Cigweldaeb Weldskill 250, 350 & Weldskill 4r Wirefeeder 0-5182 - Ae

250
WELDSKILL
350 MIG WELDING MACHINE
4R WIREFEEDER (Optional)
Operating Manual
Art # A-09908_AB
Version No: AE Issue Date: December 27,2013 Manual No.: 0-5182

Operating Features:
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new CIGWELD product. We are proud to
have you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service provider call +1300 654 674, or visit
us on the web at www.victortechnologies.com
This Operating Manual has been designed to instruct you on the

correct use and operation of your CIGWELD product. Your satisfaction
with this product and its safe operation is our ultimate concern.
Therefore please take the time to read the entire manual, especially
the Safety Precautions. They will help you to avoid potential hazards
that may exist when working with this product.
YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.
CIGWELD is the Market Leading Brand of Arc Welding Products for
Victor Technologies. We are a mainline supplier to major welding
industry sectors in the Asia Pacific and emerging global markets
including; Manufacturing, Construction, Mining, Automotive,
Engineering, Rural and DIY.
We distinguish ourselves from our competition through 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.
Welding Power Supply

Operating Manual Number 0-5182 for:
WeldSkill 250 Compact MIG Plant (Asia) Part Number W1003400

WeldSkill 350 Compact MIG Plant (Asia) Part Number W1003500
WeldSkill 250 Compact MIG Plant (South Pacific) Part Number W1004500
WeldSkill 350 Compact MIG Plant (South Pacific) Part Number W1004600
WeldSkill 4R Wirefeeder Plant (Optional-All Regions) Part Number W3000401
Published by:
CIGWELD Pty Ltd
71 Gower Street
Preston, Victoria, Australia, 3072
www.victortechnologies.com
Copyright 2011, 2012, 2013 by CIGWELD
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the pub-
lisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: March 10, 2011

Version AE Date: December 27, 2013
Record the following information for Warranty purposes:
Where Purchased: _____________________________________
Purchase Date: _____________________________________
Equipment Serial #: _____________________________________

TABLE OF CONTENTS
SECTION 1:ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS.............................. 1-1

1.01 Arc Welding Hazards........................................................................................ 1-1
1.02 Principal Safety Standards............................................................................... 1-5
1.03 Declaration of Conformity................................................................................ 1-6
SECTION 2:INTRODUCTION................................................................................ 2-1
2.01 How to Use This Manual.................................................................................. 2-1
2.02 Equipment Identification.................................................................................. 2-1
2.03 Receipt of Equipment....................................................................................... 2-1
2.04 Symbol Chart................................................................................................... 2-2
2.05 Description ..................................................................................................... 2-3
2.06 User Responsibility.......................................................................................... 2-3
2.07 Packaged Items............................................................................................... 2-3
2.08 Duty Cycle........................................................................................................ 2-5
2.09 WeldSkill 250 MIG Power Source Specifications............................................. 2-6
2.10 WeldSkill 350 MIG Power Source Specifications............................................. 2-7
2.11 WeldSkill 4R Wirefeeder Specifications........................................................... 2-8
2.12 Optional Accessories ..................................................................................... 2-8
SECTION 3:INSTALLATION ................................................................................ 3-1
3.01 Environment ................................................................................................... 3-1
3.02 Location .......................................................................................................... 3-1
3.03 Ventilation ....................................................................................................... 3-1
3.04 Mains Supply Voltage Requirements............................................................... 3-1
3.05 Installation and Users Responsibility............................................................... 3-2
3.06 Assessment of Area......................................................................................... 3-2
3.07 Methods of Reducing Electromagnetic Emissions........................................... 3-2
SECTION 4:OPERATION .................................................................................... 4-1
4.01 Power Source Front Panel .............................................................................. 4-1
4.02 Power Source Internal Welding Controls......................................................... 4-3
4.03 4R Wirefeeder Front Panel............................................................................... 4-6
4.04 Shielding Gas Regulator Operating Instructions.............................................. 4-6
SECTION 5:SET UP FOR THE WELDSKILL 250 & 350 POWER SOURCE ........................... 5-1
5.01 Setup For The WeldSkill 250 & 350 MIG Power Source ................................ 5-1
5.02 Wire Reel Brake .............................................................................................. 5-3
5.03 Setup For The WeldSkill 250 & 350 MIG Power Source When Fitted With
Wirefeeder....................................................................................................... 5-3
5.04 Wire Reel Brake .............................................................................................. 5-5
5.05 How to Lift WELDSKILL 4R Wirefeeder ..........................................................5-6
TABLE OF CONTENTS
SECTION 6:BASIC WELDING GUIDE ..................................................................... 6-1

6.01 MIG (GMAW/FCAW) Basic Welding Technique................................................ 6-1
SECTION 7:SERVICE ....................................................................................... 7-1
7.01 Routine Service and Calibration Requirements................................................ 7-1
7.02 Cleaning the Feed Rolls.................................................................................... 7-3
7.03 Basic Troubleshooting..................................................................................... 7-3
7.04 Solving Problems Beyond the Welding Terminals............................................ 7-3
7.05 Solving Problems Beyond the Welding Terminals - Porosity .......................... 7-3
7.06 Solving Problems Beyond the Welding Terminals – Inconsistent Wire Feed.... 7-4
7.07 Welding Problems........................................................................................... 7-5
7.08 Power Source / Wirefeeder Problems.............................................................. 7-6
APPENDIX 1:KEY SPARE PARTS.......................................................................... A-1
APPENDIX 2:VOLT/AMP CURVES......................................................................... A-4
APPENDIX 3:WELDSKILL 250 MIG POWER SOURCE CIRCUIT DIAGRAM........................... A-5
APPENDIX 4:WELDSKILL 350 MIG POWER SOURCE CIRCUIT DIAGRAM........................... A-6
APPENDIX 5:4R WIREFEEDER CIRCUIT DIAGRAM..................................................... A-7
CIGWELD LIMITED WARRANTY
Terms of Warranty – January 2011
Warranty Schedule – January 2011
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

safety instructions weldskill 250, 350
SECTION 1:
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
! WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/
INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the
operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through
study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other
practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not
attempt to weld.
Safe practices are outlined in the Australian Standard AS1674.2-2007 entitled: Safety in welding and allied processes Part 2: Electrical. This
publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
10. Ground the workpiece to a good electrical (earth) ground.

1.01 Arc Welding Hazards
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace dam-
aged parts at once.
WARNING
13. In confined spaces or damp locations, do not use a welder
ELECTRIC SHOCK can kill. with AC output unless it is equipped with a voltage reducer.
Touching live electrical parts can cause fatal shocks Use equipment with DC output.
or severe burns. The electrode and work circuit 14. Wear a safety harness to prevent falling if working above floor
is electrically live whenever the output is on. The level.
input power circuit and machine internal circuits
are also live when power is on. In semiautomatic 15. Keep all panels and covers securely in place.
or automatic wire welding, the wire, wire reel, drive
roll housing, and all metal parts touching the weld-
ing wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
WARNING
1. Do not touch live electrical parts.
ARC RAYS can burn eyes and skin; NOISE can
2. Wear dry, hole-free insulating gloves and body protection. damage hearing. Arc rays from the welding process
3. Insulate yourself from work and ground using dry insulating produce intense heat and strong ultraviolet rays that
mats or covers. can burn eyes and skin. Noise from some processes
can damage hearing.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch 1. Use a Welding Helmet or Welding Faceshield fitted with a
open, or remove line fuses so power cannot be turned on proper shade of filter (see ANSI Z49.1 and AS 1674 listed in
accidentally. safety Standards) to protect your face and eyes when welding
or watching.
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes. 2. Wear approved safety glasses. Side shields recommended.
6. Turn off all equipment when not in use. Disconnect power to 3. Use protective screens or barriers to protect others from flash
equipment if it will be left unattended or out of service. and glare; warn others not to watch the arc.
7. Use fully insulated electrode holders. Never dip holder in water 4. Wear protective clothing made from durable, flame-resistant
to cool it or lay it down on the ground or the work surface. material (wool and leather) and foot protection.
Do not touch holders connected to two welding machines 5. Use approved ear plugs or ear muffs if noise level is high.
at the same time or touch other people with the holder or
electrode. 6. Never wear contact lenses while welding.
8. Do not use worn, damaged, undersized, or poorly spliced
cables.
9. Do not wrap cables around your body.
Manual 0-5182 1-1 Safety Instructions

weldskill 250, 350 safety instructions
WARNING
WARNING
WELDING can cause fire or explosion.
FUMES AND GASES can be hazardous to your
health. Sparks and spatter fly off from the welding arc.
The flying sparks and hot metal, weld spatter, hot
Welding produces fumes and gases. Breathing workpiece, and hot equipment can cause fires and
these fumes and gases can be hazardous to your burns. Accidental contact of electrode or welding
health. wire to metal objects can cause sparks, overheat-
1. Keep your head out of the fumes. Do not breath the fumes. ing, or fire.
2. If inside, ventilate the area and/or use exhaust at the arc to 1. Protect yourself and others from flying sparks and hot
remove welding fumes and gases. metal.
3. If ventilation is poor, use an approved air-supplied respira- 2. Do not weld where flying sparks can strike flammable mate-
tor. rial.
4. Read the Material Safety Data Sheets (MSDSs) and the 3. Remove all flammables within 35 ft (10.7 m) of the welding
manufacturer’s instruction for metals, consumables, coat- arc. If this is not possible, tightly cover them with approved
ings, and cleaners. covers.
5. Work in a confined space only if it is well ventilated, or while 4. Be alert that welding sparks and hot materials from welding
wearing an air-supplied respirator. Shielding gases used for can easily go through small cracks and openings to adjacent
welding can displace air causing injury or death. Be sure the areas.
breathing air is safe. 5. Watch for fire, and keep a fire extinguisher nearby.
6. Do not weld in locations near degreasing, cleaning, or spray- 6. Be aware that welding on a ceiling, floor, bulkhead, or partition
ing operations. The heat and rays of the arc can react with can cause fire on the hidden side.
vapours to form highly toxic and irritating gases.
7. Do not weld on closed containers such as tanks or drums.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from 8. Connect work cable to the work as close to the welding area
the weld area, the area is well ventilated, and if necessary, as practical to prevent welding current from travelling long,
while wearing an air-supplied respirator. The coatings and any possibly unknown paths and causing electric shock and fire
metals containing these elements can give off toxic fumes if hazards.
welded.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire
at contact tip when not in use.
Safety Instructions 1-2 Manual 0-5182

Recommended Protective Filters for Electric Welding

Approximate range of Welding Minimum Shade Number of
Description of Process
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) 300 to 400 12
-with 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)
Resistance Welding — Safety Spectacles or eye shield
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.

WARNING
! WARNING
FLYING SPARKS AND HOT METAL can cause This product, when used for welding or cutting,
injury. produces fumes or gases which contain chemicals
Chipping and grinding cause flying metal. As welds know to the State of California to cause birth defects
cool, they can throw off slag. and, in some cases, cancer. (California Health &
Safety code Sec. 25249.5 et seq.)
1. Wear approved face shield or safety goggles. Side shields
recommended. NOTE
2. Wear proper body protection to protect skin. Considerations About Welding And The Effects of
Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Sec-
WARNING tion of the U.S. Congress, Office of Technology Assessment,
Biological Effects of Power Frequency Electric & Magnetic Fields
CYLINDERS can explode if damaged. - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Gov-
ernment Printing Office, May 1989): “...there is now a very large
Shielding gas cylinders contain gas under high pres-
volume of scientific findings based on experiments at the cellular
sure. If damaged, a cylinder can explode. Since gas
level and from studies with animals and people which clearly es-
cylinders are normally part of the welding process,
tablish that low frequency magnetic fields and interact with, and
be sure to treat them carefully.
produce changes in, biological systems. While most of this work
1. Protect compressed gas cylinders from excessive heat, is of very high quality, the results are complex. Current scientific
mechanical shocks, and arcs. understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does
2. Install and secure cylinders in an upright position by chaining not yet allow us to draw definite conclusions about questions of
them to a stationary support or equipment cylinder rack to possible risk or to offer clear science-based advice on strategies
prevent falling or tipping. to minimize or avoid potential risks.”
3. Keep cylinders away from any welding or other electrical To reduce magnetic fields in the workplace, use the following
circuits. procedures.
4. Never allow a welding electrode to touch any cylinder. 1. Keep cables close together by twisting or taping them.
5. Use only correct shielding gas cylinders, regulators, hoses, 2. Arrange cables to one side and away from the operator.
and fittings designed for the specific application; maintain
them and associated parts in good condition. 3. Do not coil or drape cable around the body.
6. Turn face away from valve outlet when opening cylinder 4. Keep welding power source and cables as far away from body
valve. as practical.
7. Keep protective cap in place over valve except when cylinder

is in use or connected for use.
8. Read and follow instructions on compressed gas cylinders,
ABOUT PACEMAKERS:
associated equipment, and CGA publication P-1 listed in The above procedures are among those also
Safety Standards. normally recommended for pacemaker wearers.
Consult your doctor for complete information.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and
hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.

1.02 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from Ameri-
can Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Su-
perintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding
and Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Pro-
tection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from Na-
tional Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.
Safety in welding and allied processes Part 1: Fire Precautions. AS
1674.1- 1997 from SAI Global Limited, www.saiglobal.com.
Safety in welding and allied processes Part 2: Electrical, AS
1674.2- 2007 from SAI Global Limited, www.saiglobal.com.
Filter for eye protectors - Filters for protection against radiation
generated in welding and allied operations AN/NZS 1338.1:1992
from SAI Global Limited, www.saiglobal.com.

1.03 Declaration of Conformity
Manufacturer: CIGWELD
Address: 71 Gower St, Preston
Victoria 3072
Australia
Description of equipment: Welding Equipment (GMAW). WeldSkill 250, 350 MIG Power Source, Wirefeeder
and associated accessories.
Serial numbers are unique with each individual piece of equipment and details description, parts used to
manufacture a unit and date of manufacture.
The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive
73/23/EU, as recently changed in Directive 93/68/EU and to the National legislation for the enforcement of the
Directive.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among
them are:
• IEC 60974-10 applicable to Industrial Equipment - generic emissions and regulations.
• AS 1674 Safety in welding and allied processes.
• AS 60974.1 / IEC 60974-1 applicable to welding equipment and associated accessories.
Extensive product design verification is conducted at the manufacturing facility as part of the routine design
and manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is in-
corporated into the manufacturing process to ensure the manufactured product meets or exceeds all design
specifications.
CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance,
ultra safe operation and world class quality for more than 30 years and will continue to achieve excellence.

INTRODUCTION weldskill 250, 350
SECTION 2:
INTRODUCTION
2.01 How to Use This Manual 2.02 Equipment Identification
To ensure safe operation, read the entire manual, The unit’s identification number (specification or part
including the chapter on safety instructions and number), model, and serial number usually appear
warnings. on a nameplate attached to the control panel. In
some cases, the nameplate may be attached to the
Throughout this manual, the words WARNING,
rear panel. Equipment which does not have a control
CAUTION, and NOTE may appear. Pay particular at-
panel such as gun and cable assemblies is identified
tention to the information provided under these head-
only by the specification or part number printed on
ings. These special annotations are easily recognized
the shipping container. Record these numbers on the
as follows:
bottom of page i for future reference.
! WARNING
2.03 Receipt of Equipment
When you receive the equipment, check it against
A WARNING gives information regarding the invoice to make sure it is complete and inspect
possible personal injury. the equipment for possible damage due to shipping.
If there is any damage, notify the carrier immediately
to file a claim. Furnish complete information concern-
CAUTION ing damage claims or shipping errors to the location
A CAUTION refers to possible equipment in your area listed in the inside back cover of this
damage. manual.
NOTE Include all equipment identification numbers as

described above along with a full description of the
A NOTE offers helpful information con- parts in error.
cerning certain operating procedures.
Move the equipment to the installation site before
Additional copies of this manual may be purchased by uncrating the unit. Use care to avoid damaging the
contacting Cigweld at the address and phone number equipment when suing bars, hammers, etc., to uncrate
for your location listed in the inside back cover of this the unit.
manual. Include the Owner’s Manual number and
equipment identification numbers.
Manual 0-5182 2-1 Introduction

weldskill 250, 350 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 Meters Per Minute
Auxiliary Power Variable Inductance

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

V Voltage Input
Auxiliary Power
Introduction 2-2 Manual 0-5182

2.05 Description 2.07 Packaged Items
The WeldSkill 250 and 350 MIG Power Sources are WeldSkill 250 MIG Plant (Part No: W1004500)
Gas Metal Arc Welders (GMAW – commonly known
(South Pacific Version)
as MIG) with integrated wire feeder units. The Power
Sources are designed to meet the broad operating • WeldSkill 250 MIG Power Source (compact)
needs of the modern user and meet the requirements
• Tweco WeldSkill Fabgun 250 MIG Torch
of Australian Standard AS 60974.1 and International
Standard IEC 60974-1. • Work lead
• WeldSkill Argon Regulator/Flowmeter
The WeldSkill 250 and 350 MIG Power Sources pro-
vide excellent performance on mild steel, stainless • Cylinder Chain
steel, aluminium, silicon bronze and some hard facing • 200mm Spool Adaptor
wires with Argon based shielding gases. These Power
• Feed rolls: 0.6/0.8mm V Groove;
Sources also provide excellent results on mild steel
using Carbon Dioxide shielding gas. 0.9/1.2mm V Groove (fitted),
1.0/1.2mm U Groove;
The WeldSkill 250 and 350 MIG Power Sources are
supplied as complete packages that are ready to 0.8/0.9mm V Knurled, 1.2/1.6mm V Knurled.
weld (not including shielding gas, electrode wire • Contact tips: 0.6mm; 0.8mm, 0.9mm
and Hiderok™ welding helmet). The units can also (fitted);1.0mm, 1.2mm, 1.6mm
be fitted with an optional remote wirefeeder which • Shielding Gas Hose Assembly
provides portability when welding in positions with
limited access. The instructions in this manual detail • Operating Manual
how to correctly set up these machines and provide WeldSkill 350 MIG Plant (Part No: W1004600)
guidelines on gaining the best production efficiency
(South Pacific Version)
from the power source. Please read this manual
thoroughly before using your welder. • WeldSkill 350 MIG Power Source (compact)
• Tweco WeldSkill Fabgun 400 MIG Torch
2.06 User Responsibility
• Work lead
This equipment will perform as per the information • WeldSkill Argon Regulator/Flowmeter
contained herein when installed, operated, maintained
• Cylinder Chain
and repaired in accordance with the instructions pro-
vided. This equipment must be checked periodically. • 200mm Spool Adaptor
Defective equipment (including welding leads) should • Feed rolls: 0.6/0.8mm V Groove;
not be used. Parts that are broken, missing, plainly
0.9/1.2mm V Groove (fitted),
worn, distorted or contaminated, should be replaced
immediately. Should such repairs or replacements 1.0/1.2mm U Groove;
become necessary, it is recommended that such 1.2/1.6mm U Groove, 0.8/0.9mm V Knurled,
repairs be carried out by appropriately qualified per- 1.2/1.6mm V Knurled.
sons approved by CIGWELD. Advice in this regard
can be obtained by contacting accredited CIGWELD • Contact tips: 0.6mm; 0.8mm, 0.9mm (fitted);
Distributor. 1.0mm, 1.2mm, 1.6mm
• Shielding Gas Hose Assembly
This equipment or any of its parts should not be altered
from standard specification without prior written • Operating Manual
approval of CIGWELD. The user of this equipment
shall have the sole responsibility for any malfunction
which results from improper use or unauthorised
modification from standard specification, faulty
maintenance, damage or improper repair by anyone
other than appropriately qualified persons approved
by CIGWELD.

WeldSkill 250 MIG Plant (Part No: W1003400)
(Asia Version)
• WeldSkill 250 MIG Power Source (compact)
• Mig Torch MB 26 style
• Work lead
• Cylinder Chain
• 200mm Spool Adaptor
1.0/1.2mm U Groove;
0.8/0.9mm V Knurled, 1.2/1.6mm V Knurled.
• Contact tips: 0.6mm; 0.8mm, 0.9mm
(fitted);1.0mm, 1.2mm, 1.6mm
• Shielding Gas Adaptor
• Operating Manual
WeldSkill 350 MIG Plant (Part No: W1003500)
(Asia Version)
• WeldSkill 350 MIG Power Source (compact)
• MIG Torch MB 36 style
• Work lead
• Cylinder Chain
1.0/1.2mm U Groove;
1.2/1.6mm U Groove, 0.8/0.9mm V Knurled,
1.2/1.6mm V Knurled.
• Contact tips: 0.6mm; 0.8mm, 0.9mm
(fitted);1.0mm, 1.2mm, 1.6mm
WeldSkill 4R Wirefeeder Plant (Part No: W3000401)
(All Regions)
• WeldSkill 4R Wirefeeder
• 8m Interconnection Lead (fitted)

2.08 Duty Cycle
Art# A-09909_AC
WeldSkill 250 Welding Current (amps)
Duty Cycle for 350
WeldSkill 350
WeldSkill 350Welding Current
Welding Current (amps)
(amps)
Art # A-08724
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated
welding current output without exceeding the temperature limits of the insulation of the component parts. To
explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is
designed to operate at a 30% duty cycle, 350 amperes at 31.5 volts. This means that it has been designed and
built to provide the rated amperage (350A) for 3 minutes, i.e. arc welding time, out of every 10 minute period
(30% of 10 minutes is 3 minutes). During the other 7 minutes of the 10 minute period the Welding Power
Source must idle and be allowed to cool. The thermal cutout will operate if the duty cycle is exceeded.

2.09 WeldSkill 250 MIG Power Source Specifications
Description WeldSkill 250 MIG
Plant Part Numbers W1003400 & W1004500

Plant Dimensions H 1050mm x W 470mm x D 1020mm
Power Source Mass 100kg
Cooling Fan Cooled
Energy Input (Refer NOTE below) This Column applies to the This Column applies to a
Factory Fitted 2.5mm2 (20A) 4.0mm2 (25A) Primary
Primary Lead with 15A Lead with a 25A Supply
Supply Plug Plug.
Input Cable Requirements Factory Fitted 4.0mm2 2 core + earth
heavy duty R90 insulation
type
Nominal Supply Voltage 240VAC ± 10% 240VAC ± 10%
Number of Phases 1 1
Nominal Supply Frequency 50Hz 50Hz
Effective Input Current (I1eff) ♥15 Amps ♥24 Amps
Maximum Input Current (I1max) 33 Amps 54 Amps
Single Phase Generator Requirement ♣ 8kVA ♣13kVA
Welding Current Range 50 – 190A 50 – 270A
Open Circuit Voltage Range 22 to 46 V 22 to 46 V
MIG (GMAW) 190A @ 20%, 23.5V 250A @ 20%, 26.5V
Welding Output, 40oC, 10 min. 110A @ 60%, 19.5V 144A @ 60%, 21.2V
85A @ 100%, 18.3V 112A @ 100%, 19.6V
Operating Temperature Range 0ºC - 40ºC 0ºC - 40ºC
Number of Output Voltage Switch Settings 12
Protection Class IP21S
TableWeldSkill
Table 2-1 2-1 WeldSkill 250 Specification
250 Power Source Specification

♥ The Effective Input Current should be used for the determination of cable size & supply requirements.
Motor start fuses or thermal circuit breakers are recommended for this application. Check local require-
ments for your situation in this regard.
♣ Generator Requirements at the Maximum Output Duty Cycle.
Reduced output ratings apply with the supplied 15A primary lead. To achieve the maximum rated output
& duty cycle ratings the 20A primary lead must be replaced with a larger primary lead as specified in
section 3.04. This must be carried out be a qualified electrical tradesperson.
NOTE
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings,
all capacities, measurements, dimensions and weights quoted are approximate only. Achievable
capacities and ratings in use and operation will depend upon correct installation, use, applications,
maintenance and service.

2.10 WeldSkill 350 MIG Power Source Specifications
Description WeldSkill 350 MIG
Plant Part Numbers W1003500 & W1004600

Plant Dimensions H 1050mm x W 470mm x D 1020mm
Power Source Mass 112kg
Cooling Fan Cooled
Input Cable Requirements 1.5mm2 + 3 core & earth heavy duty R90 insulation type
Nominal Supply Voltage 415VAC ± 10%
Number of Phases 3
Nominal Supply Frequency 50Hz
Effective Input Current (I1eff) ♥14 Amps
Maximum Input Current (I1max) 25 Amps
Three Phase Generator Requirement ♣18kVA
Welding Current Range 35 – 380A
Open Circuit Voltage Range 17 to 42 V
MIG (GMAW) 350A @ 30%, 31.6V
Welding Output, 40oC, 10 min. 250A @ 60%, 26.3V
205A @ 100%, 24.4V
Operating Temperature Range 0ºC - 40ºC
Number of Output Voltage Switch Settings 24
Protection Class IP21S
Table
Table 2-2 2-2 WeldSkill
WeldSkill 350 Specification
350 Power Source Specification
♥ The Effective Input Current should be used for the determination of cable size & supply requirements.
Motor start fuses or thermal circuit breakers are recommended for this application. Check local
requirements for your situation in this regard.
♣ Generator Requirements at the Maximum Output Duty Cycle.
NOTE
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings,
all capacities, measurements, dimensions and weights quoted are approximate only. Achievable
capacities and ratings in use and operation will depend upon correct installation, use, applications,
maintenance and service.

2.11 WeldSkill 4R Wirefeeder Specifications
Description WeldSkill 4R Wirefeeder

Wirefeeder Plant Part Number W3000401
Wirefeeder Plant Dimensions H 490mm x W 420mm x D 670mm
Wirefeeder Plant Mass 25kg
Wire Feed Motor Voltage 24VDC
Gas Solenoid Voltage 36VAC
Minimum Wire Speed 2 m/min
Maximum Wire Speed 22 m/min
Operating Temperature Range 0ºC – 40ºC
Interconnection Plug 12 pin
Interconnection Length 8 metre
Table 2-3 WeldSkill 4R Wirefeeder Specification

2.12 Optional Accessories
Part Number Description

7977729 Feed Roll 0.6/0.8mm V Groove - hard wire
7977733 Feed Roll 0.8/ 0.9mm U Groove - soft wire
7977730 Feed Roll 1.0/1.2mm U Groove - soft wire
7977348 Feed Roll 1.2/1.6mm U Groove - soft wire
7977734 Feed Roll 0.8/0.9mm V Knurled - flux cored
7977347 Feed Roll 1.2/1.6mm V Knurled - flux cored
FAB250X12 MIG Torch 250A Euro (South Pacific Only)
FAB400X12 MIG Torch 400A Euro (South Pacific Only)
210254 WeldSkill Regulator/Flowmeter (South Pacific Only)
Table 2-4 Optional Accessories for WeldSkill 250, 350 MIGs and 4R Wirefeeder

INstallation weldskill 250, 350
SECTION 3:
INSTALLATION
3.01 Environment 3.03 Ventilation
These units are not designed for use in environments Since the inhalation of welding fumes can be harmful,
with increased hazard of electric shock. ensure that the welding area is effectively ventilated.
A. Examples of environments with increased hazard
of electric shock are:
3.04 Mains Supply Voltage
Requirements
1. In locations in which freedom of movement
is restricted, so that the operator is forced to The Mains supply voltage should be within 10% of
perform the work in a cramped (kneeling, sit- the rated Mains supply voltage. Too low a voltage
ting or lying) position with physical contact with may cause poor welding performance. Too high a
conductive parts; supply voltage will cause components to overheat
2. In locations which are fully or partially limited and possibly fail.
by conductive elements, and in which there is The Welding Power Source must be:
a high risk of unavoidable or accidental contact
by the operator, or • Correctly installed, if necessary, by a qualified
electrician.
3. In wet or damp hot locations where humidity
or perspiration considerable reduces the skin • Correctly earthed (electrically) in accordance
resistance of the human body and the insulation with local regulations.
properties of accessories. • Connected to the correct size power point and
B. Environments with increased hazard of electric fuse for each Power Source as per the Specifica-
shock do not include places where electrically conduc- tions on pages 2-6 and 2-7.
tive parts in the near vicinity of the operator, which The WeldSkill 250 MIG Power Source is supplied with
can cause increased hazard, have been insulated. a 20 Amp input lead and is designed for a 240 VAC
supply voltage.
3.02 Location
The following Mains Current Circuit recommendations
Be sure to locate the welder according to the follow- are required to obtain the maximum welding current
ing guidelines: and duty cycle from these welding products:
Mains Supply Mains Minimum Machines
1. In areas, free from moisture and dust. Voltage Supply Mains Duty Cycle
2. Ambient temperature between 0ºC to 40ºC. Setting Lead Size Current
Circuit Size
3. In areas, free from oil, steam and corrosive 240V 2.5 mm2 15 Amp 190 A @ 20%
gases. 240V 4 mm2 25 Amp 250 A @ 20%
4. In areas, not subjected to abnormal vibration or
shock. Table 3-1 WeldSkill 250 Supply Requirements
5. In areas, not exposed to direct sunlight or NOTE

rain. Motor start fuses or thermal circuit break-
6. Place at a distance of 300mm or more from walls ers are recommended for this application.
or similar that could restrict natural air flow for Check local requirements for your situa-
cooling. tion in this regard.
7. The enclosure design of this power source
meets the requirements of IP21S as outlined in
AS 60529. This provides adequate protection
against solid objects, and direct protection from
vertical drops as outlined in the aforementioned
standard. Under no circumstances should the
unit be operated or connected in a micro envi-
ronment that will exceed the stated conditions.
For further information please refer to AS 60529.
Manual 0-5182 3-1 Installation

weldskill 250, 350 INstallation
The WeldSkill 350 MIG Power Source is supplied with 3.06 Assessment of Area
a 15 Amp input lead and is designed for a 415 VAC
supply voltage. Before installing welding equipment, the user shall
make an assessment of potential electromagnetic
The WeldSkill 350 MIG Power Source is suitable for problems in the surrounding area. The following shall
below Mains supply voltages: be taken into account:
Mains Supply Mains Minimum Machines Duty
Voltage Supply Lead Mains Cycle 1. Other supply cables, control cables, signalling
Setting Size Current and telephone cables; above, below and adjacent
Circuit Size to the welding equipment.
415V 1.5 mm2 15 Amp 350A @ 30%
2. Radio and television transmitters and receiv-
Table 3-2 WeldSkill 350 Supply Requirements ers.
NOTE 3. Computer and other control equipment.
Motor start fuses or thermal circuit break- 4. Safety critical equipment, e.g. guarding of in-
ers are recommended for this application. dustrial equipment.
Check local requirements for your situa- 5. The health of people around, e.g. the use of
tion in this regard. pacemakers and hearing aids.
6. Equipment used for calibration and measure-
! WARNING
ment.
7. The time of day that welding or other activities
Extra precautions for Electromagnetic are to be carried out.
Compatibility may be required when this 8. The immunity of other equipment in the en-
Welding Power Source is used in a do- vironment: the user shall ensure that other
mestic situation. equipment being used in the environment is
compatible: this may require additional protec-
3.05 Installation and Users tion measures.
Responsibility The size of the surrounding area to be considered
will depend on the structure of the building and other
The user is responsible for installing and using the
activities that are taking place. The surrounding area
welding equipment according to the manufacturer’s
may extend beyond the boundaries of the premises.
instructions. If electromagnetic disturbances are
detected then it shall be the responsibility of the user
of the welding equipment to resolve the situation with
3.07 Methods of Reducing
the technical assistance of the manufacturer. In some Electromagnetic Emissions
cases this remedial action may be as simple as earth-
A. Mains Supply
ing the welding circuit, see NOTE. In other cases it
could involve constructing an electromagnetic screen Welding equipment should be connected to the mains
enclosing the Welding Power Source and the work, supply according to the manufacturer’s recommen-
complete with associated input filters. In all cases, dations. If interference occurs, it may be necessary
electromagnetic disturbances shall be reduced to the to take additional precautions such as filtering of
point where they are no longer troublesome. the mains supply. Consideration should be given to
shielding the supply cable of permanently installed
NOTE
welding equipment in metallic conduit or equivalent.
The welding circuit may or may not be Shielding should be electrically continuous through-
earthed for safety reasons. Changing the out it’s length. The shielding should be connected
earthing arrangements should only be au- to the Welding Power Source so that good electrical
thorised by a person who is competent to contact is maintained between the conduit and the
assess whether the changes will increase Welding Power Source enclosure.
the risk of injury, e.g. by allowing parallel
welding current return paths which may
damage the earth circuits of other equip-
ment. Further guidance is given in IEC
974-13 Arc Welding Equipment - Installa-
tion and use (under preparation).
Installation 3-2 Manual 0-5182

INstallation weldskill 250, 350
B. Maintenance of Welding Equipment E. Earthing of the Workpiece
The welding equipment should be routinely maintained Where the workpiece is not bonded to earth for electri-
according to the manufacturer’s recommendations. All cal safety, nor connected to earth because of it’s size
access and service doors and covers should be closed and position, e.g. ship’s hull or building steelwork,
and properly fastened when the welding equipment a connection bonding the workpiece to earth may
is in operation. The welding equipment should not reduce emissions in some, but not all instances. Care
be modified in any way except for those changes and should be taken to prevent the earthing of the work-
adjustments covered in the manufacturer’s instruc- piece increasing the risk of injury to users, or damage
tions. In particular, the spark gaps of arc striking and to other electrical equipment. Where necessary, the
stabilizing devices should be adjusted and maintained connection of the workpiece to earth should be made
according to the manufacturer’s recommendations. by direct connection to the workpiece, but in some
countries where direct connection is not permitted, the
C. Welding Cables
bonding should be achieved by suitable capacitance,
The welding cables should be kept as short as possible selected according to national regulations.
and should be positioned close together, running at
F. Screening and Shielding
or close to the floor level.
Selective screening and shielding of other cables
D. Equipotential Bonding
and equipment in the surrounding area may allevi-
Bonding of all metallic components in the welding ate problems of interference. Screening the entire
installation and adjacent to it should be considered. welding installation may be considered for special
However. Metallic components bonded to the work applications.
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.
Manual 0-5182 3-3 Installation

weldskill 250, 350 INstallation
Installation 3-4 Manual 0-5182

operation weldskill 250, 350
SECTION 4:
OPERATION
4.01 Power Source Front Panel
9 9 Art # 0-09919
Art # 0-09918
1 1
1 1
2 2
4
7
11
12
1
2
3
10 3
10 4
9 5
8 6
7
8 8
TORCH REMOTE
6
TORCH REMOTE
6
7 7
5 11 5 11
Figure 4-1 WeldSkill 250 & 350 MIG Front Panel
1. POWER ON INDICATOR/MAIN POWER CONTROL SWITCH

The Power ON Indicator illuminates when the Main Power Control Switch ON/OFF knob is in the ON posi-
tion and the correct mains voltage is present.
! WARNING
When the light is lit, the machine is connected to the Mains supply voltage and the internal electrical
components are at Mains voltage potential.
2. WIRESPEED CONTROL
The Wirespeed Control knob controls the welding current via the electrode wirefeed rate. ie the speed of
the wirefeed motor.
Operation 4-1 Manual 0-5182

weldskill 250, 350 operation
3. VOLTAGE CONTROL SWITCH - FINE (WELDSKILL 350 ONLY)
The Fine Voltage Control switch increases the welding voltage (in smaller increments than the Coarse
switch) as it is rotated in a clockwise direction.
CAUTION
The Coarse & Fine Voltage Control switches MUST NOT BE SWITCHED during the welding
process.
4. VOLTAGE CONTROL SWITCH - COARSE (WELDSKILL 350 ONLY)
The Coarse Voltage Control increases the welding voltage (in larger increments than the Fine switch) as
it is rotated in a clockwise direction.
CAUTION
The Coarse & Fine Voltage Control switches MUST NOT BE SWITCHED during the welding pro-
cess.
5. TORCH POLARITY LEAD
This lead selects the welding voltage polarity of the electrode wire. Plug it into the positive welding terminal
(+) when using steel, stainless steel or aluminium electrode wire. Plug the Torch Polarity Lead into the
negative welding terminal (-) when using gasless electrode wire. If in doubt, consult the manufacturer of
the electrode wire for the correct polarity.
6. POSITIVE WELDING TERMINAL
Positive Welding Terminal. Welding current flows from the Power Source via heavy duty bayonet type
terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound
electrical connection.
7. NEGATIVE WELDING TERMINAL
Negative Welding Terminal. Welding current flows from the Power Source via heavy duty bayonet type
terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound
electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused
in the terminal.
8. MIG TORCH ADAPTOR (Euro Style)
The MIG torch adaptor is the connection point for the MIG welding torch. Connect the torch by pushing
the torch connector into the brass torch adaptor firmly and screwing the plastic torch nut clockwise to
secure in position. To remove the MIG Torch simply reverse these directions.
9. OVERHEAT INDICATOR
This welding power source is protected by a self resetting thermostat. The overheat indicator will illumi-
nate if the duty cycle of the power source has been exceeded. Should the overheat indicator illuminate
the output of the power source will be disabled. Once the power source cools down this indicator will go
OFF and the overheat condition will automatically reset. Note that the mains power switch should remain
in the on position such that the fan continues to operate thus allowing the unit to cool sufficiently. Do not
switch the unit off should a overheat condition be present.
Manual 0-5182 4-2 Operation

10. VOLTAGE CONTROL SWITCH (WELDSKILL 250 ONLY)
The Voltage Control Switch is a 12 position that increases the welding voltage as it is rotated in a clockwise
direction.
CAUTION
The Voltage Control switch MUST NOT BE SWITCHED during the welding process.
11. REMOTE SOCKET
12 PIN
1 trigger
2 1 2 Motor Positive (24VDC)
3 Motor Negative
5 4 3
4 CW of remote wirespeed pot
9 8 7 6 5 ACW of remote wirespeed pot
12 11 10 6 wiper of 5k remote wirespeed pot
7 trigger
8 solenoid
9 solenoid
POWER SOURCE 12 PIN REMOTE SOCKET 10 no connection
11 no connection
Art # A-09921_AB
12 no connection
Figure 4-2 WeldSkill 250 & 350 MIG Remote Socket
CAUTION
The Voltage Control Switch must not be switched whilst welding.
4.02 Power Source Internal Welding Controls

A B
C
SPOT (s)
10 LOCAL
15
TRIGGER
3A 5 19 4T
LATCH
415V 0
REMOTE
2T
SPOT NORMAL
BURNBACK
D
8A
27V
GAS PURGE INCH
Art # A-09920_AC F E
Figure 4-3 Internal welding controls

A. SPOT TIME
SPOT (s)
10 15
5 19
0
Art # 0-10092
When the TRIGGER MODE SELECTOR switch is switched to the SPOT position, the SPOT TIME control
adjusts the duration of a single spot weld.
B. TRIGGER MODE SWITCH
The Trigger Mode Selector switch selects the desired welding mode.
Art # A-09922
TRIGGER
4T
LATCH
2T
SPOT NORMAL
Mode Functional Description

This mode of welding is used to weld two or more components together with
a continuous weld. Pressing and holding the MIG torch trigger switch will
NORMAL (2T)
activate the power source such that welding can commence. Releasing the
MIG torch trigger switch will de-activate the power source.
This mode of welding is used to produce short welding runs of a pre-set
duration. This duration is set using the Spot Time Control (A). Pressing and
holding the MIG torch trigger switch will activate the power source until such
SPOT
time as the desired Spot time has elapsed after which the power source will
de-activate.
The spot time period is set by the SPOT TIME control (A) located in the
wiredrive compartment.
This mode of welding is mainly used for long weld runs. The MIG torch
LATCH (4T) trigger switch is depressed (and released) to activate the power source, and
then depressed (and released) a second time to de-activate the power source.
This obviates the need for the operator to depress the trigger for the complete
length of the weld run.
Table 4-1 Trigger Mode Switch Functional Description
C. LOCAL/REMOTE MODE SWITCH
The Local/Remote switch is used to switch between local and Remote modes.
Local Mode
Set the switch in the Local position when using the power source only (With no optional external
wirefeeder).
Remote Mode
Set the switch in the Remote position when using an optional remote wirefeeder. This will enable the
wirefeeder and allow the wirespeed to be controlled from the remote wirefeeder wirespeed control. The
other controls such as trigger mode, inch, gas purge, spot, burnback will still be controlled from the
power source.
D. WIRE INCH SWITCH
INCH
Art # 0-10094
The Wire Inch Switch is used to feed the MIG wire through the MIG torch. When the push button switch
is pressed down, the electrode wire is fed through the Wirefeed system & MIG torch. No gas flows and
welding voltage is not present when the Wire Inch Switch is activated.
! WARNING
Keep torch away from eyes and face.
E. GAS PURGE
GAS PURGE
Art # A-10095
The Gas Purge Switch is used to purge gas (or impurities such as air) out of the gas system. When the
push button switch is pressed, the shielding gas flows through the Wirefeed system & out of the MIG
torch nozzle. The Wirefeed motor does not operate and welding voltage is not present when the Gas Purge
Switch is activated.
F. BURNBACK
BURNBACK
Art # A-10093
Burnback time is used to adjust the amount of MIG wire protruding from the MIG torch contact tip (stick
out) after the completion of welding. Rotating the Burnback control in a clockwise direction increases the
Burnback time. Rotating the Burnback control in an anticlockwise direction reduces the Burnback time.

4.03 4R Wirefeeder Front Panel
WIRESPEED
4R
Art # 0-09925_AB
1. WIRESPEED CONTROL
The Wirespeed Control Knob controls the welding current via the electrode wirefeed rate, ie the speed of the
wirefeed motor.
2. MIG TORCH ADAPTOR (Euro Style)
The MIG torch adaptor is the connection point for the MIG welding torch. Connect the torch by pushing the
torch connector into the brass torch adaptor firmly and screwing the plastic torch nut clockwise to secure in
position. To remove the MIG Torch simply reverse these directions.
4.04 Shielding Gas Regulator Operating Instructions
! WARNING
This equipment is designed for use with welding grade (Inert) shielding gases only.
NOTE
WeldSkill Argon Regulator / Flowmeter is not included in Asia Versions Part Nos W1003400 and
W1003500.
Shielding Gas Regulator Safety
This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working
pressure required for the equipment using it.
If the equipment is improperly used, hazardous conditions are created that may cause accidents. It is the
users responsibility to prevent such conditions. Before handing or using the equipment, understand and
comply at all times with the safe practices prescribed in this instruction.
SPECIFIC PROCEDURES for the use of regulators are listed below.
1. NEVER subject the regulator to inlet pressure greater than its rated inlet pressure.

2. NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition.
NEVER loosen a connection or attempt to remove any part of a regulator until the gas pressure has
been relieved. Under pressure, gas can dangerously propel a loose part.
3. DO NOT remove the regulator from a cylinder without first closing the cylinder valve and releasing gas
in the regulator high and low pressure chambers.
4. DO NOT use the regulator as a control valve. When downstream equipment is not in use for extended
periods of time, shut off the gas at the cylinder valve and release the gas from the equipment.
5. OPEN the cylinder valve SLOWLY. Close after use.
User Responsibilities
This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in
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 to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to
a cylinder containing any other gas.
Art: A-05087
Figure 4-4 Fit Regulator to Cylinder
Installation
1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting the regulator.
Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of
ignition. Wipe with a clean lintless cloth.
2. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking
agree and that the regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed
for a particular gas or gases to a cylinder containing any other gas.
3. Connect the regulator inlet connection to cylinder or pipeline and tighten it firmly but not excessively,
with a suitable spanner.
4. Connect and tighten the outlet hose firmly and attach down-stream equipment.

5. To protect sensitive down-stream equipment 1. Slowly turn adjusting screw/knob in (clock-
a separate safety device may be necessary if wise) direction until the outlet gauge indicates
the regulator is not fitted with a pressure relief the required flow rate.
device.
NOTE
Operation
It may be necessary to re-check the shield-
With the regulator connected to cylinder or pipeline, ing gas regulator flow rate following the
and the adjustment screw/knob fully disengaged, first weld sequence due to back pressure
pressurize as follows: present within shielding gas hose as-
sembly.
1. Stand to one side of regulator and slowly open
the cylinder valve. If opened quickly, a sudden 2. To reduce flow rate, allow the welding grade
pressure surge may damage internal regulator shielding gas to discharge from regulator by
parts. opening the downstream valve. Bleed weld-
ing grade shielding gas into a well ventilated
2. With valves on downstream equipment closed,
area and away from any ignition source. Turn
adjust regulator to approximate working pres-
adjusting screw counterclockwise, until the
sure. It is recommended that testing for leaks
required flow rate is indicated on the gauge.
at the regulator connection points be carried
Close downstream valve.
out using a suitable leak detection solution or
soapy water. Shutdown
3. Purge air or other unwanted welding grade Close cylinder valve whenever the regulator is not in
shielding gas from equipment connected to use. To shut down for extended periods (more than
the regulator by individually opening then 30 minutes).
closing the equipment control valves. Com-
1. Close cylinder or upstream valve tightly.
plete purging may take up to ten seconds or
more, depending upon the length and size of 2. Open downstream equipment valves to drain
the hose being purged. the lines. Bleed gas into a well ventilated area
and away from any ignition source.
Adjusting Flow Rate
3. After gas is drained completely, disengage
adjusting screw and close downstream equip-
ment valves.
4. Before transporting cylinders that are not se-
cured on a cart designed for such purposes,
remove regulators.
Art: A-05088_AB
Figure 4-5 Adjust Flow Rate
With the regulator ready for operation, adjust working

flow rate as follows:

set up weldskill 250, 350
SECTION 5:
SET UP FOR THE WELDSKILL 250 & 350 POWER SOURCE
5.01 Setup For The WeldSkill 250 & 350 MIG Power Source
Power Source Connections
A. Remove all packaging materials.
B. Connect the work lead to the negative welding terminal (-) [positive welding terminal (+) for flux cored
electrode wire]. If in doubt, consult the electrode wire manufacturer.
C. Position a gas cylinder on the rear tray of the Power Source and lock securely to the Power Source cyl-
inder bracket with the chain provided. If this arrangement is not used or the Power Source is not fitted
with a gas cylinder tray then ensure that the gas cylinder is secured to a building pillar, wall bracket or
otherwise securely fixed in an upright position.
D. Connect the TORCH power cable to the positive welding terminal (+) [negative welding terminal (-) for
flux cored electrode wire]. If in doubt, consult the electrode wire manufacturer.
E. Fit the gas regulator and flowmeter to the gas cylinder then connect the gas hose from the rear of the
Power Source to the Flowmeter outlet.
F. Dual groove feed rollers are supplied as standard. They can accommodate 0.9/1.2mm diameter hard
wires. Select the roller required with the chosen wire size marking facing outwards.
GROOVE “A” GROOVE “B”
Art # A-08739
GROOVE “B” SIZE GROOVE “A” SIZE
G. Fit the electrode wire spool to the wire reel hub. (Note that there is an adaptor supplied when using
200mm diameter wire spools). Ensure that the drive dog-pin engages the mating hole in the wire spool.
Push the spool securing clip into place to retain the wire spool securely. The electrode wire should feed
from the bottom of the spool.
H. MIG Torch, EURO MIG Torch Connection
Fit the MIG Torch to the Power Source by pushing the torch connector into the brass torch adaptor and
screwing the plastic torch nut clockwise to secure the torch to the torch adaptor. Remove the contact tip
from the torch handset.
Manual 0-5182 5-1 Setup

weldskill 250, 350 set up
Setup for MIG (GMAW) Welding with Setup for MIG (GMAW) Welding
Gas Shielded Shielded MIG Wire with Gas Gasless MIG Wire
300mm Wire spool installation
Art# 0-09923_AD
200mm Wire spool installation
Figure 5-1 WeldSkill 250 & 350 Setup and Spool Hub
Setup 5-2 Manual 0-5182

Inserting Wire Into The Wire Feed Mechanism
Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide, between the rollers,
through the centre guide, between the rollers, through the outlet guide and into the MIG torch.
! WARNING
DO NOT WEAR GLOVES WHILE THREADING THE WIRE OR CHANGING THE WIRE SPOOL.
B. Lower the pressure lever and with the torch lead reasonably straight, feed the electrode wire through the
torch. Fit the appropriate contact tip, eg a 0.9mm tip for 0.9mm wire.
C. Press the Torch switch to feed the wire through the torch.
! WARNING
The electrode wire will be at welding voltage potential whilst it is being fed through the wirefeeder
system if the wire is fed by using the TORCH SWITCH.
Drive Roller Pressure Adjustment
The moveable rollers apply pressure to the grooved feed rollers via a scaled adjustable tension screw. These
devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage. If
slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit
liner should be checked for kinks and clogging by metal flakes and swarf. If it is not the cause of slipping, the
feedroll pressures can be increased by rotating the scaled tension screws clockwise. The use of excessive
pressure may cause rapid wear of the feed rollers, shafts and bearing.
5.02 Wire Reel Brake

The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking.
If it is considered necessary, adjustment can be made by turning the large nut inside the open end of the hub
clockwise to tighten the brake. Correct adjustment will result in the wire reel circumference continuing no
further than 20mm after release of the trigger. The electrode wire should be slack without becoming dislodged
from wire spool.
CAUTION
Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical
component and possibly an increased incidence of electrode wire Burnback into contact tip.
5.03 Setup For The WeldSkill 250 & 350 MIG Power Source When Fitted With
Wirefeeder
Power Source Connections
A. Remove all packaging materials.
B. Connect the work lead to the negative welding terminal (-) [positive welding terminal (+) for flux cored
electrode wire]. If in doubt, consult the electrode wire manufacturer.
C. Position a gas cylinder on the rear tray of the Power Source and lock securely to the Power Source cyl-
inder bracket with the chain provided. If this arrangement is not used or the Power Source is not fitted
with a gas cylinder tray then ensure that the gas cylinder is secured to a building pillar, wall bracket or
otherwise securely fixed in an upright position.
Wirefeeder Connections
A. Connect the welding power cable from the Wirefeeder's interconnection cables to the positive welding
terminal (+) [negative welding terminal (-) for flux cored electrode wire]. If in doubt, consult the elec-

trode wire manufacturer. (Power Source Torch Polarity Lead not required to be connected when using
wirefeeder)
B. Connect the control cable from the Wirefeeder to the control socket on the Power Source.
C. Fit the gas regulator and flowmeter to the gas cylinder then connect the gas hose from the rear of the
Wirefeeder to the Flowmeter outlet.
D. Dual groove feed rollers are supplied as standard. They can accommodate 0.9/1.2mm diameter hard
wires. Select the roller required with the chosen wire size marking facing outwards.
GROOVE “A” GROOVE “B”
Art # A-08739
GROOVE “B” SIZE GROOVE “A” SIZE
E. Fit the electrode wire spool to the wirefeeder wire reel hub. (Note that there is an adaptor supplied when
using 200mm diameter wire spools). Ensure that the drive dog-pin engages the mating hole in the wire
spool. Push the spool securing clip into place to retain the wire spool securely. The electrode wire should
feed from the bottom of the spool.
F. MIG Torch, EURO MIG Torch Connection
Fit the MIG Torch to the Wirefeeder by pushing the torch connector into the brass torch adaptor and
screwing the plastic torch nut clockwise to secure the torch to the torch adaptor. Remove the contact tip
from the torch handset.
TO SHIELDING GAS TO SHIELDING GAS

REGULATOR REGULATOR
Setup for MIG (GMAW) Welding Setup for MIG (GMAW) Welding
with Gas Shielded MIG Wire with Gasless MIG Wire
200mm Diameter
300mm Diameter
Wire Spool
Wire Spool
200mm Diameter
Wire Spool Adaptor
Spool Hub Nut Spool Hub Nut
Art # A-09924_AC
300mm Wire spool installation 200mm Wire spool installation
Figure 5-2 WeldSkill 250 & 350 WF Setup and WF Spool Hub

Inserting Wire Into The Wire Feed Mechanism
A. Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide, between the
rollers, through the centre guide, between the rollers, through the outlet guide and into the MIG torch.
! WARNING
DO NOT WEAR GLOVES WHILE THREADING THE WIRE OR CHANGING THE WIRE SPOOL.
B. Lower the pressure lever and with the torch lead reasonably straight, feed the electrode wire through the
torch. Fit the appropriate contact tip, eg a 0.9mm tip for 0.9mm wire.
C. Press the Torch switch to feed the wire through the torch.
! WARNING
The electrode wire will be at welding voltage potential whilst it is being fed through the wirefeeder
system if the wire is fed by using the TORCH SWITCH.
Drive Roller Pressure Adjustment
The moveable rollers apply pressure to the grooved feed rollers via a scaled adjustable tension screw. These
devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage. If
slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit
liner should be checked for kinks and clogging by metal flakes and swarf. If it is not the cause of slipping, the
feed roll pressures can be increased by rotating the scaled tension screws clockwise. The use of excessive
pressure may cause rapid wear of the feed rollers, shafts and bearing.
5.04 Wire Reel Brake
The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking.
If it is considered necessary, adjustment can be made by turning the large nut inside the open end of the hub
clockwise to tighten the brake. Correct adjustment will result in the wire reel circumference continuing no
further than 20mm after release of the trigger. The electrode wire should be slack without becoming dislodged
from wire spool.
CAUTION
Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical
component and possibly an increased incidence of electrode wire Burnback into contact tip.

5.05 How to Lift WELDSKILL 4R Wirefeeder
WARNING
DO NOT lift the WELDSKILL 4R Wirefeeder by the Handle using mechanical means. The WELD-
SKILL 4R Wirefeeder may fall from a hook/mechanical hoist as the small bracket on the handle is
not designed to secure a lifting hook/mechanical hoist in the corner of the Handle. The Handle is
designed for lifting by hand only.
The WELDSKILL 4R Wirefeeder Handle is designed for lifting the Wirefeeder by hand only.
Handle
Art # A-11480

BASIC WELDING GUIDE WELDSKILL 250, 350
SECTION 6:
BASIC WELDING GUIDE
6.01 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 semiautomatically; 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 6-1
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 semiautomatically;
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 6-2
Manual 0-5182 6-1 Basic Welding Guide

WELDSKILL 250, 350 BASIC WELDING GUIDE
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 6-3
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 6-4
Butt & Horizontal Welds
5° to 15°
Longitudinal Angle
30° to 60°
Transverse Angle
Direction of
Travel
Art # A-08994
Horizontal Figure 6-5

Fillet Weld
Basic Welding Guide 6-2 Manual 0-5182

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 6-6
Direction of Travel
30° to 60°
Transverse Angle 5° to 15°
Longitudinal
Angle
Art # A-08996
Overhead Figure
Weld 6-7
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) Varialbes
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 6-8
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 6-9
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 6-10

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 0.024” (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 3.06.4) and the welding
Voltage Control (refer to section 3.06.10). 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


service weldskill 250, 350
SECTION 7:
SERVICE
7.01 Routine Service and Calibration Requirements
! WARNING
There are extremely dangerous voltage and power levels present inside this Power Source. Do not
attempt to open or repair unless you are an accredited CIGWELD Service Provider. Disconnect the
Welding Power Source from the Mains Supply Voltage before disassembling.
1. Routine Inspection, Testing & Maintenance
The inspection and testing of the power source and associated accessories shall be carried out in accordance
with Section 5 of AS 1674.2 - 2007: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an
insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Cigweld's
original specifications.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined
in AS 1674.2 - 2007, then the above tests should be carried out prior to entering this location.
Testing Schedule
a) For transportable equipment, at least once every 3 months; and
b) For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, includ-
ing the date of the most recent inspection.
A transportable power source is deemed to be any equipment that is not permanently connected and fixed in
the position in which it is operated.
Insulation Resistance
Minimum insulation resistance for in-service Cigweld Power Sources shall be measured at a voltage of 500V
between the parts referred to in Table 7-1 below. Power sources that do not meet the insulation resistance
requirements set out below shall be withdrawn from service and not returned until repairs have been performed
such that the requirements outlined below are met.
Minimum Insulation
Components to be Tested
Resistance (MΩ)
Input circuit (including any connected control circuits) to welding circuit
5
(including any connected control circuits)
All circuits to exposed conductive parts 2.5
Welding circuit (including any connected control circuits) to any auxiliary
10
circuit which operates at a voltage exceeding extra low voltage
Welding circuit (including any connected control circuits) to any auxiliary
1
circuit which operates at a voltage not exceeding extra low voltage
Separate welding circuit to separate welding circuit 1
Table 7-1: Minimum Insulation Resistance Requirements: Cigweld Power Sources
Earthing
The resistance shall not exceed 1Ω between any metal of a power source where such metal is required to be
earthed, and -
a) The earth terminal of a fixed power source; or
b) The earth terminal of the associated plug of a transportable power source
Service 7-1 Manual 0-5182

weldskill 250, 350 service
Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring sup-
plying Cigweld welding power sources should be inspected by a licensed electrical worker in accordance with
the requirements below -
a) For outlets/wiring and associated accessories supplying transportable equipment - at least once every
3 months; and
b) For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12
months.
General Maintenance Checks
Welding equipment should be regularly checked by an accredited Cigweld Service Provider to ensure that:
• Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly
connected and in good condition.
• Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short
circuit.
• The Welding System is clean internally, especially from metal filing, slag, and loose material.
Accessories
Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be
inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable
condition. All unsafe accessories shall not be used.
Repairs
• If any parts are damaged for any reason, it is recommended that replacement be performed by an ac-
credited Cigweld Service Provider.
2. Power Source Calibration
Schedule
Output testing of all Cigweld Power Sources and applicable accessories shall be conducted at regular intervals
to ensure they fall within specified levels. Calibration intervals shall be as outlined below -
a) For transportable equipment, at least once every 3 months; and
b) For fixed equipment, at least once every 12 months.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined
in AS 1674.2 - 2007, then the above tests should be carried out prior to entering this location.
Calibration Requirements
Where applicable, the tests outlined in Table 7-2 below shall be conducted by an accredited CIGWELD service
agent.
Testing Requirements
Output current (A) to be checked to ensure it falls within applicable Cigweld power source specifications
Output Voltage (V) to be checked to ensure it falls within applicable Cigweld power source specifications
Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required Cigweld power
source / wire feeder specifications
Table 7-2: Calibration Parameters
Periodic calibration of other parameters such as wave balance (AC), timing functions and high frequency start
is not required unless a specific fault has been identified.
Calibration Equipment
All equipment used for Power Source calibration shall be in proper working condition and be suitable for con-
ducting the measurement in question. Only test equipment with valid calibration certificates (NATA certified
laboratories) shall be utilized.
Manual 0-5182 7-2 Service
7.02 Cleaning the Feed Rolls
Clean the grooves in the drive rolls frequently. This can be done by using a small wire brush. Also wipe off, or
clean the grooves on the upper feed roll. After cleaning, tighten the feed roll retaining knobs.
7.03 Basic Troubleshooting
! WARNING
There are dangerous voltage and power levels present inside this product. Do not attempt to open
or repair unless you are a qualified electrical tradesperson and you have had training in power
measurements and troubleshooting techniques.
If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited
CIGWELD Service Provider for repair.
The basic level of troubleshooting is that which can be performed without special equipment or knowledge
and without removing the covers from the Wirefeeder.
7.04 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 Incon-
sistent wire feed.
7.05 Solving Problems Beyond the Welding Terminals - Porosity

When there is a shielding 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 shielding 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 flow
and flow meter. meter is correctly adjusted to 15 litres per minute.
2 Gas leaks. Check for shielding gas leaks between the regulator/cylinder
connection and in the shielding gas hose to the Power Source.
3 Internal shielding gas hose in the Ensure the hose from the solenoid valve to the torch adaptor
Power 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 shielding
gas flow.
5 Welding dirty, oily, painted, oxidised Clean contaminates off the work piece.
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.
7 Maintain the MIG torch in good A Ensure that the shielding gas holes are not blocked and
working order. shielding gas is exiting out of the torch nozzle.
B Do not restrict shielding gas flow by allowing spatter to build
up inside the torch nozzle.
C Check that the MIG torch O-rings are not damaged.

CAUTION
Disengage the drive roll when testing for shielding gas flow by ear.
7.06 Solving Problems Beyond the Welding Terminals – Inconsistent Wire Feed
Wire feeding problems can be reduced by checking the following points.
FAULT CAUSE
1 Wire spool brake is too tight Feed roller driven by motor in the cabinet will slip.
2 Wire spool brake is too loose Wire spool can unwind and tangle.
3 Worn or incorrect feed roller size A Use ‘U’ groove drive feed roller matched to the aluminium wire
size you are welding.
B Use ‘V’ groove drive feed roller matched to the hard wire size
you are welding.
C Use ‘knurled V’ groove drive feed roller matched to the flux
cored wire size you are welding.
4 Mis-alignment of inlet/outlet Wire will rub against the mis-aligned guides and reduces wire
guides 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 If the work lead has a poor electrical contact to the work piece
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

7.07 Welding Problems
FAULT CAUSE REMEDY
1 Undercut A Welding arc voltage too high. A Reduce voltage by reducing the
Voltage Control switch positions
or turn the Wirespeed control knob
anticlockwise.
B Incorrect torch angle B Adjust angle
C Excessive heat input C Increase the torch travel speed or
reduce welding current by reducing
the Voltage Control switch positions
and turn the Wirespeed control knob
anti-clockwise.
2 Lack of penetration A Welding current too low A Increase welding current by
increasing the Wirespeed control
knob clockwise and increasing
Voltage Control switch positions.
B Joint preparation too narrow or B Increase joint angle or gap
gap too tight
C Shielding gas incorrect C Change to a gas which gives higher
penetration
3 Lack of fusion Arc voltage to low Increase Arc voltage by increasing
the Voltage Control switch positions.
4 Excessive spatter A Arc voltage too high A Lower voltage by reducing the
Voltage Control switch positions
or turn the Wirespeed control knob
B Arc voltage too low anti-clockwise.
B Raise voltage by increasing the
Voltage Control switches or turn the
Wirespeed control knob clockwise.
5 Irregular weld shape A Incorrect voltage and current A Adjust voltage and current by
settings. Convex, Arc voltage adjusting the Voltage Control switch
too low positions and the Wirespeed control
Concave, voltage too high knob.
B Wire is wandering B Replace contact tip
C Incorrect shielding gas C Check gas selection
D Insufficient or excessive heat D Adjust the Wirespeed control knob
input or the Voltage Control switch.
6 Arc does not have The MIG torch has been Connect the MIG torch to the
a crisp sound that connected to the wrong voltage positive welding terminal (+) for
short arc exhibits polarity on the front panel solid wires and gas shielded flux
when the wirefeed cored wires.
speed and voltage are
adjusted correctly

7 Weld cracking A Weld beads too small A Decrease torch travel speed
B Weld penetration narrow and B Reduce current and voltage and
deep increase the MIG Torch 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 by reducing the
Voltage Control switches.
E Cooling rate too fast E Slow the cooling rate by preheating
part to be welded or cool slowly.
8 Cold weld puddle A Faulty rectifier unit A Have an Accredited CIGWELD
Service Provider test then replace
the faulty component.
B Loss of a phase in the Mains B Check mains power
supply voltage.
C Loose welding cable connection. C Check all welding cable connections.
D Low Mains supply voltage D Contact supply authority
7.08 Power Source / Wirefeeder Problems
FAULT CAUSE REMEDY
1 Mains supply voltage A Primary fuse is blown. A Replace primary fuse.

is ON. Indicator light B Broken connection in primary B Have an Accredited CIGWELD
is not lit and welding circuit. Service Provider check primary
arc can not be circuit.
established.
2 Mains indicator Burnt out Indicator light. Have an Accredited CIGWELD
light is not lit but Service Provider replace Indicator
welding arc can be light.
established.
3 Mains supply A Faulty torch trigger A Repair or replace torch trigger
voltage is ON and switch/leads
power Indicator B Circuit breaker tripped B Reset Circuit Breaker(s)
is lit however unit
will not commence
welding when the
torch trigger switch is
depressed.
4 Mains supply voltage A Electrode wire stuck in conduit A Check for clogged / kinked MIG
is ON, no wire feed liner or contact tip (burn-back Torch conduit liner or worn
but gas flows from jam). contract tip. Replace faulty
the MIG Torch when components.
the torch trigger B Faulty control PCB B Have an Accredited CIGWELD
switch is depressed. Service Provider investigate the
fault.

5 Wire feeds when A Mig torch polarity lead is not A Connect the MIG torch polarity
the torch trigger connected into a welding output lead to either the positive welding
switch is depressed terminal. output terminal or negative output
but arc cannot be terminal as required.
established. B Poor or no work lead contact. B Clean work clamp area and ensure
good electrical contact.
6 Inconsistent wire feed A Worn or dirty contact tip A Replace if necessary.
B Worn feed roll. B Replace if necessary.
C Excessive back tension from wire C Reduce brake tension on spool
reel hub. hub
D Worn, kinked or dirty conduit liner D Clean or replace conduit liner
7 No gas flow A Gas hose is cut. A Replace or repair.
B Gas passage contains impurities. B Disconnect gas hose from the rear
of Power Source or wirefeeder
then raise gas pressure and blow
out impurities.
C Gas regulator turned off. C Turn on.
D Empty Cylinder D Replace cylinder.
8 Gas flow continues Gas valve has jammed open due Have an Accredited CIGWELD
after the torch trigger to impurities in the gas or the gas Service Provider repair or replace
switch has been line. gas valve.
released.
9 Wire does not feed A Faulty trigger switch / lead A Repair or replace Torch / trigger
when torch trigger lead
depressed B Circuit breaker tripped B Reset Circuit Breaker(s)
10 Wire continues to A Power Source in 4T (LATCH) mode A Change to 2T (NORMAL) mode

feed when torch B Torch trigger leads shorted B Repair or replace Torch / trigger
trigger released lead
11 Wire feeds when the Power Source Overtemperature Cease welding and allow Power
torch trigger switch is Protection circuit has operated Source to Cool for 10 minutes.
depressed but arc can Overheat led will extinguish when
not be established the Power Source has cooled
and OVERHEAT led is sufficiently.
illuminated


appendix weldskill 250, 350
APPENDIX 1:
KEY SPARE PARTS
17 10
7
6
19
1 5
14 16
3
9
8
2
18
13
12
15 11 Art # A-10328_AB
WELDSKILL 250 MIG SPARE PARTS

Seq. Part No Description
1 W7004501 Contactor
2 W7004502 PCB Control
3 W7004503 Solenoid Valve, 36VAC
4 W7004505 Switch, On/Off, 415V
5 W7004506 Fan Assembly, 220V
6 W7004540 Wire Drive Assembly
7 W7004541 Local Remote Switch
8 W7004513 Control Transformer
9 W7004515 Inch/Purge Switch
10 W7004518 Switch 2T/4T/Spot
11 W7004526 Main Transformer
12 W7004528 Inductor
13 W7004529 Rectifier Assembly (includes thermostat) 300A
14 W7004530 Switch Voltage 12 Position
15 W7004531 Capacitor 22000uF, 110V
16 W7004527 Auxiliary Contact
17 W7004504 Wire Reel Hub
18 W7004512 Socket Dinse, 50mm
19 W7004542 Euro Adaptor, (includes rear stem assembly)
Manual 0-5182 A-1 Appendix

weldskill 250, 350 Appendix
7 1
6 16
10
4 18
3
9
8 5
2
17 13
11
14
15
Art # A-10329_AB
12

1 W7004501 Contactor
2 W7004502 PCB Control
4 W7004505 Switch, On/Off, 415V
5 W7004506 Fan Assembly, 220V
7 W7004541 Local Remote Switch
8 W7004537 Control Transformer
9 W7004515 Inch/Purge Switch
10 W7004518 Switch 2T/4T/Spot
11 W7004500 Main Transformer
12 W7004507 Inductor Assembly
13 W7004508 Rectifier Assembly (includes thermostat) 400A
14 W7004509 Switch, Coarse Voltage
15 W7004510 Switch, Fine Voltage
17 W7004512 Socket Dinse, 50mm
Appendix A-2 Manual 0-5182

2
Art # A-10330_AB
WELDSKILL 4R WIREFEEDER SPARE PARTS
WELDSKILL 4R WIREFEEDER SPARE PARTS


APPENDIX 2:
VOLT/AMP CURVES
WeldSkill 250
WeldSkill VAVACurve
250 Curve
50.0
45.0
40.0
35.0
30.0
Volts
25.0
20.0
15.0
10.0
5.0
0.0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
Amps Art # 0-08731
WeldSkill 350 VA Curve

Weldskill 350 VA Curve
45.0
40.0
35.0
30.0
25.0
Volts
20.0
15.0
10.0
5.0
0.0
0 50 100 150 200 250 300 350 400
Amps Art # 0-08732

+
KM-1 V1 V3
TR1 35
0V
11 22 33 44 55 66 77 88
KM-5B
Manual 0-5182
29
appendix
26
C2
FU1
3A
36
+ + + + C1
R1
100/40W 100n/1KV
22000uF
22000uF 22000uF 22000uF
R3
KM-2 15R/50W
33
240V
1 2 3 4 5 6 7 8 37
28 32 V2 V4
SWITCH-12 40 22B DCL
12
11 -
10 M
S4 41
S1 _ Motor power
21B
R2
0.5Ω/30W
3
2
1
1
2
CN3 CN9 CN5 CN4 LED1 Power indicator
31 20B 21B 22B 17 18
31 1 20A 24 1
2 21A 1 2
A-5
3 22A 2 3
240V 0
20V 20V 4 27 12 4
TC LED2 Over heat
CN2
220V 20D 36V 25 19 30V CN6 CONTROL PCB
I.P.S 13 1 Thermostat1
APPENDIX 3:
Spot 8 9 14 2
30 30 7 8 27
FU2 18 6 11 Thermostat2
8A Spot timer VR2 100K 5 10
4 7 CN1
FS KM-4 S3 36V
3 6 20D 1
17 2 15 21D 2
23 1 16 22D 3 TC
KM 25
Burn back 0 20C 21C22C 3 4 5
CN7 CN8
1
2
3
4
1
2
3
VR3 100K
8
5 3 6 4
S4 4T 5 2
Spot switch T.S
Gas valve 1 2
7 9 S4
YV 42 Spot switch/4T Gun
4 6 1 3
46 47
VR1 5K
Art # A-09926_AB
WELDSKILL 250 MIG POWER SOURCE CIRCUIT DIAGRAM
20D 43 21C 22C 3 44 45

Welding current potentiometer
Appendix
weldskill 250, 350
TR1
+
A1 A2 A3 A4 A5 A6 A7 A8 A9
V1 V2 V3
Appendix
KM-1
U A
415V
26
B1 B2 B3 B4 B5 B6 B7 B8 B9
KM-2 R1 C1
V 100/40W 100n/1KV
415V B
29
FU1 C1 C2 C3 C4 C5 C6 C7 C8 C9
weldskill 250, 350
3A 33
KM-3
W
415V C V4 V5 V6
S1 S2 DCL
28 32
SWITCH -
40 22B
12
11
10 M
S4-4 41
S1 _ Motor power
21B
R2
0.5Ω/30W
3
2
1
1
2
31 31
CN3 CN9 CN5 CN4 LED1 Power indicator
A-6
20B 21B 22B 17 18
1 20A 24 1
2 21A 1 2
3 22A 2 3
415V 0V 20V 20V 4 27 12 4
LED2 Over heat
APPENDIX 4:
TC CN2
220V 20D 36V 25 19 27V CN6
I.P.S CONTROL PCB 13 1 Thermostat1
Spot 8 9 14 2
FU2 7 8 27
30 30 18 Thermostat2
6 11
8A Spot timer VR2 100K 5 10
4 7 CN1
FS KM-4 S3 36V
3 6 20D 1
17
2 15 21D 2
23 1 16 22D 3 TC
KM 25
Burn back 0 20C 21C22C 3 4 5
CN7 CN8
1
2
3
4
1
2
3
VR3 100K
8
5 3 6 4
S4 4T 5 2
Spot switch T.S
Gas valve 1 2
7 9 S4
YV 42 Spot switch/4T Gun
4 6 1 3
46 47
VR1 5K
WELDSKILL 350 MIG POWER SOURCE CIRCUIT DIAGRAM
Art # A-09927_AB
20D 43 21C 22C 3 44 45

Appendix
Manual 0-5182
Welding current potentiometer
APPENDIX 5:
4R WIREFEEDER CIRCUIT DIAGRAM
5
10
8
5
12
2
11
1
9
3
P1
6
4
Potentiometer
Wirespeed
10
11
12
1
2
3
4
5
6
7
8
9
P1
max
min
+ mid
Motor
3
Solenoid Valve
-
Torch
Art # A-09928_AB
2
1


CIGWELD LIMITED WARRANTY
LIMITED WARRANTY: CIGWELD, A Victor Technologies Company, hereafter, “CIGWELD” warrants to custom-
ers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship
or material. Should any failure to conform to this warranty appear within the time period applicable to the
CIGWELD products as stated below, CIGWELD shall, upon notification thereof and substantiation that the
product has been stored, installed, operated, and maintained in accordance with CIGWELD’s specifications,
instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair,
neglect, alteration, or accident, correct such defects by suitable repair or replacement, at CIGWELD’s sole
option, of any components or parts of the product determined by CIGWELD to be defective.
CIGWELD MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND
IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: CIGWELD SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL,
INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS
INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELD
with respect to any contract, or anything done in connection therewith such as the performance or breach
thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by CIG-
WELD whether 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.
Terms of Warranty – January 2011
1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply
of goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain
situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including war-
ranties as to merchantability and fitness for purpose) associated with the supply of goods and services.
A consumer should seek legal advice as to the nature and extent of these protected interests. In some
circumstances, the supplier of goods and services may legally stipulate that the said conditions, warran-
ties, guarantees, rights and remedies are limited or entirely excluded. The warranties set out in Clause 2
shall be additional to any non excludable warranties to which the Customer may be entitled pursuant to
any statute.
2. Subject to Clause 3. CIGWELD gives the following warranties to the Customer:
Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantable
quality and reasonably fit for the purpose for which they are supplied by CIGWELD.
CIGWELD will repair or, at its option, replace those of the goods which, upon examination, are found by
CIGWELD to be defective in workmanship and/or materials.
CIGWELD reserves the right to request documented evidence of date of purchase.
3. The Warranty in Clause 2;
Is conditional upon:
The Customer notifying CIGWELD or our Accredited Distributor in writing of its claim within seven (7) 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. The goods being
used in accordance with the Manufacturer’s Operating Manuals, and under competent supervision.
Does not apply to:
Obsolete goods sold at auction, second-hand goods and prototype goods.
Breakdown or malfunction caused by accident, misuse or normal wear and tear.
Repairs or replacement made other than by CIGWELD or Accredited Service Providers, unless by prior
arrangement with CIGWELD.
Replacement parts or accessories which may affect product safety or performance and which are not
manufactured, distributed or approved by CIGWELD.
4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supply of
goods which are not of a kind ordinarily acquired for personal, domestic or household use or consumption
to any one or more of the following (the choice of which shall be at the option of CIGWELD).
The replacement of the goods or the supply of equivalent goods.
The repair of goods.
The payment of cost of replacing the goods or acquiring equivalent goods.
The payment of the cost of having goods repaired.
5. Except as provided in Clauses 2 to 4 above, to the extent permitted by statute, CIGWELD hereby excludes
all liability for any loss, damage, death or injury of any kind whatsoever occasioned to the Customer in
respect of the supply of goods including direct, indirect, consequential or incidental loss, damage or injury
of any kind.
Warranty Schedule – January 2011
These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of
sale from the Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the
warranty period extend more than the time stated plus one year from the date CIGWELD delivered the product
to the Accredited Distributor. Unless otherwise stated the warranty period includes parts and labour. CIGWELD
reserves the right to request documented evidence of date of purchase.
WELDSKILL 250 AND 350 MIG POWER SOURCES WARRANTY PERIOD

WELDSKILL 4R WIREFEEDER PARTS LABOUR
Original main power rectifier, main power magnetics and control printed circuit 1 Year 1 Year
boards
All other circuits and components including, but not limited to, relays, switches, 1 Year 1 Year
contactors, solenoids, fans and power switch.
WELDSKILL 250 AND 350 MIG ACCESSORIES WARRANTY PERIOD
MIG torch and work lead. 3 Months

MIG torch consumable items. NIL
Gas regulator/flowmeter (excluding seat assembly, pressure gauges, elastomer
1 Year
seals and“O”rings).
Regulator seat assemblies and pressure gauges. 6 Months
Elastomer seals and“O”rings used in the equipment. 3 Months

Please note that the information detailed in this statement supersedes any prior published data produced by
CIGWELD.
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Cigweld, Australia Victor Technologies, China
71 Gower Street No.100 Lao Hongjing Rd,
Preston, Victoria Minhang District
Australia, 3072 Shanghai 200235
Telephone: 61-3-9474-7400 China
Fax: 61-3-9474-7391 Telephone: 86-21-64072626
Email: enquiries@cigweld.com.au Fax: 86-21-64483032
Victor Technologies USA Victor Technologies Asia Sdn Bhd

2800 Airport Road Lot 151, Jalan Industri 3/5A
Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang
Telephone: (940) 566-2000 48000 Rawang Selangor Darul Ehsan
800-426-1888 West Malaysia
Fax: 800-535-0557 Telephone: 603+ 6092 2988
Email: sales@thermalarc.com Fax : 603+ 6092 1085
Victor Technologies Canada Victor Technologies Italy

2070 Wyecroft Road OCIM, S.r.L.
Oakville, Ontario Via Benaco, 3
Canada, L6L5V6 20098 S. Giuliano
Telephone: (905)-827-1111 Milan, Italy
Fax: 905-827-3648 Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Victor Technologies Europe
Victor Technologies International
Europe Building
Chorley North Industrial Park 2070 Wyecroft Road
Chorley, Lancashire Oakville, Ontario
England, PR6 7Bx Canada, L6L5V6
Telephone: 44-1257-261755 Telephone: (905)-827-9777
Fax: 44-1257-224800 Fax: 905-827-9797
PT. Victor Technologies Utama Indonesia

Jl. Angsana II Blok AE No. 28
Delta Silicon I, Cikarang - Sukaresmi
Bekasi, 17550
Indonesia
Tel: +62 21 8990 6095
Fax: +62 21 8990 6096 / 1867
http://www.victortechnologies.com
Asia Pacific Regional Headquarters
71 Gower Street
Preston, Victoria, Australia, 3072
Telephone: +61 3 9474 7400
FAX: +61 3 9474 7391
Email: enquiries@cigweld.com.au
www.cigweld.com.au

Cigweldaeb Weldskill 250, 350 & Weldskill 4r Wirefeeder 0-5182 - Ae

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Cigweldaeb Weldskill 250, 350 & Weldskill 4r Wirefeeder 0-5182 - Ae

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250

Version No: AE Issue Date: December 27,2013 Manual No.: 0-5182

This Operating Manual has been designed to instruct you on the

YOU ARE IN GOOD COMPANY!

We distinguish ourselves from our competition through market-

Above all, we are committed to develop technologically advanced

Welding Power Supply

WeldSkill 250 Compact MIG Plant (Asia) Part Number W1003400

WeldSkill 4R Wirefeeder Plant (Optional-All Regions) Part Number W3000401

Copyright 2011, 2012, 2013 by CIGWELD

All rights reserved.

Publication Date: March 10, 2011

Record the following information for Warranty purposes:

Where Purchased: _____________________________________

Purchase Date: _____________________________________

Equipment Serial #: _____________________________________

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

SECTION 6:BASIC WELDING GUIDE ..................................................................... 6-1

APPENDIX 2:VOLT/AMP CURVES......................................................................... A-4

APPENDIX 3:WELDSKILL 250 MIG POWER SOURCE CIRCUIT DIAGRAM........................... A-5

APPENDIX 4:WELDSKILL 350 MIG POWER SOURCE CIRCUIT DIAGRAM........................... A-6

APPENDIX 5:4R WIREFEEDER CIRCUIT DIAGRAM..................................................... A-7

CIGWELD LIMITED WARRANTY

Terms of Warranty – January 2011

Warranty Schedule – January 2011

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

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

Manual 0-5182 1-1 Safety Instructions

Safety Instructions 1-2 Manual 0-5182

Recommended Protective Filters for Electric Welding

Manual 0-5182 1-3 Safety Instructions

7. Keep protective cap in place over valve except when cylinder

Safety Instructions 1-4 Manual 0-5182

Manual 0-5182 1-5 Safety Instructions

Safety Instructions 1-6 Manual 0-5182

NOTE Include all equipment identification numbers as

Manual 0-5182 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 Meters Per Minute

Auxiliary Power Variable Inductance

115V 15A Receptacle Rating-

Introduction 2-2 Manual 0-5182

Manual 0-5182 2-3 Introduction

Introduction 2-4 Manual 0-5182

WeldSkill 250 Welding Current (amps)

Duty Cycle for 350

Manual 0-5182 2-5 Introduction

Description WeldSkill 250 MIG

Plant Part Numbers W1003400 & W1004500

Introduction 2-6 Manual 0-5182

Description WeldSkill 350 MIG

Plant Part Numbers W1003500 & W1004600

Manual 0-5182 2-7 Introduction