CIGWELD TRANSMIG 180 User manual

OPERATINGMANUAL
TRANSMIG180
MIGWELDINGPLANT
PartNumber705180
719322 Issue5 Nov06,96

CIGWELD Transmig 180
CONTENTS Page
1.INTRODUCTION1
1.1Safety1
1.2ProtectiveFilterLenses1
1.3WeldingProtection2
1.4UserResponsibility2
1.5DutyCycle2
2.SPECIFICATIONS3
2.1PowerSourceSpecifications3
2.2MIGTorchSpecifications3
2.3WireDriveSpecifications4
2.4PlantContents4
2.5OptionalAccessories4
3.INSTALLATIONRECOMMENDATIONS5
3.1Environment5
3.2Location5
3.3Ventilation5
3.4MainsSupplyVoltageRequirements5
3.5AlternativeMainsSupplyVoltageConnection6
4.WIRESPOOLHUBADJUSTMENT6
4.1Standard300mmSpoolSet-up6
4.2Handi200mmSpoolSet-up7
4.3Mini100mmSpoolSet-up7
5.SETUPFORTRANSMIG1807
6.POWERSOURCECONTROLS,INDICATORSANDFEATURES9
6.1POWER ONLight9
6.2VoltageControlSwitch9
6.3OVER TEMPERATURE Light9
6.4WirespeedControl9
6.5BurnbackAdjustment10
6.6PolarityReversalTerminals™
6.7ThermalOverload....^
6.8WhefeederDriverRollerPressureAdjustment• ™
6.9WireSpoolBrake11
7.TWECOMIGTORCH(717579)H
7.1Introduction"
7.2MIGTorchComponents12
7.3MIGTorchConsumableParts12
Pagei

Transmig180
CONTENTS Page
7.4InstallingA NewWireConduit13
7.5MIGTorchMaintenance14
8.BASICWELDINGTECHNIQUE14
8.1SettingofthePowerSource& Wirefeeder14
8.2PositionofMIGTorch14
8.3DistancefromtheMIGTorchNozzletotheWorkPiece14
8.4MIGTorchTravelSpeed14
8.5ElectrodeWireSizeSelection14
9.ROUTINEMAINTENANCE& INSPECTION15
10.BASICTROUBLESHOOTING15
10.1SolvingProblemsBeyondtheWeldingTerminals15
10.7WeldingProblems17
10.3PowerSourceProblems18
10.4KeySpareParts19
11.Transmig180Volt/Ampcurves20
12.TRANSMIG180CIRCUITDIAGRAMS20
12.1PowerSource20
12.2ControlPCB21
Pageii

Transmig180
TABLES
Page
Table1 - Filterlenssizeversesweldingcurrent2
Table2 - MIGTorchcomponents12
Table3 - MIGTorchgasdiffusers12
Table4 - MIGTorchcontacttips12
Table5 - MIGTorchnozzles13
Table6 - MIGTorchconduitliners13
FIGURES
Page
Figure1 - Transmig180dutycyclecurve2
Figure2 - Contactoradjustment(wire7)6
Figure3 - Inputterminalblockadjustment(wire7A)6
Figure4 - Standard300mmspoolset-up6
Figure5 - Handi200mmspoolset-up7
Figure6 - Mini100mmspoolset-up7
Figure7 - MIGTorchandpolarityconnections8
Figure8 MIGTorchbreakdown11
Figure9 - MIGTorchangle14
Figure10- Transmig180Volt/Ampcurves20
Pageiii

Transmig180
Page1
1.INTRODUCTION
TheTransmig180isa semi-automaticGasMetalArcWelder(GMAW-commonlyMIG)withan
integratedwirefeedsystem.Theplantisdesignedtomeetthebroadoperatingneedsofthelightmetal
fabricators,automotiverepairers,lightruralworkshopsandhomeworkshopswhereexcellentarc
characteristicsarevital.ThisproductisdesignedandmanufacturedinAustraliatoAustralianStandard
AS1966.1-1985.
TheTransmig180givesexcellentperformanceonmildsteel,stainlesssteel,aluminium,siliconbronzeand
somehardfacingwireswithArgonbasedshieldinggases.Italsogivesexcellentresultsonmildsteelusing
carbondioxide(C02)shieldinggas.
Thisproductissuppliedasa completepackagereadytoweld(apartfromgascylinderandelectrodewire).
ThefollowinginstructionsexplainhowtocorrectlysetupthePowerSourceandprovideguidelineson
gainingthebestproductionefficiencyfromtheplant.Pleasereadtheseinstructionsthoroughlybefore
usingyourTransmig180welder.
1.1Safety
Thefollowingbasicsafetyrulesshouldalwaysbefollowed:
i)EnsurethePowerSourceiscorrectlyinstalled,ifnecessary,bya qualifiedelectrician
ii)EnsurethePowerSourceisearthedcorrectly(electrically)inaccordancewithlocal
regulations.
iii)Excessiveheatintheweldingcablesmaycausefire.Neverweldwithpoorelectrical
connections,damagedweldingcablesorexceedtheweldingcablecurrentratingas
thiswillproduceexcessiveheatandmaycausea fire.
iv)Alwayswearthecorrectprotectiveclothingforprotectionfromsparks,molten
particlesandarcrays.
v)Whenweldinginconfinedspaces,alwaysensureadequateventilationandconstant
observationoftheoperator.
vi)Keepcombustiblematerialsawayfromtheweldingarea.Havea suitablefire
extinguisherhandy.
vii)Neverwatchtheweldingarcwithnakedeyes.Alwaysuseandweara weldingmask
fittedwiththecorrectfilterlens.
viii)Donotstandondampgroundwhenwelding.
ix)Formorecompletesafetyadvicepleasereadthesafetyliteratureincludedwiththe
equipmentbeforestartingtoweld.
1.2ProtectiveFilterLenses
Protectivefilterlensesareprovidedtoreducetheintensityofradiationenteringtheeyethusfiltering
outharmfulinfra-red,ultra-violetradiationanda percentageofthevisiblelight.Suchfilterlensesare
incorporatedwithinfaceshields.Topreventdamagetothefilterlensesfrommoltenorhardparticles
anadditionalhardclearglassorspecialplasticexternalcoverlensshouldbeused.Thiscoverlens
shouldalwaysbekeptinplaceandreplacedbeforethedamageimpairsyourvisionwhilewelding.

1.3WeldingProtection
Itisrecommendedtousea weldinghelmet,
conformingtoAustralianStandards
AS/NZS1337-1992whenelectricarc
welding.Usea weldinghelmetin
serviceableconditionwiththecorrectfilter
lensfittedasperTable1.
1.5
Approximaterangeof
weldingcurrent
Filterlensrequired
forMIG
Upto150 Shade10
150-250 Shade11
250-300 Shade12
300-350 Shade13
Over350 Shade14
1.4UserResponsibility
Thisequipmentwillperformaspertheinformationcontainedhereinwheninstalled,operated,
maintainedandrepairedinaccordancewiththeinstructionsprovided.Thisequipmentmustbe
checkedperiodically.Defectiveequipment(includingweldingleads)shouldnotbeused.Partsthat
arebroken,missing,plainlyworn,distortedorcontaminated,shouldbereplacedimmediately.
Shouldsuchrepairsorreplacementsbecomenecessary,itisrecommendedthatsuchrepairsbe
carriedoutbyappropriatelyqualifiedpersonsapprovedbyCIGWELD.Adviceinthisregardcanbe
obtainedbycontactingCIGWELD.
Thisequipmentoranyofitspartsshouldnotbealteredfromstandardspecificationwithoutprior
writtenapprovalofCIGWELD.Theuserofthisequipmentshallhavethesoleresponsibilityforany
malfunctionwhichresultsfromimproperuseorunauthorisedmodificationfromstandard
specification,faultymaintenance,damageorimproperrepairbyanyoneotherthanappropriately
qualifiedpersonsapprovedbyCIGWELD.
DutyCycle
Therateddutycycleofa welding
PowerSourceistheoperatingtimeit
maybeusedatitsratedoutput
currentwithoutexceedingthe
temperaturelimitsoftheinsulationof
thecomponentparts.Theareatothe
leftofthecurveisthesafeoperating
areaforthisproduct.InAustraliaa
dutycycleperiodof5 minutesis
specifiedinAustralianStandardAS
1966Part1-1990.Toexplainthe5
minute dutycycleperiodthe
followingexampleisused.Suppose
aweldingPowerSourceisdesignedtooperateat30%dutycycle,140amperesat20.5loadvolts.
Thismeansthatithasbeendesignedandbuilttoprovidetheratedamperage(140A)attherated
loadvoltage(20.5V),for1.5minutesoutofevery5 minuteperiod(30%of5 minutesis1.5
minutes).Duringtheother3.5minutesofthe5 minuteperiodthePowerSourcemustidleandbe
allowedtocool.Thethermalcut-outwilloperateifthedutycycleisexceeded.
DutyCycle(percentage)
WeldingCurrent(amps)
180
Page2
Table1 - Filterlenssizeversesweldingcurrent
Figure1 - Transmig180dutycyclecurve

Transmig180
PlantAssemblypartnumber 705180
PlantMass 60kg
PlantDimensions(packed) H625mmx W 345mmx D 560mm
PowerSourceDimensions(lessMIGTorch) H470mmx W 460mmx D 800mm
OpenCircuitVoltageRange 18.5to36.0VDC
WeldingArcVoltageRange 13to21VDC
OutputCurrentRange 25to180ADC
RatedOutputDutyCycle 180A
@18%
140A@ 30%
100%DutyCycleOutputRating 75ADC
DutyCyclePeriod 5or10minutes
NumberofOutputVoltageSettings 8
ElectrodeWireSizeRange 0.6-0.9Hard/0.9-1.2Soft
WireSpeedRange 1.0to15.0metres/minute
WireSpoolSizeDiameter 100mm/ 200mm/ 300mm
BurnbackTimeRange 0.0to0.5seconds
OperatingTemperatureRange 0°Cto40°C(32°Fto104°F)
NumberofPhases 1
Frequency 50/ 60Hz
MainsSupplyVoltage(PrimaryInputVoltage) 220V 240V
VRatedInputCurrent@ 75Aoutput(100%DutyCycle) 9.7A 8.9A
RatedkVA@ 75Aoutput(100%DutyCycle) 2.1WA 2.1kVA
MaximumInputCurrent@ 180Aoutput 29.3A 26.9A
GeneratorRequirementsat180Aoutput 6.5kVA 6.5kVA
RecommendedOutletSize 15A 15A
SupplyVA@ noload 400VA 400VA
SupplyWatts@ noload 250W 250W
SupplyVA@ 180Aoutput 6.5kVA 6.5kVA
SupplyWatts@ 180Aoutput 5.7kW 5.7kW
PowerSourceEfficiency@ 180A output 61% 61%
PowerFactor@ 180Aoutput 0.88 0.88
+RecommendedFuseSize 25A(23SWG) 20A(24SWG)
VTheRatedInputCurrentshouldbeusedforthedeterminationofcablesize& supply
requirements.
+Motorstartfusesorthermalcircuitbreakers(notmagneticcircuitbreakers)arerecommended
forthisapplication.AustralianStandardAS3000(Clause2.4.3.4)permitstheuseofa fuseor
circuitbreakerratedattwotimestheratedinputcurrent.
2.2MIGTorchSpecifications
TorchPartNumber 717579
TorchType TWECO180A (EliminatorConsumables)
TorchCableLength 3.0metres(10ft)
Page3
2.SPECIFICATIONS
2.1PowerSourceSpecifications

2.3WireDriveSpecifications
MotorSupplyVoltage 24VAC
MotorSupplyVA 120VA
ControlSupplyVoltage 24VAC
ControlSupplyVA 30VA
MinimumWireSpeed 1metreperminute(40inchesperminute)
MaximumWireSpeed 15metreperminute(590inchesperminute)
WireDiameter MildSteel:0.6mm(.024"),0.8mm(.030"),0.9mm(.035")
StainlessSteel:0.6mm(.024"),0.8mm(.030"),0.9mm(.035")
Aluminium:0.9mm(.035"),1.0mm(.040"),1.2mm(.045")
FluxCored:0.8mm(.030"),0.9mm(.035"),1.2mm(.045")
WireSpoolSize 100mmor200mmor300mm
3lantContents
PartNumber Description
705197 WheelingKit
705195GRY CylinderCarrier
705260GRY CylinderBracket
703625 CylinderChain
719322 OperatingInstructions
705174 3MetreWorkLead(fitted)
301526 Regulator/ Flowmeter
717579 TWECOMIGTorch180A
705366 Handispoolhub (for200mmspooladaptation)
7977036 FeedRoller0.6/0.8Hard (fitted)
705368 Torchaccessorykit
2.5OptionalAccessories
PartNumber Description
705252 Handle
7977036 Feedroll,0.6/0.8HardWire
7977660 Feedroll,0.9/1.2HardWire
7977037 Feedroll,1.0/1.2HardWir
PartNumber Description
7977731 Feedroll,0.8/0.9SoftWire
7977264 Feedroll,1.0/1.2SoftWire
7977732 Feedroll,0.8/0.9Fluxcored
704277 Feedroll,1.0/1.2Fluxcored
Page4

Transmig180
3.INSTALLATIONRECOMMENDATIONS
3.1Environment
TheTransmig180isNOTdesignedforuseinenvironmentswithincreasedhazardofelectricshock
asdennedinAS3195-1990.
a)Examplesofenvironmentswithincreasedhazardofelectricshockare-
i)Inlocationsinwhichfreedomofmovementisrestricted,sothattheoperatoris
forcedtoperformtheworkina cramped(kneeling,sittingorlying)positionwith
physicalcontactwithconductiveparts;
ii)Inlocationswhicharefullyorpartiallylimitedbyconductiveelements,andinwhich
thereisa highriskofunavoidableoraccidentalcontactbytheoperator,or
iii)Inwetordamphotlocationswherehumidityorperspirationconsiderablereducesthe
skinresistanceofthehumanbodyandtheinsulationpropertiesofaccessories.
b)Environmentswithincreasedhazardofelectricshockdonotincludeplaceswhere
electricallyconductivepartsinthenearvicinityoftheoperator,whichcancauseincreased
hazard,havebeeninsulated.
3.2Location
BesuretolocatethePowerSourceaccordingtothefollowingguidelines:
a)Inareas,freefrommoistureanddust.
b)Ambienttemperature0°Cto40°C.
c)Inareas,freefromoil,steamandcorrosivegases.
d)Inareas,notsubjectedtoabnormalvibrationorshock.
e)Inareas,notexposedtodirectsunlightorrain.
f)Placeata distanceof30cmormorefromwallsorsimilarthatcouldrestrictnaturalairflow
forcooling.
g)Theminimumgroundclearanceforthisproductis65mm.
3.3Ventilation
Sincetheinhalationofweldingfumescanbeharmful,ensurethattheweldingareaiseffectively
ventilated.
3.4MainsSupplyVoltageRequirements
TheMainssupplyvoltageshouldbewithin± 10%oftheratedMainssupplyvoltage.Toolowa
voltagemaycausepoorweldingperformanceorthewirefeedertomalfunction.Toohigha supply
voltagewillcausecomponentstooverheatandpossiblyfail.
TheTransmig180issuppliedwitha 15Ainputlead(and15Aplug)toconnecttoa 15Apower
outletandisfactorysetfor240Voperation
CAUTION 1: CIGWELD advises that you should avoid the use of extension leads as this can
reduce the Mains supply voltage below 10% of the rated Mains supply voltage.
Refertosection3.5fortheinstructionstoconvertyourTransmig180to220Voperation.
Page5

3.5AlternativeMainsSupplyVoltageConnection
TheTransmig180canberewiredtooperateona Mainssupplyvoltageof220V.
WARNING 1: CIGWELD advises that a qualified electrical tradesperson rewire your Transmig
180 for 220V operation.
a)DisconnecttheTransmig180fromtheMainssupplyvoltage.
b)DisconnectwireNo7 fromterminalL3thenreconnectittoterminalL2onthecontactor.
RefertoFigure2.
c)DisconnectwireNo7Afromthe240Vpositionontheinputterminalblockthenreconnect
wireNo7Atothe220Vpositionontheinputterminalblockterminal.RefertoFigure3.
d)TheTransmig180isnowreadyfor220VMainssupplyvoltage.
Figure2 - Contactoradjustment(wire7)Figure3 - Inputterminalblockadjustment(wire7A)
4.WIRESPOOLHUBADJUSTMENT
4.1Standard300mmSpoolSet-up
Steelflatwasher16mmID
\
Steelflatwasher16mmID\
Frictionwasher
(7976411) Wirespoolhub
(702337)
Nut5/8"BSW
(7958040)
Figure4 - Standard300mmspoolset-up
Page6

Transmig180
4.2Handi200mmSpoolSet-up
Spring
(7976405)
Steelflatwasher16mmID
Frictionwasher
(7976411 Wirespoolhub
(705366)
Nut5/8"BSW
(7958040)
Figure5 - Handi200mmspoolset-up
4.3Mini100mmSpoolSet-up Nut5/8"BSW
(7958040)
Steelflatwasher16mmID
Figure6 - Mini100mmspoolset-up
5.SETUPFORTRANSMIG180
a)Removeallpackagingmaterials.
CAUTION 2: Ensure airflow through the vent holes in the base are not restricted.
b)Positiona gascylinderonthecarrierandlocksecurelytothePowerSourcecylinder
bracketwiththechainprovided.Ifthisarrangementisnotusedthenensurethatthegas
cylinderissecuredtoa buildingpillar,wallbracketorotherwisesecurelyfixedinan
uprightposition.
c)FitthegasRegulator/Flowmetertothegascylinder.
d)ConnectthegashosefromtherearofthePowerSourcetotheFlowmeteroutlet.
e)A dualgroovefeed rollerissuppliedasstandardwiththeplant.Thiscanaccommodate
0.6mmand0.8mmdiameterhardwires.Selecttherollerrequiredwiththechosenwiresize
markedfaceoutwards.
f)Adjustwirehubassemblytosuiteitherstandard,handiorminispoolsizechosen;referto
section4 onpage6.
NOTE 1: The Transmig 180 is factory fitted with the standard spool hub which is suitable for
300mm spools.
g)Fittheelectrodewirespooltothewirespoolhublocatedbehindwirecompartmentdoor.
Foreitherthestandardorhandispoolsizes,ensurethatthedrivedog-pinengagesintothe
spoolmatinghole.Pushthe'R'clipintoplacetoretainthewirespoolsecurely.Thewire
shouldfeed fromthebottomofthespool.
Page7

h)FittheTWECOMIGTorchtothewiredriveassemblyinthewirecompartment.Referto
Figure9.
i)ConnectbothblackTorchtriggerleadstotheTorchtriggerterminals.RefertoFigure9.
j)RemovethecontacttipfromtheMIGTorch.
k)Liftupthewirefeederpressureleverandpasstheelectrodewirethroughtheinletguide,
betweentherollersthenintotheMIGTorch.
I)LowerthepressureleverandwiththeMIGTorchleadreasonablystraight,feedthewire
throughtheMIGTorch.Fittheappropriatecontacttip.
m)FittheinternalgashoseontothegasnippleintheMIGTorch.
CAUTION3:The electrode wire will beatwelding voltage potential whilst itisbeingfed
through the system.
PositiveWeldingTerminal
WorkLead
TorchLead
Connecttwoblackleads
fromtheMIGTorchto
thetwowayterminal
SecurescrewtofixtheMIGTorchinto
position.Donotovertightenasthiswillresult
intheinsertpullingoutofthefeedplate.
NegativeWeldingTerminal
VoltageControlSelection
WireSpeedControl
MIGTorch
Securetorchlead(usinga
supplied:M6*10mmscrew,
starwasher,flatwasher) to
achievea soundelectrical
connectiontotheMIGTorch
Connectthegashoseontothe
MIGTorchgasconnection
Figure7 - MIGTorchandpolarityconnections
Page8

Transmig180
6.POWERSOURCECONTROLS,INDICATORSANDFEATURES
PowerOnLight
VoltageControl
Switch
ThermalOverload
Light
WirespeedControl
BurnbackAdjustment
AccessHole
6.1POWER ONLight
ThePOWER ONlightisprovidedtoindicatewhenthePowerSourceisconnectedtotheMains
supplyvoltage.
CAUTION 4: When the light is lit, the Power Source is connected to the Mains supply voltage
and the internal electrical components are at Mains voltage potential.
•
6.2VoltageControlSwitch
TheVoltageControlswitchsetsthevoltageleveltotheweldingterminalswiththevoltage
increasingas it is rotatedin theclockwisedirection
CAUTION 5: The Voltage Control switch MUST NOT BE TURNED during welding.
6.3OVER TEMPERATURE Light
TheOVER TEMPERATURE lightwillflashtoindicatethatthetransformerorrectifierhave
exceededtheirtemperaturerating(normallycausedbyexceedingthePowerSourcedutycycle)and
weldingcurrentisinterrupted.
Whenthishappens,allowtheinternalcomponentsofthePowerSourcetocoolbyleavingtheMains
supplyvoltageONfor10to15minutes.ThePowerSourceisreadyforoperationwhentheOVER
TEMPERA TURE indicatorstaysextinguished.
6.4WirespeedControl
TheWirespeedControlknobcontrolstheweldingcurrentviatheelectrodewirefeedrate(i.e.the
speedofthewirefeedmotor).
Page9

6.6PolarityReversalTerminals
ThePolarityReversalTerminalsarelocatedinthewirespoolcompartment.Theelectrodewire
weldingvoltagepolarityisselectedbyconnectingtheTorchPolarityLeadandtheworkleadtothe
PolarityReversalTerminals.
ConnecttheTorchPolarityLeadtothepositiveweldingterminal(+)whenusingsteel,stainlesssteel
oraluminiumelectrodewire.RefertoFigure9.AlternativelyconnecttheTorchPolarityLeadto
thenegativeweldingterminal(-)whenusinggaslesselectrodewire.Ifindoubt,consultthe
manufactureroftheelectrodewireforthecorrectpolarity.
CAUTION 6: Welding current flows to the MIG Torch via the output terminal/lug connection.
It is essential that the bolt is secured tightly to achieve a sound electrical
connection. Loose welding terminal connections can cause overheating and result
in the terminal beingfused beyond repair.
6.7ThermalOverload
Thecriticalcomponentsforthermalprotectionarethetransformerandrectifierstack.Botharefitted
witha thermaloverloadcutoutdevice.TheOVER TEMPERATURE indicatorwillflashtoindicate
thatthetransformerorrectifierhaveexceededtheirtemperaturerating(normallycausedby
exceedingthePowerSourcedutycycle)andweldingcurrentisinterrupted.
Iftheoverloadoperates,asindicatedbytheOVER TEMPERATURE indicator,thenthePower
Sourceshouldbelefttocoolwiththefanoperatingforapproximately10to15minutesbefore
resumingwelding.
IfthePowerSourceisoperatedwithinitsdutycycle,thenthethermaloverloadfeaturewillnot
operateandtherewillbenodangeroftransformer,damage.Refertosection1.5foranexplanation
ofdutycycleandsection2 forthePowerSourceSpecifications.
6.8WirefeederDriverRollerPressureAdjustment
Themoveablerollerappliespressuretothegroovedrollerviaa screwadjustablespringpressure.
Theadjustablespringscrewshouldbeadjustedtoa minimumpressurethatwillprovidesatisfactory
wirefeedwithoutslippage.Ifslippingoccurs,andinspectionofthewirecontacttiprevealsnowear,
distortionorburn-backjam,theconduitlinershouldbecheckedforkinksandcloggingbymetal
flakesandswarf.RefertoCAUTION7.Ifthisisnotthecauseofslipping,thefeedrollpressurecan
beincreasedbyrotatingtheadjustablespringscrewclockwise.Theuseofexcessivepressuremay
causerapidwearofthefeedroller,motorshaftandmotorbearings.
NOTE 2: Genuine TWECO contact tips and lines should be used Many non-genuine liners
use inferior materials that can cause wirefeed problems.
Page10
6.5BurnbackAdjustment
TheBurnbacktimecanbeadjustedbyplacinga flatbladedscrewdriverintotheBurnback
AdjustmentaccessholeandengagingtheBurnbacktrimpotentiometer.Rotatingintheanti
clockwisedirectionincreasesBurnbacktimewhiletheclockwisedirectiondecreasesBurnbacktime.

Transmig180
6.9WireSpoolBrake
Thewirespoolhubincorporatesa frictionbrakethatissetduringmanufactureforoptimumbraking.
Ifitisconsiderednecessary,adjustmentcanbemadebyturningthelargenutinsidetheopenendof
thewirespoolhub.Clockwiserotationwilltightenthebrake.Correctadjustmentwillresultinthe
spoolcircumferencecontinuingnofurtherthan20mmafterreleaseoftheTorchtriggerswitch.The
wireshouldbeslackwithoutbecomingdislodgedfromthespool.
CAUTION 7: Excessive tension on the brake will cause rapid wear of mechanical wire feed
parts, overheating of electrical componentry and possibly an increased incidence
of wire Burnback into the contact tip.
7.TWECOMIGTORCH(717579)
7.1Introduction
TheTWECO180AgunfittedtotheTransmig180offersrobustconstruction,unparalleledreliability
andeasyreplacementofconsumableparts.TheTWECO180AMIGTorchhasanoperating
capacityinexcessofthecapacityoftheTransmig180andcanbeexpectedtogivetroublefree
service.
TWECOMIGTorchesmaybefittedtomanydifferenttypesofMIGweldingplantssothatyour
wholeshopcanbeconvertedtoTWECO.Notonlywillthisgivegreaterreliability(andhence
greaterproductivity),butitwillreducestockholdingsofconsumableparts.Seeyour
CIGWELDdistributorfordetails.
Figure8 MIGTorchbreakdown
Page11

7.2MIGTorchComponents
Item PartNo. Description Qty
1 EL22I50P Nozzle(refertoTable5) l
2 EL16T35 Contacttip(refertoTable4) l
3 EL52 Gasdiffuser(refertoTable3) l
4 OTW90810 Conductortube l
5 OTW90814 GunHanger l
6 — 2.8mmPushonterminal
7 717523 TriggerAssembly l
8 OTW94D/1 TriggerScrew l
9 OTW35/80A/1 HandleCap l
10 OTW9080C CableAssembly l
11 OTW44C SetScrew l
12 717524 ConduitAssembly l
13 OTW44/25 HexKey 1
Table2 - MIGTorchcomponents
7.3MIGTorchConsumableParts
NOTE 3: * denotes parts that are supplied as standard with MIG Torch 717579.
a)GasDiffusers
Table3 - MIGTorchgasdiffusers
b)ContactTips
STANDARD TAPERED
WireSize(mm) PartNo.
0.6 notavailable
0.8
EL1630
0.9 EL1635
1.0 EL1640
1.2 EL1645
1.2Alum EL16A364
WireSize(mm) PartNo.
0.6 EL16T23
0.8 EL16T30
0.9 *EL16T35
1.0
EL16T40
1.2
EL16T45
1.2Alum EL16AT364
Table4 - MIGTorchcontacttips
Page12
PartNo.
*EL52(slideonnozzles)
PartNo.
EL52CT(screwonnozzles)

Transmig180
c)Nozzles
BoreSize(mm) PartNo.
9.5
EL22A37
9.5
EL22A37F
12.7
EL22A50
12.7 - EL22A50F
12.7
*EL22I50P
15.9
EL22A62
15.9 EL22A62F
15.9
EL22I62P
19.1
EL22A75
19.1
EL22A75F
15.9
EL22I62FAS
(SpotNozzle)
BoreSize(mm) PartNo.
9.5
EL22CT37
9.5
EL22CT37F
12.7
EL22CT50
12.7 EL22CT50F
12.7
EL22CT50P
15.9
EL22CT62
15.9
EL22CT62F
15.9
EL22CT62P
19.1
EL22CT75
19.1 EL22CT75F
CT= CoarseThread
F= FlushTip P=ProtrudingTip
d)
Table5 - MIGTorchnozzles
Conduits
HARD& SOFTELECTRODEWIRES
WireSize(mm) PartNo.
0.6 717524
0.8 717524
0.9 *717524
1.0 717524
1.2 OTW45/40
7.4
b)
Table6 - MIGTorchconduitliners
InstallingA NewWireConduit
a)BesuretheMIGTorchcableisarrangedina straightline,freefromtwists,wheninstalling
orremovinga wireconduitliner.RemovetheoldconduitlinerbyfirstremovingtheMIG
Torchesnozzle,contacttipandgasdiffuser.ThenloosenAllenscrewintheconnector
plugandpulltheoldwireconduitlineroutofthecableassemblyfromtheconnectorplug
end.
Toinstalla newwireconduitliner,firstinspecttheo-ringgassealontheconduitlinerfor
cutsordamage.Startfromtheconnectorplugendoftheassemblyandbeginpushingthe
conduitlinerthroughtheconnectorplug,cableassemblyandintothegun.Iftheconduit
linershouldlodgealongtheway,gentlywhiporworkthecableassemblytoaidforward
movement.
Whenthewireconduitlinerstopmeetstheendoftheconnectorplugandthenewrawend
extendsthroughtheendoftheconductortube,theAllenscrewintheconnectorplugmust
besecurelytightenedontotheconduitlinertopreventitsbackwardmovement.
IMPORTANT 1: When the conduit liner is fully inserted into the cable assembly and the conduit
liner stop isfirmly against the Connector Plug, the "raw end" of the conduit liner
will protrude out of the open end of the gun conductor tube. Trim the conduit
liner to a length of 35mm to 36mm past the conductor tube. The trimmed end
which seats in the Gas Diffuser must be filed and reamed smooth on the inside
and outside radii so wire feed will not be obstructed
c)
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8.2PositionofMIGTorch
TheangleofMIGTorchtotheweldhasaneffect
onthewidthoftheweldrun.RefertoFigure9.Figure9 - MIGTorchangle
8.3DistancefromtheMIGTorchNozzletotheWorkPiece
TheelectrodestickoutfromtheMIGTorchnozzleshouldbebetween2.0mmto5.0mm.This
distancemayvarydependingonthetypeofjointthatisbeingwelded.
8.4MIGTorchTravelSpeed
Speedatwhicha weldtravelsinfluencesthewidthoftheweldandpenetrationoftheweldingrun.
8.5ElectrodeWireSizeSelection
Thechoiceofelectrodewiresizeinconjunctionwithshieldinggasuseddependson:
•Thicknessofthemetaltobewelded• Thedepositionraterequired
•Typeofjoint• Thebeadprofiledesired
•Capacityofthewirefeedunitandpowersource• Thepositionofwelding
•Theamountofpenetrationrequired• Costofelectrodewire
Page14
d)ReplaceGasDiffuser,ContactTip,andNozzle.
e)TightentheAllenscrewintheconductortube.
CAUTION 8:Donot over tighten the conductor tube screwasthis action will result inthe
distortion of the conduit liner and will lead to wire feedability problems.
7.5MIGTorchMaintenance
RemovedustandmetallicparticlesfromtheTorchconduitlinerbyforcingclean,drycompressedair
intotheconduitlineroncea week.Thiswillminimisewirefeedingproblems.
8.BASICWELDINGTECHNIQUE
8.1SettingofthePowerSource& Wirefeeder
ThesettingoftheTransmig180requiressomepracticebytheoperator,theweldingplanthaving
twocontrolsettingsthathavetobalance.ThesearetheWirespeedcontrolandtheVoltageControl
switch.TheweldingcurrentisdeterminedbytheWirespeedcontrol,thecurrentwillincreasewith
increasedWirespeed,resultingina shorterarc.Lesswirespeedwillreducethecurrentandlengthen
thearc.Increasingtheweldingvoltagehardlyalterstheweldingcurrentlevel,butlengthensthearc.
Bydecreasingthevoltage,a shorterarcisobtained withlittlechangeinweldingcurrent.
Whenchangingtheelectrodewirediameters,differentcontrolsettingsarerequired.A thinner
electrodewireneedsmoreWirespeedtoachievethesamecurrentlevel.
AsatisfactoryweldcannotbeobtainediftheWirespeedandVoltageControlSwitchsettingsarenot
adjustedtosuittheelectrodewirediameteranddimensionsoftheworkpiece.
IftheWirespeedistoohighfortheweldingvoltage,"stubbing"willoccurasthewiredipsintothe
moltenpoolanddoesnotmelt.Weldingintheseconditionsnormallyproducesa poorwelddueto
lackoffusion.If,however,theweldingvoltageistoohigh,largedropswillformontheendofthe
electrodewire,causingspatter.Thecorrect
settingofvoltageandWirespeedcanbeseenin
theshapeofthewelddepositandheardbya
smoothregulararcsound.

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9.ROUTINEMAINTENANCE& INSPECTION
TheonlyroutinemaintenancerequiredfortheTransmig180isa thoroughcleaningandinspection,withthe
frequencydependingontheusageandtheoperatingenvironment.
CAUTION 9: Disconnect the Transmig 180 from the Mains supply voltage before disassembling.
SpecialmaintenanceisnotnecessaryforthecontrolunitpartsinthePowerSource.Ifthesepartsare
damagedforanyreason,replacementisrecommended.
CAUTION 10: Do not blow air into the Power Source during cleaning. Blowing air into the
Power Source can cause metal particles to interfere with sensitive electronic
components and cause damage to the Power Source.
TocleanthePowerSource,disconnectiffromtheMainssupplyvoltagethenopentheenclosureandusea
vacuumcleanertoremoveanyaccumulateddust.ThePowerSourceshouldalsobewipedclean.If
necessary,solventsthatarerecommendedforcleaningelectricalapparatusmaybeused.
TroubleshootingandrepairingtheTransmig180shouldbecarriedoutonlybythosewhoarefamiliarwith
electricalequipment.
CAUTION 11: Do not attempt to diagnose or repair unless you have had training in electronic
measurement and troubleshooting techniques.
10.BASICTROUBLESHOOTING
Thebasicleveloftroubleshootingisthatwhichcanbeperformedwithoutspecialequipmentorknowledge,
andwithoutremovingthecoversfromthePowerSource.
Ifmajorcomponentsarefaulty,thenthePowerSourceshouldbereturnedtoanAccreditedCIGWELD
ServiceAgentforrepair.
10.1SolvingProblemsBeyondtheWeldingTerminals
ThegeneralapproachtofixGasMetalArcWelding(GMAW)problemsistostartatthewirespool
thenworkthroughtotheMIGTorch.ThetwomainproblemareaswithGMAWare:
a)Porosity
Whenthereisa gasproblemtheresultisusuallyporositywithintheweldmetal.Porosity
alwaysstemsfromsomecontaminantwithinthemoltenweldpoolthatisintheprocessof
escapingduringsolidificationofthemoltenmetal.
Contaminantsrangefromnogasaroundtheweldingarctodirtontheworkpiecesurface.
Porositycanbereducedbycheckingthefollowingpoints.
1.Gascylindercontentsandflowmeter.- Ensurethatthegascylinderisnotempty
andtheflowmeteriscorrectlyadjustedto
15litresperminute.
2.Gasleaks.- Checkforgasleaksbetweenthe
regulator/cylinderconnectionandinthegas
hosetothePowerSource.
3.InternalgashoseinthePowerSource.- Ensurethehosefromthesolenoidvalveto
theMIGTorchhasnotfracturedandthe
hoseisconnectedtotheMIGTorchgas
nipple.
4.Weldingina windyenvironment.- Shieldtheweldareafromthewindor
increasethegasflow.
Transmig180

5.Weldingdirty,oily,painted,oxidisedor
greasyplate.
6.DistancebetweentheMIGTorch
nozzleandtheworkpiece.
Cleancontaminatesofftheplate
KeepthedistancebetweentheMIGTorch
nozzleandtheworkpiecetoa minimum.
Refertosection8.3onpage14.
7.MaintaintheMIGTorchingood
workingorder. -Ensurethatthegasholesarenotblockedand
gasisexitingoutoftheMIGTorchnozzle.
RefertoCAUTION12.
Donotrestrictgasflowbyallowingspatter
tobuildupinsidetheMIGTorchnozzle.
CheckthattheMIGTorchO-ringsarenot
damaged.
CAUTION 12: Disengage the drive roll when testing for gas flow by ear.
b)Inconsistentwirefeed
Wirefeedingproblemscanbereducedbycheckingthefollowingpoints.
1.Wirespoolbrakeistootight.
2.Wirespoolbrakeistooloose.
3.Wornorincorrectfeedrollersize.
4.Mis-alignmentofinlet/outletguides.
5.Linerblockedwithswarf
6.Incorrectorworncontacttip
Feedrollerdrivenbymotorinthecabinet
willslip.
Wirespoolcanunwindandtangle.
Use'U'groovedrivefeed rollermatchedto
thealuminiumwiresizeyouarewelding.
Use'V'groovedrivefeed rollermatchedto
thesteelwiresizeyouarewelding.
Use'knurledV'groovedrivefeedroller
matchedtothefluxcoredwiresizeyouare
welding.
Wirewillrubagainstthemis-alignedguides
andreduceswirefeedability.
Increasedamountsofswarfisproducedby
thewirepassingthroughthefeed roller
whenexcessivepressureisappliedtothe
pressurerolleradjuster.
Swarfcanalsobeproducedbythewire
passingthroughanincorrectfeedroller
grooveshapeorsize.
Swarfisfedintothelinerwhereit
accumulatesthusreducingwirefeedability.
Thecontacttiptransferstheweldcurrent
tothewire.Iftheholeinthecontacttipis
toolargethenarcingmayoccurinsidethe
contacttipresultingintheelectrodewire
jamminginthecontacttip.
Whenusingsoftwiresuchasaluminiumit
maybecomejammedinthecontacttipdue
toexpansionofthewirewhenheated.
Contacttipdesignedforsoftwiresshould
beused.
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