Murex Transmatic 4C Guide

GB
Valid for serial no. 435--xxx--xxxx0459 706 074 090514
Transmatic 4C
Instruction manual and
spare parts list

-- 2 --
TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 4...................................................
3.1 Equipment 5................................................................
4 TECHNICAL DATA 5.................................................
5 INSTALLATION 6....................................................
5.1 Lifting instructions 6.........................................................
6 OPERATION 7.......................................................
6.1 Connections and control devices 7............................................
6.2 Symbol and function explanations 8...........................................
6.3 Wire feed pressure 9........................................................
6.4 Replacing and inserting wire 9................................................
6.5 Changing feed roller 10.......................................................
7 MAINTENANCE 10....................................................
7.1 Inspection and cleaning 10....................................................
8 ORDERING SPARE PARTS 11..........................................
DIAGRAM 12............................................................
SPARE PARTS LIST 13...................................................
WEAR PARTS 18........................................................
ACCESSORIES 20.......................................................

-- 3 --
bm42d1ea
1DIRECTIVE
DECLARATION OF CONFORMITY
Murex Welding Products Ltd, EN8 7TF England, declares that Wire feed unit Transmatic 4C from
serial number 435 onwards, conforms to standard IEC/EN 60974--5, in accordance with the require-
ments of directive (73/23/EEC) and appendix (93/68/EEC) and standard EN 50199 in accordance with
the requirements of directive (89/336/EEC) and appendix (93/68/EEC).
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------
Henry Selenius
Managing Director
ESAB Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
On behalf of Murex Welding Products Ltd.
Laxå 2005--02--01
Manufactured by ESAB Welding Equipment AB.
S--695 81 Laxå Sweden
2SAFETY
Users of a welding equipment have the ultimate responsibility for ensuring that anyone who works
on or near the equipment observes all the relevant safety precautions. Safety precautions must
meet the requirements that apply to this type of welding equipment. The following recommendations
should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well--acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the equipment when it is
started up.
Sno--one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
SDo not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
GB

-- 4 --
bm42d1ea
WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding.
Ask for your employer’s safety practices which should be based on manufacturers’ hazard data.
ELECTRIC SHOCK - Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
Read and understand the instruction manual before
installing or operating.
We can provide you with all necessary welding protection and accessories.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
This product is solely intended for arc welding.
3 INTRODUCTION
The Transmatic 4C wire feed unit is intended for MIG/MAG welding with the
Transweld Challenger 400 power source.
The feed unit can be used together with wire on MarathonPact, or on wire bobbin
Ø 300 mm.
It can be installed either at the power source, suspended above the workplace, on a
support arm or on the floor with or without wheel set.
GB

-- 5 --
bm42d1ea
Accessories for the product can be found on page 20.
3.1 Equipment
The wire feed unit is supplied with connection set (5m), instruction manual and
stickers.
4 TECHNICAL DATA
Transmatic 4C
Power supply 42 V 50--60 Hz
Power requirement 336 VA
Motor current Imax 3.5 A
Settings data
Wire feed speed
Burnback time
1.5--22.0 m/min
0--0.7 s
Gun connection EURO
Max. diameter wire bobbin 300 mm
Wire dimension
Fe
Ss
Al
Cored wire
0.6--1.6 mm
0.6--1.2 mm
1.0--1.6 mm
0.8--1.6 mm
Weight 13.2 kg
Dimensions (l x b x h) 569 x 259 x 355 mm
Shielding gas
max pressure
Gases for MIG/MAG welding
5 bar
Maximum permissible load at
60% duty cycle
100% duty cycle
365 A
280 A
Enclosure class
basic version
with sealed bobbin holder*
with MarathonPact
IP2X
IP23
IP23
* Accessories, see page 20.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Apparatus marked IP2X are intended for indoor use.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading. The duty cycle is valid for 40˚C.
GB

-- 6 --
bm42d1ea
5 INSTALLATION
The installation must be executed by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user’s responsibility to take adequate precautions.
WARNING!
When welding in an environment with increased electrical danger, only power
sources intended for this environment may be used. These power sources are
marked with the symbol
5.1 Lifting instructions
Order number for lifting eyelet can be found on page 20.
Note! If another mounting device is used, this should be insulated from the wire feed
unit.
GB

-- 7 --
bm42d1ea
6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
WARNING!
Assure that the side panels are closed during operation.
WARNING!
To prevent the reel from sliding off the hub: Lock the
reel in place by turning the red knob as shown on the
warning label attached next to the hub.
WARNING!
Rotating parts can cause injury, take great care.
WARNING!
There is a risk of tipping if the wire feed unit is fitted with a counterbalance arm.
Secure the equipment, especially if used on an uneven or sloping surface.
NOTE! When moving the equipment use intended handle. Never pull on the gun.
6.1 Connections and control devices
Connecting control cable
When connecting the control cable, it is
important to secure the cable with the
load--removing grommet.
Ensure that the cover is properly screwed
into place.
GB

-- 8 --
bm42d1ea
1Wire feed speed control 5Connection for welding current from power
source, (OKC)
2Switch for activation of 2/4 stroke,
wire inch or gas purging 6Connection for shielding gas
3Burnback control 7Connection for control cable from power
source
4Connection for welding gun, (EURO)
6.2 Symbol and function explanations
Wire feed speed
This sets the required feed speed of the filler wire in m/minute.
2stroke
With 2--stroke, the gas flow starts followed by the wire feed when the trigger switch is
pressed in. The welding process is concluded when the trigger switch is released,
the wire feed stops and the gas stops flowing.
4stroke
With 4 stroke, the gas flow starts when the trigger switch is pressed in and the wire
feed starts when it is released. The welding process continues until the switch is
pressed in again, the wire feed stops and when the switch is released the gas stops
flowing.
Wire inch
Cold wire feed is used to feed wire without welding voltage and gas flow.
Activation of cold wire feed: press in the trigger switch and the wire feed starts.
Gas purging
Gas purging is used to measure that gas flow or to flush the gas hoses to clean them
of any air and moisture before commencing welding. Gas purging is carried out with
the voltage and wire feed disabled.
Activation of gas purging: press in the trigger switch and gas purging starts.
GB

-- 9 --
bm42d1ea
Burnback time
Burnback time is a delay between the time when the wire brakes until the time when
the power source switches off the welding voltage. Too short burnback time results in
a long wire stickout after completion of welding, with a risk of the wire being caught
in the weld pool. Too long a burnback time results in a shorter stickout, with
increased risk of the arc striking back to the contact tip.
6.3 Wire feed pressure
Start by making sure that the wire moves smoothly through the wire guide. Then
set the pressure of the wire feeder’s pressure rollers. It is important that the
pressure is not too great.
Fig 1 Fig 2
To check that the feed pressure is set correctly, you can feed out the wire against
an insulated object, e.g. a piece of wood.
When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feed
rollers should slip.
If you hold the gun approx. 50 mm from the piece of wood, the wire should be
fed out and bend (fig. 2).
6.4 Replacing and inserting wire
SOpen the side panel.
SDisconnect the pressure sensor by folding it backwards, the pressure arm is
folded up.
SStraighten out 10--20 cm of the new wire. File away burrs and sharp edges from
the end of the wire before inserting it into the wire feed unit.
SMake sure that the wire goes properly into the feed roller’s track and into the
outflow nozzle or wire guide.
SFold down the pressure arm and secure it to the pressure sensor.
SClose the side pannel.
GB

-- 1 0 --
bm42d1ea
6.5 Changing feed roller
SOpen the side panel.
SDisconnect the pressure sensor (1) by folding it
backwards.
SDisconnect the feed rollers (2) by unscrewing the
nuts (3) and pulling out the rollers.
During installation, repeat the above in the reverse
order.
Choice of groove in the feed roller
Turn the feed roller with the dimensioning mark for the
required groove towards you.
7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
CAUTION!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any faults.
7.1 Inspection and cleaning
Wire feed unit
Check regularly that the wire feed unit is not clogged with dirt.
SCleaning and replacement of the wire feed unit mechanism’s worn parts should
take place at regular intervals in order to achieve trouble--free wire feed. Note
that if pre--tensioning is set too hard, this can result in abnormal wear on the
pressure roller, feed roller and wire guide.
The brake hub
The hub is adjusted when delivered, if
readjustment is required, follow the instructions
below. Adjust the brake hub so that wire is slightly
slack when wire feed stops.
SAdjusting the braking torque:
STurn the red handle to the locked position.
SInsert a screwdriver into the springs in the hub.
Turn the springs clockwise to reduce the braking torque
Turn the springs counterclockwise to increase the braking torque. NB: Turn
both springs through the same amount.
GB

-- 1 1 --
bm42d1ea
Welding gun
SCleaning and replacement of the welding gun’s wear parts should take place at
regular intervals in order to achieve trouble--free wire feed. Blow the wire guide
clean regularly and clean the contact tip.
8 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized serviceman.
Use only original spare and wear parts.
Transmatic 4C is designed and tested in accordance with the international and Europe-
an standards IEC/EN 60974--5 and EN 50199. It is the obligation of the service unit
which has carried out the service or repair work to make sure that the product still
conforms to the said standard.
GB

Edition 090514
Diagram
-- 1 2 --
bm42e

Transmatic 4C
Edition 090514
Spare parts list
-- 1 3 --
bm42r
Valid for serial no. 435--xxx--xxxx
Ordering number
0459 495 884 Transmatic 4C
Spare parts are to be ordered through the nearest MUREX agency. Kindly indicate type of unit, serial
number, denominations and ordering numbers according to the spare parts list.
Maintenance and repair work should be performed by an experienced person, and electrical work only
by a trained electrician. Use only recommended spare parts.

Transmatic 4C
Edition 090514
-- 1 4 --
bm42sha1
C = component designation in the circuit diagram
Item 30--4 Ordering no. Denomination Notes C
HA1 10459 654 001 Handle
HA2 10459 497 003 Side panel
HA3 10459 547 001 Spring lock
HA4 10459 498 003 Side panel
HA5 10156 633 003 Reel cover
HA6 30458 689 002 Pole screw M4x25
HA7 1O--ring OR 3.6 x 1.6
HA8 10459 489 001 Connection cover
HA9 10040 936 901 Clamp
HA10 10192 784 016 Sleeve plug 15 pole panel socket 13XS12
0192 784 102 Sleeve For 15 pole socket
HA11 10487 254 880 Electronic board Circuit board 13AP1
HA12 4Circuit board holder 6.3 mm
HA13 40467 695 001 Rubber foot Ø 20/6.4x3, When ordering: 4 pieces deliv-
ered.
HA14 10160 609 881 Welding current terminal 13XP2
HA15 10466 325 001 Gasket
HA16 1Spacer ring Included in item HA13
HA17 1Washer Included in item HA13
HA18 1Nut Included in item HA13
HA19 10459 147 881 Cable set
HA20 10467 911 881 Capacitor 0.1 ìF 250V with cable lugs 13C1
HA21 1Washer Ø 22/10.5x2
HA22 2Spring washer Ø 20/10.2x1.1
HA23 1 Screw M10x20
HA24 2Flat pin 6.3x0.8
HA25 4 Screw M6x8
HA26 10459 000 890 Wire feed mechanism See page 16
HA27 10459 256 001 Insulating plate
HA28 10456 496 001 Hose, red L=0.50, Ø 9/5mm, to be ordered per metre
HA29 1Hose clamp Ø 11.3/10.8
HA30 10193 054 006 Solenoid valve 13YV1
HA31 10194 130 120 Nut MF10x1
HA32 20321 475 885 Knob
HA33 10349 485 758 Potentiometer 2.2 kÙ13RP2
HA34 10147 866 009 Cover rubber
HA35 10147 866 008 Switch 2--position 13SA2
HA36 10194 055 010 Rotary switch 4--position 13SA1
HA37 10321 475 893 Knob
HA38 10349 302 094 Potentiometer 100 kÙ13RP1
HA39 10459 505 006 Label

Transmatic 4C
Edition 090514
-- 1 5 --
bm42sha1

T
r
a
n
s
m
a
t
i
c
4
C
Edition 090514
-- 1 6 --
bm42shg1
C = component designation in the circuit diagram
(W) = wear part (V) = V--groove
Item Qty Ordering no. Denomination Notes C
0459 000 890 Wire feed mechanism Type MEM 30
Includes items HG1 -- HG21 and HG23 -- HG44
HG1 10466 489 001 Drive unit 13M1
HG2 10332 351 013 Shaft (with pinion) Included in item HG1
HG3 10215 701 007 Locking washer Included in item HG1
HG4 10191 496 114 Woodruff wedge Included in item HG1
HG5 10455 046 003 Gear housing
HG6 1 Screw M6x40
HG7 2Washer Ø 12/6.4x1.5
HG8 10455 048 001 Insulating tube
HG9 1Nut M6
HG10 10467 911 880 Capacitor 0.1 ìF 250V with cable lugs 13C2
HG11 1Flat pin 6.3x0.8 M6
HG12 4 Screw M6x12
HG13 10455 045 001 Insulating sleeve
HG14 10455 044 001 Current connection
HG15 1 Screw M8x25
HG16 1Washer Ø 16/8.4x1.5
HG17 1Belleville washer Ø 16/8.2x0.9
HG18 1Nut M8
HG19 10459 224 883 Cable set Includes sleeves and insulating sleeves.
HG20 10455 047 001 Front flange
HG21 10469 837 880 Outlet nozzle (W) Ø 2mm for 0.6--1.6mm Fe, Ss and cored wire
HG22 40153 043 002 Insulating washer
HG23 10469 838 001 Cover
HG24 2 Screw M6x12
HG25 10459 440 001 Drive gear (W)
HG26 1Washer Ø 16/5x1
HG27 1 Screw M4x12
HG28 2Axle feed roll See item HG102
HG29 20459 441 880 Gear adapter (W)
HG30 20369 557 003 Feed roller (W) (V) For Ø 1.0 & 1.2mm Fe, Ss, Al and cored wire
HG31 2Locking nut See item HG102
HG32 30458 689 001 Screw for nozzle
HG33 1Pin bolt See item HG101
HG34 10455 049 001 Inlet nozzle (W) Ø 3mm for 0.6--1.6mm Fe, Ss, Al and cored wire
HG35 1Pressure device See item HG101
HG36 10455 072 002 Intermediate nozzle (W) For Fe, Ss and cored wire
HG37 1Pressure arm See item HG100
HG38 1Locking washer See item HG100
HG39 1Torsion spring See item HG100
HG40 1Shaft See item HG100
HG41 40455 906 001 Spacer sleeve
HG42 20455 907 001 Pressure roller
HG43 302157 027 08 Locking washer
HG44 20459 518 001 Axel pressure roll
For more wear parts see page 18.
SPARE PARTS SETS
Item Ordering no. Denomination Notes
HG100 0459 227 880 Pressure arm set Includes items HGH37, HG38, HG39 and HG40
HG101 0459 228 880 Pressure device set Includes items HG33, HG35 and one screw M3x12.
HG102 0458 722 880 Axle and nut Includes items HG28 and HG31.

T
r
a
n
s
m
a
t
i
c
4
C
Edition 090514
-- 1 7 --
bm42shg1

Transmatic 4C
Edition 090514
Wear parts
-- 1 8 --
bm42whn1
S= Standard, HD = Heavy Duty
Item Ordering no. Denomination Notes
HN1 0455 072 002
0456 615 001 Intermediate nozzle (S) Intermediate nozzle For Fe, Ss & cored wire For Al Wire
HN2 0469 837 880
0469 837 881 Outlet nozzle (S) Outlet nozzle For Fe, Ss & cored wire, Ø 2.0 mm steel for 0.6--1.6 mm For Al wire, Ø 2.0 mm plastic for 0.8--1.6 mm
HN3 0191 496 114 Woodruff wedge
HN4 0459 440 001 Motor gear euro
HN5 Washer Ø 16/5x1
HN6 Screw M4x12
HN7 Screw M6x12
HN8 Washer Ø 12/6.4x1.5
HN9 0469 838 001 Cover
HN10 0458 722 880 Axle and Nut
HN11 0369 557 001 Feed roller For Fe, Ss & cored wire, Ø 0.6 & 0.8 mm, V groove
0369 557 002 Feed roller For Fe, Ss & cored wire, Ø 0.8 & 1.0 mm, V groove
0369 557 003 Feed roller (S)For Fe, Ss & cored wire, Ø 1.0 & 1.2 mm, V groove
0369 557 004 Feed roller For Cored wire, Ø 1.0/1.2 & 1.4/1.6 mm, V--Knurled groove
0369 557 011 Feed roller For Al wire, Ø 0.8 & 0.9 mm, U groove
0369 557 006 Feed roller For Al wire, Ø 1.0 & 1.2 mm, U groove
HN12 0459 441 880 Gear adapter
HN13 0455 049 001 Inlet nozzle
HN14 0455 906 001 Spacer sleeve
HN15 0455 907 001 Pressure roller Flat
HN16 0215 702 708 Locking washer
HN17 0459 518 001 Axel pressure roll
HN18 Nut M10
HN19 0458 748 002 Insulating washer
HN20 0458 748 001 Insulating bushing
HN21 0156 602 001
0332 318 001 Inlet nozzle (S) Inlet nozzle (HD)For Fe, Ss, Al & Cored wire, Ø 2 mm plastic for 0.6--1.6 mm For Fe, Ss & Cored wire, Ø 2.4 mm steel for 1.2--2.0 mm
Welding with aluminium wire
In order to weld with aluminium wire, proper rollers, nozzles and liners for aluminium wire MUST be
used, It is recommended to use 3 m long welding gun for aluminium wire, equipped with appropriate
wear parts.

Transmatic 4C
Edition 090514
-- 1 9 --
bm42whn1

Edition 090514
Transmatic 4C
Accessories
-- 2 0 --
bm42a11a
1Bobbin cover, plastic Ø 300mm ........... 0458 674 880
1Adapter for 5 kg bobbin .................... 0455 410 001
1
2
Lifting eye ...............................
Brake hub ...............................
0458 706 880
0146 967 881
1
2
Turning piece ............................
Quick connector MarathonPact...........
0458 703 880
F102 440 880
1Wheel kit ................................ 0458 707 880