2RT TRANSMIG WIRE FEEDER Operating Manual Revision: AA Issue Date: October 25, 2011 Manual No.
WE APPRECIATE YOUR BUSINESS! Congratulations on your new Cigweld product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call +1300 654 674, or visit us on the web at www.thermadyne.
! 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. Operating Manual Number 0-5196 for: Cigweld Transmig 2RT Wirefeeder Part Number W3000500 Published by: Thermadyne Industries, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermadyne.
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 6: KEY SPARE PARTS........................................................................... 6-1 6.01 2RT Wire Feeder replacement parts................................................................. 6-1 APPENDIX 1: OPTIONS AND ACCESSORIES............................................................. A-1 APPENDIX 2: 2RT WIRING SCHEMATIC.................................................................. A-2 CIGWELD LIMITED WARRANTY..................................................
TRANSMIG 2RT 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 2RT 2. Wear approved safety glasses. Side shields recommended. 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING ARC RAYS can burn eyes and skin; NOISE can damage hearing. 4. Wear protective clothing made from durable, flameresistant material (wool and leather) and foot protection. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin.
TRANSMIG 2RT 2. Do not weld where flying sparks can strike flammable material. 3. Remove all flammables within 10M of the welding arc. If this is not possible, tightly cover them with approved covers. WARNING FUMES AND GASES can be hazardous to your health. 4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 5.
TRANSMIG 2RT 3. Keep cylinders away from any welding or other electrical circuits. 4. Never allow a welding electrode to touch any cylinder. 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.
TRANSMIG 2RT 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 2RT 1.03 Declaration of Conformity Manufacturer: CIGWELD Address: 71 Gower St, Preston Victoria 3072 Australia Description of equipment: Welding Equipment (GMAW, FCAW, ) including, but not limited to CIGWELD Transmig 2RT wire feeder 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.
INTRODUCTION TRANSMIG 2RT SECTION 2: INTRODUCTION 2.01 How to Use This Manual 2.02 Equipment Identification This Operating Manual usually applies to the part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the word WARNING, CAUTION and NOTE may appear. Pay particular attention to the information provided under these headings.
TRANSMIG 2RT INTRODUCTION 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.
INTRODUCTION TRANSMIG 2RT 2.07 Transportation Methods 2.05 Description The Transmig 2RT Wirefeeder is fully compliant to Standard IEC 60974.5.The Transmig 2RT Wirefeeder when used in conjunction with the Transmig 250i Multi Process Welder provides excellent MIG welding performance across a broad range of applications when used with the correct welding consumables and procedures.
TRANSMIG 2RT INTRODUCTION 2.09 Specifications Description Wirefeeder Plant Part Number Wirefeeder Plant Dimensions Wirefeeder Plant Mass Wire Feed Motor Voltage Gas Solenoid Voltage Transmig 2RT Wirefeeder W3000500 H 453mm x W 238mm x D 553mm 25kg 24 VDC 24 VDC 30% @ 350A 60% @ 250A 100% @ 205A 1.2 MPM 17.
INSTALLATION/SETUP TRANSMIG 2RT 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 IEC 60974.5. 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 2RT equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure. NOTE The welding circuit may or may nor be earthed for safety reasons. Changing the earthing arrangements should only be authorised by a person who is competent to assess whether the changes will increase the risk of injury, e.g.
INSTALLATION/SETUP TRANSMIG 2RT 3.06 2RT Wire Feeder Controls, Indicators and Features 1. Left Knob: WFS (Wire Feed Speed) Control Amperage Control The 2RT Wirefeeder is designed to be used with the Transmig 250i. Select MIG Process and REMT in the Advanced Features menu on the Transmig 250i to enable the controls on the 2RT wirefeeder. See the 250i Operating manual for details. Wirespeed 1 Left Knob 2 3 Left Knob The Left Knob controls the Wirespeed in the wirefeeder.
TRANSMIG 2RT INSTALLATION/SETUP 3. MIG Torch Adaptor (Euro Style) The MIG Torch adaptor is the connection point for the MIG welding Torch. Connect the MIG Torch by pushing the MIG Torch connector into the brass MIG Torch adaptor firmly and screwing the plastic MIG Torch nut clockwise to secure in position. To remove the MIG Torch simply reverse these directions. 4. Remote Control Socket The 8 pin Remote Control Socket is used to connect remote control devices to the 2RT Wirefeeder.
INSTALLATION/SETUP TRANSMIG 2RT 3.07 Transmig 250i Power Source Controls, Indicators and Features NOTE: See Transmig 250i Operator Manual for more information.
TRANSMIG 2RT INSTALLATION/SETUP 5. 2T - 4T Trigger Latch Button CONTINUATION OF 250I POWER SOURCE CONTROLS 1. VRD Indicator ON 6. Advanced Features Button OFF WARNING When the red VRD indicator is on and welding is being performed, the presence of dangerous voltage may be present at the electrode. Gas Purge. 2. Power Indicator The green power indicator will be illuminated when the welder is turned on and indicates the presence of power. 7. Left Knob: Amperage Control (Wirespeed) 3.
INSTALLATION/SETUP TRANSMIG 2RT 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 Left Knob (Control No 7). 10. Right Digital Display CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal. 15.
TRANSMIG 2RT INSTALLATION/SETUP 3.09 Wire Feeder Set Up MIG (GMAW) Welding with Gas Shielded MIG Wire The Transmig 250i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Torch that can be used with the 2RT Wire Feeder. The Fusion MIG Torch is designed with an ergonomic handle and fewer parts to cause performance problems. The Fusion MIG Torch uses standard readily available Tweco Fusion consumable parts.
INSTALLATION/SETUP TRANSMIG 2RT 3.10 Wire Feeder Set-up for MIG (FCAW) Welding with Gasless MIG Wire The Transmig 250i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Torch that can be used with the 2RT Wire Feeder. The Fusion MIG Torch is designed with an ergonomic handle and fewer parts to cause performance problems. The Fusion MIG Torch uses standard readily available Tweco Fusion consumable parts.
TRANSMIG 2RT INSTALLATION/SETUP 3.11 Attaching the Tweco Professional MIG Torch (Euro) 1. Align the pins on the MIG Torch Cable with the pin holes of the MIG Torch receptacle on the front of the system. Press the MIG Torch in and secure by turning the locking ring to the right (clockwise). Refer to Figure 3-8. Attach MIG Torch. Turn locking ring to the right Art # A-10398 Figure 3-8: Mount MIG Torch Cable to Adapter Socket 2.
INSTALLATION/SETUP TRANSMIG 2RT 3.12 Installing a Handi Spool (200mm diameter) In order to fit a Handi Spool (200mm diameter) assemble parts in the sequence shown in Figure 3-9. Installation of wire spool. 1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull . 2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool rotates counter clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool. 3.
TRANSMIG 2RT INSTALLATION/SETUP 3.13 Installing a Standard Spool (300mm diameter) As delivered from the factory, the unit is set for a 15 kg or 300mm spool. Installation of wire spool. Refer to Figure 3-10. 1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull . 2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool rotates counter clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool.
INSTALLATION/SETUP TRANSMIG 2RT 3.14 Inserting Wire into the Feed Mechanism WARNING ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power source before proceeding. Do not reattach the input power until told to do so in these instructions. 1. Loosen the Spring Pressure Adjusting Knob if needed and swing it down (First part of Figure. 3-11) 2. Move the Pressure (top) Roller Arm by swinging it to the right. (Second part of Figure. 3-11) 3.
TRANSMIG 2RT INSTALLATION/SETUP 3.15 Feed Roller Pressure Adjustment NOTE Before attempting to set the drive roller pressure you must select GMAW mode on the front panel. See Transmig 250i manual Section 3 for information on how to select this feature. Once selected it will allow the activation of the drive roll when the trigger on the MIG Torch is activated. The roller on the swing arm applies pressure to the grooved roller via an adjustable tension devise.
INSTALLATION/SETUP TRANSMIG 2RT NOTE 3.17 Changing the Feed Roll Installation of all styles of feed rolls for the Transmig 250i are identical. NOTE Feedrolls often come with a rust prohibitive coating that needs to be cleaned off before installation. A Feedroll consists of two different sized grooves. As delivered from the factory the drive roll is installed for 0.9mm / 1.2mm. The stamped marking on the feedroll refers to the groove furthest from the stamped marking.
TRANSMIG 2RT INSTALLATION/SETUP Input Guide Lockscrew Output Guide Lockscrew MIG Torch Adapter Lock Bolt Art # A-10346_AB Input Wire Guide Output Wire Guide Figure 3-15: Wire Guide Installation 3.19 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 tri-lobe nut inside the open end of the wire reel hub. Clockwise rotation will tighten the brake.
INSTALLATION/SETUP TRANSMIG 2RT 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. NOTE Correct adjustment will result in the wire reel circumference continuing no further than 20mm after release of the MIG Torch trigger switch. The wire should be slack without becoming dislodged from the reel. 5. OPEN the cylinder valve SLOWLY. Close after use.
TRANSMIG 2RT INSTALLATION/SETUP NOTE All valves downstream of the regulator must be opened to obtain a true flow rate reading on the outlet gauge. (Welding power source must be triggered) Close the valves after the pressure has been set. 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.
INSTALLATION/SETUP TRANSMIG 2RT Adjusting Flow Rate Art: A-05088_AB Figure 3-19: Adjust Flow Rate With the regulator ready for operation, adjust working flow rate as follows: 1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate. NOTE It may be necessary to re-check the shielding gas regulator flow rate following the first weld sequence due to back pressure present within shielding gas hose assembly. 2.
TRANSMIG 2RT INSTALLATION/SETUP Notes INSTALLATION/SETUP 3-20 Manual 0-5196
BASIC WELDING TRANSMIG 2RT SECTION 4: BASIC WELDING GUIDE Shielding Gas (Optional) Molten Metal Slag 4.01 MIG (GMAW/FCAW) Basic Welding Technique GAS METAL ARC WELDING (GMAW): This process, also known as MIG welding, CO2 welding, Micro Wire Welding, short arc welding, dip transfer welding, wire welding etc., is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a solid continuous, consumable electrode and the work.
TRANSMIG 2RT BASIC WELDING Travel Speed The speed at which the molten pool travels influences the width of the weld and penetration of the welding run. MIG Welding (GMAW) Variables Most of the welding done by all processes is on carbon steel. The items below describe the welding variables in short-arc welding of 0.6mm to 6.4mm mild sheet or plate. The applied techniques and end results in the GMAW process are controlled by these variables.
BASIC WELDING TRANSMIG 2RT Establishing the Arc and Making Weld Beads Gas Nozzle 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. Contact Tip (Tube) Tip to Work Distance Electrode Wire Actual Stick-out 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.
TRANSMIG 2RT BASIC WELDING Electrode Wire Size Selection The choice of Electrode wire size and shielding gas used depends on the following • Thickness of the metal to be welded • Type of joint • Capacity of the wire feed unit and Power Source • The amount of penetration required • The deposition rate required • The bead profile desired • The position of welding • Cost of the wire 4.
BASIC WELDING TRANSMIG 2RT Problem 2 - Inconsistent Wire Feed ! WARNING Disengage the feed roll when testing for gas flow by ear. 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 unwound 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 2RT BASIC WELDING Basic MIG (GMAW/FCAW) Welding Troubleshooting FAULT 1 Undercut CAUSE REMEDY A Welding arc voltage too high. A Decrease voltage or increase the wire feed speed. B Incorrect MIG Torch angle B Adjust angle. 2 Lack of penetration C Excessive heat input C Increase the MIG Torch travel speed and/or decrease welding current by decreasing the voltage or decreasing the wire feed speed.
PROBLEMS/SERVICE TRANSMIG 2RT SECTION 5: ROUTINE SERVICE REQUIREMENTS 5.01 Cleaning the Welding Power Source Warning! Disconnect input power before maintaining. Maintain more often if used under severe conditions Each Use Visual check of torch Consumable parts Visual check of regulator and pressure Weekly Visually inspect the torch body and consumables Visually inspect the cables and leads.
TRANSMIG 2RT PROBLEMS/SERVICE 5.02 Cleaning the Feed Rolls Clean the grooves in the drive rolls frequently. This can be done by using a small wire brush. Also wipe off, or clean the grooves on the upper feed roll. After cleaning, tighten the feed roll retaining knobs. CAUTION Do not use compressed air to clean the Welding Power Source. Compressed air can force metal particles to lodge between live electrical parts and earthed metal parts within the Welding Power Source.
REPLACEMENT PARTS TRANSMIG 2RT SECTION 6: KEY SPARE PARTS 6.01 2RT WIRE FEEDER REPLACEMENT PARTS Figure 6-1 TRANSMIG 2RT SPARE PARTS (LEFT SIDE) ITEM PART NUMBER 1 W7005311 Spool Hub Assembly 2 W7005353 Wire Drive Assembly, (Does not include motor or feed rolls) 3 W6000900 Guide, Inlet 0.6-1.6mm 4 See Appendix 1 Roll, Pressure No Groove 5 See Appendix 1 Roll, Feed Dual V 6 W6000801 Guide, Outlet 0.9-1.2mm 7 W7005354 Motor, Wire Drive, RH, 20VDC.
TRANSMIG 2RT REPLACEMENT PARTS Notes REPLACEMENT PARTS 6-2 Manual 0-5196
APPENDIX TRANSMIG 2RT APPENDIX 1: OPTIONS AND ACCESSORIES Description Part Number Tweco Professional Fusion 250 MIG Torch, 3.6 metre Euro OTWF212X3035 Tweco 4, 400A MIG torch, 3.6 metre Euro OTWX412/3545 Table A-1: Options and Accessories FLUX CORED HARD (0.6 to 1.0) (0.8,0.9,1.0) FLUX CORED (1.2, 1.6) SOFT (0.9, 1.0, 1.2) Top Drive Roll Bottom Art # A-10349 Drive Roll Figure A-1: Drive Roll Chart Wire Size 0.6mm 0.8mm 0.9mm 1.0mm 1.2mm 0.8mm 0.9mm 1.0mm 1.2mm 1.6mm 0.9mm 1.0mm 1.
TRANSMIG 2RT APPENDIX APPENDIX 2: 2RT WIRING SCHEMATIC Figure A-2: 2RT Wiring Schematic APPENDIX A-2 Manual 0-5196
CIGWELD LIMITED WARRANTY LIMITED WARRANTY: CIGWELD, 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 – APRIL 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 – APRIL 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.
Printed in: U.S.A. 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.
