CIGWELD WeldSkill 120 Turbo User manual

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

LEADER IN ARC WELDING TECHNOLOGY
We appreciate your business!
Con
g
ratulations on
y
our new CIGWELD product. We are proud to have
y
ou
as our customer and will strive to provide
y
ou with the best service and
reliability in the industry. This product is backed by our extensive warrant
y
and world-wide service network. To locate
y
our nearest distributor or
service agency call 1300-654-674, or visit us on the web at
www.cigweld.com.au.
This Operating Manual has been designed to instruct
y
ou on the correct
use and operation of
y
our 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, especiall
y
the Safet
y
Precautions.
The
y
will help
y
ou to avoid potential hazards that ma
y
exist when workin
g
with this product.
YOU ARE IN GOOD COMPANY
The Brand of Choice for Contractors and Fabricators. CIGWELD is the
Market Leadin
g
Brand of Arc Weldin
g
Products for Thermad
y
ne Industries
Inc.
We are a mainline supplier to ma
j
or weldin
g
industr
y
sectors in the Asia
Pacific and emer
g
in
g
g
lobal markets includin
g
; Manufacturin
g
,
Construction, Mining, Automotive, Engineering, Rural and DIY.
We distinguish ourselves from our competition through market leadin
g
dependable brands that have stood the test of time, technical innovation,
competitive prices, excellent deliver
y
, superior customer service and
technical support, to
g
ether with excellence in sales and marketin
g
expertise.
We are committed to develop technolo
g
icall
y
advanced products to
achieve a safer working environment for industry operators.
ii Dec 22, 2006

WARNING 1
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
Instruction Manual Number 719527 for:
120 Turbo Manual Metal Arc Welder Spec Number W1002000
140 Turbo Manual Metal Arc Welder Spec Number W1002100
Published by:
CIGWELD Pty Ltd
71 Gower Street
Preston, Victoria, Australia, 3072
www.cigweld.com.au
Copyright 2007 by
CIGWELD
All rights reserved.
A reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in
this Manual, whether such error results from negligence, accident, or any other cause.
Publication Date: Dec 21, 2006
Record the following information for Warranty purposes:
Where Purchased: ___________________________________________
Purchase Date: ___________________________________________
Equipment Serial #: ___________________________________________
Dec 22, 2006 iii

120 Turbo,140 Turbo
TABLE OF CONTENTS
SECTION 1: Arc Welding Safety Instructions and Warnings..........................................................5
SECTION 2: Introduction ..................................................................................................................10
SECTION 3: Electromagnetic Compatibility ...................................................................................10
SECTION 4: General Information.....................................................................................................11
SECTION 5: Safe Practices For The Use Of Welding Equipment.................................................12
SECTION 6: Resuscitation For Electric Shock Victims.................................................................13
SECTION 7: Specifications...............................................................................................................15
SECTION 8: Installation Recommendations...................................................................................15
SECTION 9: Operation ......................................................................................................................17
SECTION 10: Setup For Arc Welding ................................................................................................17
SECTION 11: Arc Welding Electrodes...............................................................................................18
SECTION 12: Arc Welding Practice...................................................................................................19
SECTION 13: Arc Welding Technique...............................................................................................21
SECTION 14: Distortion ......................................................................................................................24
SECTION 15: Routine Maintenance & Inspection............................................................................26
SECTION 16: Basic Troubleshooting................................................................................................26
TABLES
Table 1 - Filter lens size verses welding current/electrode size..................................................................................................................................13
Table 2 - Types of Electrodes.......................................................................................................................................................................................18
4 Dec 22, 2006

120 Turbo,140 Turbo
SECTION 1: Arc Welding Safety Instructions and Warnings
WARNING 2
ARC WELDING can be hazardous.
Protect yourself and others from possible serious injury or death. Keep children away. Pace maker wearers keep away until
consulting your doctor. Do not lose these instructions. Read operating / instruction manual before installing, operating or
servicing this equipment.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly
observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before
using this equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld. Certain practices apply to equipment
connected to power lines; other practices apply to engine driven equipment.
Safe practices are out lined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. 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.
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 terminal 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 10 cal 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, under sized or poorly spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with 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 voltage 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.
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. Wear a welding helmet fitted with a proper shade of filter (see ANSI
249.1 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 protection.
5. Use approved earplugs or earmuffs if noise level is high.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73
Welding or Cutting
operation
Electrode size Metal Thickness or
Welding Current
Filter
shade
no.
Welding or Cutting operation Electrode size Metal
Thickness or Welding
Current
Filter
shade no.
Torch soldering All 2 Gas metal arc welding
Torch brazing All 2 or 3 Non Ferrous base metal All 11
Oxygen cutting Ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding (TIG) All 12
Medium 1 – 6 in., 25 – 150 mm 4 or 5 Atomic Hydrogen welding All 12
Heavy Over 6 in., 150 mm 5 or 6 Carbon Arc welding All 12
Gas welding Plasma arc Welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Carbon Arc Gouging
Medium 1/8 – 1/2 in., 3 – 12 mm 5 or 6 Light 12
Heavy Over 1/2 in., 12 mm 6 or 8 Heavy 14
Shielded metal-arc welding (stick) electrodes Plasma arc cutting
Under 5/32 in., 4 mm 10 Light Under 300 Amp 9
Under 5/32 to ¼ in., 4 to 6.4mm 12 Medium 300 to 400 Amp 12
Over ¼ in., 6.4 mm 14 Heavy Over 400 Amp 14
Dec 22, 2006 5

120 Turbo,140 Turbo
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 (MSDS) 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 re moved 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.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot work
piece, and hot equipment can cause fires and burns.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, over heating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material
Remove all flammables within 35ft (10.7 m) of the welding arc. If this is
not possible, tightly cover them with approved covers.
3. Be alert that welding sparks and hot materials from welding can easily
go through small cracks and openings to adjacent areas.
4. Watch for fire, and keep a fire extinguisher nearby.
5. Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
6. Do not weld on closed containers such as tanks or drums.
7. 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.
8. Do not use welder to thaw frozen pipes.
9. Remove stick electrode from holder or cut off welding wire at contact tip
when not in use.
6 Dec 22, 2006
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.
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 carefuIIy.
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.
WARNING 3
ENGINES can be dangerous.
ENGINE EXHAUST GASES can kill. 1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away from any
building air intakes.
Engines produce harmful exhaust gases
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any
sparks or open flames.
3.
A
llow engine to cool before fuelling. If possible, check and add fuel to cold
engine before beginning job.
4. Do not overfill tank - allow room for fuel to expand away from any building
air intakes.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
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.

120 Turbo,140 Turbo
1. Keep all doors, panels, covers, and guards closed and securely in place.
2. Stop engine before installing or connecting unit.
6. Re-install panels or guards and close doors when servicing is finished and
before starting engine.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can burn
eyes and skin.
Batteries contain acid and generate explosive gases
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and unde
r
pressure
1. Do not remove radiator cap when engine is hot. Allow engine to cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known 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 can 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 evidence in a single coherent framework. Even more frustrating, it does not
yet allow us to draw definite conclusions 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 work place, use the following procedures:
1. Keep cables close together by twisting or taping them. 2. Do not coil or drape cables around the body.
3. Arrange cables to one side and away from the operator. 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. Consult your doctor for complete
information.
Dec 22, 2006 7

120 Turbo,140 Turbo
1.01 Declaration of Conformity
Manufacturer and Merchandiser of Quality Consumables and Equipment: CIGWELD
Address: 71 Gower St, Preston
Victoria 3072
Australia
Description of equipment: Welding Equipment (MMAW). CIGWELD 120 Turbo & 140 Turbo 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:
* AS60974.6 2006 applicable to welding equipment and associated accessories.
* AS/NZS 3652-(EMC Directive EN50199) applicable to arc welding equipment - generic emissions and regulations.
* EN60974-1 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 incorporated 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.
1.02 Limited Warranty
LIMITED WARRANTY: CIGWELD, A Thermadyne Company, hereafter, “CIGWELD” warrants to customers 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 CIGWELD whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly
provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of CIGWELD is authorized to change this warranty
in any way or grant any other warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN CIGWELD’S SOLE JUDGEMENT
MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY CIGWELD PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS
SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.
8 Dec 22, 2006

120 Turbo,140 Turbo
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 – July 2007
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 warranties 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, warranties, 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 2007
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.
CIGWELD ARC WELDING EQUIPMENT WARRANTY PERIOD
120 Turbo, 140 Turbo
Main Power Magnetics.........................................................................................................................................................................
.
.
.........................1 year
All other circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, power switch semi-
conductors ...........................................................................................................................................................................................
.
.
.........................1 year
ACCESSORIES
Electrode Holder and Work Clamp.......................................................................................................................................................
.
.
.......................3 months
Hand shield..........................................................................................................................................................................................
.
.
.......................3 months
Please note that the information detailed in this statement supersedes any prior published data produced by CIGWELD.
WARNING 4
For the purpose of safety and performance and to protect your CIGWELD Equipment Warranty always use genuine CIGWELD
replacement parts and accessories.
Dec 22, 2006 9

120 Turbo,140 Turbo
SECTION 2: Introduction
2.01 How to Use This Manual
This Owner’s Manual usually applies to just the underlined
specification or part numbers listed on the page 3. If none are
underlined, they are all covered by this manual.
To ensure safe operation, read the entire manual, including the
chapter on safety instructions and warnings.
Throughout this manual, the word WARNING,
CAUTION and NOTE may appear. Pay particular attention to the
in formation provided under these headings. These special
annotations are easily recognized as follows:
WARNING
Gives information regarding possible personal injury.
Warnings will be enclosed in a box such as this.
CAUTION
Refers to possible equipment damage. Cautions will be
shown in bold type.
NOTE
Offers helpful information concerning certain operating
procedures. Notes will be shown in italics.
2.02 Equipment Identification
The unit’s identification number (specification or part number),
model, and serial number usually appear on a nameplate attached
to the machine.
Equipment which does not have a nameplate attached to the
machine is identified only by the specification or part number
printed on the shipping container. Record these numbers for future
reference.
2.03 Receipt of Equipment
When you receive the equipment, check it against the invoice to
make sure it is complete and inspect the equipment for possible
damage due to shipping. If there is any damage, notify the carrier
immediately to file a claim. Furnish complete information
concerning damage claims or shipping errors to:
CIGWELD, Customer Care Department, 71 Gower St, Preston,
Victoria, Australia, 3072.
Include all equipment identification numbers as described above
along with a full description of the parts in error.
Additional copies of this manual may be purchased by contacting
CIGWELD, Customer Care Department, at the address given
above. Include the Owner’s Manual number and equipment
identification numbers.
SECTION 3: Electromagnetic Compatibility
WARNING 5
Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a
domestic situation.
3.01 Installation and use - Users Responsibility
The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If
electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the
situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the
welding circuit, see NOTE 1. In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power
Source and the work, complete with associated input filters. In all cases, electromagnetic disturbances shall be reduced to the point
where they are no longer troublesome.
NOTE 1
The welding circuit may or may nor be earthed for safety reasons. Changing the earthing arrangements should only be
authorised by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing
parallel welding current return paths which may damage the earth circuits of other equipment. Further guidance is given
in IEC 974-13 Arc Welding Equipment - Installation and use (under preparation).
3.02 Assessment of Area
Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding
area. The following shall be taken into account
i) Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the
welding equipment.
ii) Radio and television transmitters and receivers.
iii) Computer and other control equipment.
10 Dec 22, 2006

120 Turbo,140 Turbo
iv) Safety critical equipment, e.g. guarding of industrial equipment.
v) The health of people around, e.g. the use of pacemakers and hearing aids.
vi) Equipment used for calibration and measurement.
vii) The time of day that welding or other activities are to be carried out.
viii) The immunity of other equipment in the environment: the user shall ensure that other equipment being used in
the environment is compatible: this may require additional protection measures.
The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking
place. The surrounding area may extend beyond the boundaries of the premises.
3.03 Methods of Reducing Electromagnetic Emissions
a) Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If
interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration
should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent.
Shielding should be electrically continuous throughout it’s length. The shielding should be connected to the Welding Power
Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure.
b) Maintenance of Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and
service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding
equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of arc striking and stabilising devices should be adjusted and maintained according
to the manufacturer’s recommendations.
c) Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at or close to the
floor level.
d) Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered. However. Metallic
components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic
components and the electrode at the same time. The operator should be insulated from all such bonded metallic
components.
e) Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of it’s size and position, e.g.
ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all
instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to
other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by direct connection
to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable
capacitance, selected according to national regulations.
f) Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of
interference. Screening the entire welding installation may be considered for special applications.
SECTION 4: General Information
4.01 120 Turbo
This compact, portable, home handyman arc welder has infinitely adjustable welding current from 40 to 100 amps and is designed
to operate from a domestic 240V, 10 amp outlet. It runs standard general purpose 2.5mm electrodes for light gauge work,
generally less than 3.0mm thick.
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4.02 140 Turbo
This compact heavy duty, fan cooled, portable, home handyman arc welder has infinitely adjustable welding current from 50 to 130
amps and is designed to operate from a 240V, 15 amp outlet It runs standard general purpose 2.5mm electrodes for light gauge
work, generally less than 3.0mm thick, and 3.2mm electrodes for heavier materials.
4.03 User Responsibility
This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in
accordance with the instructions provided. This equipment must be checked periodically. Defective equipment (including welding
leads) should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced
immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by
appropriately qualified persons approved by CIGWELD. Advice in this regard can be obtained by contacting accredited CIGWELD
Distributor.
This equipment or any of its parts should not be altered from standard specification without prior written 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.
4.04 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output
without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the
following example is used. Suppose a Welding Power Source is designed to operate at a 15% duty cycle, 90 amperes at 23.6
volts. This means that it has been designed and built to provide the rated amperage (90A) for 1.5 minutes, i.e. arc welding time,
out of every 10 minute period (15% of 10 minutes is 1.5 minutes). During the other 8.5 minutes of the 10 minute period the
Welding Power Source must idle and allowed to cool.
SECTION 5: Safe Practices For The Use Of Welding Equipment
In many situations the “striking” voltage can be hazardous. Any person touching simultaneously the electrode lead/terminal and the work
lead/terminal may receive a serious electrical shock. Additional precautions must be exercised where two Welding Power Sources are
being used close to each other because, under certain conditions, the voltages between the welding terminals of the two Welding Power
Sources could be two times the specified open circuit voltage.
It is essential that the Welding Power Source is correctly installed, if necessary, by a qualified electrician and maintained in sound
mechanical and electrical condition. It is also important that the Welding Power Source be switched off when not in use.
5.01 Precautions to be Taken by Operators
♦ Whenever practicable, all parts of the welding circuit should be isolated from earth and other conducting material and under no
circumstances should any earthing conductor of the electrical installation be used in place of the work lead.
♦ The Mains supply voltage should be switched off before connecting or disconnecting welding leads. Welding lead connections
must have clean contact surfaces and must be securely tightened. Poor connections will result in overheating and loss of
welding current. All parts of the welding circuit, including the return paths, are to be considered electrically alive, so the
operator must ensure that no part of the body is placed in such a position that it will provide a path for an electric current.
♦ Welding operators should avoid direct contact with the work to be welded or against any metal in contact with the work. When
this cannot be avoided the operator must not touch any exposed portion of the electrode holder with any part of the body.
Should this occur, the operator will risk completing the electrical circuit through the body.
♦ When welding in confined spaces, where reasonable movement is restricted, particular care must be taken to ensure that the
area is well ventilated and the operator is under constant observation by a person who can immediately switch off the power
and give assistance in an emergency.
♦ The flux covering of an electrode cannot be assumed to provide effective insulation, consequently an insulating glove must be
worn when placing an electrode into its holder, or should it be necessary to handle an electrode once it is in contact with its
holder.
♦ During pauses between welding runs, electrode holders should be so placed that they cannot make electrical contact with
persons or conductive objects.
♦ The welding leads, both the electrode lead and the work lead, must be protected from damage. Damaged leads must not be
used.
♦ Keep combustible materials away from the welding area. Have a suitable fire extinguisher handy.
♦ Do not stand on damp ground when welding.
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5.02 Personal Protection
The radiation from an electric arc during the welding process can seriously harm eyes and skin. It is essential that the following
precautions be taken:
♦ Gloves should be flameproof gauntlet type to protect hands and wrists from heat burns and harmful radiations. They should be
kept dry and in good repair.
♦ Protective clothing must protect the operator from burns, spatter and harmful radiation. Woollen clothing is preferable to cotton
because of its greater flame resistance. Clothing should be free from oil or grease. Wear leggings and spats to protect the
lower portion of the legs and to prevent slag and molten metal from falling into boots or shoes.
♦ Welding handshield
It is a requirement to use a welding handshield, complying to a relevant standard, when electric arc welding. Use a welding
handshield in serviceable condition and fitted with an eye filter lens to safely reduce harmful radiation from the arc as per Table
1.
Welding current range Electrode Diameter Suggested Filter Lens
40 to 70A 2.0mm Shade 8
55 to 90A 2.5mm Shade 8
90 to 135A 3.2mm Shade 10
135 to 200A 4.0mm Shade 10
Table 1 - Filter lens size verses welding current/electrode size
Protective filter lenses are provided to reduce the intensity of radiation entering the eye thus filtering out harmful infra-red, ultra-
violet radiation and a percentage of the visible light. Such filter lenses are incorporated within welding handshields. To prevent
damage to the filter lenses from molten or hard particles an additional hard clear glass or special plastic external cover lens is
provided. This cover lens should always be kept in place and replaced before the damage impairs your vision while welding.
Notes:
♦ Recognised standards for recommended practices for occupational eye protection include AS/ANZ 1336 and EN 175.
♦ For maximum possible protection, the use of full helmet equipment is recommended.
♦ The indicated filter lens shade numbers are minimum. If any discomfort is felt, higher shade numbers (i.e. darker filters)
should be used.
SECTION 6: Resuscitation For Electric Shock Victims
Electric shock may kill immediately. Early resuscitation is required if a life is to be saved. Every Second Counts! Electrical currents may:
♦ Stop the heart;
♦ Cause contraction of the muscles of the body;
♦ Paralyse breathing due to paralysis of the centre of respiration in the brain;
♦ Cause burns.
The victims often cannot free themselves from the current and may not be able to breathe due to fixation of the chest.
6.01 Resuscitation
Efficient resuscitation requires training which is available from the St John’s Ambulance Association, Red Cross and other sources.
1 Don’t become a victim. Switch off power if possible. If
not, remove victim from contact, using some insulating
material.
2 If unconscious, place victim on their side and clear vomit
and other foreign matter from mouth. Check for breathing
by look, listen and feel. If not breathing, commence
expired air resuscitation (E.A.R.). This should take no
longer than 3 or 4 seconds.
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3 Place victim flat on their back on a hard surface, open
airway - using head tilt and jaw support as shown.
4 Begin artificial breathing - 5 full breaths in 10 seconds,
sealing nostrils with cheek or holding nose closed.
5 Check carotid pulse in neck. If pulse is present,
continue E.A.R.
15 breaths per minute for adults.
20 breaths per minute for children.
6 If pulse is absent and you have been trained, begin cardio
pulmonary resuscitation (C.P.R).
Cardiac Compression - depress lower end of breast bone
(sternum) 4cm to 5cm, less for small children.
One rescuer - 2 breaths, 15 compressions in 15 seconds,
i.e. 4 cycles per minute.
Two rescuers - 1 breath, 5 compressions in 5 seconds, i.e.
12 cycles per minute.
7 Check for return of pulse and breathing after 1 minute
and at least every 2 minutes. Continue uninterrupted
until trained assistance is available. When breathing
and pulse return, turn on side and continue
observation.
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SECTION 7: Specifications
7.01 120 Turbo and 140 Turbo Specifications
Description (Refer NOTE 2) 120 Turbo 140 Turbo
Product Part Number W1002000 W1002100
Cooling Fan Cooled Fan Cooled
Welder Type & Welding process
Light Duty,
Leakage reactance,
Manual Metal Arc Welding
Medium Duty,
Leakage reactance,
Manual Metal Arc Welding
Welding Power Source mass 15.5kg 16kg
Dimensions H 400mm x W 220mm x D 280mm H 470mm x W 215mm x D 295mm
Manufactured to Australian Standard AS60974.6-2006 AS60974.6-2006
Number of Phases Single phase Single phase
Nominal Supply Voltage 240V 240V
Nominal Supply Frequency 50Hz 50Hz
Effective Input Current ∇9.5 Amps ∇12 Amps
Flexible Supply Cable Size 10A Heavy Duty 15A Heavy Duty
Thermal Protection Yes; Self Resetting Yes; Self Resetting
Maximum Input Current (I1 max) 21.7 Amps 30 Amps
Single Phase Generator Requirement  5.3kVA  7.2kVA
Recommended Rated Outlet 10 Amps 15 Amps
Recommended Wire Fuse Size 16A 16A
Welding Current Range 40 - 100A 50 - 130A
Welding Current @ 25% duty cycle 50A 80A
Welding Current @ 5% duty cycle 120A 140A
Open Circuit Voltage 47V 48V
∇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 2
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.
7.02 Plant Contents
Description 120 Turbo 140 Turbo
Welding Power Source 99
Electrode lead (fitted) 99
Work lead (fitted) 99
Face shield 99
Wire brush/Chipping hammer 99
99
Operating Manual
SECTION 8: Installation Recommendations
8.01 Environment
These units are designed for use in environments with increased hazard of electric shock.
a) Examples of environments with increased hazard of electric shock are -
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i) In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a
cramped (kneeling, sitting or lying) position with physical contact with conductive parts;
ii) In locations which are fully or partially limited by conductive elements, and in which there is a high risk of
unavoidable or accidental contact by the operator, or
iii) In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the
human body and the insulation properties of accessories.
b) Environments with increased hazard of electric shock do not include places where electrically conductive parts in the
near vicinity of the operator, which can cause increased hazard, have been insulated.
8.02 Location
Be sure to locate the welder according to the following guidelines:
a) In areas, free from moisture and dust.
b) Ambient temperature between 0o C to 400C.
c) In areas, free from oil, steam and corrosive gases.
d) In areas, not subjected to abnormal vibration or shock.
e) In areas, not exposed to direct sunlight or rain.
f) Place at a distance of 300mm or more from walls or similar that could restrict natural air flow for cooling.
8.03 Ventilation
Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.
8.04 Mains Supply Voltage Requirements
The Mains supply voltage should be within ±10% of the rated Mains supply voltage. Too low a voltage may cause poor welding
performance. Too high a supply voltage will cause components to overheat and possibly fail.
The Welding Power Source must be:
♦ Correctly installed, if necessary, by a qualified electrician.
♦ Correctly earthed (electrically) in accordance with local regulations.
♦ Connected to the correct size power point and fuse as per the Specifications on pages 15.
8.05 Welding Handshield Assembly
♦ Remove the main face shield assembly and the hand grip from the packaging.
♦ Hook the handle into the main face shield assembly as shown in Figure 1 below.
♦ Clip the welding lense supplied into position as shown in Figure 2 below.
Figure 1 - Hook handle into the main
face shield assembly
Figure 2 - Clip welding lense into
position as shown
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SECTION 9: Operation
Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to workpiece and electrode
lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short
term overload without adverse effects. The welding current range values should be used as a guide only. Current delivered to the arc is
dependent on the welding arc voltage, and as welding arc voltage varies between different classes of electrode, welding current at any one
setting would vary according to the type of electrode in use. The operator should use the welding current range values as a guide, then
finally adjust the current setting to suit the application.
9.01 120 Turbo and 140 Turbo Controls
a) ON/OFF Switch
This switch connects the Mains supply voltage to the welding
transformer when in the ON position which enables the user to
commence welding.
b) Thermal Overload Light
The welding transformer is protected by a self resetting
thermostat. If the overload light illuminates then wait for the
overload light to extinguish before resuming your arc welding.
c) Welding Current Control
The welding current is increased by turning the Current Control
clockwise or decreased by turning the Current Control anti-
clockwise.
SECTION 10: Setup For Arc Welding
WARNING 6
Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Mains
power supply is switched off.
CAUTION 1
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power
Source.
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SECTION 11: Arc Welding Electrodes
Metal arc welding electrodes consist of a core wire surrounded by a flux coating. The flux coating is applied to the core wire by an extrusion
process.
The coating on arc welding electrodes serves a number of purposes:
a) To provide a gaseous shield for the weld metal, and preserve it from contamination by the atmosphere whilst in a
molten state.
b) To give a steady arc by having ‘arc stabilisers’ present, which provide a bridge for current to flow across.
c) To remove oxygen from the weld metal with ‘deoxidisers’.
d) To provide a cleansing action on the work piece and a protective slag cover over the weld metal to prevent the
formation of oxides while the metal is solidifying. The slag also helps to produce a bead of the desired contour.
e) To introduce alloys into the weld deposits in special type electrodes.
11.02 Types of Electrodes
Arc Welding electrodes are classified into a number of groups depending on their applications. There are a great number of
electrodes used for specialised industrial purposes which are not of particular interest for everyday general work. These include
some low hydrogen types for high tensile steel, cellulose types for welding large diameter pipes, etc.
The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be encountered; are all easy
to use and all will work on even the most basic of welding machines.
Table 2 - Types of Electrodes
11.03 Size of Electrode
The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine
available. Small welding machines will only provide sufficient current (amperage) to run the smaller size electrodes.
For most work, a 2.5mm electrode will be quite sufficient. A 2.5mm electrode will give just as strong a joint but may require a few
more weld runs to be put down to fill the joint.
For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A little practice will
soon establish the most suitable electrode for a given application.
11.04 Storage of Electrodes
Always store electrodes in a dry place and in their original containers.
11.05 Electrode Polarity
Electrodes are generally connected to the ELECTRODE HOLDER and the WORK LEAD to the work piece but if in doubt consult
your nearest accredited CIGWELD Distributor.
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11.06 Effects of Arc Welding Various Materials
a) High tensile and alloy steels
The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if
suitable precautions are not taken, the occurrence in this zone of under-bead cracks may result. Hardened zone and under-
bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings,
using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.
b) Austenitic manganese steels
The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is absolutely
essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.
c) Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks
when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the
porosity caused by gas held in this type of iron.
d) Copper and alloys
The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections necessary to
give proper fusion of weld and base metal.
SECTION 12: Arc Welding Practice
The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally enough, different
types of electrodes would be used for different metals as described in the preceding section.
12.01 Welding Position
The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat, horizontal,
vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these. Some
of the common types of welds are shown in Figure 3 to Figure 10.
Figure 3 – Flat position, down hand butt weld Figure 4 - Flat position, gravity fillet weld
Figure 5 - Horizontal position, butt weld Figure 6 - Horizontal - Vertical (HV) position
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Figure 7 -Vertical position, butt weld Figure 8 - Vertical position, fillet weld
Figure 9 - Overhead position, butt weld Figure 10 - Overhead position fillet, weld
12.02 Joint Preparations
In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work
on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the
weld metal and to produce sound joints.
In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut
surfaces. Typical joint designs are shown in Figure 11.
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