130 weldskill 170 inverter arc welding machines...cigweld weldskill 130 and 170 inverter arc welders...

170AMP

240 V

130AMP DC

130

Operating ManualVersion No: AE Issue Date: September 21, 2007 Manual No.: 0-5048Operating Features:

WELDSKILL®

INVERTERARC WELDING MACHINES

170

Art # A-08153

WE APPRECIATE YOUR BUSINESS!Congratulations on your new Cigweld product. We are proud tohave you as our customer and will strive to provide you with thebest service and reliability in the industry. This product is backedby our extensive warranty and world-wide service network. Tolocate your nearest distributor or service agency call+1300 654 674, or visit us on the web at www.cigweld.com.au.

This Operating Manual has been designed to instruct you on thecorrect use and operation of your CIGWELD product. Yoursatisfaction with this product and its safe operation is our ultimateconcern. Therefore please take the time to read the entire manual,especially the Safety Precautions. They will help you to avoidpotential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!The Brand of Choice for Contractors and Fabricators Worldwide.

CIGWELD is the Market Leading Brand of Arc Welding Productsfor Thermadyne Industries Inc. We are a mainline supplier to majorwelding industry sectors in the Asia Pacific and emerging globalmarkets 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. Wepride ourselves on technical innovation, competitive prices,excellent delivery, superior customer service and technical support,together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advancedproducts to achieve a safer working environment for industryoperators.

! WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing,operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement,the Manufacturer assumes no liability for its use.

Cigweld Weldskill 130 and 170 Inverter Arc WeldersInstruction Manual Number 0-5048 for:Part Numbers W1001900, W1001901, W1002801 and W1002901

Published by:Thermadyne Industries, Inc.82 Benning StreetWest Lebanon, New Hampshire, USA 03784(603) 298-5711

www.thermadyne.com

Copyright 2007 byThermadyne Industries, Inc.

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the publisheris prohibited.

The publisher does not assume and hereby disclaims any liability to any party for anyloss or damage caused by any error or omission in this Manual, whether such errorresults from negligence, accident, or any other cause.

Publication Date: September 21, 2007Revision AE Date November 30, 2007

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

i

TABLE OF CONTENTS

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

1.01 Arc Welding Hazards ...................................................................................... 1-11.02 PRINCIPAL SAFETY STANDARDS .................................................................. 1-51.03 DECLARATION OF CONFORMITY ................................................................... 1-6

SECTION 2:INTRODUCTION ...................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-12.02 Equipment Identification................................................................................. 2-12.03 Receipt Of Equipment ..................................................................................... 2-12.04 Symbol Chart ................................................................................................. 2-22.05 Description ..................................................................................................... 2-32.06 User Responsibility ........................................................................................ 2-32.07 Packaged Items .............................................................................................. 2-32.08 Transporting Methods .................................................................................... 2-32.09 Duty Cycle ...................................................................................................... 2-32.10 Specifications ................................................................................................. 2-42.11 Options and Accessories ................................................................................ 2-4

SECTION 3:INSTALLATION ....................................................................................... 3-1

3.01 Environment ................................................................................................... 3-13.02 Location ......................................................................................................... 3-13.03 Ventilation ....................................................................................................... 3-13.04 Mains Supply Voltage Requirements .............................................................. 3-13.05 Electromagnetic Compatibility ........................................................................ 3-23.06 Setup For Manual Arc Welding ....................................................................... 3-43.07 Setup For TIG Welding ................................................................................... 3-5

SECTION 4:OPERATION........................................................................................... 4-1

4.01 Overview ........................................................................................................ 4-14.02 Front Panel ..................................................................................................... 4-14.03 Arc Welding Electrodes .................................................................................. 4-24.04 Types of Electrodes ........................................................................................ 4-24.05 Size of Electrode ............................................................................................. 4-34.06 Storage of Electrodes ..................................................................................... 4-34.07 Electrode Polarity ........................................................................................... 4-34.08 Effects of Arc Welding Various Materials ........................................................ 4-34.09 Arc Welding Practice ...................................................................................... 4-44.10 Welding Position ............................................................................................ 4-44.11 Joint Preparations .......................................................................................... 4-54.12 Arc Welding Technique ................................................................................... 4-64.13 The Welder ..................................................................................................... 4-64.14 Striking the Arc ............................................................................................... 4-64.15 Arc Length ...................................................................................................... 4-64.16 Rate of Travel ................................................................................................. 4-64.17 Making Welded Joints .................................................................................... 4-7

TABLE OF CONTENTS (continued)

TABLE OF CONTENTS

4.18 Distortion ....................................................................................................... 4-94.19 The Cause of Distortion .................................................................................. 4-94.20 Overcoming Distortion Effects ........................................................................ 4-9

SECTION 5:SERVICE .............................................................................................. 5-1

5.01 Routine Maintenance & Inspection................................................................. 5-15.02 Cleaning the Welding Power Source ............................................................... 5-15.03 Face Shield Maintenance ................................................................................ 5-15.04 Basic Troubleshooting .................................................................................... 5-15.05 Welding Problems .......................................................................................... 5-25.06 Welding Power Source Problems ................................................................... 5-5

CIGWELD LIMITED WARRANTY

Terms of Warranty – 2007

Warranty Schedule – 2007

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

WELDSKILL 130, 170

1-1September 21, 2007

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can causefatal shocks or severe burns. The electrodeand work circuit is electrically livewhenever the output is on. The inputpower circuit and machine internal circuitsare also live when power is on. Insemiautomatic or automatic wire welding,the wire, wire reel, drive roll housing, andall metal parts touching the welding wireare electrically live. Incorrectly installed orimproperly grounded equipment is ahazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and bodyprotection.

3. Insulate yourself from work and ground using dryinsulating mats or covers.

4. Disconnect input power or stop engine beforeinstalling or servicing this equipment. Lock inputpower disconnect switch open, or remove linefuses so power cannot be turned on accidentally.

5. Properly install and ground this equipmentaccording to its Owner’s Manual and national,state, and local codes.

6. Turn off all equipment when not in use. Disconnectpower to equipment if it will be left unattended orout of service.

7. Use fully insulated electrode holders. Never dipholder in water to cool it or lay it down on theground or the work surface. Do not touch holdersconnected to two welding machines at the sametime or touch other people with the holder orelectrode.

8. Do not use worn, damaged, undersized, or poorlyspliced cables.

9. Do not wrap cables around your body.

10.Ground the workpiece to a good electrical (earth)ground.

11.Do not touch electrode while in contact with thework (ground) circuit.

12.Use only well-maintained equipment. Repair orreplace damaged parts at once.

SECTION 1:ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESEINSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING ORSERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment orproperty, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices mustbe learned through study and training before using this equipment. Some of these practices apply to equipmentconnected to power lines; other practices apply to engine driven equipment. Anyone not having extensivetraining 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 alliedprocesses Part 2: Electrical. This publication and other guides to what you should learn before operating thisequipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION,MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

WELDSKILL 130, 170

1-2 September 21, 2007

13. In confined spaces or damp locations, do not usea welder with AC output unless it is equipped witha voltage reducer. Use equipment with DC output.

14.Wear a safety harness to prevent falling if workingabove floor level.

15.Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISEcan damage hearing.

Arc rays from the welding processproduce intense heat and strong ultravioletrays that can burn eyes and skin. Noisefrom some processes can damagehearing.

1. Wear a welding helmet fitted with a proper shadeof filter (see ANSI Z49.1 listed in Safety Standards)to protect your face and eyes when welding orwatching.

2. Wear approved safety glasses. Side shieldsrecommended.

3. Use protective screens or barriers to protect othersfrom flash and glare; warn others not to watchthe arc.

4. Wear protective clothing made from durable,flame-resistant material (wool and leather) andfoot protection.

5. Use approved ear plugs or ear muffs if noise levelis high.

WARNING

FUMES AND GASES can be hazardous toyour health.

Welding produces fumes and gases.Breathing these fumes and gases can behazardous to your health.

1. Keep your head out of the fumes. Do not breaththe fumes.

2. If inside, ventilate the area and/or use exhaust atthe arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-suppliedrespirator.

4. Read the Material Safety Data Sheets (MSDSs)and the manufacturer’s instruction for metals,consumables, coatings, and cleaners.

5. Work in a confined space only if it is well ventilated,or while wearing an air-supplied respirator.Shielding gases used for welding can displace aircausing injury or death. Be sure the breathing airis safe.

6. Do not weld in locations near degreasing, cleaning,or spraying operations. The heat and rays of thearc can react with vapors to form highly toxic andirritating gases.

Welding or Cutting operation

Electrode size Metal Thickness or Welding Current

Filter shade

no.

Welding or Cutting operation Electrode size Metal Thickness or Welding

Current

Filter shade

no.Torch soldering All 2Torch brazing All 2 or 3 Non Ferrous base metal All 11

Ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding (TIG) All 12

Medium 1 – 6 in., 25 – 150 mm 4 or 5 Atomic Hydrogen welding All 12

Heavy Over 6 in., 150 mm 5 or 6 Carbon Arc welding All 12

Plasma arc Welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Carbon Arc GougingMedium 1/8 – 1/2 in., 3 – 12 mm 5 or 6 Light 12Heavy Over 1/2 in., 12 mm 6 or 8 Heavy 14

Under 5/32 in., 4 mm 10 Light Under 300 Amp 9Under 5/32 to ¼ in., 4 to 6.4mm 12 Medium 300 to 400 Amp 12Over ¼ in., 6.4 mm 14 Heavy Over 400 Amp 14

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73

Plasma arc cutting

Oxygen cutting

Gas metal arc welding

Gas welding

Shielded metal-arc welding (stick) electrodes

WELDSKILL 130, 170


7. Do not weld on coated metals, such as galvanized,lead, or cadmium plated steel, unless the coatingis removed from the weld area, the area is wellventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metalscontaining these elements can give off toxic fumesif welded.

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the weldingarc. The flying sparks and hot metal, weldspatter, hot workpiece, and hot equipmentcan cause fires and burns. Accidentalcontact of electrode or welding wire tometal objects can cause sparks,overheating, or fire.

1. Protect yourself and others from flying sparks andhot metal.

2. Do not weld where flying sparks can strikeflammable material.

3. Remove all flammables within 35 ft (10.7 m) ofthe welding arc. If this is not possible, tightly coverthem with approved covers.

4. Be alert that welding sparks and hot materials fromwelding can easily go through small cracks andopenings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead,or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanksor drums.

8. Connect work cable to the work as close to thewelding area as practical to prevent weldingcurrent from traveling long, possibly unknownpaths and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

10.Remove stick electrode from holder or cut offwelding wire at contact tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL cancause injury.

Chipping and grinding cause flying metal.As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Sideshields recommended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas underhigh pressure. If damaged, a cylinder canexplode. Since gas cylinders are normallypart of the welding process, be sure totreat them carefully.

1. Protect compressed gas cylinders from excessiveheat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright positionby chaining them to a stationary support orequipment cylinder rack to prevent falling ortipping.

3. Keep cylinders away from any welding or otherelectrical circuits.

4. Never allow a welding electrode to touch anycylinder.

5. Use only correct shielding gas cylinders,regulators, hoses, and fittings designed for thespecific application; maintain them and associatedparts in good condition.

6. Turn face away from valve outlet when openingcylinder valve.

7. Keep protective cap in place over valve exceptwhen cylinder is in use or connected for use.

8. Read and follow instructions on compressed gascylinders, associated equipment, and CGApublication P-1 listed in Safety Standards.

WELDSKILL 130, 170


WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilatedareas.

2. If used in a closed area, vent engine exhaustoutside and away from any building air intakes.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is nearany sparks or open flames.

3. Allow engine to cool before fueling. If possible,check and add fuel to cold engine before beginningjob.

4. Do not overfill tank — allow room for fuel toexpand.

5. Do not spill fuel. If fuel is spilled, clean up beforestarting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cutfingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guardsclosed and securely in place.

2. Stop engine before installing or connectingunit.

3. Have only qualified people remove guards orcovers for maintenance and troubleshootingas necessary.

4. To prevent accidental starting duringservicing, disconnect negative (-) batterycable from battery.

5. Keep hands, hair, loose clothing, and toolsaway from moving parts.

6. Reinstall panels or guards and close doorswhen servicing is finished and before startingengine.

WARNING

SPARKS can cause BATTERY GASES TOEXPLODE; BATTERY ACID can burn eyesand skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on abattery.

2. Stop engine before disconnecting or connectingbattery cables.

3. Do not allow tools to cause sparks when workingon a battery.

4. Do not use welder to charge batteries or jump startvehicles.

5. Observe correct polarity (+ and –) on batteries.

WELDSKILL 130, 170


WARNING

STEAM AND PRESSURIZED HOTCOOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hotand under pressure.

1. Do not remove radiator cap when engine is hot.Allow engine to cool.

2. Wear gloves and put a rag over cap area whenremoving cap.

3. Allow pressure to escape before completelyremoving cap.

WARNING

This product, when used for welding orcutting, produces fumes or gases whichcontain chemicals know to the State ofCalifornia to cause birth defects and, insome cases, cancer. (California Health &Safety code Sec. 25249.5 et seq.)

NOTE

Considerations About Welding And TheEffects of Low Frequency Electric andMagnetic Fields

The following is a quotation from the GeneralConclusions Section of the U.S. Congress, Office ofTechnology Assessment, Biological Effects of PowerFrequency Electric & Magnetic Fields - BackgroundPaper, OTA-BP-E-63 (Washington, DC: U.S.Government Printing Office, May 1989): “...there isnow a very large volume of scientific findings basedon experiments at the cellular level and from studieswith animals and people which clearly establish thatlow frequency magnetic fields and interact with, andproduce changes in, biological systems. While mostof this work is of very high quality, the results arecomplex. Current scientific understanding does notyet allow us to interpret the evidence in a singlecoherent framework. Even more frustrating, it doesnot yet allow us to draw definite conclusions aboutquestions of possible risk or to offer clear science-based advice on strategies to minimize or avoidpotential risks.”

To reduce magnetic fields in the workplace, use thefollowing procedures.

1. Keep cables close together by twisting ortaping them.

2. Arrange cables to one side and away from theoperator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as faraway from body as practical.

ABOUT PACEMAKERS:

The above procedures are among thosealso normally recommended forpacemaker wearers. Consult your doctorfor complete information.

1.02 PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1,from American Welding Society, 550 N.W. LeJeuneRd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910,from Superintendent of Documents, U.S. GovernmentPrinting Office, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation forWelding and Cutting of Containers That Have HeldHazardous Substances, American Welding SocietyStandard AWS F4.1, from American Welding Society,550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, fromNational Fire Protection Association, BatterymarchPark, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGAPamphlet P-1, from Compressed Gas Association,1235 Jefferson Davis Highway, Suite 501, Arlington,VA 22202.

Code for Safety in Welding and Cutting, CSA StandardW117.2, from Canadian Standards Association,Standards Sales, 178 Rexdale Boulevard, Rexdale,Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eyeand Face Protection, ANSI Standard Z87.1, fromAmerican National Standards Institute, 1430Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B,from National Fire Protection Association,Batterymarch Park, Quincy, MA 02269.

Safety in welding and allied processes Part 2:Electrical, AS1674.2-2007 from SAI Global Limited,www.saiglobal.com

WELDSKILL 130, 170


1.03 DECLARATION OF CONFORMITY

Manufacturer: CIGWELDAddress: 71 Gower St, Preston

Victoria 3072

Australia

Description of equipment: Welding Equipment (MMAW, GTAW) including, but not limited to CIGWELD Weldskill130, 170 and associated accessories.

Serial numbers are unique with each individual piece of equipment and details description, partsused to manufacture a unit and date of manufacture.

The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive73/23/EU, as recently changed in Directive 93/68/EU and to the National legislation for the enforcement of theDirective.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements among themare:

• AS/NZS 3652-(EMC Directive EN50199) applicable to arc welding equipment - generic emissions and

regulations.

• EN60974-1 applicable to welding equipment and associated accessories.

• AS60974.1 applicable to welding equipment and associated accessories.Extensive product design verification is conducted at the manufacturing facility as part of the routine designand manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing isincorporated into the manufacturing process to ensure the manufactured product meets or exceeds all designspecifications.

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.

WELDSKILL 130, 170


SECTION 2:INTRODUCTION

2.02 Equipment Identification

The unit’s identification number (specification or partnumber), model, and serial number usually appearon a nameplate attached to the control panel. In somecases, the nameplate may be attached to the rearpanel. Equipment which does not have a control panelsuch as gun and cable assemblies is identified onlyby the specification or part number printed on theshipping container. Record these numbers on thebottom of page i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it againstthe invoice to make sure it is complete and inspectthe equipment for possible damage due to shipping.If there is any damage, notify the carrier immediatelyto file a claim. Furnish complete informationconcerning damage claims or shipping errors to thelocation in your area listed in the inside back cover ofthis manual.

Include all equipment identification numbers asdescribed above along with a full description of theparts in error.

Move the equipment to the installation site before un-crating the unit. Use care to avoid damaging theequipment when using bars, hammers, etc., to un-crate the unit.

2.01 How To Use This Manual

This Owner’s Manual applies to just specification orpart numbers listed on page i.

To ensure safe operation, read the entire manual,including the chapter on safety instructions andwarnings.

Throughout this manual, the words WARNING,CAUTION, and NOTE may appear. Pay particularattention to the information provided under theseheadings. These special annotations are easilyrecognized as follows:

! WARNING

A WARNING gives information regardingpossible personal injury.

CAUTION

A CAUTION refers to possible equipmentdamage.

NOTE

A NOTE offers helpful informationconcerning certain operating procedures.

Additional copies of this manual may be purchasedby contacting Cigweld at the address and phonenumber for your location listed in the inside back coverof this manual. Include the Owner’s Manual numberand equipment identification numbers.

Electronic copies of this manual can also bedownloaded at no charge in Acrobat PDF format bygoing to the Cigweld web site listed below and clickingon the Literature Library link:

http://www.cigweld.com.au

WELDSKILL 130, 170


2.04 Symbol Chart

Note that only some of these symbols will appear on your model.

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static Frequency Converter-Transformer-Rectifier

Dangerous Voltage

Off

On

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Receptacle Rating-Auxiliary Power

Art

# A

-049

37

115V 15A

t

t1

t2

%X

IPM

MPM

t

V

Fuse

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous WeldMode

Press to initiate wirefeed and welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Disturbance InGround System

Welding Gun

Burnback Time

Press and hold for preflow, releaseto start arc. Press to stop arc, andhold for preflow.

4 Step TriggerOperation

2 Step TriggerOperation

WELDSKILL 130, 170


2.05 Description

Weldskill 130

This compact, portable, inverter welding machine hasinfinitely adjustable welding current from 5 to 130amps. It runs standard general purpose 2.5mmelectrodes for light gauge work, generally less than3.0mm thick and 3.2mm electrodes for heaviermaterials. The unit also has a lift TIG function thatoffers stable TIG welding characteristics when usedwith a suitable TIG torch and shielding gas.

Weldskill 170

This compact heavy duty, inverter welding machinehas infinitely adjustable welding current from 5 to 170amps. It runs standard general purpose 2.5mmelectrodes for light gauge work, generally less than3.0mm thick, and 3.2mm electrodes for heaviermaterial. The unit also has a lift TIG function that offersstable TIG welding characteristics when used with asuitable TIG torch and shielding gas.

2.06 User Responsibility

This equipment will perform as per the informationcontained herein when installed, operated, maintainedand repaired in accordance with the instructionsprovided. This equipment must be checkedperiodically. Defective equipment (including weldingleads) should not be used. Parts that are broken,missing, plainly worn, distorted or contaminated,should be replaced immediately. Should such repairsor replacements become necessary, it isrecommended that such repairs be carried out byappropriately qualified persons approved byCIGWELD. Advice in this regard can be obtained bycontacting accredited CIGWELD Distributor.

This equipment or any of its parts should not bealtered from standard specification without priorwritten approval of CIGWELD. The user of thisequipment shall have the sole responsibility for anymalfunction which results from improper use orunauthorised modification from standardspecification, faulty maintenance, damage or improperrepair by anyone other than appropriately qualifiedpersons approved by CIGWELD.

2.07 Packaged Items

Description Weldskill 130 Weldskill 170 Welding Power Source

Electrode Lead Work Lead Operating Manual

NOTE:

Part numbers W1002801 and W1002901come complete with a plastic tool case.

2.08 Transporting Methods

These units are equipped with a handle for carryingpurposes.

! WARNING

ELECTRIC SHOCK can kill. DO NOT TOUCHlive electrical parts. Disconnect inputpower conductors from de-energizedsupply line before moving the weldingpower source.

! WARNING

FALLING EQUIPMENT can cause seriouspersonal injury and equipment damage.

Lift unit with handle on top of case.

Use handcart or similar device of adequate capacity.

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

2.09 Duty Cycle

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

WELDSKILL 130, 170


2.10 Specifications

Description Weldskill 130 Weldskill 170

Power Source Part Number W1002800 W1002900

Cooling Fan Cooled Fan Cooled

Welder Type Inverter Power Source Inverter Power Source

Welding Power Source Mass 5.5kg 6.5kg

Dimensions H 280mm x W 120mm x D 220mm H 330mm x W 130mm x D 230mm

Manufactured to Australian Standard

AS60974.1-2006 AS60974.1-2006

Number of Phases Single Phase Single Phase

Nominal Supply Voltage 240V ±15% 240V ±15%

Nominal Supply Frequency 50Hz 50Hz

Welding Current Range 5 - 130 Amps 5 - 170 Amps

Factory Fitted Supply Plug Rating 10 Amps 15 Amps

Effective Input Current (I1eff) 10 Amps 15 Amps

Maximum Input Current (I1 max) 23 Amps 31 Amps

Single Phase Generator Requirement

6 KVA 8.2 KVA

Welding Output, 40°C ,10 min. (quoted figures refer to MMAW output)

130A @ 20%, 25.2V 75A @ 60%, 23.1V

58A @ 100%, 22.3V

170A @ 25%, 26.8V 110A @ 60%, 24V

85A @ 100%, 23.2V

Protection Class IP23S IP23S

NOTE

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

2.11 Options and Accessories

Description Part Number TIG Torch Weldskill 130 Inverter W7003006

TIG Torch Weldskill 170 Inverter W7003021

TIG torch Accessory Kit BGSAK2 Flow Meter/Regulator 210254

WELDSKILL 130, 170


SECTION 3:INSTALLATION

3.04 Mains Supply VoltageRequirements

The Mains supply voltage should be within •± 15% ofthe rated Mains supply voltage. Too low a voltage maycause poor welding performance. Too high a supplyvoltage will cause components to overheat andpossibly fail.

The Welding Power Source must be:

• Correctly installed, if necessary, by a qualifiedelectrician.

• Correctly earthed (electrically) in accordancewith local regulations.

• Connected to the correct size power point andfuse as per the Specifications on page 2-4.

IMPORTANT NOTE

This product has been fitted with a supplyplug as indicated in Section 2.11. Note thatthe welding output range applicable with thefitted supply plug is detailed in Section 2.11.

In order to achieve maximum weldingoutput and duty cycle it is recommendedto increase the rating of the Supply Plugas detailed in Section 2.12

! WARNING

Any electrical work must be carried outby a qualified Electrical Tradesperson.

3.01 Environment

These units are designed for use in environments withincreased hazard of electric shock.

A. Examples of environments with increased hazardof electric shock are:

1. In locations in which freedom of movementis restricted, so that the operator is forced toperform the work in a cramped (kneeling,sitting or lying) position with physical contactwith conductive parts.

2. In locations which are fully or partially limitedby conductive elements, and in which thereis a high risk of unavoidable or accidentalcontact by the operator.

3. In wet or damp hot locations where humidityor perspiration considerable reduces the skinresistance of the human body and theinsulation properties of accessories.

B. Environments with increased hazard of electricshock do not include places where electricallyconductive parts in the near vicinity of the operator,which can cause increased hazard, have beeninsulated.

3.02 Location

Be sure to locate the welder according to the followingguidelines:

A. In areas, free from moisture and dust.

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

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

D. In areas, not subjected to abnormal vibration orshock.

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

F. Place at a distance of 300mm or more from wallsor similar that could restrict natural air flow forcooling.

3.03 Ventilation

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

WELDSKILL 130, 170


3.05 Electromagnetic Compatibility

! WARNING

Extra precautions for ElectromagneticCompatibility may be required when thisWelding Power Source is used in adomestic situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using thewelding equipment according to the manufacturer’sinstructions. If electromagnetic disturbances aredetected then it shall be the responsibility of the userof the welding equipment to resolve the situation withthe technical assistance of the manufacturer. In somecases this remedial action may be as simple asearthing the welding circuit, see NOTE below. In othercases it could involve constructing an electromagneticscreen enclosing the Welding Power Source and thework, complete with associated input filters. In allcases, electromagnetic disturbances shall be reducedto the point where they are no longer troublesome.

NOTE

The welding circuit may or may nor beearthed for safety reasons. Changing theearthing arrangements should only beauthorised by a person who is competentto assess whether the changes willincrease the risk of injury, e.g. by allowingparallel welding current return paths whichmay damage the earth circuits of otherequipment. Further guidance is given inIEC 974-13 Arc Welding Equipment -Installation and use (under preparation).

B. Assessment of Area

Before installing welding equipment, the user shallmake an assessment of potential electromagneticproblems in the surrounding area. The following shallbe taken into account

1. Other supply cables, control cables, signallingand telephone cables; above, below andadjacent to the welding equipment.

2. Radio and television transmitters andreceivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding ofindustrial equipment.

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

6. Equipment used for calibration andmeasurement.

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

8. The immunity of other equipment in theenvironment: the user shall ensure that otherequipment being used in the environment iscompatible: this may require additionalprotection measures.

The size of the surrounding area to be consideredwill depend on the structure of the building and otheractivities that are taking place. The surrounding areamay extend beyond the boundaries of the premises.

C. Methods of Reducing Electromagnetic Emis-sions

1. Mains Supply

Welding equipment should be connected tothe mains supply according to themanufacturer’s recommendations. Ifinterference occurs, it may be necessary totake additional precautions such as filteringof the mains supply. Consideration should begiven to shielding the supply cable ofpermanently installed welding equipment inmetallic conduit or equivalent. Shieldingshould be electrically continuous throughoutit’s length. The shielding should be connectedto the Welding Power Source so that goodelectrical contact is maintained between theconduit and the Welding Power Sourceenclosure.

2. Maintenance of Welding Equipment

The welding equipment should be routinelymaintained according to the manufacturer’srecommendations. All access and servicedoors and covers should be closed andproperly fastened when the weldingequipment is in operation. The weldingequipment should not be modified in any wayexcept for those changes and adjustmentscovered in the manufacturer’s instructions. Inparticular, the spark gaps of arc striking andstabilising devices should be adjusted andmaintained according to the manufacturer’srecommendations.

3. Welding Cables

The welding cables should be kept as shortas possible and should be positioned closetogether, running at or close to the floor level.

WELDSKILL 130, 170


4. Equipotential Bonding

Bonding of all metallic components in thewelding installation and adjacent to it shouldbe considered. However. Metallic componentsbonded to the work piece will increase the riskthat the operator could receive a shock bytouching the metallic components and theelectrode at the same time. The operatorshould be insulated from all such bondedmetallic components.

5. Earthing of the Workpiece

Where the workpiece is not bonded to earthfor electrical safety, nor connected to earthbecause of it’s size and position, e.g. ship’shull or building steelwork, a connectionbonding the workpiece to earth may reduceemissions in some, but not all instances. Careshould be taken to prevent the earthing of theworkpiece increasing the risk of injury tousers, or damage to other electricalequipment. Where necessary, the connectionof the workpiece to earth should be made bydirect connection to the workpiece, but insome countries where direct connection is notpermitted, the bonding should be achieved bysuitable capacitance, selected according tonational regulations.

6. Screening and Shielding

Selective screening and shielding of othercables and equipment in the surrounding areamay alleviate problems of interference.Screening the entire welding installation maybe considered for special applications.

WELDSKILL 130, 170


3.06 Setup For Manual Arc Welding

! WARNING

Before connecting the work clamp to thework and inserting the electrode in theelectrode holder make sure the Mainspower supply is switched off.

CAUTION

Remove any packaging material prior touse. Do not block the air vents at the frontor rear of the Welding Power Source.

WeldSkill

WORK

WORK CLAMPNEGATIVEOUTPUTTERMINAL

POSITIVEOUTPUTTERMINAL

ROD

ARC

ELECTRODE HOLDER

240V AC POWER SOURCE

Art # A-08154

Set ProcessSelection Switch toMANUAL ARCWELDING mode

Figure 3-1: Set-up for Arc Welding

WELDSKILL 130, 170


3.07 Setup For TIG Welding

! WARNING

Before connecting the work clamp to thework and inserting the electrode in the TIGtorch make sure the Mains power supplyis switched off.

CAUTION

Remove any packaging material prior touse. Do not block the air vents at the frontor rear of the Welding Power Source.

240V AC POWER SOURCE

Art # A-08155

NEGATIVEOUTPUTTERMINAL

POSITIVEOUTPUTTERMINAL

Set ProcessSelection Switch toLIFT TIG mode

WeldSkill

Figure 3-2: Set-up for TIG Welding

WELDSKILL 130, 170


WELDSKILL 130, 170


WeldSkill

MANUAL

ARC

LIFTTIG

POWER OVER HEAT WELD CURRENT (A)

60100

120

1305

20

40(A) Process Selection Switch

(D) Welding Current Control

Negative Output Terminal Positive Output Terminal

Art # A-08156

(C) Over Heat Indicator

(B) Power On Indicator

SECTION 4:OPERATION

4.01 Overview

Conventional operating procedures apply when usingthe Welding Power Source, i.e. connect work leaddirectly to workpiece and electrode lead is used tohold electrode. The welding current range valuesshould be used as a guide only. Current delivered tothe arc is dependent on the welding arc voltage, andas welding arc voltage varies between different classesof electrode, welding current at any one setting wouldvary according to the type of electrode in use. Theoperator should use the welding current range valuesas a guide, then finally adjust the current setting tosuit the application.

4.02 Front Panel

A. Process Selection Switch

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

B. Power ON Indicator

The Power ON Indicator illuminates when the ON/OFFswitch is in the ON position and the correct mainsvoltage is present.

C. Over Heat Indicator

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

D. Welding Current Control

The welding current is increased by turning the WeldCurrent (A) control knob clockwise or decreased byturning the Weld Current (A) control knob anti-clockwise. The welding current should be setaccording to the specific application. Refer toapplication notes in this section for furtherinformation.

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

This switch controls the Mains Supply Voltage to thePower Source.

Figure 4-1: Front Panel

WELDSKILL 130, 170


4.03 Arc Welding Electrodes

Metal arc welding electrodes consist of a core wire surrounded by a flux coating. The flux coating is applied tothe core wire by an extrusion process.

The coating on arc welding electrodes serves a number of purposes:

A. To provide a gaseous shield for the weld metal, and preserve it from contamination by the atmospherewhilst in a molten state.

B. To give a steady arc by having ‘arc stabilisers’ present, which provide a bridge for current to flow across.

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

D. To provide a cleansing action on the work piece and a protective slag cover over the weld metal to preventthe formation of oxides while the metal is solidifying. The slag also helps to produce a bead of the desiredcontour.

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

4.04 Types of Electrodes

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

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

Art # A-07686

Table 4-1: Types of Electrodes

WELDSKILL 130, 170


4.05 Size of Electrode

The electrode size is determined by the thickness ofmetals being joined and can also be governed by thetype of welding machine available. Small weldingmachines will only provide sufficient current(amperage) to run the smaller size electrodes.

For most work, a 2.5mm electrode will be quitesufficient. A 2.5mm electrode will give just as stronga joint but may require a few more weld runs to beput down to fill the joint.

For thin sections, it is necessary to use smallerelectrodes otherwise the arc may burn holes throughthe job. A little practice will soon establish the mostsuitable electrode for a given application.

4.06 Storage of Electrodes

Always store electrodes in a dry place and in theiroriginal containers.

4.07 Electrode Polarity

Electrodes are generally connected to the ELECTRODEHOLDER and the WORK LEAD to the work piece butif in doubt consult your nearest accredited CIGWELDDistributor.

4.08 Effects of Arc Welding VariousMaterials

A. High tensile and alloy steels

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

B. Austenitic manganese steels

The effect on manganese steel of slow cooling fromhigh temperatures is to embrittle it. For this reason itis absolutely essential to keep manganese steel coolduring welding by quenching after each weld or skipwelding to distribute the heat.

C. Cast Iron

Most types of cast iron, except white iron, areweldable. White iron, because of its extremebrittleness, generally cracks when attempts are madeto weld it. Trouble may also be experienced whenwelding white-heart malleable, due to the porositycaused by gas held in this type of iron.

D. Copper and alloys

The most important factor is the high rate of heatconductivity of copper, making preheating of heavysections necessary to give proper fusion of weld andbase metal.

WELDSKILL 130, 170


4.09 Arc Welding Practice

The techniques used for arc welding are almost identical regardless of what types of metals are being joined.Naturally enough, different types of electrodes would be used for different metals as described in the precedingsection.

4.10 Welding Position

The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding inflat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positionsintermediate between these. Some of the common types of welds are shown in Figures 4-2 through 4-9.

Art # A-07687

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

Art # A-07688

Figure 4-3: Flat position, gravity fillet weld

Art # A-07689

Figure 4-4: Horizontal position, butt weld

Art # A-07690

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

Art A-07691

Figure 4-6: Vertical position, butt weld

Art # A-07692

Figure 4-7: Vertical position, fillet weld

Art# A-07693

Figure 4-8: Overhead position, butt weld

Art # A-07694

Figure 4-9: Overhead position fillet, weld

WELDSKILL 130, 170


4.11 Joint Preparations

In many cases, it will be possible to weld steel sections without any special preparation. For heavier sectionsand for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces beingjoined to ensure proper penetration of the weld metal and to produce sound joints.

In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should beremoved from oxy-cut surfaces. Typical joint designs are shown in Figure 4-10.

Gap varies from 1.6mm to 4.8mm dependingon plate thickness

JointOpen Square Butt

1.6mm max

1.6mm

Single Vee Butt Joint Not less than 70°

Double Vee Butt Joint

1.6mmLap Joint

Tee Joints (Fillet both sides of the

joint)

Edge Joint

Fillet Joint

Corner Weld

Plug Weld Plug Weld

Not less than 70°

Single Vee Butt Joint Not less than 45°

1.6mm max

Art # A-07695

Figure 4-10: Typical joint designs for arc welding

WELDSKILL 130, 170


4.12 Arc Welding Technique

A Word to Beginners

For those who have not yet done any welding, thesimplest way to commence is to run beads on a pieceof scrap plate. Use mild steel plate about 6.0mm thickand a 3.2mm electrode. Clean any paint, loose scaleor grease off the plate and set it firmly on the workbench so that welding can be carried out in thedownhand position. Make sure that the work clampis making good electrical contact with the work, eitherdirectly or through the work table. For light gaugematerial, always clamp the work lead directly to thejob, otherwise a poor circuit will probably result.

4.13 The Welder

Place yourself in a comfortable position beforebeginning to weld. Get a seat of suitable height anddo as much work as possible sitting down. Don’t holdyour body tense. A taut attitude of mind and a tensedbody will soon make you feel tired. Relax and you willfind that the job becomes much easier. You can addmuch to your peace of mind by wearing a leatherapron and gauntlets. You won’t be worrying thenabout being burnt or sparks setting alight to yourclothes.

Place the work so that the direction of welding isacross, rather than to or from, your body. Theelectrode holder lead should be clear of anyobstruction so that you can move your arm freelyalong as the electrode burns down. If the lead is slungover your shoulder, it allows greater freedom ofmovement and takes a lot of weight off your hand. Besure the insulation on your cable and electrode holderis not faulty, otherwise you are risking an electricshock.

4.14 Striking the Arc

Practice this on a piece of scrap plate before goingon to more exacting work. You may at first experiencedifficulty due to the tip of the electrode “sticking” tothe work piece. This is caused by making too heavy acontact with the work and failing to withdraw theelectrode quickly enough. A low amperage willaccentuate it. This freezing-on of the tip may beovercome by scratching the electrode along the platesurface in the same way as a match is struck. As soonas the arc is established, maintain a 1.6mm to 3.2mmgap between the burning electrode end and the parentmetal. Draw the electrode slowly along as it meltsdown.

Another difficulty you may meet is the tendency, afterthe arc is struck, to withdraw the electrode so far thatthe arc is broken again. A little practice will soonremedy both of these faults.

Art # A-07696

Figure 4-11: Striking an arc

4.15 Arc Length

The securing of an arc length necessary to produce aneat weld soon becomes almost automatic. You willfind that a long arc produces more heat. A very longarc produces a crackling or spluttering noise and theweld metal comes across in large, irregular blobs.The weld bead is flattened and spatter increases. Ashort arc is essential if a high quality weld is to beobtained although if it is too short there is the dangerof it being blanketed by slag and the electrode tip beingsolidified in. If this should happen, give the electrodea quick twist back over the weld to detach it. Contactor “touch-weld” electrodes such as Ferrocraft 21 donot stick in this way, and make welding much easier.

4.16 Rate of Travel

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

If the travel is too fast, the bead will be narrow andstrung out and may even be broken up into individualglobules. If the travel is too slow, the weld metal pilesup and the bead will be too large.

WELDSKILL 130, 170


Art # A-07700

4.17 Making Welded Joints

Having attained some skill in the handling of anelectrode, you will be ready to go on to make upwelded joints.

A. Butt Welds

Set up two plates with their edges parallel, as shownin Figure 4-12, allowing 1.6mm to 2.4mm gapbetween them and tack weld at both ends. This is toprevent contraction stresses from the cooling weldmetal pulling the plates out of alignment. Plates thickerthan 6.0mm should have their mating edges bevelledto form a 70° to 90° included angle. This allows fullpenetration of the weld metal to the root. Using a3.2mm Ferrocraft 21 electrode at 100 amps, deposita run of weld metal on the bottom of the joint.

Do not weave the electrode, but maintain a steadyrate of travel along the joint sufficient to produce awell-formed bead. At first you may notice a tendencyfor undercut to form, but keeping the arc length short,the angle of the electrode at about 20° from vertical,and the rate of travel not too fast, will help eliminatethis. The electrode needs to be moved along fastenough to prevent the slag pool from getting aheadof the arc. To complete the joint in thin plate, turn thejob over, clean the slag out of the back and deposit asimilar weld.

Art # A-07697

Figure 4-12: Butt weld

Art # A-07698

Figure 4-13: Weld build up sequence

Heavy plate will require several runs to complete thejoint. After completing the first run, chip the slag outand clean the weld with a wire brush. It is importantto do this to prevent slag being trapped by the secondrun. Subsequent runs are then deposited using eithera weave technique or single beads laid down in the

sequence shown in Figure 4-13. The width of weaveshould not be more than three times the core wirediameter of the electrode. When the joint is completelyfilled, the back is either machined, ground or gougedout to remove slag which may be trapped in the root,and to prepare a suitable joint for depositing thebacking run. If a backing bar is used, it is not usuallynecessary to remove this, since it serves a similarpurpose to the backing run in securing proper fusionat the root of the weld.

B. Fillet Welds

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

A piece of angle iron is a suitable specimen with whichto begin, or two lengths of strip steel may be tackedtogether at right angles. Using a 3.2mm Ferrocraft21 electrode at 100 amps, position angle iron withone leg horizontal and the other vertical. This is knownas a horizontal-vertical (HV) fillet. Strike the arc andimmediately bring the electrode to a positionperpendicular to the line of the fillet and about 45°from the vertical. Some electrodes require to be slopedabout 20° away from the perpendicular position toprevent slag from running ahead of the weld. Referto Figure 4-14. Do not attempt to build up much largerthan 6.4mm width with a 3.2mm electrode, otherwisethe weld metal tends to sag towards the base, andundercut forms on the vertical leg. Multi-runs can bemade as shown in Figure 4-15. Weaving in HV filletwelds is undesirable.

Art # A-07699

Figure 4-14: Electrode position for HV fillet weld

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

WELDSKILL 130, 170


C. Vertical Welds

1. Vertical Up

Tack weld a three feet length of angle iron toyour work bench in an upright position. Use a3.2mm Ferrocraft 21 electrode and set thecurrent at 100 amps. Make yourselfcomfortable on a seat in front of the job andstrike the arc in the corner of the fillet. Theelectrode needs to be about 10° from thehorizontal to enable a good bead to bedeposited. Refer Figure 4-16. Use a short arc,and do not attempt to weave on the first run.When the first run has been completed de-slag the weld deposit and begin the secondrun at the bottom. This time a slight weavingmotion is necessary to cover the first run andobtain good fusion at the edges. At thecompletion of each side motion, pause for amoment to allow weld metal to build up at theedges, otherwise undercut will form and toomuch metal will accumulate in the centre ofthe weld. Figure 4-17 illustrates multi-runtechnique and Figure 4-18 shows the effectsof pausing at the edge of weave and ofweaving too rapidly.

Art # A-07701

Figure 4-16: Single run vertical fillet weld

Art # A-07702

Figure 4-17: Multi run vertical fillet weld

Art # A-07703

Figure 4-18: Examples of vertical fillet welds

2. Vertical Down

The Ferrocraft 21 electrode makes welding inthis position particularly easy. Use a 3.2mmelectrode at 100 amps. The tip of the electrodeis held in light contact with the work and thespeed of downward travel is regulated so thatthe tip of the electrode just keeps ahead ofthe slag. The electrode should point upwardsat an angle of about 45°.

3. Overhead Welds

Apart from the rather awkward positionnecessary, overhead welding is not muchmore difficult that downhand welding. Set upa specimen for overhead welding by firsttacking a length of angle iron at right anglesto another piece of angle iron or a length ofwaste pipe. Then tack this to the work benchor hold in a vice so that the specimen ispositioned in the overhead position as shownin the sketch. The electrode is held at 45° tothe horizontal and tilted 10° in the line of travel(Figure 4-19). The tip of the electrode may betouched lightly on the metal, which helps togive a steady run. A weave technique is notadvisable for overhead fillet welds. Use a3.2mm Ferrocraft 12XP electrode at 100amps, and deposit the first run by simplydrawing the electrode along at a steady rate.You will notice that the weld deposit is ratherconvex, due to the effect of gravity before themetal freezes.

Art # A-07704

Figure 4-19: Overhead fillet weld

WELDSKILL 130, 170


4.18 Distortion

Distortion in some degree is present in all forms ofwelding. In many cases it is so small that it is barelyperceptible, but in other cases allowance has to bemade before welding commences for the distortionthat will subsequently occur. The study of distortionis so complex that only a brief outline can be attemptedhear.

4.19 The Cause of Distortion

Distortion is cause by:

A. Contraction of Weld Metal:

Molten steel shrinks approximately 11 per cent involume on cooling to room temperature. This meansthat a cube of molten metal would contractapproximately 2.2 per cent in each of its threedimensions. In a welded joint, the metal becomesattached to the side of the joint and cannot contractfreely. Therefore, cooling causes the weld metal toflow plastically, that is, the weld itself has to stretch ifit is to overcome the effect of shrinking volume andstill be attached to the edge of the joint. If the restraintis very great, as, for example, in a heavy section ofplate, the weld metal may crack. Even in cases wherethe weld metal does not crack, there will still remainstresses “locked-up” in the structure. If the jointmaterial is relatively weak, for example, a butt joint in2.0mm sheet, the contracting weld metal may causethe sheet to become distorted.

B. Expansion and Contraction of Parent Metal inthe Fusion Zone:

While welding is proceeding, a relatively small volumeof the adjacent plate material is heated to a very hightemperature and attempts to expand in all directions.It is able to do this freely at right angles to the surfaceof the plate (i.e., “through the weld”), but when itattempts to expand “across the weld” or “along theweld”, it meets considerable resistance, and to fulfilthe desire for continued expansion, it has to deformplastically, that is, the metal adjacent to the weld is ata high temperature and hence rather soft, and, byexpanding, pushes against the cooler, harder metalfurther away, and tends to bulge (or is “upset”). Whenthe weld area begins to cool, the “upset” metalattempts to contract as much as it expanded, but,because it has been “upset”, it does not resume itsformer shape, and the contraction of the new shapeexerts a strong pull on adjacent metal. Several thingscan then happen.

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

Art # A-07705

Figure 4-20: Parent metal expansion

Art # A-07706

Figure 4-21: Parent metal contraction

4.20 Overcoming Distortion Effects

There are several methods of minimising distortioneffects.

A. Peening

This is done by hammering the weld while it is stillhot. The weld metal is flattened slightly and becauseof this the tensile stresses are reduced a little. Theeffect of peening is relatively shallow, and is notadvisable on the last layer.

B. Distribution of Stresses

Distortion may be reduced by selecting a weldingsequence which will distribute the stresses suitablyso that they tend to cancel each other out. See Figures4-25 through 4-28 for various weld sequences. Choiceof a suitable weld sequence is probably the mosteffective method of overcoming distortion, althoughan unsuitable sequence may exaggerate it.Simultaneous welding of both sides of a joint by twowelders is often successful in eliminating distortion.

C. Restraint of Parts

Forcible restraint of the components being welded isoften used to prevent distortion. Jigs, positions, andtack welds are methods employed with this in view.

WELDSKILL 130, 170

4-10 September 21, 2007

D. Presetting

It is possible in some cases to tell from pastexperience or to find by trial and error (or lessfrequently, to calculate) how much distortion will takeplace in a given welded structure. By correct pre-setting of the components to be welded,constructional stresses can be made to pull the partsinto correct alignment. A simple example is shown inFigure 4-22.

E. Preheating

Suitable preheating of parts of the structure other thanthe area to be welded can be sometimes used toreduce distortion. Figure 4-23 shows a simpleapplication. By removing the heating source from band c as soon as welding is completed, the sectionsb and c will contract at a similar rate, thus reducingdistortion.

Art # A-07710

Figure 4-25: Welding sequence

Art # A-07711

Figure 4-26: Step back sequence

Art # A-07712

Figure 4-27: Chain intermittent welding

Art # A-07713

Figure 4-28: Staggered intermittent welding

Art # A-07707

Figure 4-22: Principle of presetting

Figure 4-23: Reduction of distortion by preheating

Art # A-07708

Art # A-07709

Figure 4-24: Examples of distortion

WELDSKILL 130, 170


SECTION 5:SERVICE

5.01 Routine Maintenance &Inspection

! WARNING

There are extremely dangerous voltageand power levels present inside thisproduct. Do not attempt to open or repairunless you are a qualified electricaltradesperson. Disconnect the WeldingPower Source from the Mains SupplyVoltage before disassembling.

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

• The main earth wire of the electrical installationis intact.

• Power point for the Welding Power Source iseffectively earthed and of adequate currentrating.

• Plugs and cord extension sockets are correctlywired.

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

• Welding terminals are shrouded to preventinadvertent contact or short circuit.

• The frame of the Welding Power Source iseffectively earthed.

• Welding leads and electrode holder are in goodcondition.

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

5.02 Cleaning the Welding PowerSource

! WARNING

Refer to WARNING on page 3-2.

To clean the Welding Power Source, open theenclosure and use a vacuum cleaner to remove anyaccumulated dirt, metal filings, slag and loosematerial. Keep the shunt and lead screw surfaces cleanas accumulated foreign material may reduce thewelders output welding current.

CAUTION

Do not use compressed air to clean theWelding Power Source. Compressed aircan force metal particles to lodge betweenlive electrical parts and earthed metal partswithin the Welding Power Source. Thismay result in arcing between this parts andtheir eventual failure.

5.03 Face Shield Maintenance

The face shield and lens should be cleaned after usewith a soft cloth.

5.04 Basic Troubleshooting

! WARNING

There are extremely dangerous voltageand power levels present inside thisproduct. Do not attempt to open or repairunless you are a qualified electricaltradesperson and you have had trainingin power measurements andtroubleshooting techniques.

If major complex subassemblies are faulty, then theWelding Power Source must be returned to anAccredited CIGWELD Service Agent for repair.

The basic level of troubleshooting is that which canbe performed without special equipment orknowledge.

WELDSKILL 130, 170


5.05 Welding Problems

Insufficient Gap

Incorrect Sequence

Art # A-05866

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

4 Portions of the weld run do not fuse to the surface of the metal or edge of the joint

A Small electrodes used on heavy cold plate

A Use larger electrodes and preheat the plate

B Welding current is too low B Increase welding currentC Wrong electrode angle C Adjust angle so the

welding arc is directed more into the base metal

D Travel speed of electrode is too high

D Reduce travel speed of electrode

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

Possible CauseDescription Remedy

1 Gas pockets or voids in weld metal (Porosity)

A Electrodes are damp A Dry electrodes before use

B Welding current is too high B Reduce welding currentC Surface impurities such as

oil, grease, paint, etcC Clean joint before welding

2 Crack occurring in weld metal soon after solidification commences

A Rigidity of joint A Redesign to relieve weld joint of severe stresses or use crack resistance electrodes

B Insufficient throat thickness B Travel slightly slower to alloy greater build-up in throat

C Cooling rate is too high C Preheat plate and cool slowly

3 A gap is left by failure of the weld metal to fill the root of the weld

A Welding current is too low A Increase welding current

B Electrode too large for joint B Use smaller diameter electrode

C Insufficient gap C Allow wider gapD Incorrect sequence D Use correct build-up

sequence


WELDSKILL 130, 170


Art # A-05867

Lack of inter-run fusion

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

Lack of root fusion

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

Figure 5-2: Example of Lack of Fusion

5 A groove has been formed in the base metal adjacent to the toe of a weld and has not been filled by the weld metal (undercut).

A Welding current is too high. A Reduce welding current

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

C Angle of the electrode is incorrect.

C Electrode should not be inclined less than 45° to the vertical face

D Joint preparation does not allow correct electrode angle.

D Allow more room in joint for manipulation of the electrode.

E Electrode too large for joint. E Use smaller gauge electrode.

F Insufficient deposit time at edge of weave.

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


Art # A-07714

Figure 5-3: Examples of undercut

WELDSKILL 130, 170


6 Non-metallic particles are trapped in the weld metal (slag inclusion)

A Non-metallic particles may be trapped in undercut from previous run

A If bad undercut is present, clean slag out and cover with a run from a smaller diameter electrode

B Joint preparation too restricted

B Allow for adequate penetration and room for cleaning out the slag

C Irregular deposits allow slag to be trapped

C If very bad, chip or grind out irregularities

D Lack of penetration with slag trapped beneath weld bead

D Use smaller electrode with sufficient current to give adequate penetration. Use suitable tools to remove all slag from corners

E Rust or mill scale is preventing full fusion

E Clean joint before welding

F Wrong electrode for position in which welding is done

F Use electrodes designed for position in which welding is done, otherwise proper control of slag is difficult


Not cleaned, or incorrect electrode

Slag trapped inundercut

Slag trapped in root

Art # A-05868

Figure 5-4: Examples of Slag Inclusion

WELDSKILL 130, 170


5.06 Welding Power Source Problems

1 The welding arc cannot be established

A The Primary supply voltage has not been switched ON

A Switch ON the Primary supply voltage

B The Welding Power Source switch is switched OFF

B Switch ON the Welding Power Source

C Loose connections internally

C Have an Accredited Cigweld Service Provider repair the connection

2 Maximum output welding current cannot be achieved with nominal Mains supply voltage

Defective control circuit Have an Accredited Cigweld Service Provider inspect then repair the welder

3 Welding current reduces when welding

Poor work lead connection to the work piece

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

4 TIG electrode melts when arc is struck

TIG torch is connected to the (+) VE terminal

Connect the TIG torch to the (-) VE terminal

5 Arc flutters during TIG welding Tungsten electrode is too large for the welding current

Select the correct size of tungsten elecrode


WELDSKILL 130, 170


CIGWELD LIMITED WARRANTY

LIMITED WARRANTY: CIGWELD, A Thermadyne Company, hereafter, “CIGWELD” warrants to customers ofits authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship ormaterial. Should any failure to conform to this warranty appear within the time period applicable to the CIGWELDproducts as stated below, CIGWELD shall, upon notification thereof and substantiation that the product hasbeen 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, alter-ation, or accident, correct such defects by suitable repair or replacement, at CIGWELD’s sole option, of anycomponents or parts of the product determined by CIGWELD to be defective.

CIGWELD MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND INLIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY ORFITNESS 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 BUSI-NESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELDwith respect to any contract, or anything done in connection therewith such as the performance or breachthereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished byCIGWELD whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shallnot, except as expressly provided herein, exceed the price of the goods upon which such liability is based. Noemployee, agent, or representative of CIGWELD is authorized to change this warranty in any way or grant anyother warranty.

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

The warranty is effective for the time stated below beginning on the date that the authorized distributor deliv-ers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extendmore than the time stated plus one year from the date CIGWELD delivered the product to the authorizeddistributor.

Terms of Warranty – 2007

1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supplyof goods and services, protects consumers’ interests by ensuring that consumers are entitled in certainsituations to the benefit of various conditions, warranties, guarantees, rights and remedies (includingwarranties as to merchantability and fitness for purpose) associated with the supply of goods and ser-vices. A consumer should seek legal advice as to the nature and extent of these protected interests. Insome circumstances, the supplier of goods and services may legally stipulate that the said conditions,warranties, guarantees, rights and remedies are limited or entirely excluded. The warranties set out inClause 2 shall be additional to any nonexcludable warranties to which the Customer may be entitled pursu-ant to any statute.

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

Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantablequality 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 byCIGWELD to be defective in workmanship and/or materials.

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

3. The Warranty in Clause 2;

Is conditional upon:

The Customer notifying CIGWELD or our Accredited Distributor in writing of its claim within seven (7) daysof becoming aware of the basis thereof, and at its own expense returning the goods which are the subjectof the claim to CIGWELD or nominated Accredited Distributor/Accredited Service Provider. The goodsbeing used in accordance with the Manufacturer’s Operating Manuals, and under competent supervision.

Does not apply to:

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

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

Repairs or replacement made other than by CIGWELD or Accredited Service Providers, unless by priorarrangement with CIGWELD.

Replacement parts or accessories which may affect product safety or performance and which are notmanufactured, distributed or approved by CIGWELD.

4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supplyof goods which are not of a kind ordinarily acquired for personal, domestic or household use or consump-tion to any one or more of the following (the choice of which shall be at the option of CIGWELD).

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

The repair of goods.

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

The payment of the cost of having goods repaired.

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

Warranty Schedule – 2007

These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of salefrom the Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the war-ranty period extend more than the time stated plus one year from the date CIGWELD delivered the product tothe Accredited Distributor. Unless otherwise stated the warranty period includes parts and labour. CIGWELDreserves the right to request documented evidence of date of purchase.

WARRANTY PERIODINVERTER ARC WELDING POWER SOURCEWeldskill 130 and 170 ........................................................................................................................... 1 year

Control P.C. Boards ................................................................................................................................. 1 year All other circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, power switch semiconductors.............................................................................. 1 year ACCESSORIES Electrode holder and work lead................................................................................................... 3 Months

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

Thermadyne USA2800 Airport RoadDenton, Tx 76207 USATelephone: (940) 566-2000800-426-1888Fax: 800-535-0557Email: [email protected]

Thermadyne Canada2070 Wyecroft RoadOakville, OntarioCanada, L6L5V6Telephone: (905)-827-1111Fax: 905-827-3648

Thermadyne EuropeEurope BuildingChorley North Industrial ParkChorley, LancashireEngland, PR6 7BxTelephone: 44-1257-261755Fax: 44-1257-224800

Thermadyne, ChinaRM 102A685 Ding Xi RdChang Ning DistrictShanghai, PR, 200052Telephone: 86-21-69171135Fax: 86-21-69171139

Thermadyne Asia Sdn BhdLot 151, Jalan Industri 3/5ARawang Integrated Industrial Park - Jln Batu Arang48000 Rawang Selangor Darul EhsanWest MalaysiaTelephone: 603+ 6092 2988Fax : 603+ 6092 1085

Cigweld, Australia71 Gower StreetPreston, VictoriaAustralia, 3072Telephone: 61-3-9474-7400Fax: 61-3-9474-7510

Thermadyne ItalyOCIM, S.r.L.Via Benaco, 320098 S. GiulianoMilan, ItalyTel: (39) 02-98 80320Fax: (39) 02-98 281773

Thermadyne International2070 Wyecroft RoadOakville, OntarioCanada, L6L5V6Telephone: (905)-827-9777Fax: 905-827-9797

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Corporate Headquarters71 Gower StreetPreston, Victoria, Australia, 3072Telephone: +61 3 9474 7400Fascimile: +61 3 9474 7488Email: [email protected]