Revision: AB Issue Date: March 3, 2008 Manual No.: 0-5062
Operating Features:
100
AMP
DC
240
V
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.
This Operating Manual has been designed to instruct you on the
correct use and operation of your CIGWELD product. Your satisfaction
with this product and its safe operation is our ultimate concern.
Therefore please take the time to read the entire manual, especially
the Safety Precautions. They will help you to avoid potential hazards
that may exist when working with this product.
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 Thermadyne Industries Inc. We are a mainline supplier to major
welding industry sectors in the Asia Pacifi c and emerging global
markets including; Manufacturing, Construction, Mining, Automotive,
Engineering, Rural and DIY.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment for industry
operators.
!
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.
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermadyne.com
Copyright 2008 by
Thermadyne Industries, Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher 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.
Publication Date: March 3, 2008
Revision AB Date: July 15, 2008
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
5.06 Welding Power Source Problems ................................................................... 5-5
CIGWELD LIMITED WARRANTY
Terms of Warranty – March 2008
Warranty Schedule – March 2008
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ........................... Inside Rear Cover
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.
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 and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the Australian Standard AS1674.2-2007 entitled: Safety in welding and allied
processes Part 2: Electrical. This publication and other guides to what you should learn before operating
this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION,
MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause
fatal shocks or severe burns. The electrode
and work circuit is electrically live whenever
the output is on. The input power circuit
and machine internal circuits are also live
when power is on. In semiautomatic or
automatic wire welding, the wire, wire
reel, drive roll housing, and all metal parts
touching the welding wire are electrically
live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
5. Properly install and ground this equipment
according to its Owner’s Manual and national,
state, and local codes.
6. Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or
out of service.
7. Use fully insulated electrode holders. Never dip
holder in water to cool it or lay it down on the
ground or the work surface. Do not touch holders
connected to two welding machines at the same
time or touch other people with the holder or
electrode.
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth)
ground.
11. Do not touch electrode while in contact with the
work (ground) circuit.
2. Wear dry, hole-free insulating gloves and body
protection.
3. Insulate yourself from work and ground using dry
insulating mats or covers.
4. Disconnect input power or stop engine before
installing or servicing this equipment. Lock input
power disconnect switch open, or remove line fuses
so power cannot be turned on accidentally.
March 3, 2008
12. Use only well-maintained equipment. Repair or
replace damaged parts at once.
13. In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.
14. Wear a safety harness to prevent falling if working
above floor level.
15. Keep all panels and covers securely in place.
1-1
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.
1. Use a Welding Helmet or Welding Faceshield fi tted
with a proper shade of fi lter (see ANSI Z49.1 and
AS1674.1 listed in Safety Standards) to protect
your face and eyes when welding or watching.
Recommended Protective Filters for Electric Welding
Description of Process
Manual Metal Arc Welding - covered
electrodes (MMAW)
Gas Metal Arc Welding (GWAW)
(MIG) other than Aluminium and
Stainless Steel
Gas Metal Arc Welding (GMAW)
(MIG) Aluminium and Stainless Steel
Gas Tungsten Arc Welding (GTAW)
(TIG)
Flux-cored Arc Welding (FCAW) -
with or without shielding gas.
Air - Arc Gouging
Plasma - Arc Cutting
Plasma - Arc Spraying
Plasma - Arc Welding
Submerged - Arc Welding
Resistance Welding
Approximate Range of
Welding Current in Amps
Less than or equal to 100 8
Greater than 400 13
Less than or equal to 150 10
Greater than 400 14
Less than or equal to 250 12
Less than or equal to 100 10
Greater than 350 14
Less than or equal to 300 11
Greater than 500 14
Less than or equal to 400 12
Less than or equal to 20 8
3. Use protective screens or barriers to protect others
from fl ash and glare; warn others not to watch the
arc.
4. Wear protective clothing made from durable,
fl ame-resistant material (wool and leather) and
foot protection.
5. Use approved ear plugs or ear muffs if noise level
is high.
Minimum Shade Number of
Filter(s)
100 to 200 10
200 to 300 11
300 to 400 12
150 to 250 11
250 to 300 12
300 to 400 13
250 to 350 13
100 to 200 11
200 to 250 12
250 to 350 13
300 to 400 12
400 to 500 13
50 to 100 10
100 to 400 12
400 to 800 14
—
20 to 100 10
100 to 400 12
400 to 800 14
—
—
Safety Spectacles or eye
15
2(5)
shield
1-2
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.
March 3, 2008
WARNING
FUMES AND GASES can be hazardous to
your health.
Welding produces fumes and gases.
Breathing these fumes and gases can be
hazardous to your health.
1. Keep your head out of the fumes. Do not breath
the fumes.
2. If inside, ventilate the area and/or use exhaust at
the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals,
consumables, coatings, and cleaners.
5. Work in a confined space only if it is well ventilated,
or while wearing an air-supplied respirator.
Shielding gases used for welding can displace air
causing injury or death. Be sure the breathing air
is safe.
6. Do not weld in locations near degreasing, cleaning,
or spraying operations. The heat and rays of the
arc can react with vapors to form highly toxic and
irritating gases.
WELDSKILL 100 INVERTER
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.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher
nearby.
6. Be aware that welding on a ceiling, floor, bulkhead,
or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks
or drums.
8. Connect work cable to the work as close to the
welding area as practical to prevent welding current
from traveling long, possibly unknown paths and
causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal.
As welds cool, they can throw off slag.
7. Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating
is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded.
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the
welding arc. The flying sparks and hot
metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns.
Accidental contact of electrode or welding
wire to metal objects can cause sparks,
overheating, or fire.
1. Protect yourself and others from flying sparks and
hot metal.
2. Do not weld where flying sparks can strike
flammable material.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to
treat them carefully.
1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position
by chaining them to a stationary support or
equipment cylinder rack to prevent falling or
tipping.
3. Keep cylinders away from any welding or other
electrical circuits.
March 3, 2008
1-3
WELDSKILL 100 INVERTER
1-4
March 3, 2008
!
4. Never allow a welding electrode to touch any
cylinder.
5. Use only correct shie lding 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. Read and follow instructions on compressed
gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
WARNING
Engines can be dangerous.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Stop engine before installing or connecting
unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting
as necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from
battery.
5. Keep hands, hair, loose clothing, and tools
away from moving parts.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated
areas.
2. If used in a closed area, vent engine exhaust
outside and away from any building air intakes.
WARNING
ENGINE FUEL c a n caus e fire or
explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near
any sparks or open flames.
3. Allow engine to cool before fueling. If possible,
check and add fuel to cold engine before beginning
job.
6. Reinstall panels or guards and close doors
when servicing is finished and before starting
engine.
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a
battery.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when working
on a battery.
4. Do not use welder to charge batteries or jump start
vehicles.
5. Observe correct polarity (+ and –) on batteries.
4. Do not overfill tank — allow room for fuel to
expand.
5. Do not spill fuel. If fuel is spilled, clean up before
starting engine.
WARNING
!
WELDSKILL 100 INVERTER
To reduce magnetic fields in the workplace, use the
following procedures.
1. Keep cables close together by twisting or
taping them.
STEAM AND PRESSURIZED HOT COOLANT
can burn face, eyes, and skin.
The coolant in the radiator can be very hot
and under pressure.
1. Do not remove radiator cap when engine is hot.
Allow engine to cool.
2. Wear gloves and put a rag over cap area when
removing cap.
3. Allow pressure to escape before completely
removing cap.
This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals know to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety code Sec. 25249.5 et seq.)
Considerations About Welding And The
Effects of Low Frequency Electric and
Magnetic Fields
WARNING
NOTE
2. Arrange cables to one side and away from the
operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far
away from body as practical.
ABOUT PACEMAKERS:
The abo ve proce dur es are among
those also normally recommended for
pacemaker wearers. Consult your doctor
for complete information.
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. LeJeune Rd., Miami, FL 33126.
The following is a quotation from the General
Conclusions Section of the U.S. Congress, Office of
Technology Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background
Paper, OTA-BP-E-63 (Washington, DC: U.S.
Government Printing Office, May 1989): “...there is
now a very large volume of scientific findings based
on experiments at the cellular level and from studies
with animals and people which clearly establish that
low frequency magnetic fields and interact with,
and produce changes in, biological systems. While
most of this work is of very high quality, the results
are complex. Current scientific understanding does
not yet allow us to interpret the evidence in a single
coherent framework. Even more frustrating, it does
not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear sciencebased advice on strategies to minimize or avoid
potential risks.”
National Electrical Code, NFPA Standard 70, from
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, from Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Arlington,
VA 22202.
Code for Safety in Welding and Cutting, CSA Standard
W117.2, from Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and
Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New
York, NY 10018.
Cutting and Welding Processes, NFPA Standard
51B, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
Safety in welding and allied processes Part 2:
Electrical, AS1674.2-2007 from SAI Global Limited,
www.saiglobal.com
March 3, 2008
1-5
WELDSKILL 100 INVERTER
1.03 DECLARATION OF CONFORMITY
Manufacturer: CIGWELD
Address: 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.
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 CISPR 11:2004 applicable to Industrial Equipment - generic emissions and regulations.
• EN60974-1 applicable to welding equipment and associated accessories.
• AS60974.1 applicable to welding equipment and associated accessories.
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
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.
1-6
March 3, 2008
SECTION 2:
!
INTRODUCTION
WELDSKILL 100 INVERTER
2.01 How To Use This Manual
This Owner’s Manual applies to just specification or
part numbers listed on page i.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotations are easily
recognized as follows:
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
2.02 Equipment Identification
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. Equipment which does not have a control
panel such as gun and cable assemblies is identified
only by the specification or part number printed on
the shipping container. Record these numbers on the
bottom of page i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If
there is any damage, notify the carrier immediately to
file a claim. Furnish complete information concerning
damage claims or shipping errors to the location
in your area listed in the inside back cover of this
manual.
Include all equipment identification numbers as
described above along with a full description of the
parts in error.
NOTE
A NOTE offers helpful information
c o nc e rn i n g c e rt a i n o p e r at i ng
procedures.
Additional copies of this manual may be purchased by
contacting Cigweld at the address and phone number
for your location listed in the inside back cover of this
manual. Include the Owner’s Manual number and
equipment identification numbers.
Electronic copies of this manual can also be
downloaded at no charge in Acrobat PDF format by
going to the Cigweld web site listed below and clicking
on the Literature Library link:
http://www.cigweld.com.au
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to uncrate the unit.
March 3, 2008
2-1
WELDSKILL 100 INVERTER
2-2
March 3, 2008
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Dangerous Voltage
Off
On
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Remote
Duty Cycle
Percentage
Amperage
Voltage
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Receptacle RatingAuxiliary Power
Art # A-04937
115V 15A
t
t1
t2
%
X
IPM
MPM
t
V
Fuse
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Preflow Time
Postflow Time
Spot Time
Spot Weld Mode
Continuous Weld
Mode
Press to initiate wirefeed and
welding, release to stop.
Purging Of Gas
Inches Per Minute
Meters Per Minute
Disturbance In
Ground System
Welding Gun
Burnback Time
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
4 Step Trigger
Operation
2 Step Trigger
Operation
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
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