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