Tweco 350-4R User Manual
250
350
4R
WELDSKILL
MIG WELDING MACHINE
WIREFEEDER (Optional)
Operating Manual
Version No: AE Issue Date: December 27,2013 Manual No.: 0-5182
Operating Features:
Art # A-09908_AB
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 provider call +1300 654 674, or visit
us on the web at www.victortechnologies.com
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
Victor Technologies. We are a mainline supplier to major welding
industry sectors in the Asia Pacific 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.
!
WARNING
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.
Welding Power Supply
Operating Manual Number 0-5182 for:
WeldSkill 250 Compact MIG Plant (Asia) Part Number W1003400
WeldSkill 350 Compact MIG Plant (Asia) Part Number W1003500
WeldSkill 250 Compact MIG Plant (South Pacific) Part Number W1004500
WeldSkill 350 Compact MIG Plant (South Pacific) Part Number W1004600
WeldSkill 4R Wirefeeder Plant (Optional-All Regions) Part Number W3000401
Published by:
CIGWELD Pty Ltd
71 Gower Street
Preston, Victoria, Australia, 3072
www.victortechnologies.com
Copyright 2011, 2012, 2013 by CIGWELD
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 10, 2011
Version AE Date: December 27, 2013
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 Duty Cycle ....................................................................................................... 2-5
2.09 WeldSkill 250 MIG Power Source Specifications ............................................ 2-6
2.10 WeldSkill 350 MIG Power Source Specifications ............................................ 2-7
2.11 WeldSkill 4R Wirefeeder Specifications .......................................................... 2-8
2.12 Optional Accessories .................................................................................... 2-8
SECTION 3:INSTALLATION ............................................................................... 3-1
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 Installation and Users Responsibility .............................................................. 3-2
3.06 Assessment of Area ........................................................................................ 3-2
3.07 Methods of Reducing Electromagnetic Emissions .......................................... 3-2
SECTION 4:OPERATION ................................................................................... 4-1
4.01 Power Source Front Panel ............................................................................. 4-1
4.02 Power Source Internal Welding Controls ........................................................ 4-3
4.03 4R Wirefeeder Front Panel .............................................................................. 4-6
4.04 Shielding Gas Regulator Operating Instructions ............................................. 4-6
SECTION 5:SET UP FOR THE WELDSKILL 250 & 350 POWER SOURCE .......................... 5-1
5.01 Setup For The WeldSkill 250 & 350 MIG Power Source ................................
5.02 Wire Reel Brake ............................................................................................. 5-3
5.03 Setup For The WeldSkill 250 & 350 MIG Power Source When Fitted With
Wirefeeder ...................................................................................................... 5-3
5.04 Wire Reel Brake ............................................................................................. 5-5
5.05 How to Lift WELDSKILL 4R Wirefeeder ..........................................................5-6
5-1
TABLE OF CONTENTS
SECTION 6:BASIC WELDING GUIDE .................................................................... 6-1
6.01 MIG (GMAW/FCAW) Basic Welding Technique ............................................... 6-1
SECTION 7:SERVICE ...................................................................................... 7-1
7.01 Routine Service and Calibration Requirements ............................................... 7-1
7.02 Cleaning the Feed Rolls ................................................................................... 7-3
7.03 Basic Troubleshooting .................................................................................... 7-3
7.04 Solving Problems Beyond the Welding Terminals ........................................... 7-3
7.05 Solving Problems Beyond the Welding Terminals - Porosity ......................... 7-3
7.06 Solving Problems Beyond the Welding Terminals – Inconsistent Wire Feed ... 7-4
7.07 Welding Problems .......................................................................................... 7-5
7.08 Power Source / Wirefeeder Problems ............................................................. 7-6
APPENDIX 1:KEY SPARE PARTS ......................................................................... A-1
APPENDIX 2:VOLT/AMP CURVES ........................................................................ A-4
APPENDIX 3:WELDSKILL 250 MIG POWER SOURCE CIRCUIT DIAGRAM .......................... A-5
APPENDIX 4:WELDSKILL 350 MIG POWER SOURCE CIRCUIT DIAGRAM .......................... A-6
APPENDIX 5:4R WIREFEEDER CIRCUIT DIAGRAM .................................................... A-7
CIGWELD LIMITED WARRANTY
Terms of Warranty – January 2011
Warranty Schedule – January 2011
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
safety instructions weldskill 250, 350
!
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.
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.
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.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
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.
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 fitted with a
proper shade of filter (see ANSI Z49.1 and AS 1674 listed in
safety Standards) to protect your face and eyes when welding
or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
6. Never wear contact lenses while welding.
8. Do not use worn, damaged, undersized, or poorly spliced
cables.
9. Do not wrap cables around your body.
Manual 0-5182
1-1
Safety Instructions
weldskill 250, 350 safety instructions
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
vapours to form highly toxic and irritating gases.
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 air-supplied 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.
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 travelling 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.
Safety Instructions
1-2
Manual 0-5182
safety instructions weldskill 250, 350
Approximate range of Welding
Minimum Shade Number of
Less than or equal to 100
8
100 to 200
10
200 to 300
11
300 to 400
12
250 to 350
13
)
Less than or equal to 100
10
100 to 200
11
200 to 250
12
250 to 350
13
Greater than 350
14
Less than or equal to 300
11
300 to 400
12
400 to 500
13
Greater than 500
14
100 to 400
12
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 Less than or equal to 400 12
Plasma-Arc Cutting
Plasma-Arc Spraying — 15
Plasma-Arc Welding
Submerged Arc Welding — 2(5)
Resistance Welding — Safety Spectacles or eye shield
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.
Current in Amps
Greater than 400 13
Less than or equal to 150 10
150 to 250 11
250 to 300 12
300 to 400 13
Greater than 400 14
Less than or equal to 250 12
50 to 100 10
400 to 800 14
Less than or equal to 20 8
20 to 100 10
100 to 400 12
400 to 800 14
Filter(s)
Manual 0-5182
1-3
Safety Instructions
weldskill 250, 350 safety instructions
WARNING
FLYING SPARKS AND HOT METAL can cause
injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
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.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain
them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder
valve.
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
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 science-based advice on strategies
to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close together by twisting or taping them.
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.
!
WARNING
NOTE
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
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.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
ABOUT PACEMAKERS:
The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.
Safety Instructions
1-4
Manual 0-5182
safety instructions weldskill 250, 350
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.
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 1: Fire Precautions. AS
1674.1- 1997 from SAI Global Limited, www.saiglobal.com.
Safety in welding and allied processes Part 2: Electrical, AS
1674.2- 2007 from SAI Global Limited, www.saiglobal.com.
Filter for eye protectors - Filters for protection against radiation
generated in welding and allied operations AN/NZS 1338.1:1992
from SAI Global Limited, www.saiglobal.com.
Manual 0-5182
1-5
Safety Instructions
weldskill 250, 350 safety instructions
1.03 Declaration of Conformity
Manufacturer: CIGWELD
Address: 71 Gower St, Preston
Victoria 3072
Australia
Description of equipment: Welding Equipment (GMAW). WeldSkill 250, 350 MIG Power Source, Wirefeeder
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:
• IEC60974-10applicabletoIndustrialEquipment-genericemissionsandregulations.
• AS1674Safetyinweldingandalliedprocesses.
• AS60974.1/IEC60974-1applicabletoweldingequipmentandassociatedaccessories.
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.
Safety Instructions
1-6
Manual 0-5182
introduction weldskill 250, 350
SECTION 2:
INTRODUCTION
2.01 How to Use This Manual
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.
NOTE
A NOTE offers helpful information con
cerning certain operating 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.
-
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.
Move the equipment to the installation site before
uncrating the unit. Use care to avoid damaging the
equipment when suing bars, hammers, etc., to uncrate
the unit.
Manual 0-5182 Introduction
2-1
weldskill 250, 350 introduction
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
Hertz (cycles/sec)
Frequency
X
%
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Remote
Duty Cycle
Percentage
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
t2
Preflow Time
Postflow Time
2 Step Trigger
Operation
t1
Press to initiate wirefeed and
welding, release to stop.
115V 15A
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Receptacle RatingAuxiliary Power
Constant Current
Constant Voltage
Or Constant Potential
High Te mperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
V
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
Burnback Time
t
Disturbance In
Ground System
IPM
MPM
Inches Per Minute
Meters Per Minute
Art # A-04937
Introduction
2-2
Manual 0-5182
introduction weldskill 250, 350
2.05 Description
The WeldSkill 250 and 350 MIG Power Sources are
Gas Metal Arc Welders (GMAW – commonly known
as MIG) with integrated wire feeder units. The Power
Sources are designed to meet the broad operating
needs of the modern user and meet the requirements
of Australian Standard AS 60974.1 and International
Standard IEC 60974-1.
The WeldSkill 250 and 350 MIG Power Sources provide excellent performance on mild steel, stainless
steel, aluminium, silicon bronze and some hard facing
wires with Argon based shielding gases. These Power
Sources also provide excellent results on mild steel
using Carbon Dioxide shielding gas.
The WeldSkill 250 and 350 MIG Power Sources are
supplied as complete packages that are ready to
weld (not including shielding gas, electrode wire
and Hiderok™ welding helmet). The units can also
be fitted with an optional remote wirefeeder which
provides portability when welding in positions with
limited access. The instructions in this manual detail
how to correctly set up these machines and provide
guidelines on gaining the best production efficiency
from the power source. Please read this manual
thoroughly before using your welder.
2.07 Packaged Items
WeldSkill 250 MIG Plant (Part No: W1004500)
(South Pacific Version)
• WeldSkill250MIGPowerSource(compact)
• TwecoWeldSkillFabgun250MIGTorch
• Worklead
• WeldSkillArgonRegulator/Flowmeter
• CylinderChain
• 200mmSpoolAdaptor
• Feedrolls:0.6/0.8mmVGroove;
0.9/1.2mm V Groove (fitted),
1.0/1.2mm U Groove;
0.8/0.9mm V Knurled, 1.2/1.6mm V Knurled.
• Contact tips: 0.6mm; 0.8mm, 0.9mm
(fitted);1.0mm, 1.2mm, 1.6mm
• ShieldingGasHoseAssembly
• OperatingManual
WeldSkill 350 MIG Plant (Part No: W1004600)
(South Pacific Version)
• WeldSkill350MIGPowerSource(compact)
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.
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.
• TwecoWeldSkillFabgun400MIGTorch
• Worklead
• WeldSkillArgonRegulator/Flowmeter
• CylinderChain
• 200mmSpoolAdaptor
• Feedrolls:0.6/0.8mmVGroove;
0.9/1.2mm V Groove (fitted),
1.0/1.2mm U Groove;
1.2/1.6mm U Groove, 0.8/0.9mm V Knurled,
1.2/1.6mm V Knurled.
• Contact tips:0.6mm; 0.8mm,0.9mm(tted);
1.0mm, 1.2mm, 1.6mm
• ShieldingGasHoseAssembly
• OperatingManual
Manual 0-5182 Introduction
2-3
weldskill 250, 350 introduction
WeldSkill 250 MIG Plant (Part No: W1003400)
(Asia Version)
• WeldSkill250MIGPowerSource(compact)
• MigTorchMB26style
• Worklead
• CylinderChain
• 200mmSpoolAdaptor
• Feedrolls:0.6/0.8mmVGroove;
0.9/1.2mm V Groove (fitted),
1.0/1.2mm U Groove;
0.8/0.9mm V Knurled, 1.2/1.6mm V Knurled.
• Contact tips: 0.6mm; 0.8mm, 0.9mm
(fitted);1.0mm, 1.2mm, 1.6mm
• ShieldingGasHoseAssembly
• ShieldingGasAdaptor
• OperatingManual
WeldSkill 350 MIG Plant (Part No: W1003500)
(Asia Version)
• WeldSkill350MIGPowerSource(compact)
• MIGTorchMB36style
• Worklead
• CylinderChain
• 200mmSpoolAdaptor
• Feedrolls:0.6/0.8mmVGroove;
0.9/1.2mm V Groove (fitted),
1.0/1.2mm U Groove;
1.2/1.6mm U Groove, 0.8/0.9mm V Knurled,
1.2/1.6mm V Knurled.
• Contact tips: 0.6mm; 0.8mm, 0.9mm
(fitted);1.0mm, 1.2mm, 1.6mm
• ShieldingGasHoseAssembly
• ShieldingGasAdaptor
• OperatingManual
WeldSkill 4R Wirefeeder Plant (Part No: W3000401)
(All Regions)
• WeldSkill4RWirefeeder
• 8mInterconnectionLead(tted)
• 200mmSpoolAdaptor
• ShieldingGasAdaptor
• OperatingManual
Introduction
2-4
Manual 0-5182
introduction weldskill 250, 350
2.08 Duty Cycle
Art# A-09909_AC
WeldSkill 250 Welding Current (amps)
Duty Cycle for 350
WeldSkill 350 Welding Current (amps)
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 30% duty cycle, 350 amperes at 31.5 volts. This means that it has been designed and
built to provide the rated amperage (350A) for 3 minutes, i.e. arc welding time, out of every 10 minute period
(30% of 10 minutes is 3 minutes). During the other 7 minutes of the 10 minute period the Welding Power
Source must idle and be allowed to cool. The thermal cutout will operate if the duty cycle is exceeded.
Manual 0-5182 Introduction
2-5
weldskill 250, 350 introduction
Cooling Fan
2.09 WeldSkill 250 MIG Power Source Specifications
Description WeldSkill 250 MIG
Plant Part Numbers W1003400 & W1004500
Plant Dimensions H 1050mm x W 470mm x D 1020mm
Power Source Mass 100kg
Cooled
Energy Input (Refer NOTE below) This Column applies to the
Factory Fitted 2.5mm
2
(20A)
Primary Lead with 15A
Supply Plug
Input Cable Requirements Factory Fitted 4.0mm
This Column applies to a
4.0mm
2
(25A) Primary
Lead with a 25A Supply
Plug.
2
2 core + earth
heavy duty R90 insulation
type
Nominal Supply Voltage
240VAC 240VAC % ± 10% ± 10
Number of Phases 1 1
Nominal Supply Frequency 50Hz 50Hz
Effective Input Current (I
Maximum Input Current (I
Single Phase Generator Requirement
)
1eff
) 33 Amps 54 Amps
1max
♥
15 Amps
♣
8kVA
♥
24 Amps
♣
13kVA
Welding Current Range 50 – 190A 50 – 270A
Open Circuit Voltage Range 22 to 46 V 22 to 46 V
MIG (GMAW)
Welding Output, 40
o
C, 10 min.
190A @ 20%, 23.5V
110A @ 60%, 19.5V
85A @ 100%, 18.3V
250A @ 20%, 26.5V
144A @ 60%, 21.2V
112A @ 100%, 19.6V
Operating Temperature Range 0ºC - 40ºC 0ºC - 40ºC
Number of Output Voltage Switch Settings 12
Protection Class IP21S
Table 2-1 WeldSkill 250 Power Source Specification
♥ The Effective Input Current should be used for the determination of cable size & supply requirements.
Motor start fuses or thermal circuit breakers are recommended for this application. Check local require-
ments for your situation in this regard.
♣ Generator Requirements at the Maximum Output Duty Cycle.
Reduced output ratings apply with the supplied 15A primary lead. To achieve the maximum rated output
& duty cycle ratings the 20A primary lead must be replaced with a larger primary lead as specified in
section 3.04. This must be carried out be a qualified electrical tradesperson.
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.
Introduction
2-6
Manual 0-5182
introduction weldskill 250, 350
2.10 WeldSkill 350 MIG Power Source Specifications
Description WeldSkill 350 MIG
Plant Part Numbers W1003500 & W1004600
Plant Dimensions H 1050mm x W 470mm x D 1020mm
Power Source Mass 112kg
Cooling Fan Cooled
Input Cable Requirements 1.5mm2 + 3 core & earth heavy duty R90 insulation type
Nominal Supply Voltage
415VAC ± 10%
Number of Phases 3
Nominal Supply Frequency 50Hz
Effective Input Current (I
Maximum Input Current (I
Three Phase Generator Requirement
)
1eff
) 25 Amps
1max
♥
14 Amps
♣
18kVA
Welding Current Range 35 – 380A
Open Circuit Voltage Range 17 to 42 V
MIG (GMAW)
Welding Output, 40
o
C, 10 min.
350A @ 30%, 31.6V
250A @ 60%, 26.3V
205A @ 100%, 24.4V
Operating Temperature Range 0ºC - 40ºC
Number of Output Voltage Switch Settings 24
Protection Class IP21S
Table 2-2 WeldSkill 350 Power Source Specification
The Effective Input Current should be used for the determination of cable size & supply requirements.
♥
Motor start fuses or thermal circuit breakers are recommended for this application. Check local
requirements for your situation in this regard.
Generator Requirements at the Maximum Output Duty Cycle.
♣
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.
Manual 0-5182 Introduction
2-7
weldskill 250, 350 introduction
2.11 WeldSkill 4R Wirefeeder Specifications
Description WeldSkill 4R Wirefeeder
Wirefeeder Plant Part Number W3000401
Wirefeeder Plant Dimensions H 490mm x W 420mm x D 670mm
Wirefeeder Plant Mass 25kg
Wire Feed Motor Voltage 24VDC
Gas Solenoid Voltage 36VAC
Minimum Wire Speed 2 m/min
Maximum Wire Speed 22 m/min
Operating Temperature Range
Interconnection Plug 12 pin
Interconnection Length 8 metre
Table 2-3 WeldSkill 4R Wirefeeder Specification
0ºC – 40ºC
2.12 Optional Accessories
Part Number Description
7977729 Feed Roll 0.6/0.8mm V Groove - hard wire
7977703 Feed Roll 0.9/1.2mm V Groove - hard wire
7977346 Feed Roll 1.2/1.6mm V Groove - hard wire
7977733 Feed Roll 0.8/ 0.9mm U Groove - soft wire
7977730 Feed Roll 1.0/1.2mm U Groove - soft wire
7977348 Feed Roll 1.2/1.6mm U Groove - soft wire
7977734 Feed Roll 0.8/0.9mm V Knurled - flux cored
7977347 Feed Roll 1.2/1.6mm V Knurled - flux cored
FAB250X12 MIG Torch 250A Euro (South Pacific Only)
FAB400X12 MIG Torch 400A Euro (South Pacific Only)
210254 WeldSkill Regulator/Flowmeter (South Pacific Only)
Table 2-4 Optional Accessories for WeldSkill 250, 350 MIGs and 4R Wirefeeder
Introduction
2-8
Manual 0-5182
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