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OPERATING MANUAL

MULTI PROCESS WELDING INVERTER

Version No: 

AB  |  

Issue Date: 

03-02-2019  |  

Manual No: 

0-5550

INPUT SUPPLY

240V 15A*

SAFETY DEVICE

OUTPUT CURRENT

255A

DC

*

INT. WIRE FEEDER

SPOOLS UP TO 300mm

Transmig 255i

Transmig 255i

*Refer to Specification Table for rating information. 

Summary of Contents for CIGWELD Transmig 255i

Page 1: ...G INVERTER Version No AB Issue Date 03 02 2019 Manual No 0 5550 INPUT SUPPLY 240V 15A SAFETY DEVICE OUTPUT CURRENT 255A DC INT WIRE FEEDER SPOOLS UP TO 300mm Transmig 255i Transmig 255i Refer to Speci...

Page 2: ...1 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 W...

Page 3: ...ng 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 an improvement that does not get...

Page 4: ...3072 Tel 61 3 9474 7400 Fax 61 3 9474 7391 www cigweld com au Copyright 2019 by CIGWELD Pty Ltd All rights reserved Reproduction of this work in whole or in part without written permission of the pub...

Page 5: ...in force within the EEA has been used in the design AS 60974 1 2006 Arc Welding Equipment Welding Power Sources IEC 60974 1 2000 MOD IEC 60974 10 2014 Arc Welding Equipment Part 10 Electromagnetic Com...

Page 6: ...ON 4 OPERATION 4 1 4 01 Overview 4 1 4 02 Transmig 255i Power Source Controls Indicators and Features 4 1 SECTION 5 MIG GMAW WELDING 5 1 5 01 Shielding Gas Regulator Flowmeter Operating Instructions 5...

Page 7: ...ng 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 Calibrat...

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

Page 9: ...workpiece to a good electrical earth ground 11 Do not touch electrode while in contact with the work ground circuit 12 Use only well maintained equipment Repair or replace damaged parts at once 13 In...

Page 10: ...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 40...

Page 11: ...ts 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...

Page 12: ...fumes or gases which contain chemicals know 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 Weldin...

Page 13: ...march Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in...

Page 14: ...GENERAL INFORMATION 1 6 Manual 0 5550 OPERATING MANUAL Transmig 255i Transmig 255i This Page Intentionally Blank...

Page 15: ...equipment to 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 opera...

Page 16: ...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...

Page 17: ...n distorted or contaminated should be replaced immediately Should such repairs or replacements become necessary it is recommended that such repairs be carried out by appropriately qualified persons ap...

Page 18: ...ycle period the following example is used Suppose a Welding Power Source is designed to operate at a 20 duty cycle 255 amperes at 26 8 volts This means that it has been designed and built to provide t...

Page 19: ...e 30 255A Welding Current Range STICK Mode 10 230A Welding Current Range TIG Mode 10 255A Supply Lead and Plug Rating 15 Amps 2 5mm Ratings Below Apply to the Factory Fitted Supply Lead Plug 25 Amps 4...

Page 20: ...y Cycle Due to 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...

Page 21: ...Feed Roll 1 2 1 6mm V groove knurled ux cored W7004913 Shielding Gas Hose Assembly WSPLIER MIG Pliers Table 2 2 Transmig 255i Optional Accessories CAUTION ExceedingTIGTorch Duty Cycles may cause over...

Page 22: ...ding Gloves 646755 WeldSkill Heavy Duty Welding Gloves W4018001 Heavy Duty Backpack 454331 ProLite Auto Darkening Welding Helmet BLUE 454332 ProLite Auto Darkening Welding Helmet SPACE 454333 Prolite...

Page 23: ...ns on page 2 5 WARNING Any electrical work must be carried out by a qualified ElectricalTradesperson 3 01 Environment These units are designed for use in environments with increased hazard of electric...

Page 24: ...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...

Page 25: ...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...

Page 26: ...OPERATING MANUAL Transmig 255i Transmig 255i INSTALLATION 3 4 Manual 0 5550 This Page Intentionally Blank...

Page 27: ...rrent range values should be used as a guide only Current delivered to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrode wire wel...

Page 28: ...igital meter will display a pre set preview value of Wirefeed Speed This value can be adjusted by varying the Amperage Control Knob 4 STICK and LIFT TIG Modes The digital meter is used to display the...

Page 29: ...sitive welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the MIG torch via the MIG torch polarity lead electrode holder lead or wo...

Page 30: ...ter Wiper arm connection to 5k ohm remote control Amps GTAW TIG mode potentiometer 8 Wiper arm connection to 5k ohm remote control Volts GMAW MIG mode potentiometer Table 4 1 Note that the remote loca...

Page 31: ...enter down slope mode as soon as the trigger switch is released ie if the multifunction control knob is set to 5 the unit will ramp down from the present welding current to zero over 5 seconds If no...

Page 32: ...The voltage meter will hold the value until 1 any of the front panel controls are adjusted in which case the unit will revert to preview mode 2 welding is recommenced in which case actual welding amp...

Page 33: ...will operate at all times on the remote control socket irrespective of the position of the local remote switch ie in both local and remote modes Should a remote device be connected and the remote loca...

Page 34: ...cooling purposes and will automatically switch off when not required 23 Hot Start Feature Not Shown This feature operates in Stick Manual Arc mode The Hot Start feature improves the arc start characte...

Page 35: ...ractices 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...

Page 36: ...her 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 damag...

Page 37: ...ator flowmeter 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...

Page 38: ...aptor MIG Gun Adaptor MIG Gun Connector Art A 10927 Figure 5 3 Attaching MIG Torch 5 03 Installing Spool 300mm diameter As delivered from the factory the unit is fitted with a Wire Spool Hub which acc...

Page 39: ...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 Insert the locking pin back into the spool hub in the rear positio...

Page 40: ...et guide and into the MIG torch Re secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Figure 5 6 Remove the contact tip from the MIG torch With the MIG Tor...

Page 41: ...ased by rotating 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 r...

Page 42: ...the Mig torch polarity lead to the positive welding terminal If in doubt consult the electrode wire manufacturer Welding current flows from the Power Source via Dinse terminals It is essential however...

Page 43: ...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 Secure the welding grade shieldi...

Page 44: ...Options and Accessories for Feed Roll types and Part Numbers F Place the MIG wire spool onto the spool holder Refer to Sections 5 03 for 300mm diameter spools or 5 04 for 200mm diameter spools G Feed...

Page 45: ...itive Welding Terminal Negative Welding Terminal MIG Polarity Lead Art A 13931 240VAC 15A Mains Supply Note For Maximum duty cycle to be achieved Supply Plug and Lead must be upgraded to 4mm2 Supply L...

Page 46: ...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 l...

Page 47: ...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 Sh...

Page 48: ...ng 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 mak...

Page 49: ...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...

Page 50: ...gle 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 longitudinal angle is the a...

Page 51: ...oltage 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 diame...

Page 52: ...0 8mm Handispool 5kg 720288 General purpose all positional stainless steel wire providing excellent results when used with correct shielding gas Suitable for the general welding of a wide range of sta...

Page 53: ...ding gas 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 Pow...

Page 54: ...d 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...

Page 55: ...ontrol 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...

Page 56: ...OPERATING MANUAL Transmig 255i Transmig 255i MIG GMAW WELDING 5 22 Manual 0 5550 This Page Intentionally Blank...

Page 57: ...imes with the 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...

Page 58: ...or gases to a 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 th...

Page 59: ...y 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 che...

Page 60: ...o achieve a sound electrical connection F Fit the welding grade shielding gas regulator flowmeter to the shielding gas cylinder refer to Section 6 01 then connect the shielding gas hose from the TIG t...

Page 61: ...3933 240VAC 15A Mains Supply Note For maximum duty cycle to be achieved Supply Plug and Lead must be upgraded to 4mm2 Supply Lead 25A Supply Plug Refer to Speci cation Table on Page 2 5 Connect to shi...

Page 62: ...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 Shiel...

Page 63: ...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...

Page 64: ...oo slow Increase 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 pos...

Page 65: ...sten 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 Sel...

Page 66: ...OPERATING MANUAL Transmig 255i Transmig 255i TIG GTAW WELDING 6 10 Manual 0 5550 This Page Intentionally Blank...

Page 67: ...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 13 for further informa...

Page 68: ...rnace 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 mangan...

Page 69: ...Figure 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...

Page 70: ...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 design...

Page 71: ...to your 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 f...

Page 72: ...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 handli...

Page 73: ...ximately 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 tw...

Page 74: ...ave 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 obt...

Page 75: ...men for 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...

Page 76: ...acting 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 mat...

Page 77: ...ccessful 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 th...

Page 78: ...amples of Distortion Art A 07710_AB 1 Block Sequence The spaces between the welds are lled 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 Sequ...

Page 79: ...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...

Page 80: ...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 s...

Page 81: ...Fusion 6 Gas pockets 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 W...

Page 82: ...OPERATING MANUAL Transmig 255i Transmig 255i MANUAL ARC MMAW WELDING 7 16 Manual 0 5550 This Page Intentionally Blank...

Page 83: ...and 2 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 in...

Page 84: ...s 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 tha...

Page 85: ...3 below shall be conducted by an accredited CIGWELD service agent Testing Requirements Output current A to be checked to ensure it falls within applicable Cigweld power source specifications Output V...

Page 86: ...is parts and their eventual failure 8 04 Power Source Problems FAULT CAUSE REMEDY 1 Mains Supply Voltage is On the On Off switch on the rear panel is in the On position and the Power indicator on the...

Page 87: ...uished prior to commencement of welding 5 Unit will not feed wire in MIG mode A Incorrect Feed Roll fitted for wire type being used A Fit the correct feed roll for MIG wire type being used Refer to se...

Page 88: ...f C Turn on regulator D Empty gas cylinder D Replace gas cylinder 10 Gas flow continues after the torch trigger switch has been released MIG mode Gas valve has jammed open due to impurities in the gas...

Page 89: ...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...

Page 90: ...ble for other feed rolls available 9 W7005604 Fan 10 W7003010 Input Recti er 2 required 11 W7004908 Gas Solenoid Valve Assembly 12 W7005605 Gas Inlet Fitting quick connect type 13 W7004909 Dinse Socke...

Page 91: ...ED BLACK 1 2 FJ 1 2 3 4 5 6 7 8 IN 1 2 3 4 5 6 7 8 IMOUT D OC C A 15V B OC2 D OC C A 15V B GND 1 2 3 4 OT 75A 75A 1 2 3 POWER1 1 2 3 POWER 24V GND 24V 24V GND 24V OK 0V GND 1 2 J OUT2 24V GND 24V GND...

Page 92: ...OPERATING MANUAL Transmig 255i Transmig 255i APPENDIX A 2 Manual 0 5550 This Page Intentionally Blank...

Page 93: ...RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN CIGWELD S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY CIGWELD PRODUCT PURCHASER S RIGHTS UNDER...

Page 94: ...ding 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...

Page 95: ...OPERATING MANUAL Transmig 220i Transmig 255i Transmig 255i This Page Intentionally Blank...

Page 96: ...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 058...

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