WeldSkill 155 - 185 Operating Manual

Art # A-13435_AB
OUTPUT CURRENT MIG STICK WARRANTY*

WARRANTY* OUTPUT CURRENT STICK
155A
DC ELECTRODE
3.2mm MAX
2 185A
DC ELECTRODE
4.0mm MAX
155 Inverter W1008155 185 Inverter W1008185
Version No: AB Issue Date: 07-09-2017 Manual No: 0-5492

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new CIGWELD product. We are proud to have you
as our customer and will strive to provide you with the best service and
reliability in the industry. This product is backed by our extensive warranty
and world-wide service network.
This Operating Manual has been designed to instruct you on the correct
use and operation of your CIGWELD product. Your satisfaction with this
product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions.
They will help you to avoid potential hazards that may exist when working
with this product.
We have made every effort to provide you with accurate instructions,

drawings, and photographs of the product(s) while 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received, then check for a newer version of the manual on our website or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 a Market Leading Brand of Arc Welding Products for ESAB.
We are a mainline supplier to major welding industry sectors in the Asia
Pacific and emerging global markets including; Manufacturing, Construc-
tion, 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 marketing expertise.
Above all, we are committed to develop technologically advanced products

to achieve a safer working environment for industry operators.
WARNING
! Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgement,
the Manufacturer assumes no liability for its use.
CIGWELD WeldSkill 155 and 185 Welding Inverters

Instruction Manual Number 0-5492 for:
Part Numbers W1008155 and W1008185
Published by:
CIGWELD Pty Ltd
CIGWELD An ESAB Brand
71 Gower Street,
Preston, Victoria, Australia, 3072
+61 3 9474 7400 +61 3 9474 7391
www.cigweld.com.au
Copyright 2017
CIGWELD Pty Ltd
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the

publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
For Printing Material Specification refer to document 47x1915.
Publication Date: 17-08-2017

Revision Date: 07-09-2017
Record the following information for Warranty purposes:
Where Purchased: _____________________________________
Purchase Date: _____________________________________
Equipment Serial #: _____________________________________
i
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Goug-
ing,” Booklet 0-5407. Do NOT permit untrained persons to install, operate, or maintain this
equipment. Do NOT attempt to install or operate this equipment until you have read and fully
understand these instructions. If you do not fully understand these instructions, contact
your supplier for further information. Be sure to read the Safety Precautions before installing
or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or
inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be
checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn,
distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer
recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was pur-
chased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this
equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage,
improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AND OTHERS!
DECLARATION OF CONFORMITY
According to
The Arc Welding Power Source Directive AS 60974.1-2006 (equivalent to IEC 60974-1 Ed. 2.1)
The EMC Directive IEC 60974-10:2014 published on 06 February 2014
Type of equipment
Welding Inverter Power Source
Type designation etc.

Welding Performance
Brand name or trade mark

Cigweld
Manufacturer or his authorised representative established within the EEA

Name, address, telephone No:
Cigweld Pty Ltd
71 Gower Street
Preston, Victoria, Australia, 3072
Phone: +61 3 9474 7400
The following harmonised standard in force within the EEA has been used in the design:
AS 60974.1-2006, Arc Welding Equipment - Welding Power Sources (IEC 60974-1:2000, MOD)
IEC 60974-10-2014, Arc Welding Equipment - Part 10: Electromagnetic Compatibility (EMC) Requirements
AS 1674.2-2007, Safety in Welding and Allied Processes
Additional Information: Restrictive use, Class A equipment, intended for use in location other than resid
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety
requirements stated above.
Date Signature Position
25-07-2017 Vice President,

Ken Konopa Global Welding

2017
TABLE OF CONTENTS
SECTION 1:
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS...................................... 1-1
1.01 Arc Welding Hazards........................................................................................ 1-1
1.02 PRINCIPAL SAFETY STANDARDS.................................................................... 1-5
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual................................................................................. 2-1
2.02 Equipment Identification.................................................................................. 2-1
2.03 Receipt Of Equipment...................................................................................... 2-1
2.04 Symbol Chart................................................................................................... 2-2
2.05 Description...................................................................................................... 2-3
2.06 User Responsibility.......................................................................................... 2-3
2.07 Packaged Item................................................................................................. 2-3
2.08 Transporting Methods...................................................................................... 2-3
2.09 Duty Cycle........................................................................................................ 2-4
2.10 Specifications.................................................................................................. 2-4
2.11 Optional Accessories....................................................................................... 2-6
SECTION 3:
INSTALLATION........................................................................................ 3-1
3.01 Environment.................................................................................................... 3-1
3.02 Location........................................................................................................... 3-1
3.03 Ventilation........................................................................................................ 3-1
3.04 Mains Supply Voltage Requirements............................................................... 3-1
3.05 Generators....................................................................................................... 3-1
3.06 Extension Leads............................................................................................... 3-1
3.07 Electromagnetic Compatibility......................................................................... 3-2
SECTION 4:
OPERATION............................................................................................ 4-1
4.01 Overview.......................................................................................................... 4-1
4.02 Power Source Controls, Indicators and Features............................................. 4-1
SECTION 5:
MIG (GMAW) WELDING.............................................................................. 5-1
5.01 Shielding Gas Regulator/Flowmeter Operating Instructions............................. 5-1
5.02 Attaching the MIG Torch (Euro)....................................................................... 5-3
5.03 Installing Minispool (100mm diameter) .......................................................... 5-4
5.04 Installing Handispool (200mm diameter)........................................................ 5-5
5.05 Inserting Wire into the Wire Feed Mechanism................................................. 5-6
5.06 Feed Roller Pressure Adjustment..................................................................... 5-7
5.07 Changing the Feed Roll.................................................................................... 5-7
5.08 Wire Reel Brake............................................................................................... 5-8
5.09 Setup for MIG (GMAW) Welding with Gas Shielded Mig Wire......................... 5-8
5.10 Setup for MIG (GMAW) Welding with Gasless MIG Wire (Flux Cored).......... 5-10
5.11 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded Mig Wire
(WeldSkill 185 Only)...................................................................................... 5-11
5.12 MIG (GMAW/FCAW) Basic Welding Technique.............................................. 5-12
5.13 CIGWELD MIG Wire Selection Chart.............................................................. 5-17
5.14 MIG (GMAW/FCAW) Welding Troubleshooting.............................................. 5-18
TABLE OF CONTENTS
SECTION 6:
STICK (MMAW) WELDING........................................................................... 6-1
6.01 Setup For STICK (MMAW) Welding................................................................. 6-1
6.02 Arc Welding Electrodes.................................................................................... 6-2
6.03 Types of Electrodes.......................................................................................... 6-2
6.04 Size of Electrode.............................................................................................. 6-3
6.05 Storage of Electrodes....................................................................................... 6-3
6.06 Electrode Polarity............................................................................................. 6-3
6.07 Effects of Arc Welding Various Materials......................................................... 6-4
6.08 Arc Welding Practice........................................................................................ 6-4
6.09 Welding Position.............................................................................................. 6-4
6.10 Joint Preparations............................................................................................ 6-5
6.11 Arc Welding Technique.................................................................................... 6-6
6.12 The Welder....................................................................................................... 6-6
6.13 Striking the Arc................................................................................................ 6-6
6.14 Arc Length....................................................................................................... 6-6
6.15 Rate of Travel................................................................................................... 6-6
6.16 Making Welded Joints...................................................................................... 6-6
6.17 Distortion......................................................................................................... 6-9
6.18 The Cause of Distortion................................................................................... 6-9
6.19 Overcoming Distortion Effects......................................................................... 6-9
6.20 Welding Problems......................................................................................... 6-11
SECTION 7:
TIG (GTAW) WELDING................................................................................ 7-1
7.01 Shielding Gas Regulator/Flowmeter Operating Instructions............................. 7-1
7.02 Setup For Lift TIG (GTAW) Welding................................................................. 7-3
7.03 TIG (GTAW) Basic Welding Technique............................................................. 7-5
7.04 TIG (GTAW) Welding Problems........................................................................ 7-7
SECTION 8:
ROUTINE SERVICE REQUIREMENTS AND POWER SOURCE PROBLEMS .................... 8-1
8.01 Routine Maintenance & Inspection.................................................................. 8-1
8.02 Cleaning the Welding Power Source................................................................ 8-1
8.03 Cleaning the Feed Rolls.................................................................................... 8-1
8.04 Basic Troubleshooting..................................................................................... 8-1
8.05 Welding Power Source Problems.................................................................... 8-2
SECTION 9: KEY SPARE PARTS........................................................................... 9-1
9.01 WeldSkill 155 Key Spare Parts......................................................................... 9-1
9.02 WeldSkill 185 Key Spare Parts......................................................................... 9-2
9.03 E-180 MIG Torch 3m (P/N W4018800) Key Spare Parts.................................. 9-3
APPENDIX 1: WELDSKILL 155 CIRCUIT DIAGRAM..................................................... A-1
APPENDIX 2: WELDSKILL 185 CIRCUIT DIAGRAM..................................................... A-2
CIGWELD - LIMITED WARRANTY TERMS
WARRANTY SCHEDULE – WELDSKILL 155 & 185 INVERTERS

This Page Intentionally Blank
SECTION 1:
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
WARNING
! PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACE-
MAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ
OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if
the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned
through study and training before using this equipment. Some of these practices apply to equipment connected to
power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and
cutting practices should not attempt to weld.
Safe practices are outlined in the Australian Standard AS1674.2-2007 entitled: Safety in welding and allied processes
Part 2: Electrical. This publication and other guides to what you should learn before operating this equipment are listed
at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK
PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards 6. Turn off all equipment when not in use. Discon-
nect power to equipment if it will be left unat-
WARNING tended or out of service.
ELECTRIC SHOCK can kill.
7. Use fully insulated electrode holders. Never dip
Touching live electrical parts can cause fatal holder in water to cool it or lay it down on the
shocks or severe burns. The electrode and work ground or the work surface. Do not touch hold-
circuit is electrically live whenever the output ers connected to two welding machines at the
is on. The input power circuit and machine same time or touch other people with the holder
internal circuits are also live when power is on. or electrode.
In semiautomatic or automatic wire welding, the 8. Do not use worn, damaged, undersized, or
wire, wire reel, drive roll housing, and all metal poorly spliced cables.
parts touching the welding wire are electrically
live. Incorrectly installed or improperly grounded 9. Do not wrap cables around your body.
equipment is a hazard. 10. Ground the workpiece to a good electrical
(earth) ground.
1. Do not touch live electrical parts.
11. Do not touch electrode while in contact with the
2. Wear dry, hole-free insulating gloves and body
work (ground) circuit.
protection.
12. Use only well-maintained equipment. Repair or
3. Insulate yourself from work and ground using
replace damaged parts at once.
dry insulating mats or covers.
13. In confined spaces or damp locations, do
4. Disconnect input power or stop engine before
not use a welder with AC output unless it is
installing or servicing this equipment. Lock
equipped with a voltage reducer. Use equipment
input power disconnect switch open, or remove
with DC output.
line fuses so power cannot be turned on acci-
dentally. 14. Wear a safety harness to prevent falling if work-
ing above floor level.
5. Properly install and ground this equipment
according to its Owner’s Manual and national, 15. Keep all panels and covers securely in place.
state, and local codes.
0-5492 1-1 GENERAL INFORMATION

WARNING 2. Wear approved safety glasses. Side shields
ARC RAYS can burn eyes and skin; NOISE can recommended.
damage hearing. 3. Use protective screens or barriers to protect
others from flash and glare; warn others not to
Arc rays from the welding process produce in- watch the arc.
tense heat and strong ultraviolet rays that can
burn eyes and skin. Noise from some processes 4. Wear protective clothing made from durable,
can damage hearing. flame-resistant material (wool and leather) and
foot protection.
1. Use a Welding Helmet or Welding Faceshield
fitted with a proper shade of filter (see ANSI 5. Use approved ear plugs or ear muffs if noise
Z49.1 and AS 1674 listed in Safety Standards) level is high.
to protect your face and eyes when welding or
6. Never wear contact lenses while welding.
watching.
Recommended Protective Filters for Electric Welding

Approximate Range of Minimum Shade Number of
Description of Process
Welding Current in Amps Filter(s)
Less than or equal to 100 8
100 to 200 10
Manual Metal Arc Welding - covered
200 to 300 11
electrodes (MMAW)
300 to 400 12
Greater than 400 13
Gas Metal Arc Welding (GWAW) 150 to 250 11
(MIG) other than Aluminium and 250 to 300 12
Stainless Steel 300 to 400 13
Greater than 400 14
Gas Metal Arc Welding (GMAW) Less than or equal to 250 12
(MIG) Aluminium and Stainless Steel 250 to 350 13
100 to 200 11
Gas Tungsten Arc Welding (GTAW)
200 to 250 12
(TIG)
250 to 350 13
Greater than 350 14
Flux-cored Arc Welding (FCAW) -with 300 to 400 12
or without shielding gas. 400 to 500 13
Greater than 500 14
Air - Arc Gouging Less than or equal to 400 12
50 to 100 10
Plasma - Arc Cutting 100 to 400 12
400 to 800 14
Plasma - Arc Spraying — 15
20 to 100 10
Plasma - Arc Welding
100 to 400 12
400 to 800 14
Submerged - Arc Welding — 2(5)
— Safety Spectacles or eye
Resistance Welding
shield
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.
GENERAL INFORMATION 1-2 0-5492
WARNING 4. Be alert that welding sparks and hot materials
FUMES AND GASES can be hazardous to your from welding can easily go through small cracks
health. and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher
Welding produces fumes and gases. Breathing nearby.
these fumes and gases can be hazardous to
your health. 6. Be aware that welding on a ceiling, floor, bulk-
head, or partition can cause fire on the hidden
1. Keep your head out of the fumes. Do not breath side.
the fumes.
7. Do not weld on closed containers such as tanks
2. If inside, ventilate the area and/or use exhaust at or drums.
the arc to remove welding fumes and gases.
8. Connect work cable to the work as close to the
3. If ventilation is poor, use an approved air-sup- welding area as practical to prevent welding
plied respirator. current from travelling long, possibly unknown
4. Read the Material Safety Data Sheets (MSDSs) paths and causing electric shock and fire haz-
and the manufacturer’s instruction for metals, ards.
consumables, coatings, and cleaners. 9. Do not use welder to thaw frozen pipes.
5. Work in a confined space only if it is well 10. Remove stick electrode from holder or cut off
ventilated, or while wearing an air-supplied welding wire at contact tip when not in use.
respirator. Shielding gases used for welding can
WARNING
displace air causing injury or death. Be sure the
FLYING SPARKS AND HOT METAL can cause
breathing air is safe.
injury.
6. Do not weld in locations near degreasing, clean-
ing, or spraying operations. The heat and rays Chipping and grinding cause flying metal. As
of the arc can react with vapours to form highly welds cool, they can throw off slag.
toxic and irritating gases.
1. Wear approved face shield or safety goggles.
7. Do not weld on coated metals, such as galva- Side shields recommended.
nized, lead, or cadmium plated steel, unless the
2. Wear proper body protection to protect skin.
coating is removed from the weld area, the area
is well ventilated, and if necessary, while wear- WARNING
ing an air-supplied respirator. The coatings and CYLINDERS can explode if damaged.
any metals containing these elements can give
off toxic fumes if welded. Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
WARNING Since gas cylinders are normally part of the
WELDING can cause fire or explosion. welding process, be sure to treat them carefully.
Sparks and spatter fly off from the welding arc. 1. Protect compressed gas cylinders from exces-
The flying sparks and hot metal, weld spatter, sive heat, mechanical shocks, and arcs.
hot workpiece, and hot equipment can cause
2. Install and secure cylinders in an upright posi-
fires and burns. Accidental contact of electrode
tion by chaining them to a stationary support
or welding wire to metal objects can cause
or equipment cylinder rack to prevent falling or
sparks, overheating, or fire.
tipping.
1. Protect yourself and others from flying sparks 3. Keep cylinders away from any welding or other
and hot metal. electrical circuits.
2. Do not weld where flying sparks can strike flam- 4. Never allow a welding electrode to touch any
mable material. cylinder.
3. Remove all flammables within 35 ft (10.7 m) of 5. Use only correct shielding gas cylinders,
the welding arc. If this is not possible, tightly regulators, hoses, and fittings designed for
cover them with approved covers. the specific application; maintain them and
associated parts in good condition.

6. Turn face away from valve outlet when opening The following is a quotation from the General
cylinder valve. Conclusions Section of the U.S. Congress, Office
of Technology Assessment, Biological Effects of
7. Keep protective cap in place over valve except
Power
when cylinder is in use or connected for use.
Frequency Electric & Magnetic Fields - Background
8. Read and follow instructions on compressed Paper, OTA-BP-E-63 (Washington, DC: U.S. Gov-
gas cylinders, associated equipment, and CGA ernment Printing Office, May 1989): “...there is now
publication P-1 listed in Safety Standards. a very large volume of scientific findings based on
experiments at the cellular level and from studies
WARNING with animals and people which clearly establish that
MOVING PARTS can cause injury. 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
Moving parts, such as fans, rotors, and belts can are complex. Current scientific understanding does
cut fingers and hands and catch loose clothing. not yet allow us to interpret the evidence in a single
1. Keep all doors, panels, covers, and guards coherent framework. Even more frustrating, it does
closed and securely in place. not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-
2. Stop engine before installing or connecting unit. based advice on strategies to minimize or avoid
3. Have only qualified people remove guards or potential risks.”
covers for maintenance and troubleshooting as To reduce magnetic fields in the workplace, use the
necessary. following procedures.
4. To prevent accidental starting during servicing, 1. Keep cables close together by twisting or taping
disconnect negative (-) battery cable from bat- them.
tery.
2. Arrange cables to one side and away from the
5. Keep hands, hair, loose clothing, and tools away operator.
from moving parts.
3. Do not coil or drape cable around the body.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine. 4. Keep welding power source and cables as far
away from body as practical.
WARNING
! This product, when used for welding or cut- WARNING
The above procedures are among those also
ting, produces fumes or gases which contain
chemicals known to the State of California to normally recommended for pacemaker wearers.
cause birth defects and, in some cases, cancer. Consult your doctor for complete information.
(California Health & Safety code Sec. 25249.5
et seq.)
NOTE!
Considerations About Welding And The Effects of
Low Frequency Electric and Magnetic Fields.

1.02 PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Stan-
dards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from Ameri-
can National Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Battery-
march 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.
Filters for eye protectors - Filters for protection against radiation generated in welding and allied operations
AS/NZS 1338.1:1992 from SAI Global Limited, www.saiglobal.com.


SECTION 2:
INTRODUCTION
2.01 How To Use This Manual 2.02 Equipment Identification
This Owners Manual only applies to the Part Numbers The unit’s identification number (specification or
listed on page i. part number), model, and serial number usually ap-
pear on a nameplate attached to the control panel. In
To ensure safe operation, read the entire manual, some cases, the nameplate may be attached to the
including the chapter on safety instructions and rear panel. Equipment which does not have a control
warnings. panel such as gun and cable assemblies is identified
Throughout this manual, the words WARNING, only by the specification or part number printed on
CAUTION, and NOTE may appear. Pay particular at- the shipping container. Record these numbers on the
tention to the information provided under these head- bottom of page i for future reference.
ings. These special annotations are easily recognized
as follows: 2.03 Receipt Of Equipment
NOTE! When you receive the equipment, check it against the
An operation, procedure, or background infor- invoice to make sure it is complete and inspect the
mation which requires additional emphasis or is equipment for possible damage due to shipping. If
helpful in efficient operation of the system. there is any damage, notify the carrier immediately to
WARNING file a claim. Furnish complete information concerning
! A procedure which, if not properly followed,
may cause injury to the operator or others in the
damage claims or shipping errors to the location in
your area listed in the inside back cover of this manual.
operating area. Include all equipment identification numbers as
CAUTION described above along with a full description of the
! A procedure which, if not properly followed,
may cause damage to the equipment.
parts in error.
Move the equipment to the installation site before
WARNING un-crating the unit. Use care to avoid damaging the
Gives information regarding possible electrical equipment when using bars, hammers, etc., to un-
shock injury. Warnings will be enclosed in a box crate the unit.
such as this.
DANGER
Means immediate hazards which, if not avoided,
will result in immediate, serious personal injury
or loss of life.
Additional copies of this manual may be purchased
by contacting CIGWELD at the address and phone
number for your location listed in the inside back cover
of this manual. Include the Owner’s Manual number
and equipment identification numbers.
Electronic copies of this manual can also be down-
loaded at no charge in Acrobat PDF format by going
to the CIGWELD web site listed below and clicking on
the Literature Library link:
http://www.cigweld.com.au
0-5492 2-1 INTRODUCTION

2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On Single Phase Wire Feed Function
Wire Feed Towards

Off Three Phase Workpiece With
Output Voltage Off.
Three Phase Static
Dangerous Voltage Frequency Converter- Welding Gun
Transformer-Rectifier
Increase/Decrease Remote Purging Of Gas
X
Continuous Weld
Circuit Breaker Duty Cycle
Mode
AC Auxiliary Power % Percentage Spot Weld Mode
Fuse Panel/Local Spot Time

t
Shielded Metal
Amperage t1 Preflow Time
Arc Welding (SMAW)
Gas Metal Arc

Voltage t2
Postflow Time
Welding (GMAW)
Gas Tungsten Arc 2 Step Trigger

Hertz (cycles/sec) Welding (GTAW) Operation
Press to initiate wirefeed and
Air Carbon Arc welding, release to stop.
Frequency
Cutting (CAC-A)
Negative Constant Current 4 Step Trigger

Operation
Press and hold for preflow, release
Constant Voltage to start arc. Press to stop arc, and
Positive hold for preflow.
Or Constant Potential
Direct Current (DC) High Temperature t Burnback Time
Protective Earth Disturbance In

(Ground) Fault Indication Ground System
Line Arc Force IPM Inches Per Minute
Line Connection Touch Start (GTAW) MPM Metres Per Minute
Auxiliary Power Variable Inductance Spool Gun

Art # A-04937_AB
115V 15A Receptacle Rating-

V Voltage Input
Auxiliary Power
INTRODUCTION 2-2 0-5492

2.05 Description other than appropriately qualified persons approved
by CIGWELD.
This CIGWELD WeldSkill 155 and 185 offer the
many benefits of a professional welding machine 2.07 Packaged Item
in a compact, portable, easy to use and affordable
self-contained single phase welding inverter. Ideal for WeldSkill 155 Inverter (Part No. W1008155)
welders who want to do light fabrication, maintenance
• WeldSkill 155 Inverter Power Source
and repairs or DIY around the home without
compromising on quality or safety. These multi- • 3m Lead with Twist Lock Electrode Holder
process welding inverters are capable of performing • 3m Lead with Work Clamp
MIG (FCAW/GMAW), Stick (MMAW) and Lift TIG • E-180 MIG torch, 3m, Euro
(GTAW) welding processes. The Weldskill 155 and
185 are backed by a 2 year warranty*, equipped with • Feed Rolls: 0.8/0.9 Flux Cored (fitted)
a 10Amp plug, digital voltage and amperage meters, 0.8/0.9 V Groove
an integrated wire feed unit, Voltage Reduction Device • Shielding Gas Hose
(VRD applicable in Stick mode only), quick connect
gas connection and a host of other features. And • Cutskill Argon Regulator/Flowmeter
most importantly the two models are fully compliant • Operating Manual
to Australian Standard AS 60974.1 and IEC 60974.1.
WeldSkill 185 Inverter (Part No. W1008185)

The WeldSkill 155 and 185 provide excellent welding • WeldSkill 185 Inverter Power Source
performance across a broad range of applications
when used with the correct welding consumables • 3m Lead with Twist Lock Electrode Holder
and procedures. The following instructions detail how • 3m Lead with Work Clamp
to correctly and safely set up the machine and give • E-180 MIG torch, 3m, Euro
guidelines on gaining the best efficiency and quality
• Feed Rolls: 0.8/0.9 Flux Cored (fitted)
from the power sources. Please read these instruc-
tions thoroughly before using the units. 0.8/0.9 V Groove
*NOTE • Shielding Gas Hose
Refer to the complete Warranty Schedule at the • Cutskill Argon Regulator/Flowmeter
back of the manual.. • Operating Manual
2.06 User Responsibility 2.08 Transporting Methods

This equipment will perform as per the information These units are equipped with a handle for carrying
contained herein when installed, operated, maintained purposes.
and repaired in accordance with the instructions WARNING
provided. This equipment must be checked periodi- ELECTRIC SHOCK can kill. DO NOT TOUCH live
cally. Defective equipment (including welding leads) electrical parts. Disconnect input power conductors
should not be used. Parts that are broken, missing, from de-energized supply line before moving the
plainly worn, distorted or contaminated, should be welding power source.
replaced immediately. Should such repairs or replace-
WARNING
ments become necessary, it is recommended that
such repairs be carried out by appropriately qualified ! FALLING EQUIPMENT can cause serious personal
injury and equipment damage.
persons approved by CIGWELD. Advice in this regard
can be obtained by contacting accredited CIGWELD Lift unit with handle on top of case.
Distributor.
Use handcart or similar device of adequate capacity.
This equipment or any of its parts should not be al-
tered from standard specification without prior written If using a fork lift vehicle, place and secure unit on a
approval of CIGWELD. The user of this equipment proper skid before transporting.
shall have the sole responsibility for any malfunction
which results from improper use or unauthorised
modification from standard specification, faulty
maintenance, damage or improper repair by anyone
2.09 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated
welding current output without exceeding the temperature limits of the insulation of the component parts. To
explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is
designed to operate at a 15% duty cycle, 90 amperes at 23.6 volts. This means that it has been designed and
built to provide the rated amperage (90A) for 1.5 minutes, i.e. arc welding time, out of every 10 minute period
(15% of 10 minutes is 1.5 minutes). During the other 8.5 minutes of the 10 minute period the Welding Power
Source must idle and allowed to cool.
2.10 Specifications
Description WeldSkill 155 WeldSkill 185
Part Number W1008155 W1008185
Power Source Dimensions H371mmxW205mmxD478mm H371mmxW205mmxD478mm
Power Source Weight 13.7 KG 13.7 KG
Cooling Fan Cooled Fan Cooled
Welder Type Multi Process Inverter Power Multi Process Inverter Power
Source Source
Australian Standard AS 60974.1-2006 / IEC 60974-1 AS 60974.1-2006 / IEC 60974-1
Number of Phases Single Phase Single Phase
Nominal Supply Voltage 240V AC ± 15% 240V AC ± 15%
Nominal Supply Frequency 50/60 Hz 50/60 Hz
Welding Current Range (MIG 30 - 155 A 30 - 185 A
mode)
Nominal DC Open Circuit Voltage 69 V 69 V
MIG Weld Mode (Trigger Switch Depressed when (Trigger Switch Depressed when
not Welding) not Welding)
Open Circuit Voltage (VRD <35 V <35 V
On) Stick Weld Mode
Open Circuit Voltage (VRD 69 V 69 V
Off) Stick Weld Mode
Effective Input Current (I1eff ) 10 Amps 10 Amps
refer Note 2
Maximum Input Current (I1max) 35 Amps 40 Amps
Minimum Single Phase 8.0 kVA (at 0.8 Power Factor) 10.0 kVA (at 0.8 Power Factor)
Generator Recommendation
(refer Note 4) 6.0 kW (at 1.0 Power Factor) 8.0 kW (at 1.0 Power Factor)
MIG (GMAW) Welding Output, 155 A @15%, 21.8V 185 A @10%, 23.3 V
40ºC, 10 min. 85 A @ 60%, 18.3V 85 A @60%, 18.3 V
66 A @ 100%, 17.3V 66 A @100%, 17.3 V
STICK (MMAW) Welding Output, 135 A @ 15%, 25.4 V 160 A @ 10%, 26.4 V
40ºC, 10 min. 67 A @ 60%, 22.7 V 65 A @ 60%, 22.6 V
52 A @ 100%, 22.1 V 50 A @ 100%, 22 V
TIG (GTAW) Welding Output, 135 A @ 25%, 15.4 V 160 A @ 20%, 16.4 V
40ºC, 10 min. 86 A @ 60%, 13.4 V 93 A @ 60%, 13.7 V
67 A @ 100%, 12.7 V 72 A @ 100%, 12.9 V
Protection Class IP21S IP21S
Table 2-1: Specifications

NOTE 1
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.
NOTE 2
The Effective Input Current should be used for the determination of cable size & supply requirements.
NOTE 3
Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your
situation in this regard.
NOTE 4
Minimum Generator Recommendation at the Maximum Output Duty Cycle.
Due to large variations in performance and specifications of different brands and types of generators, CIGWELD cannot
guarantee full welding output power or duty cycle on every brand or type of generator.
Some small generators incorporate low cost circuit breakers on their outputs. These circuit breakers usually will have a
small reset button, and will trip much faster than a switchboard type circuit breaker. This may result in not being able
to achieve full output or duty cycle from the power source / generator combination. For this reason we recommend a
generator that incorporates switchboard type circuit breakers.
CIGWELD recommends that when selecting a generator, that the particular power source / generator combination be
adequately trialled to ensure the combination performs to the users expectations.
NOTE 5
CIGWELD reserves the right to change product performance and specifications without notice.
NOTE 6
If an extension lead is required to be used it is recommended to use a minimum size of 1.5mm2 Heavy Duty Extension
Lead. Longer extension leads may impact welding performance and operation.

2.11 Optional Accessories
We recommend genuine CIGWELD products.
The biggest range and best quality with guaranteed performance.
Part Number Description
W4018800 E-180 Mig Torch 3m, Euro (suits WeldSkill 155 & 185)
W6000600 Nozzle
OTW11/23/R Contact Tip 0.6mm
W6000606 Gas Diffuser
WS1240015/R Conduit Liner Steel 5m, 0.6-1.0mm Blue (hard wires)
WS1240031/R Conduit Liner Steel 4m, 1.0-1.2mm Red (hard wires)
WS1260026/R Conduit Liner Teflon 4m, 0.8-1.2mm Red (soft wires)
WS0010304/R Jump Liner 1.0-1.2mm
7977732 Feed Roll 0.8/0.9mm V groove knurled (flux cored) (fitted)
704277 Feed Roll 1.2/1.6mm V groove knurled (flux cored)
7977036 Feed Roll 0.6/0.8mm V groove (hard wires)
7977660 Feed Roll 0.9/1.2mm V groove (hard wires)
7977731 Feed Roll 0.8/0.9mm U groove (soft wires)
7977264 Feed Roll 1.0/1.2mm U groove (soft wires)
W7003021 TIG Torch 17V, flex neck, 3m lead with 50mm2 dinse (suits WeldSkill 155)
W4013801 TIG Torch 17V with 4m lead and gas valve (suits WeldSkill 185)
W4013800 TIG Torch 17V with 4m lead and gas valve and remote control (suits WeldSkill 185)
BGSAK2 TIG Torch Accessory Kit for 17, 26 & 18 TIG Torches
W4011250 Tweco SGT250 Spool Gun (suits WeldSkill 185)
210254 CutSkill Argon Regulator/Flowmeter
WSPLIER MIG Pliers
W7004913 Shielding Gas Hose Assembly
W4011501 WeldSkill Welding Equipment Trolley

WeldSkill Welding Leadset 4m, 25mm2 cable, 50mm2 dinse, 250A Twistlock
WS42550
Electrode Holder
WeldSkill Welding Leadset 5m, 35mm2 cable, 50mm2 dinse, 400A Twistlock
WS53550
Electrode Holder
Table 2-2

TIG Torch Consumables
BG10N49/R Nozzle Alumina 8mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N46/R Nozzle Alumina 12.5mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N22/R Collet 1.0mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG10N30/R Collet Body 1.0mm, for 17, 26 & 18 TIG Torches (pkt of 5)
BG57Y02/R Back Cap – Long for 17, 26 & 18 TIG Torches (pkt of 2)
BG57Y04/R Back Cap – Short for 17, 26 & 18 TIG Torches (pkt of 2)
Table 2-3
TIG Electrodes
699846 Ceriated Electrode 1.6mm x 175mm AC/DC Grey (Pkt of 10)
Table 2-4
Related Products
646754 WeldSkill TIG Welding Gloves
646755 WeldSkill Heavy Duty Welding Gloves
454304 WeldSkill Auto Darkening Welding Helmet Fixed Shade 11 Black
454305 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Blue
454314 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Carbon Fibre
454321 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Racer
454322 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Tribal
454323 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 White Carbon
454324 WeldSkill Auto Darkening Welding Helmet Variable Shade 9-13 Oz Flag
Note: CIGWELD Electrodes see page 6-2
Table 2-5

This Page Intentionally Blank.

SECTION 3:
INSTALLATION
3.01 Environment 3.04 Mains Supply Voltage
Requirements
These units are designed for use in environments with
increased hazard of electric shock. The Mains Supply Voltage should be within ± 15%
A. Examples of environments with increased hazard of the rated Mains Supply Voltage. If actual Mains
of electric shock are: Supply Voltage is outside this range Welding Cur-
rent may not be available and may cause internal
1. In locations in which freedom of movement components to fail.
is restricted, so that the operator is forced
to perform the work in a cramped (kneeling, Refer to Specifications on page 2-4 for Supply Volt-
sitting or lying) position with physical contact age information.
with conductive parts. The Welding Power Source must be:
2. In locations which are fully or partially limited • Correctly installed, if necessary, by a qualified
by conductive elements, and in which there electrician.
is a high risk of unavoidable or accidental
• Correctly earthed (electrically) in accordance
contact by the operator.
with local regulations.
B. Environments with increased hazard of electric • Connected to the correct size power point and
shock do not include places where electrically conduc- fuse as per the Specifications on page 2-4.
tive parts in the near vicinity of the operator, which
can cause increased hazard, have been insulated.
IMPORTANT NOTE!
3.02 Location This product has been fitted with a supply
plug as indicated in Section 2.10. Note that the
Be sure to locate the welder according to the follow- welding output range applicable with the fitted
ing guidelines: supply plug is detailed in Section 2.10.
A. In areas, free from moisture and dust.
B. Ambient temperature between -10° C to 40° C. ! WARNING
Any electrical work must be carried out by a
C. In areas, free from oil, steam and corrosive gases. qualified Electrical Tradesperson.
D. In areas, not subjected to abnormal vibration or

shock. 3.05 Generators
E. In areas, not exposed to direct sunlight or rain. Refer to Note 4 on page 2-5 for recommendations
when using with a Generator.
F. Place at a distance of 300mm or more from walls
or similar that could restrict natural air flow for
cooling.
3.06 Extension Leads
If an extension lead is required to be used it is recom-
3.03 Ventilation mended to use a minimum size of 1.5mm² Heavy Duty
Extension Lead. Longer extension leads may impact
Since the inhalation of welding fumes can be harmful,
welding performance and operation.
ensure that the welding area is effectively ventilated.
0-5492 3-1 INSTALLATION

3.07 Electromagnetic Compatibility 7. The time of day that welding or other activities
are to be carried out.
WARNING
! Extra precautions for Electromagnetic Compat-
ibility may be required when this Welding Power
8. The immunity of other equipment in the en-
vironment: the user shall ensure that other
Source is used in a domestic situation. equipment being used in the environment
is compatible: this may require additional
A. Installation and Use - Users Responsibility protection measures.
The user is responsible for installing and using the The size of the surrounding area to be considered
welding equipment according to the manufacturer’s will depend on the structure of the building and other
instructions. If electromagnetic disturbances are activities that are taking place. The surrounding area
detected then it shall be the responsibility of the user may extend beyond the boundaries of the premises.
of the welding equipment to resolve the situation
C. Methods of Reducing Electromagnetic Emissions
with the technical assistance of the manufacturer. In
some cases this remedial action may be as simple as 1. Mains Supply
earthing the welding circuit, see NOTE below. In other
Welding equipment should be connected to the
cases it could involve constructing an electromagnetic
mains supply according to the manufacturer’s
screen enclosing the Welding Power Source and the
recommendations. If interference occurs, it
work, complete with associated input filters. In all
may be necessary to take additional precau-
cases, electromagnetic disturbances shall be reduced
tions such as filtering of the mains supply.
to the point where they are no longer troublesome.
Consideration should be given to shielding the
NOTE! supply cable of permanently installed welding
The welding circuit may or may not be earthed equipment in metallic conduit or equivalent.
for safety reasons. Changing the earthing Shielding should be electrically continuous
arrangements should only be authorised by a throughout it’s length. The shielding should
person who is competent to assess whether the be connected to the Welding Power Source
changes will increase the risk of injury, e.g. by so that good electrical contact is maintained
allowing parallel welding current return paths between the conduit and the Welding Power
which may damage the earth circuits of other Source enclosure.
equipment. Further guidance is given in IEC
2. Maintenance of Welding Equipment
974-13 Arc Welding Equipment - Installation
and use (under preparation). The welding equipment should be routinely
maintained according to the manufacturer’s
B. Assessment of Area recommendations. All access and service
Before installing welding equipment, the user shall doors and covers should be closed and
make an assessment of potential electromagnetic properly fastened when the welding equip-
problems in the surrounding area. The following shall ment is in operation. The welding equipment
be taken into account should not be modified in any way except for
those changes and adjustments covered in
1. Other supply cables, control cables, signal- the manufacturer’s instructions. In particular,
ling and telephone cables; above, below and the spark gaps of arc striking and stabilising
adjacent to the welding equipment. devices should be adjusted and maintained
2. Radio and television transmitters and receiv- according to the manufacturer’s recommenda-
ers. tions.
3. Computer and other control equipment. 3. Welding Cables
4. Safety critical equipment, e.g. guarding of The welding cables should be kept as short
industrial equipment. as possible and should be positioned close
together, running at or close to the floor level.
5. The health of people around, e.g. the use of
pacemakers and hearing aids.
6. Equipment used for calibration and measure-
ment.
INSTALLATION 3-2 0-5492

4. Equipotential Bonding
Bonding of all metallic components in the
welding installation and adjacent to it should
be considered. However. Metallic components
bonded to the work piece will increase the
risk that the operator could receive a shock
by touching the metallic components and
the electrode at the same time. The operator
should be insulated from all such bonded
metallic components.
5. Earthing of the Workpiece
Where the workpiece is not bonded to earth
for electrical safety, nor connected to earth be-
cause of it’s size and position, e.g. ship’s hull
or building steelwork, a connection bonding
the workpiece to earth may reduce emissions
in some, but not all instances. Care should
be taken to prevent the earthing of the work-
piece increasing the risk of injury to users, or
damage to other electrical equipment. Where
necessary, the connection of the workpiece
to earth should be made by direct connec-
tion to the workpiece, but in some countries
where direct connection is not permitted,
the bonding should be achieved by suitable
capacitance, selected according to national
regulations.
6. Screening and Shielding
Selective screening and shielding of other
cables and equipment in the surrounding
area may alleviate problems of interference.
Screening the entire welding installation may
be considered for special applications.
0-5492 3-3 INSTALLATION

INSTALLATION 3-4 0-5492

SECTION 4:
OPERATION
4.01 Overview
Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead
directly to workpiece and the electrode wire is fed via the MIG Torch (Consult the electrode wire manufaturers
information for the correct polarity). The welding current range values should be used as a guide only. Current
delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between different
classes of electrode wire, welding current at any one setting would vary accordingly to the type of electrode
wire in use. The operator should use the welding current range values as a guide, then fianlly adjust the current
setting to suit the application.
4.02 Power Source Controls, Indicators and Features
4 1
3
5 2
9
8 18
6 16
15
7
14
12
17
10 13
11
19
20
Art # A-13437
Figure 4-1 WeldSkill 185 as Pictured

0-5492 4-1 OPERATION
1. Process Selection Control
The process selection control is used to select the desired welding mode. Three modes are available, MIG
(GMAW/FCAW), Lift TIG (GTAW), STICK (MMAW) modes. Refer to section 5.09 or 5.10 for MIG (GMAW/FCAW)
set up details, section 7.02 for Lift TIG (GTAW) set-up details or section 6.01 for Stick (MMAW) set-up details.
Note that when the unit is powered off the mode selection control will automatically default to MIG mode.
This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the unit and
mistakenly be in contact with the work piece during power up.
2. Trigger Mode Control (MIG and Lift TIG Modes WeldSkill 185 only)
The trigger mode control is used to switch the functionality of the torch trigger between 2T (normal) and 4T
(latch mode).
2T Normal Mode
In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold
the torch trigger to activate the power source (weld). Release the torch trigger switch to cease welding.
4T Latch Mode
This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the
operator can press and release the torch trigger and the output will remain active. To deactivate the power
source, the trigger switch must again be depressed and released, thus eliminating the need for the operator
to hold the torch trigger.
3. Power Indicator
The power indicator is illuminated when nominal 240V AC mains power is applied to the power source and
the ON/OFF switch located on the rear panel is in the ON position.
4. Over Temp Indicator
This welding power source is protected by a self resetting thermostat. The Over Temp indicator will illuminate
if the machine has over heated which normally occurs if the duty cycle of the power source has been exceeded.
Should the Over Temp indicator illuminate the output of the power source will be disabled. Leave the power
source turned On to allow the internal components to cool down. Once the power source cools down sufficiently
the Over Temp indicator will automatically go off. Note that the On/Off switch should remain in the On position
such that the fan continues to operate thus allowing the power source to cool sufficiently. Do not switch the
power source Off if an Over Temp condition is present.
5. VRD ON/OFF Indicator Lights
A VRD (voltage reduction device) is a hazard reducing device designed to reduce electric shock hazards present
on the output of welding power source when operating in STICK (MMAW) mode. Note that the presence of
VRD should not be used as a substitute for the use of appropriate safety practices as indicated in Section One
of this manual.
The green VRD ON light illuminates (red light is off) when the VRD is active. Under this condition the open
circuit voltage of the unit is limited to below 35V DC, thus reducing the potential of serious electric shock
(such as when changing electrodes).
The red VRD OFF light illuminates (green light is off) when the VRD is inactive. Under this condition the output
voltage of the unit will be at welding potential which in some cases may exceed 35V DC.
OPERATION 4-2 0-5492

6. Wirespeed Control (MIG) Amps Control (Stick & TIG)
In MIG (GMAW/FCAW) modes , the Wirespeed Control knob adjusts the speed of the wire feed motor (which in
turn adjusts the output current by varying the amount of MIG wire delivered to the welding arc). The optimum
wire speed required will dependent on the type of welding application. The setup guide on the inside of the
wire feed compartment door provides a brief summary of the required output settings for a basic range of
MIG welding applications.
The amps control knob adjusts the amount of welding current delivered by the power source. In Stick (MMAW)
and TIG (GTAW) modes, the Amps control knob directly adjusts the power inverter to deliver the desired level
of output current.
7. Voltage Control
In MIG (GMAW/FCAW) mode, the voltage control knob is used to adjust the output voltage of the unit. The
welding voltage is increased by turning the knob clockwise or decreased by turning the knob anti-clockwise.
The optimum voltage level required will be dependent on the type of welding application. The setup chart on
the inside of the wire feed compartment door provides a brief summary of the required output settings for a
basic range of MIG welding applications.
8. Digital Amps Meter (Left Digital Display)
MIG Mode
This digital meter is used to display the pre-set (preview) Wirefeed Speed in Metres Per Minute (MPM)
in MIG mode and actual welding amperage of the power source when welding. At times of non-welding,
the digital meter will display a pre-set (preview) value of Wirefeed Speed (MPM). This value can be
adjusted by varying the Wirespeed Control Knob (6).
STICK and LIFT TIG Modes
The digital meter is used to display the pre-set (preview) amperage in STICK / LIFT TIG modes and
actual welding amperage of the power source when welding. At times of non-welding, the amperage
meter will display a pre-set (preview) amperage value in both STICK and LIFT TIG modes. This value
can be adjusted by varying the Amps Control Knob (6).
When welding, this digital meter will display actual welding amperage in all modes.
At the completion of welding, the digital meter will hold the last recorded amperage value for a period
of approximately 10 seconds in all modes. The amperage meter will hold the value until; (1) any of
the front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is
recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds
elapses following the completion of welding in which case the unit will return to preview mode.
NOTE
The preview functionality provided on this power source is intended to act as a guide only. Some differences may be
observed between preview values and actual welding values due to factors including the mode of welding, differences
in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus
spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate
measurement methods be utilised to ensure output values are accurate.

9. Digital Voltage Meter (Right Digital Display)
MIG Mode
This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding
voltage of the power source when welding. At times of non-welding, the digital meter will display a pre-
set (preview) value of Voltage. This value can be adjusted by varying the Voltage Control Knob (7).
STICK and LIFT TIG Modes
This digital meter is used to display the Welding Output Terminal Voltage in STICK / LIFT TIG modes
during non-welding or welding. This value Cannot be adjusted by varying the Voltage Control Knob (7).
When welding, this digital meter will display actual welding voltage in all modes.
At the completion of welding, the digital meter will hold the last recorded voltage value for a period
of approximately 10 seconds in all modes. The voltage meter will hold the value until; (1) any of the
front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is
recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds
elapses following the completion of welding in which case the unit will return to preview mode.
NOTE
The preview functionality provided on this power source is intended to act as a guide only. Some differences may be
observed between preview values and actual welding values due to factors including the mode of welding, differences
in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus
spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate
measurement methods be utilised to ensure output values are accurate.
10. 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.
11. MIG Torch Polarity Lead
The polarity lead is used to connect the MIG torch to the appropriate positive or negative output terminal
(allowing polarity reversal for different welding applications). In general, the polarity lead should be connected
in to the positive welding terminal (+) when using steel, stainless steel or aluminium electrode wire. When
using gasless wire, the polarity lead is generally connected to the negative welding terminal (-). If in doubt,
consult the manufacturer of the electrode wire for the correct polarity. It is essential, however, that the male
plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the Dinse terminal.

12. Remote Control Socket (WeldSkill 185 only)
The 8 pin Remote Control Socket is used to connect remote control devices (i.e. Spool Gun or Tig Torch) to
the welding power source. To make connections, align keyway, insert plug, and rotate threaded collar fully
clockwise.
1 Negative
Trigger Switch
2 Spool Gun Motor
3
2 1 Positive
4
5 4 3
5 Remote Wirespeed (Spool Gun) in GMAW mode
8 7 6 W
6 Remote Amps in GTAW mode
7
8
A-13456
Socket Pin Function

1 Spool gun motor negative
2 Trigger Switch Input
3 Trigger Switch Input
4 Spool gun motor positive
5 5k ohm (maximum) connection to 5k ohm remote control potentiometer.
6 Zero ohm (minimum) connection to 5k ohm remote control potentiometer.
Wiper arm connection to 5k ohm remote control Wirespeed MIG (GMAW) mode potentiometer.
7
Wiper arm connection to 5k ohm remote control Amps TIG (GTAW) mode potentiometer.
8 Not connected
Table 4-1
Note that the remote/local switch (item 19) located in the wirefeed compartment should be set to remote for
the amperage/voltage controls to be operative.
13. Positive Welding Output Terminal
The positive welding terminal is used to connect the welding output of the power source to the appropriate
welding accessory such as the MIG torch (via the MIG torch polarity lead), electrode holder lead or work lead.
Positive welding current flows from the power source via this Dinse terminal. It is essential, however, that the
male plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION
14. Negative Welding Output Terminal

The negative welding terminal is used to connect the welding output of the power source to the work lead. Most
General Purpose electrodes are connected with work lead to negative. Consult the electrode manufacturer’s
information for the correct polarity.
Welding current flows from the workpiece via this Dinse type terminal to the power source. It is essential,
however, that the male dinse type plug is inserted and turned securely to achieve a sound electrical connection.
Do not over tighten.
CAUTION

15. Arc Control (Inductance)
The arc control operates in MIG(GMAW) mode only and is used to adjust the intensity of the welding arc.
Lower arc control settings make the arc softer with less weld spatter. Higher arc control settings give a stronger
driving arc which can increase weld penetration.
16. Gas Inlet (MIG mode only)
The Gas Inlet connection is a quick connect type inlet fitting used to supply the appropriate MIG welding gas
to the unit. Refer to section 5.09 for MIG set up details.
WARNING
! Only Inert Shielding Gases specifically designed for welding applications should be used.
17. Fan
The Fan is turned ON/OFF by the Power Switch on the rear panel of the machine.
18. On/Off Switch
This switch is used to turn the unit ON/OFF. When this switch is turned ON the Power Indicator on the front
panel will illuminate.
NOTE
If the Power Source is repeatedly switched On then Off rapidly or the supply to the power source is turned On and Off
rapidly it may not turn On due to inbuilt protective devices acting. If this occurs leave the Power Source On/Off switch
turned to the Off position for several minutes to allow for the protective devices to reset.
19. Local / Remote Switch (located in wirefeed compartment of WeldSkill 185 only)
The Local / Remote switch is used only when the unit is in Lift Tig Mode and a Tig Torch with Remote Current
Control or the unit is in Mig Mode and a Spool Gun is fitted to the unit via the 8 Pin remote control socket (item
12) located on the front panel. When the Local/Remote switch is in the Remote position, the unit will detect the
remote device and work accordingly. When in the Local Mode, the unit will not detect the remote device and
will operate from the power source controls only. Note that the trigger will operate at all times on the remote
control socket irrespective of the position of the Local / Remote switch (ie in both local and remote modes).
When the Local/Remote switch is set to Remote mode, if the unit is in Lift Tig mode and a Tig Torch with
Remote Current Control is connected the current output value will be controlled only by the Tig Torch Remote
Control. If the unit is in Mig Mode and a Spool Gun fitted with wirespeed control is connected the Spool Gun
wirefeed speed will be controlled by the Spool Gun Control. The power source control will be disabled.
20. Burnback Control (located in wirefeed compartment)
The burnback control is used to adjust the amount of MIG wire that protrudes from the MIG torch after the
completion of MIG welding (commonly referred to as stick out). To decrease the burnback time (or lengthen
the amount of wire protruding from the MIG torch at the completing of welding), turn the burnback control
knob anti clockwise. To increase the burnback time (or shorten the amount of wire protruding from the torch
at the completing of welding), turn the Burnback Control knob clockwise.
21. Hot Start Feature (Not Shown)
This feature operates in Stick (MMAW) mode. The Hot Start feature improves the arc start characteristics by
momentarily increasing the welding current to a level above the preset amperage (Welding Current). This is a
preset feature and is not adjustable.
22. Anti Stick Feature (Not Shown)
This feature operates in Stick (MMAW) mode.
The anti stick feature senses when the electrode sticks and automatically reduces the current to prevent the
Stick Electrode from sticking to the work piece. This is a preset feature and is not adjustable.

SECTION 5:
MIG (GMAW) WELDING
5.01 Shielding Gas Regulator/Flowmeter Operating Instructions
WARNING
! This equipment is designed for use with welding grade (Inert) shielding gases only..
Shielding Gas Regulator/Flowmeter Safety
This regulator/flowmeter 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/flowmeters are listed below.
1. NEVER subject the regulator/flowmeter to inlet pressure greater than its rated inlet pressure.
2. NEVER pressurize a regulator/flowmeter 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/flowmeter until
the gas pressure has been relieved. Under pressure, gas can dangerously propel a loose part.
3. DO NOT remove the regulator/flowmeter from a cylinder without first closing the cylinder valve and
releasing gas in the regulator/flowmeter high and low pressure chambers.
4. DO NOT use the regulator/flowmeter 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
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.
CAUTION
Match regulator/flowmeter to cylinder. NEVER CONNECT a regulator/flowmeter designed for a particular gas or gases to
a cylinder containing any other gas.
Art: A-05087
Figure 5-1: Fit Regulator/flowmeter to Cylinder
Manual 0-5492 5-1 MIG (GMAW) WELDING

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/flowmeter.
Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of
ignition. Wipe with a clean lint free cloth.
2. Match regulator/flowmeter to cylinder. Before connecting, check that the regulator/flowmeter label
and cylinder marking agree and that the regulator/flowmeter inlet and cylinder outlet match. NEVER
CONNECT a regulator/flowmeter designed for a particular gas or gases to a cylinder containing any
other gas.
3. Connect the regulator/flowmeter inlet connection to cylinder or pipeline and tighten it firmly but not
excessively, with a suitable spanner.
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/
flowmeter is not fitted with a pressure relief device.
Operation
With the regulator/flowmeter connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged,
pressurize as follows:
1. Stand to one side of regulator/flowmeter and slowly open the cylinder valve. If opened quickly, a sudden
pressure surge may damage internal regulator/flowmeter parts.
2. With valves on downstream equipment closed, adjust regulator/flowmeter to approximate working
pressure. It is recommended that testing for leaks at the regulator/flowmeter 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/
flowmeter by individually opening then closing the equipment control valves. Complete purging may
take up to ten seconds or more, depending upon the length and size of the hose being purged.
Adjusting Flow Rate
Art: A-05088_AB
Figure 5-2: Adjust Flow Rate
With the regulator/flowmeter ready for operation, adjust working flow rate as follows:
1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required
flow rate.
NOTE 5
It may be necessary to re-check the shielding gas regulator/flowmeter flow rate following the first weld sequence due
to back pressure present within shielding gas hose assembly..
MIG (GMAW) WELDING 5-2 Manual 0-5492

2. To reduce flow rate, allow the welding grade shielding gas to discharge from regulator/flowmeter by
opening the downstream valve. Bleed welding 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/flowmeter is not in use. To shut down for extended periods (more
than 30 minutes).
1. Close cylinder or upstream valve tightly.
2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away
from any ignition source.
3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.
4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove
regulators/flowmeters.
5.02 Attaching the MIG Torch (Euro)

Fit the MIG Torch to the power source by pushing the MIG torch connector into the MIG torch adaptor and
screwing the plastic torch nut clockwise to secure the MIG torch to the MIG torch adaptor.
Art # A-13441
Figure 5-3: Attaching MIG Torch

5.03 Installing Minispool (100mm diameter)
As delivered from the factory, the unit is fitted with a Wire Spool Hub which accepts a Handispools of 200mm
diameter.
In order to fit a Minispool (100mm diameter) assemble parts in the sequence shown below in Figure 5-4.
The nut and spring tighten the brake. The brake is correctly adjusted when the spool stops within 10 to 20mm
(measured at the outer edge of the spool) after Mig Torch trigger is released. Wire should be slack without
becoming dislodged from the spool.
CAUTION
Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical componentry and
possibly an increased incidence of wire Burnback into contact tip.
100mm Spool
Spring Spacer
Nut
Art # A-13442
Figure 5-4: 100mm Spool Installation

5.04 Installing Handispool (200mm diameter)
As delivered from the factory, the unit is set for a Handispool (200mm diameter).
In order to re-fit a 200mm spool assemble parts in the sequence shown below in Figure 5-5.
Adjustment of the nut will control the Mig Wire Spool Brake. Clockwise rotation of this nut tightens the brake.
The Brake is correctly adjusted when the spool stops within 10 to 20mm (measured at the outer edge of the
spool) after Mig Torch trigger is released. Wire should be slack without becoming dislodged from the spool.
CAUTION
possibly an increased incidence of wire Burnback into contact tip.
Ensure that the alignment pin on the wire spool hub aligns with the hole allocated in the Handispool.
NOTE
This spool hub nut can be removed by unscrewing in an anticlockwise direction and locating in the appropriate position.
Nut Spool Hub

Spool Hub Nut
Spacer
Spring Art # A-13443

200mm Spool
Figure 5-5: 200mm Handispool Installation

5.05 Inserting Wire into the Wire Feed Mechanism
Release the tension from the pressure roller by turning the adjustable wire drive tension screw in an anti-
clockwise direction. Then to release the pressure roller arm pull the pressure roller arm tension screw forward
to release the pressure roller arm (Figure 5-6). With the MIG welding wire feeding from the bottom of the spool
(Figure 5-7) pass the wire through the inlet guide, between the rollers, through the outlet guide and into the
MIG torch. Re-secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly
(Figure 5-6). Remove the contact tip from the MIG torch. With the MIG Torch lead reasonably straight, feed
the wire through the torch by depressing the trigger switch. Fit the appropriate contact tip.
WARNING
! Before connecting the work clamp to the work piece make sure the mains power supply is switched off.
The wire will be at welding voltage potential while it is being feed through the system.
Keep Mig Torch away from eyes and face.
Wire Drive Tension Screw
Pressure Roller Arm
Outlet Guide
Art # A-13444
Figure 5-6: Wire Drive Assembly Components
Outlet Guide
Art # A-13445
MIG Welding Wire Inlet Guide

Figure 5-7: Mig Welding Wire - Installation

5.06 Feed Roller Pressure Adjustment
The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure 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 pressure can be increased by rotating the pressure screw clockwise.
WARNING
! Before changing the feed roller ensure that the mains supply to the power source is switched off..
CAUTION
The use of excessive pressure may cause rapid wear of the feed rollers, shafts and bearing.
5.07 Changing the Feed Roll

To change feed roll remove the feed roll retaining screw by turning in an anticlockwise direction. Once the feed
roll is removed then to replace feed roll simply reverse these directions.
A dual groove feed roller is fitted as standard. It can accommodate 0.8/0.9mm Gasless Flux Cored Wires.
Select the roller required with the chosen wire size marking facing outward.
GROOVE “A” GROOVE “B”
GROOVE “B” SIZE GROOVE “A” SIZE

A-09583
Figure 5-8: Dual Groove Feed Roller
Feed Roll
Feed Roll Retaining Screw
Art # A-13446
Figure 5-9: Changing the Feed Roll

5.08 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 10-20mm after release of the trigger. The wire should be slack without becoming dislodged from
wire spool.
CAUTION
possibly an increased incidence of electrode wire Burnback into contact tip.
Wire Reel Break Adjustment Nut
Art # A-13447
Figure 5-10: Wire Reel Brake
5.09 Setup for MIG (GMAW) Welding with Gas Shielded Mig Wire
A. Fit the MIG Torch to the Power Source. (Refer to section 5.02 Attaching the MIG Torch).
B. Connect the Mig torch polarity lead to the positive welding terminal (+). If in doubt, consult the wire
manufacturer. Welding current flows from the Power Source via Dinse terminals. It is essential, however,
that the male plug is inserted and turned securely to achieve a sound electrical connection.
C. Switch the Power Source On/Off switch located on the rear of the Power Source to the On position and
ensure the Power indicator on the Front Panel is illuminated. Set the MIG Torch trigger switch operation
either 2T or 4T mode (WeldSkill 185 only). Refer to section 4.02.2.
D. Select MIG mode with the process selection control. (refer to Section 4.02.1 for further information).
E. Fit the correct Feed Roll for the Gas Shielded MIG wire being used. Refer to section 2.11 Options and
Accessories for Feed Roll types and Part Numbers
240VAC
10A
Mains Supply Supply Input Lead
Shielding Gas Cylinder Negative Welding Terminal
Shielding Gas Cylinder
Positive Welding Terminal Shielding Gas Hose

MIG Polarity Lead Fitted with Quick
MIG Torch
Connect Gas Inlet Connection
Art # A-13448
Work Lead
Figure 5-11: Setup for Mig Welding with Gas Shielded Mig Wire

F. Place the MIG wire spool onto the spool holder. Refer to sections 5.03 for 100mm diameter spools or 5.04
for 200mm diameter spools.
G. Feed wire through the wire drive mechanism. Refer to section 5.05.
H. Connect the work lead to the negative welding terminal (-). If in doubt, consult the wire manufacturer.
Welding current flows from the Power Source via Dinse terminals. It is essential, however, that the male
I. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section 5.01)
then connect the shielding gas hose from the shielding gas regulator/flowmeter outlet to the quick connect
Shielding Gas Inlet fitting gas on the rear of the WeldSkill 155 or WeldSkill 185 Power Source. Ensure that
the shielding gas hose connection is sufficiently tight at the regulator connection and the quick connect
fitting "locks" into place correctly on the rear of the power source.
J. As a guide for the welding parameter settings for the welding job refer to the Weld Guide located on the
inside of the wirefeed compartment door. Power Source settings are adjusted using the front panel controls.
Refer to section 4.02.
WARNING
! Before connecting the work clamp to the work piece make sure the mains power supply is switched off..
WARNING
! Secure the welding grade shielding gas cylinder in an upright position by chaining it to a
suitable stationary support to prevent falling or tipping..
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.

5.10 Setup for MIG (GMAW) Welding with Gasless MIG Wire (Flux Cored)
A. Fit the MIG Torch to the Power Source. (Refer to section 5.02 Attaching the MIG Torch).
B. Connect the Mig Torch polarity lead to the negative welding terminal (-). If in doubt, consult the wire
manufacturer. Welding current flows from the power source via Dinse terminals. It is essential, however,
C. Switch the Power Source On/Off switch (refer 4.02.18) located on the rear of the Power Source to the On
position and ensure the Power indicator on the Front Panel is illuminated. Set the MIG Torch trigger switch
operation either 2T ot 4T mode (WeldSkill 185 only). Refer to section 4.02.2.
D. Select MIG mode with the process selection control (refer to Section 4.02.1 for further information).
E. Fit the correct V Knurled Feed Roll for the Gasless MIG wire being used. Refer to section 2.11 Options and
Accessories for Feed Roll types and Part Numbers
F. Place the MIG wire spool onto the spool holder. Refer to sections 5.03 for 100mm diameter spools or 5.04
for 200mm diameter spools.
G. Feed wire through the wire drive mechanism. Refer to section 5.05.
240VAC
10A
Mains Supply
MIG Torch
Negative Welding Terminal (-)

MIG Polarity Lead
Positive Welding Terminal (+)
Work Lead
Art # A-13449
Figure 5-12: Setup for Mig Welding with Gasless Mig Wire
H. Connect the work lead to the positive welding terminal (+). If in doubt, consult the wire manufacturer.
Welding current flows from the power source via Dinse terminals. It is essential, however, that the male
I. As a guide for the welding parameter settings for the welding job refer to the Weld Guide located on the
inside of the wirefeed compartment door. Power Source settings are adjusted using the front panel controls.
Refer to section 4.02.
WARNING
! Before connecting the work clamp to the work piece make sure the mains power supply is switched off..
CAUTION

5.11 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded Mig Wire
(WeldSkill 185 Only)
A. Select MIG mode with the process selection control (refer to Section 4.02.01 for further information).
B. Connect the Mig torch polarity lead to the positive welding terminal (+). If in doubt, consult the wire
manufacturer. Welding current flows from the Power Source via Dinse type terminals. It is essential,
however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
C. Fit the Euro Spool Gun to the power source using the front panel EURO torch adaptor (refer also to section
5.02 Attaching the Mig Gun). Connect the 8 pin Remote Control Plug to the 8 pin Remote Control Socket
on the power source. Ensure 8 pin plug is correctly fitted to the 8 pin socket on front panel and collar on
plug is tightened firmly.
D. Connect the work lead to the negative welding terminal (-). If in doubt, consult the wire manufacturer.
Welding current flows from the Power Source via Dinse type terminals. It is essential, however, that the
male plug is inserted and turned securely to achieve a sound electrical connection.
E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section 5.01)
then connect the shielding gas hose from the shielding gas regulator/flowmeter outlet to the quick connect
Shielding Gas Inlet fitting gas on the rear of the WeldSkill 185 Power Source. Ensure that the shielding gas
hose connection is sufficiently tight at the regulator connection and the quick connect fitting "locks" into
place correctly on the rear of the power source.
F. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.
G. Select MIG mode with the process selection control (refer to section 4.02.01 for further information).
H. Set the Local/Remote Switch located inside the wire drive compartment, to Remote.
240VAC
10A
Mains Supply
Shielding Gas Cylinder Negative Welding Terminal
Remote Control Socket
Positive Welding Terminal

MIG Polarity Lead
Spool Gun
Work Lead Art # A-13516
Figure 5-13: Setup for Spool Gun Welding with Gas Shielded Mig Wire with WeldSkill 185
WARNING
! Before connecting the work clamp to the work piece make sure the mains power supply is switched off.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to
prevent falling or tipping.
CAUTION

5.12 MIG (GMAW/FCAW) Basic Welding Technique
Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing
the very basic concepts in using the Mig mode of welding, where a welding gun is hand held, and the electrode
(welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert
welding grade shielding gas mixture.
GAS METAL ARC WELDING (GMAW): This process, also known as MIG welding, CO2 welding, Micro Wire
Welding, short arc welding, dip transfer welding, wire welding etc., is an electric arc welding process which
fuses together the parts to be welded by heating them with an arc between a solid continuous, consumable
electrode and the work. Shielding is obtained from an externally supplied welding grade shielding gas or welding
grade shielding gas mixture. The process is normally applied semi automatically; however the process may
be operated automatically and can be machine operated. The process can be used to weld thin and fairly thick
steels, and some non-ferrous metals in all positions.
Shielding Gas
Nozzle
Molten Weld Metal Electrode
Arc
Solidified
Weld Metal Base Metal
GMAW Process Art # A-8991_AB
Figure 5-14
FLUX CORED ARC WELDING (FCAW): This is an electric arc welding process which fuses together the parts to
be welded by heating them with an arc between a continuous flux filled electrode wire and the work. Shielding
is obtained through decomposition of the flux within the tubular wire. Additional shielding may or may not be
obtained from an externally supplied gas or gas mixture. The process is normally applied semi automatically;
however the process may be applied automatically or by machine. It is commonly used to weld large diameter
electrodes in the flat and horizontal position and small electrode diameters in all positions. The process is used
to a lesser degree for welding stainless steel and for overlay work.
Shielding Gas
(Optional) Nozzle
(Optional)
Molten Metal
Flux Cored
Molten Electrode
Slag
Slag
Arc
Solidified
Weld Metal Base Metal
FCAW Process Art # A-08992_AB
Figure 5-15
Position of MIG Torch

The angle of MIG torch to the weld has an effect on the width of the weld.
Push Vertical Drag/Pull
Art # A-07185_AB
Figure 5-16

The welding gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below)
Hold the gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper filter
lenses and use the proper safety equipment.
CAUTION
Do not pull the welding gun back when the arc is established. This will create excessive wire extension (stick-out) and
make a very poor weld.
The electrode wire is not energized until the gun trigger switch is depressed. The wire may therefore be placed
on the seam or joint prior to lowering the helmet.
5° to 15°
Longitudinal
Angle
Direction of
90° Travel
Transverse
Angle
Art # A-08993
Figure 5-17
Butt & Horizontal Welds
5° to 15°
Longitudinal Angle
30° to 60°
Transverse Angle
Direction of
Travel
Art # A-08994
HorizontalFigure
Fillet 5-18
Weld
10° to 20° Longitudinal
10° Angle
Longitudinal Angle
30° to 60° 30° to 60°

Transverse Transverse
Angle Angle
Direction of Travel
Vertical Fillet Welds Art # A-08995
Figure 5-19
Direction of Travel
30° to 60°
Transverse Angle 5° to 15°
Longitudinal
Angle
Art # A-08996
OverheadFigure
Weld 5-20
Distance from the MIG Torch Nozzle to the Work Piece
The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20.0mm. This distance
may vary depending on the type of joint that is being welded.
Travel Speed
The speed at which the molten pool travels influences the width of the weld and penetration of the welding run.
MIG Welding (GMAW) Variables
Most of the welding done by all processes is on carbon steel. The items below describe the welding variables
in short-arc welding of 24gauge (0.024”, 0.6mm) to ¼” (6.4mm) mild sheet or plate. The applied techniques
and end results in the GMAW process are controlled by these variables.
Preselected Variables
Preselected variables depend upon the type of material being welded, the thickness of the material, the welding
position, the deposition rate and the mechanical properties. These variables are:
• Type of electrode wire
• Size of electrode wire
• Type of gas (not applicable to self shielding wires FCAW)
• Gas flow rate (not applicable to self shielding wires FCAW)
Primary Adjustable Variables
These control the process after preselected variables have been found. They control the penetration, bead
width, bead height, arc stability, deposition rate and weld soundness. They are:
• Arc Voltage
• Welding current (wire feed speed)
• Travel speed
Secondary Adjustable Variables
These variables cause changes in primary adjustable variables which in turn cause the desired change in the
bead formation. They are:
1. Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain
at about 10mm stick-out.
2. Wire Feed Speed. Increase in wire feed speed increases weld current, Decrease in wire feed speed
decreases weld current.
Gas Nozzle
Contact Tip (Tube)
Tip to Electrode Wire
Work Distance Actual Stick-out
Average Arc Length

Art # A-08997_AD
Electrode Stick-Out
Figure 5-21

3. Nozzle Angle. This refers to the position of the welding gun in relation to the joint. The transverse angle
is usually one half the included angle between plates forming the joint. The longitudinal angle is the
angle between the centre line of the welding gun and a line perpendicular to the axis of the weld. The
longitudinal angle is generally called the Nozzle Angle and can be either trailing (pulling) or leading
(pushing). Whether the operator is left handed or right handed has to be considered to realize the
effects of each angle in relation to the direction of travel.
Transverse
Angle
Longitudinal
Angle
Axis of Weld
Art # A-08998_AB
Transverse and Longitudinal
Nozzle Axes
Figure 5-22
Direction of Gun Travel
Leading or “Pushing”
90° Trailing or “Pulling”
Angle Angle
(Forward Pointing) (Backward Pointing)
Nozzle Angle, Right Handed Operator Art # A-08999_AC
Figure 5-23
Establishing the Arc and Making Weld Beads

Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a
sample metal of the same material as that of the finished piece.
The easiest welding procedure for the beginner to experiment with MIG welding is the flat position. The
equipment is capable of flat, vertical and overhead positions.
For practicing MIG welding, secure some pieces of 16 or 18 gauge (0.06” 1.5mm or 0.08” 2.0mm) mild steel
plate 6” x 6” (150 x 150mm). Use 0.030” (0.8mm) flux cored gasless wire or a solid wire with shielding gas.

Setting of the Power Source
Power source and Wirefeeder setting requires some practice by the operator, as the welding plant has two
control settings that have to balance. These are the Wirespeed control (refer to section 4.02.06) and the welding
Voltage Control (refer to section 4.02.07). The welding current is determined by the Wirespeed control, the
current will increase with increased Wirespeed, resulting in a shorter arc. Less wire speed will reduce the
current and lengthen the arc. Increasing the welding voltage hardly alters the current level, but lengthens the
arc. By decreasing the voltage, a shorter arc is obtained with a little change in current level.
When changing to a different electrode wire diameter, different control settings are required. A thinner electrode
wire needs more Wirespeed to achieve the same current level.
A satisfactory weld cannot be obtained if the Wirespeed and Voltage settings are not adjusted to suit the
electrode wire diameter and the dimensions of the work piece.
If the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten
pool and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If,
however, the welding voltage is too high, large drops will form on the end of the wire, causing spatter. The
correct setting of voltage and Wirespeed can be seen in the shape of the weld deposit and heard by a smooth
regular arc sound. Refer to the Weld Guide located on the inside of the wirefeed compartment door for setup
information.
Electrode Wire Size Selection
The choice of Electrode wire size and shielding gas used depends on the following
• Thickness of the metal to be welded
• Type of joint
• Capacity of the wire feed unit and Power Source
• The amount of penetration required
• The deposition rate required
• The bead profile desired
• The position of welding
• Cost of the wire

5.13 CIGWELD MIG Wire Selection Chart
DESCRIPTION DIAMETER PACK PART NUMBER APPLICATION
0.6mm Minispool 0.9kg WS0906
0.6mm Handispool 5kg WS5006
General purpose welding wire suitable for the

WELDSKILL 0.8mm Minispool 0.9kg WS0908 all positional Gas Metal Arc Welding (GWAW)
SOLID of mild and low alloy steels, used in general
WELDING fabrication and for welding of light to medium
WIRE 0.8mm Handispool 5kg WS5008 gauge sheet and tubular steel sections. Note
that a suitable shielding gas is required.
0.9mm Minispool 0.9kg WS0909
0.9mm Handispool 5kg WS5009
0.8mm Minispool 0.9kg WG0908
WeldSkill Gasless wire is an all positional

WELDSKILL 0.8mm Handispool 4.5kg WG4508 self-shielded flux cored wire recommended
GASLESS for single pass welding applications only. It
WELDING is excellent for single-pass lap, fillet and butt
WIRE 0.9mm Minispool 0.9kg WG0909 welding of thin gauged galvanised and mild
steels.
0.9mm Handispool 4.5kg WG4509
0.8mm Minispool 1kg 721285

AUTOCRAFT General purpose all positional stainless steel
wire providing excellent results when used
316LSI SOLID
0.8mm Handispool 5kg 720288 with correct shielding gas. Suitable for the
STAINLESS STEEL general welding of a wide range of stainless
MIG WIRE steels (300 & 400 series).
0.9mm Handispool 5kg 720283
0.9mm Minispool 0.5kg 721223

AUTOCRAFT Excellent general purpose Aluminium MIG
wire suitable for the welding of a wide
AL5356 SOLID
1.0mm Minispool 0.5kg 721224 range of wrought and cast Aluminium alloys
ALUMINIUM containing Magnesium. Note that a suitable
MIG WIRE shielding gas is required.
1.0mm Handispool 2kg 723224
Used for lower strength welding of steels

AUTOCRAFT in automotive applications. It can also be
SILICON BRONZE 0.8mm Handispool 5kg 720159 used for welding copper-silicon alloys in hot
MIG WIRE water systems, heat exchangers and marine
components.
NOTE: MINISPOOL = 100MM DIAMETER, HANDISPOOL = 200MM DIAMETER
Table 5-1: Cigweld MIG Wire Selection Chart

5.14 MIG (GMAW/FCAW) Welding Troubleshooting
Solving Problems Beyond the Welding Terminals
The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then
work through to the MIG torch. There are two main areas where problems occur with GMAW, Porosity and
Inconsistent wire feed
Solving Problems Beyond the Welding Terminals - Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from
some contaminant within the molten weld pool which is in the process of escaping during solidification of
the molten metal. Contaminants range from no gas around the welding arc to dirt on the work piece surface.
Porosity can be reduced by checking the following points.
FAULT CAUSE
1 Shielding gas cylinder contents Ensure that the shielding gas cylinder is not empty and the
and flow meter. flow meter is correctly adjusted to 15 litres per minute.
2 Gas leaks. Check for gas leaks between the regulator/cylinder connection
and in the gas hose to the Power Source.
3 Internal gas hose in the Power Ensure the hose from the solenoid valve to the torch adaptor
Source. has not fractured and that it is connected to the torch adaptor.
4 Welding in a windy environment. Shield the weld area from the wind or increase the gas flow.
5 Welding dirty, oily, painted, Clean contaminates off the work piece.
oxidised or greasy plate.
6 Distance between the MIG torch Keep the distance between the MIG torch nozzle and the work
nozzle and the work piece. piece to a minimum. Refer to section 5.11
7 Maintain the MIG torch in good A Ensure that the gas holes are not blocked and gas is exiting
working order. out of the torch nozzle.
B Do not restrict gas flow by allowing spatter to build up inside
the torch nozzle.
C Check that the MIG torch O-rings are not damaged.
Table 5-2: Solving Problems beyond the Welding Terminals-Porosity
WARNING
! Disengage the feed roll when testing for gas flow by ear..

Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed
Wire feeding problems can be reduced by checking the following points.
FAULT CAUSE
1 Feed roller driven by motor in the A Wire spool brake is too tight. (Refer 5.08).
wirefeed compartment slipping. B Incorrect feed roll fitted for wire used. Check and
change to correct feed roll if necessary. (Refer options
and accessories table 2.11 for feed roll options)
2 Wire spool unwinded and tangled. Wire spool brake is too loose. (Refer 5.08)
3 Worn or incorrect feed roller size A Use a feed roller matched to the size you are welding.
B Replace feed roller if worn.
4 Wire rubbed against the mis-aligned Mis-alignment of inlet/outlet guides
guides and reduced wire feedability.
5 Liner blocked with swarf A Increased amounts of swarf are produced by the
wire passing through the feed roller when excessive
pressure is applied to the pressure roller adjuster.
B Swarf can also be produced by the wire passing
through an incorrect feed roller groove shape or size.
C Swarf is fed into the conduit liner where it
accumulates thus reducing wire feedability.
6 Incorrect or worn contact tip A The contact tip transfers the weld current to the
electrode wire. If the hole in the contact tip is too
large then arcing may occur inside the contact tip
resulting in the wire jamming in the contact tip
B When using soft wire such as aluminium it may
become jammed in the contact tip due to expansion of
the wire when heated. A contact tip designed for soft
wires should be used.
7 Poor work lead contact to work piece If the work lead has a poor electrical contact to the
work piece then the connection point will heat up and
result in a reduction of power at the arc.
8 Bent liner This will cause friction between the wire and the liner
thus reducing wire feedability
Table 5-3: Wire Feeding Problems

Basic MIG (GMAW) Welding Troubleshooting
FAULT CAUSE REMEDY
1 Undercut A Welding arc voltage too A Decrease voltage or increase the wire feed speed.
high.
B Incorrect torch angle B Adjust angle.
C Excessive heat input C Increase the torch travel speed and/or decrease
welding current by decreasing the voltage or
decreasing the wire feed speed.
2 Lack of penetration A Welding current too low A Increase welding current by increasing wire feed
speed and increasing voltage.
B Joint preparation too B Increase joint angle or gap.
narrow or gap too tight
C Shielding gas incorrect C Change to a gas which gives higher penetration.
3 Lack of fusion Voltage too low Increase voltage.
4 Excessive spatter A Voltage too high A Decrease voltage or increase the wirespeed control.
B Voltage too low B Increase the voltage or decrease wirespeed.

5 Irregular weld shape A Incorrect voltage A Adjust voltage and current by adjusting the voltage
and current settings. control and the wirespeed control.
Convex, voltage too low.
Concave, voltage too
high.
B Wire is wandering. B Replace contact tip.
C Incorrect shielding gas C Check shielding gas.
D Insufficient or excessive D Adjust the wirespeed control or the voltage control.
heat input
6 Weld cracking A Weld beads too small A Decrease travel speed
B Weld penetration narrow B Reduce current and voltage and increase Mig torch
and deep travel speed or select a lower penetration shielding
gas.
C Excessive weld stresses C Increase weld metal strength or revise design
D Excessive voltage D Decrease voltage.
E Cooling rate too fast E Slow the cooling rate by preheating part to be
welded or cool slowly.
7 Cold weld puddle A Loose welding cable A Check all welding cable connections.
connection.
B Low primary voltage B Contact supply authority.
C Fault in power source C Have an Accredited CIGWELD Service Provider to
test then replace the faulty component.
8 Arc does not have The MIG torch has been Connect the MIG torch to the positive (+) welding
a crisp sound that connected to the wrong terminal for most solid wires and gas shielded flux
short arc exhibits voltage polarity on the cored wires. Connect MIG Torch to the negative (-)
when the wirefeed front panel. welding terminal for most Gasless Wires. Refer
speed and voltage to the electrode wire manufacturer for the correct
are adjusted polarity.
correctly.
Table 5-4: MIG (GMAW) Welding Problems

SECTION 6:
STICK (MMAW) WELDING
6.01 Setup For STICK (MMAW) Welding
A. Select Stick mode with the process selection control (refer to Section 4.02.01 for further information).
B. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode
manufacturer. Welding current flows from the Power Source via Dinse type terminals. It is essential,
C. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufac-
turer. Welding current flows from the power source via Dinse type terminals. It is essential, however,
WARNING
! Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Mains
power supply is switched off.
CAUTION
! Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.
NOTE!
Consult the electrode manufacturer’s information for the correct polarity.-
240VAC
10A
Mains Supply
MIG Torch Polarity Lead not connected
Electrode Holder Lead Negative Welding Terminal
Positive Welding Terminal
Art # A-13438
Work Lead
Figure 6-1: Setup For STICK (MMAW) Welding
0-5492 6-1 STICK (MMAW) Welding

6.02 Arc Welding Electrodes
Metal arc welding electrodes consist of a core wire surrounded by a flux coating. The flux coating is applied
to the core wire by an extrusion process.
The coating on arc welding electrodes serves a number of purposes:
A. To provide a gaseous shield for the weld metal, and preserve it from contamination by the atmosphere
whilst in a molten state.
B. To give a steady arc by having ‘arc stabilisers’ present, which provide a bridge for current to flow across.
C. To remove oxygen from the weld metal with ‘deoxidisers’.
D. To provide a cleansing action on the work piece and a protective slag cover over the weld metal to prevent
the formation of oxides while the metal is solidifying. The slag also helps to produce a bead of the desired
contour.
E. To introduce alloys into the weld deposits in special type electrodes.
6.03 Types of Electrodes

Arc Welding electrodes are classified into a number of groups depending on their applications. There are a
great number of electrodes used for specialised industrial purposes which are not of particular interest for
everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for
welding large diameter pipes, etc.
The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be
encountered; are all easy to use and all will work on even the most basic of welding machines.
CIGWELD Electrode Selection Chart
Description Diameter Pack Part No. Application
2.5mm 1kg 322135
2.5mm 2.5kg 612182
General purpose electrode suitable for all positional
Satincraft 13 3.2mm 1kg 322136
welding and galvanised steel.
3.2mm 2.5kg 612183
4.0mm 5kg 611184
2.0mm 1kg 322128
2.0mm 2.5kg 612231
2.5mm 1kg 322129 General purpose, extra performance electrode
Ferrocraft 12XP 2.5mm 2.5kg 612232 recommended for all positional (inc. Vertical down)
3.2mm 1kg 322138 welding of mild and galvanised steel.
3.2mm 2.5kg 612233
4.0mm 5kg 611234
2.0mm 1 kg WEG1020
2.0mm 2.5 kg WEG2520
2.5mm 1 kg WEG1025
2.5mm 2.5 kg WEG2525 User-friendly GP electrode for welding thin section
WeldSkill GP 2.5mm 5 kg WEG5025 mild and galvanised steels. Excellent for vertical
3.2mm 1 kg WEG1032 down fillet welding applications.
3.2mm 2.5 kg WEG2532
3.2mm 5 kg WEG5032
4.0mm 5 kg WEG5040
2.5mm 2 kg 53162534G0
Spezial OK Hydrogen Controlled type offering exceptional AC/DC
3.2mm 1.6 kg 53163234G0
53.16 Twincoat performance in all welding positions.
4.0mm 2.2 kg 53164044G0
2.5mm 2.5 kg 611602 Stainless Steel type for 19Cr/10Ni stainless grades
Satincrome
3.2mm 2.5 kg 611603 including 201, 202, 301, 302, 303, 304, 304L, 305,
308L-17
4.0mm 2.5 kg 611604 308, etc
Cigweld Electrode Selection Chart continued over page

STICK (MMAW) Welding 6-2 0-5492
CIGWELD Electrode Selection Chart cont'd
Description Diameter Pack Part No. Application
2.5mm 2.5 kg 611692 Stainless Steel type for 309 and 309L grades. It is
Satincrome
3.2mm 2.5 kg 611693 also suitable for welding of dissimilar welding of
309Mo-17
4.0mm 2.5 kg 611694 other 300 series stainless steels.
2.0mm 2,5 kg 611661
2.5mm 2.5 kg 611662
Satincrome Stainless Steel type for welding of matching Mo
3.2mm 2.5 kg 611663
316L-17 bearing grades, 316 and 316L.
2.5/3.2mm Blisterpack 322215
4.0mm 2.5 kg 611664
2.5mm 2.5 kg 611702
High alloy stainless steel type for welding of unknown
3.2mm 2.5 kg 611703
Weldall steels, repair of die or tool steels and for joining
2.5/3.2mm Blisterpack 322216 dissimilar steels. (Not recommended for cast iron).
4.0mm 2.5 kg 611704
For repair and maintenance welding of S.G. cast iron,
Castcraft 55 3.2mm 2.5 kg 611723 meehanite and other cast irons. It produces a higher
strength weld than Castcraft 100.
2.5mm 2.5 kg 611732
Soft, Ductile Nickel type electrode for repair and
3.2mm 2.5 kg 611733
Castcraft 100 maintenance welding of a wide range of cast irons. It
Blisterpack Blisterpack 322217 has better “wetting” action than Castcraft 55.
4.0mm 2.5 kg 611734
Table 6-1 Types of Electrodes
6.04 Size of Electrode

The electrode size is determined by the thickness of metals being joined and can also be governed by the type
of welding machine available. Small welding machines will only provide sufficient current (amperage) to run
the smaller size electrodes.
For most work, a 2.5mm electrode will be quite sufficient. A 2.5mm electrode will give just as strong a joint
but may require a few more weld runs to be put down to fill the joint.
For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job.
A little practice will soon establish the most suitable electrode for a given application.
6.05 Storage of Electrodes

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

Electrodes are connected to the Electrode Holder, and the Work Lead is connected to the work piece. Consult
the Electrode manufacturer's information for the correct polarity.

6.07 Effects of Arc Welding Various
Materials
A. High tensile and alloy steels
The two most prominent effects of welding these Art # A-07687
steels are the formation of a hardened zone in the

weld area, and, if suitable precautions are not taken, Figure 6-2: Flat position, down hand butt weld
the occurrence in this zone of under-bead cracks
may result. Hardened zone and under-bead cracks in
the weld area may be reduced by using the correct
electrodes, preheating, using higher current settings,
using larger electrodes sizes, short runs for larger
electrode deposits or tempering in a furnace.
B. Austenitic manganese steels Art # A-07688
The effect on manganese steel of slow cooling from Figure 6-3: Flat position, gravity fillet weld
high temperatures is to embrittle it. For this reason it
is absolutely essential to keep manganese steel cool
during welding by quenching after each weld or skip
welding to distribute the heat.
C. Cast Iron
Most types of cast iron, except white iron, are weld- Art # A-07689
able. White iron, because of its extreme brittleness,

generally cracks when attempts are made to weld Figure 6-4: Horizontal position, butt weld
it. Trouble may also be experienced when welding
white-heart malleable, due to the porosity caused by
gas held in this type of iron.
D. Copper and alloys
The most important factor is the high rate of heat
Art # A-07690
conductivity of copper, making preheating of heavy
sections necessary to give proper fusion of weld and
Figure 6-5: Horizontal - Vertical (HV) position
base metal.
6.08 Arc Welding Practice

The techniques used for arc welding are almost
identical regardless of what types of metals are being
joined. Naturally enough, different types of electrodes
would be used for different metals as described in the
preceding section.
Art A-07691
6.09 Welding Position Figure 6-6: Vertical position, butt weld
The electrodes dealt with in this publication can be
used in most positions, i.e. they are suitable for weld-
ing in flat, horizontal, vertical and overhead positions.
Numerous applications call for welds to be made in
positions intermediate between these. Some of the
common types of welds are shown in Figures 6-2
through 6-9.
Art # A-07692
Figure 6-7: Vertical position, fillet weld

Art# A-07693 Art # A-07694
Figure 5-6: Overhead position, butt weld Figure 6-9: Overhead position fillet, weld
6.10 Joint Preparations

In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections
and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being
joined to ensure proper penetration of the weld metal and to produce sound joints.
In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be
removed from oxy-cut surfaces. Typical joint designs are shown in Figure 6-10.
Open Square Butt Single Vee Butt Joint Not less than
70°
Joint 1.6mm (1/16” ) max
Gap varies from
1.6mm (1/16”) to 4.8mm (3/16”)
depending on plate thickness
1.6mm (1/16”)
Not less than
Single Vee Butt Joint 45° Double Vee Butt Joint Not less than
70°
1.6mm (1/16”) max
Lap Joint 1.6mm (1/16”)
Tee Joints
Fillet Joint (Fillet both sides of the
joint)
Corner Weld Edge Joint
Plug Weld Plug Weld
Art # A-07695_AE
Figure 6-10: Typical joint designs for arc welding

6.11 Arc Welding Technique 20°
Art # A-07696_AB
A Word to Beginners
For those who have not yet done any welding, the
simplest way to commence is to run beads on a piece 1.6 mm (1/16”)
of scrap plate. Use mild steel plate about 6.0mm thick
and a 3.2mm electrode. Clean any paint, loose scale or
grease off the plate and set it firmly on the work bench
Figure 6-11: Striking an arc
so that welding can be carried out in the downhand
position. Make sure that the work clamp is making
good electrical contact with the work, either directly 6.14 Arc Length
or through the work table. For light gauge material,
always clamp the work lead directly to the job, oth- The securing of an arc length necessary to produce a
erwise a poor circuit will probably result. neat weld soon becomes almost automatic. You will
find that a long arc produces more heat. A very long
arc produces a crackling or spluttering noise and the
6.12 The Welder weld metal comes across in large, irregular blobs.
The weld bead is flattened and spatter increases. A
Place yourself in a comfortable position before begin-
short arc is essential if a high quality weld is to be
ning to weld. Get a seat of suitable height and do as obtained although if it is too short there is the danger
much work as possible sitting down. Don’t hold your of it being blanketed by slag and the electrode tip being
body tense. A taut attitude of mind and a tensed body solidified in. If this should happen, give the electrode
will soon make you feel tired. Relax and you will find a quick twist back over the weld to detach it. Contact
that the job becomes much easier. You can add much or “touch-weld” electrodes such as Ferrocraft 21 do
to your peace of mind by wearing a leather apron and not stick in this way, and make welding much easier.
gauntlets. You won’t be worrying then about being
burnt or sparks setting alight to your clothes. 6.15 Rate of Travel
Place the work so that the direction of welding is After the arc is struck, your next concern is to maintain
across, rather than to or from, your body. The elec- it, and this requires moving the electrode tip towards
trode holder lead should be clear of any obstruction the molten pool at the same rate as it is melting away.
so that you can move your arm freely along as the At the same time, the electrode has to move along the
electrode burns down. If the lead is slung over your plate to form a bead. The electrode is directed at the
shoulder, it allows greater freedom of movement and weld pool at about 20° from the vertical. The rate of
takes a lot of weight off your hand. Be sure the insula- travel has to be adjusted so that a well-formed bead
is produced.
tion on your cable and electrode holder is not faulty,
otherwise you are risking an electric shock. If the travel is too fast, the bead will be narrow and
strung out and may even be broken up into individual
6.13 Striking the Arc globules. If the travel is too slow, the weld metal piles
up and the bead will be too large.
Practice this on a piece of scrap plate before going on
to more exacting work. You may at first experience 6.16 Making Welded Joints
difficulty due to the tip of the electrode “sticking” to
the work piece. This is caused by making too heavy Having attained some skill in the handling of an elec-
a contact with the work and failing to withdraw the trode, you will be ready to go on to make up welded
electrode quickly enough. A low amperage will accen- joints.
tuate it. This freezing-on of the tip may be overcome by NOTE!
scratching the electrode along the plate surface in the The welding current range values should be
same way as a match is struck. As soon as the arc is used as a guide only. Current delivered to the
established, maintain a 1.6mm to 3.2mm gap between arc is dependent on the welding arc voltage,
the burning electrode end and the parent metal. Draw and as welding arc voltage varies between
the electrode slowly along as it melts down. different classes of electrode, welding current
at any one setting would vary according to the
Another difficulty you may meet is the tendency, after type of electrode in use. The operator should
the arc is struck, to withdraw the electrode so far use the welding current range values as a guide,
that the arc is broken again. A little practice will soon then finally adjust the current setting to suit the
remedy both of these faults. application.

A. Butt Welds purpose to the backing run in securing proper fusion
at the root of the weld.
Set up two plates with their edges parallel, as shown in
Figure 6-12, allowing 1.6mm to 2.4mm gap between B. Fillet Welds
them and tack weld at both ends. This is to prevent
These are welds of approximately triangular cross-
contraction stresses from the cooling weld metal
section made by depositing metal in the corner of
pulling the plates out of alignment. Plates thicker
two faces meeting at right angles. Refer to Figure 6-3.
than 6.0mm should have their mating edges bevelled
to form a 70° to 90° included angle. This allows full A piece of angle iron is a suitable specimen with which
penetration of the weld metal to the root. Using a to begin, or two lengths of strip steel may be tacked
3.2mm Ferrocraft 21 electrode at 100 amps, deposit together at right angles. Using a 3.2mm Ferrocraft 21
a run of weld metal on the bottom of the joint. electrode at 100 amps, position angle iron with one
leg horizontal and the other vertical. This is known
Do not weave the electrode, but maintain a steady
as a horizontal-vertical (HV) fillet. Strike the arc and
rate of travel along the joint sufficient to produce a
immediately bring the electrode to a position perpen-
well-formed bead. At first you may notice a tendency
dicular to the line of the fillet and about 45° from the
for undercut to form, but keeping the arc length short,
vertical. Some electrodes require to be sloped about
the angle of the electrode at about 20° from vertical,
20° away from the perpendicular position to prevent
and the rate of travel not too fast, will help eliminate
slag from running ahead of the weld. Refer to Figure
this. The electrode needs to be moved along fast
6-14. Do not attempt to build up much larger than
enough to prevent the slag pool from getting ahead
6.4mm width with a 3.2mm electrode, otherwise
of the arc. To complete the joint in thin plate, turn the
the weld metal tends to sag towards the base, and
job over, clean the slag out of the back and deposit
undercut forms on the vertical leg. Multi-runs can be
a similar weld.
made as shown in Figure 6-15. Weaving in HV fillet
20°-30°
welds is undesirable.
Electrode Tack Weld
45° from
vertical
60° - 70° from line

Tack Weld
Art # A-07697_AB of weld
Figure 6-12: Butt weld
Art # A-07699_AB
Figure 6-14: Electrode position for HV fillet weld
Art # A-07700_AB
Art # A-07698
Figure 6-13: Weld build up sequence 6

3 5
Heavy plate will require several runs to complete the
joint. After completing the first run, chip the slag out 1 2 4
and clean the weld with a wire brush. It is important
to do this to prevent slag being trapped by the second
run. Subsequent runs are then deposited using either Figure 6-15: Multi-runs in HV fillet weld
a weave technique or single beads laid down in the
sequence shown in Figure 6-13. The width of weave
should not be more than three times the core wire
diameter of the electrode. When the joint is completely
filled, the back is either machined, ground or gouged
out to remove slag which may be trapped in the root,
and to prepare a suitable joint for depositing the
backing run. If a backing bar is used, it is not usually
necessary to remove this, since it serves a similar
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron to
your work bench in an upright position. Use a
3.2mm Ferrocraft 21 electrode and set the cur-
rent at 100 amps. Make yourself comfortable
on a seat in front of the job and strike the arc Art # A-07703
in the corner of the fillet. The electrode needs
Figure 6-18: Examples of vertical fillet welds
to be about 10° from the horizontal to enable
a good bead to be deposited. Refer Figure
6-16. Use a short arc, and do not attempt to 2. Vertical Down
weave on the first run. When the first run has The Ferrocraft 21 electrode makes welding in
been completed de-slag the weld deposit and this position particularly easy. Use a 3.2mm
begin the second run at the bottom. This time electrode at 100 amps. The tip of the electrode
a slight weaving motion is necessary to cover is held in light contact with the work and the
the first run and obtain good fusion at the speed of downward travel is regulated so that
edges. At the completion of each side motion, the tip of the electrode just keeps ahead of the
pause for a moment to allow weld metal to slag. The electrode should point upwards at
build up at the edges, otherwise undercut will an angle of about 45°.
form and too much metal will accumulate in
the centre of the weld. Figure 6-17 illustrates 3. Overhead Welds
multi-run technique and Figure 5-18 shows Apart from the rather awkward position nec-
the effects of pausing at the edge of weave essary, overhead welding is not much more
and of weaving too rapidly. difficult that downhand welding. Set up a
Art # A-07701 specimen for overhead welding by first tacking
a length of angle iron at right angles to another
piece of angle iron or a length of waste pipe.
Then tack this to the work bench or hold in a
vice so that the specimen is positioned in the
overhead position as shown in the sketch. The
electrode is held at 45° to the horizontal and
tilted 10° in the line of travel (Figure 6-19). The
tip of the electrode may be touched lightly on
the metal, which helps to give a steady run. A
weave technique is not advisable for overhead
fillet welds. Use a 3.2mm Ferrocraft 12XP
Figure 6-16: Single run vertical fillet weld electrode at 100 amps, and deposit the first
Art # A-07702
run by simply drawing the electrode along at
a steady rate. You will notice that the weld
deposit is rather convex, due to the effect of
gravity before the metal freezes.
Figure 6-17: Multi run vertical fillet weld

B. Expansion and Contraction of Parent Metal in the
Art # A-07704
Fusion Zone:
While welding is proceeding, a relatively small vol-
ume of the adjacent plate material is heated to a
very high temperature and attempts to expand in all
directions. It is able to do this freely at right angles
to the surface of the plate (i.e., “through the weld”),
but when it attempts to expand “across the weld” or
“along the weld”, it meets considerable resistance,
Figure 6-19: Overhead fillet weld and to fulfil the desire for continued expansion, it has
to deform plastically, that is, the metal adjacent to the
6.17 Distortion weld is at a high temperature and hence rather soft,
and, by expanding, pushes against the cooler, harder
Distortion in some degree is present in all forms of
metal further away, and tends to bulge (or is “upset”).
welding. In many cases it is so small that it is barely
When the weld area begins to cool, the “upset” metal
perceptible, but in other cases allowance has to be
attempts to contract as much as it expanded, but,
made before welding commences for the distortion
because it has been “upset”, it does not resume its
that will subsequently occur. The study of distortion is
former shape, and the contraction of the new shape
so complex that only a brief outline can be attempted
exerts a strong pull on adjacent metal. Several things
hear.
can then happen.
6.18 The Cause of Distortion The metal in the weld area is stretched (plastic defor-
mation), the job may be pulled out of shape by the
Distortion is cause by: powerful contraction stresses (distortion), or the weld
A. Contraction of Weld Metal: may crack, in any case, there will remain “locked-up”
stresses in the job. Figures 6-20 and 6-21 illustrate
Molten steel shrinks approximately 11 per cent in how distortion is created.
volume on cooling to room temperature. This means Weld Upsetting
Art # A-07705_AB
that a cube of molten metal would contract approxi-
mately 2.2 per cent in each of its three dimensions. Expansion with
compression
In a welded joint, the metal becomes attached to the
Hot Cool
side of the joint and cannot contract freely. Therefore, Hot
cooling causes the weld metal to flow plastically, that

is, the weld itself has to stretch if it is to overcome the Figure 6-20: Parent metal expansion
effect of shrinking volume and still be attached to the
Weld Permanent Upset
edge of the joint. If the restraint is very great, as, for Art # A-07706_AC
example, in a heavy section of plate, the weld metal Contraction

may crack. Even in cases where the weld metal does with tension
not crack, there will still remain stresses “locked-
up” in the structure. If the joint material is relatively
weak, for example, a butt joint in 2.0mm sheet, the Figure 6-21: Parent metal contraction
contracting weld metal may cause the sheet to become
distorted.
6.19 Overcoming Distortion Effects
There are several methods of minimising distortion
effects.
A. Peening
This is done by hammering the weld while it is still
hot. The weld metal is flattened slightly and because of
this the tensile stresses are reduced a little. The effect
of peening is relatively shallow, and is not advisable
on the last layer.

B. Distribution of Stresses Art # A-07709
Distortion may be reduced by selecting a welding

sequence which will distribute the stresses suitably
so that they tend to cancel each other out. See Figures
6-25 through 6-28 for various weld sequences. Choice
of a suitable weld sequence is probably the most ef-
fective method of overcoming distortion, although an
unsuitable sequence may exaggerate it. Simultaneous
welding of both sides of a joint by two welders is often
successful in eliminating distortion.
C. Restraint of Parts
Figure 6-24: Examples of distortion
Forcible restraint of the components being welded is
often used to prevent distortion. Jigs, positions, and 3
tack welds are methods employed with this in view. 1
2
D. Presetting
It is possible in some cases to tell from past experi-
ence or to find by trial and error (or less frequently, Art # A-07710_AB
Block Sequence.
to calculate) how much distortion will take place in a The spaces between the welds are
filled in when the welds are cool.
given welded structure. By correct pre-setting of the
components to be welded, constructional stresses Figure 6-25: Welding sequence
can be made to pull the parts into correct alignment.
A simple example is shown in Figure 6-22.
1
E. Preheating 2
3
Suitable preheating of parts of the structure other 4
than the area to be welded can be sometimes used to
reduce distortion. Figure 6-23 shows a simple applica-
tion. By removing the heating source from b and c as
soon as welding is completed, the sections b and c Art # A-07711_AB
will contract at a similar rate, thus reducing distortion.
Figure 6-26: Step back sequence
Art # A-07712
Art # A-07707
Figure 6-22: Principle of presetting
Art # A-07708
Figure 6-27: Chain intermittent welding
B C
Art # A-07713_AB
Preheat Preheat
Weld
Dotted lines show effect if no preheat is used
Figure 6-23: Reduction of distortion by preheating
Figure 6-28: Staggered intermittent welding

6.20 Welding Problems
Description Possible Cause Remedy
1 Gas pockets or voids in weld metal A Electrodes are damp A Dry electrodes before use
(Porosity)
　　 B Welding current is too high B Reduce welding current
　　 C Surface impurities such as oil, C Clean joint before welding
grease, paint, etc
2 Crack occurring in weld metal soon A Rigidity of joint A Redesign to relieve weld
after solidification commences 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 A Welding current is too low A Increase welding current
metal to fill the root of the weld
　　 B Electrode too large for joint B Use smaller diameter
electrode
　　 C Insufficient gap C Allow wider gap
　　 D Incorrect sequence D Use correct build-up
sequence
Art # A-05866_AC
Incorrect Sequence
Insufficient Gap
Figure 6-29: Example of Insufficient Gap or Incorrect Sequence

4 Portions of the weld run do not fuse A Small electrodes used on A Use larger electrodes and
to the surface of the metal or edge of heavy cold plate preheat the plate
the joint
B Welding current is too low B Increase welding current
C Wrong electrode angle C Adjust angle so the welding

arc is directed more into the
base metal
D Travel speed of electrode is D Reduce travel speed of
too high electrode
E Scale or dirt on joint surface E Clean surface before
welding

Lack of fusion caused by dirt,
electrode angle incorrect,
rate of travel too high
Art # A-05867_AC Lack of

inter-run fusion
Lack of side fusion,
scale dirt, small electrode,
amperage too low Lack of root fusion
Figure 6-30: Example of Lack of Fusion
5 A groove has been formed in the base A Welding current is too high. A Reduce welding current
metal adjacent to the toe of a weld
and has not been filled by the weld
metal (undercut).
　　 B Welding arc is too long. B Reduce the length of the
welding arc
　　 C Angle of the electrode is C Electrode should not be
incorrect. inclined less than 45° to the
vertical face
　　 D Joint preparation does not D Allow more room in joint
allow correct electrode angle. for manipulation of the
electrode.
　 E Electrode too large for joint. E Use smaller gauge
electrode.
F Insufficient deposit time at F
Pause for a moment at
edge of weave.
edge of weave to allow weld
　　 metal build-up.
Art # A-07714
Figure 6-31: Examples of undercut

6 Non-metallic particles are trapped in A Non-metallic particles may A If bad undercut is present,
the weld metal (slag inclusion) be trapped in undercut from clean slag out and cover
previous run with a run from a smaller
diameter electrode
　　 B Joint preparation too B Allow for adequate

restricted penetration and room for
cleaning out the slag
　　 C Irregular deposits allow slag C If very bad, chip or grind
to be trapped out irregularities
　　 D Lack of penetration with slag D Use smaller electrode with
trapped beneath weld bead sufficient current to give
adequate penetration. Use
suitable tools to remove all
slag from corners
　　 E Rust or mill scale is E Clean joint before welding

preventing full fusion
F Wrong electrode for position F Use electrodes designed for
in which welding is done position in which welding
is done, otherwise proper
control of slag is difficult
　　
Slag
trapped in
undercut
Not cleaned,
or incorrect
electrode
Slag trapped in root
Art # A-05868_AC
Figure 6-32: Examples of Slag Inclusion

Table 6-2: Welding Problems


SECTION 7:
TIG (GTAW) WELDING
7.01 Shielding Gas Regulator/Flowmeter Operating Instructions
WARNING
! This equipment is designed for use with welding grade (Inert) shielding gases only.
Shielding Gas Regulator/Flowmeter Safety

This regulator/flowmeter 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/flowmeters are listed below.
1. NEVER subject the regulator/flowmeter to inlet pressure greater than its rated inlet pressure.
2. NEVER pressurize a regulator/flowmeter 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/flowmeter until
the gas pressure has been relieved. Under pressure, gas can dangerously propel a loose part.
3. DO NOT remove the regulator/flowmeter from a cylinder without first closing the cylinder valve and
releasing gas in the regulator/flowmeter high and low pressure chambers.
4. DO NOT use the regulator/flowmeter 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
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.
CAUTION
! Match regulator/flowmeter to cylinder. NEVER CONNECT a regulator/flowmeter designed for a particular gas or gases to
a cylinder containing any other gas.
Art: A-05087
Figure 7-1: Fit Regulator/flowmeter to Cylinder
0-5492 7-1 TIG (GTAW) Welding

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/flowmeter.
Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of
ignition. Wipe with a clean lint free cloth.
2. Match regulator/flowmeter to cylinder. Before connecting, check that the regulator/flowmeter label
and cylinder marking agree and that the regulator/flowmeter inlet and cylinder outlet match. NEVER
CONNECT a regulator/flowmeter designed for a particular gas or gases to a cylinder containing any
other gas.
3. Connect the regulator/flowmeter inlet connection to cylinder or pipeline and tighten it firmly but not
excessively, with a suitable spanner.
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/
flowmeter is not fitted with a pressure relief device.
Operation
With the regulator/flowmeter connected to cylinder or pipeline, and the adjustment screw/knob fully disen-
gaged, pressurize as follows:
1. Stand to one side of regulator/flowmeter and slowly open the cylinder valve. If opened quickly, a sudden
pressure surge may damage internal regulator/flowmeter parts.
2. With valves on downstream equipment closed, adjust regulator/flowmeter to approximate working
pressure. It is recommended that testing for leaks at the regulator/flowmeter 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/
flowmeter by individually opening then closing the equipment control valves. Complete purging may
take up to ten seconds or more, depending upon the length and size of the hose being purged.
Adjusting Flow Rate
Art: A-05088_AB
Figure 7-2: Adjust Flow Rate
With the regulator/flowmeter ready for operation, adjust working flow rate as follows:
1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required
flow rate.
NOTE!
It may be necessary to re-check the shielding gas regulator/flowmeter flow rate following the first weld sequence due to
back pressure present within shielding gas hose assembly.
2. To reduce flow rate, allow the welding grade shielding gas to discharge from regulator/flowmeter by
opening the downstream valve. Bleed welding grade shielding gas into a well ventilated area and away
TIG (GTAW) Welding 7-2 0-5492

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/flowmeter is not in use. To shut down for extended periods (more
than 30 minutes).
1. Close cylinder or upstream valve tightly.
2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away
from any ignition source.
3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.
4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove
regulators/flowmeters.
7.02 Setup For Lift TIG (GTAW) Welding

A. Select Lift TIG mode with the process selection control (refer to Section 4.02.1 for further information).
B. Connect the TIG Torch to the negative welding terminal (-). Refer to Note below for Optional TIG Torch
information. Welding current flows from the power source via Dinse type terminals. It is essential,
C. For WeldSkill 155 use Tig Torch W7003021. Refer to Table 2-2 on Page 2-6 for Options and accessories.
There are two TIG Torch options for WeldSkill 185. Refer to Table 2-2 on Page 2-6 for Options and
accessories.
For WeldSkill 185, connect the TIG torch trigger switch and remote current control if applicable via
the 8 pin socket located on the front of the Power Source. The TIG torch will require a trigger switch
to weld in LIFT TIG Mode.
D. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power Source
via Dinse type terminals. It is essential, however, that the male plug is inserted and turned securely to
achieve a sound electrical connection.
E. Connect the Argon Regulator/Flowmeter to the Welding Grade Argon Shielding Gas Cylinder then
connect the TIG Torch gas hose to regulator. Before turning on shielding gas check that all fittings are
tight and the gas valve on the TIG torch is turned off. Before commencing to TIG weld open TIG torch
gas valve to allow sufficient shielding gas flow when welding. Refer to Section 7.03 for recommended
Shielding Gas flow rates and other TIG Welding information.
WARNING
! Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary
support to prevent falling or tipping.
Open Gas Cylinder Valve carefully.

WARNING
! Before connecting the work clamp to the work piece and inserting the electrode in the TIG torch make sure the Mains
power supply is switched off.
CAUTION
! Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.
NOTE!
The TIG Torch is NOT supplied. It is an optional accessory. Refer to Table 2-2 on Page 2-6 for optional accessory informa-
tion.
Refer over page to Lift TIG Welding Setup diagrams.

NOTE!
If the TIG torch has a trigger switch or a remote TIG torch current control fitted then it will require to be connected to the 8
pin socket. (Refer to section 4.02.12 Remote Control Socket for further information)..
Shielding Gas Regulator/Flowmeter
240VAC
10A
Shielding Gas Cylinder Mains Supply
Mig Torch Polarity Lead not connected

Negative Welding Terminal (-)

Work Lead
Art # A-13440
TIG Torch
Figure 7-3: Setup For Lift TIG (GTAW) Welding for WeldSkill 155
240VAC 10A
Mains Supply
Shielding Gas Regulator/Flowmeter
Shielding Gas Cylinder
Negative Welding
Mig Torch Polarity Lead not connected Terminal (-)
8 Pin Socket
Work Lead
Art # A-13439
TIG Torch
Figure 7-4: Setup For Lift TIG (GTAW) Welding for WeldSkill 185

7.03 TIG (GTAW) Basic Welding Technique
Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a weld-
ing process in which fusion is produced by an electric arc that is established between a single tungsten
(non-consumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas
or welding grade shielding gas mixture which is generally Argon based. A filler metal may also be added
manually in some circumstances depending on the welding application.
Art # A-09658_AC
Gas Cup
Either Ceramic,
Work Piece High-lmpact or
Can Be Any Commercial Water Cooled
Metal Metal
Tungsten Electrode
Non-Consumable
Welds Made With or Without
Inert Gas
Addition of Filler Metal
Shields Electrode
and Weld Puddle
Figure 7-5: TIG Welding Application Shot
Tungsten Electrode Current Ranges

Electrode Diameter DC Current (Amps)
0.040” (1.0mm) 30-60
1/16” (1.6mm) 60-115
3/32” (2.4mm) 100-165
1/8” (3.2mm) 135-200
5/32” (4.0mm) 190-280
3/16” (4.8mm) 250-340
Table 7-1: Current Ranges for Various Tungsten Electrode Sizes
Guide for Selecting Filler Wire Diameter

Filler Wire Diameter DC Current Range (Amps)
1/16” (1.6mm) 20-90
3/32” (2.4mm) 65-115
1/8” (3.2mm) 100-165
3/16” (4.8mm) 200-350
Table 7-2: Filler Wire Selection Guide
NOTE!
The operator should use the welding current range values as a guide only, then finally adjust the current setting to suit
the application.

Tungsten Electrode Types
Electrode Type
Welding Application Features Colour Code
(Ground Finish)
AC & DC welding of mild Longer life, More stable

steel, stainless steel, copper, arc, Easier starting, Wider
Ceriated 2% Grey
aluminium, magnesium and their current range, Narrower more
alloys concentrated arc.
Table 7-3
TIG Welding Filler Rods

Comweld Aust Std AWS Std Part No. Part No. Part No. Type/Application
Rod 1.6mm 2.4mm 3.2mm
LW1 R4 ER70S-4 321411 — — For mild-medium strength steels.
LW1-6 R6 ER70S-6 321417 — — Pipes, tubing, roll cages, etc.
Supersteel R2 ER70S-2 321370 — —
CrMo1 RB2 ER80S-B2 — 321379 — For welding of high strength
CrMo2 RB3 ER90S-B3 — 321383 — Cr-Mo steels used at elevated
temperatures.
308L R308L ER308L 321406 321407 — For stainless steels. Stainless pipes,
309L R309L ER309L 321403 321404 — tubing, architectural uses, etc.
316L R316L ER316L 321400 321401 —
Table 7-4
Base Metal DC Current DC Current Tungsten Filler Rod Argon Gas Joint Type
Thickness for Mild for Stainless Electrode Diameter (if Flow Rate
Steel Steel Diameter required) Litres/min
0.040” 35-45 20-30 0.040” 1/16” 5-7 Butt/Corner
1.0mm 40-50 25-35 1.0mm 1.6mm Lap/Fillet
0.045” 45-55 30-45 0.040” 1/16” 5-7 Butt/Corner
1/16” 60-70 40-60 1/16” 1/16” 7 Butt/Corner
1/8” 80-100 65-85 1/16” 3/32” 7 Butt/Corner
3/16” 115-135 100-125 3/32” 1/8” 10 Butt/Corner
1/4” 160-175 135-160 1/8” 5/32” 10 Butt/Corner
Table 7-5
TIG Welding is generally regarded as a specialised process that requires operator competency. While many of
the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG
Welding process is outside the scope of this Operating Manual. For further information please refer to www.
cigweld.com.au or contact Cigweld.

7.04 TIG (GTAW) Welding Problems
FAULT CAUSE REMEDY
1 Excessive bead build up or Welding current is too Increase weld current and/or faulty joint
poor penetration or poor low preparation.
fusion at edges of weld.
2 Weld bead too wide and Welding current is too Decrease weld current.
flat or undercut at edges high
of weld or excessive burn
through.
3 Weld bead too small or Travel speed too fast Reduce travel speed.
insufficient penetration or
ripples in bead are widely
spaced apart.
4 Weld bead too wide or Travel speed too slow Increase travel speed.
excessive bead build up or
excessive penetration in
butt joint.
5 Uneven leg length in fillet Wrong placement of Re-position filler rod.
joint filler rod
6 Electrode melts or oxidises A Torch lead connected A Connect torch lead to negative welding
when an arc is struck. to positive welding terminal.
terminal.
B No shielding gas B Check the shielding gas lines for kinks
flowing to welding or breaks and shielding gas cylinder
region. contents.
C Torch is clogged with C Clean torch.
dust or dirt.
D Shielding gas hose is D Replace shielding gas hose.
damaged.
E Shielding gas regulator E Turn On Shielding Gas and adjust
turned off. Shielding Gas flow rate for the welding
job. Refer to Table 7-5 on Page 7-7.
F The electrode is too F Increase electrode diameter or reduce the
small for the welding welding current.
current.
7 Dirty weld pool A Electrode contaminated A Clean the electrode by grinding off the
by contact with work contaminates.
piece or filler rod
material.
B Work piece surface has B Clean surface.
foreign material on it.
C Shielding gas C Check shielding gas lines for cuts and
contaminated with air. loose fitting or change shielding gas
cylinder.
8 Poor weld finish Inadequate shielding Increase shielding gas flow or check
gas. shielding gas line for shielding gas flow
problems.

FAULT CAUSE REMEDY
9 Arc start is not smooth. A Tungsten electrode A Select the right size tungsten electrode.
is too large for the Refer to Table 7-1 Cigweld Tungsten
welding current. Electrode Selection Chart.
B The wrong electrode B Select the right size tungsten electrode
is being used for the type. Refer to Table 7-1 Cigweld Tungsten
welding job. Electrode Selection Chart.
C Shielding gas flow rate C Select the right shielding gas flow rate
is too high. for the welding job. Refer to Table 7-5 on
page 7-7
D Incorrect shielding gas D Select the correct shielding gas.
is being used.
E Poor work clamp E Improve connection to work piece.
connection to work
piece.
10 Arc flutters during TIG Tungsten electrode Select the right size tungsten electrode.
welding. is too large for the Refer to Table 7-1 Cigweld Tungsten
welding current. Electrode Selection Chart.
Table 7-6: TIG (GTAW) Welding Problems

SECTION 8:
ROUTINE SERVICE REQUIREMENTS AND POWER SOURCE
PROBLEMS
8.01 Routine Maintenance & 8.02 Cleaning the Welding Power
Inspection Source
WARNING WARNING
There are extremely dangerous voltage and There are extremely dangerous voltage and
power levels present inside this product. Do power levels present inside this product. Do
not attempt to open or repair unless you are a not attempt to open or repair unless you are a
qualified electrical tradesperson. Disconnect the qualified electrical tradesperson. Disconnect the
Welding Power Source from the Mains Supply Welding Power Source from the Mains Supply
Voltage before disassembling. Voltage before disassembling.
Welding equipment should be regularly checked by a To clean the Welding Power Source, open the en-
qualified electrical tradesperson to ensure that: closure and use a vacuum cleaner to remove any
accumulated dirt, metal filings, slag and loose mate-
• The main earth wire of the electrical installation rial. Keep the shunt and lead screw surfaces clean as
is intact. accumulated foreign material may reduce the welders
• Power point for the Welding Power Source is output welding current.
effectively earthed and of adequate current rat- CAUTION
ing.
• Plugs and cord extension sockets are correctly
! Do not use compressed air to clean the Welding
Power Source. Compressed air can force metal
wired. particles to lodge between live electrical parts
• Flexible cord is of the 3-core tough rubber or and earthed metal parts within the Welding
plastic sheathed type of adequate rating, cor- Power Source. This may result in arcing between
rectly connected and in good condition. this parts and their eventual failure.
• Welding terminals are shrouded to prevent
inadvertent contact or short circuit.
8.03 Cleaning the Feed Rolls
• The frame of the Welding Power Source is ef- Clean the grooves in the drive rolls frequently. This
fectively earthed. can be done by using a small wire brush. Also wipe
off or clean the grooves on the upper feed roll. After
• Welding leads and electrode holder are in good
cleaning, tighten the feed roll retaining knobs.
condition.
• The Welding Power Source is clean internally, 8.04 Basic Troubleshooting
especially from metal filing, slag, and loose ma-
terial. If any parts are damaged for any reason, WARNING
replacement is recommended. There are extremely dangerous voltage and
power levels present inside this product. Do not
attempt to open or repair unless you are a quali-
fied electrical tradesperson and you have had
training in power measurements and trouble-
shooting techniques.
If major complex subassemblies are faulty, then the
Welding Power Source must be returned to an Ac-
credited CIGWELD Service Agent for repair.
The basic level of troubleshooting is that which can be
performed without special equipment or knowledge.
0-5492 8-1 SERVICE

8.05 Welding Power Source Problems
PROBLEM CAUSE REMEDY
1 Mains Supply Voltage is A Power source is not in the A Set the power source to MIG
On, the On/Off switch on correct mode of operation. mode. Refer to Section 4.02.1.
the rear panel is in the On
position and the Power B MIG Torch Polarity Lead is B Connect the MIG Torch Polarity
indicator on the front panel not connected. Lead to the positive or negative
is illuminated however the output terminal. Refer to
power source will not MIG Section 4.02.11.
weld.
C Work Lead is not C Ensure that the Work Lead is
connected to the work connected to the work piece
piece. and has a good connection to
the work piece. Refer to Set Up
for MIG Section 5.09 or 5.10.
D MIG torch is not correctly D Ensure that the MIG torch is
connected to the Euro correctly connected to the Euro
Style MIG Torch Adaptor. Style MIG Torch Adaptor. Refer
to Section 4.02.5 & 5.02.
2 Mains Supply Voltage is A Power source is not in the A Set the power source to STICK
On, the On/Off switch on correct mode of operation. mode. Refer to Section 4.02.1.
the rear panel is in the On
position and the Power B Work Lead is not B Ensure that the Work Lead is
indicator on the front panel connected to the work connected to the work piece
is illuminated however piece. and has a good connection to
the power source will not the work piece.
STICK weld.
3 Mains Supply Voltage is A Power source is not in the A Set the power source to LIFT
On, the On/Off switch on correct mode of operation. TIG mode. Refer to Section
the rear panel is in the On 4.02.1.
position and the Power B Work Lead is not B Ensure that the Work Lead is
indicator on the front panel connected to the work connected to the work piece
is illuminated however the piece. and has a good connection to
power source will not TIG the work piece.
weld.
C TIG Torch 8 Pin Control C Connect 8 Pin TIG Torch control
Plug not connected plug securely and correctly to
correctly or loose/faulty the 8 Pin control socket of the
connection in plug. front of the Transmig 175i+
(WeldSkill 185 only) Power Source. (WeldSkill 185
only)
Repair or replace if faulty.
(WeldSkill 185 only)
D Faulty TIG Torch Trigger. D Repair or replace TIG Torch
(WeldSkill 185 only) Trigger switch/lead.
SERVICE 8-2 0-5492

4 Mains Supply Voltage is This may occur due to If this occurs leave the Power
On, the On/Off switch in the activation of an in- Source On/Off switch in the Off
the rear panel is in the On built protective device position for several minutes to
position but the Power if the Power Source is allow the protective device to
On indicator on the front repeatedly switched On reset.
panel is Not illuminated then Off rapidly or the
and the digital displays on supply to the Power
the front panel are also not Source is switched On
illuminated and the power then Off rapidly.
source will not weld.
5 Over Temp Indicator is Duty cycle of power source Leave the power source
illuminated and unit will has been exceeded. switched ON and allow it to
not commence welding cool. Note that Over Temp
when the torch trigger indicator must be extinguished
switch is depressed. prior to commencement of
welding.
6 Unit will not feed wire in A Incorrect Feed Roll fitted A Fit the correct feed roll for MIG
MIG mode. for wire type being used. wire type being used. Refer to
(WeldSkill 185 only) section 2.11 for optional feed
rolls available and Section
5.07 for feed roll fitting details.
(WeldSkill 185 only)
B Pressure Roller Arm is B Secure Pressure Roller in the
not secured in the down down position and ensure that
position or not correctly it is correctly adjusted. Refer to
adjusted. Section 5.05 and 5.06.
C Electrode wire stuck in C Check for clogged / kinked MIG
conduit liner or contact tip torch conduit liner or worn
(burn-back jam). contact tip. Replace faulty
components.
D Internal fault in power D Have an Accredited CIGWELD
source Service Provider investigate the
fault.
7 Welding wire continues to A Trigger mode selection A Change the trigger mode
feed when torch trigger is switch is in 4T latch mode. selection switch from 4T latch
released. mode to 2T normal mode.
B Torch trigger leads B Repair or replace torch trigger
shorted. switch/lead.
8 Welding arc cannot be A MIG torch polarity lead A Connect the MIG torch polarity
established in MIG mode. is not connected into a lead to either the positive
welding output terminal. welding output terminal or
the negative welding output
terminal as required.
B Poor or no work lead B Clean work clamp area and
contact. ensure good electrical contact.
0-5492 8-3 SERVICE

9 Inconsistent wire feed. A Worn or dirty contact tip. A Replace if necessary.
B Worn feed roll. B Replace.
C Excessive brake tension on C Reduce brake tension on spool

wire reel hub. hub
D Worn, kinked or dirty D Clean or replace conduit liner
conduit liner
10 No gas flow in MIG mode. A Gas hose is damaged. A Replace or repair.
B Gas passage contains B Disconnect gas hose from

impurities. the rear of power source
or wirefeeder and blow out
impurities.
C Gas regulator turned off. C Turn on regulator.
D Empty gas cylinder. D Replace gas cylinder.
11 Gas flow continues after Gas valve has jammed Have an accredited CIGWELD
the torch trigger switch open due to impurities in service provider repair or
has been released (MIG the gas or the gas line. replace gas valve.
mode).
12 Power indicator will not The mains supply voltage Ensure that the mains supply
illuminate and welding arc has exceeded voltage voltage is within 240VAC ±
cannot be established. limits of the power source. 15%.
13 TIG electrode melts when TIG torch is connected to Connect the TIG torch to the (-)
arc is struck. the (+) VE terminal. VE terminal.
14 Arc flutters during TIG Tungsten electrode is Select the correct size of
welding. too large for the welding tungsten electrode. Refer to
current. Table 6-1.
Table 8-1
SERVICE 8-4 0-5492

SECTION 9: KEY SPARE PARTS
9.01 WeldSkill 155 Key Spare Parts
7
4
2 8
Art # A-13452
Figure 9-1
WELDSKILL 155 POWER SOURCE KEY SPARE PARTS

ITEM PART NUMBER DESCRIPTION
1 W7006865 PCBA Power Inverter
2 W7006866 PCBA Front Panel
3 W7006806 PCBA EMC Filter
4 W7006867 Fan Assembly
5 W7006868 Wire Drive Assembly
6 W7006869 Gas Solenoid Valve 24VDC
7 W7006870 Spool Hub Assembly
8 W7006884 PCBA Wire Feed Filter
Table 9-1
0-5492 9-1 KEY SPARE PARTS

9.02 WeldSkill 185 Key Spare Parts
7
4
8
2
Art # A-13451
Figure 9-2
WELDSKILL 185 POWER SOURCE KEY SPARE PARTS

ITEM PART NUMBER DESCRIPTION
1 W7006880 PCBA Power Inverter
2 W7006881 PCBA Front Panel
3 W7006806 PCBA EMC Filter
4 W7006867 Fan Assembly
5 W7006868 Wire Drive Assembly
6 W7006869 Gas Solenoid Valve 24VDC
7 W7006870 Spool Hub Assembly
8 W7006884 PCBA Wire Feed Filter
Table 9-2
KEY SPARE PARTS 9-2 0-5492

9.03 E-180 MIG Torch 3m (P/N W4018800) Key Spare Parts
5
3 4
1 2
6
Figure 9-3
MIG TORCH KEY SPARE PARTS

ITEM
Art # A-13453
PART NUMBER DESCRIPTION
1 W6000600 Nozzle
2 OTW11/35/R Contact Tip 0.9mm
3 W6000606 Diffuser
4 W6000607 Conductor Tube
5 W6000608 Trigger Assembly
6 W6000609 Handle Mouldings (includes handle mouldings, screws, cable
support)
WS1240015/R Conduit Liner Steel 5m, 0.6-1.0mm Blue (hard wires)
WS1240031/R Conduit Liner Steel 4m, 1.0-1.2mm Red (hard wires)
7
WS1260026/R Conduit Liner Teflon 4m, 0.8-1.2mm Red (soft wires)
WS0010304/R Jump Liner 1.0-1.2mm
Table 9-3
0-5492 9-3 KEY SPARE PARTS

This page is intentionally blank.
KEY SPARE PARTS 9-4 0-5492

Art # A-13454_AB C1
S1
0-5492
N1
Slow Start Circuit 340V DC R1 R3 R4 R100 R157
A P7 J1/J3 Connect to CN8
EMC Filter Circuit
INPUT D1
Q5 Q6 C18
240V AC RT1 C20 T1 POSITIVE
3 D3
N EMC Board Hall +
G1 R37 R38 G4 R35 R36 L3/L4
RT2 D5 Absorption Circuit

E E1 E4 C4
P5
1 R14 R15
B1 C6
4 C10
C21 C22 C23 C25 C71 M1 D6
240V AC
2
CN1 R43 R44
S1: Power Switch D8
+24V Q8 Q9
1 C33 C34
N1: Filter inductance FS 2
GND 5 D9
RT1/RT2: PTC G3 G2
DC Power Input R55 R60 R56 R57 R23 R28 R29 R32 R158
J1/J3: Relay C12
B1: Rectifier H1 E3 E2
CN7 NEGATIVE
FS: Fan 1 Sample Feedback -
0V
1 2
H1: Local Torch Signal 2
Auxiliary Power Supply
Q5: Magnetic Valve Driving Signal
CN8 Output Current Feedback CN9 1 23
T2
T.r1: Thermostat Q5 CN3 G1 E1 G3 E3 G4 G2 E4 E2 + Red
1
- Yellow
VR4: Burnback 1 2
M Blue Hall
+24V 2 3
WF: Wire Feeder Driving Circuit 0 Black
3 4
Hall: Hall Sensor
CN5 CN5
T2: Auxiliary Inductor 1 1
Q5/Q6/Q8/Q9: IGBT T.r1 2 2
CN6
3 3
T1: Main Transformer 1 4 4 LED1 LED5 LED8 LED9 LED2 LED3 LED4
K2: MIG/TIG/STICK 2 5 5 POWER OVER TEMP VRD-ON VRD-OFF MIG TIG STICK
6 6
7 7
DS1
SCM: Timing Control Interface Circuit 8 8
VR4 CN10 9 9
Display Circuit K2
Wire Feed Circuit 10 10
1
CN5 11 11
2
1 12 12 DS2
+5V
2 13 13
3 14 14 Display Board
4
Main Board VR1 VR2 VR3
5 A1
CN11 1 2 CN12 1 23 CN13 1 23 CN4 1 23 A1
6
A2
7
8 CS
9 DIO CN1
APPENDIX 1: WELDSKILL 155 CIRCUIT DIAGRAM
10 INT2 CN2 VR2: Voltage Adjust

1
11 CLK R43/R44: Discharge Resistor Filter Circuit
2 2 WF VR3: Arc Control
12 A2
C20/R37/R38: Q5 (RC Absorption) M1: Current Transformer 1 3
13 Voltage Adjust D1/D3/D5/D6/D8/D9: FRD
14 Current Adjust C18/R35/R36: Q6 (RC Absorption) DS1: Current Display Filter Board R14/R15/C4/C6/C10: Absorptiong Circuit
C33/R55/R60: Q8 (RC Absorption) DS2: Voltage Display C21/C22/C23/C25/C71: DC Filter Capacitor
C34/R56/R57: Q9 (RC Absorption) VR1: Current Adjust
A-1 APPENDIX
Art # A-13455_AB
C1
S1
N1
Slow Start Circuit 340V DC R1 R3 R4 R100 R157
A P7 J1/J3 Connect to CN8
APPENDIX
EMC Filter Circuit
INPUT D1
Q5 Q6 C18
240V AC RT1 C20 T1 POSITIVE
3 D3
N EMC Board Hall +
G1 R37 R38 G4 R35 R36 L3/L4
RT2 D5 Absorption Circuit

E E1 E4 C4
P5
1 R14 R15
B1 C6
4 C10
C21 C22 C23 C25 C71 M1 D6
240V AC
2
CN1 R43 R44
S1: Power Switch D8
+24V Q8 Q9
1 C33 C34
N1: Filter inductance FS 2
GND 5 D9
RT1/RT2: PTC G3 G2
DC Power Input R55 R60 R56 R57 R23 R28 R29 R32 R158
J1/J3: Relay C12
B1: Rectifier H1 E3 E2
CN7 NEGATIVE
FS: Fan 1 Sample Feedback -
0V
1 2
H1: Local Torch Signal 2
Auxiliary Power Supply
Q5: Magnetic Valve Driving Signal
CN8 Output Current Feedback CN9 1 2 3
T2
T.r1: Thermostat Q5 CN3 G1 E1 G3 E3 G4 G2 E4 E2 + Red
1
- Yellow
VR4: Burnback 1 2
M Blue Hall
+24V 2 3
H2: Avation Socket Driving Circuit 0 Black
A-2
3 4
WF: Wire Feeder
CN5 CN5
S2: Local/Remote Switch 1 1
Hall: Hall Sensor T.r1 2 2
CN6
3 3
T2: Auxiliary Inductor 1 4 4 LED1 LED5 LED8 LED9 LED2 LED3 LED4
Q5/Q6/Q8/Q9: IGBT 2 5 5 POWER OVER TEMP VRD-ON VRD-OFF MIG TIG STICK
6 6
T1: Main Transformer 7 7
DS1
K1: 2T/4T SCM: Timing Control Interface Circuit 8 8 K1
VR4 CN10 9 9
K2: MIG/TIG/STICK Display Circuit
Wire Feed Circuit 10 10
1
11 11
2 K2
12 12 DS2
13 13
14 14 Display Board
Main Board LED6 2T LED7 4T VR1 VR2 VR3
CN5
1 CN11 1 2 CN12 1 2 3 CN13 1 2 3 CN4 1 2 3 A1
+5V
2 A2
3
CN2
4
5 A1 1
6 2 R43/R44: Discharge Resistor M1: Current Transformer
S2
7
1 C20/R37/R38: Q5 (RC Absorption) DS1: Current Display
APPENDIX 2: WELDSKILL 185 CIRCUIT DIAGRAM
8 CS CN1 Filter Circuit

3
9 DIO C18/R35/R36: Q6 (RC Absorption) DS2: Voltage Display
5 1
10 INT2
2 2 C33/R55/R60: Q8 (RC Absorption) VR1: Current Adjust
11 CLK
4 3
12 A2 1 2 3 4 5 6 7 8 C34/R56/R57: Q9 (RC Absorption) VR2: Voltage Adjust
6
13 Voltage Adjust WF
14 H2
Filter Board R14/R15/C4/C6/C10: Absorptiong Circuit VR3: Arc Control
Current Adjust
C21/C22/C23/C25/C71: DC Filter Capacitor D1/D3/D5/D6/D8/D9: FRD
0-5492
CIGWELD - LIMITED WARRANTY TERMS
LIMITED WARRANTY: CIGWELD Pty Ltd, An ESAB Brand, hereafter, “CIGWELD” warrants to customers of its autho-
rized 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, oper-
ated, 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, INDI-
RECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTER-
RUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELD with respect
to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the
manufacture, sale, delivery, resale, or use of any goods covered by or furnished by CIGWELD whether arising out of
contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein,
exceed the price of the goods upon which such liability is based. No employee, agent, or representative of CIGWELD
is authorized to change this warranty in any way or grant any other warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE
USED WHICH IN CIGWELD’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY CIGWELD
PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER
BY NON-AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the
products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than
the time stated plus one year from the date CIGWELD delivered the product to the authorized distributor.
Any claim under this warranty must be made within the warranty period which commences on the date of purchase
of the product. To make a claim under the warranty, take the product (with proof of purchase from a Cigweld Ac-
credited Seller) to the store where you purchased the product or contact Cigweld Customer Care 1300 654 674 for
advice on your nearest Service Provider. CIGWELD reserves the right to request documented evidence of date of
purchase. CIGWELD or our Accredited Distributor must be notified in writing of its claim within seven (7) days of
becoming aware of the basis thereof, and at its own expense returning the goods which are the subject of the claim
to CIGWELD or nominated Accredited Distributor/Accredited Service Provider
This warranty is given.
Cigweld Pty Ltd
A.B.N. 56007226815
71 Gower Street, Preston
Victoria, Australia, 3072
Phone: 1300 654 674
Email: enquiries@cigweld.com.au
Website: www.cigweld.com.au
This warranty is provided in addition to other rights and remedies you have under law: Our goods come with guar-
antees which cannot be excluded under the Australian Consumer Law. You are entitled to replacement or refund
for a major failure and to compensation for other reasonably foreseeable loss or damage. You are also entitled to
have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to
a major failure.
Please note that the information detailed in this statement supersedes any prior published data produced by CIGWELD.
WARRANTY SCHEDULE – WELDSKILL 155 & 185 INVERTERS
WARRANTY WARRANTY PERIOD – (Parts and Labour)
WeldSkill 155 and 185 Inverter Power Source 2 Years
ACCESSORIES WARRANTY PERIOD
MIG torch, electrode holder lead and work lead 3 Months
MIG torch consumable items NIL

Gas regulator/flowmeter (excluding seat assem-
bly, pressure gauges, elastomer seals and "O" 1 Year
rings
Regulator seat assemblies and pressure gauges 6 Months
Elastomer seals and "O" rings used in the equip-
3 Months
ment
CIGWELD Limited Warranty does not apply to;

- Obsolete goods sold at auction, second-hand goods and prototype goods.
- Consumable Parts for MIG, TIG, Plasma welding, Plasma cutting and Oxy fuel torches, O-rings, fuses,
filters or other parts that fail due to normal wear.
Note:
* No employee, agent, or representative of CIGWELD is authorized to change this warranty in any way
or grant any other warranty, and CIGWELD shall not be bound by any such attempt. Correction of non-
conformities, in the manner and time provided herein, constitutes fulfilment of CIGWELD’s obligations to
purchaser with respect to the product.
* This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or ac-
cessories which, in CIGWELD's sole judgment, impaired the safety or performance of any CIGWELD prod-
uct and if the unit is altered or serviced by an unauthorised CIGWELD Service Provider. Purchaser’s rights
under this warranty are void if the product is sold to purchaser by unauthorized persons.
CIGWELD Pty Ltd Malaysia - Indonesia -
CIGWELD An ESAB Brand Lot 151, Jalan Industri 3/5A JL Akasia II Blok A-05 No. 10A
71 Gower Street, Preston VIC 3072 Australia Rawang Integrated Industrial Park, Delta Silicon - Lippo Cikarang
Customer Care: Jln Batu Arang Bekasi, 17550
Tel: 1300 654 674 | Fax: 03 9474 7391 48000 Rawang Selangor Darul Ehsan Indonesia
Email: enquiries@cigweld.com.au West Malaysia
International Enquiries Toll Free: 0 800 1842 867
Tel: +61 3 9474 7508 | Fax: +61 3 9474 7488 Tel: 60 3 6092 2988 | Fax: 60 3 6092 1085 Tel: +62 21 8990 6095 | Fax: +62 21 8990 6096
cigweld.com.au

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Art # A-13435_AB

OUTPUT CURRENT MIG STICK WARRANTY*

155 Inverter W1008155 185 Inverter W1008185

Version No: AB Issue Date: 07-09-2017 Manual No: 0-5492

We have made every effort to provide you with accurate instructions,

YOU ARE IN GOOD COMPANY!

We distinguish ourselves from our competition through market-leading,

Above all, we are committed to develop technologically advanced products

CIGWELD WeldSkill 155 and 185 Welding Inverters

All rights reserved.

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

For Printing Material Specification refer to document 47x1915.

Publication Date: 17-08-2017

Record the following information for Warranty purposes:

Where Purchased: _____________________________________

Purchase Date: _____________________________________

Equipment Serial #: _____________________________________

Type designation etc.

Brand name or trade mark

Manufacturer or his authorised representative established within the EEA

Date Signature Position

25-07-2017 Vice President,

APPENDIX 2: WELDSKILL 185 CIRCUIT DIAGRAM..................................................... A-2

CIGWELD - LIMITED WARRANTY TERMS

WARRANTY SCHEDULE – WELDSKILL 155 & 185 INVERTERS

0-5492 1-1 GENERAL INFORMATION

Recommended Protective Filters for Electric Welding

0-5492 1-3 GENERAL INFORMATION

GENERAL INFORMATION 1-4 0-5492

0-5492 1-5 GENERAL INFORMATION

GENERAL INFORMATION 1-6 0-5492

0-5492 2-1 INTRODUCTION

On Single Phase Wire Feed Function

Wire Feed Towards

Increase/Decrease Remote Purging Of Gas

AC Auxiliary Power % Percentage Spot Weld Mode

Fuse Panel/Local Spot Time

Gas Metal Arc

Gas Tungsten Arc 2 Step Trigger

Negative Constant Current 4 Step Trigger

Direct Current (DC) High Temperature t Burnback Time

Protective Earth Disturbance In

Line Arc Force IPM Inches Per Minute

Line Connection Touch Start (GTAW) MPM Metres Per Minute

Auxiliary Power Variable Inductance Spool Gun

115V 15A Receptacle Rating-

INTRODUCTION 2-2 0-5492

WeldSkill 185 Inverter (Part No. W1008185)

2.06 User Responsibility 2.08 Transporting Methods

INTRODUCTION 2-4 0-5492

0-5492 2-5 INTRODUCTION

210254 CutSkill Argon Regulator/Flowmeter

WSPLIER MIG Pliers

W7004913 Shielding Gas Hose Assembly

W4011501 WeldSkill Welding Equipment Trolley

INTRODUCTION 2-6 0-5492

0-5492 2-7 INTRODUCTION

INTRODUCTION 2-8 0-5492

D. In areas, not subjected to abnormal vibration or

0-5492 3-1 INSTALLATION