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SERVICE MANUAL

Transmig 165

ST

Transmig 165

ST

SERVICE MANUAL

Transmig 165

ST

Transmig 165

ST

TROUBLESHOOTING 10-4 Manual 0-5442

10.05 Clear Cover Sheet Removal

!

Read and follow safety information in Section 10.02 before proceeding.

1. Clear protective sheet
Take out clear protective sheet.

1

Art # A-13006

10.06 Visually Inspect

Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning

or arcing of PCB, transformers, switches, or rectifier when a failure occurs. Carefully inspect all components

within these units.
Look in particular for the following:
a)  Loose or broken wires or connectors.
b)  Burned or scorched parts or wires or evidence of arcing.
c)  Any accumulation of metal dust or filings that may have caused shorting or arcing.
If any parts are damaged, they must be replaced. Refer to the Spare Parts section for a complete list of com-

ponents used in the Power Source.
Locate the faulty component(s) then replace where necessary.

10.07 Preliminary DC Bus measurement of the main inverter board

!

Read and follow safety information in Section 10.02 before proceeding.

DC Bus Testing

Multimeter Lead Placement

Voltage with Supply voltage OFF

Upper capacitor bank

Positive meter lead to testpoint 1

Negative meter lead to testpoint 2

0 VDC

Lower capacitor bank

Positive meter lead to testpoint 3

Negative meter lead to testpoint 4

0 VDC

Table 10-3 DC BUS, Multimeter set to measure DC volts

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Summary of Contents for Transmig 165ST

Page 1: ...UAL MULTI PROCESS WELDING INVERTER Transmig 165ST Transmig 165ST INPUT SUPPLY 240V 15A SAFETY DEVICE OUTPUT CURRENT 165A DC INT WIRE FEEDER SPOOLS UP TO 200mm Version No AA Issue Date October 2015 Manual No 0 5442 ...

Page 2: ... manual However errors do occur and we apologize if there are any contained in this manual Due to our constant effort to bring you the best products we may make an improvement that does not get reflected in the manual If you are ever in doubt about what you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer s...

Page 3: ...Australia 3072 Tel 61 3 9474 7400 Fax 61 3 9474 7391 www cigweld com au Copyright 2015 CIGWELD Pty Ltd All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error result...

Page 4: ... 3 1 3 05 Electromagnetic Compatibility 3 2 3 06 Volt Ampere Curves 3 4 SECTION 4 OPERATION 4 1 4 01 Overview 4 1 4 02 Transmig 165ST Power Source Controls Indicators and Features 4 1 SECTION 5 MIG GMAW WELDING 5 1 5 01 Shielding Gas Regulator Flowmeter Operating Instructions 5 1 5 02 Attaching the Tweco Professional Fusion MIG Torch Euro 5 4 5 03 Installing Minispool 100mm diameter 5 4 5 04 Insta...

Page 5: ...eshooting Power Source Faults 10 1 10 02 Checking Unit Before Applying Power 10 2 10 03 Tools Needed for Troubleshooting and Servicing 10 3 10 04 Case Removal 10 3 10 05 Clear Cover Sheet Removal 10 4 10 06 Visually Inspect 10 4 10 07 Preliminary DC Bus measurement of the main inverter board 10 4 10 08 Preliminary check of the main inverter board 10 5 10 09 Check main On Off Switch 10 7 10 10 Chec...

Page 6: ...ing Back Panel 12 2 12 03 Installing Front Panel 12 4 12 04 Installing Main Control Panel and Clear Cover Sheet 12 5 12 05 Installing Case 12 7 SECTION 13 KEY SPARE PARTS 13 1 13 01 Tweco Fusion 150 MIG Torch 13 1 13 02 Power Source 13 2 CIGWELD LIMITED WARRANTY TERMS WARRANTY SCHEDULE TRANSMIG 165ST ...

Page 7: ...iece 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 f...

Page 8: ... 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 GMAW 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 A...

Page 9: ... 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 th...

Page 10: ...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 ...

Page 11: ...mphlet 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 Protection ANSI Standard Z87 1 from American National Standards Institute 14...

Page 12: ...tandard 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 con...

Page 13: ... power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters Turn Off inverters disconnect input power and discharge input capacitors according to instructions in Troubleshooting Section before touching any parts WARNING STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship P...

Page 14: ...ints such as drive rolls Have only qualified persons remove doors panels covers or guards for maintenance as necessary Keep hands hair loose clothing and tools away from moving parts Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power WARNING OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty...

Page 15: ...mmunications equipment Have only qualified persons familiar with electronic equipment install test and service H F producing units The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation If notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep h...

Page 16: ...SERVICE MANUAL Transmig 165ST Transmig 165ST GENERAL INFORMATION 1 10 Manual 0 5442 Notes ...

Page 17: ...your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to unpack the unit 2 01 How To Use This Manual To ensure safe operation read the entire...

Page 18: ...W Increase Decrease Circuit Breaker AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Preflow Time Postflow Time Spot Ti...

Page 19: ...d 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 an Accredited CIGWELD Distributor This equipment or any of its parts should not be altered from standard specification without prior written...

Page 20: ... 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 be allowed to cool Art A 12899 0 10 20 ...

Page 21: ...e DinseTM Style 50 Protection Class IP23S Welding Environment Classification Suitable for Welding in Category C Environments Suitable for Indoor and Outdoor Welding MIG GMAW FCAW Welding Welding Current Range 20 165A Welding Voltage Range 10 25V DC Wirefeed Speed Range Metres per Minute 1 9 16 5 mpm Min 18 22rpm to Max 170 180rpm Welding Output 40ºC 10 min 165A 30 22 3V 113A 60 19 7V 88A 100 18 4V...

Page 22: ...t the particular power source generator combination be adequately trialled to ensure the combination performs to the users expectations Note 4 CIGWELD reserves the right to change product performance and specifications without notice Note 5 Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities measurements dimensions and weights quoted are ap...

Page 23: ...onment These units are designed for use in environments with increased hazard of electric shock as outlined in AS 60974 1 and AS 1674 2 Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock Please refer to relevant local standards for further information prior to using in such areas A Examples of environments with increased hazard o...

Page 24: ... television transmitters and receivers 3 Computer and other control equipment 4 Safety critical equipment e g guarding of industrial equipment 5 The health of people around e g the use of pacemakers and hearing aids 6 Equipment used for calibration and measurement 7 The time of day that welding or other activities are to be carried out 8 The immunity of other equipment in the environment the user ...

Page 25: ...ded 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 ...

Page 26: ...rage Curves shows maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown 240VAC Input 0 10 20 30 40 50 60 70 0 5 25 75 125 0 100 1 165 50 200 AMPS S T L O V Lift TIG Max MIG Max Stick Max Art A 13004 Figure 3 1 Transmig 165ST Volt Ampere Curves ...

Page 27: ...uide only Current delivered to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrode wire welding current at any one setting would vary according to the type of electrode wire in use The operator should use the welding current range values as a guide then finally adjust the current setting to suit the application 4 02 Transmig 165S...

Page 28: ... the power source In MMAW STICK and GTAW TIG modes the amperage control knob directly adjusts the power inverter to deliver the desired level of output current In GMAW FCAW modes MIG the amperage knob adjusts the speed of the wire feed motor which in turn adjusts the output current by varying the amount of MIG wire delivered to the welding arc The optimum wire speed required will dependent on the ...

Page 29: ...inal 8 Multifunction Control MIG Arc Voltage or Stick Arc Force The multifunction control knob is used to adjust voltage or arc force parameters depending on the welding mode selected MIG ARC VOLTAGE Control when GMAW FCAW MIG Mode is Selected In this mode the control knob is used to adjust the output voltage of the unit The welding voltage is increased by turning the knob clockwise or decreased b...

Page 30: ... in contact with the work piece during power up Also note that the VRD operates in GTAW TIG mode Refer to 4 02 2 for further information 12 Over Temperature Indicator This welding power source is protected by a self resetting thermostat The Over Temp indicator will illuminate if the duty cycle of the power source has been exceeded Should the Over Temp indicator illuminate the output of the power s...

Page 31: ... The Hot Start feature improves the arc start characteristics by momentarily increasing the welding current to a level above the preset amperage Welding Current This is a preset feature and is not adjustable When in Stick Mode and the machine detects a short circuit between the electrode and the work piece The output current increases by approximately 50 of the preset value for 0 1 seconds Note th...

Page 32: ...OPERATION 4 6 Manual 0 5442 SERVICE MANUAL Transmig 165ST Transmig 165ST Notes ...

Page 33: ...es prescribed in this instruction SPECIFIC PROCEDURES for the use of regulators flowmeters are listed below 1 NEVER subject the regulator flowmeter to inlet pressure greater than its rated inlet pressure 2 NEVER pressurize a regulator flowmeter that has loose or damaged parts or is in a questionable condition NEVER loosen a connection or attempt to remove any part of a regulator flowmeter until th...

Page 34: ...ther gas Art A 05087 Figure 5 1 Fit Regulator flowmeter 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 flowmeter Crack the valve open then close momentarily pointing the outlet away from people and sources of ignition Wipe with a clean lint free cloth 2 Match re...

Page 35: ...lowmeter ready for operation adjust working flow rate as follows 1 Slowly turn adjusting screw knob in clockwise direction until the outlet gauge indicates the required flow rate NOTE It may be necessary to re check the shielding gas regulator flowmeter flow rate following the first weld sequence due to back pressure present within shielding gas hose assembly 2 To reduce flow rate allow the weldin...

Page 36: ...inispool 100mm diameter assemble parts in the sequence shown below in Figure 5 4 Adjustment of the nut with nylon insert will control the Mig Wire Spool Brake Clockwise rotation of this nut with nylon insert tightens the brake The brake is correctly adjusted when the spool stops within 10 to 20mm measured at the outer edge of the spool after Mig Torch trigger is released Wire should be slack witho...

Page 37: ...Mig Torch trigger is released Wire should be slack without becoming dislodged from the spool CAUTION Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical componentry and possibly an increased incidence of electrode wire Burnback into contact tip Ensure that the alignment pin on the wire spool hub aligns with the hole allocated in the Handispool NOTE Thi...

Page 38: ...e roller arm and wire drive tension screw and adjust the pressure accordingly Figure 5 6 Remove the nozzle then contact tip from the MIG torch With the MIG Torch lead reasonably straight feed the wire through the torch by depressing the trigger switch Fit the contact tip that is designed for the wire that has been fed through the MIG torch then fit the nozzle onto the MIG torch WARNING Before conn...

Page 39: ...tating the pressure screw clockwise WARNING Before changing the feed roller ensure that the mains supply to the power source is switched off CAUTION The use of excessive pressure may cause rapid wear of the feed rollers shafts and bearing 5 07 Changing the Feed Roll To change feed roll remove the feed roll retaining screw by turning in an anticlockwise direction Once the feed roll is removed then ...

Page 40: ...sential however that the male plug is inserted and turned securely to achieve a sound electrical connection C Switch the Power Source On Off switch located on the rear of the Power Source to the On position and ensure the Power indicator on the Front Panel is illuminated Set the MIG Torch trigger switch operation either 2T or 4T mode Refer to section 4 02 10 D Select MIG mode with the process sele...

Page 41: ... of the wirefeed compartment door Power Source settings are adjusted using the front panel controls Refer to section 4 02 WARNING Before connecting the work clamp to the work make sure the mains power supply is switched off WARNING Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping CAUTION Loose weldi...

Page 42: ...ough the MIG torch by depressing the MIG torch triggered DO NOT let the wire touch any conductive material or your skin as the wire is electrical HOT when the torch triggered is depressed Secondary voltage and the feed rollers run at constant run in speed for about 3 seconds After the 3 seconds the secondary voltage is still present but the feed rollers run the wire speed you set on the Wirespeed ...

Page 43: ...k Shielding is obtained from an externally supplied welding grade shielding gas or welding grade shielding gas mixture The process is normally applied semi automatically however the process may be operated automatically and can be machine operated The process can be used to weld thin and fairly thick steels and some non ferrous metals in all positions Art A 8991_AB Shielding Gas Molten Weld Metal ...

Page 44: ...le 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 u...

Page 45: ...epending on the type of joint that is being welded Travel Speed The speed at which the molten pool travels influences the width of the weld and penetration of the welding run MIG Welding GMAW Variables Most of the welding done by all processes is on carbon steel The items below describe the welding variables in short arc welding of 24gauge 0 024 0 6mm to 6 4mm mild sheet or plate The applied techn...

Page 46: ...eld current Decrease in wire feed speed decreases weld current Art A 08997_AD Gas Nozzle Electrode Wire Average Arc Length Electrode Stick Out Tip to Work Distance Actual Stick out Contact Tip Tube Figure 5 20 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 longit...

Page 47: ...s 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 ...

Page 48: ...SERVICE MANUAL Transmig 165ST Transmig 165ST MIG GMAW WELDING 5 16 Manual 0 5442 5 12 CIGWELD MIG Wire Selection Chart Table 5 1 Cigweld MIG Wire Selection Chart ...

Page 49: ...as cylinder is not empty and the flow meter is correctly adjusted to 15 litres per minute 2 Gas leaks Check for gas leaks between the regulator cylinder connection and in the gas hose to the Power Source 3 Internal gas hose in the Power Source Ensure the hose from the solenoid valve to the torch adaptor has not fractured and that it is connected to the torch adaptor 4 Welding in a windy environmen...

Page 50: ...ed 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 ...

Page 51: ... and the wirespeed control B Wire is wandering B Replace contact tip C Incorrect shielding gas C Check shielding gas D Insufficient or excessive heat input D Adjust the wirespeed control or the voltage control 6 Weld cracking A Weld beads too small A Decrease travel speed B Weld penetration narrow and deep B Reduce current and voltage and increase Mig torch travel speed or select a lower penetrati...

Page 52: ...quired delivery flow rate 3 Close the cylinder valve Watch to see if the high pressure or contents gauge drops if it does you have a leak in the connection between the regulator and the cylinder 4 Once leak testing has been performed and there are no leaks in the system slowly open the cylinder valve and proceed WARNING If a leak has been detected anywhere in the system dis continue use and have t...

Page 53: ...es prescribed in this instruction SPECIFIC PROCEDURES for the use of regulators flowmeters are listed below 1 NEVER subject the regulator flowmeter to inlet pressure greater than its rated inlet pressure 2 NEVER pressurize a regulator flowmeter that has loose or damaged parts or is in a questionable condition NEVER loosen a connection or attempt to remove any part of a regulator flowmeter until th...

Page 54: ...ther gas Art A 05087 Figure 6 1 Fit Regulator flowmeter 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 flowmeter Crack the valve open then close momentarily pointing the outlet away from people and sources of ignition Wipe with a clean lint free cloth 2 Match re...

Page 55: ...lowmeter ready for operation adjust working flow rate as follows 1 Slowly turn adjusting screw knob in clockwise direction until the outlet gauge indicates the required flow rate NOTE It may be necessary to re check the shielding gas regulator flowmeter flow rate following the first weld sequence due to back pressure present within shielding gas hose assembly 2 To reduce flow rate allow the weldin...

Page 56: ...the regulator flowmeter outlet Note that the TIG torch shielding gas hose is connected directly to the regulator flowmeter Before turning on shielding gas check that all fittings are tight and the gas valve on the TIG torch is turned off The power source is not fitted with a shielding gas solenoid to control the gas flow in TIG mode therefore the TIG torch will require a gas valve Refer to Section...

Page 57: ...AB Work lead MIG Torch polarity lead not connected TIG Torch Connect to shielding gas regulator flowmeter Negative welding terminal Positive welding terminal 240VAC 15A Mains Supply Refer to the WARNING on page 6 4 regarding securing the gas cylinder Figure 6 3 Setup for Lift TIG GTAW Welding ...

Page 58: ... depending on the welding application Welds Made With or Without Addition of Filler Metal Work Piece Can Be Any Commercial Metal Gas Cup Either Ceramic High lmpact or Water Cooled Metal Inert Gas Shields Electrode and Weld Puddle Tungsten Electrode Non Consumable Art A 09658_AC Figure 6 4 TIG Welding Application Shot Tungsten Electrode Current Ranges Electrode Diameter DC Current Amps 0 040 1 0mm ...

Page 59: ...ainless steels Stainless pipes tubing architectural uses etc Table 6 4 Base Metal Thickness DC Current for Mild Steel DC Current for Stainless Steel Tungsten Electrode Diameter Filler Rod Diameter if required Argon Gas Flow Rate Litres min Joint Type 0 040 1 0mm 35 45 40 50 20 30 25 35 0 040 1 0mm 1 16 1 6mm 5 7 Butt Corner Lap Fillet 0 045 1 2mm 45 55 50 60 30 45 35 50 0 040 1 0mm 1 16 1 6mm 5 7 ...

Page 60: ...eg length in fillet joint Wrong placement of filler rod Re position filler rod 6 Electrode melts or oxidises when an arc is struck A TIG Torch lead connected to positive welding terminal A Connect TIG Torch lead to negative welding terminal B No shielding gas flowing to welding region B Check the shielding gas lines for kinks or breaks and shielding gas cylinder contents C Torch is clogged with du...

Page 61: ...art is not smooth A Tungsten electrode is too large for the welding current A Select the right size electrode Refer to Table 6 1 Cigweld Electrode Selection Chart B The wrong electrode is being used for the welding job B Select the right electrode type Refer to Table 6 3 Cigweld Electrode Selection Chart C Gas flow rate is too high C Select the right rate for the welding job Refer to Table 6 5 D I...

Page 62: ...quired delivery flow rate 3 Close the cylinder valve Watch to see if the high pressure or contents gauge drops if it does you have a leak in the connection between the regulator and the cylinder 4 Once leak testing has been performed and there are no leaks in the system slowly open the cylinder valve and proceed WARNING If a leak has been detected anywhere in the system dis continue use and have t...

Page 63: ...ale plug is inserted and turned securely to achieve a sound electrical connection C Select Stick mode with the process selection control refer to Section 4 02 11 for further information WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Mains power supply is switched off CAUTION Remove any packaging material prior to use Do not bl...

Page 64: ...urnace Hydrogen controlled Electrodes must be used for this application Use Ferrocraft 61 or 16TXP for normal strength 500 MPa steels and Alloycraft range for higher strength steels 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 ...

Page 65: ... 7 2 Flat Position Down Hand Butt Weld Art A 07688 Figure 7 3 Flat Position Gravity Fillet Weld Art A 07689 Figure 7 4 Horizontal Position Butt Weld Art A 07690 Figure 7 5 Horizontal Vertical HV Position Art A 07691 Figure 7 6 Vertical Position Butt Weld Art A 07692 Figure 7 7 Vertical Position Fillet Weld ...

Page 66: ...n 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 7 10 Gap varies from 1 6mm 1 16 to 4 8mm 3 16 depending on plate thickness Joint Open Square Butt 1 6mm 1 16 max 1 6mm 1 16 Single Vee Butt Joint Not less than 70 Double Vee But...

Page 67: ...ur clothes Place the work so that the direction of welding is across rather than to or from your body The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down If the lead is slung over your shoulder it allows greater freedom of movement and takes a lot of weight off your hand Be sure the insulation on your cable and electro...

Page 68: ...ng out and may even be broken up into individual globules If the travel is too slow the weld metal piles up and the bead will be too large Making Welded Joints Having attained some skill in the handling of an electrode you will be ready to go on to make up welded joints A Butt Welds Set up two plates with their edges parallel as shown in Figure 7 12 allowing 1 6mm to 2 4mm gap between them and tac...

Page 69: ...y triangular cross section made by depositing metal in the corner of two faces meeting at right angles Refer to Figure 7 5 A piece of angle iron is a suitable specimen with which to begin or two lengths of strip steel may be tacked together at right angles Using a 3 2mm Ferrocraft 21 electrode at 100 amps position angle iron with one leg horizontal and the other vertical This is known as a horizon...

Page 70: ...eave on the first run When the first run has been completed de slag the weld deposit and begin the second run at the bottom This time a slight weaving motion is necessary to cover the first run and obtain good fusion at the edges At the completion of each side motion pause for a moment to allow weld metal to build up at the edges otherwise undercut will form and too much metal will accumulate in t...

Page 71: ... overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch The electrode is held at 45º to the horizontal and tilted 10º in the line of travel Figure 7 19 The tip of the electrode may be touched...

Page 72: ...racting weld metal may cause the sheet to become distorted B Expansion and Contraction of Parent Metal in the Fusion Zone While welding is proceeding a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions It is able to do this freely at right angles to the surface of the plate i e through the weld but when it attempts ...

Page 73: ...ul in eliminating distortion C Restraint of Parts Forcible restraint of the components being welded is often used to prevent distortion Jigs positions and tack welds are methods employed with this in view D Presetting It is possible in some cases to tell from past experience or to find by trial and error or less frequently to calculate how much distortion will take place in a given welded structur...

Page 74: ...amples of Distortion Art A 07710_AB 1 Block Sequence The spaces between the welds are filled in when the welds are cool 2 3 Figure 7 25 Welding Sequence Art A 07711_AB 4 3 2 1 Figure 7 26 Step back Sequence Art A 07712 Figure 7 27 Chain Intermittent Welding Art A 07713_AB Figure 7 28 Staggered Intermittent Welding ...

Page 75: ... WEG2525 WEG5025 WEG1032 WEG2532 WEG5032 WEG5040 User friendly GP electrode for welding thin section mild and galvanised steels Excellent for vertical down fillet welding applications Ferrocraft 16 Twincoat 2 5mm 3 2mm 4 0mm 5 kg 5 kg 5 kg 611752 611753 611754 Hydrogen Controlled type offering exceptional AC DC performance in all welding positions Satincrome 308L 17 2 5mm 3 2mm 4 0mm 2 5 kg 2 5 kg...

Page 76: ... iron Castcraft 55 3 2mm 4 0mm 2 5 kg 2 5 kg 611723 611724 For repair and maintenance welding of S G cast iron meehanite and other cast irons It produces high strength weld than Castcraft 100 Castcraft 100 2 5mm 3 2mm Blisterpack 4 0mm 2 5 kg 2 5 kg Blisterpack 2 5 kg 611732 611733 322217 611734 Soft Ductile Nickel type electrode for repair and maintenance welding of a wide range of cast irons It ...

Page 77: ...ip or grind out irregularities D Lack of penetration with slag trapped beneath weld bead D Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to remove all slag from comers E Rust or mill scale is preventing full fusion E Clean joint before welding F Wrong electrode for position in which welding is done F Use electrodes designed for position in which weld...

Page 78: ...ckets or voids in weld metal porosity A High levels of sulphur in steel A Use an electrode that is designed for high sulphur steels B Electrodes are damp B Dry electrodes before use C Welding current is too high C Reduce welding current D Surface impurities such as oil grease paint etc D Clean joint before welding E Welding in a windy environment E Shield the weld area from the wind F Electrode da...

Page 79: ... 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 including 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 B Insulation Resistance Minimum insulation resistance ...

Page 80: ...als as outlined below 1 For transportable equipment at least once every 3 months and 2 For fixed equipment at least once every 12 months Description Required Parameters VRD Open Circuit Voltage Less than 35V at nominal input voltage VRD Turn ON Resistance Less than 200 ohms VRD Turn OFF Time Less than 0 3 seconds Table 8 2 VRD Periodic Tests E General Maintenance Checks Welding equipment should be...

Page 81: ...nts Where applicable the tests outlined in Table 8 3 below shall be conducted by an accredited CIGWELD service provider 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 ...

Page 82: ...ove any accumulated dirt metal filings slag and loose material Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current 8 03 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 ro...

Page 83: ...sformer than in a conventional power supply The AC is then rectified to extremely smooth DC The diagram to the below shows the basic electrical wiring of a DC output inverter power supply AC High Frequency AC High Frequency Art A 09846_AB High Amperage High Amperage High Amperage Low Amperage Low Amperage Low Amperage Low Amperage High Voltage High Voltage High Voltage Low Voltage Low Voltage Low ...

Page 84: ...SERVICE MANUAL Transmig 165ST Transmig 165ST THEORY OF OPERATION 9 2 Manual 0 5442 Notes ...

Page 85: ...15 with fan on until over temperature light extinguishes Remove blockages from airflow ducts Replace fan Check fan wiring header is plugged securely into Control board Check fan wiring is not damaged 4 Mode switch does not change welding mode A Faulty Front Panel Control PCB A Replace Front Panel Control PCB 5 The wirefeed motor and the weld output do not operate when the torch trigger switch is d...

Page 86: ...hielding gas Wind blows shielding gas away Incorrect TIG tungsten electrode Poorly prepared or worn TIG tungsten A B C D E F G H Use correct weld cable size Tighten welding connections Tighten earth clamp Correct weld polarity Refer to weld consumable manufacturers recommended polarity Connect shielding gas Shield welding area from draughts Use correct tungsten type Regrind tungsten to correct sha...

Page 87: ...rews 1 Art A 13005 a Remove the two top screws from the front rear mouldings b Remove the centre screws from the front rear mouldings c Loosen slightly the two bottom screws from the front rear mouldings d Remove the three bottom screws and the two top screws securing the cover panel e Gently lever apart the front rear mouldings remove the cover panel 2 Ground screw Carefully lift the case to acce...

Page 88: ...Burned or scorched parts or wires or evidence of arcing c Any accumulation of metal dust or filings that may have caused shorting or arcing If any parts are damaged they must be replaced Refer to the Spare Parts section for a complete list of com ponents used in the Power Source Locate the faulty component s then replace where necessary 10 07 Preliminary DC Bus measurement of the main inverter boa...

Page 89: ... Output Diodes Positive meter lead to testpoint 7 Negative meter lead to testpoint 8 0 2 0 8 VDC Table 10 4 Output Diodes Multimeter set to measure Diode Voltage IGBT Testing Multimeter Lead Placement Diode Voltage IGBT 1 Positive meter lead to testpoint 9 Negative meter lead to testpoint 10 0 2 0 8 VDC IGBT 2 Positive meter lead to testpoint 11 Negative meter lead to testpoint 12 0 2 0 8 VDC IGBT...

Page 90: ...150 to 350 Ω IGBT 3 Positive meter lead to testpoint 19 Negative meter lead to testpoint 13 150 to 350 Ω IGBT 4 Positive meter lead to testpoint 20 Negative meter lead to testpoint 15 150 to 350 Ω Table 10 6 IGBT s Multimeter set to measure ohms Ω 4 3 1 2 5 6 7 8 10 9 12 11 14 13 16 15 17 18 19 20 21 22 A 09988 Inrush PTC Multimeter Lead Placement Impedance PTC Positive meter lead to testpoint 21 ...

Page 91: ...Table 10 8 Power Switch Multimeter set to measure ohms Ω 10 10 Check main input rectifier Input Rectifier Testing Multimeter Lead Placement Diode Voltage AC1 to DC Positive meter lead to AC1 Negative meter lead to testpoint DC 0 2 0 8 VDC AC2 to DC Positive meter lead to AC2 Negative meter lead to testpoint DC 0 2 0 8 VDC AC1 to DC Positive meter lead to testpoint DC Negative meter lead to testpoi...

Page 92: ...rdous voltage and power levels pres ent Do not touch any live parts 4 3 1 2 5 6 7 8 10 9 12 11 14 13 16 15 17 18 19 20 21 22 A 09988 DC Bus Testing Multimeter Lead Placement Voltage with Supply voltage OFF Upper capacitor bank Positive meter lead to testpoint 1 Negative meter lead to testpoint 2 168 VDC 10 Lower capacitor bank Positive meter lead to testpoint 3 Negative meter lead to testpoint 4 1...

Page 93: ...p p square wave 15 VDC pk 4 IGBT 2 pwm drive signal 15V p p square wave 15 VDC pk 5 IGBT 1 pwm drive signal 15V p p square wave 15 VDC pk 6 Rectified secondary of current transformer TR8 15 VDC pk 7 0V 0 VDC Table 10 11 IN Header pin function connects to DRIVE header on control PCB PWM Header Pin Pin function Signal 1 0VDC 0 VDC 2 Motor pwm drive signal 5 VDC pk Table 10 12 PWM Header pin function...

Page 94: ... signal 1 24V VRD positive South Pacific Version Only 24 VDC 2 Solenoid negative 0 VDC 3 24V solenoid positive 24 VDC 4 0V 0 VDC Table 10 17 QF FJ Header pin function Connects to QF DY header on control PCB GAS Header Pin Pin function signal 1 24V solenoid positive 24 VDC 2 Solenoid negative 0 VDC Table 10 18 GAS Header pin function connects to Solenoid 2 Control PCB Imin IFB PWM Vmin MB GUN QF DY...

Page 95: ... 15V p p square wave 15 VDC pk 4 IGBT 2 pwm drive signal 15V p p square wave 15 VDC pk 5 IGBT 1 pwm drive signal 15V p p square wave 15 VDC pk 6 Rectified secondary of current transformer TR8 15 VDC pk 7 0V 0 VDC Table 10 23 DRIVE Header pin function connects to IN header on inverter PCB WVIN Header Pin Pin function Signal 1 Positive welding terminal positive VDC 2 No connection n c 3 Negative wel...

Page 96: ...ader pin function connects to NTCS header on inverter PCB MB Header Pin Pin function Signal 1 Not Used 2 Not Used 3 Not Used 4 2T 4T pushbutton 0V when button pushed 0VDC 5 Not Used 6 Stick mode used for remote local 7 Not Used 8 MODE pushbutton 0V when button pushed 0VDC 9 15VDC 15 VDC 10 Remote Local switch 11 Inductance pot terminal 2 12 Volts setpoint 0 5 VDC 13 Inductance pot terminal 1 14 Am...

Page 97: ... Not Used 3 Not Used 4 2T 4T pushbutton 0V when button pushed 0VDC 5 Not Used 6 Stick mode used for remote local 7 Not Used 8 MODE pushbutton 0V when button pushed 0VDC 9 15VDC 15 VDC 10 Remote Local switch 11 Inductance pot terminal 2 12 Volts setpoint 0 5 VDC 13 Inductance pot terminal 1 14 Amps setpoint 0 5 VDC 15 5VDC 5 VDC 16 0V 0 VDC Table 10 31 J1 Header pin function connects to MB header o...

Page 98: ...ower source Power Input SW0 Switch Number Description 1 2 3 4 Function 165ST Calibration Mode ON ON ON OFF Used for calibrating wirefeed speed Amps Volts meters 165ST Operating Mode OFF ON OFF ON Transmig 165ST Normal Operating Mode Not Design for 165ST OFF OFF ON ON DO NOT USE This configuration is for an export model Not Design for 165ST ON OFF ON ON DO NOT USE This configuration is for an expor...

Page 99: ...of a resistance to give 25V at 250A Set front panel AMPS potentiometer to minimum Adjust Imin trimpot until output amps is 10A 0 2A Set front panel AMPS potentiometer to maximum Adjust Imin trimpot until output amps is 165A 1A Recheck settings Set front panel AMPS potentiometer to maximum 3 Output Voltage Calibration Select MIG mode on the front panel Remove the load from the output terminals Set ...

Page 100: ... W05 MAX SPEED A 09995 Select MIG mode on the front panel Remove the load from the output terminals Set front panel WIRESPEED AMPS potentiometer to minimum Adjust W02 trimpot until motor volts is 4 2V 0 2V Set front panel WIRESPEED AMPS potentiometer to maximum Adjust W05 trimpot until motor volts is 24 7V 0 2V Recheck settings Set SW0 1 to OFF SW0 1 to ON SW0 3 to OFF SW0 4 to ON to disable calib...

Page 101: ...form The PWM wave from digital control PCB 5V div Testpoint B waveform The PWM set point from 6P of U02 5V div Testpoint C waveform The drive PWM from SG3524 11P 5V div Testpoint D waveform The MOSFET gate drive PWM 5V div Testpoint E F waveform U01 SG3524 Pin 1 Pin 2 5V div Testpoint G waveform U01 SG3524 Pin 3 5V div Art A 12985 ...

Page 102: ...capacitors to discharge after disconnection from mains supply voltage AC 1 AC 3 2 4 Q1 TR1 C19 C16 C17 R25 R24 R32 R33 T18 1 T16 1 T14 1 T17 1 T15 1 T13 1 R102 R100 R101 R103 C100 COUT1 COUT2 C18 TRANSFORMER R39 C20 C21 R38 PRI A PRI A TR8 DC C23 C24 R39 1 R38 1 R104 C102 1 2 3 WVOUT C101 R107 R106 1 2 3 WVOUT 1 PTC J1 CIN1 CIN2 CU3 CU4 R200 CY1 R200 1 DC DC DC AC2 AC1 T19 1 T20 1 OUT OUT T1 T2 R2...

Page 103: ...oltage Secondary output voltage from the transformer is rectified by the output diodes T13 T14 T15 T16 T17 T18 T19 and T20 to DC This DC is controlled by the PWM of the primary side igbt transistors and is filtered by an inductor before connecting to the welding output terminals A thermal overload device thermistor is fixed to the rectifier heatsink When an over temperature occurs the control circ...

Page 104: ...UBLESHOOTING 10 20 Manual 0 5442 10 16 Circuit Diagram Art A 13009 W7004911 CT Output W7004905 Wiredrive Assembly W7004939 PCB Control W7004935 PCB Front Panel W7004907 Fan Assembly W7004902 PCB EMC Filter W7004900 PCB Power Input Rectifier W7003010 ...

Page 105: ...165ST Manual 0 5442 11 1 DISASSEMBLY PROCEDURE 11 01 Safety Precautions for Disassembly Read and follow safety information in Section 10 02 before proceeding Unplug unit before beginning Disassembly procedure SECTION 11 DISASSEMBLY PROCEDURE ...

Page 106: ...connector 3 Disconnect SOURCE harness from SOURCE connector 4 Disconnect CR harness from CR connector 5 Disconnect FUNs harness from FUNs connector 6 Disconnect NTCS harness from NTCS connector 7 Disconnect IGBT OT harness from IGBT OT connector 8 Disconnect GUN harness from GUN connector 9 Disconnect QF DY harness from QF DY connector 10 Disconnect WVIN harness from WVIN connector 11 Disconnect M...

Page 107: ...SERVICE MANUAL Transmig 165ST Transmig 165ST Manual 0 5442 11 3 DISASSEMBLY PROCEDURE 1 5 4 3 2 6 13 7 8 9 12 11 10 A 09963 IFB PWM MB GUN QF DY WVIN IGBT OT NTCS FUNs CR SOURCE DRIVE A 10018 ...

Page 108: ...d and follow safety information in Section 10 02 before proceeding with disassembly 1 Screws on front panel 2 Negative output terminal bolts Unscrew Negative output terminal bolts 3 Torch cable bolts Unscrew torch cable terminal bolts 4 Positive output terminal bolts Unscrew output terminal bolts Art A 13013 1 2 3 4 A 09964 ...

Page 109: ...l 0 5442 11 5 DISASSEMBLY PROCEDURE 11 04 Front Panel Operator Interface Circuit Board PCB3 Removal Read and follow safety information in Section 10 02 before proceeding with disassembly 1 Remove Control Panel screw 4 2 Front Panel PCB 1 Art A 13014 2 ...

Page 110: ...ire screw Disconnect Input cord ground wire from Main Power PCB1 using a 150mm adjustable wrench 2 Terminal from supply cable Disconnect two terminals from switch 3 Wire from Main PCB1 Disconnect the two wires from switch Rear panel mounting SCREW Remove screw holding rear panel to chassis 4 Disconnect harness from J8 connector on Control PCB2 and carefully lift the wire free from the unit 1 2 3 A...

Page 111: ... been remove in picture 2 SW1 locking tabs Squeeze the locking tabs and push SW1 out from the rear panel 3 Strain relief screws Remove the two 2 screws from the strain relief 4 Remove Fan 5 Input Power Cord ground wire filter Cut the tie wrap and remove the Ferrite core from the ground wire 6 Pull the Input Power Cord out It may be necessary to use a flat blade screw driver against the strain reli...

Page 112: ...EMBLY PROCEDURE 11 8 Manual 0 5442 11 07 Base Panel Removal Read and follow safety information in Section 10 02 before proceeding with disassembly 1 Remove Wire Feeder Screws 2 Remove Main PCB assembly Screws 3 Remove Central Panel Screws 1 3 2 A 10007 ...

Page 113: ...165ST Manual 0 5442 12 1 ASSEMBLY PROCEDURE 12 01 Installing Base Board 1 Main Power PCB assembly 2 Install main PCB assembly screws 3 Install central Panel Screws 4 Install wire feeder 1 A 10009 4 3 2 A 10008 SECTION 12 ASSEMBLY PROCEDURES ...

Page 114: ...ose to the nipple using a gas hose line clamp 2 Install ON OFF switch 3 Install wire cord and 2 screws 4 Reconnect Input Wire on the ON OFF switch 5 Reinstall Ferrite core onto Ground Wire 6 Install fan 7 Reconnect power ON OFF switch to terminals on Main Power PCB 8 Reconnect Ground Wire to filter PCB 9 Reconnect Rear Panel screws 1 6 2 4 5 Art A 12989 3 ...

Page 115: ...SERVICE MANUAL Transmig 165ST Transmig 165ST Manual 0 5442 12 3 ASSEMBLY PROCEDURE 8 7 A 10011 9 A 10012 ...

Page 116: ...B assembly into front panel and install screws 1 A 10013 Art A 13010 2 3 Reconnect torch polarity cable to the torch connector 4 Reconnect positive output terminal bolts and tighten with 17mm wrench Note reconnect wires pay attention to the wire colour 5 Reconnect negative output terminal bolts and tighten with 17mm wrench note reconnect wires and pay attention to the wire colour 5 3 4 A 10015 ...

Page 117: ...onnector 5 Plug harness into FUNs connector 6 Plug harness into NTCs connector 7 Plug harness into IGBT OT connector 8 Plug harness into GUN connector 9 Plug harness into QF DY connector 10 Plug harness into WVIN connector 11 Plug harness into MB connector 12 Plug harness into PWM connector 13 Plug harness into IFB connector Verify harness connections with the system schematic to insure all connec...

Page 118: ...SERVICE MANUAL Transmig 165ST Transmig 165ST ASSEMBLY PROCEDURE 12 6 Manual 0 5442 14 Art A 13011 ...

Page 119: ...5ST Manual 0 5442 12 7 ASSEMBLY PROCEDURE 12 05 Installing Case 1 Install Case 2 Install Ground Screw which connects the ground wire to the cover 3 Install Screws Tighten screws Tighten Screws Front Rear Install Screws 1 Art A 13012 2 A 09960 ...

Page 120: ...SERVICE MANUAL Transmig 165ST Transmig 165ST ASSEMBLY PROCEDURE 12 8 Manual 0 5442 Notes ...

Page 121: ...ITEM PART NO DESCRIPTION 1 OTW22 50 Nozzle 13mm OTW22 62 Nozzle 16mm 2 OTW14 23 Contact Tip 0 6mm OTW14 30 Contact Tip 0 8mm OTW14 35 Contact Tip 0 9mm OTW14 40 Contact Tip 1 0mm OTW14 45 Contact Tip 1 2mm 3 OTW32 Insulator 4 OTW52 Gas Diffuser 5 62J 45S Conductor Tube 45 Degree 6 W7005001 Trigger Assembly 7 W7005000 Handle Mouldings 8 OTW42 3035 Liner 0 8 0 9mm Hard Wire OTW42 4045 Liner 1 0 1 2m...

Page 122: ...Roll Retaining Thumbscrew 7 7977036 Feed Roll 0 6 0 8mm V groove fitted as standard Refer to options and accessories table for other feed rolls available 8 W7004907 Fan Assembly 9 W7003010 Input Rectifier 2 required 10 W7004908 Gas Solenoid Valve 11 W7004909 Dinse Socket 50mm 12 704461 Dinse Plug Male 50mm 13 W7004910 Input Supply Switch 14 W7004911 CT Output 15 W7004912 Wire Hub Assembly 16 W7004...

Page 123: ...TS 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 ...

Page 124: ...ngs fuses filters or other parts that fail due to normal wear Note No employee agent or representative of CIGWELD is authorized to change this warranty in any way or grant any other warranty and CIGWELD shall not be bound by any such attempt Correction of non conformities in the manner and time provided herein constitutes fulfilment of CIGWELD s obligations to purchaser with respect to the product...

Page 125: ...SERVICE MANUAL Transmig 165ST Transmig 165ST This Page Intentionally Blank ...

Page 126: ...ries Tel 61 3 9474 7508 Fax 61 3 9474 7488 Malaysia Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Tel 60 3 6092 2988 Fax 60 3 6092 1085 Indonesia JL Akasia II Blok A 05 No 10A Delta Silicon Lippo Cikarang Bekasi 17550 Indonesia Toll Free 0 800 1842 867 Tel 62 21 8990 6095 Fax 62 21 8990 6096 CIGWELD COM AU ...

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