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OPERATING MANUAL

Transmig 220i

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This Operating Manual has been designed to instruct you on the correct
use and operation of your CIGWELD product. Your satisfaction with this
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take the time to read the entire manual, especially the Safety Precautions.
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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received, then check for a newer version of the manual on our website or
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Summary of Contents for Transmig 355i

Page 1: ... 2021 Manual No 0 5586 INPUT SUPPLY 415V 3 ph SAFETY DEVICE OUTPUT CURRENT 355A DC Refer to Specification Table for rating information O m AUTO PROCESS AUTO SET MIG MULTI PROCESS MIG STICK TIG IN 3 1 COMPATIBLE WITH SPOOL PUSHPULL GUN OPTIONAL SPOOLS UP TO 300mm 4 ROLL WIRE DRIVE ...

Page 2: ...nal Customers 61 3 9474 7508 Please register your warranty online immediately after purchase for complete warranty coverage and to guarantee your proof of purchase http warranties cigweld com au FOR YOUR CHANCE TO WIN REGISTER YOUR WARRANTY ONLINE GREAT PRIZES R R RE E EG G G GI I IS S S ST T TE E ER R R Y Y YO O O OU U UR R R OPERATING MANUAL ...

Page 3: ...l 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manual If you are ever in doubt about what you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer support...

Page 4: ...ustralia 3072 Tel 61 3 9474 7400 Fax 61 3 9474 7391 www cigweld com au Copyright 2020 2021 by 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...

Page 5: ...ied processes Part 2 Electrical AS 60974 1 2020 Arc Welding Equipment Part 1 Welding Power Sources AS NZS 3760 2010 In service Safety Inspection and Testing of Electrical Equipment EN IEC 60974 1 2018 A1 2019 Arc Welding Equipment Part 1 Welding Power Sources EN 60974 10 2014 A1 2015 Arc Welding Equipment Part 10 EMC requirements Additional information Restrictive use Class A equipment intended fo...

Page 6: ...es 4 1 4 03 Advanced Features Details 4 9 SECTION 5 MIG GMAW WELDING 5 1 5 01 Shielding Gas Regulator Flowmeter Operating Instructions 5 1 5 02 Optional Wire Feeder Controls Indicators and Features 5 4 5 03 Optional Wire Feeder Setup MIG GMAW Welding with Gas Shielded MIG Wire 5 5 5 04 Optional Wire Feeder Setup MIG FCAW Welding with Gasless MIG Wire 5 6 5 05 Assembly and Fitting of Optional Weldi...

Page 7: ...que 6 6 6 04 TIG GTAW Welding Problems 6 8 SECTION 7 MANUAL ARC MMAW WELDING 7 1 7 01 Setup for STICK MMAW Welding 7 1 7 02 Stick MMAW Basic Welding Technique 7 2 7 03 Electrode Selection Chart 7 13 7 04 Stick MMAW Welding Troubleshooting 7 14 SECTION 8 ROUTINE SERVICE REQUIREMENTS AND POWER SOURCE PROBLEMS 8 1 8 01 Routine Service and Calibration Requirements 8 1 8 02 Cleaning the Welding Power S...

Page 8: ...This Page Intentionally Blank ...

Page 9: ... 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 le...

Page 10: ...ximate 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 Arc Welding GMA...

Page 11: ...sparks overheating or fire 1 Protect yourself and others from flying sparks and hot metal 2 Do not weld where flying sparks can strike flammable material 3 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 4 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjace...

Page 12: ...efects 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...

Page 13: ...can Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mia...

Page 14: ...OPERATING MANUAL GENERAL INFORMATION 1 6 Manual 0 5586 This Page Intentionally Blank ...

Page 15: ... the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 01 How To Use This Manual To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided unde...

Page 16: ... 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 Art A 04937_AD 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 Time Spot Weld Mode Continuous Weld...

Page 17: ... 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 unauthorized modification from standard specification faulty maintenance damage or improper repair by anyone other than appropriately qualified persons approved by CIGWELD 2 07 Tra...

Page 18: ...riod the following example is used Suppose a Welding Power Source is designed to operate at a 60 duty cycle 355 amperes at 31 8 volts This means that it has been designed and built to provide the rated amperage 355A for 6 minutes i e arc welding time out of every 10 minute period 60 of 10 minutes is 6 minutes During the other 4 minutes of the 10 minute period the Welding Power Source must idle and...

Page 19: ...ble for Welding in Category C Environments Suitable for Indoor and Outdoor Welding Open Circuit Voltage VRD On 35V DC Open Circuit Voltage VRD Off 74 V DC Welding Current Range MIG Mode 30 355A Welding Current Range STICK Mode 10 355A Welding Current Range TIG Mode 10 355A Supply Lead 4mm Effective Input Current I1eff Refer Note 2 15 5Amps Maximum Input Current I1max 20Amps Efficiency 92 Idle stat...

Page 20: ...o large variations in performance and specifications of different brands and types of generators CIGWELD cannot guarantee full welding output power or duty cycle on every brand or type of generator Some small generators incorporate low cost circuit breakers on their outputs These circuit breakers usually will have a small reset button and will trip much faster than a switchboard type circuit break...

Page 21: ...1360 CIGWELD TBi Push Pull Gun 8m and Sync Box 646779 Twistlock Electrode Holder Lead 400A 5m W4013801 TIG Torch 17V with 4m lead 200A 20 W4013800 TIG Torch 17V with 4m lead and remote control 200A 20 W4014601 TIG Torch 26V with 4m lead 240A 20 W4015005 Transmig 355i Trolley with inbuilt cylinder carrier 7977729 Feed Roll 0 6 0 8mm V groove hard 7977703 Feed Roll 0 9 1 2mm V groove hard fitted 797...

Page 22: ...G Torches pkt of 5 BG10N31 R Collet Body 1 6mm for 17 26 18 TIG Torches pkt of 5 BG10N32 R Collet Body 2 4mm for 17 26 18 TIG Torches pkt of 5 BG10N28 R Collet Body 3 2mm for 17 26 18 TIG Torches pkt of 5 BG57Y02 R Back Cap Long for 17 26 18 TIG Torches pkt of 2 BG57Y04 R Back Cap Short for 17 26 18 TIG Torches pkt of 2 Table 2 3 TIG Tungsten Electrodes Cigweld Tungsten Electrodes suitable for AC ...

Page 23: ... Shade 9 13 Racer 454322 WeldSkill Auto Darkening Welding Helmet Variable Shade 9 13 Tribal 454324 WeldSkill Auto Darkening Welding Helmet Variable Shade 9 13 Oz Flag 454335 WeldSkill Auto Darkening Welding Helmet Variable Shade 9 13 Flaming Skull 454336 WeldSkill Auto Darkening Welding Helmet Variable Shade 9 13 Pink Lady 454332 ProLite Auto Darkening Welding Helmet Variable Shade 9 13 Space 4543...

Page 24: ...OPERATING MANUAL INTRODUCTION 2 10 Manual 0 5586 This Page Intentionally Blank ...

Page 25: ...nment These units are designed for use in environments with increased hazard of electric shock as outlined in AS 60974 1 and AS 1674 2 A Examples of environments with increased hazard of electric shock are 1 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...

Page 26: ...ransmitters 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 shall ensure ...

Page 27: ...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 wor...

Page 28: ...OPERATING MANUAL INSTALLATION 3 4 Manual 0 5586 This Page Intentionally Blank ...

Page 29: ...he 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 355i Power Source Controls Indicator...

Page 30: ...Per Minute MPM in MIG mode and actual welding amperage of the power source when welding At times of non welding the digital meter will display a pre set preview value of Wirefeed Speed This value can be adjusted by varying the Amperage Control Knob 6 In Auto MIG mode the digital meter will also display the plate thickness and the wirefeed speed and plate thickness can be alternatively displayed by...

Page 31: ...re exact settings are required in the case of procedural work it is recommended that alternate measurement methods be utilised to ensure output values are accurate 6 Amperage Control Wirespeed The amperage control knob adjusts the amount of welding current delivered by the power source In MMAW stick and GTAW TIG modes the amperage control knob directly adjusts the power inverter to deliver the des...

Page 32: ...INCH button is active in GMAW FCAW mode MIG only Press and hold the INCH button to Inch the MIG welding wire through the MIG Gun 10 Advanced Features Button Press and release the Advanced Features button to enter or exit from the advanced programming mode To exit simply press and release the button again User can scroll through Advanced Features by using AMPS Control Knob 6 and can scroll through ...

Page 33: ...main depressed for the welding output to be active Press and hold the torch trigger to activate the power source weld Release the torch trigger switch to cease welding 4T Latch Mode This mode of welding is mainly used for long welding runs to reduce operator fatigue In this mode the operator can press and release the torch trigger and the output will remain active To deactivate the power source th...

Page 34: ...al however that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the Dinse terminal 20 8 Pin Control Socket The 8 pin Remote Control Socket is used to connect remote control devices such as Spool Gun TIG Torch Remote Control and Push Pull Gun with Synchr...

Page 35: ...To make connections align keyway insert plug and rotate threaded collar fully clockwise The socket information is included in the event the supplied cable is not suitable and it is necessary to wire a plug or cable to interface with the 10 pin receptacle A B C D E F G H I J A 10636 Figure 4 3 10 Pin Control Socket Socket Pin Part Number Description A Remote Voltage Control Potentiometer Wiper B Mo...

Page 36: ...a fan as needed feature Fan as needed automatically switches the cooling fan off when it is not required This has two main advantages 1 to minimize power consumption and 2 to minimise the amount of contaminants such as dust that are drawn into the power source Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required 26 Internal Swit...

Page 37: ...atures mode and the torch trigger is pressed or welding is commenced it will exit Advanced Features mode saving any change made MIG GMAW FCAW Mode Advanced Features Menu Map POS Advanced Menu MIG Mode IND PRE STH DWE 0 5 S S T 0 1 4 S Advanced Menu MIG Options or Range Press Advanced Button to Exit to Welding Mode 01 10 0 01 2 S 1 5 22 MPM 0 5 10 S 0 5 S 0 5 S SPO 1 5 Max WFS MPM SYN with CRA CUR ...

Page 38: ...E 1 0 S 0 5 S Dwell Time is the time used for the non weld time in Stitch weld mode Pre Flow MIG Setting PRE 0 2 S 0 5 S Shielding gas flows for the time specified before an arc is initiated Post Flow MIG Setting POS 0 5 S 0 5 S Shielding gas flows for the time specified after an arc has extinguished Crater Fill CRF OFF ON OFF The crater fill adds slowly decreasing current at the end of a weld thi...

Page 39: ...s solenoid is to be turned off Remote Local R L LOC LOC 8P 10P P P When in the local mode the unit will not detect the remote device and will operate from the power source controls only When in 8P or P P Remote mode the 8 PIN control socket is active and remote current wirespeed controls will be active P P is for push pull gun and 8P is for spool gun When in 10 PIN Remote mode the 10 PIN control s...

Page 40: ...nit will enter down slope mode as soon as the trigger switch is released ie if Down Slope is set to 5 0 S the unit will ramp down from the present welding current to zero over 5 seconds In 4T latched to enter down slope mode the trigger switch must be held in for the selected time period ie press and release trigger switch to commence welding then press and hold trigger switch again to enter down ...

Page 41: ...its Comments Hot Start HOT 10 Amps 0 100 A Hot Start is used to improve the start characteristics for stick electrode e g low hydrogen electrode Arc Force ARC 50 0 100 Arc Force control provides an adjustable amount of welding force or dig control This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit up in certain situations wi...

Page 42: ...tory Default Settings restored This function is accessed by pressing the Advanced FEATURE and MEMORY buttons at the same time for three seconds 3s The VOLTS and AMPS LEDs will flash 3 times displaying SYS RST to indicate a Factory Reset has been completed Art A 14703 Figure 4 7 Restore Factory Default Settings ...

Page 43: ...cribed 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 the gas p...

Page 44: ... 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 regulator flowme...

Page 45: ...r 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 welding grade...

Page 46: ...is from 5 to 5 turning the Voltage Control knob clockwise increases the voltage along the Heat Scale and the voltage control knob will adjust the heat setting off the Auto MIG synergic line which is set at 0 on the Heat Control Description Transmig 4RX Wirefeeder Wirefeeder Plant Part Number W3000410 Wirefeeder Plant Dimensions H 453mm x W 238mm x D 553mm Wirefeeder Plant Mass 21kg Wire Feed Motor...

Page 47: ... refer to Optional AccessoriesTable 2 2 on Page 2 7 Connect the Interconnection cable assembly from the rear of the 4RX wirefeeder to the the front of the 355i welding power source Connect the MIG Torch to the front of the 4RX as you would to the front of the 355i Power Source Refer to Section 5 06 The R L setting in ADVANCED FEATURES should be set to 10P 10pin for the power source See 4 03 Settin...

Page 48: ...2 2 on Page 2 7 The Wire Feeder is fitted with an 8M interconnection cable assembly to connect from the back of the 4RX to the front of the 355i welding power source Connect the MIG Torch to the front of the 4RX as you would to the front of the 355i Power Source Refer to Section 5 06 The R L setting in ADVANCED FEATURES should be set to 10P 10pin for the power source See 4 03 Setting the Internal ...

Page 49: ...ided ensuring the tab on the front of the tray captures the hand hold on the front of the 355i power source Re install the screw through the hole in the centre of the top tray into the top of the 355i case Ensure that all fixing screws are in place and tightened 4 Place the 4RX Wire Feeder rubber feet on the top tray hole 5 Position a gas cylinder on the rear tray of the Trolley and lock securely ...

Page 50: ...Art A 14706 Warning If Cylinder is fitted to the Trolley it must be fitted in the correct position and secured firmly in the upright position using the Chain provided to prevent it from falling or tipping Figure 5 7 Welding Trolley and Welding Equipment ...

Page 51: ...torch adaptor Art A 14707 3P 415V Figure 5 8 Attaching MIG Torch 5 07 Installing Spool 300mm diameter As delivered from the factory the unit is fitted with a Wire Spool Hub which accepts a Spool of 300mm diameter Remove the locking pin from the spool hub Install the wire spool over the spool hub locating the hole in the spool with the alignment pin on the spool hub Insert the locking pin back into...

Page 52: ...l the Handi Spool over the spool hub locating the hole in the Handi Spool with the alignment pin on the Spool Hub Insert the locking pin back into the spool hub in the rear position as shown ensuring the wire spool is firmly secured in position Spool Hub Locking Pin Spool Hub Alignment Pin Art A 14709 Figure 5 10 200mm Handispool Installation ...

Page 53: ...re roller arm and wire drive tension screw and adjust the pressure accordingly Figure 5 11 Remove the 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 appropriate contact tip WARNING Before connecting the work clamp to the work make sure the mains power supply is switched off The electrode wire will ...

Page 54: ...e 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 11 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 to replac...

Page 55: ...t will result in the wire reel circumference continuing no further than 10 20mm after release of the trigger The electrode wire should be slack without becoming dislodged from wire spool CAUTION Overtension of brake will cause rapid wear of mechanicalWIREFEED parts overheating of electrical componentry and possibly an increased incidence of electrode wire Burnback into contact tip Ensure that the ...

Page 56: ...ding gas regulator flowmeter outlet to the quick connect Shielding Gas Inlet fitting gas on the rear of the Transmig 355i Power Source Ensure that the shielding gas hose connection is sufficiently tight at the regulator connection and the quick connect fitting locks into place correctly on the rear of the power source WARNING Secure the welding grade shielding gas cylinder in an upright position b...

Page 57: ...e thickness Note once an Arc is established the left digital display will keep displaying the wirefeed speed if you desire to display the plate thickness again you need to press the left knob M Heat Control Figure 5 21 Heat Control In Auto MIG mode adjusting the Wire Feed Speed Control may also Synergically adjust the voltage value In Auto MIG mode adjusting the voltage control knob will adjust th...

Page 58: ... selection control refer to Section 4 02 12 for further information E Fit the correct Feed Roll for the Gas Shielded MIG wire being used Refer to Section 2 11 Options and Accessories for Feed Roll types and Part Numbers F Place the MIG wire spool onto the spool holder Refer to Section 5 07 for 300mm diameter spools or 5 08 for 200mm diameter spools G Feed wire through the wire drive mechanism Refe...

Page 59: ...ding Gas Hose Positive Welding Terminal MIG Torch Polarity Lead MIG Torch Work Lead Negative Welding Terminal Art A 1 Shielding Gas Hose Fitted with Quick Connect Shielding Gas Hose Art A 14714 3P 415V Figure 5 23 Setup for Manual MIG GMAW Welding with Gas Shielded MIG Wire ...

Page 60: ...d Roll types and Part Numbers F Place the MIG wire spool onto the spool holder Refer to Section 5 07 for 300mm diameter spools or 5 08 for 200mm diameter spools G Feed wire through the wire drive mechanism Refer to Section 5 09 H Connect the work lead to the positive welding terminal If in doubt consult the electrode wire manufacturer Welding current flows from the power source via Dinse terminals...

Page 61: ...ransmig 220i Manual 0 5586 5 19 MIG GMAW WELDING MIG Torch Work Lead Positive Welding Terminal Negative Welding Terminal MIG Polarity Lead Art A 14715 3P 415V Figure 5 24 Setup for MIG GMAW Welding with Gasless Mig Wire ...

Page 62: ...ing gas regulator flowmeter outlet to the quick connect Shielding Gas Inlet fitting gas on the rear of the Transmig 355i Power Source Ensure that the shielding gas hose connection is sufficiently tight at the regulator connection and the quick connect fitting locks into place correctly on the rear of the power source F Refer to the Weld Guide located on the inside of the wirefeed compartment door ...

Page 63: ...GMAW WELDING Negative Welding Terminal Work Lead Spool Gun Positive Welding Terminal Shielding Gas Hose Fitted with Quick Connect MIG polarity lead Remote Control Socket Art A 14716 3P 415V Figure 5 25 Setup for Spool Gun Welding with Gas Shielded Mig Wire ...

Page 64: ...5 01 then connect the shielding gas hose from the shielding gas regulator flowmeter outlet to the quick connect Shielding Gas Inlet fitting gas on the rear of the Transmig 355i Power Source Ensure that the shielding gas hose connection is sufficiently tight at the regulator connection and the quick connect fitting locks into place correctly on the rear of the power source F Refer to the Weld Guide...

Page 65: ...tive Welding Terminal Work Lead Push pull Gun Positive Welding Terminal Shielding Gas Hose Fitted with Quick Connect MIG polarity lead Remote Control Socket Art A 14723 3P 415V Synchroniser Box Figure 5 26 Setup for PUSH PULL GUN MIG GMAW Welding with Gas Shielded Mig Wire ...

Page 66: ...utomatically 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 Solidified Weld Metal Nozzle Electrode Arc Base Metal GMAW Process Figure 5 27 FLUX CORED ARC WELDING FCAW This is an electric arc welding process which fuse...

Page 67: ...l the welding gun back when the arc is established This will create excessive wire extension stick out and make a very poor weld The electrode wire is not energized until the gun trigger switch is depressed The wire may therefore be placed on the seam or joint prior to lowering the helmet Butt Horizontal Welds Direction of Travel 5 to 15 Longitudinal Angle 90 Transverse Angle Art A 08993 Figure 5 ...

Page 68: ... welding variables in short arc welding of 24 gauge 0 024 0 6mm to 6 4mm mild sheet or plate The applied techniques and end results in the GMAW process are controlled by these variables Preselected Variables Preselected variables depend upon the type of material being welded the thickness of the material the welding position the deposition rate and the mechanical properties These variables are Typ...

Page 69: ...is refers to the position of the welding gun in relation to the joint The transverse angle is usually one half the included angle between plates forming the joint The longitudinal angle is the angle between the centre line of the welding gun and a line perpendicular to the axis of the weld The longitudinal angle is generally called the Nozzle Angle and can be either trailing pulling or leading pus...

Page 70: ... the current level but lengthens the arc By decreasing the voltage a shorter arc is obtained with a little change in current level When changing to a different electrode wire diameter different control settings are required A thinner electrode wire needs more Wirespeed to achieve the same current level A satisfactory weld cannot be obtained if the Wirespeed and Voltage settings are not adjusted to...

Page 71: ...ated solid hardfacing wire for surfacing of steel components subject to wet or dry hard particle abrasion combined with low to moderate impact loading AUTOCRAFT AL5356 SOLID ALUMINIUM MIG WIRE 0 9mm Spool 7kg 722226 Excellent general purpose Aluminium MIG wire suitable for the welding of a wide range of wrought and cast Aluminium alloys containing Magnesium Note that a suitable shielding gas is re...

Page 72: ... 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 environment Shield the w...

Page 73: ...he pressure roller adjuster B Swarf can also be produced by the wire passing through an incorrect feed roller groove shape or size C Swarf is fed into the conduit liner where it accumulates thus reducing wire feedability 6 Incorrect or worn contact tip A The contact tip transfers the weld current to the electrode wire If the hole in the contact tip is too large then arcing may occur inside the con...

Page 74: ...peed 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 penetration shielding g...

Page 75: ... safe practices prescribed in this instruction SPECIFIC PROCEDURES for the use of regulators are listed below 1 NEVER subject the regulator to inlet pressure greater than its rated inlet pressure 2 NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition NEVER loosen a connection or attempt to remove any part of a regulator until the gas pressure has been reli...

Page 76: ... cylinder containing any other gas Art A 05087 Figure 6 1 Fit Regulator to Cylinder Installation 1 Remove cylinder valve plastic dust seal Clean the cylinder valve outlet of impurities that may clog orifices and damage seats before connecting the regulator Crack the valve open then close momentarily pointing the outlet away from people and sources of ignition Wipe with a clean lint free cloth 2 Ma...

Page 77: ...on 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 welding grade shielding gas to d...

Page 78: ...e TIG torch to 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 r...

Page 79: ... Negative Welding Terminal Work Lead TIG Torch TIG Remote Control Art A 14717 Connect to shielding gas regulator flowmeter Note This 8 pin connection plug is for TIG torch trigger connection and remote TIG torch current control if applicable 3P 415V Figure 6 3 Setup for Lift TIG GTAW Welding ...

Page 80: ...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 30 60 1 16 1 6...

Page 81: ...21401 For stainless 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 1...

Page 82: ...ase travel speed 5 Uneven leg length in fillet joint Wrong placement of filler rod Re position filler rod 6 Electrode melts or oxidises when an arc is struck A Torch lead connected to positive welding terminal A Connect torch lead to negative welding terminal B No gas flowing to welding region B Check the gas lines for kinks or breaks and gas cylinder contents C Torch is clogged with dust or dirt ...

Page 83: ...e 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 Incorrect shielding gas is being used ...

Page 84: ...OPERATING MANUAL TIG GTAW WELDING 6 10 Manual 0 5586 This Page Intentionally Blank ...

Page 85: ...essential however that the male 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 12 for further information Note in Stick Mode additional features for Hot Start and Arc force are available Refer to Stick Mode Advanced Features Page 4 13 WARNING Before connecting the work clamp to the work make...

Page 86: ...n 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 after each wel...

Page 87: ...at 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 88: ...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 Butt Joint 1 6mm ...

Page 89: ...hes 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 electrode hold...

Page 90: ... 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 tack weld at both...

Page 91: ...gular 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 horizontal ver...

Page 92: ...rst 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 the centre of t...

Page 93: ...ad 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 lightl...

Page 94: ...etal 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 to expand acro...

Page 95: ...liminating 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 structure By co...

Page 96: ...ortion 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 97: ... 5mm 3 2mm 2 5 kg 2 5 kg 611602 611603 Stainless Steel type for 19Cr 10Ni stainless grades including 201 202 301 302 303 304 304L 305 308 etc Satincrome 309Mo 17 2 5mm 3 2mm 4 0mm 2 5 kg 2 5 kg 2 5 kg 611692 611693 611694 Stainless Steel type for 309 and 309L grades It is also suitable for welding of dissimilar welding of other 300 series stainless steels Satincrome 316L 17 2 0mm 2 5mm 3 2mm 2 5 3...

Page 98: ... the weld metal A Non metallic particles may be trapped in undercut from previous run A If a bad undercut is present clean slag bout and cover with a run from a smaller gauge electrode B Joint preparation too restricted B Allow for adequate penetration and room for cleaning out the slag C Irregular deposits allow slag to be trapped C If very bad chip or grind out irregularities D Lack of penetrati...

Page 99: ...t angle so the welding arc is directed more into the base metal D Travel speed of electrode is too high D Reduce travel speed of electrode E Scale or dirt on joint surface E Clean surface before welding Art A 05867_AC Lack of inter run fusion Lack of side fusion scale dirt small electrode amperage too low Lack of root fusion Lack of fusion caused by dirt electrode angle incorrect rate of travel to...

Page 100: ... ARC MMAW WELDING 7 16 Manual 0 5586 FAULT CAUSE REMEDY Not cleaned or incorrect electrode Slag trapped in undercut Slag trapped in root Art A 05868_AC Figure 3 Example of Slag Inclusion Table 7 2 Welding Problems MMAW Stick ...

Page 101: ...ed 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 for in s...

Page 102: ...d 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 regularly che...

Page 103: ...bration Parameters Periodic calibration of other parameters such as timing functions are not required unless a specific fault has been identified C Calibration Equipment All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question Only test equipment with valid calibration certificates NATA certified laboratories sh...

Page 104: ...d A Power source is not in the correct mode of operation A Set the power source to STICK mode Refer to Section 4 02 12 B Work Lead is not connected to the work piece B Ensure that the Work Lead is con nected to the work piece and has a good connection to the work piece 3 Mains Supply Voltage is On the On Off switch on the rear panel is in the On position and the Power indicator on the front panel ...

Page 105: ...eads shorted B Repair or replace torch trigger switch lead 7 Welding arc cannot be established in MIG mode A MIG torch polarity lead is not connected into a weld ing output terminal A Connect the MIG torch polarity lead to either the positive welding output terminal or the negative welding output terminal as re quired B Poor or no work lead contact B Clean work clamp area and ensure good electrica...

Page 106: ...redited Cigweld Service Provider 3 Err311 Err314 Internal communication error Reset to the Factory Default Settings refer to Section 4 03 If after that this error still occurs contact an ac credited CIGWELD service provider 4 Err402 A Remote 10 pin mode is not selected if using the 4RX wirefeeder A Check if the Remote 10 Pin mode has been selected on the advanced menu Refer to Section 4 03 Remote ...

Page 107: ... OTW24AH 62 Adjustable Nozzle Heavy Duty 16mm OTW24AH 75 Adjustable Nozzle Heavy Duty 19mm 2 OTW14H 35 Contact Tip Heavy Duty 0 9mm OTW14H 40 Contact Tip Heavy Duty 1 0mm OTW14H 45 Contact Tip Heavy Duty 1 2mm OTW14H 116 Contact Tip Heavy Duty 1 6mm OTW14H 564 Contact Tip Heavy Duty 2 0mm OTW14T 30 Contact Tip 0 8mm Tapered OTW14T 35 Contact Tip 0 9mm Tapered OTW14T 45 Contact Tip 1 2mm Tapered 3 ...

Page 108: ...OPERATING MANUAL KEY SPARE PARTS 9 2 Manual 0 5586 9 02 Power Source Art A 14720_AB 2 1 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2 24 25 26 Figure 9 2 ...

Page 109: ...rive Assembly 9 W7006663 Control Panel 10 W7006664 PCB Control 11 W7006665 Control Knob 12 W7006667 Circuit Breaker 8A 13 W7006668 Spool Hub 14 W7006669 Gas Solenoid Valve 15 W7006670 PCB EMC 16 W7006671 PCB Control 17 W7006672 PCB Bias Supply 18 W7006673 Input Supply ON OFF Switch 19 W7006675 PCB Filter 20 W7006676 PCB Output 21 W7006677 PCB Inverter 22 W7006678 Filter EMC 23 W7006679 Input Recti...

Page 110: ...OPERATING MANUAL KEY SPARE PARTS 9 4 Manual 0 5586 This page intentionally blank ...

Page 111: ...15 AC28V 5A MB14 1 2 3 MB16 OUT 1 VCC 2 GND 3 VEE 4 IN 5 IN 6 HALL SENSOR 1 2 3 4 MB18 1 2 3 CN1 AC50V 2A SOURCE FOR FAN IGBT DRIVER PCBA 1 2 3 4 5 MB5 DRIVER B DRIVER A MB1 MB2 MB4 FAN FAN1 FAN FAN2 FAN FAN3 1 2 3 4 5 6 MB12 1 2 3 4 CN2 1 2 3 MB3 1 2 3 MB4A 1 2 3 4 MB13 1 2 3 MB19 1 2 3 4 MB10 8A 250V MOTOR 1 2 3 4 5 6 7 8 9 10 10 PIN SOCKET A B C D E F G H I J 1 2 3 4 5 6 7 8 8 PIN SOCKET 1 2 3 ...

Page 112: ...OPERATING MANUAL APPENDIX A 2 Manual 0 5550 This Page Intentionally Blank ...

Page 113: ... THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN CIGWELD S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY CIGWELD PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products...

Page 114: ...Oxy fuel torches O rings 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 r...

Page 115: ...OPERATING MANUAL Transmig 220i This Page Intentionally Blank ...

Page 116: ...4 7508 Fax 61 3 9474 7488 CIGWELD COM AU Malaysia No 14 Jalan Teknologi 3 1 Selangor Science Park 1 Kota Damansara 47810 Petaling Jaya Selangor Darul Ehsan Malaysia Tel 60 3 6145 0995 Fax 60 3 6145 0585 Indonesia JI Pulogadung No 45 Kawasan Industri Pulogadung Jakarta 13930 Indonesia Tel 62 21 460 0188 Fax 62 21 461 2929 Singapore ESAB Asia Pacific 38 Joo Koon Circle 629063 Singapore Tel 65 6861 4...

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