350i TRANSMIG 450i Multi process 550i welding inverter A-10625 Operating Manual Revision: AE Operating Features: Issue Date: May 7, 2013 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 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS..................... 5-1 5.01 5.02 5.03 5.04 Power Source / Wirefeeder Problems.............................................................. 5-1 Routine Service and Calibration Requirements................................................ 5-2 Cleaning the Welding Power Source................................................................ 5-4 Cleaning the Feed Rolls...........................................................
TRANSMIG 350i, 450i, 550i 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 350i, 450i, 550i 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 350i, 450i, 550i 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 350i, 450i, 550i 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 350i, 450i, 550i 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.
TRANSMIG 350i, 450i, 550i 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: TRANSMIG 350i, 450i, 550i MULTI PROCESS INVERTER Power Source and associated accessories. * Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.
TRANSMIG 350i, 450i, 550i 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 350i, 450i, 550i 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 350i, 450i, 550i 2.05 Description 2.07 Transporting Methods The Cigweld Transmig 350i, 450i and 550i are three phase multi process welding inverters that are capable of performing GMAW/FCAW (MIG), MMAW (Stick) and GTAW (Lift TIG) welding processes.
TRANSMIG 350i, 450i, 550i 2.08 Packaged Items Transmig 550i Plant (Part No. W1005550) • Transmig 550i Inverter Power Source Transmig 350i Plant (Part No. W1005350) • Transmig VA4000 wirefeeder with 15m interconnection lead • Transmig 350i Inverter Power Source • Transmig 4RT wirefeeder with 8m interconnection lead fitted • Tweco Professional Supra XT Mig Torch • Comet Professional Argon regulator/flowmeter • Tweco Professional No.4 Mig Torch • Feed roll: 1.3/1.
TRANSMIG 350i, 450i, 550i 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 60% duty cycle, 550 amperes at 41.5 volts.
TRANSMIG 350i, 450i, 550i 2.10 Specifications Description TRANSMIG 350i Plant Part Number W1005350 Power Source (Packed)Part Number W1005352 TRANSMIG 450i W1005450 W1005451 W1005452 72 kg 72 kg Power Source Mass Power Source Dimensions TRANSMIG 550i 72 kg W1005550 W1005552 H 580mm x W 350mm x D 640mm Cooling Welder Type Fan Cooled Multi Process Inverter Power Source Applicable Standards AS 60974.
TRANSMIG 350i, 450i, 550i NOTE Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service. In the interest of continuous improvement, CIGWELD Pty, Ltd reserves the right to change the specifications or design of any of its products without prior notice.
TRANSMIG 350i, 450i, 550i As an example, if we were Gouging with an 8mm electrode at 400A, we can see from the graph that we can expect 400A at 57% duty cycle. For a 3 minute duty cycle period, this means our arc time is 57% of 3 minutes, which is 1 minute & 40 seconds, during the other 1 minute & 20 seconds the machine must be allowed to cool. NOTE Gouging is specified for a 3 minute duty cycle period only. 2.
TRANSMIG 350i, 450i, 550i SECTION 3: INSTALLATION, OPERATION AND SETUP conditions. For further information please refer to AS 60529. 3.01 Environment These units are designed for use in environments with increased hazard of electric shock as outlined in H. Precautions must be taken against the power source toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use. AS 60974.1 and AS 1674.2. A.
TRANSMIG 350i, 450i, 550i C. Methods of Reducing Electromagnetic Emissions manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see NOTE below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work, complete with associated input filters. In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer troublesome. 1.
TRANSMIG 350i, 450i, 550i taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations. 6.
TRANSMIG 350i, 450i, 550i 22 18 19 20 21 17 A-10629 Figure 3-1: Front Panel and Controls 1. Amperage Control (Wirespeed) The amperage control knob adjusts the amount of welding current delivered by the power source. In MMAW (stick) and GTAW (Lift TIG) modes, the amperage control knob directly adjusts the power inverter to deliver the desired level of output current.
TRANSMIG 350i, 450i, 550i 2. Voltage Control The voltage control knob adjusts the amount of welding voltage delivered by the power source. In MMAW (stick) and GTAW (Lift TIG) modes, the voltage control knob is inactive. In 10 PIN and 19 PIN GMAW/FCAW modes (MIG), the voltage knob directly adjusts the power inverter to deliver the desired level of output voltage. NOTE The preview functionality provided on this power source is intended to act as a guide only.
TRANSMIG 350i, 450i, 550i 5. Inch Button The INCH button is active in 10 PIN GMAW/FCAW mode (MIG) only. Press and hold the INCH button to inch the wire in the Wirefeeder (Active in 10 Pin mode only). 6. Local / Remote Button The REMOTE button is used to select REMOTE or LOCAL mode of operation. The REMOTE button is used only when a remote control device (such as a TIG torch with remote current control, or a Wirefeeder) is fitted to the unit via the remote control socket (items 5 & 6).
TRANSMIG 350i, 450i, 550i 8. Process Selection Button The process selection control is used to select the desired welding mode. Three modes are available, GMAW/FCAW (MIG), GTAW (Lift TIG) and MMAW (Stick) and Gouging (Transmig 550i only) modes. Refer to section 3.15 or 3.16 for FCAW/GMAW (MIG) set up details, section 3.17 for GTAW (Lift TIG) set-up details or section 3.18 for MMAW (stick) set-up details.
TRANSMIG 350i, 450i, 550i 11. Thermal Overload Indicator Light (Fault) This welding power source is protected by a self resetting thermostat. The indicator will illuminate if the duty cycle of the power source has been exceeded. Should the thermal overload indicator illuminate the output of the power source will be disabled. Once the power source cools down this light will go OFF and the over temperature condition will automatically reset.
TRANSMIG 350i, 450i, 550i NOTE The preview functionality provided on this power source is intended to act as a guide only. Some difference may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer).
TRANSMIG 350i, 450i, 550i 15. Advanced Features The TRANSMIG 350i, 450i and 550i have a series of Advanced features that allow the control of multiple parameters. These are accessed by pressing the AMPS and VOLTS knobs at the same time. Once in the Advanced Features mode, turn the AMP control to select the Parameter, and turn the VOLTS control to adjust the value.
TRANSMIG 350i, 450i, 550i 16. Fan as Needed The TRANSMIG 350i, 450i and 550i are fitted with a fan as needed feature. Fan as needed automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimise the amount of contaminants such as dust that are drawn into the power source. Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required. 17.
TRANSMIG 350i, 450i, 550i 20. 10 Pin Control Socket The 10 pin receptacle is used to connect a Wirefeeder or other suitable remote control device to the welding Power Source circuitry: To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
TRANSMIG 350i, 450i, 550i 21. 19 Pin Wirefeeder Control Socket The WIREFEEDER 19 pin receptacle is used to connect a Wirefeeder to the welding Power Source circuitry. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. The socket information is included in the event the supplied cable is not suitable and it is necessary to wire a plug or cable to interface with the WIREFEEDER 19 pin receptacle.
TRANSMIG 350i, 450i, 550i 22. Control Circuit Breakers 22 A-10638 Figure 3-3: Circuit Breakers These Circuit Breakers protects the unit from electrical faults. The SOLENOID 4A and MOTOR 5A circuit breakers are for Wirefeeders connected to the 10 pin control socket. The 42VAC 8A and 110VAC 4A circuit breakers are for Wirefeeders connected to the 19 pin control socket. The Fan 3A circuit breaker protects the fan circuit in the event of a fault.
TRANSMIG 350i, 450i, 550i 3.07 Shielding Gas Regulator Operating Instructions ! WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Regulator Safety This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it. If the equipment is improperly used, hazardous conditions are created that may cause accidents.
TRANSMIG 350i, 450i, 550i Installation 1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices and damage seats before connecting the regulator. Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition. Wipe with a clean lint free cloth. 2. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking agree and that the regulator inlet and cylinder outlet match.
TRANSMIG 350i, 450i, 550i 2. To reduce flow rate, allow the welding grade shielding gas to discharge from regulator by opening the downstream valve. Bleed welding grade shielding gas into a well ventilated area and away from any ignition source. Turn adjusting screw counterclockwise, until the required flow rate is indicated on the gauge. Close downstream valve. Shutdown Close cylinder valve whenever the regulator is not in use. To shut down for extended periods (more than 30 minutes). 1.
TRANSMIG 350i, 450i, 550i C. Fit the gas regulator and flowmeter to the gas cylinder then connect the gas hose from the rear of the Wirefeeder to the flowmeter outlet. D. Dual groove feed rollers are supplied as standard. Select the roller required with the chosen wire size marking facing outwards. GROOVE “A” GROOVE “B” Art # A-08739 GROOVE “A” SIZE GROOVE “B” SIZE E. Fit the electrode wire spool to the wire reel hub. Ensure that the drive dog-pin engages the mating hole in the wire spool.
TRANSMIG 350i, 450i, 550i Positive Welding Terminal (+) Negative Welding Terminal (-) 19 Pin Control Socket Work Lead Powered Wirefeeder (19 Pin) Mig Torch A-10639 Figure 3-7: Setup for Mig Welding with Gas Shielded Mig Wire Manual 0-5205 3-19 INSTALLATION, OPERATION AND SETUP
TRANSMIG 350i, 450i, 550i 3.09 Setup for MIG (GMAW) Welding with Gasless Mig Wire POWER SOURCE CONNECTIONS A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source. B. Connect the work 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 350i, 450i, 550i ! WARNING DO NOT WEAR GLOVES WHILE THREADING THE WIRE OR CHANGING THE WIRE SPOOL. G. Lower the pressure levers and with the torch lead reasonably straight, feed the electrode wire through the torch. Fit the appropriate contact tip, eg a 0.9mm tip for 0.9mm wire. H Press the INCH button to feed the wire through the torch. (Only applicable to wirefeeders connected to the 10 pin socket.
TRANSMIG 350i, 450i, 550i 3.10 Setup for TIG (GTAW) Welding With Gas Shielding A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source. B. Connect the work lead to the positive 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.
TRANSMIG 350i, 450i, 550i 3.11 Setup for STICK (MMAW) Welding A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source. B. Connect the Electrode Holder 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. C.
TRANSMIG 350i, 450i, 550i 3.12 Setup for GOUGING (Transmig 550i only) A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source. B. Connect the Carbon Arc Gouging Torch to the positive welding terminal (+). If in doubt, consult the carbon 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. C.
TRANSMIG 350i, 450i, 550i 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 350i, 450i, 550i 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 350i, 450i, 550i 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 Weld Figure 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 350i, 450i, 550i 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 350i, 450i, 550i 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 350i, 450i, 550i Transmig 350i,450 i,550 i MULTI PROCESS WELDING INVERTER Cigweld Welding Wire Selection Chart Description Diameter Shield-Cor 11 1.2mm Spool 15kg 720923 1.6mm Spool 15kg 720925 1.2mm Spool 15kg 720919 1.6mm Spool 15kg 720921 0.8mm Spool 15kg 720114 0.9mm Handispool 5kg 720161 0.9mm Spool 15kg 720090 1.0mm Spool 15kg 720094 1.2mm Spool 15kg 720096 1.6mm Spool 15kg 720095 0.8mm Handispool 5kg 720288 0.9mm Handispool 5kg 720283 0.
TRANSMIG 350i, 450i, 550i 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 350i, 450i, 550i 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 A Use a feed roller matched to the size you are welding. B Replace feed roller if worn.
TRANSMIG 350i, 450i, 550i 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 350i, 450i, 550i 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 350i, 450i, 550i 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 0-5205 4-11 BASIC WELDING GUIDE
TRANSMIG 350i, 450i, 550i 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 350i, 450i, 550i 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.
TRANSMIG 350i, 450i, 550i If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. If the travel is too slow, the weld metal piles up and the bead will be too large. Making Welded Joints Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints. A. Butt Welds Set up two plates with their edges parallel, as shown in Figure 4-21, allowing 1.6mm to 2.
TRANSMIG 350i, 450i, 550i 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 350i, 450i, 550i Art # A-07701 Figure 4-25: Single Run Vertical Fillet Weld Art # A-07702 Figure 4-26: Multi Run Vertical Fillet Weld Art # A-07703 Figure 4-27: Examples of Vertical Fillet Welds 2. Vertical Down The Ferrocraft 21 electrode makes welding in this position particularly easy. Use a 3.2mm electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag.
TRANSMIG 350i, 450i, 550i Art # A-07704 Figure 4-28: Overhead Fillet Weld 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 350i, 450i, 550i Weld Art # A-07706_AC Permanent Upset Contraction with tension Figure 4-30: Parent Metal Contraction Overcoming Distortion Effects There are several methods of minimizing distortion effects. A. Peening This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer. B.
TRANSMIG 350i, 450i, 550i Art # A-07709 Figure 4-33: Examples of Distortion 3 2 1 Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool.
TRANSMIG 350i, 450i, 550i Electrode Selection Chart (Further information on CIGWELD electrodes can be found at the website www.cigweld.com.au.) CIGWELD Electrode Selection Chart Description Diameter Pack Part No. 2.5mm 2.5mm 3.2mm 3.2mm 4.0mm 2.0mm 2.0mm 2.5mm 2.5mm 3.2mm 3.2mm 4.0mm 2.0mm 2.0mm 2.5mm 2.5mm 2.5mm 3.2mm 3.2mm 3.2mm 4.0mm 2.5mm 2.5mm 3.2mm 3.2mm 4.0mm 2.5mm 3.2mm 4.0mm 2.5mm 3.2mm 4.0mm 2.0mm 2.5mm 3.2mm 2.5/3.2mm 4.0mm 2.5mm 3.2mm 2.5/3.2mm 4.0mm 1kg 2.5kg 1kg 2.5kg 5kg 1kg 2.
TRANSMIG 350i, 450i, 550i 4.04 Stick (MMAW) Welding Troubleshooting FAULT 1 Welding current varying CAUSE REMEDY ARC FORCE control knob is set at a value that causes the welding current to vary excessively with the arc length. A Welding current too low 2 A gap is left by failure of the weld B Electrode too large for metal to fill the joint. root of the weld. C Insufficient gap.
TRANSMIG 350i, 450i, 550i 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 350i, 450i, 550i 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 350i, 450i, 550i 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 350i, 450i, 550i Base Metal Thickness DC Current DC Current for Mild for Stainless Steel Steel Tungsten Electrode Diameter Filler Rod Diameter (if required) Argon Gas Flow Rate Litres/min Joint Type 0.040” 1.0mm 35-45 40-50 20-30 25-35 0.040” 1.0mm 1/16” 1.6mm 5-7 Butt/Corner Lap/Fillet 0.045” 1.2mm 45-55 50-60 30-45 35-50 0.040” 1.0mm 1/16” 1.6mm 5-7 Butt/Corner Lap/Fillet 1/16” 1.6mm 60-70 70-90 40-60 50-70 1/16” 1.6mm 1/16” 1.6mm 7 Butt/Corner Lap/Fillet 1/8” 3.
TRANSMIG 350i, 450i, 550i 4.06 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive beard 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.
TRANSMIG 350i, 450i, 550i 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 350i, 450i, 550i BASIC WELDING GUIDE 4-28 Manual 0-5205
TRANSMIG 350i, 450i, 550i SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source / Wirefeeder Problems FAULT 1 Mains supply voltage is ON, power indicator is illuminated however unit will not commence welding when the torch trigger switch is depressed. 2 Mains supply voltage is ON. Indicator light is not lit and welding arc cannot be established. 3 Fault Indicator is illuminated and unit will not commence welding when the torch trigger switch is depressed.
TRANSMIG 350i, 450i, 550i 5.02 Routine Service and Calibration Requirements ! WARNING There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do not attempt to open or repair unless you are an accredited CIGWELD Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.
TRANSMIG 350i, 450i, 550i Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying Cigweld welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below 1. For outlets/wiring and associated accessories supplying transportable equipment - at least once every 3 months; and 2. For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12 months. D.
TRANSMIG 350i, 450i, 550i B. Calibration Requirements Where applicable, the tests outlined in Table 6-3 below shall be conducted by an accredited CIGWELD service agent.
TRANSMIG 350i, 450i, 550i SECTION 6: KEY SPARE PARTS 6.
TRANSMIG 350i, 450i, 550i A-10643_AB Item 12 13 14 14 15 15 16 17 18 19 20 21 22 23 Part Number W7005219 W7005201 W7005203 W7005228 W7005204 W7005229 W7005220 W7005221 W7005222 W7005223 W7005224 W7005225 W7005226 W7005227 Description Sensor, Hall Effect (all models) PCB, IGBT driver (all models) PCB, IGBT snubber (all models) except 350i Power Source Part No. W1005359 PCB, IGBT snubber 350i Power Source Part No. W1005359 PCB, current transformer (all models)except 350i Power Source Part No.
TRANSMIG 350i, 450i,550i SECTION 7: Volt/ampERE curves 7.
TRANSMIG 350i, 450i, 550i VOLT/AMP CURVES 7-2 Manual 0-5205
E L3 L2 FAN 230VAC CB1 CB1 8-1 TS1 RLY1 CB2 EMC FILTER C13 1 2T3 1 2 3T2 6 26V 5 9 34V 8 34V 7 4 42V 3 9 19V 8 19V 7 13 10V 12 6 19V 5 19V 4 B A 1X1-9 1X1-8 1X1-6 & 7 1X1-1 & 2 1X1-4 & 5 1X3-1 1X3-3 1X3-4 1X3-5 1X13-3 1X13-2 1X13-1 2X1-2 2X1-3 2X1-1 G1 E1 NEGATIVE R1 C2 C3 G3 E3 IGBT DRIVE W7005202 E2 G2 G4 E4 20UF 20UF W7005201 R2 E1 G1 X4-E X4-S X4-F MAIN CONTROL BOARD G2 E2 4 X 20UF C1 RA1 2X2-3 1X11-2 INPUT RECTIFIER 2X2-4
TRANSMIG 350i, 450i, 550i CIRCUIT DIAGRAM 8-1 Manual 0-52052
CIGWELD - LIMITED WARRANTY TERMS LIMITED WARRANTY: CIGWELD Pty Ltd, A Victor Technologies 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 2011 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 2011 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 Victor Technologies 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@cigweld.com.au www.cigweld.com.
