CIGWELD W4016300 User manual

Manual 0-5228 1 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
CIGWELD Pty. Ltd
71 Gower Street
Preston, Victoria, Australia, 3072
Telephone: [phone]
www.cigweld.com.au
Manual 0-5228
Revision No.: AA
Issue Date: September 14, 2012
Spool Cover for VAF4, VAF4HD
and WeldSkill 4R Wirefeeders
Part Number: W4016300
Assembly Instructions
General Information
The Cigweld spool cover is designed to be used together with VAF4, VAF4 HD and WeldSkill 4R Wirefeeders. These
instructions will guide you through the proper assembly procedure of the spool cover.
Supplied Parts (For Transmig VAF4 and VAF4 HD Wirefeeders)
The following components are included in this kit:
Item Description Quantity
1 Bolt, M12 x 30 2
2 Star Washer, M12 2
3 Flat Washer, M12 2
4 Screw, Countersunk, M5 x 12 2
5 Spool Cover Mounting Bracket 1
6 Spool Cover 1
7 Spool Cover Mounting Bracket 1
Table 1 Spool Cover Assembly
Art # A-11347
1
2
3
4
5
6
7
Figure 1 Spool Cover Assembly (For Transmig VAF4 and VAF4 HD Wirefeeders)

Spool Cover Assembly Instruction 2 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
!
WARNING
Disconnect input power to the power source before installing or removing this control.
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.
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit
is electrically live whenever the output is on. The input power circuit and machine internal circuits
are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel,
drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power
disconnect switch open, or remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local
codes.
6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of
service.
7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the
work surface. Do not touch holders connected to two welding machines at the same time or touch other
people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.

Manual 0-5228 3 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
10.Ground the workpiece to a good electrical (earth) ground.
11.Do not touch electrode while in contact with the work (ground) circuit.
12.Use only well-maintained equipment. Repair or replace damaged parts at once.
13.In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a volt-
age reducer. Use equipment with DC output.
14.Wear a safety harness to prevent falling if working above floor level.
15.Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage hearing.
Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn
eyes and skin. Noise from some processes can damage hearing.
1. Use a Welding Helmet or Welding Faceshield fitted with a proper shade of filter (see ANSI Z49.1 and AS 1674
listed in Safety Standards) to protect your face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protec-
tion.
5. Use approved ear plugs or ear muffs if noise level is high.
6. Never wear contact lenses while welding.
WARNING
FUMES AND GASES can be hazardous to your health.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables,
coatings, and cleaners.
5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding
gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can
react with vapours to form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is
removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied
respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

Spool Cover Assembly Instruction 4 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding
wire to metal objects can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them
with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and open-
ings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as practical to prevent welding current from
travelling long, possibly unknown paths and causing electric shock and fire hazards.
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.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific
application; maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
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, associated equipment, and CGA publication P-1
listed in Safety Standards.

Manual 0-5228 5 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
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.
!
WARNING
This product, when used for welding or cutting, produces fumes or gases which contain chemicals
know to the State of California to cause birth defects and, in some cases, cancer. (California Health
& Safety code Sec. 25249.5 et seq.)
NOTE
Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology
Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government
Printing Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at
the cellular level and from studies with animals and people which clearly establish that low frequency magnetic
fields and interact with, and produce changes in, biological systems. While most of this work is of very high
quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evi-
dence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclu-
sions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid
potential risks.”
To reduce magnetic fields in the workplace, use the following procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also normally recommended for pacemaker wearers. Con-
sult your doctor for complete information.

Spool Cover Assembly Instruction 6 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
Recommended Protective Filters for Electric Welding
Description of Process Approximate Range of
Welding Current in Amps
Minimum Shade Number of
Filter(s)
Manual Metal Arc Welding - covered
electrodes (MMAW)
Less than or equal to 100 8
100 to 200 10
200 to 300 11
300 to 400 12
Greater than 400 13
Gas Metal Arc Welding (GWAW)
(MIG) other than Aluminium and
Stainless Steel
Less than or equal to 150 10
150 to 250 11
250 to 300 12
300 to 400 13
Greater than 400 14
Gas Metal Arc Welding (GMAW)
(MIG) Aluminium and Stainless Steel
Less than or equal to 250 12
250 to 350 13
Gas Tungsten Arc Welding (GTAW)
(TIG)
Less than or equal to 100 10
100 to 200 11
200 to 250 12
250 to 350 13
Greater than 350 14
Flux-cored Arc Welding (FCAW) -with
or without shielding gas.
Less than or equal to 300 11
300 to 400 12
400 to 500 13
Greater than 500 14
Air - Arc Gouging Less than or equal to 400 12
Plasma - Arc Cutting
50 to 100 10
100 to 400 12
400 to 800 14
Plasma - Arc Spraying —15
Plasma - Arc Welding
Less than or equal to 20 8
20 to 100 10
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

Manual 0-5228 7 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
Assembly Procedure For Transmig VAF4 and VAF4 HD Wirefeeders
Spool cover is assembled in the following steps:
1. Remove the spool hub assembly.
a. Remove the clip from the spool hub.
b. Unscrew the 3-lobe screw.
c. Remove the spool hub parts and the spacer in the following sequence. Note that the spacer is not
required when fitting the spool cover.
Hexagon Nut
Spring Washer
Flat Washer,large hole
Spacer
Shaft
Friction Washer
Hub Wire Reel
Keyed Washer
Compression Spring
Flat Washer, small hole
3-lobe Screw
Retaining Clip
Art # A-11514
Figure 2 Removing Spool Hub Assembly (For Transmig VAF4 and VAF4 HD Wirefeeders)
2. Assemble the Spool Cover Mounting Brackets, one inside and one outside the spool cover, with the two
countersunk screws M5 x 12.
3. Secure the spool cover assembly to the spool support arm with M12 x 30 Bolts, Star Washers, M12, and
Flat Washers, M12 as shown in the diagram below.
Art # A-11344
Spool Cover Mounting Brackets
Spool Cover
Countersunk Screws,
M5×12
Hub Wire Reel
Keyed Washer
Compression Spring
Flat Washer, small hole
3-lobe Screw
Retaining Clip
Friction Washer
M12 x 30 Bolts;
Star Washers, M12;
Flat Washers, M12
Figure 3 Installing Spool Cover (For Transmig VAF4 and VAF4 HD Wirefeeders)

Spool Cover Assembly Instruction 8 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
3. Install the spool hub component parts over the spool hub shaft in the following sequence.
Friction Washer
Spool Hub
Keyed Washer
Spring
Flat Washer
3-lobe Screw
Retaining Clip
Art # A-11349
Figure 4 Spool Hub Assembly (For Transmig VAF4 and VAF4 HD Wirefeeders)
WARNING
Fully tighten all fasteners.

Manual 0-5228 9 Spool Cover Assembly Instruction
SPOOL COVER ASSEMBLY ( W4016300 ) INSTRUCTIONS
Refer to the figures below for the assembled spool cover:
Art # A-11356
Figure 5a Assembled Spool Cover (door opened) (For Transmig VAF4 and VAF4 HD Wirefeeders)
Art # A-11348
Figure 5b Assembled Spool Cover (For Transmig VAF4 and VAF4 HD Wirefeeders)

Spool Cover Assembly Instruction 10 Manual 0-5228
SPOOL COVER ASSEMBLY (W4016300) INSTRUCTIONS
Assembly Procedure For WeldSkill 4R Wirefeeder
1. Remove the spool hub assembly in the sequence as shown in the figure below (except for the spool hub
base).
Spool Hub Nut
Bolt
Flat Washer
Flange
Spool Hub
Art # A-11515
Spool Hub Base
Spool Cover
Fibre Washer
Spring
Figure 6 Removing Spool Hub Assembly (For WeldSkill 4R Wirefeeders)
2. Remove the spool hub base and the spool cover by loosening the M8 bolt.
M8 Bolt
Art # A-11516
Spool Hub Base
M8 Fasteners
Figure 7 Removing M8 Fasteners (For WeldSkill 4R Wirefeeders)
3. Fit the new spool cover and spool hub base using the M8 fasteners. (Please refer to Figure 7)