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CIGWELD Transmig 400 i Operating Manual Download Page 56

TRANSMIG 400 i

A-2

July 18, 2008

APPENDIX 2: TRANSMIG 400 i INTERCONNECT DIAGRAM

CN130

CN131

CN131

CN130

CN132

CN132

CN3

CN3

+

-

FAN1

G5

E5

G6

E6

G4

E4

CN18

CN18

PCB3

Control Souce

Circuit Board

[WK-5548]

CN27

CN27

PCB6

Control

Circuit Board

[WK-6163]

G1

E1

G2

E2

G7

E7

G8

E8

G3

E3

PCB5

Conect Circuit Board

[WK-5696]

CN30

CN31

CN31

CN30

CN32

CN32

PCB7

Filter Circuit Board

[WK-5689]

11

5V

24

V

0V

11

5V

24

V

0V

0V

40

0V

T1

1
2

CN

2

0

3

CN

1

1

1
2
3
4

1
2
3

CN

3

3

1
2
3

CN

1

8

CN1

1 2 3 4 5 6 7

1 2 3

CN16

1 2 3 4

CN2

1 2 3 4 5 6

CN13

1 2 3 4 5

CN15

CN19

1 2 3

CN20

1 2 3 4 5 6

CN21

1 2 3 4 5 6 7

CN22

1 2 3 4 5 6

CN23

1 2 3 4 5 6 7

MCB1

MCB2

1
2

CN

2

0

3
4

Ground

PCB21

Filter

Circuit Board

[WK-4917]

+

-

(1)

(2)

(0)

K(7

G(6

R(3)

S(4)

T(5)

D1

PCB2

Link

Circuit Board

[WK-5597]

CN1

1 2

R2

Q1

C

G

E

Q2

C

G

E

Q3

C

G

E

Q4

C

G

E

Q5

C

G

E

Q6

C

G

E

PCB8

IGBT Gate

Circuit Board

[WK-5479]

Q7

C

G

E

Q8

C

G

E

Q9

C

G

E

Q10

C

G

E

Q11

C

G

E

Q12

C

G

E

PCB9

IGBT Gate

Circuit Board

[WK-5479]

CN

2

1
2
3
4

CN

1

1
2

CN

2

1
2
3
4

PCB4

Detect

Circuit Board

[WK-4819]

CN

4

1
2
3
4

CN1

CN6

CN5

CN5

CN6

CN4

N

P

R2

N

P

R2

TB1

TB2

TB2

TB1

TB3

TB4

G2

E2

G1

E1

G5

E5

G6

E6

PCB1

Main

Circuit Board

[WK-5493]

3

CN

1

1
2
3

CT2

CT1

SIDE CHASSIS 

REAR

PANEL

E

TB3

TB4

Q13

C

G

E

Q14

C

G

E

Q15

C

G

E

Q16

C

G

E

Q17

C

G

E

Q18

C

G

E

PCB10

IGBT Gate

Circuit Board

[WK-5479]

Q19

C

G

E

Q20

C

G

E

Q21

C

G

E

Q22

C

G

E

Q23

C

G

E

Q24

C

G

E

PCB11

IGBT Gate

Circuit Board

[WK-5479]

CN

2

1
2
3
4

CN

1

1
2

CN

2

1
2
3
4

G3

E3

G4

E4

G8

E8

G7

E7

3

CN

1

1
2
3

S1

CN7

1 2 3

CT4

CT3

CN3

1 2 3 4 5

CN2

1 2 3

CN

1

1
2
3
4
5
6

TB13

TB14

TB15

TB10

TB11

TB12

TB5

TB6

TB7

TB18

TB19

TB20

C

CE

E

C

CE

E

C

CE

E

C

CE

E

UB3

UB1

PCB22

CE Filter

Circuit Board

[WK-5022]

CN1

1 2 3 4 5

TB1

L103

+

L108

L102

L101

L104 L107

CN1

1 2 3

CN

2

1
2
3
4
5

CN

3

1
2

C1

C3

C2

C4

L109

L111 L112

L106

1
2

CN

7

3
4

S

R

S

R

0V

24V

115V

D E

H F

J

C

K

G

B

I

L

A

N

M

EC

CON1

Summary of Contents for Transmig 400 i

Page 1: ...50 60 Hz 3 PHASE GTAW MMAW GMAW FCAW CC CV DC 415 V INVERTER Operating Manual TRANSMIG Revision AB Issue Date July 18 2008 Manual No 0 4959 Operating Features INVERTER ARC WELDER 400 i...

Page 2: ...to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide CIGWELD is a Market Leading Brand of Arc...

Page 3: ...w thermadyne com Copyright 2008 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher d...

Page 4: ...3 01 Environment 3 1 3 02 Location 3 1 3 03 Electrical Input Connections 3 1 3 04 Mains Supply Voltage Requirements 3 2 3 05 High Frequency Introduction 3 3 3 06 High Frequency Interference 3 3 3 07...

Page 5: ...1 Setting of the Power Source 5 5 5 03 2 Position of MIG Torch 5 5 5 03 3 Travel Speed 5 5 5 03 4 Electrode Wire Size Selection 5 5 5 03 5 Deposition Rate Comparison 5 5 SECTION 6 SERVICE 6 1 6 01 Ro...

Page 6: ......

Page 7: ...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 locati...

Page 8: ...gases used for welding can displace air causing injury or death Be sure the breathing air is safe 6 Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the ar...

Page 9: ...ick electrode from holder or cut off welding wire at contact tip when not in use WARNING FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can th...

Page 10: ...s rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have o...

Page 11: ...reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or dr...

Page 12: ...l Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements among them are AS NZS 3652 EMC Directive EN50199 applicable to arc...

Page 13: ...web site listed below and clicking on the Literature Library link http www cigweld com au 2 02 Equipment Identification The unit s identification number specification or part number model and serial n...

Page 14: ...cuit 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 Powe...

Page 15: ...TAW and Control and Hot Start for Shielded Metal Arc Welding SMAW processes The power source is totally enclosed in an impact resistant flame resistant and non conductive plastic case NOTE Volt Ampere...

Page 16: ...Mode Select Switch Panel Circuit Board Sequence Control Fan Control Circuit Fan Input Power Primary Circuit Sensor Down Transformers AC115V AC24V T3 Over Current Protect Thermal Detector Output Voltag...

Page 17: ...0A 60 22 0V 200A 100 18 0V Welding Output 400 C 10 min Quoted figures refer to GMAW output 400A 25 34 0V 300A 60 29 0V 200A 100 24 0V Protection Class IP23S Table 2 1 Specifications Cigweld continuous...

Page 18: ...TRANSMIG 400 i 2 6 July 18 2008 THIS PAGE LEFT INTENTIONALLY BLANK...

Page 19: ...b In locations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or accidental contact by the operator or c In wet or damp hot locations whe...

Page 20: ...Correctly installed if necessary by a qualified electrician Correctly earthed electrically in accordance with local regulations Connected to the correct size 415V Mains Current Circuit as per the Spec...

Page 21: ...rom the machine can occur if the case is metal and is not properly grounded It can occur through apertures such as open access panels The shielding of the high frequency unit in the Power Source will...

Page 22: ...ings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature CAUTION Continually exceeding the duty cy...

Page 23: ...d collar fully clockwise A J B K I C L N H D M G F E A B C E Front view of 14 Socket Receptacle 5k ohms Art A 07653_AB D E F H I J K L M N G Figure 4 2 14 Pin Socket Receptacle Socket Pin Function A T...

Page 24: ...rheating and result in the male plug being fused in the bayonet terminal 5 ON OFF Switch This switch connects the Primary supply voltage to the inverter when in the ON position This enables the Power...

Page 25: ...ANCE when MIG welding It controls the dynamic properties of the arc in dip transfer welding mode When this parameter is set to 0 i e minimum inductance the arc has a fast response with a resulting cri...

Page 26: ...tration on root runs and side wall wash on vertical up fillet welds Root Runs During root runs the weld pool forms a keyhole shape If too much weld current is used the hole blows out and the weld coll...

Page 27: ...r knob sets the STICK and TIG WELD current DC V Weld Voltage Volt when lit parameter knob sets the MIG voltage Parameter Description Contactor ON OFF Contactor operation in MIG Mode only Operation PAN...

Page 28: ...ld current for 20 seconds after weld has been completed A selected weld parameter value can be adjusted at any time even while welding Intelligent Fan Control The intelligent cooling system is designe...

Page 29: ...ameters into Memory Press and HOLD the SAVE button for 3 seconds Beep will sound and Digital Meter display will show a number 1 Select a memory location by rotating the control knob 1 to 5 is displaye...

Page 30: ...dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use T...

Page 31: ...cordingly NOTE Consult the wire feeder manual on how to adjust the wire feed speed and connect the MIG gun WARNING Before connecting the work clamp to the work and inserting the electrode in the elect...

Page 32: ...indow Internal warnings such as over temperature low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen 4 Save Load Buttons By using the Save...

Page 33: ...required Use the Scroll Buttons to move to the parameter to be set The LED will show which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter Commence...

Page 34: ...d the machine will give a beep to confirm the weld parameters from the control panel are saved The Save Load buttons must be depressed for 3 seconds to store settings LOAD retrieve a Program to Contro...

Page 35: ...30 60 1 16 1 6mm 60 95 60 115 3 32 2 4mm 125 150 100 165 1 8 3 2mm 130 225 135 200 5 32 4 0mm 190 280 190 280 3 16 4 8mm 250 340 250 340 5 01 3 Tungsten Electrode Types Electrode Type Ground Finish We...

Page 36: ...e is a guide only other diameter wires may be used according to the welding application 5 01 5 Shielding Gas Selection Alloy Shielding Gas Aluminum alloys Welding Argon Carbon Steel Welding Argon Stai...

Page 37: ...0mm 40 50 25 35 0 040 1 0mm 1 16 1 6mm 5 7 Lap Fillet 45 55 30 45 Butt Corner 0 045 1 2mm 50 60 35 50 0 040 1 0mm 1 16 1 6mm 5 7 Lap Fillet 60 70 40 60 Butt Corner 1 16 1 6mm 70 90 50 70 1 16 1 6mm 1...

Page 38: ...avy sections necessary to give proper fusion of weld and base metal Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications refer to table bel...

Page 39: ...lar arc sound 5 03 2 Position of MIG Torch The angle of MIG torch to the weld has an effect on the width of the weld run 5 03 4 Electrode Wire Size Selection The choice of electrode wire size in conju...

Page 40: ...TRANSMIG 400 i 5 6 July 18 2008 THIS PAGE LEFT INTENTIONALLY BLANK...

Page 41: ...ure Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge To clean the unit open the enclosure and use a vacuum cleaner to remove any accumulated dirt and...

Page 42: ...bles Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of power supply 6 Months Replace all broken parts Bring the unit to an authorized CIGWELD Service Provider to remov...

Page 43: ...n metal Contaminants range from no gas around the welding arc to dirt on the work piece surface Porosity can be reduced by checking the following points 1 Gas cylinder contents and flow meter Ensure t...

Page 44: ...sive pressure is applied to the pressure roller adjuster Wire debris can also be produced by the wire passing through an incorrect feed roller groove shape or size Wire debris is fed into the liner wh...

Page 45: ...the WELD V control 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 co...

Page 46: ...lectrode melts when arc is struck Electrode is connected to the terminal Connect the electrode to the terminal 7 Dirty weld pool A Electrode contaminated through contact with work piece or filler rod...

Page 47: ...nected B Connect it to the terminal C Gas flow incorrectly set cylinder empty or the torch valve is off C Select the right flow rate change cylinders or turn torch valve on 12 Arc start is not smooth...

Page 48: ...resses or use crack resistance electrodes B Insufficient throat thickness B Travel slightly slower to alloy greater build up in throat C Cooling rate is too high C Preheat plate and cool slowly 3 A ga...

Page 49: ...le C Adjust 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 be...

Page 50: ...trapped C If very bad chip 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 suitab...

Page 51: ...Loose connections internally C Have an Accredited Cigweld Service Provider repair the connection 2 Maximum output welding current cannot be achieved with nominal Mains supply voltage Defective control...

Page 52: ...t too high A B Primary current is too high because welding arc is too long Mains supply voltage is more than 10 below nominal voltage A B Reduce length of welding arc Have an accredited Cigweld Servic...

Page 53: ...r plug on input PCB and the Mains voltage No weld current is available Buzzer sounds constantly Switch machine OFF then ON to reset E83 error 11 E85 error code displayed Pre charge abnormality Due to...

Page 54: ...at least once every 3 months and b For fixed equipment at least once every 12 months The owners of the equipment shall keep a suitable record of the periodic tests NOTE A transportable power source is...

Page 55: ...MET argon regulator 301527 Regulator only CIGWELD COMET argon flowmeter 0 15 lpm 301710 Flowmeter only CIGWELD COMET argon flowmeter 10 40 lpm 301711 Flowmeter only CIGWELD COMET argon regulator flowm...

Page 56: ...TGate Circuit Board WK 5479 Q7 C G E Q8 C G E Q9 C G E Q10 C G E Q11 C G E Q12 C G E PCB9 IGBTGate Circuit Board WK 5479 CN2 1 2 3 4 CN1 1 2 CN2 1 2 3 4 PCB4 Detect Circuit Board WK 4819 CN4 1 2 3 4 C...

Page 57: ...CHASSIS FRONT PANEL EB Ground TB8 PCB14 TRANS Board WK 5594 D7 D2 D4 CT2 CT1 L1 TB16 TB22 TB16 TB22 CT4 CT3 TB17 CT3 TB31 TB32 TB30 CON1 UB2 UB4 UB2 UB1 R7 UB4 UB3 R8 1 2 CN33 3 4 1 2 CN21 3 4 1 2 CN...

Page 58: ...TRANSMIG 400 i A 4 July 18 2008 THIS PAGE LEFT INTENTIONALLY BLANK...

Page 59: ...IAL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSI NESS INTERRUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELD with respect to any contract or...

Page 60: ...our Accredited Distributor in writing of its claim within seven 7 days of becoming aware of the basis thereof and at its own expense returning the goods which are the subject of the claim to CIGWELD o...

Page 61: ...abour CIGWELD reserves the right to request documented evidence of date of purchase CIGWELD PROFESSIONAL INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR Transtig 200 Pi Transtig 200 AC DC Transarc 30...

Page 62: ......

Page 63: ...1135 Fax 86 21 69171139 Thermadyne Utama Indonesia Kawasan Industri Jababeka JI Jababeka VI Blok P No 3 Cikarang Bekasi 17550 Indonesia Tel 62 21 893 6071 Fax 62 21 893 6067 6068 http www thermadyne c...

Page 64: ...Asia Paci c Regional Headquarters 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 FAX 61 3 9474 7488 Email cigweldsales cigweld com au www cigweld com au...

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