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WELDSKILL 250 Service Manual 350 4R

1. 6 14 WELDSKILL 350 MIG POWER SOURCE CIRCUIT DIAGRAM WELDSKILL 250 350 CO Jojouronuo3od 1uauno Sv vv 2 ITT 275 qoc LO dv 2660 V UY S 3 AS ATA LY 9 9 T jo Lp uoums 109 75 bo 6 L p 5 1 I O 0 DAJLA Se SL IIMS pods lv O pa 75 hoe P 8 001 EAA 8NO 22052122020 a 91 c a LI 9 9 L P es PINA 01 7001 Jour V8 qQesouuoeur Et CHA 5 SI 0 0 AN 49 4 8 A znd 6 109 Desounou 82d ST ages 9NO ALT 61 AVE aoz 0 TINAG Paba AL kay JIAO ENT Ea aa ai cl Le MOT AO ASIP VTT K 1 VC voc NO 81 LI Hcc doc zy 5 6NO __ M MOEBS O zy 101071 dlc IS sad T gzz NE HOLMS Da v y cs Is MN 9A SA 2 m ASIP SR 0 VE 60 80 LI 90 lt ITO INA 6c g ASTE AMNI U00L AOF OOI Ta Kad UA d 2 Ki O Q O Q Te 6A 89 Ld 9d 54 va ta 9T UU ID DOI AS TINY Ma A Bil 4 maa 4 O O O O O 6V Jev ty ov Gv ev IV D DOUUUUUUUUUUUUOUOUUUUUOUUUU OUOUUUUUUU DAL DISASSEMBLY
2. 7 8 7 07 Output Rectifier 0 8 00 7 9 SECTION 8 ASSEMBLY PROCEDURES 8 1 8 01 Installing Output Rectifier 4 4 8 1 8 02 Installing Back Panel 0 2 8 03 Installing Front Panel 6 4 8 04 7 Installing Main Control Panel 6 6 8 05 Installing 8 7 SECTION 9 REPLACEMENT PARTS wiincossntndscocentacovdcsuesdasmudunecivedastudneteraiwedmeeswlen 9 1 9 01 EEE 9 1 SECTION 10 OPTIONS AND ACCESSORIES 10 1 10 01 Options and Accessories AAAH 10 1 CIGWELD LIMITED WARRANTY TERMS OF WARRANTY JANUARY 2011 WARRANTY SCHEDULE JANUARY 2011 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 250 350 SECTION 1 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
3. a PARA PAANI 3 5 3 06 AA 3 5 LGE 3 5 3 08 Mains Supply Voltage Requirements eren 3 6 3 09 Electrical Input Connections aNG AGING 3 7 3 10 Electromagnetic nes 3 7 3 11 Installation and Users Responsibility 3 7 3 12 Assessment of ES oO ERES 3 8 3 13 Methods of Reducing Electromagnetic Emissions 3 0 3 14 X Volt Ampere nnnm nennen 3 9 SEGTIUN 4 OPERATION _ 4 1 4 01 Power Source Front Panel 2 2 0040000000 nnne 4 1 4 02 Power Source Internal Welding 5 4 3 403 4RWirefeeder Front 4 6 4 04 Shielding Gas Regulator Operating 4 6 4 05 Setup For The WeldSkill 250 amp 350 MIG Power Source 4 9 4 06 4 11 4 07 Setup For The WeldSkill 250 amp 350 MIG Power Source When Fitted With lil m 4 11 408 Wire Reel Brake 4 13 4 09 How to Lift WELDSKILL 4R 4 13 SECTION 5 MAIN CIRCUIT DESCRIPTION 5 1 5 01
4. This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it If the equipment is improperly used hazardous conditions are created that may cause accidents It is the users responsibility to prevent such conditions Before handing or using the equipment understand and comply at all times with the safe practices prescribed in this instruction SPECIFIC PROCEDURES for the use of regulators are listed below 1 NEVER subject the regulator to inlet pressure greater than its rated inlet pressure Manual 0 5186 4 6 Operation OPERATION WELDSKILL 250 350 2 NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition NEVER loosen a connection or attempt to remove any part of a regulator until the gas pressure has been re lieved Under pressure gas can dangerously propel a loose part 3 DO NOT remove the regulator from a cylinder without first closing the cylinder valve and releasing gas in the regulator high and low pressure chambers 4 DO NOT use the regulator as a control valve When downstream equipment is not in use for extended periods of time shut off the gas at the cylinder valve and release the gas from the equipment 5 OPEN the cylinder valve SLOWLY Close after use User Responsibilities This equipment will perform safely and reliable only when installed operated and maintained and repaired in
5. z ia ORAA uw Quit r __ 2 paa Coe 7 L UAUA i SS Pot C26 5 c n33 4 bt NICE ROVE HEM o MINI 8 gt R64 ab AL p ot RIS OG 7 po 936 7 2 ko 629 puk A A EC c32 m 0299 27 N ci 9 9 021 er 719 P x 27164 HRE 6 946 Clia 09 ong E te ya 947 C48 HH n e DI 1 254 2 82 46 mos HH His 4 01205 la CL 2S poo 9 La c38 _ aio eee 82 CES 0245 2 d 9 5 2 44 nag CE ere 026 Le ABE nso 443 Li E aroe an CET mm rem 5 10 Art 10201 Assembly Procedures 8 6 Manual 0 5186 ASSEMBLY PROCEDURE WELDSKILL 250 350 8 05 Installing Case 1 Install Case 2 Install Screws Tighten screws 1 Install Screws Tighten Screws Front amp Rear Manual 0 5186 0 Assembly Procedures WELDSKILL 250 350 ASSEMBLY PROCEDURES Notes Assembly Procedures 6 8 Manual 0 5186 REPLACEMENT PARTS 9 01 Power Source SECTION 9 REPLACEMENT PARTS DAs 224 INA V e
6. 4 Connect and tighten the outlet hose firmly and attach down stream equipment 5 To protect sensitive down stream equipment a separate safety device may be necessary if the regulator is not fitted with a pressure relief device Operation 4 7 Manual 0 5186 WELDSKILL 250 350 Operation With the regulator connected to cylinder or pipeline and the adjustment screw knob fully disengaged pressurize as follows 1 Stand to one side of regulator and slowly open the cylinder valve If opened quickly a sudden pressure surge may damage internal regulator parts 2 With valves on downstream equipment closed adjust regulator to approximate working pres sure It is recommended that testing for leaks at the regulator connection points be carried out using a suitable leak detection solution or soapy water 3 Purge air or other unwanted welding grade shielding gas from equipment connected to the regulator by individually opening then closing the equipment control valves Com plete purging may take up to ten seconds or more depending upon the length and size of the hose being purged Adjusting Flow Rate e n At A 05088 AB Figure 4 5 Adjust Flow Rate With the regulator ready for operation adjust working flow rate as follows 1 Slowly turn adjusting screw knob in clock wise direction until the outlet gauge indicates the required flow rate NOTE It may be necessary to re check the shield ing gas regulator flow
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8. gt gt AM LAN PA Manual 0 5186 9 1 WELDSKILL 250 350 Art 10328 Replacement Parts WELDSKILL 250 350 REPLACEMENT PARTS N IN Art A 10329 AB WELDSKILL 350 MIG SPARE PARTS WELDSKILL 350 MIG SPARE PARTS Panno __ _ Rectifier Assembly includes thermostat 400A Replacement Parts 9 2 Manual 0 5186 REPLACEMENT PARTS WELDSKILL 250 350 Art A 10330_AB WELDSKILL 4R WIREFEEDER SPARE PARTS Description Deseriptiom O Euro Adaptor includes rear stem assembly Manual 0 5186 9 3 Heplacement Parts WELDSKILL 250 350 REPLAGEMENT PARTS Notes Replacement Parts 9 4 Manual 0 5186 OPTIONS AND ACCESSORIES WELDSKILL 250 350 SECTION 10 OPTIONS AND ACCESSORIES 10 01 Options and Accessories Part Number Description 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 10 1 Optional Accessories for WeldSkill 250 350 MIGs and 4R Wirefeeder Manual 0 5186 10 1 potions and Accessories WELDSKILL 250 350 OPTIONS AND ACCESSORIES Notes Options and Accessories 10 2 Manual 0 5186 CIGWELD LIMITED WARRANTY LIMITED WARRANTY CIGWELD A Victor Technologies Company hereafter CIGWELD wa
9. 11 Reconnect 4R wirefeeder control wires to the connector block Assembly Procedures 8 4 Manual 0 5186 ASSEMBLY PROCEDURE WELDSKILL 250 350 Dor Jh s 85688 care Bhe cae Di ae s 8508 K 22 D cm Bhe mt aso Jh as 3 On ma NOD Pr gt A Art A 10278 Manual 0 5186 0 9 Assembly Procedures WELDSKILL 250 350 ASSEMBLY PROCEDURES 8 04 Installing Main Control Panel Refer to diagram page 8 7 1 Connect CN1 harness from CN1 connector Connect CN2 harness from CN2 connector Connect CN3 harness from CN3 connector Connect CN4 harness from CN4 connector Connect CN5 harness from CN5 connector 2 3 4 5 6 Connect CN6 harness from CN6 connector 7 Connect CN7 harness from CN7 connector 8 Connect CN8 harness from CN8 connector 9 Connect CNY harness from CN9 connector 10 M4 screw install 4 screws onto control panel Verify harness connections with the system schematic to insure all connections are correct 4 6 7 ng 184 mg Mae 2 2 7 gt 06 9 a TA Ria 24 m 2 ap 062 lt D 9 4 ai cipe 0 gt R28 i na p 4 an ON na oY R60 4 we rit um a RA OHS 765 55
10. 16 8 V SW1 Coarse 2 SW2 Fine 1 21 3 V SW1 Coarse 3 SW2 Fine 1 29 1V SW1 Coarse 3 SW2 Fine 2 30 5 V SW1 Coarse SW2 Fine 3 32 1 V SW1 Coarse SW2 Fine 4 33 8 V SW1 Coarse SW2 Fine 5 35 5 V SW1 Coarse SW2 Fine 6 37 6 V SW1 Coarse 3 SW2 Fine 7 39 7 V SW1 Coarse 3 SW2 Fine 8 42 2 V Table 6 19 Open Circuit Voltage WELDSKILL 350 2 Magnetising Current Measure magnetising current Meter used AC Current Meter Model WELDSKILL 250 WELDSKILL 350 Magnetising Current A 0 5 3 0 0 5 6 0 Table 6 20 Magnetising Current WELDSKILL 250 WELDSKILL 350 Check that the output voltage decays to zero within 15 seconds after trigger is released Meter used DC Voltmeter Troubleshooting 6 18 Manual 0 5186 WELDSKILL 250 350 6 13 WELDSKILL 250 MIG POWER SOURCE CIRCUIT DIAGRAM TROUBLESHOOTING JUALIN 22 212
11. Adaptor e Feed rolls 0 6 0 8mm V Groove 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 e Contact tips 0 6mm 0 8mm 0 9mm fitted 1 0mm 1 2mm 1 6mm e Shielding Gas Hose Assembly Operating Manual Manual 0 5186 INTRODUCTION WeldSkill 250 MIG Plant Part No W1003400 Asia Version WeldSkill 250 MIG Power Source compact Mig Torch MB 26 style Work lead Cylinder Chain 200mm Spool Adaptor Feed rolls 0 6 0 8mm V Groove 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 shielding Gas Hose Assembly shielding Gas Adaptor Operating Manual WeldSkill 350 MIG Plant Part No W1003500 Asia Version WeldSkill 350 MIG Power Source compact MIG Torch MB 36 style Work lead Cylinder Chain 200mm Spool Adaptor Feed rolls 0 6 0 8mm V Groove 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 shielding Gas Hose Assembly shielding Gas Adaptor Operating Manual WeldSkill 4R Wirefeeder Plant Part No W3000401 All Regions WeldSkill 4R Wirefeeder 8m Interconnection Lead fitted 200mm Spool Adaptor shielding Gas Adaptor Operating Manual Manual 0 5186 2 3 WELDSKILL 250 350 Introduction WELDSK
12. DIRT can injure eyes Wear safety glasses with side shields or face shield during Servicing Be careful not to short metal tools parts or wires together during testing and servicing 77 WARNING HOT PARTS can cause sever burns Do not touch hot parts bare handed Allow cooling period before working on equipment To handle not parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 4 Ta de Ag Q4 00 7 WARNING EXPLODING PARTS can cause injury Failed parts can explode or cause other parts to explode when power 15 applied to inverters Always wear a face shield and long sleeves when servicing inverters WARNING SHOCK HAZARD from testing Turn Off welding power source and wire feeder or stop engine before making or changing meter lead connections Use at least one meter lead that has a self retaining spring clip such as an alligator clip Read instructions for test equipment WARNING FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories Use equipment of adequate capacity to lift and support unit If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit WARNING MOVING PARTS can cause injury Keep away from moving parts such as fans Keep away from pinch points such as drive rolls Have only qualified
13. Internal welding controls Operation 4 3 Manual 0 5186 WELDSKILL 250 350 OPERATION A SPOT TIME SPOT s 10 45 Art 0 10092 When the TRIGGER MODE SELECTOR switch is switched to the SPOT position the SPOT TIME control adjusts the duration of a single spot weld B TRIGGER MODE SWITCH The Trigger Mode Selector switch selects the desired welding mode Art A 09922 TRIGGER 2T SPOT NORMAL Mode Functional Description This mode of welding is used to weld two or more components together with NORMAL 2T a continuous weld Pressing and holding the MIG torch trigger switch will activate the power source such that welding can commence Releasing the MIG torch trigger switch will de activate the power source This mode of welding is used to produce short welding runs of a pre set duration This duration is set using the Spot Time Control A Pressing and holding the MIG torch trigger switch will activate the power source until such time as the desired Spot time has elapsed after which the power source will de activate The spot time period is set by the SPOT TIME control A located in the wiredrive compartment This mode of welding is mainly used for long weld runs The MIG torch LATCH 4T trigger switch is depressed and released to activate the power source and then depressed and released a second time to de activate the power source This obviates the need for the operator to depress the trigg
14. Replace all the capacitors if i The rubber safety valve has ruptured li The plastic around the capacitor terminals has melted 6 A large arc occurs when the electrode wire touches the work piece 20 seconds after a weld has been completed Resistor R3 15 ohm 50W is open circuit or it has bad electrical connections The normally closed contacts in the contactor KM are open when the contactor is de energised Replace R3 if it is open circuit repair the termination point s after the fault has been isolated Replace the contactor KM if its contacts are not normally closed when it is de energised Manual 0 5186 Table 6 17 Power Source Faults 6 17 Troubleshooting WELDSKILL 250 350 TROUBLESHOOTING 6 12 Test Specification 1 Open Circuit Voltage OCV Measure open circuit voltage at the output terminals for each of the following settings Meter used DC Voltmeter Switch Settings WELDSKILL 250 Open Circuit Voltage 0CV Position 1 225 V Position 2 23 6 V Position 3 24 8 V Position 4 26 2 V Position 5 278 Position 6 296 Position 7 916V Position 8 338 Position 9 961V Position 10 39 1 Position 11 424 Position 12 46 3 V Table 6 18 Open Circuit Voltage WELDSKILL 250 WELDSKILL 350 Open Circuit Voltage Switch Settings OCV SW1 Coarse 1 SW2 Fine 1
15. Should Such repairs or replacements become necessary It is recommended that such repairs be carried out by ap propriately 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 ap proval of CIGWELD The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorised modifica tion from standard specification faulty maintenance damage or improper repair by anyone other than ap propriately qualified persons approved by CIGWELD Introduction INTRODUCTION 2 07 Packaged Items WeldSkill 250 MIG Plant Part No W1004500 South Pacific Version WeldSkill 250 MIG Power Source compact Tweco WeldSkill Fabgun 250 MIG Torch e Work lead WeldSkill Argon Regulator Flowmeter e Cylinder Chain 200mm Spool Adaptor e Feed rolls 0 6 0 8mm V Groove 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 e Shielding Gas Hose Assembly e Operating Manual WeldSkill 350 MIG Plant Part No W1004600 South Pacific Version WeldSkill 350 MIG Power Source compact Tweco WeldSkill Fabgun 400 MIG Torch e Work lead WeldSkill Argon Regulator Flowmeter e Cylinder Chain 200mm Spool
16. defective electrical connection Repair the torch Check for 30V AC on PCB at pins CN5 1 amp 5 2 Repair fault Check the continuity from connector to the wire speed potentiometer Repair the defective electrical connection Check continuity between the wirefeed motor and connector Repair fault Check fuse circuit breaker Check the continuity from connector to the wire speed potentiometer Repair the defective electrical connection Repair the broken wire s or termination point s after the fault has been isolated Manual 0 5186 6 15 Table 6 16 Power Source or Wirefeeder Faults Troubleshooting WELDSKILL 250 350 5 Power Source Faults TROUBLESHOOTING The following table is a guide for analysing problems and making repairs to the Power Source Fault depressed intermittent basis established Troubleshooting 1 The wirefeed motor and the contactor do not operate when the torch trigger switch is 2 Control fuse or circuit breaker ruptures on an 3 The contactor operates when the torch trigger switch is depressed but a welding arc can not be Possible Cause Control fuse or circuit breaker is open circuit or the wires to the fuse holder are broken The primary winding in the auxiliary transformer is open circuit or the wires to the primary winding are broken The STANDBY SWITCH is in the STANDBY position An extension
17. lead is being used which decreases the Mains supply voltage to the Power Source Thus the control fuse or circuit breaker has to carry a higher current The contactor contacts are burnt and are not making a good electrical contact The Coarse or Fine switch contacts are burnt and are not making a good electrical contact Bad electrical connection s between the Mains supply voltage wires and the primary side of the main transformer Bad electrical connection s between the primary side of the main transformer taps and the Coarse or Fine switches 6 16 Remedy A Replace the fuse or repair the fuse holder wires Replace the auxiliary transformer or repair the wires to it Switch to ON Remove the extension lead amp plug the welder s Mains Supply lead directly into the Mains outlet Measure the voltage drop across all contactor contacts while the Power source is Supplying welding current to load bank If the measured voltage is greater than 100mV then replace the contactor Measure the voltage drop across all closed contacts while the Power source is Supplying welding current to a load bank If the measured voltage 15 greater than 100mV then replace the defective switch Repair the broken wire s or termination point s after the fault has been isolated Repair the broken wire s or termination point s after the fault has been isolated Manual 0 5186 TROUBLESHOOTING 4 A welding
18. persons remove doors panels covers or guards for maintenance as necessary Keep hands hair loose clothing and tools away from moving parts safety Instructions and Warnings WELDSKILL 250 350 Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power WARNING MAGNETIC FIELDS can affect Implanted Medical Devices Wearers of Pacemakers and other Implanted Medical Devices Should keep away from servicing areas until consulting their doctor and the device manufacturer WARNING OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit WARNING RADIATION can cause interference High frequency H F can interfere with radio navigation Safety services computers and communications equipment Have only qualified persons familiar with electronic equipment install test and service H F producing units The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation If notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and Shielding to minimize
19. pin 1 to go high 028 amp 029 are now reverse biased allowing U5 pin 8 to send phase angle control pulses to SCR s U3 amp U4 The collector of Q7 which is now low causes U1 pin 5 to fall below pin 6 and the output pin 7 goes low turning on Q3 which causes U1 pin 3 to go high and charges C6 U1 pin 1 goes high turning on Q2 which turns on Q1 engaging the contactor and enabling welding output When the torch trigger switch is closed U7 is turned on via R51 4 R12 The output of 07 will be closed and U8 pin 1 will be high U8 pin 4 will also be high putting a positive going clock signal into U2 The output of U2 pin 1 remains low as U2 pin 4 is being held high in SPOT or 2T mode Troubleshooting 6 10 Manual 0 5186 TROUBLESHOOTING WELDSKILL 250 350 5 Motor drive To determine wirespeed a voltage 15 derived from the 15V rail through R65 to be supplied into the wirespeed potentiometer Established by the front panel mounted wirespeed potentiometer R63 R64 a voltage set point is fed to 05 pin 12 Motor voltage 15 fed also into 05 pin 12 but as a negative voltage U5D 15 set up as an error amplifier with its gain determined by R61 amp R62 so the output of U5 pin 14 will be the difference between the demand signal from the front panel potentiometer amp the motor voltage The motor power comes from the auxiliary transformer 30VAC winding into connector CN5 Diodes 022 4 023 rectify this and feed it to Q9 through R47 09 turns off w
20. the power source will be disabled Once the power source cools down this indicator will go OFF and the overheat condition will automatically reset Note that the mains power switch should remain in the on position such that the fan continues to operate thus allowing the unit to cool sufficiently Do not switch the unit off should a overheat condition be present Manual 0 5186 4 2 Operation OPERATION WELDSKILL 250 350 10 VOLTAGE CONTROL SWITCH WELDSKILL 250 ONLY The Voltage Control Switch is a 12 position that increases the welding voltage as it is rotated in a clockwise direction A CAUTION The Voltage Control switch MUST NOT BE SWITCHED during the welding process 11 REMOTE SOCKET trigger Motor Positive 24VDC Motor Negative CW of remote wirespeed pot ACW of remote wirespeed pot wiper of 5k remote wirespeed pot trigger solenoid solenoid no connection no connection no connection 2 3 4 5 6 T 8 9 POWER SOURCE 12 PIN REMOTE SOCKET Art A 09921 AB Figure 4 2 WeldSkill 250 amp 350 MIG Remote Socket A CAUTION The Voltage Control Switch must not be switched whilst welding 4 02 Power Source Internal Welding Controls AS 4 4B __ CIGWELD aan WeldSkill 45 LOCAL TRIGGER TO 415V 8 REMOTE 4 BURNBACK o GAS PURGE INCH Figure 4 3
21. tip from the torch handset Operation 4 9 Manual 0 5186 WELDSKILL 250 350 OPERATION Q bY lam 6 Tp 2 OO M jl Setup for MIG GMAW Welding with setup for MIG GMAW Welding Gas Shielded Shielded MIG Wire with Gas Gasless MIG Wire 300mm Diameter Wire Spool 300mm Wire spool installation 200mm Diameter Wire Spool 200mm Diameter Wire Spool Adaptor 200mm Wire spool installation Figure 4 6 WeldSkill 250 amp 350 Setup and Spool Hub Manual 0 5186 4 10 Operation OPERATION WELDSKILL 250 350 Inserting Wire Into The Wire Feed Mechanism Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide between the rollers through the centre guide between the rollers through the outlet guide and into the MIG torch A WARNING DO NOT WEAR GLOVES WHILE THREADING THE WIRE OR CHANGING THE WIRE SPOOL B Lower the pressure lever and with the torch lead reasonably straight feed the electrode wire through the torch Fit the appropriate contact tip eg a 0 9mm tip f
22. 05 2 3 Disassembly Procedure 6 Manual 0 5186 DISASSEMBLY PROCEDURE WELDSKILL 250 350 7 05 Back Panel Removal N Read and follow safety information in Section 6 02 before proceeding with disassembly 1 Disconnect input cord from terminals Ground wire screw Disconnect power cord form cable anchorage Disconnect input cord ground wire from rear panel Disconnect the fan control wires from terminal BI w Unscrew the rear panel fixed screw v f ang NE 1 A ING LO LIFT POWER 6 readandunderstandtiislabei SOURCE ITH GAS pre CYLINDER i j il m DUTY CYOLES OVER 10 MINUTE PERIOD DUTY CYCLES OVER 10 PORVOO Art A 10206 Manual 0 5186 Disassembly Procedure WELDSKILL 250 350 DISASSEMBLY PROCEDURE 7 06 Power Switch 1 and Power Cord Removal Read and follow safety information in Section 6 02 before proceeding with disassembly 2 Gas inlet Remove gas inlet from rear panel SW1 locking tabs squeeze the locking tabs and push SW1 out from the rear panel strain relief screws Remove the two 2 screws from the strain relief Remove Fan Input Power Cord ground wire filter Cut the tie wrap and remove the Ferrite core from the ground wire Pull the Input Power Cord out It may be necessary to use a flat blade screw driver against the strain relief tabs prying outward Internal side if strain relie
23. 1 E Rieke C vg 4 ET 942 CHH ia pei C25 s i RS mote r NG _ wa R is C40 R34 riba RI 020 Lo gt 8 nme 9 EH 4 4 07 AIN nag Cal NEHA R64 L 0022 29 eee 7 _ ot c M CTS 9 27 P z n s Cai ks meets 2 iya EN 2 ce 7 2 oa 24 77 Tu a pists t KIN Ez 1 63 48 R24 7 eas 6 016 Ra AN TN EF G r n 2 4 mE SS pa le 02204 nee na H Ls 023 279 630 E E ef 9 Bday RISA 20 Eo 7 NL d 024 7 yg 6415 nes CE ere 026 Le 19 RCE gt dt J HHS 957 gt mo inmir 50 27 E bd kay naa wa ON p a 5 10 Art A 10201 nal NG 9 LO cele 5 04 C41 na 59 erve 5 18 e jee je 3 ___ ves me e HO bf meL 10 OL e He c17 oJ Pag E ue cH cee ee_e 1 mie 5 _ eje RG nag NG a7 9 R45 Re
24. 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 5186 3 1 Safety and Installation WELDSKILL 250 350 SAFETY AND INSTALLATION 3 02 WeldSkill 250 MIG Power Source Specifications Plant Part Numbers W1003400 amp W1004500 Plant Dimensions H 1050mm x W 470mm x D 1020mm Energy Input Refer NOTE below This Column applies to the This Column applies to a Factory Fitted 2 5mm 20A 4 0mm 25A Primary Primary Lead with 15A Lead with a 25A Supply oupply Plug Plug Input Cable Requirements Factory Fitted 4 0mm 2 core earth heavy duty R90 insulation type Effective Input Current Maximum Input Current limax MIG GMAW 190A 20 23 5V 200A 20 26 5V Welding Output 40 C 10 min 110A 60 19 5V 144A 60 21 2V 85 100 18 3V 112A 100 19 6V Operating Temperature Range 0 40 0 C 40 Number of Output Voltage Switch Settings Protection Class IP21S Table 3 1 WeldSkill 250 Specification v The Effective Input Current should be used for the determination of cable size amp 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 Red
25. 40 6 O Pa e NG o Re60 wee 020 Mee jo rse 1e wx Nese 9L 116 ren 1G 12 IG R1 le 61001134 20601 2109 E O ee Fe Art A 10202 Manual 0 5186 3 Disassembly Procedure WELDSKILL 250 350 DISASSEMBLY PROCEDURE 7 03 Front Panel Assembly Removal Read and follow safety information in Section 6 02 before proceeding with disassembly 1 Remove wirespeed control knob by loosening the set screw Remove output voltage select switch by loosening the set screw Output terminal bolts Unscrew power supply output terminal bolts Mig torch adaptor remove adaptor cover by loosening the set screw Remove ON OFF switch Remove 4R wirefeeder control socket wires DA Aa Screws on front panel POWER A ens OFF WIRESPEED AT U 8 250 MIG Art A 10203 Disassembly Procedure 4 Manual 0 5186 DISASSEMBLY PROCEDURE WELDSKILL 250 350 EE S Art A 10204 Manual 0 5186 5 Disassembly Procedure WELDSKILL 250 350 DISASSEMBLY PROCEDURE 7 04 Wirefeeder Assembly Removal AN and follow safety information in Section 6 02 before proceeding with disassembly 1 Disconnect the wirefeeder connector 2 Unscrews the wirefeeder fixed bolts 3 Unscrew torch polarity lead cable terminal bolts and remove it Art 102
26. 8 Manual 0 5186 TROUBLESHOOTING WELDSKILL 250 350 CN5HeaderPin PinFunctiom 30VAC wiredrive power supply 30VAC Table 6 9 CN5 Header Pin Function connect to control transformer CNG Header Pin L T aaa 223 12 Spot Switch Signal ________ SpotSwitchSignal J o _______ Spottimesetpoint J o o O Spot time setpoint _ Table 6 10 CN6 Header Pin Function connect to control transformer CN7 Header Pin PinFunction 2T 4T Switch Signal YY 4 2T 4T Switch Signal 15VDC ___3 ___ OVDC OVDC Tourch Switch 15VDC Table 6 11 CN7 Header Pin Function connect tourch seitch and 21 4T switch a saa a M setpoint 0 umm ___ 15VDC 15VDC Table 6 12 CN8 Header Pin Function connect to wirespeed potentiometer CN9 Header Pin Lo 00 0 YY 1 OV wirefeeder brake Wirefeeder Driver 24VDC Table 6 13 CN9 Header Pin Function connect to wirefeeder Manual 0 5186 6 9 Troubleshooting WELDSKILL 250 350 TROUBLESHOOTING 6 10 Circuit Diagram for Control PCB 1 Circuit Diagram for Control PCB MOTOR POWER 1718 9 5 MOTOR POWER LED OVER HEAT LED a 2 5 8 52 WIRE INCH SPOT TIMER SPOT SWITCH 7 BURN BACK 15 ans RUDY h
27. ILL 250 350 INTRODUCTION Notes Introduction 2 4 Manual 0 5186 SAFETY AND INSTALLATION WELDSKILL 250 350 SECTION 3 SAFETY AND INSTALLATION 3 01 Duty Cycle 100 90 80 70 60 50 Safe 40 Operating 30 Region 20 25A plug and lead for 250 Duty Cycle percentage 15A plug for 250 10 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 Art A 09909_AC WeldSkill 250 Welding Current amps 90 80 70 60 Safe 50 Duty Cycle percentage Operating 40 Region P Duty Cycle for 350 20 10 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 WeldSkill 350 Welding Current amps Figure 3 1 Weldskill 250 amp 350 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 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
28. LIGWELD WeldSkill WELDSHILL on MIG WELDING MACHINE WIREFFEDER Optional A CIGWELD Se Ta D 99 Art 10132 Service Manual Reversion AC Issue Date December 27 2013 Manual No 0 5186 Operating Features 240 af Ie oc ie pp LIGWELD WeldSkill 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 war ranty 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 Service Manual has been designed to instruct you on the correct use and operation of your CIGWELD product Your satisfaction with this produc
29. Main Circuit Description 5 1 TABLE OF CONTENTS SECTION 6 TROUBLESHOOTING 6 1 6 01 Power Source Wirefeeder Faults 6 1 6 02 Checking Unit Before Applying 6 2 6 08 Tools Needed for Troubleshooting and 6 2 6 04 Case Removal 6 3 BO 6 4 6 06 Main Output Rectifier 6 5 B07 Check main 6 6 0 083 Check Main AC 6 7 000 6 8 6 10 Circuit Diagram for Control 6 10 6 11 Advanced IrouDplesriQOLfig s acu odote aaa 6 14 6012 0151611 6 RR 6 18 6 13 WELDSKILL 250 MIG POWER SOURCE CIRCUIT DIAGRAM 6 19 6 14 WELDSKILL 350 MIG POWER SOURCE CIRCUIT DIAGRAM 6 20 SECTION 7 DISASSEMBLY PROCEDURE 7 1 7 01 safety Precautions for Disassembly 42 7 1 7 02 Control Board NCI OV 7 2 7 09 Front Panel Assembly Removal cc rotate ma 7 4 7 04 Wirefeeder Assembly 7 6 7 05 Back Panel Removal 1 7 7 06 Power Switch 51 and Power
30. PROCEDURE WELDSKILL 250 350 SECTION 7 DISASSEMBLY PROCEDURE 7 01 Safety Precautions for Disassembly A and follow safety information in Section 6 02 before proceeding Unplug unit before beginning Disassembly procedure Manual 0 5186 1 Disassembly Procedure WELDSKILL 250 350 7 02 Control Board Removal DISASSEMBLY PROCEDURE AN and follow safety information in Section 6 02 before proceeding with disassembly Remove case refer to 6 04 before remove control board Refer to graphics on page 7 3 1 Disconnect CN2 harness from CN2 connector cO N a Km N 10 M4 screw remove 4 screws from control panel Ensure to unplug all harness from the main control PCB Disconnect CN1 harness from connector Disconnect CN3 harness from CN3 connector Disconnect CN4 harness from CN4 connector Disconnect CNS harness from CN5 connector Disconnect CN6 harness from CN6 connector Disconnect CN7 harness from CN7 connector Disconnect CN8 harness from CN8 connector Disconnect CN9 harness from connector Disassembly Procedure Manual 0 5186 DISASSEMBLY PROCEDURE WELDSKILL 250 350 DG an STAM 2 ____ gt N 2 f y 3 TS TA W iden m 7 4 41 ELR ber pio gt oe m t MEAE M 4 94 SH 4 a 94
31. Wirefeeder The levels of current present in these units can cause burning or arcing of PCB transformers switches rectifier or contactor when a failure occurs Carefully inspect all components within these units Look in particular for the following a Loose or broken wires or connectors b Burned or scorched parts or wires or evidence of arcing c Any accumulation of metal dust or filings that may have caused shorting or arcing If any parts are damaged they must be replaced Refer to the Spare Parts section for a complete list of components used in the Power Source Locate the faulty component s then replace where necessary At this point apply voltage to the Power Source A CAUTION There are extremely dangerous voltage and power levels present inside these Power Sources Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Troubleshooting 6 14 Manual 0 5186 TROUBLESHOOTING WELDSKILL 250 350 Once power is applied to the Power Source there are extremely hazardous voltage and power levels present Do not touch any live parts 4 Power Source or Wirefeeder Faults The following table is a guide for analyzing problems and making repairs to the Power Source and or Wirefeeder Fault The wirefeed motor and the contactor do not operate when the torch trigger switch is depressed The contactor operates when the torch trigger swit
32. Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Victor Technologies Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 Telephone 44 1257 261755 Fax 44 1257 224800 PT Victor Technologies Utama Indonesia JI Angsana Blok AE No 28 Delta Silicon Cikarang Sukaresmi Bekasi 17550 Indonesia Tel 62 21 8990 6095 Fax 62 21 8990 6096 1867 http www victortechnologies com Victor Technologies China No 100 Lao Hongjing Rd Minhang District shanghai 200235 China Telephone 86 21 64072626 Fax 86 21 64483032 Victor Technologies Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Victor Technologies Italy OCIM S r L Via Benaco 3 20098 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Victor Technologies International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 Asia Pacific Regional Headquarters 71 Gower Street Preston Victoria Australia 3072 Ci G WELD Telephone 61 3 9474 7400 an FAX 61 3 9474 7391 Email enquiries cigweld com au www cigweld com au
33. _ A oM Figure 4 1 WeldSkill 250 amp 350 MIG Front Panel 1 POWER ON INDICATOR MAIN POWER CONTROL SWITCH The Power ON Indicator illuminates when the Main Power Control Switch ON OFF knob is in the ON posi tion and the correct mains voltage Is present WARNING When the light is lit the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential 2 WIRESPEED CONTROL The Wirespeed Control knob controls the welding current via the electrode wirefeed rate ie the speed of the wirefeed motor Operation 4 1 Manual 0 5186 WELDSKILL 250 350 OPERATION 3 VOLTAGE CONTROL SWITCH FINE WELDSKILL 350 ONLY The Fine Voltage Control switch increases the welding voltage in smaller increments than the Coarse switch as it is rotated in a clockwise direction A CAUTION The Coarse amp Fine Voltage Control switches MUST NOT BE SWITCHED during the welding process 4 VOLTAGE CONTROL SWITCH COARSE WELDSKILL 350 ONLY The Coarse Voltage Control increases the welding voltage in larger increments than the Fine switch as it is rotated in a clockwise direction A CAUTION The Coarse amp Fine Voltage Control switches MUST NOT BE SWITCHED during the welding pro cess 5 TORCH POLARITY LEAD This lead selects the welding voltage polarity of the electrode wire Plug it into the positive welding terminal w
34. accordance with the instructions provided Equipment must be checked periodically and repaired replaced or reset as necessary for continued safe and reliable performance Defective equipment should not be used Parts that are broken missing obviously worn distorted or contaminated should be replaced immediately The user of this equipment will generally have the sole responsibility for any malfunction which results from improper use faulty maintenance or by repair by anyone other than an accredited repairer A CAUTION Match regulator to cylinder NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas S kom 05087 Figure 4 4 Fit Regulator to Cylinder Installation 1 Remove cylinder valve plastic dust seal Clean the cylinder valve outlet of impurities that may clog orifices and damage seats before connecting the regulator Crack the valve open then close momentarily pointing the outlet away from people and sources of ignition Wipe with a clean lintless cloth 2 Match regulator to cylinder Before connecting check that the regulator label and cylinder marking agree and that the regulator inlet and cylinder outlet match NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas 3 Connect the regulator inlet connection to cylinder or pipeline and tighten it firmly but not excessively with a suitable spanner
35. age to the arc when the main transformer secondary voltage drops below the arc voltage Resistor R3 150hm 50W provides a discharge path for the output filter capacitors via a normally closed contact on the main contactor KM An output inductor ensures smoothing of the welding arc and reduces spatter A filter network consisting of a capacitor C1 and resistor R1 provides high frequency protection for the rectifier A thermal overload device thermostat is each fixed to the rectifier and transformer in series and connected to the Control PCB In normal operation the normally closed thermostats complete the circuit When an over temperature occurs the affected thermostat opens and breaks the circuit and thermal overload indicator LED on the front panel illuminates The trigger is disabled effectively disabling contactor KM which controls power to the main transformer and disables the gas solenoid valve and motor drive Main Circuit Description WELDSKILL 250 350 MAIN CIRCUIT DESCRIPTION Notes Main Circuit Description 5 2 Manual 0 5186 TROUBLESHOOTING WELDSKILL 250 350 SECTION 6 TROUBLESHOOTING 6 01 Power Source Wirefeeder Faults The following table is a guide for analysing problems and making repairs to the Power Source Wirefeeder FAULT CAUSE REMEDY Mains supply voltage Primary fuse is blown Replace primary fuse is ON Indicator light Broken connection in primary Have an Accredited CIGWELD is not lit and wel
36. al to prevent welding current from travelling long possibly unknown paths and causing electric shock and fire hazards safety Instructions and Warnings SAFETY INSTRUCTIONS AND WARNINGS 1 9 Do not use welder 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 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 pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat me chanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protectiv
37. and all metal parts touching the welding wire are electri cally live Incorrectly installed or improperly grounded equipment is a hazard 15 Keep all panels and covers securely in place WARNING ARC RAYS can burn eyes and skin NOISE can dam age hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and 2 Wear dry hole free insulating gloves and body protection skin Noise from some processes can damage hearing 3 Insulate yourself from work and ground using dry insulating 1 Use a Welding Helmet or Welding Faceshield fitted with a mats or covers proper shade of filter see ANSI 749 1 and AS 1674 listed in safety Standards to protect your face and eyes when welding 4 Disconnect input power or stop engine before installing or or watching Servicing this equipment Lock input power disconnect switch open or remove line fuses so power cannot be turned ac 2 Wear approved safety glasses Side shields recommended cidentally 3 Use protective screens or barriers to protect others from flash 5 Properly install and ground this equipment according to its and glare warn others not to watch the arc Owner s Manual and national state and local codes 4 Wear protective clothing made from durable flame resistant 6 Turn off all equipment when not in use Disconnect power to material wool and leather and foot protection equipment if it will be left una
38. ar on your model Wire Feed Towards Workpiece With Output Voltage Off Three Phase Static Frequency Converter Transformer Rectifier E Continuous Weld Circuit Breaker X Duty Cycle Mode Auxiliary Power Percentage Spot Weld Mode Shielded Metal Gas Metal Arc Gas Tungsten Arc 2 Step Trigger 7 Hertz cycles sec Welding GTAW V Operation Press to initiate wirefeed and Air Carbon Arc welding release to stop 4 Step Trigger p no Operation Press and hold for preflow release Posit Constant Voltage to start arc Press to stop arc and Or Constant Potential hold for preflow Direct Current DC High Temperature SS Burnback Time Protective Earth Disturbance In Ground ault Indication Ground System Line Connection NG La Touch Start GTAW Meters Per Minute Auxiliary Power Variable Inductance 115V 15 Receptacle Rating Art A 04937 Safety Instructions and Warnings 1 6 Manual 0 5186 SAFETY INSTRUCTIONS AND WARNINGS 1 05 Servicing Hazards A WARNING The symbols shown below are used throughout this manual to call attention to and identify possible haz ards When you see the symbol watch out and follow the related instructions to avoid the hazard Only qualified persons should test maintain and repair this unit Only qualified persons should test maintain and repair this unit WARNING ELECTRIC SHOCK
39. arc can be established but the welding current diminishes Higher Coarse Fine switch positions must be set to obtain the same welding conditions Bad electrical connection s between the secondary side of the main transformer and the rectifier Bad electrical connection s between the secondary rectifier and the positive or negative welding terminals Poor electrical contact between the work clamp amp the work piece WELDSKILL 250 350 Repair the termination point s after the fault has been Isolated Repair the termination point s after the fault has been isolated Repair or replace work clamp Clean the work piece around the work clamp area to ensure a good electrical connection 5 A welding arc can be established but the excessive welding spatter is produced for control setting that normally produce minimal spatter The inductor windings have overheated or short circuited due to Fan failure li Blockage of the front air vents Duty cycle has been exceeded for prolonged periods The output capacitors ie 22000uF are not connected to the DC terminals of the secondary rectifier The output capacitors are open Circuit Examine the inductor winding for burn marks or discolouration due to excessive heat Replace the inductor if its windings have short circuited Repair the termination point s between the capacitors and the DC terminals of the secondary rectifier
40. arketing expertise Above all we are committed to develop technologically advanced products to achieve a safer working environment for industry operators A WARNING N 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 service Manual Number 0 5186 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 pub lisher 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 May 9 2012 Version AC Date December 27 2013 Record the following information for Wa
41. asurements 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 5186 3 3 Safety and Installation WELDSKILL 250 350 SAFETY AND INSTALLATION 3 04 WeldSkill 4R Wirefeeder Specifications Table 3 3 WeldSkill 4R Wirefeeder Specification Safety and Installation 3 4 Manual 0 5186 SAFETY AND INSTALLATION WELDSKILL 250 350 3 05 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 3 06 Location Be sure to locate the welder according to the f
42. can kill Do not touch live electrical parts Turn Off welding power source and wire feeder and disconnect and lockout input power using line disconnect switch circuit breakers or by removing plug from receptacle or stop engine before servicing unless the procedure specifically requires an energized unit Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground Do not leave live unit unattended If this procedure requires and energized unit have only sonnel familiar with and following standard safety practices do the job When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free Disconnect input power conductors from de energized supply line BEFORE moving a welding power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters Turn Off inverters disconnect input power and discharge input capacitors according to instructions in Troubleshooting section before touching any parts b lt gt WARNING STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or Ship PC boards WARNING FIRE OR EXPLOSION hazard Do not place unit on over or near combustible surfaces Do not service unit near flammables Manual 0 5186 1 7 WELDSKILL 250 350 WARNING FLYING METAL or
43. cause rapid wear of mechanical WIREFEED parts overheating of electrical component and possibly an increased incidence of electrode wire Burnback into contact tip 4 09 How to Lift WELDSKILL 4R Wirefeeder A WARNING DO NOT lift the WELDSKILL Wirefeeder by the Handle using mechanical means The WELD SKILL 4R Wirefeeder may fall from a hook mechanical hoist as the small bracket on the handle 15 not designed to secure a lifting hook mechanical hoist in the corner of the Handle The Handle 15 designed for lifting by hand only The WELDSKILL 4R Wirefeeder Handle is designed for lifting the Wirefeeder by hand only Handle Do Not Lift Wirefeeder by Mechanical Means Handle is to be used for Lifting by Hand Only Art A 11480 Operation 4 13 Manual 0 5186 WELDSKILL 250 350 OPERATION Notes Manual 0 5186 4 14 Operation MAIN CIRCUIT DESCRIPTION WELDSKILL 250 350 SECTION 5 MAIN CIRCUIT DESCRIPTION 5 01 Main Circuit Description NOTE This general description should be read in conjunction with the respective WELDSKILL Circuit Diagram refer previous section In Single phase Power Sources the standby switch connects directly to the incoming supply In Three phase Power Sources the standby switch connects to two phases of the incoming supply The standby switch contacts are open when the machine is placed in standby mode t
44. ccident 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 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 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 JANUARY 2011 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 s
45. ch is depressed but the wirefeed motor does not rotate The wirefeed motor Operates at maximum Speed and cannot be adjusted Wirefeed motor operates when the torch trigger switch is depressed but the gas valve and the Power Source contactor do not operate Possible Cause The 20V AC supply control voltage from the auxiliary transformer is not connected to the Control PCB The thermostat contacts are open circuit or the wires to the thermostat are broken Bad electrical connection between the torch trigger switch and connector on PCB at pins 7 3 or CN7 4 MIG Torch has been damaged internally trigger wires are making contact with welding power cable The 30VAC for the wire feed motor is not connected to PCB Bad electrical connection between the wiper arm on the wire speed potentiometer and connector on PCB at pin CN8 2 or CN8 3 Bad electrical connection between the wirefeed motor and connector on PCB at pins CN9 3 or CN9 1 Motor fuse circuit breaker FU2 open Bad electrical connection between the wire speed potentiometer and connector on PCB at pin CN8 1 Bad electrical connection s between the connector on PCB at pin CN1 1 amp CN1 3 and the wires to the contactor coil or gas valve A Remedy Check for 20 on PCB at pins CN3 1 8 CN3 3 Repair fault Replace the thermostat or repair the thermostat wires Check the continuity from connector to the torch trigger switch Repair the
46. ding Circuit service Provider check primary arc can not be established Mains indicator light is not lit but welding arc can be established Mains supply voltage is ON and power Indicator Burnt out Indicator light Faulty torch trigger Circuit breaker tripped Circuit Have an Accredited CIGWELD service Provider replace Indicator light Repair or replace torch trigger switch leads Reset Circuit Breaker s is lit however unit will not commence welding when the torch trigger switch is depressed Check for clogged kinked MIG Torch conduit liner or worn contract tip Replace faulty components Have an Accredited CIGWELD service Provider investigate the fault Mains supply voltage Electrode wire stuck in conduit is ON no wire feed liner or contact tip burn back but gas flows from jam the MIG Torch when the torch trigger switch is depressed Faulty control PCB Connect the MIG torch polarity lead to either the positive welding output terminal or negative output terminal as required Clean work clamp area and ensure good electrical contact Wire feeds when Mig torch polarity lead is not the torch trigger connected into a welding output switch is depressed terminal but arc cannot be established Poor or no work lead contact Inconsistent wire feed Worn or dirty contact tip Replace if necessary Worn feed roll Replace if necessary Excessive back tension from wire Reduce brake ten
47. discharge of C6 through the burnback potentiometer will determine the duration U1A will remain on and therefore how long the contactor amp solenoid will remain on after the trigger is released 8 Brake When the torch trigger is pressed op amp 05 pin 1 output will be high The base of Q10 will be high amp 010 will be off When the torch trigger is opened opamp U5 pin 1 output goes low charging C30 and as the voltage across C30 goes above 15V Q10 will start to turn on As Q10 turns on it will trigger scr U6 through R69 The scr U6 is connected across the motor so the motor will be shorted when U6 is turned on causing the motor to brake rapidly R70 provides a path for stray leakage gate current of U6 to prevent false turn on of the brake scr U6 Diode D26 provides a rapid discharge of C30 to ensure the motor scr s amp brake scr s are never both on at the same time 9 Thermostats Thermostats are connected in series to CN2 the over temperature LED is connected to CN4 terminals 3 amp 4 The thermostats are normally closed types When both thermostats connected to CN2 are closed 04 is turned on by R1 D1 and 9 R10 provides a path for base leakage current of Q4 With Q4 turned on U1 pin 2 will be low ready for normal operation If either thermostat is opened 04 will turn off causing the voltage on U1 pin 2 to rise turning the contactor amp solenoid off The base of Q6 will go high through R16 amp R18 which are n
48. e and extent of these protected interests In some circumstances the supplier of goods and services may legally stipulate that the said conditions warran ties guarantees rights and remedies are limited or entirely excluded The warranties set out in Clause 2 shall be additional to any non excludable warranties to which the Customer may be entitled pursuant to any statute 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 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 ofthe 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 a
49. e cap in place over valve except when cylinder 15 in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety standards Manual 0 5186 SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 250 350 Recommended Protective Filters for Electric Welding Description of Process Approximate range of Welding Minimum Shade Number of Current in Amps 5 165 than or equal 100 electrodes MMAW Gas Metal Arc Welding GWAW MIG other than Aluminium and Stainless Steel Gas Metal Arc Welding GMAW MIG Aluminium and Stell 2500380 1 13 Gas Tungsten Arc Welding GTAW TIG Flux cored Arc Welding FCAW with or without shielding gas Air Air Arc Gouging Air Arc Gouging Less than or equal to 400 12 50 to 100 PlasmaArc Cutting 100 to 400 400 to 800 Lessthanorequalto20 28 20010 MN 1001540 400 to 800 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 Table 1 1 Manual 0 5186 1 3 Safety Instructions and Warnings WELDSKILL 250 350 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 co
50. eld 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 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 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 work piece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 10 7 m 35 ft of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practic
51. en CN3 2 CN6 2 12 14 Trigger closed Table 6 15 Outputs from Control PCB Manual 0 5186 6 13 Troubleshooting WELDSKILL 250 350 TROUBLESHOOTING 6 11 Advanced Troubleshooting If the problem cannot be solved by the basic external troubleshooting guide the Power Source covers and or the Wirefeeder covers will have to be removed The advanced level of troubleshooting allows the technician with few common tools to remove the covers and analyse failures A CAUTION Never open the Power Source covers unless the Mains supply voltage to the Power Source 15 disconnected from the Mains power point 1 Test Equipment and Tools e Digital Multimeter e DC clip on ammeter e Screwdriver and 8mm across flats nutdriver e GRO 20 Mhz bandwidth amp isolating transformer 2 Power Source or Wirefeeder Faults A CAUTION Leave the Mains supply voltage disconnected from the Power Source during the visual inspection a Wirefeeder i Remove all the case screws that fix the right hand panel to the Wirefeeder the right hand panel as seen from the front b Power Source i Remove all the case screws that fix the left hand panel to the Power Source the left hand panel as seen from the front li Remove all the case screws that fix the right hand panel to the Power Source the right hand panel as seen from the front 3 Visually Inspect Visually inspect the inside of the Power Source or
52. er for the complete length of the weld run Table 4 1 Trigger Mode Switch Functional Description C LOCAL REMOTE MODE SWITCH The Local Remote switch is used to switch between local and Remote modes Local Mode Set the switch in the Local position when using the power source only With no optional external wirefeeder Remote Mode Set the switch in the Remote position when using an optional remote wirefeeder This will enable the wirefeeder and allow the wirespeed to be controlled from the remote wirefeeder wirespeed control The other controls such as trigger mode inch gas purge spot burnback will still be controlled from the power source Manual 0 5186 4 4 Operation OPERATION WELDSKILL 250 350 D WIRE INCH SWITCH INCH Art 0 10094 The Wire Inch Switch is used to feed the MIG wire through the MIG torch When the push button switch is pressed down the electrode wire is fed through the Wirefeed system amp MIG torch No gas flows and welding voltage is not present when the Wire Inch Switch is activated A WARNING Keep torch away from eyes and face GAS PURGE E GAS PURGE Art A 10095 The Gas Purge Switch is used to purge gas or impurities such as air out of the gas system When the push button switch is pressed the shielding gas flows through the Wirefeed system amp out of the MIG torch nozzle The Wirefeed motor does not operate and welding voltage is not present when the Gas Purge Switch
53. f to help remove the cord La DO NOT LIFT POWER SOURCE WITH GAS Lm BI CYLINDER ATTACHED eee a MAG Output SON VIN 2304 25 i 2 core earth 4 2 core earth heavy Cable Sae RI insiston type oc udi BE LU Art A 10207 Disassembly Procedure 8 Manual 0 5186 DISASSEMBLY PROCEDURE WELDSKILL 250 350 7 07 Output Rectifier Removal Read and follow safety information in Section 6 02 before proceeding with disassembly 1 Remove AC input screws 2 Remove positive output terminal bolts 3 Remove positive output terminal bolts 4 Unscrew fixed screws from inductor Art A 10208 Manual 0 5186 9 Disassembly Procedure WELDSKILL 250 350 DISASSEMBLY PROCEDURE Notes Disassembly Procedure 10 Manual 0 5186 ASSEMBLY PROCEDURE WELDSKILL 250 350 SECTION 8 ASSEMBLY PROCEDURES 8 01 Installing Output Rectifier Assembly 1 Main output rectifier assembly Install main rectifier assembly to inductor plate 2 3 Reconnect secondary of main transformer to rectifier 4 Reconnect positive dinse to rectifier output positive 5 Reconnect negative dinse to rectifier negative 224 af Art 10273 Manual 0 5186 0 1 Assembly Procedures WELDSKILL 250 350 ASSEMBLY PROCEDURES 8 02 Installing Back Panel 1 Install power cord clockwise rotation until tight Install gas inlet Install fan Reconnec
54. 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 sup plied 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 05 Transportation Methods 7 Disconnect input power ductors from de energized supply line before moving the welding power source Lift unit with handle on top of case Use handcart or similar device of adequate capacity If using a fork lift vehicle secure the unit on a proper skid before trans porting Introduction WELDSKILL 250 350 2 06 User Responsibility This equipment will perform as per the information con tained 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
55. g 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 JANUARY 2011 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 war ranties as to merchantability and fitness for purpose associated with the supply of goods and services A consumer should seek legal advice as to the natur
56. heating of electri cal component and possibly an increased incidence of electrode wire Burnback into contact tip 4 07 Setup For The WeldSkill 250 amp 350 MIG Power Source When Fitted With Wirefeeder Power Source Connections A Remove all packaging materials B Connect the work lead to the negative welding terminal positive welding terminal for flux cored electrode wire If in doubt consult the electrode wire manufacturer C Position a gas cylinder on the rear tray of the Power Source and lock securely to the Power Source inder bracket with the chain provided If this arrangement is not used or the Power Source is not fitted with a gas cylinder tray then ensure that the gas cylinder is secured to a building pillar wall bracket or otherwise securely fixed in an upright position Operation 4 11 Manual 0 5186 WELDSKILL 250 350 OPERATION Wirefeeder Connections A Connect the welding power cable from the Wirefeeder s interconnection cables to the positive welding gt UJ TI terminal negative welding terminal for flux cored electrode wire If in doubt consult the elec trode wire manufacturer Power Source Torch Polarity Lead not required to be connected when using wirefeeder Connect the control cable from the Wirefeeder to the control socket on the Power Source Fit the gas regulator and flowmeter to the gas cylinder then connect the gas hose from the rear of the Wirefeeder t
57. hen using steel stainless steel or aluminium electrode wire Plug the Torch Polarity Lead into the negative welding terminal when using gasless electrode wire If in doubt consult the manufacturer of the electrode wire for the correct polarity 6 POSITIVE WELDING TERMINAL Positive Welding Terminal Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection 7 NEGATIVE WELDING TERMINAL Negative Welding Terminal Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection A CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal 8 MIG TORCH ADAPTOR Euro Style The MIG torch adaptor is the connection point for the MIG welding torch Connect the torch by pushing the torch connector into the brass torch adaptor firmly and screwing the plastic torch nut clockwise to secure in position To remove the MIG Torch simply reverse these directions 9 OVERHEAT INDICATOR This welding power source is protected by a self resetting thermostat The overheat indicator will illumi nate if the duty cycle of the power source has been exceeded Should the overheat indicator illuminate the output of
58. henever the is above 14V Q9 is the zero crossing detector for the phase angle control amplifier U5C When Q9 is on C33 is shorted and U5 pin 9 is high When Q9 turns off C33 charges down through R56 When the voltage on U5 pin 9 equals the voltage pin 10 pin 8 changes state providing gate current to the scr s U3 amp U4 ocrs U3 amp U4 along with diodes 015 amp 016 form a full wave bridge with 30VAC from the auxiliary transformer as its input The motor is connected to the output of this bridge so the phase angle control of U3 amp U4 will cause variation in the motor voltage and hence the motor speed 6 Spot timer When SPOT MODE is selected on the front panel CN6 terminals 3 amp 4 are connected Upon trigger capacitor C24 charges through R31 018 R52 R30 and the spot time potentiometer on the internal panel When C24 charges to above the voltage on U5 pin 5 the output of U5B changes state turning off 07 and disabling the motor drive and the contactor amp solenoid R46 and D21 cause U5 pin 5 to be pulled high effectively disabling the spot timer until the trigger is released and the op amp U5B is reset The SPOT potentiometer determines the charging rate for C24 thus establishing the SPOT TIME 7 Burnback When the torch trigger is closed transistor Q3 which charges C6 When the torch trigger is opened U1 pin remains on as C6 discharges through the internal panel BURNBACK potentiometer The rate of
59. hus isolating the cooling fan and auxiliary transformer from the incoming mains Supply There is no control voltage supply available when the machine is placed in standby mode Hence no controls will function until the operator switches the standby switch from the standby position to the on position For protection of the wiring there is on the WELDKSILL 200 and 350 a 3A fuse or circuit breaker in series with the input to the standby switch A WARNING In the standby position the machine is not electrically isolated from the mains supply voltage The main transformer consists of a primary coil which is connected to the incoming mains via the main contactor A CAUTION Contactor KM does not electrically isolate the main transformer from the mains supply voltage when is de energised secondary output voltage from the main transformer is controlled by the Coarse amp Fine switch settings These Switches determine which main transformer taps are to be connected to the mains supply voltage The main contactor KM is controlled by the torch trigger switch via the Control PCB The secondary side of the main transformer is connected to a single phase bridge rectifier on the WELDSKILL 250 and to a three phase bridge rectifier on the WELDSKILL 350 The rectifier converts the AC voltage from the secondary of the main transformer to DC voltage Manual 0 5186 Output filter capacitors on the WELDSKILL 250 provide volt
60. i THERMOSTAT 1 bop 21 CONTACTOR POWER Art A 10150 Figure 1 Circuit Diagram Control PCB for Weldskill 250 amp 350 2 Power Supply 40 VAC CT is derived from the auxiliary transformer This AC voltage is full wave rectified by diodes D6 07 D8 09 and the resultant DC voltage is smoothed by C11 amp C12 to provide a low ripple DC supply of approximately 28V This voltage is regulated to 15V by regulators W1 amp W2 and smoothed by capacitors C19 amp C20 3 Standby Torch trigger switch open Transistor Q8 input is held to ground by R39 The collector of Q8 is held high by R38 020 is reverse biased and 07 is off The collector of 07 is high so Uba pin 2 is held above pin 3 and the output pin 1 is low disabling the motor control via D28 amp D29 In SPOT mode 2T mode the switch connected to CN7 terminals 1 amp 2 will be closed This pulls U2 pin 4 high through R71 R72 amp R73 forcing U2 pin 1 to be low 4 Torch trigger switch closed When the torch trigger switch is closed 15V feeds through R59 R60 4 R53 to turn on 08 The collector of 08 goes low pulling the emitter of 07 low This pulls the collector low causing U5 pin 2 to fall below pin 3 and causing
61. ific 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 conclu sions 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 B Arrange cables to one side and away from the operator Do not coil or drape cable around the body Keep welding power source and cables as far away from body as practical safety Instructions and Warnings SAFETY INSTRUCTIONS AND WARNINGS 1 4 Sm ABOUT PACEMAKERS The above procedures 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 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards 29 CFR 1910 from Superinten dent 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 Ameri can 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 F
62. ilizing devices should be adjusted and maintained according to the manufacturer s recommendation 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 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 Earthing of the Work Piece Where the work piece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the work piece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the work piece to earth should be made by direct connection to the work piece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations ecreening and Shielding oelective screening and shielding of other cables and equipment in the s
63. int 14 AC Contactor Testing Multimeter Lead Placement Positive meter lead to oe 5 gt 1 0 Positive meter lead to Positive meter lead to testpoint9 9 Positive meter lead to IMO Positive meter lead to Positive meter lead to testpoint 10 10 meter lead to testpoint 7 Positive meter lead to ELLE 12 Positive meter lead to Positive meter lead to testpoint8 9 Positive meter lead to testpoint 11 Positive meter lead to testpoint 1 ositive mete ka oe 3 010050 Positive meter lead to Positive meter lead to testpoint 14 14 Table 6 4 AC Contactor Multimeter set to measure Diode Voltage Measurements may be made directly onto the main input rectifier AC1 and AC2 may be measured from the pins on the mains supply plug with the main power switch set to the ON position Manual 0 5186 b Troubleshooting WELDSKILL 250 350 TROUBLESHOOTING 6 09 Control PCB NG ___ CN4 CN7 RING as C41 9 er e je el 1G 701 10 mer s 1G 008 000 000 000 1001134 K20601 2109 C16 ___ O CNS Art A 10156 CN1 Header Pin AC Contactor control N A OV CN2 Header Pin Sigal 2 15VDC CN3 Header Pin 00 Control Signal power supply Control Signal power supply PinFuntion Signal Table 6 8 CN4 Header Pin Function connect to power LED and overheat LED Troubleshooting 6
64. ire 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 183 Safe Practices for Occupation and Educational Eye and Face Pro tection ANSI Standard 287 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 5186 SAFETY INSTRUCTIONS AND WARNINGS WELDSKILL 250 350 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 a
65. is activated F BURNBACK BURNBACK Art A 10093 Burnback time is used to adjust the amount of MIG wire protruding from the MIG torch contact tip stick out after the completion of welding Rotating the Burnback control in a clockwise direction increases the Burnback time Rotating the Burnback control in an anticlockwise direction reduces the Burnback time Operation 4 5 Manual 0 5186 WELDSKILL 250 350 OPERATION 4 03 4R Wirefeeder Front Panel gt 3 3 a 2 9 1 10 o WIRESPEED AR ol oe Art 0 09925_AB kd 1 WIRESPEED CONTROL The Wirespeed Control Knob controls the welding current via the electrode wirefeed rate ie the speed of the wirefeed motor 2 MIG TORCH ADAPTOR Euro Style The MIG torch adaptor is the connection point for the MIG welding torch Connect the torch by pushing the torch connector into the brass torch adaptor firmly and screwing the plastic torch nut clockwise to secure in position To remove the MIG Torch simply reverse these directions 4 04 Shielding Gas Regulator Operating Instructions A WARNING This equipment is designed for use with welding grade Inert shielding gases only NOTE WeldSkill Argon Regulator Flowmeter 15 not included in Asia Versions Part Nos W1003400 and W1003500 Shielding Gas Regulator Safety
66. 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 3 13 Methods of Reducing 1 Electromagnetic Emissions 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 its 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 Safety and Installation SAFETY AND INSTALLATION 2 Maintenance of Welding Equipment 3 8 The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding 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 stab
67. l 1 Connection end of ground GREEN or GREEN YELLOW conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connect ends of active BROWN and Neutral BLUE input conductors to a suitable power supply system that complies with all appliance local electrical codes Input Power Each unit incorporates an INRUSH circuit When the MAIN CIRCUIT SWITCH is turned on the inrush circuit provides pre charging for the input capacitors A relay in the Main Power PCB1 will turn on after the input capacitors have charged to operating voltage after approximately 5 seconds Manual 0 5186 3 7 WELDSKILL 250 350 3 10 Electromagnetic Compatibility WARNING Cc Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source 15 used in a domestic situation 3 11 Installation and 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
68. lding performance Too high a supply voltage will cause components to overheat and possibly fail The Welding Power Source must be e Correctly installed if necessary by a qualified electrician e Correctly earthed electrically in accordance with local regulations e Connected to the correct size power point and fuse as per the Specifications on page 3 2 3 3 and 3 4 The WeldSkill 250 MIG Power Source is supplied with a 20 Amp input lead and is designed for a 240 VAC supply voltage The following Mains Current Circuit recommendations are required to obtain the maximum welding current and duty cycle from these welding products Mains Supply Mains Machines Voltage Supply mall Setting Lead Size current Duty Cycle Circuit Size 240V 15Amp 220A 20 240V 25Amp 250A 25 Table 3 4 WeldSkill 250 Supply Requirements NOTE Motor start fuses or thermal circuit breakers are recommended for this application Check local requirements for your situation in this regard The WeldSkill 350 MIG Power Source is supplied with a 15 Amp input lead and is designed for a 415 VAC supply voltage The WeldSkill 350 MIG Power Source is suitable for below Mains supply voltages Minimum Mains Machines Duty Current Cycle Setting 5129 Circuit Size 415V 15 350A 30 Table 3 5 WeldSkill 350 Supply Requirements NOTE Motor start fuses or thermal circuit breakers are recommended for this application Check local requi
69. le hazards that apply and would look something like this 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 machine Equipment which does not have a nameplate attached to the machine is identified only by the specification or part number printed on the shipping container Record these num bers for future reference Manual 0 5186 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 2 04 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
70. o longer held low by D10 amp Q4 Q6 will turn on causing the over temperature LED to turn on Manual 0 5186 6 11 Troubleshooting WELDSKILL 250 350 TROUBLESHOOTING 10 Inch The INCH button is connected to CN6 terminals 7 amp 8 When the INCH button is pressed U5 A pin 3 is pulled high causing U5 pin 1 to go high enabling motor drive operation As Q7 U1B Q3 do not change state the contactor amp solenoid are not activated Only the wire drive motor operates when the INCH button is pressed 11 Latch The LATCH switch is connected to terminals 1 amp 2 When the LATCH switch on the internal panel is open U2 pin 4 is held low by R24 When the trigger is pressed 07 is turned on via R51 R12 The output of U7 will be closed and U8 pin 1 will be high U8 pin 4 will also be high putting a positive going clock signal into U2 The output of U2 pin 1 changes state from low to high turning on Q8 the trigger transistor via D25 When the trigger is released 07 will turn off and U8 pin 4 will go low The output of U2 will still be high and the trigger transistor Q8 will still be on keeping the machine triggered When the trigger is pressed U7 is turned on via R51 amp R12 The output of U7 will be closed and U8 pin 1 will be high U8 pin 4 will also be high putting a positive going clock signal into U2 The output of U2 pin 1 changes state from high to low turning off Q8 the trigger transistor via D25 12 Inputs
71. o the Flowmeter outlet Dual groove feed rollers are supplied as standard They can accommodate 0 9 1 2mm diameter hard wires Select the roller required with the chosen wire size marking facing outwards GROOVE GROOVE B Art 08739 GROOVE SIZE GROOVE A SIZE Fit the electrode wire spool to the wirefeeder wire reel hub Note that there is an adaptor supplied when using 200mm diameter wire spools Ensure that the drive dog pin engages the mating hole in the wire spool Push the spool securing clip into place to retain the wire spool securely The electrode wire should feed from the bottom of the spool MIG Torch EURO MIG Torch Connection Fit the MIG Torch to the Wirefeeder by pushing the torch connector into the brass torch adaptor and screwing the plastic torch nut clockwise to secure the torch to the torch adaptor Remove the contact tip from the torch handset Inserting Wire Into The Wire Feed Mechanism A Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide between the B C rollers through the centre guide between the rollers through the outlet guide and into the MIG torch A WARNING DO NOT WEAR GLOVES WHILE THREADING THE WIRE OR CHANGING THE WIRE SPOOL Lower the pressure lever and with the torch lead reasonably straight feed the electrode wire through the torch Fit the appropriate contact tip eg a 0 9mm tip for 0 9mm wi
72. of components used in the Power Source Locate the faulty component s then replace where necessary Troubleshooting 6 4 Manual 0 5186 TROUBLESHOOTING WELDSKILL 250 350 6 06 Check Main Output Rectifier and follow safety information in Section 6 02 before proceeding Art 10154 Output Rectifier Testing Multimeter Lead Placement Diode Voltage AC1 to DC Positive meter lead to testpoint 1 0 2 0 8VDC Positive meter lead to testpoit2 AC2 to DC Positive meter lead to testpoint 3 0 2 0 8VDC Positive meter lead to testpoint 2 HY HAH Positive meterleadtotestpoimtt Positive meter lead to testpoit3 Table 6 2 Output Rectifier Multimeter set to measure Diode Voltage Manual 0 5186 6 5 Troubleshooting WELDSKILL 250 350 TROUBLESHOOTING 6 07 Check main On Off Switch Art A 10155 Table 6 3 Power Switch Multimeter set to measure ohms Q Troubleshooting 6 6 Manual 0 5186 TROUBLESHOOTING WELDSKILL 250 350 6 08 Check Main AC Contractor Positive meter lead to testpoint 5 0 to 0 5 0 Positive meter lead to testpoint 9 Positive meter lead to testpoint 6 010050 Positive meter lead to testpoint 10 Positive meter lead to testpoint 7 ontactor ON 0to 0 50 t d Positive meter lead to testpoint 12 Positi ter lead to testpoint 8 ositive meter lead to tes 010050 Positive meter lead to testpoint 11 Positive meter lead to testpoint 13 IMO Positive meter lead to testpo
73. ollowing guidelines e n areas free from moisture and dust e Ambient temperature between 14 F 10 C to 104 F 40 C e n areas free from oil steam and corrosive gases e n areas not subjected to abnormal vibration or shock n areas not exposed to direct sunlight or rain e Place at a distance of 12 300mm or more from walls or similar that could restrict natural air flow for cooling The enclosure design of this power source meets the requirements of 1 215 as outlined in AS 60529 This provides adequate protection against solid objects greater than 12mm and direct protection from vertical drops Under no circumstances should the unit be operated or connected in a micro environment that will exceed the stated conditions For further information please refer to AS 60529 e 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 A WARNING Thermal Arc advises that this equipment be electrically connected by a qualified electrician 3 07 Ventilation since the inhalation of welding fumes can be harmful ensure that the welding area is effectively ventilated Manual 0 5186 3 5 Safety and Installation WELDSKILL 250 350 SAFETY AND INSTALLATION 3 08 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 we
74. om primary line voltage before working on unit significant DC voltage can remain on capacitors after unit is Wait until all front panel LED s are off before removing case A Before troubleshooting or applying power to unit complete the following checks to avoid causing further damage 6 03 Tools Needed for Troubleshooting and Servicing Art A 09849 Troubleshooting 6 2 Manual 0 5186 TROUBLESHOOTING WELDSKILL 250 350 6 04 Case Removal and follow safety information in Section 6 02 before proceeding 1 Cover AN Remove Screws Art A 10152 Remove all the screws from the cover panel 2 Door Panel Carefully lift the door panel from power source Remove screws from the cover panel IN lt gt Remove Screws Art 10153 Manual 0 5186 6 3 Troubleshooting WELDSKILL 250 350 TROUBLESHOOTING 6 05 Visually Inspect Visually inspect the inside of the Power Source The levels of current present in these units can cause burning or arcing of PCB transformers switches or rectifier when a failure occurs Carefully inspect all components within these units Look in particular for the following a Loose or broken wires or connectors b Burned or scorched parts or wires or evidence of arcing Any accumulation of metal dust or filings that may have caused shorting or arcing If any parts are damaged they must be replaced Refer to the Spare Parts section for a complete list
75. operator as practical 5 Connect work clamp to workpiece as close to the weld as pos sible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recommended 1 8 Manual 0 5186 INTRODUCTION WELDSKILL 250 350 SECTION 2 INTRODUCTION 2 01 How to Use This Manual This Manual usually applies to the part numbers listed on page To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the word WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These Special annotations are easily recognized as follows A WARNING Gives information regarding possible per sonal injury Warnings will be enclosed box such as this A CAUTION Refers to possible equipment damage Cau tions will be shown in bold type NOTE Offers helpful information concerning certain operating procedures Notes will be shown in italics You will also notice icons from the safety section ap pearing throughout the manual These are to advise you of specific types of hazards or cautions related to the portion of information that follows Some may have multip
76. or 0 9mm wire C Press the Torch switch to feed the wire through the torch A WARNING The electrode wire will be at welding voltage potential whilst it is being fed through the wirefeeder system if the wire is fed by using the TORCH SWITCH Drive Roller Pressure Adjustment The moveable rollers apply pressure to the grooved feed rollers via a scaled adjustable tension screw These devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage If Slipping occurs and inspection of the wire contact tip reveals no wear distortion or burn back jam the conduit liner should be checked for kinks and clogging by metal flakes and swarf If it is not the cause of slipping the feedroll pressures can be increased by rotating the scaled tension screws clockwise The use of excessive pressure may cause rapid wear of the feed rollers shafts and bearing 4 06 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking If it is considered necessary adjustment can be made by turning the large nut inside the open end of the hub clockwise to tighten the brake Correct adjustment will result in the wire reel circumference continuing no further than 20mm after release of the trigger The electrode wire should be slack without becoming dislodged from wire spool A CAUTION Overtension of brake will cause rapid wear of mechanical WIREFEED parts over
77. rate following the first weld sequence due to back pressure present within shielding gas hose as sembly Manual 0 5186 4 8 OPERATION 2 reduce flow rate allow the welding grade Shielding gas to discharge from regulator by Opening the downstream valve Bleed weld ing grade shielding gas into a well ventilated area and away from any ignition source Turn adjusting screw counterclockwise until the required flow rate is indicated on the gauge Close downstream valve Shutdown Close cylinder valve whenever the regulator is not in use To shut down for extended periods more than 30 minutes 1 2 Close cylinder or upstream valve tightly Open downstream equipment valves to drain the lines Bleed gas into a well ventilated area and away from any ignition source After gas is drained completely disengage adjusting screw and close downstream equip ment valves Before transporting cylinders that are not se cured on a cart designed for such purposes remove regulators Operation OPERATION WELDSKILL 250 350 4 05 Setup For The WeldSkill 250 amp 350 MIG Power Source Power Source Connections A Remove all packaging materials B Connect the work lead to the negative welding terminal positive welding terminal for flux cored electrode wire If in doubt consult the electrode wire manufacturer C Position a gas cylinder on the rear tray of the Power Source and lock securely to the Power So
78. re Press the Torch switch to feed the wire through the torch A WARNING The electrode wire will be at welding voltage potential whilst it is being fed through the wirefeeder system if the wire is fed by using the TORCH SWITCH Drive Roller Pressure Adjustment The moveable rollers apply pressure to the grooved feed rollers via a scaled adjustable tension screw These devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage If Slipping occurs and inspection of the wire contact tip reveals no wear distortion or burn back jam the conduit liner should be checked for kinks and clogging by metal flakes and swarf If it is not the cause of slipping the feed roll pressures can be increased by rotating the scaled tension screws clockwise The use of excessive pressure may cause rapid wear of the feed rollers shafts and bearing Manual 0 5186 4 12 Operation OPERATION WELDSKILL 250 350 4 08 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking If it is considered necessary adjustment can be made by turning the large nut inside the open end of the hub clockwise to tighten the brake Correct adjustment will result in the wire reel circumference continuing no further than 20mm after release of the trigger The electrode wire should be slack without becoming dislodged from wire spool A CAUTION Overtension of brake will
79. re 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 e 60974 10 applicable to Industrial Equipment generic emissions and regulations e AS 1674 Safety in welding and allied processes e AS 60974 1 IEC 60974 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 Manual 0 5186 1 5 Safety Instructions and Warnings WELDSKILL 250 350 SAFETY INSTRUCTIONS AND WARNINGS 1 04 Symbol Chart Note that only some of these symbols will appe
80. rements for your situation in this regard Any electrical work must be carried out by a qualified Electrical Tradesperson Mains Supply Mains Voltage Supply Lead Safety and Installation 3 6 Manual 0 5186 SAFETY AND INSTALLATION 3 09 Electrical Input Connections A WARNING a ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE is present after removal of input power DO NOT TOUCH live electrical parts SHUT DOWN welding power source disconnect input power employing lockout tagging procedures Lock out tagging procedures consist of padlocking line disconnect switch in open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other disconnecting device e Electrical Input Requirements Operate the welding power source from a single phase 50 60 Hz AC power supply The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections Should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit Do not connect an input WHITE or BLACK conductor to the ground terminal Do not connect the ground GREEN conductor to an input line termina
81. rrants to custom ers 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 CIG WELD whether arisin
82. rranty purposes Where Purchased Purchase Date Equipment Serial TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND 8 1 1 1 01 Are Welding pid dT Ska srs ints So uus 1 1 1 02 Principal Safety GLAN OSES 1 4 1 08 Declaration of 1 5 05 1 6 TOS ee ee ee 1 7 1 06 ENE MONTANO AASA 1 8 SECTION 2 INTRODUCTION 2 1 2 01 How to Use DD 2 1 2 02 Equipment Identification eee 2 1 2 03 Receipt of 022 2 44 421 144 11 2 1 2 04 se neue teste AA 2 1 202 eDEPEUE 2 1 206 Ser OI PAP 2 2 2 07 PA ae I ANA AA TEE 2 2 SECTION 3 SAFETY AND INSTALLATION 3 1 3 01 3 1 3 02 WeldSkill 250 MIG Power Source 3 2 3 03 WeldSkill 350 MIG Power Source 3 3 3 04 WeldSkill Wirefeeder Specifications 224 3 4 3 05 OM AGING sects
83. 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 12 equipment Repair or replace damaged 13 In confined spaces or damp locations do not use welder with AC output unless it is equipped with a voltage reducer Use WARNING equipment with DC output ELECTRIC SHOCK can kill 14 Wear a safety harness to prevent falling if working above floor level Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is lectrically 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
84. sion on spool reel hub hub Worn kinked or dirty conduit liner Clean or replace conduit liner 7 No gas flow Gas hose is cut Replace or repair Gas passage contains impurities Disconnect gas hose from the rear of Power Source or wirefeeder then raise gas pressure and blow out impurities Gas regulator turned off Turn on Empty Cylinder Replace cylinder Manual 0 5186 6 1 Troubleshooting WELDSKILL 250 350 TROUBLESHOOTING 8 Gas flow continues Gas valve has jammed open due Have an Accredited CIGWELD after the torch trigger to impurities in the gas or the gas service Provider repair or replace Switch has been line gas valve released Wire does not feed Faulty trigger switch lead Repair or replace Torch trigger when torch trigger lead depressed Circuit breaker tripped Reset Circuit Breaker s Wire continues to Power Source in LATCH mode Change to 2T NORMAL mode feed when torch Torch trigger leads shorted Repair or replace Torch trigger trigger released lead Wire feeds when the Power Source Overtemperature Cease welding and allow Power torch trigger switch is Protection circuit has operated source to Cool for 10 minutes depressed but arc can Overheat led will extinguish when not be established the Power Source has cooled and OVERHEAT led is sufficiently illuminated Table 6 1 Power Source Wirefeed Faults 6 02 Checking Unit Before Applying Power Turn SW1 to OFF position and disconnect unit fr
85. t Rear Panel screws Reconnect power cord to cable anchorage Reconnect power cord ground wire to rear panel Reconnect input power cord to terminal from AC contactor pe ld d o 1 Reconnect control wires to fan DO NOT LIFT POWER SOURCE WITH GAS CYLINDER ATTACHED o Art A 10274 Assembly Procedures 8 2 Manual 0 5186 ASSEMBLY PROCEDURE WELDSKILL 250 350 A LO 6 SOURCE GAS CYLINDER ATTAYHED N motn DONOT REMOVE DESTROY OR COVER THIS WARNING 2 core N Cang CYCLES OVER 10 PERIOD Art 10275 Manual 0 5186 0 3 Assembly Procedures WELDSKILL 250 350 ASSEMBLY PROCEDURES 8 03 Installing Front Panel 1 Install potentiometer and knob Align the knob pointer to line up with maximum correct calibration mark on the panel then set screw Install output voltage selection switch Install power and overheat indicators Output dinse install output dinse 4R wirefeeder connection socket Install connection socket by screwer Torch polarity lead cable clockwise turn anchorage until tight 5224 ge gt NO ON OFF switch Install on off switch and reconnect input wires to switch align the switch pointer to line up mark on panel 8 Install front panel screws and tighten screws 9 Connect the output cable of rectifier assembly to output dinse 10 Install MIG torch adaptor and cover plate
86. t 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 We have made every effort to provide you with accurate instructions drawings and photographs of the product s we used when writing this manual However errors do occur and we apologize if there are any contained in this manual Due to our constant effort to bring you the best products we may make an improvement that does not get reflected in the manual If you are ever in doubt about what you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer support for assistance 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 market leading 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 m
87. tated 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 WELDSKILL 250 AND 350 MIG POWER SOURCES WARRANTY PERIOD WELDSKILL 4R WIREFEEDER PARTS LABOUR Original main power rectifier main power magnetics and control printed circuit boards All other circuits and components including but not limited to relays switches 1 Year 1 Year contactors solenoids fans and power switch WELDSKILL 250 AND 350 MIG ACCESSORIES WARRANTY PERIOD MIG torch and work lead 3 Months MIG torch consumable items NIL Gas regulator flowmeter excluding seat assembly pressure gauges elastomer T seals and 0 rings Regulator seat assemblies and pressure gauges 6 Months Elastomer seals and rings used in the equipment 3 Months Please note that the information detailed in this statement supersedes any prior published data produced by CIGWELD CIGWELD GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7391 Email enquiries cigweld com au Victor Technologies USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Victor Technologies Canada 2070
88. the possibility of interference A WARNING READ INSTRUCTIONS Use Testing Booklet Part No 150 853 when servicing this unit Consult the Owner s Manual for welding safety precautions Use only genuine replacement parts from the manufacturer safety Instructions and Warnings SAFETY INSTRUCTIONS AND WARNINGS 1 06 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electromagnetic fields There has been and still is some concern about such fields However after examining more than 500 studies Spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them or using a Cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from
89. to Control PCB Terminal Input Descriptions Reference AC supply for circuit dud CN3 1 20 Vac AC supply for circuit Eis CN3 3 20 Vac AC supply for wire drive motor did CN5 1 30 Vac ias Input signal for torch trigger CN7 3 CN7 3 0 Torch trigger switch open CN3 2 7 3 81012 trigger switch closed Input signal for thermostat CN2 2 2 2 8 12 Thermostat closed CN3 2 CN2 2 0 Thermostat open Reference signal from wirespeed potentiometer wiper CN8 2 CN8 2 1 1 Wirespeed potentiometer minimum CN3 2 CN8 2 7 0 Vde Wirespeed potentiometer maximum Latch switch CN7 1 CN7 1 0 Latch switch open CN3 2 CN7 1 11 5Vdc Latch switch closed Table 6 14 Inputs to Control PCB 7978050 Troubleshooting 6 12 Manual 0 5186 TROUBLESHOOTING WELDSKILL 250 350 13 Outputs from Control PCB Terminal Output Descriptions Reference DC supply to wire drive motor CN9 3 0 to 24 ES AC supply to contactor and gas solenoid CN1 1 0 Vac contactor solenoid on EIS Reference voltage for wirespeed potentiometer CNS S CN8 3 7 0 Vdc ena cna POWER led CN4 2 CN4 1 1 to 3 POWER led on OVER TEMPERATURE led CN4 3 CN4 3 15Vdc Thermostat closed CN4 2 CN4 3 1 to 3 Vde Thermostat open 15V supply for INCH button CNG 7 15 Vdc dics BURNBACK CN6 2 CN6 2 0 Vdc Trigger op
90. ttended or out of service 5 Use approved ear plugs or ear muffs if noise level is high 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 6 Never wear contact lenses while welding 8 Donotuse worn damaged undersized or poorly spliced cables WARNING 9 Do not wrap cables around your body FUMES AND GASES can be hazardous to your health 10 Ground the workpiece to a good electrical earth ground Welding produces fumes and gases Breathing these f h t health 11 Do not touch electrode while in contact with the work ground Tumes and gases can be hazardous to your hea circuit 1 Keep your head out of the fumes Do not breath the fumes Manual 0 5186 1 1 Safety Instructions and Warnings WELDSKILL 250 350 2 If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets 5055 and the manu facturer s instruction for metals consumables coatings and cleaners 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 Do not w
91. uced output ratings apply with the supplied 15A primary lead To achieve the maximum rated output amp 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 Safety and Installation 3 2 Manual 0 5186 SAFETY AND INSTALLATION WELDSKILL 250 350 3 03 WeldSkill 350 MIG Power Source Specifications Open Circuit Voltage Range 17 to 42V MIG GMAW 390A 30 31 6V Welding Output 40 C 10 min 290A 60 26 3V 205A 100 24 4V Operating Temperature Range 0 C 40 C Number of Output Voltage Switch Settings Protection Class IP21S Table 3 2 WeldSkill 350 Specification v The Effective Input Current should be used for the determination of cable size 4 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 me
92. urce inder bracket with the chain provided If this arrangement is not used or the Power Source is not fitted with a gas cylinder tray then ensure that the gas cylinder is secured to a building pillar wall bracket or otherwise securely fixed in an upright position D Connect the TORCH power cable to the positive welding terminal negative welding terminal for flux cored electrode wire If in doubt consult the electrode wire manufacturer E Fit the gas regulator and flowmeter to the gas cylinder then connect the gas hose from the rear of the Power Source to the Flowmeter outlet F Dual groove feed rollers are supplied as standard They can accommodate 0 9 1 2mm diameter hard wires Select the roller required with the chosen wire size marking facing outwards GROOVE GROOVE B Art 08739 GROOVE SIZE GROOVE A SIZE G Fit the electrode wire spool to the wire reel hub Note that there is an adaptor supplied when using 200mm diameter wire spools Ensure that the drive dog pin engages the mating hole in the wire spool Push the spool securing clip into place to retain the wire spool securely The electrode wire should feed from the bottom of the spool H MIG Torch EURO MIG Torch Connection Fit the MIG Torch to the Power Source by pushing the torch connector into the brass torch adaptor and screwing the plastic torch nut clockwise to secure the torch to the torch adaptor Remove the contact
93. urrounding area may alleviate problems of interference Screening the entire welding installation may be considered for special applications Manual 0 5186 SAFETY AND INSTALLATION WELDSKILL 250 350 3 14 Volt Ampere Curves Voltage Amperage Curves shows maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown WeldSkill 250 VA Curve 50 0 45 0 40 0 30 0 25 0 Volts 20 0 10 0 5 0 0 0 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 Art 0 08731 Amps Weldskill 350 VA Curve 45 0 40 0 30 0 25 0 Volts 20 0 10 0 5 0 0 0 0 50 100 150 200 250 300 350 400 Amps Art 0 08732 Figure 3 2 Fabricator 181i Volt Ampere Curves Manual 0 5186 3 9 Safety and Installation WELDSKILL 250 350 SAFETY AND INSTALLATION Notes Safety and Installation 3 10 Manual 0 5186 OPERATION WELDSKILL 250 350 SECTION 4 OPERATION 4 01 Power Source Front Panel 2 CONTROL 10 WIRESPEED WeldSkill 250 mic ned TORCH REMOTE 5 ta ee 1 0 0 0 O ere 0
94. vers and guards closed and securely in place otop engine before installing or connecting unit Have only qualified people remove guards or covers for main tenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting engine WARNING This product when used for welding or cutting pro duces fumes or gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health amp Safety code Sec 25249 5 et seq NOTE 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 amp 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 scient
95. with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer Trouble some NOTE The welding circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorised by a person who 15 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 15 given in IEC 974 13 Arc Welding Equipment Installation and use under preparation Safety and Installation WELDSKILL 250 350 3 12 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 signaling and telephone cables above below and adjacent to the welding equipment Radio and television transmitters and receivers Computer and other control equipment safety critical equipment e g guarding of industrial equipment The health of people around e g the use of pace makers and hearing aids Equipment used for calibration and measurement The time of day that welding or other activities are to be carried out The immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment

WELDSKILL 250 Service Manual 350 4R

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