Tweco 100 User Manual

100
®
INVERTER ARC WELDING MACHINE
Operating Manual
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.
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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
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: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
i
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
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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.
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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
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.
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1-3
WELDSKILL 100 INVERTER
1-4
March 3, 2008
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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
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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
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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