200i TRANSMIG Multi process welding inverter Operating Manual Revision: AC Operating Features: Issue Date: January 10, 2012 Art # A-10419 Manual No.
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! WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use.
TABLE OF CONTENTS SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS...................................... 1-1 1.01 1.02 1.03 Arc Welding Hazards........................................................................................ 1-1 Principal Safety Standards............................................................................... 1-5 Declaration of Conformity................................................................................ 1-6 SECTION 2: INTRODUCTION .......................
TABLE OF CONTENTS SECTION 4: BASIC WELDING GUIDE ............................................................................. 4-1 4.01 4.02 4.03 4.04 4.05 4.06 MIG (GMAW/FCAW) Basic Welding Technique................................................ 4-1 MIG (GMAW/FCAW) Welding Troubleshooting................................................ 4-7 Stick (MMAW) Basic Welding Technique....................................................... 4-10 Stick (MMAW) Welding Troubleshooting.................................
TRANSMIG 200i SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ! WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
TRANSMIG 200i 2. Wear approved safety glasses. Side shields recommended. WARNING ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing. 1. Use a Welding Helmet or Welding Faceshield fitted with a proper shade of filter (see ANSI Z49.1 and AS 1674 listed in Safety Standards) to protect your face and eyes when welding or watching. 3.
TRANSMIG 200i 3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. WARNING 4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. FUMES AND GASES can be hazardous to your health. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 5. Watch for fire, and keep a fire extinguisher nearby. 6.
TRANSMIG 200i 5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. 6. Turn face away from valve outlet when opening cylinder valve. 7. Keep protective cap in place over valve except when cylinder is in use or connected for use. 8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.
TRANSMIG 200i 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W.
TRANSMIG 200i 1.03 Declaration of Conformity Manufacturer and Merchandiser of Quality Consumables and Equipment: CIGWELD Address: 71 Gower St, Preston Victoria 3072 Australia Description of equipment: Welding Equipment. (GMAW, FCAW, GTAW, MMAW) including, but not limited to CIGWELD Transmig 200i Multi Process Welding Inverter and associated accessories.
TRANSMIG 200i SECTION 2: INTRODUCTION 2.01 How To Use This Manual 2.02 Equipment Identification To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel.
TRANSMIG 200i 2.04 Symbol Chart Note that only some of these symbols will appear on your model. On Single Phase Wire Feed Function Off Three Phase Wire Feed Towards Workpiece With Output Voltage Off.
TRANSMIG 200i 2.05 Description 2.07 Transporting Methods The Cigweld Transmig 200i is a self contained single phase multi process welding inverter that is capable of performing GMAW/FCAW (MIG), MMAW (Stick) and GTAW (Lift TIG) welding processes. The unit is equipped with an integrated wire feed unit, voltage reduction device (VRD applicable in stick mode only.
TRANSMIG 200i 2.09 Duty Cycle The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 20% duty cycle, 210 amperes at 24.5 volts.
TRANSMIG 200i 2.10 Specifications Description Transmig 200i Transmig 200i (South Pacific Version) (Asia Version) W1005200 W1005201 W1005200M - H435mm x W266mm x D617mm H435mm x W266mm x D617mm 26kg 26kg Fan Cooled Fan Cooled Multi Process Inverter Power Source Multi Process Inverter Power Source Australian Standard AS 60974.1 / IEC 60974-1 AS 60974.
TRANSMIG 200i 2.11 Optional Accessories Part Number W4013701 OTWX212/3035 W4013801 W4013800 W4015000 W4015103 7977036 7977660 7977731 7977264 7977732 704277 W7004913 WSPLIER 646265 Description Tweco professional Fusion 250A MIG Torch, 3.0 metre EURO TWECO #2, 250A MIG torch, 3.6 metre EURO TIG Torch 17V with 4m lead TIG Torch 17V with 4m lead and remote control Power Source Trolley with inbuilt cylinder carrier Power Source Roll Cage Feed Roll 0.6/0.8mm V groove (hard), (fitted) Feed Roll 0.9/1.
TRANSMIG 200i SECTION 3: INSTALLATION, OPERATION AND SETUP 3.01 Environment These units are designed for use in environments with increased hazard of electric shock as outlined in AS 60974.1 and AS 1674.2. A. Examples of environments with increased hazard of electric shock are: 1. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts; 2.
TRANSMIG 200i 6. Equipment used for calibration and measurement. 3.05 Electromagnetic Compatibility ! 7. The time of day that welding or other activities are to be carried out. WARNING 8. The immunity of other equipment in the environment: the user shall ensure that other equipment being used in the environment is compatible: this may require additional protection measures.
TRANSMIG 200i 4. Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However. Metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components. 5.
TRANSMIG 200i 3.06 Transmig 200i Power Source Controls, Indicators and Features 2 15 1 3 Power Voltage Reduction Device ON OFF 200 4 4 Amps 24.0 6 4 7 2 9 10 Volts Process MIG LIFT TIG STICK 4T Latch 7 2 11 8 1 Down Slope Arc Force (%) 17 12 2T Normal 6 3 8 1 Wirespeed 13 Fault Trigger 3 14 9 Soft Hard Arc Control 10 16 10 5 22 6 7 9 Art # A-10420_AB 8 Figure 3-1: Front Panel Figure 3-2: Rear Panel 1.
TRANSMIG 200i 3. Digital Amps Meter (Left Digital Display) MIG Mode This digital meter is used to display the pre-set (preview) Wirefeed Speed in Meters Per Minute (MPM) in MIG mode and actual welding amperage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Wirefeed Speed. This value can be adjusted by varying the Amperage Control Knob (4).
TRANSMIG 200i 6. Positive Welding Output Terminal The positive 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 work lead. Positive welding current flows from the power source via this heavy duty bayonet type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
TRANSMIG 200i 9. Remote Control Socket The 8 pin Remote Control Socket is used to connect remote control devices to the welding power source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
TRANSMIG 200i When MMAW (Stick) Mode is Selected In this mode the multifunction control knob is used to adjust arc force. Arc force control provides an adjustable amount of welding force (or “dig”) control. This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit-up in certain situations with particular electrodes. In general increasing the arc force control toward ‘10’ (maximum arc force) allows greater penetration control to be achieved.
TRANSMIG 200i 14. Digital Voltage Meter (Right Digital Display) MIG Mode This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding voltage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Voltage. This value can be adjusted by varying the Multifunction Control Knob (10).
TRANSMIG 200i 17. On / Off Switch This Single Phase circuit breaker performs a dual function. It is used to turn the unit on/off and it will also trip in the event of a fault. WARNING When the front digital displays are lit, the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential. Art # A-10422 Figure 3-4: Wire Feed Compartment Control 18.
TRANSMIG 200i 20. Burnback Control (located in wirefeed compartment) The burnback control is used to adjust the amount of MIG wire that protrudes from the MIG torch after the completion of MIG welding (commonly referred to as stick out). To decrease the burnback time (or lengthen the amount of wire protruding from the MIG torch at the completing of welding), turn the burnback control knob anti clockwise.
TRANSMIG 200i 3.08 Installing Spool (300mm diameter) As delivered from the factory, the unit is fitted with a Wire Spool Hub which accepts a Spool of 300mm diameter. Remove the locking pin from the spool hub. Install the wire spool over the spool hub, locating the hole in the spool, with the alignment pin on the spool hub. Insert the locking pin back into the spool hub. Spool Hub Locking Pin Spool Hub Aligenment Pin Art # A-10424 Figure 3-6: 300mm Spool Installation 3.
TRANSMIG 200i 3.10 Inserting Wire into the Wire Feed Mechanism Release the tension from the pressure roller by turning the adjustable wire drive tension screw in an anticlockwise direction. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm (Figure 3-8).
TRANSMIG 200i 3.11 Feed Roller Pressure Adjustment The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit liner should be checked for kinks and clogging by metal flakes and swarf.
TRANSMIG 200i 3.13 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking. If it is considered necessary, adjustment can be made by turning the Thumb Screw inside the open end of the hub clockwise to tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than 10-20mm after release of the trigger. The electrode wire should be slack without becoming dislodged from wire spool.
TRANSMIG 200i 4. DO NOT use the regulator as a control valve. When downstream equipment is not in use for extended periods of time, shut off the gas at the cylinder valve and release the gas from the equipment. 5. OPEN the cylinder valve SLOWLY. Close after use. User Responsibilities This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in accordance with the instructions provided.
TRANSMIG 200i Operation With the regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows: 1. Stand to one side of regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal regulator parts. 2. With valves on downstream equipment closed, adjust regulator to approximate working pressure.
TRANSMIG 200i 3.15 Setup for MIG (GMAW) Welding with Gas Shielded Mig Wire A. Select MIG mode with the process selection control. (refer to Section 3.06.13 for further information) B. Connect 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 heavy duty bayonet type terminals.
TRANSMIG 200i 3.16 Setup for MIG (GMAW) Welding with Gasless Mig Wire A. Select MIG mode with the process selection control (refer to Section 3.06.13 for further information). B. Connect the Mig Torch polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer. Welding current flows from the power source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. C.
TRANSMIG 200i 3.17 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded Mig Wire A. Select MIG mode with the process selection control (refer to Section 3.06.13 for further information). B. Connect 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 heavy duty bayonet type terminals.
TRANSMIG 200i 3.18 Setup for TIG (GTAW) Welding A. Select Lift TIG mode with the process selection control (refer to Section 3.06.13 for further information). B. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the power source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. C. Connect the work lead to the positive welding terminal (+).
TRANSMIG 200i 3.19 Setup for STICK (MMAW) Welding A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. B. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer.
TRANSMIG 200i SECTION 4: BASIC WELDING GUIDE 4.01 MIG (GMAW/FCAW) Basic Welding Technique Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the very basic concepts in using the Mig mode of welding, where a welding gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
TRANSMIG 200i Position of MIG Torch The angle of MIG torch to the weld has an effect on the width of the weld. Vertical Push Drag/Pull Art # A-07185_AB Figure 4-3 The welding gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below) Hold the gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper filter lenses and use the proper safety equipment. CAUTION Do not pull the welding gun back when the arc is established.
TRANSMIG 200i 10° to 20° Longitudinal Angle 10° Longitudinal Angle 30° to 60° Transverse Angle 30° to 60° Transverse Angle Direction of Travel Vertical Fillet Welds Art # A-08995 Figure 4-6 Direction of Travel 30° to 60° Transverse Angle 5° to 15° Longitudinal Angle Art # A-08996 Overhead Figure Weld 4-7 Distance from the MIG Torch Nozzle to the Work Piece The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20.0mm.
TRANSMIG 200i Secondary Adjustable Variables These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation. They are: 1. Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain at about 10mm stick-out 2. Wire Feed Speed. Increase in wire feed speed increases weld current, Decrease in wire feed speed decreases weld current.
TRANSMIG 200i Establishing the Arc and Making Weld Beads Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a sample metal of the same material as that of the finished piece. The easiest welding procedure for the beginner to experiment with MIG welding is the flat position. The equipment is capable of flat, vertical and overhead positions. For practicing MIG welding, secure some pieces of 16 or 18 gauge (0.06” 1.5mm or 0.08” 2.
TRANSMIG 200i Cigweld MIG Wire Selection Chart Transmig 200 i MULTI PROCESS WELDING INVERTER Cigweld Welding Wire Selection Chart Part Number Application Handispool 4.5kg 721923 0.9mm Handispool 4.5kg 721924 0.9mm Spool 14kg 721929 1.2mm Handispool 4.5kg 720302 Shield-Cor 15 is an all positional self-shielded flux cored wire recommended for single pass welding applications only. It is excellent for single-pass lap, fillet and butt welding of thin gauged galvanised and mild steels. 0.
TRANSMIG 200i 4.02 MIG (GMAW/FCAW) Welding Troubleshooting Solving Problems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG torch. There are two main areas where problems occur with GMAW, Porosity and Inconsistent wire feed Solving Problems Beyond the Welding Terminals - Porosity When there is a gas problem the result is usually porosity within the weld metal.
TRANSMIG 200i Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1 Feed roller driven by motor in the cabinet slipped. Wire spool brake is too tight. 2 Wire spool unwinded and tangled. Wire spool brake is too loose. 3 Worn or incorrect feed roller size 4 Wire rubbed against the mis-aligned guides and reduced wire feedability.
TRANSMIG 200i Basic GMAW (MIG) Welding Troubleshooting FAULT 1 Undercut CAUSE REMEDY A Welding arc voltage too A Decrease voltage or increase the wire feed speed. high. B Incorrect torch angle B Adjust angle. C Excessive heat input C Increase the torch travel speed and/or decrease welding current by decreasing the voltage or decreasing the wire feed speed. 2 Lack of penetration A Welding current too low A Increase welding current by increasing wire feed speed and increasing voltage.
TRANSMIG 200i 4.03 Stick (MMAW) Basic Welding Technique Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufficient current (amperage) to run the smaller size electrodes. For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job.
TRANSMIG 200i Art # A-07687 Figure 4-11: Flat Position, Down Hand Butt Weld Art # A-07688 Figure 4-12: Flat Position, Gravity Fillet Weld Art # A-07689 Figure 4-13: Horizontal Position, Butt Weld Art # A-07690 Figure 4-14: Horizontal-Vertical (HV) Position Art A-07691 Figure 4-15: Vertical Position, Butt Weld Art # A-07692 Figure 4-16: Vertical Position, Fillet Weld Manual 0-5209 4-11 BASIC WELDING GUIDE
TRANSMIG 200i Art# A-07693 Figure 4-17: Overhead Position, Butt Weld Art # A-07694 Figure 4-18: Overhead Position, Fillet Weld Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.
TRANSMIG 200i Arc Welding Technique - A Word to Beginners For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position. Make sure that the work clamp is making good electrical contact with the work, either directly or through the work table.
TRANSMIG 200i Rate of Travel After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.
TRANSMIG 200i B. Fillet Welds These are welds of approximately triangular cross-section made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-14. A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. Using a 3.2mm Ferrocraft 21 electrode at 100 amps, position angle iron with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) fillet.
TRANSMIG 200i C. Vertical Welds 1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm Ferrocraft 21 electrode and set the current at 100 amps. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet. The electrode needs to be about 10º from the horizontal to enable a good bead to be deposited. Refer Figure 4-25. Use a short arc, and do not attempt to weave on the first run.
TRANSMIG 200i 3. Overhead Welds Apart from the rather awkward position necessary, overhead welding is not much more difficult that downhand welding. Set up a specimen 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 specimen is positioned in the overhead position as shown in the sketch.
TRANSMIG 200i Distortion Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur. The study of distortion is so complex that only a brief outline can be attempted hear. The Cause of Distortion Distortion is caused by: A.
TRANSMIG 200i B. Distribution of Stresses Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 4-30 through 4-33 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion. C.
TRANSMIG 200i 3 2 1 Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool.
TRANSMIG 200i Electrode Selection Chart CIGWELD Electrode Selection Chart Pack Part No. Description Diameter Satincraft 13 2.5mm 2.5mm 3.2mm 3.2mm 4.0mm 1kg 2.5kg 1kg 2.5kg 5kg 322135 612182 322136 612183 611184 Application General purpose electrode suitable for all positional welding and galvanised steel. Ferrocraft 12XP 2.0mm 2.0mm 2.5mm 2.5mm 3.2mm 3.2mm 4.0mm 1kg 2.5kg 1kg 2.5kg 1kg 2.
TRANSMIG 200i 4.04 Stick (MMAW) Welding Troubleshooting FAULT CAUSE 1 Welding current varying REMEDY ARC FORCE control knob is set at a value that causes the welding current to vary excessively with the arc length. 2 A gap is left by A Welding current too low failure of the weld B Electrode too large for metal to fill the joint. root of the weld. C Insufficient gap.
TRANSMIG 200i 5 Portions of the A Small electrodes used on A Use larger electrodes and preheat the plate. weld run do not heavy cold plate. fuse to the surface B Welding current is too low. B Increase welding current. of the metal or C Adjust angle so the welding arc is directed more edge of the joint. C Wrong electrode angle. into the base metal. D Travel speed of electrode is too high. D Reduce travel speed of electrode. E Scale or dirt on joint surface. E Clean surface before welding.
TRANSMIG 200i 4.05 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (nonconsumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based.
TRANSMIG 200i Tungsten Electrode Types Electrode Type (Ground Finish) Welding Application Features Colour Code Thoriated 2% DC welding of mild steel, stainless steel and copper Excellent arc starting, Long life, High current carrying capacity Red Zirconated 1% High quality AC welding of aluminium, magnesium and their alloys. Self cleaning, Long life, Maintains balled end, High current carrying capacity.
TRANSMIG 200i TIG Welding Filler Rods Comweld Aust Std Rod AWS Std Part No. 1.6mm Part No. 2.4mm Part No. 3.2mm Type/Application LW1 LW1-6 Supersteel R4 R6 R2 ER70S-4 ER70S-6 ER70S-2 321411 321417 321370 — — — — — — For mild-medium strength steels. Pipes, tubing, roll cages, etc. CrMo1 CrMo2 RB2 RB3 ER80S-B2 ER90S-B3 — — 321379 321383 — — For welding of high strength Cr-Mo steels used at elevated temperatures.
TRANSMIG 200i 4.06 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive bead build up or poor penetration or poor fusion at edges of weld. Welding current is too low Increase weld current and/or faulty joint preparation. 2 Weld bead too wide and flat or undercut at edges of weld or excessive burn through. Welding current is too high Decrease weld current. 3 Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart. Travel speed too fast Reduce travel speed.
TRANSMIG 200i 7 Dirty weld pool A Electrode contaminated A Clean the electrode by grinding off the by contact with work contaminates. piece or filler rod material. B Work piece surface has B Clean surface. foreign material on it. C Gas contaminated with C Check gas lines for cuts and loose fitting air. or change gas cylinder. 8 Poor weld finish 9 Arc start is not smooth. Inadequate shielding gas. Increase gas flow or check gas line for gas flow problems.
TRANSMIG 200i SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source Problems FAULT CAUSE REMEDY 1 Mains supply voltage is ON, A Power source is not in the power indicator is illumicorrect mode of operation. nated however unit will not commence welding when B Faulty torch trigger. the torch trigger switch is depressed. A Set the power source to the correct mode of operation with the process selection switch. Duty cycle of power source has been exceeded.
TRANSMIG 200i 8 Gas flow continues after the torch trigger switch has been released (MIG mode). Gas valve has jammed open due to impurities in the gas or the gas line. Have an accredited CIGWELD service provider repair or replace gas valve. 9 Power indicator will not illuminate and welding arc cannot be established. The mains supply voltage has exceeded voltage limits of the power source. Ensure that the mains supply voltage is within 240VAC ± 15%. 10 TIG electrode melts when arc is struck.
TRANSMIG 200i B. Insulation Resistance Minimum insulation resistance for in-service Cigweld Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 5-2 below. Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.
TRANSMIG 200i E. General Maintenance Checks Welding equipment should be regularly checked by an accredited Cigweld Service Provider to ensure that: 1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly connected and in good condition. 2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short circuit. 3. The Welding System is clean internally, especially from metal filing, slag, and loose material. F.
TRANSMIG 200i 5.03 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling. To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated dirt, metal filings, slag and loose material.
TRANSMIG 200i 5.05 Volt-Ampere Curves Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown.
TRANSMIG 200i SECTION 6: KEY SPARE PARTS 6.01 Power Source 3 20 4 5 11 16 12 9 19 10 2 7 8 15 6 14 13 Item Part Number W7005600 PCB Power 2 W7005601 PCB Control 3 W7005602 PCB Display 4 W7005607 PCB Spool Gun 5 W7004902 PCB EMC Filter 6 W7005603 Wiredrive Assembly 7 W7004906 Feed Roll Retaining Thumbscrew 7977036 Feed Roll 0.6/0.8mm V groove (fitted as standard) (Refer to options and accessories table for other feed rolls available).
TRANSMIG 200i 6.02 Tweco Fusion 250 Mig Torch MIG Torch Part No: W4013701 1 2 3 4 5 A-09659 7 7 6 8 TWECO FUSION MIG TORCH PARTS ITEM 1 2 PART NO. DESCRIPTION OTW22/50 Nozzle 13mm OTW22/62 Nozzle 16mm 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 1.
TRANSMIG 200i SECTION 7: TRANSMIG 200i CIRCUIT DIAGRAM A N E SW1 24VDC FAN CY1 J1 R2 3R 40W POSITIVE INPUT RECTIFIER L4 V7 V8 R39 C20 C17 C23 Q1 Q2 CT1 T1 R100, 102 T14 T18 C100 C101 MD R101, 103 CON3 C22 JC MT-IN C19 PWM FUNs C21 QF/FJ PFC R56 DY2 PWM NEGATIVE IN QF/DY 15V COUT1 COUT2 CT2 HALL EFFECT L1 CB? SW3 POSITIVE NEGATIVE WIREDRIVE MOTOR Art # A-10437 MOTOR CIRCUIT BREAKER SPOOL GUN SWITCH TORCH TRIGGER REMOTE SWITCH 8 PIN REMOTE SW2 WELD
CIGWELD - LIMITED WARRANTY TERMS LIMITED WARRANTY: CIGWELD Pty Ltd, A Thermadyne Company, hereafter, “CIGWELD” warrants to customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material.
TERMS OF WARRANTY – JULY 2010 1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply of goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including warranties as to merchantability and fitness for purpose) associated with the supply of goods and services.
WARRANTY SCHEDULE – JULY 2010 These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of sale from the Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date CIGWELD delivered the product to the Accredited Distributor. Unless otherwise stated the warranty period includes parts and labour.
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Cigweld, Australia 71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7391 Email: cigweldsales@cigweld.com.au Thermadyne USA 2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.
Asia Pacific Regional Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 +61 3 9474 7391 FAX: Email: enquiries@thermadyne.com.au www.thermadyne.
