Murex Transmatic 4C Guide

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

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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.......................................................

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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).
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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