1-1 1.01 Arc Welding Hazards........................................................................................ 1-1 1.02 PRINCIPAL SAFETY STANDARDS.................................................................... 1-5 1.03 DECLARATION OF CONFORMITY..................................................................... 1-6 SECTION 2: INTRODUCTION .................
TABLE OF CONTENTS 4.18 Distortion......................................................................................................... 4-9 4.19 The Cause of Distortion................................................................................... 4-9 4.20 Overcoming Distortion Effects......................................................................... 4-9 SECTION 5: SERVICE................................................................................................ 5-1 5.
weldskill 100 INVERTER 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.
WELDSKILL 100 INVERTER 2. Wear approved safety glasses. Side shields recommended. WARNING ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing. 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. 4.
weldskill 100 INVERTER WARNING 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. FUMES AND GASES can be hazardous to your health. 4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 5. Watch for fire, and keep a fire extinguisher nearby. 1.
weldskill 100 INVERTER 4. Never allow a welding electrode to touch any cylinder. 5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. 6. Turn face away from valve outlet when opening cylinder valve. 7. Keep protective cap in place over valve except when cylinder is in use or connected for use. 8.
weldskill 100 INVERTER To reduce magnetic fields in the workplace, use the following procedures. WARNING 1. Keep cables close together by twisting or taping them. STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin. 2. Arrange cables to one side and away from the operator. The coolant in the radiator can be very hot and under pressure. 3. Do not coil or drape cable around the body. 1. Do not remove radiator cap when engine is hot. Allow engine to cool. 2.
weldskill 100 INVERTER 1.03 DECLARATION OF CONFORMITY Manufacturer: Address: CIGWELD 71 Gower St, Preston Victoria 3072 Australia Description of equipment: Welding Equipment (MMAW, GTAW) including, but not limited to CIGWELD Weldskill 100 Inverter 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.
Weldskill 100 INVERTER SECTION 2: INTRODUCTION 2.01 How To Use This Manual 2.02 Equipment Identification This Owner’s Manual applies to just specification or part numbers listed on page i. The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel.
Weldskill 100 INVERTER 2.04 Symbol Chart Note that only some of these symbols will appear on your model. On Single Phase Wire Feed Function Off Three Phase Wire Feed Towards Workpiece With Output Voltage Off.
Weldskill 100 INVERTER 2.05 Description 2.07 Packaged Items Weldskill 100 • Welding Power Source This compact, portable, inverter welding machine has infinitely adjustable welding current from 5 to 100 amps. It is capable of running 1.6mm, 2.0mm and 2.5mm electrodes for a wide range of welding applications. The unit also has a lift TIG function that offers stable TIG welding characteristics when used with a suitable TIG torch and shielding gas. • Electrode Holder Lead 2.
Weldskill 100 INVERTER 2.10 Specifications Description Power Source Part Number Cooling Welder Type WeldSkill 100 W1003100 Fan Cooled Inverter Power Source Welding Power Source Mass Dimensions Manufactured to Australian Standard Number of Phases Nominal Supply Voltage Nominal Supply Frequency Welding Current Range Factory Fitted Supply Plug Rating Effective Input Current (I1eff) Maximum Input Current (I1 max) Single Phase Generator Requirement Welding Output, 40°C ,10 min.
WELDSKILL 100 INVERTER SECTION 3: INSTALLATION 3.01 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. 2.
weldskill 100 INVERTER 3.05 Welding Handshield Assembly ! WARNING The Welding Shade Lens must be correctly fitted to the Welding Handshield prior to use. • Remove the main face shield assembly and the hand grip from the packaging. • Hook the handle into the main face shield assembly as shown in Figure 3-1 below. • Clip the welding lense supplied into position as shown in Figure 3-2 below.
weldskill 100 INVERTER B. Assessment of Area Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account 1. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the welding equipment. 2. Radio and television transmitters and receivers. 3. Computer and other control equipment. 4. Safety critical equipment, e.g. guarding of industrial equipment. 5.
weldskill 100 INVERTER 3.07 Setup For Manual Arc Welding ! WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Mains power supply is switched off. CAUTION Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.
weldskill 100 INVERTER 3.08 Setup For TIG Welding ! WARNING Before connecting the work clamp to the work and inserting the electrode in the TIG torch make sure the Mains power supply is switched off. CAUTION Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.
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weldskill 100 INVERTER SECTION 4: OPERATION 4.01 Overview B. Power ON Indicator Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to workpiece and electrode lead is used to hold electrode. The welding current range values should be used as a guide only.
weldskill 100 INVERTER 4.03 Arc Welding Electrodes Metal arc welding electrodes consist of a core wire surrounded by a flux coating. The flux coating is applied to the core wire by an extrusion process. The coating on arc welding electrodes serves a number of purposes: A. To provide a gaseous shield for the weld metal, and preserve it from contamination by the atmosphere whilst in a molten state. B. To give a steady arc by having ‘arc stabilisers’ present, which provide a bridge for current to flow across.
weldskill 100 INVERTER 4.05 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. For most work, a 2.5mm electrode will be quite sufficient. A 2.5mm electrode will give just as strong a joint but may require a few more weld runs to be put down to fill the joint.
weldskill 100 INVERTER 4.09 Arc Welding Practice The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally enough, different types of electrodes would be used for different metals as described in the preceding section. 4.10 Welding Position The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat, horizontal, vertical and overhead positions.
weldskill 100 INVERTER 4.11 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. In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces.
weldskill 100 INVERTER 4.12 Arc Welding Technique 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 of scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position.
weldskill 100 INVERTER 4.17 Making Welded Joints Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints. A. Butt Welds Set up two plates with their edges parallel, as shown in Figure 4-12, allowing 1.6mm to 2.4mm gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment. Plates thicker than 6.
weldskill 100 INVERTER 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 current at 100 amps. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet. The electrode needs to be about 10° from the horizontal to enable a good bead to be deposited. Refer Figure 4-16. Use a short arc, and do not attempt to weave on the first run.
weldskill 100 INVERTER 4.18 Distortion Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur. The study of distortion is so complex that only a brief outline can be attempted hear.
weldskill 100 INVERTER D. Presetting It is possible in some cases to tell from past experience or to find by trial and error (or less frequently, to calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the components to be welded, constructional stresses can be made to pull the parts into correct alignment. A simple example is shown in Figure 4-22. E.
weldskill 100 INVERTER SECTION 5: SERVICE 5.01 Routine Maintenance & Inspection ! WARNING There are extremely 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 Welding Power Source from the Mains Supply Voltage before disassembling.
weldskill 100 INVERTER 5.03 Face Shield Maintenance Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by CIGWELD. Advice in this regard can be obtained by contacting an accredited CIGWELD Distributor. NOTES • Inspect lenses frequently.
weldskill 100 INVERTER 5.
weldskill 100 INVERTER Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high Art # A-05867_AB Lack of inter-run fusion Lack of side fusion, scale dirt, small electrode, amperage too low Lack of root fusion Figure 5-2: Example of Lack of Fusion Description 5 A groove has been formed in the base metal adjacent to the toe of a weld and has not been filled by the weld metal (undercut). Possible Cause A Welding current is too high.
weldskill 100 INVERTER Description Possible Cause 6 Non-metallic particles are trapped in A Non-metallic particles may the weld metal (slag inclusion) be trapped in undercut from previous run Remedy A If bad undercut is present, clean slag out and cover with a run from a smaller diameter electrode B Joint preparation too restricted B Allow for adequate penetration and room for cleaning out the slag C Irregular deposits allow slag to be trapped C If very bad, chip or grind out irregularities D Lack of
weldskill 100 INVERTER 5.
CIGWELD LIMITED WARRANTY LIMITED WARRANTY: CIGWELD, A Thermadyne Company, hereafter, “CIGWELD” warrants to customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material.
Terms of Warranty – MARCH 2008 1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply of goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including warranties as to merchantability and fitness for purpose) associated with the supply of goods and services.
Warranty Schedule – MARCH 2008 These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of sale from the 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.
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Cigweld, Australia 71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510 Email: cigweldsales@cigweld.com.au Thermadyne USA 2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.
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.
