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Transmig 220i

 

 
 

 

OPERATING MANUAL

 

MULTI PROCESS WELDING INVERTER

 

OUTPUT CURRENT

 

220A

^ 

DC

 

INPUT SUPPLY

 

INT. WIRE FEEDER

 

SAFETY DEVICE

 

240V 15A

 

SPOOLS UP TO 300mm

 

Version No: 

AA | 

Issue Date: 

August 2015 | 

Manual No: 

0-5439

 

Summary of Contents for CIGWELD 220i

Page 1: ...ansmig220i OPERATING MANUAL MULTI PROCESS WELDINGINVERTER OUTPUT CURRENT 220A DC INPUT SUPPLY INT WIRE FEEDER SAFETY DEVICE 240V 15A SPOOLSUPTO300mm Version No AA Issue Date August 2015 Manual No 0 54...

Page 2: ...ENT Please register your warranty online immediately after purchase for complete warranty coverage and to guarantee your proof ofpurchase Check out our online registration for the most up to date comp...

Page 3: ...g this 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 animprovementthat does not getref...

Page 4: ...treet Preston Victoria Australia 3072 Tel 61394747400 Fax 61 3 94747391 www cigweld com au Copyright 2015 by CIGWELD Pty Ltd All rights reserved Reproduction of this work in whole or in part without w...

Page 5: ...mpatibility 3 2 SECTION 4 OPERATION 4 1 4 01 Overview 4 1 4 02 Transmig 220i Power Source Controls Indicators and Features 4 1 SECTION 5 MIG GMAW WELDING 5 1 5 01 Shielding Gas Regulator FlowmeterOper...

Page 6: ...elding Technique 7 2 7 03 Electrode Selection Chart 7 13 7 04 Stick MMAW Welding Troubleshooting 7 15 SECTION 8 ROUTINESERVICEREQUIREMENTSANDPOWERSOURCEPROBLEMS 8 1 8 01 Routine Service and Calibratio...

Page 7: ...is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive...

Page 8: ...GENERAL INFORMATION 1 2 Manual 0 5439 15 Keep all panels and covers securely in place...

Page 9: ...ding Current in Amps Minimum Shade Number of Filter s ManualMetalArcWelding 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...

Page 10: ...m welding can easily go through small cracks and openings to adjacentareas 5 Watchforfire andkeepafireextinguishernearby 6 Beawarethatweldingonaceiling floor bulkhead orpartitioncancausefireonthehidde...

Page 11: ...t Biological Effects of Power Frequency Electric Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is nowaverylargevolumeofscientificfindingsbase...

Page 12: ...ylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CodeforSafetyinWeldingandCutting CSAStandardW117 2 fromCanadianStandardsAssociation...

Page 13: ...Standard 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 gener...

Page 14: ......

Page 15: ...nd serial number usuallyappear on a nameplate attached to the control panel In somecases thenameplatemaybe attachedtothe rear panel Equipment which does not have a control panel such as gun and cable...

Page 16: ...s Continuous Weld Mode Spot Weld Mode t Spot Time t1 Preflow Time t2 Postflow Time 2 Step Trigger Operation Press to initiate wirefeed and welding release to stop 4 Step Trigger Operation Press and ho...

Page 17: ...mended that such repairs be carried out by appropriately qualified personsapprovedbyCIGWELD Adviceinthisregard canbeobtainedbycontactinganAccreditedCIGWELD Distributor Thisequipment or any of its part...

Page 18: ...e 210A for 2 minutes i e arc welding time out of every 10 minute period 20 of 10 minutes is 2 minutes During the other 8 minutes of the 10 minute period the Welding PowerSourcemustidleandallowedtocool...

Page 19: ...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 220A MIG Mode Welding V...

Page 20: ...a generator that 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 produ...

Page 21: ...bjected to abnormal vibration or shock E In areas not exposed to direct sunlight or rain F Placeatadistanceof300mmormorefromwalls or similar that could restrict naturalairflowfor cooling G The enclosu...

Page 22: ...rs 3 Computerandothercontrolequipment 4 Safety critical equipment e g guarding of industrial equipment OPERATING MANUAL 5 The health of people around e g the use of pacemakers and hearing aids 6 Equip...

Page 23: ...to earth for electrical safety nor connected to earth because of it s sizeandposition e g ship shullorbuildingsteelwork aconnectionbondingtheworkpiecetoearth mayreduceemissionsinsome butnotallinstanc...

Page 24: ...INSTALLATION 3 4 Manual0 5439 Transmig220i OPERATING MANUAL This Page Intentionally Blank...

Page 25: ...uldbeusedasa guideonly Currentdeliveredtothearcisdependentontheweldingarcvoltage andasweldingarcvoltage variesbetweendifferentclassesofelectrodewire weldingcurrentatanyonesettingwouldvaryaccording tot...

Page 26: ...ng thedigitalmeterwilldisplayapre set preview valueofWirefeedSpeed Thisvaluecanbeadjustedby varying the Amperage Control Knob 4 STICK and LIFT TIG Modes Thedigitalmeterisusedtodisplaythepre set previe...

Page 27: ...ntfortheMIGweldingtorch Connectthetorchbypushing thetorchconnectorintothebrasstorchadaptorfirmlyandscrewingtheplastictorchnut clockwiseto secure in position Toremove the MIG Torch simply reverse these...

Page 28: ...rotate threaded collar fully clockwise Negative Spool Gun Motor Positive Remote Volts in MIG GMAW FCAW Art A 10421_AC Remote Wirespeed in MIG GMAW FCAW mode Remote Amps in LIFT TIG GTAW mode Figure 4...

Page 29: ...in joint fit up in certain situations with particularelectrodes Ingeneralincreasingthearcforcecontroltoward 10 maximumarcforce allows greaterpenetrationcontroltobeachieved Arcforceisincreasedbyturnin...

Page 30: ...and mistakenly be in contact with the work piece during power up 14 Digital Voltage Meter Right Digital Display MIG Mode Thisdigitalmeterisusedtodisplaythepre set preview VoltageinMIGmodeandactualwel...

Page 31: ...dtosupplytheappropriateMIGweldinggastotheunit Refertosection 5 09 set up details WARNING Only Inert Shielding Gases specifically designed for welding applications should be used 17 On Off Switch This...

Page 32: ...torch atthe completingof welding turn the burnbackcontrolknobanticlockwise Toincreasetheburnbacktime orshortentheamountofwire protrudingfrom thetorch at the completing of welding turn the Burnback Con...

Page 33: ...DURES for the use of regulators flowmeters are listed below 1 NEVERsubjecttheregulator flowmetertoinlet pressuregreaterthanitsrated inletpressure 2 NEVER pressurize a regulator flowmeter that has loos...

Page 34: ...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 Crackth...

Page 35: ...ion 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 Itmaybenecessarytore checktheshieldinggas...

Page 36: ...re the MIG torch to the MIG torch adaptor Figure 5 3 Attaching MIG Torch 5 03 InstallingSpool 300mmdiameter As deliveredfromthefactory theunitis fittedwithaWireSpoolHubwhichaccepts a Spoolof 300mmdiam...

Page 37: ...Remove the locking pin from the spool hub Install the Handi Spool over the spool hub locating the hole in the Handi Spool with the alignment pin on the Spool Hub Insertthelockingpinbackintothespoolhub...

Page 38: ...ers through theoutletguideandintotheMIGtorch Re securethepressurerollerarmandwiredrivetensionscrewand adjustthepressureaccordingly Figure5 6 RemovethecontacttipfromtheMIGtorch WiththeMIGTorch leadreas...

Page 39: ...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 shaft...

Page 40: ...findoubt consulttheelectrode wire manufacturer Welding current flows from the Power Source via Dinse terminals It is essential however thatthemaleplugisinsertedandturnedsecurelytoachieveasoundelectric...

Page 41: ...the inside of the wirefeedcompartment door Power Source settings are adjusted usingthefront panelcontrols Refer to section 4 02 WARNING Before connecting the work clamp to the work make sure the main...

Page 42: ...MIGwirespoolontothespoolholder Refertosections5 03for300mmdiameterspoolsor5 04 for 200mm diameter spools G Feed wire through the wire drive mechanism Refer to section 5 05 H Connect the work lead to t...

Page 43: ...MAW WELDING Transmig220i Figure 5 12 Setup for MIG Welding with Gasless Mig Wire OPERATING MANUAL 240VAC 15A Mains Supply MIG Gun Positive Welding Terminal Work Lead Negative Welding Terminal MIG Pola...

Page 44: ...from the shielding gas regulator flowmeter outlet to the quick connect Shielding GasInlet fitting gas on the rear of the Transmig220i Power Source Ensure that the shielding gashoseconnection issuffici...

Page 45: ...sed to weld thin and fairly thick steels and some non ferrous metals in all positions GMAW Process Figure 5 14 Art A 8991_AB FLUXCOREDARCWELDING FCAW Thisisanelectricarcweldingprocesswhichfusestogethe...

Page 46: ...stablished 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...

Page 47: ...mm mildsheetorplate Theappliedtechniques and end results in the GMAW process are controlled by these variables Preselected Variables Preselectedvariablesdependuponthetypeofmaterialbeingwelded thethick...

Page 48: ...lyone halfthe includedanglebetweenplatesformingthejoint Thelongitudinalangleisthe anglebetweenthecentrelineoftheweldinggunandalineperpendiculartotheaxisoftheweld The longitudinalangle isgenerallycalle...

Page 49: ...lding voltage hardly alters the current level but lengthens the arc By decreasing the voltage ashorter arc is obtained with a little change incurrent level Whenchangingtoadifferent electrodewire diame...

Page 50: ...MIG GMAW WELDING 5 18 Manual0 5439 Transmig220i OPERATING MANUAL 5 13 CIGWELD MIG Wire Selection Chart Table 5 1 Cigweld MIG Wire Selection Chart...

Page 51: ...15litresperminute 2 Gas leaks Check for gas leaks between the regulator cylinder connection and in the gas hose to the Power Source 3 InternalgashoseinthePower Source Ensurethehosefromthesolenoidvalve...

Page 52: ...sfedintotheconduitlinerwhereit 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...

Page 53: ...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...

Page 54: ...MIG GMAW WELDING 5 22 Manual0 5439 Transmig220i This Page Intentionally Blank OPERATING MANUAL...

Page 55: ...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 NEVERpressurizear...

Page 56: ...t 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 Cra...

Page 57: ...t working flow rate as follows 1 Slowly turn adjusting screw knob in clockwise direction until the outlet gauge indicates the required flow rate NOTE Itmay benecessarytore checktheshieldinggasregulato...

Page 58: ...r to the shielding gas cylinder refer to Section 6 01 then connect the shielding gas hose from the TIG torch to the regulator flowmeter outlet Note that the TIG torch shielding gas hose is connected d...

Page 59: ...ding Terminal Connect to shielding gas regulator flowmeter Work Lead TIG Remote Control TIG Torch Art A 10432_AC Negative Welding Terminal Note This 8 pin connection plug is for TIG torch trigger conn...

Page 60: ...e Any Commercial Metal Gas Cup Either Ceramic High lmpact or Water Cooled Metal Welds Made With or Without Addition of Filler Metal Inert Gas Shields Electrode and Weld Puddle Tungsten Electrode Non C...

Page 61: ...s steels Stainless pipes tubing architectural uses etc Table6 4 Base Metal Thickness DC Current for Mild Steel DC Current for Stainless Steel Tungsten Electrode Diameter Filler Rod Diameter if require...

Page 62: ...crease travel speed 5 Unevenleglengthinfillet 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...

Page 63: ...rode is toolargeforthe weldingcurrent A Select the right size electrode Refer to Table 6 1 Cigweld Electrode Selection Chart B The wrongelectrode is being used for the welding job B Selecttherightelec...

Page 64: ...TIG GTAW WELDING 6 Manual0 5439 Transmig220i This Page Intentionally Blank OPERATING MANUAL...

Page 65: ...ia Dinse type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection C SelectSTICKmodewiththeprocessselectioncontrol refertoSecti...

Page 66: ...is application Use Ferrocraft 61 or 16TXP for normal strength 500 MPa steels and Alloycraft range for higher strength steels B Austenitic manganese steels Theeffectonmanganesesteelofslowcoolingfromhig...

Page 67: ...d Figure 7 3 Flat Position Gravity Fillet Weld Figure 7 4 Horizontal Position Butt Weld Figure 7 5 Horizontal Vertical HV Position Figure 7 6 Vertical Position Butt Weld Figure 7 7 Vertical Position F...

Page 68: ...l 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 Open Square Butt Joint Gap va...

Page 69: ...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 freelyalon...

Page 70: ...toindividual 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...

Page 71: ...atelytriangularcross sectionmadebydepositingmetalinthecorneroftwo faces meeting at right angles Refer to Figure 7 5 Apieceofangleironisasuitablespecimenwithwhichtobegin ortwolengthsofstripsteelmaybe t...

Page 72: ...completedde slagthewelddepositandbegin thesecondrunatthebottom Thistimeaslightweavingmotionisnecessarytocoverthefirstrunand obtaingoodfusionattheedges Atthecompletionofeachsidemotion pauseforamomentto...

Page 73: ...pecimenforoverheadweldingbyfirsttackingalengthofangleironat rightanglestoanotherpieceofangleironoralengthofwastepipe Thentackthistotheworkbench or hold in a vice so that the specimen is positioned in...

Page 74: ...sheet to become distorted B Expansion and Contraction of Parent Metal in the Fusion Zone Whileweldingisproceeding arelativelysmallvolumeoftheadjacentplatematerialisheatedtoavery hightemperatureandatte...

Page 75: ...n eliminatingdistortion 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...

Page 76: ...stortion Block Sequence The spaces between the welds are filledinwhentheweldsarecool Figure 7 25 Welding Sequence Figure 7 26 Step back Sequence Figure 7 27 Chain Intermittent Welding Figure 7 28 Stag...

Page 77: ...G1032 WEG2532 WEG5032 WEG5040 User friendlyGPelectrodeforweldingthinsectionmild and galvanised steels Excellent for vertical down fillet welding applications Ferrocraft 16 Twincoat 2 5mm 2 5mm 3 2mm 3...

Page 78: ...Castcraft 55 3 2mm 4 0mm 2 5kg 2 5kg 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...

Page 79: ...lag trapped beneath weld bead D Usesmallerelectrodewith sufficientcurrentto give adequate penetration Use suitable tools to remove all slag from comers E Rust or mill scale is preventing full fusion E...

Page 80: ...kets or voids in weld metal porosity A Highlevelsofsulphurin steel A Useanelectrodethatisdesignedforhigh sulphur steels B Electrodes are damp B Dry electrodes before use C Weldingcurrentistoo high C R...

Page 81: ...or fixed equipment at least once every 12 months Theownersoftheequipmentshallkeepasuitablerecordoftheperiodictestsand asystemoftagging including the date of the most recent inspection A transportable...

Page 82: ...ransportable equipment at least once every 3 months and 2 For fixed equipment at least once every 12 months Description Required Parameters VRDOpenCircuitVoltage Less than 35V at nominal input voltage...

Page 83: ...hetestsoutlinedinTable8 3belowshallbeconductedbyanaccreditedCIGWELD service agent Testing Requirements Outputcurrent A tobecheckedtoensureitfallswithinapplicableCigweldpowersourcespecifications Output...

Page 84: ...failure 8 04 Power Source Problems FAULT CAUSE REMEDY 1 MainsSupplyVoltageis On theOn Offswitchon therearpanelisintheOn position and the Power indicatoronthefrontpanel isilluminatedhoweverthe power s...

Page 85: ...ementofwelding 5 Unitwillnotfeedwirein MIG mode A IncorrectFeedRollfittedfor wire type being used A Fitthe correctfeed roll for MIG wiretypebeingused Referto section 2 11 for optional feed rolls avail...

Page 86: ...Turn on regulator D Empty gas cylinder D Replace gas cylinder 10 Gas flow continues after thetorchtriggerswitchhas been released MIG mode Gas valve has jammed open due to impurities in the gas or the...

Page 87: ...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 6...

Page 88: ...feed rolls available 9 W7005604 Fan 10 W7003010 Input Rectifier 2 required 11 W7004908 Gas Solenoid Valve Assembly 12 W7005605 Gas Inlet Fitting 13 W7004909 Dinse Socket 50mm 14 704461 Dinse Plug Mal...

Page 89: ...QF FJ PWM JC CON3 NEGATIVE MD MT IN WIREDRIVE MOTOR 24VDC FAN SOLENOID TH1 MAIN CONTROL BOARD SPOOL GUN BOARD CB SW3 MOTOR CIRCUIT BREAKER SPOOL GUN SWITCH TH2 SW2 REMOTE SWITCH BURNBACK TORCH TRIGGER...

Page 90: ...Transmig220i OPERATING MANUAL This Page Intentionally Blank APPENDIX A 2 Manual 0 5439...

Page 91: ...PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES AREUSED WHICHINCIGWELD SSOLEJUDGEMENTMAYIMPAIRTHESAFETYOR PERFORMANCEOF ANY CIGWELD PRODUCT PURCHASER S RIGHTS UNDE...

Page 92: ...Plasma cutting and 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 w...

Page 93: ...Transmig220i OPERATING MANUAL This Page Intentionally Blank...

Page 94: ...al Enquiries Tel 61394747508 Fax 61394747488 Malaysia Lot 151 Jalan Industri 3 5A Rawang Integrated IndustrialPark Jln BatuArang 48000 Rawang Selangor Darul Ehsan West Malaysia Indonesia JLAkasiaIIBlo...

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