Tweco 100 User Manual

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100

WELDSKILL

INVERTER ARC WELDING MACHINE

Operating Manual

Revision: AB Issue Date: March 3, 2008 Manual No.: 0-5062 Operating Features:

100

AMP

240

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.

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.thermadyne.com

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: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

TABLE OF CONTENTS

SECTION 1:

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ..................................... 1-1

1.01 Arc Welding Hazards ....................................................................................... 1-1

1.02 PRINCIPAL SAFETY STANDARDS ................................................................... 1-5

1.03 DECLARATION OF CONFORMITY .................................................................... 1-6

SECTION 2:

INTRODUCTION ..................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identiﬁcation ................................................................................. 2-1

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 Symbol Chart .................................................................................................. 2-2

2.05 Description ..................................................................................................... 2-3

2.06 User Responsibility ......................................................................................... 2-3

2.07 Packaged Items .............................................................................................. 2-3

2.08 Transporting Methods ..................................................................................... 2-3

2.09 Duty Cycle ....................................................................................................... 2-3

2.10 Speciﬁcations ................................................................................................. 2-4

2.11 Options and Accessories ................................................................................. 2-4

SECTION 3:

INSTALLATION ....................................................................................... 3-1

TABLE OF CONTENTS (continued)

3.01 Environment ................................................................................................... 3-1

3.02 Location .......................................................................................................... 3-1

3.03 Ventilation ....................................................................................................... 3-1

3.04 Mains Supply Voltage Requirements .............................................................. 3-1

3.05 Welding Handshield Assembly ........................................................................ 3-1

3.06 Electromagnetic Compatibility ........................................................................ 3-2

3.07 Setup For Manual Arc Welding........................................................................ 3-4

3.08 Setup For TIG Welding .................................................................................... 3-5

SECTION 4:

OPERATION ........................................................................................... 4-1

4.01 Overview ......................................................................................................... 4-1

4.02 Front Panel ..................................................................................................... 4-1

4.03 Arc Welding Electrodes ................................................................................... 4-2

4.04 Types of Electrodes ......................................................................................... 4-2

4.05 Size of Electrode ............................................................................................. 4-3

4.06 Storage of Electrodes ...................................................................................... 4-3

4.07 Electrode Polarity ............................................................................................ 4-3

4.08 Effects of Arc Welding Various Materials ........................................................ 4-3

4.09 Arc Welding Practice ....................................................................................... 4-4

4.10 Welding Position ............................................................................................. 4-4

4.11 Joint Preparations ........................................................................................... 4-5

4.12 Arc Welding Technique ................................................................................... 4-6

4.13 The Welder ...................................................................................................... 4-6

4.14 Striking the Arc ............................................................................................... 4-6

4.15 Arc Length ...................................................................................................... 4-6

4.16 Rate of Travel .................................................................................................. 4-6

4.17 Making Welded Joints ..................................................................................... 4-7

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

5.01 Routine Maintenance & Inspection ................................................................. 5-1

5.02 Cleaning the Welding Power Source ............................................................... 5-1

5.03 Face Shield Maintenance ................................................................................. 5-1

5.04 Basic Troubleshooting .................................................................................... 5-1

5.05 Welding Problems .......................................................................................... 5-2

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.

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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.

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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

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.

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WELDSKILL 100 INVERTER

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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

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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.

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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

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

IPM

MPM

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.

WELDSKILL 100 INVERTER

2.05 Description

Weldskill 100

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.

2.06 User Responsibility

This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment (including welding leads) should not be used. 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 accredited CIGWELD Distributor.

2.07 Packaged Items

• Welding Power Source

• Electrode Holder Lead

• Work Lead

• Plastic Tool Case

• Chipping Hammer/Wire Brush

• Welding Faceshield with Lens

• Operating Manual

2.08 Transporting Methods

This unit is equipped with a handle for carrying purposes.

WARNING

ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source.

This equipment or any of its parts should not be altered from standard speciﬁcation without prior written approval of CIGWELD. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorised modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualiﬁed persons approved by CIGWELD.

WARNING

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Lift unit with handle on top of case.

Use handcart or similar device of adequate capacity.

If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

2.09 Duty Cycle

The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 15% duty cycle, 90 amperes at 23.6 volts. This means that it has been designed and built to provide the rated amperage (90A) for 1.5 minutes, i.e. arc welding time, out of every 10 minute period (15% of 10 minutes is 1.5 minutes). During the other 8.5 minutes of the 10 minute period the Welding Power Source must idle and allowed to cool.

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WELDSKILL 100 INVERTER

2.10 Speciﬁcations

Description WeldSkill 100

Power Source Part Number W1003100 Cooling Fan Cooled Welder Type Inverter Power Source

Welding Power Source Mass 4.2kg Dimensions H 240mm x W 115mm x D 270mm Manufactured to Australian Standard Number of Phases Single Phase Nominal Supply Voltage 240V ±15% Nominal Supply Frequency 50Hz Welding Current Range 5 - 100 Amps Factory Fitted Supply Plug Rating 10 Amps Effective Input Current (I1eff) 9 Amps Maximum Input Current (I1 max) 20 Amps Single Phase Generator Requirement Welding Output, 40°C ,10 min. (quoted ﬁgures refer to MMAW output)

Protection Class IP23S

AS 60974.1-2006

5 KVA

100A @ 20%, 24V

57A @ 60%, 22.3V

45A @ 100%, 21.8V

NOTE

Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.

2.11 Options and Accessories

Description Part Number

TIG Torch Weldskill 100/130 Inverter TIG torch Accessory Kit Flow Meter/Regulator

W7003006

BGSAK2

210254

2-4

March 3, 2008

SECTION 3:

INSTALLATION

WELDSKILL 100 INVERTER

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. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator.

3. In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accessories.

B. Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.

that will exceed the stated conditions. For further information please refer to AS 60529.

H. Precautions must be taken against the power

source toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use.

3.03 Ventilation

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.

3.04 Mains Supply Voltage Requirements

The Mains supply voltage should be within ± 15% of the rated Mains supply voltage. Too low a voltage may cause poor welding performance. Too high a supply voltage will cause components to overheat and possibly fail.

The Welding Power Source must be:

• Correctly installed, if necessary, by a qualiﬁ ed electrician.

• Correctly earthed (electrically) in accordance with local regulations.

3.02 Location

Be sure to locate the welder according to the following guidelines:

A. In areas, free from moisture and dust.

B. Ambient temperature between 0° C to 40° C.

C. In areas, free from oil, steam and corrosive

gases.

D. In areas, not subjected to abnormal vibration or

shock.

E. In areas, not exposed to direct sunlight or rain.

F. Place at a distance of 300mm or more from walls

or similar that could restrict natural air ﬂ ow for cooling.

G. The enclosure design of this power source meets

the requirements of IP23S as outlined in AS 60529 . This provides adequate protection against solid objects (greater than 12mm), and adequate protection against liquids sprayed directly at 60°. Under no circumstances should the unit be operated or connected in a micro environment

• Connected to the correct size power point and fuse as per the Speciﬁ cations on page 2-4.

WARNING

Any electrical work must be carried out by a qualiﬁ ed Electrical Tradesperson.

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Art # A-08430

Art # A-08431

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.

3.06 Electromagnetic Compatibility

WARNING

Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see NOTE below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work, complete with associated input ﬁlters. In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer troublesome.

Figure 3-1: Hook handle into the main face shield

assembly

Figure 3-2: Clip welding lense into position as

shown

NOTE

The welding circuit may or may nor be earthed for safety reasons. Changing the earthing arrangements should only be authorised by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC 974-13 Arc Welding Equipment Installation and use (under preparation).

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 televi sion transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial equipment.

5. The health of people around, e.g. the use of pacemakers and hearing aids.

6. Equi p ment used f or cali brati o n and measurement.

7. The time of day that welding or other activities are to be carried out.

8. The immunity of other equipment in the environment: the user shall ensure that other equipment being used in the environment is compatible: this may require additional protection measures.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

2. Maintenance of Welding Equipment

The welding equipment should be routinely

maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and pro perly fast ened when the we ldin g equipment is in operation. The welding equipment should not be modiﬁed in any way except for those changes and adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilising devices should be adjusted and maintained according to the manufacturer’s recommendations.

3. Welding Cables

The welding cables should be kept as short

as possible and should be positioned close together, running at or close to the floor level.

4. Equipotential Bonding

Bonding of all metallic components in the

welding installation and adjacent to it should be considered. However. Metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

5. Earthing of the Workpiece

C. Met hods o f Reduc i ng Elec troma gneti c

Emissions

1. Mains Supply

Welding equipment should be connected to the

mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as ﬁltering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout it’s length. The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure.

Where the workpiece is not bonded to earth

for electrical safety, nor connected to earth because of it’s size and position, e.g. ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

6. Screening and Shielding

Selective screening and shielding of other

cables and equipment in the surrounding area may alleviate problems of interference. Screening the entire welding installation may be considered for special applications.

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e l

i l

100

WORK

WORK CLAMP

NEGATIVE OUTPUT TERMINAL

POSITIVE OUTPUT TERMINAL

ROD

ARC

ELECTRODE HOLDER

240V AC POWER SOURCE

Art # A-08372_AD

Set Process Selection Switch to MANUAL ARC WELDING mode

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.

Figure 3-3: Set-up for Arc Welding

WELDSKILL 100 INVERTER

240V AC POWER SOURCE

Art # A-08373_AC

NEGATIVE OUTPUT TERMINAL

POSITIVE OUTPUT TERMINAL

Set Process Selection Switch to LIFT TIG mode

l d

i l

100

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.

March 3, 2008

Figure 3-4: Set-up for TIG Welding

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3-6

March 3, 2008

WeldSkill

MANUAL

ARC

LIFT

TIG

POWER

OVER HEAT

WELD CURRENT (A)

100

(A) Process Selection Switch

(D) Welding Current Control

Negative Output Terminal Positive Output Terminal

Art # A-08374_AD

(B) Power On Indicator

SECTION 4:

OPERATION

WELDSKILL 100 INVERTER

4.01 Overview

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. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between different classes of electrode, welding current at any one setting would vary according to the type of electrode in use. The operator should use the welding current range values as a guide, then ﬁnally adjust the current setting to suit the application.

4.02 Front Panel

A. Process Selection Switch

Switches between Lift TIG and Manual Arc Welding modes. Refer to Section 3.06 Setup for Manual Arc Welding and 3.07 Setup for TIG Welding.

B. Power ON Indicator

The Power ON Indicator illuminates when the ON/OFF switch is in the ON position and the correct mains voltage is present.

C. Over Heat Indicator

The welding power source is protected by a self resetting thermostat. The indicator will illuminate if the duty cycle of the power source has been exceeded. If the Over Heat light illuminates wait for the Over Heat light to extinguish before resuming welding.

D. Welding Current Control

The welding current is increased by turning the Weld Current (A) control knob clockwise or decreased by turning the Weld Current (A) control knob anticlockwise. The welding current should be set according to the speciﬁc application. Refer to application notes in this section for further information.

E. ON/OFF Switch (located on rear panel-not

shown)

This switch controls the Mains Supply Voltage to the Power Source.

Figure 4-1: Front Panel

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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.

C. To remove oxygen from the weld metal with ‘deoxidisers’.

D. To provide a cleansing action on the work piece and a protective slag cover over the weld metal to prevent

the formation of oxides while the metal is solidifying. The slag also helps to produce a bead of the desired contour.

E. To introduce alloys into the weld deposits in special type electrodes.

4.04 Types of Electrodes

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

The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be encountered; are all easy to use and all will work on even the most basic of welding machines.

CIGWELD Electrode Selection Chart

Description Diameter Pack Part No. Application

Satincraft 13

Ferrocraft 12XP

2.5mm Handipak 322135

2.5mm 2.5kg 612182

2.0mm Handipak 322128

2.0mm 2.5kg 612231

2.5mm 1kg 322129

General purpose electrode suitable for all positional welding and galvanized steel

General purpose, Xtra performance electrode recommended for all positional (inc. vertical down) welding of mild and galvanized steel.

2.5mm 2.5kg 612232

Speedex 12

2.5mm 1kg SP12251

2.5mm 2.5kg SP12125

Speedex 13 2.5mm 2.5kg SP1325

Table 4-1: Types of Electrodes

User-friendly GP electrode for welding thin section mild and galvanized steels. Excellent for vertical down ﬁllet welding applications. User-friendly GP electrode producing a quiet smooth arc and a ﬂat mitered ﬁllet weld.

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.

For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A little practice will soon establish the most suitable electrode for a given application.

4.06 Storage of Electrodes

Always store electrodes in a dry place and in their original containers.

4.07 Electrode Polarity

Electrodes are generally connected to the ELECTRODE HOLDER and the WORK LEAD to the work piece but if in doubt consult your nearest accredited CIGWELD Distributor.

4.08 Effects of Arc Welding Various Materials

A. High tensile and alloy steels

The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks may result. Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.

B. Austenitic manganese steels

The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.

C. Cast Iron

Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the porosity caused by gas held in this type of iron.

D. Copper and alloys

The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections necessary to give proper fusion of weld and base metal.

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Art # A-07688

Art # A-07689

Art # A-07690

Art A-07691

Art # A-07692

Art# A-07693

Art # A-07694

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. Numerous applications call for welds to be made in positions intermediate between these. Some of the common types of welds are shown in Figures 4-2 through 4-9.

Figure 4-6: Vertical position, butt weld

Figure 4-2: Flat position, down hand butt weld

Figure 4-3: Flat position, gravity ﬁllet weld

Figure 4-4: Horizontal position, butt weld

Figure 4-7: Vertical position, ﬁllet weld

Figure 4-8: Overhead position, butt weld

Figure 4-9: Overhead position ﬁllet, weld

Figure 4-5: Horizontal - Vertical (HV) position

WELDSKILL 100 INVERTER

Gap varies from 1.6mm to 4.8mm depending

on plate thickness

Joint

Open Square Butt

1.6mm max

1.6mm

Single Vee Butt Joint

Not less than

70°

Double Vee Butt Joint

1.6mm

Lap Joint

Tee Joints

(Fillet both sides of the

joint)

Edge Joint

Fillet Joint

Corner Weld

Plug Weld Plug Weld

Not less than

70°

Single Vee Butt Joint

Not less than

45°

1.6mm max

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. Typical joint designs are shown in Figure 4-10.

Figure 4-10: Typical joint designs for arc welding

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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. Make sure that the work clamp is making good electrical contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a poor circuit will probably result.

4.13 The Welder

Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much work as possible sitting down. Don’t hold your body tense. A taut attitude of mind and a tensed body will soon make you feel tired. Relax and you will ﬁnd that the job becomes much easier. You can add much to your peace of mind by wearing a leather apron and gauntlets. You won’t be worrying then about being burnt or sparks setting alight to your clothes.

Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down. If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight off your hand. Be sure the insulation on your cable and electrode holder is not faulty, otherwise you are risking an electric shock.

4.14 Striking the Arc

Practice this on a piece of scrap plate before going on to more exacting work. You may at ﬁrst experience difﬁculty due to the tip of the electrode “sticking” to the work piece. This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it. This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck. As soon as the arc is established, maintain a 1.6mm to

3.2mm gap between the burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.

Another difﬁculty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the arc is broken again. A little practice will soon remedy both of these faults.

Figure 4-11: Striking an arc

4.15 Arc Length

The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will ﬁnd that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs. The weld bead is ﬂattened and spatter increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidiﬁed in. If this should happen, give the electrode a quick twist back over the weld to detach it. Contact or “touch-weld” electrodes such as Ferrocraft 21 do not stick in this way, and make welding much easier.

4.16 Rate of Travel

After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead. The electrode is directed at the weld pool at about 20° from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.

If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. If the travel is too slow, the weld metal piles up and the bead will be too large.

WELDSKILL 100 INVERTER

Art # A-07697

Art # A-07698

Art # A-07699

Art # A-07700

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 6.0mm should have their mating edges bevelled to form a 70° to 90° included angle. This allows full penetration of the weld metal to the root. Using a

3.2mm Ferrocraft 21 electrode at 100 amps, deposit a run of weld metal on the bottom of the joint.

Do not weave the electrode, but maintain a steady rate of travel along the joint sufﬁcient to produce a well-formed bead. At ﬁrst you may notice a tendency for undercut to form, but keeping the arc length short, the angle of the electrode at about 20° from vertical, and the rate of travel not too fast, will help eliminate this. The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc. To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.

ﬁlled, the back is either machined, ground or gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld.

B. Fillet Welds

These are welds of approximately triangular crosssection made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-5.

A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. Using a 3.2mm Ferrocraft 21 electrode at 100 amps, position angle iron with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) ﬁllet. Strike the arc and immediately bring the electrode to a position perpendicular to the line of the ﬁllet and about 45° from the vertical. Some electrodes require to be sloped about 20° away from the perpendicular position to prevent slag from running ahead of the weld. Refer to Figure 4-14. Do not attempt to build up much larger than 6.4mm width with a 3.2mm electrode, otherwise the weld metal tends to sag towards the base, and undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 4-15. Weaving in HV ﬁllet welds is undesirable.

Figure 4-12: Butt weld

Figure 4-13: Weld build up sequence

Heavy plate will require several runs to complete the joint. After completing the ﬁrst run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run. Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4-13. The width of weave should not be more than three times the core wire diameter of the electrode. When the joint is completely

Figure 4-14: Electrode position for HV ﬁllet weld

Figure 4-15: Multi-runs in HV ﬁllet weld

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Art # A-07702

Art # A-07703

Art # A-07704

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. When the ﬁrst run has been completed de-slag the weld deposit and begin the second run at the bottom. This time a slight weaving motion is necessary to cover the ﬁrst run and obtain good fusion at the edges. At the completion of each side motion, pause for a moment to allow weld metal to build up at the edges, otherwise undercut will form and too much metal will accumulate in the centre of the weld. Figure 4-17 illustrates multi-run technique and Figure 4-18 shows the effects of pausing at the edge of weave and of weaving too rapidly.

Figure 4-16: Single run vertical ﬁllet weld

Figure 4-18: Examples of vertical ﬁllet welds

2. Vertical Down

The Ferrocraft 21 electrode makes welding in

this position particularly easy. Use a 3.2mm electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should point upwards at an angle of about 45°.

3. Overhead Welds

Apart from the rather awkward position

necessary, overhead welding is not much more difﬁcult that downhand welding. Set up a specimen for overhead welding by ﬁrst tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch. The electrode is held at 45° to the horizontal and tilted 10° in the line of travel (Figure 4-19). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for overhead ﬁllet welds. Use a 3.2mm Ferrocraft 12XP electrode at 100 amps, and deposit the ﬁrst run by simply drawing the electrode along at a steady rate. You will notice that the weld deposit is rather convex, due to the effect of gravity before the metal freezes.

Figure 4-17: Multi run vertical ﬁllet weld

Figure 4-19: Overhead ﬁllet weld

WELDSKILL 100 INVERTER

Art # A-07705

Art # A-07706

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.

4.19 The Cause of Distortion

Distortion is cause by:

A. Contraction of Weld Metal:

Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In a welded joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore, cooling causes the weld metal to ﬂow plastically, that is, the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint. If the restraint is very great, as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still remain stresses “locked-up” in the structure. If the joint material is relatively weak, for example, a butt joint in

2.0mm sheet, the contracting weld metal may cause the sheet to become distorted.

B. Expansion and Contraction of Parent Metal in the Fusion Zone:

While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions. It is able to do this freely at right angles to the surface of the plate (i.e., “through the weld”), but when it attempts to expand “across the weld” or “along the weld”, it meets considerable resistance, and to fulﬁl the desire for continued expansion, it has to deform plastically, that is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by expanding, pushes against the cooler, harder metal further away, and tends to bulge (or is “upset”). When the weld area begins to cool, the “upset” metal attempts to contract as much as it expanded, but, because it has been “upset”, it does not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal. Several things can then happen.

The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful contraction stresses (distortion), or the weld may crack, in any case, there will remain “locked-up” stresses in the job. Figures 4-20 and 4- 21 illustrate how distortion is created.

Figure 4-20: Parent metal expansion

Figure 4-21: Parent metal contraction

4.20 Overcoming Distortion Effects

There are several methods of minimising distortion effects.

A. Peening

This is done by hammering the weld while it is still hot. The weld metal is ﬂattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer.

B. Distribution of Stresses

Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 4-25 through 4-28 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion.

C. Restraint of Parts

Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and tack welds are methods employed with this in view.

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WELDSKILL 100 INVERTER

Art # A-07710

Art # A-07711

Art # A-07712

Art # A-07713

Art # A-07707

Art # A-07708

Art # A-07709

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. Preheating

Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure 4-23 shows a simple application. By removing the heating source from b and c as soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.

Figure 4-25: Welding sequence

Figure 4-26: Step back sequence

Figure 4-22: Principle of presetting

Figure 4-23: Reduction of distortion by preheating

Figure 4-27: Chain intermittent welding

Figure 4-28: Staggered intermittent welding

4-10

Figure 4-24: Examples of distortion

March 3, 2008

SECTION 5:

SERVICE

WELDSKILL 100 INVERTER

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.

Welding equipment should be regularly checked by a qualiﬁed electrical tradesperson to ensure that:

• The main earth wire of the electrical installation is intact.

• Power point for the Welding Power Source is effectively earthed and of adequate current rating.

• Plugs and cord extension sockets are correctly wired.

• Flexible cord is of the 3-core tough rubber or plastic sheathed type of adequate rating, correctly connected and in good condition.

5.02 Cleaning the Welding Power Source

WARNING

Refer to WARNING on page 3-2.

To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated dirt, metal ﬁlings, slag and loose material. Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current.

CAUTION

Do not use compressed air to clean the Welding Power Source. Compressed air can force metal particles to lodge between live electrical parts and earthed metal parts within the Welding Power Source. This may result in arcing between this parts and their eventual failure.

• Welding terminals are shrouded to prevent inadvertent contact or short circuit.

• The frame of the Welding Power Source is effectively earthed.

• Welding leads and electrode holder are in good condition.

• The Welding Power Source is clean internally, especially from metal ﬁling, slag, and loose material. If any parts are damaged for any reason, replacement is recommended.

March 3, 2008

5-1

WELDSKILL 100 INVERTER

5-2

March 3, 2008

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. Immediately replace any scratched, cracked, or pitted lenses as they may impair visibility and reduce protection.

• Inspect Faceshield Shell frequently. Immediately replace any damaged or worn components.

• The Faceshield and Lens should be cleaned after use with a soft cloth.

5.04 Basic Troubleshooting

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 and you have had training in power measurements and troubleshooting techniques.

If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited CIGWELD Service Agent for repair.

The basic level of troubleshooting is that which can be performed without special equipment or knowledge.

5.05 Welding Problems

Insufﬁcient Gap

Incorrect Sequence

Art # A-05866_AB

Description Possible Cause Remedy

1 Gas pockets or voids in weld metal

(Porosity)

WELDSKILL 100 INVERTER

A Electrodes are damp A Dry electrodes before use

B Welding current is too high B Reduce welding current

2 Crack occurring in weld metal soon

after solidiﬁcation commences

3 A gap is left by failure of the weld

metal to ﬁll the root of the weld

C Surface impurities such as oil,

C Clean joint before welding

grease, paint, etc

A Rigidity of joint A Redesign to relieve weld

joint of severe stresses or use crack resistance electrodes

B Insufﬁcient throat thickness B Travel slightly slower to

alloy greater build-up in throat

C Cooling rate is too high C Preheat plate and cool

slowly

A Welding current is too low A Increase welding current

B Electrode too large for joint B Use smaller diameter

electrode C Insufﬁcient gap C Allow wider gap

D Incorrect sequence D Use correct build-up

sequence

Figure 5-1: Example of Insufﬁcient Gap or Incorrect Sequence

Description Possible Cause Remedy

4 Portions of the weld run do not fuse

to the surface of the metal or edge of the joint

March 3, 2008

A Small electrodes used on

heavy cold plate

A Use larger electrodes and

preheat the plate

B Welding current is too low B Increase welding current

C Wrong electrode angle C Adjust angle so the welding

arc is directed more into

the base metal

D Travel speed of electrode is

too high

D Reduce travel speed of

electrode E Scale or dirt on joint surface E Clean surface before

welding

5-3

WELDSKILL 100 INVERTER

5-4

March 3, 2008

Art # A-05867_AB

Lack of inter-run fusion

Lack of side fusion, scale dirt, small electrode, amperage too low

Lack of root fusion

Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high

Art # A-07714

Description Possible Cause Remedy

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).

Figure 5-2: Example of Lack of Fusion

A Welding current is too high. A Reduce welding current

B Welding arc is too long. B Reduce the length of the

welding arc

C Angle of the electrode is

incorrect.

C Electrode should not be

inclined less than 45° to the vertical face

D Joint preparation does not

allow correct electrode angle.

D Allow more room in joint

for manipulation of the electrode.

E Electrode too large for joint. E Use smaller gauge

electrode.

F Insufﬁcient deposit time at

edge of weave.

Pause for a moment at edge of weave to allow weld metal build-up.

Figure 5-3: Examples of undercut

Description Possible Cause Remedy

Not cleaned, or incorrect electrode

Slag trapped in undercut

Slag trapped in root

Art # A-05868

6 Non-metallic particles are trapped in

the weld metal (slag inclusion)

A Non-metallic particles may

be trapped in undercut from previous run

WELDSKILL 100 INVERTER

A If bad undercut is present,

clean slag out and cover with a run from a smaller diameter electrode

B Joint preparation too

restricted

C Irregular deposits allow slag

to be trapped

D Lack of penetration with slag

trapped beneath weld bead

E Rust or mill scale is

preventing full fusion

F Wrong electrode for position

in which welding is done

B Allow for adequate

penetration and room for cleaning out the slag

C If very bad, chip or grind

out irregularities

D Use smaller electrode with

sufﬁcient current to give adequate penetration. Use suitable tools to remove all slag from corners

E Clean joint before welding

F Use electrodes designed

for position in which welding is done, otherwise proper control of slag is difﬁcult

March 3, 2008

Figure 5-4: Examples of Slag Inclusion

5-5

WELDSKILL 100 INVERTER

5.06 Welding Power Source Problems

Description Possible Cause Remedy

1 The welding arc cannot be

established

A The Primary supply voltage

has not been switched ON

B The Welding Power Source

switch is switched OFF

C Loose connections internally Have an Accredited

A Switch ON the Primary

supply voltage

B Switch ON the Welding

Power Source

Cigweld Service Provider repair the connection

2 Maximum output welding current

cannot be achieved with nominal Mains supply voltage

3 Welding current reduces when

welding

4 TIG electrode melts when arc is

struck

5 Arc ﬂutters during TIG welding Tungsten electrode is too

Defective control circuit Have an Accredited

Poor work lead connection to the work piece

TIG torch is connected to the (+) VE terminal

large for the welding current

Cigweld Service Provider inspect then repair the welder

Ensure that the work lead has a positive electrical connection to the work piece

Connect the TIG torch to the (-) VE terminal

Select the correct size of tungsten elecrode

5-6

March 3, 2008

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. 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, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at CIGWELD’s sole option, of any components or parts of the product determined by CIGWELD to be defective.

CIGWELD MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: CIGWELD SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELD with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by CIGWELD 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.

PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN CIGWELD’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY CIGWELD PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. 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 authorized distributor.

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. A consumer should seek legal advice as to the nature and extent of these protected interests. In some circumstances, the supplier of goods and services may legally stipulate that the said conditions, warranties, guarantees, rights and remedies are limited or entirely excluded. The warranties set out in Clause 2 shall be additional to any nonexcludable warranties to which the Customer may be entitled pursuant to any statute.

2. Subject to Clause 3. CIGWELD gives the following warranties to the Customer:

Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantable

quality and reasonably ﬁt for the purpose for which they are supplied by CIGWELD.

CIGWELD will repair or, at its option, replace those of the goods which, upon examination, are found by

CIGWELD to be defective in workmanship and/or materials.

CIGWELD reserves the right to request documented evidence of date of purchase.

3. The Warranty in Clause 2;

Is conditional upon:

The Customer notifying CIGWELD or our Accredited Distributor in writing of its claim within seven (7) days

of becoming aware of the basis thereof, and at its own expense returning the goods which are the subject of the claim to CIGWELD or nominated Accredited Distributor/Accredited Service Provider. The goods being used in accordance with the Manufacturer’s Operating Manuals, and under competent supervision.

Does not apply to:

Obsolete goods sold at auction, second-hand goods and prototype goods.

Breakdown or malfunction caused by accident, misuse or normal wear and tear.

Repairs or replacement made other than by CIGWELD or Accredited Service Providers, unless by prior

arrangement with CIGWELD.

Replacement parts or accessories which may affect product safety or performance and which are not

manufactured, distributed or approved by 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).

The replacement of the goods or the supply of equivalent goods.

The repair of goods.

The payment of cost of replacing the goods or acquiring equivalent goods.

The payment of the cost of having goods repaired.

5. Except as provided in Clauses 2 to 4 above, to the extent permitted by statute, CIGWELD hereby excludes all liability for any loss, damage, death or injury of any kind whatsoever occasioned to the Customer in respect of the supply of goods including direct, indirect, consequential or incidental loss, damage or injury of any kind.

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. CIGWELD reserves the right to request documented evidence of date of purchase.

WARRANTY

INVERTER ARC WELDING POWER SOURCE

Weldskill 100 Inverter ...................................................................................................................... 1 year

Control P.C. Boards .......................................................................................................................... 1 year

All other circuits and components including, but not limited to, relays, switches, contactors,

solenoids, fans, power switch semiconductors.............................................................................. 1 year

ACCESSORIES

Electrode holder and work lead................................................................................................... 3 Months

Please note that the information detailed in this statement supersedes any prior published data produced by CIGWELD.

PERIOD

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.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085

Thermadyne Italy

OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne,Utama Indonesia

Kawasan Industri Jababeka JI Jababeka VI Blok P No. 3 Cikarang - Bekasi, 17550 Indonesia Tel: +62 21 893 6071 Fax: +62 21 893 6067 / 6068 http://www.thermadyne.com

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

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.au

Tweco 100 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual