CIGWELD WeldSkill 120 Turbo - User Manual

120 Turbo
140 Turbo
Operation Manual
Version No:1 Issue Date: Dec 22, 2006 Manual No: 719527
Operating Features

Summary

Arc Welding Safety Instructions and Warnings

Introduction

2.01 How to Use This Manual

Explains how to navigate and understand the manual's structure and annotations.

2.02 Equipment Identification

Details how to locate and record unit identification numbers like model and serial number.

2.03 Receipt of Equipment

Guides on checking received equipment for completeness and damage, and how to report issues.

Electromagnetic Compatibility

3.01 Installation and use - Users Responsibility

Outlines user responsibility for managing electromagnetic disturbances from welding.

3.02 Assessment of Area

Advises on assessing the environment for potential electromagnetic problems before installation.

General Information

4.01 120 Turbo

Provides general information about the 120 Turbo model, its current range, and electrode usage.

4.02 140 Turbo

Details the 140 Turbo model, its current range, and electrode compatibility for various materials.

4.03 User Responsibility

Clarifies user obligations for proper installation, operation, maintenance, and repairs.

4.04 Duty Cycle

Explains the concept of duty cycle for welding power sources and how it's measured.

Safe Practices For The Use Of Welding Equipment

5.01 Precautions to be Taken by Operators

Lists essential safety precautions for operators during welding operations.

5.02 Personal Protection

Details essential personal protective equipment and clothing for welding safety.

Resuscitation For Electric Shock Victims

6.01 Resuscitation

Provides step-by-step instructions for performing resuscitation on electric shock victims.

Specifications

7.01 120 Turbo and 140 Turbo Specifications

Presents detailed technical specifications for both 120 Turbo and 140 Turbo models.

7.02 Plant Contents

Lists the included items and accessories provided with the welding equipment.

Installation Recommendations

8.01 Environment

Advises on suitable environmental conditions for operating the welding equipment safely.

8.02 Location

Provides guidelines for selecting an appropriate and safe location for the welder.

8.03 Ventilation

Emphasizes the importance of adequate ventilation for safe welding operations.

8.04 Mains Supply Voltage Requirements

Specifies the required mains supply voltage and connection standards for the welder.

8.05 Welding Handshield Assembly

Details the steps for assembling the welding handshield with its components.

Operation

9.01 120 Turbo and 140 Turbo Controls

Describes the function of controls like the ON/OFF switch, overload light, and current control.

Setup For Arc Welding

Arc Welding Electrodes

11.02 Types of Electrodes

Classifies and describes different types of arc welding electrodes and their applications.

11.03 Size of Electrode

Explains how electrode size is determined by metal thickness and welding machine capability.

11.04 Storage of Electrodes

Provides guidance on the proper storage of welding electrodes to maintain their quality.

11.05 Electrode Polarity

Discusses the connection of electrodes and work leads, and where to seek advice.

Arc Welding Practice

12.01 Welding Position

Details various welding positions like flat, horizontal, vertical, and overhead.

12.02 Joint Preparations

Guides on preparing surfaces and joints for welding to ensure sound welds.

Arc Welding Technique

13.01 A Word to Beginners

Offers initial advice for new welders on practicing with scrap metal and basic setup.

13.02 The Welder

Provides tips on adopting a comfortable posture and safe practices for the welder.

13.03 Striking the Arc

Explains the technique for striking an arc and maintaining the correct electrode gap.

13.04 Arc Length

Discusses the importance of maintaining the correct arc length for weld quality.

13.05 Rate of Travel

Details how to adjust the travel speed for optimal weld bead formation.

13.06 Making Welded Joints

Guides on creating welded joints, including butt welds and weld build-up sequences.

Distortion

14.01 The Cause of Distortion

Explains the primary causes of distortion in welding, such as metal contraction.

14.02 Overcoming Distortion Effects

Outlines methods to minimize distortion, including peening, presetting, and preheating.

Routine Maintenance & Inspection

15.01 Cleaning the Welding Power Source

Provides instructions for cleaning the welding power source to maintain performance.

15.02 Face Shield Maintenance

Details the cleaning procedure for the face shield and lens.

Basic Troubleshooting

16.01 Welding Problems

Lists common welding faults, their causes, and remedies for issues like porosity and cracks.

16.02 Welding Power Source Problems

Addresses common power source faults, their causes, and necessary troubleshooting steps.

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

The CIGWELD 120 Turbo and 140 Turbo are compact, portable, fan-cooled Manual Metal Arc Welding (MMAW) machines designed for home handyman use. These welders are suitable for light gauge work, generally less than 3.0mm thick, with the 140 Turbo model also capable of handling 3.2mm electrodes for heavier materials. They operate from a domestic 240V, 10 amp or 15 amp outlet, respectively, and offer infinitely adjustable welding current.

Function Description:

The primary function of these devices is arc welding, a process that joins metals by creating an electric arc between an electrode and the workpiece. This arc generates intense heat, melting the metals to form a weld pool that solidifies into a strong joint. The core wire of the electrode is surrounded by a flux coating, which serves several crucial purposes:

• Gaseous Shield: It provides a protective gaseous shield around the weld metal, preventing contamination from the atmosphere while the metal is molten.
• Arc Stabilization: "Arc stabilisers" within the flux coating help maintain a steady arc, facilitating the flow of current.
• Deoxidation: "Deoxidisers" remove oxygen from the weld metal, improving weld quality.
• Cleansing Action and Slag Cover: The flux provides a cleansing action on the workpiece and forms a protective slag cover over the weld metal. This slag prevents the formation of oxides during solidification and helps produce a bead with the desired contour.
• Alloy Introduction: In special type electrodes, the flux can introduce alloys into the weld deposits, tailoring the weld properties to specific applications.

Usage Features:

The CIGWELD 120 Turbo and 140 Turbo are designed for ease of use, even for beginners.

• Current Control: Welding current is infinitely adjustable, increased by turning the Current Control clockwise and decreased by turning it anti-clockwise. The actual current delivered to the arc depends on the welding arc voltage and electrode type, so the operator should use the range values as a guide and then fine-tune the setting for the specific application.
• Thermal Overload Protection: Both models are equipped with a self-resetting thermostat that protects the welding transformer from overheating. If the overload light illuminates, the user should wait for it to extinguish before resuming welding.
• Electrode Compatibility: These welders run standard general-purpose electrodes. The 120 Turbo uses 2.5mm electrodes, while the 140 Turbo can handle both 2.5mm and 3.2mm electrodes. The choice of electrode size is crucial and depends on the thickness of the metals being joined. Smaller electrodes are used for thinner sections to prevent burn-through, while larger electrodes are suitable for heavier materials.
• Welding Positions: The electrodes dealt with in the manual are suitable for welding in various positions, including flat (downhand butt weld, gravity fillet weld), horizontal (butt weld, horizontal-vertical fillet weld), vertical (vertical up, vertical down), and overhead (butt weld, fillet weld).
• Joint Preparation: For most steel sections, no special preparation is needed. However, for heavier sections or repair work on castings, cutting or grinding an angle between the pieces is necessary to ensure proper penetration and sound joints. Surfaces to be welded should be clean and free of rust, scale, dirt, and grease. Slag should be removed from oxy-cut surfaces.
• Arc Striking and Maintenance: Beginners are advised to practice striking the arc on scrap metal. The "scratching" method (like striking a match) is recommended. Once the arc is established, a gap of 1.6mm to 3.2mm should be maintained between the electrode and the parent metal, and the electrode should be drawn slowly as it melts. Maintaining a short arc is essential for quality welds, while a long arc can lead to crackling, spluttering, and irregular weld beads. The electrode should be directed at the weld pool at about 20° from the vertical, and the travel rate adjusted to produce a well-formed bead.
• Distortion Control: Welding inherently causes some degree of distortion. Methods to minimize this include distributing stresses through suitable welding sequences, forcibly restraining parts with jigs or tack welds, presetting components to counteract anticipated distortion, and preheating parts of the structure away from the weld area. Peening (hammering the hot weld) can also reduce tensile stresses, though its effect is relatively shallow.

Maintenance Features:

Routine maintenance is crucial for ensuring the safe and efficient operation of the CIGWELD 120 Turbo and 140 Turbo.

• Regular Electrical Checks: Welding equipment should be regularly checked by a qualified electrical tradesperson to ensure the integrity of the main earth wire, proper earthing and current rating of the power point, correct wiring of plugs and cord extension sockets, and good condition of the flexible supply cord.
• Terminal and Lead Inspection: Welding terminals should be shrouded to prevent inadvertent contact or short circuits. Welding leads and the electrode holder must be in good condition.
• Internal Cleaning: The Welding Power Source should be cleaned internally, especially from metal filings, slag, and loose material. A vacuum cleaner is recommended for this task. It is important not to use compressed air, as it can force metal particles between live and earthed electrical parts, potentially leading to arcing and failure. Keeping shunt and lead screw surfaces clean helps maintain the welder's output current.
• Face Shield Maintenance: The face shield and its lens should be cleaned with a soft cloth after each use. The protective filter lenses reduce harmful radiation, and an external clear cover lens protects them from molten or hard particles. This cover lens should always be in place and replaced if damage impairs vision.
• Damaged Parts: Any parts that are broken, missing, plainly worn, distorted, or contaminated should be replaced immediately. Repairs should be carried out by appropriately qualified persons approved by CIGWELD. Unauthorized modifications to the equipment are not recommended and can void the warranty.
• Electrode Storage: Electrodes should always be stored in a dry place and in their original containers to maintain their quality and performance.

CIGWELD WeldSkill 120 Turbo Specifications

General

Welding Current Range	20 - 120A
Weight	4.5kg
Dimensions	300 x 130 x 210mm
Protection Class	IP21S
No Load Voltage	48V
Welding Process	MMA (Stick)
Electrode Size Range	1.6 - 3.2 mm
Input Voltage	240V
Duty Cycle	20% at 120A
Protection Rating	IP21