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Operating Manual
T RANSMIG 210 Compact Power Source
Remote Power Source
T RANSMIG 250 Compact Power Source
Remote Power Source
2R T RANSMIG 210/250 Wirefeeder
T RANSMIG 310 Compact Power Source
T RANSMIG 330 Remote Power Source
2R T RANSMIG 330 Wirefeeder
MIGTRN0001 Issue 2 14/09/98
704832
704808
704833
704809
704975
704836
705085
704841
OperatingManual Transmig 210, 250, 310, 330
CONTENTS
Page
1.1 Duty Cycle................................................................................................................................................ 7
2.1 Transmig 210 and Transmig 250 Specifications......................................................................................... 8
2.2 Transmig 310 and Transmig 330 Specifications......................................................................................... 9
2.3 MIG Torch Specifications ......................................................................................................................... 9
2.4 Wirefeeder Specifications ........................................................................................................................ 10
2.5 Plant Contents......................................................................................................................................... 10
2.6 Optional Accessories............................................................................................................................... 11
3.1 Environment............................................................................................................................................ 12
3.2 Location.................................................................................................................................................. 12
3.3 Ventilation .............................................................................................................................................. 12
3.4 Mains Supply Voltage Requirements ....................................................................................................... 12
3.5 Alternative Mains Supply Voltage Requirements ..................................................................................... 13
5. SET UP FOR REMOTE TRANSMIG WITH WIREFEEDER ......................................... 15
5.1 Power Source Connections ...................................................................................................................... 15
5.2 Wirefeeder Connections........................................................................................................................... 15
6.1 Indicator Light ........................................................................................................................................ 16
6.2 Standby/Coarse Voltage Control Switch and Fine Voltage Control Switch ............................................... 16
6.3 Digital Ammeter and Voltmeter (Standard for Transmig 330 Only) .......................................................... 17
6.4 Torch Polarity Lead (Compact Models Only)........................................................................................... 17
6.5 Positive and Negative Welding Terminals ................................................................................................ 17
6.6 Wirefeeder Control Socket (Remote Wirefeeder Models Only) ................................................................. 17
6.7 Thermal Overload ................................................................................................................................... 17
6.8 Choice of Inductance Setting (Transmig 210 & 250 Only) ....................................................................... 18
6.9 Wirespeed Control (Compact Models & 2R Wirefeeder Only).................................................................. 18
6.10 Spot Timer (Compact Models & 2R Wirefeeder Only)........................................................................... 18
6.11 Dwell Timer (Compact Models & 2R Wirefeeder Only)......................................................................... 18
6.12 Mode Selector Switch (Compact Models & 2R Wirefeeder Only)........................................................... 18
6.13 Burnback Control (Compact Models & 2R Wirefeeder Only)................................................................. 18
6.14 Wirefeeder Driver Roller Pressure Adjustment (Compact Models & 2R Wirefeeder Only) ...................... 19
6.15 Wire Reel Brake (Compact Models & 2R Wirefeeder Only)................................................................... 19
7.1 Introduction ............................................................................................................................................ 19
7.2 Torch Consumable Parts ......................................................................................................................... 19
DOC No: MIGTRN0001 Page 1 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 33
CONTENTS
Page
7.3 MIG Torch Components ......................................................................................................................... 21
7.4 Installing A New Conduit Liner............................................................................................................... 22
7.5 MIG Torch Maintenance ......................................................................................................................... 22
8.1 Setting of the Power Source & Wirefeeder............................................................................................... 23
8.2 Position of MIG Torch ............................................................................................................................ 23
8.3 Distance from the MIG Torch Nozzle to the Work Piece.......................................................................... 23
8.4 Travel Speed........................................................................................................................................... 23
8.5 Stitch Welding Operation ........................................................................................................................ 23
8.6 Spot Welding Operation .......................................................................................................................... 24
9.1 Improved Current Accuracy Calibration Procedure for the Digital Meter.................................................. 25
10.1 Solving Problems Beyond the Welding Terminals .................................................................................. 26
10.2 Welding Problems ................................................................................................................................. 28
10.3 Power Source Problems......................................................................................................................... 29
10.4 Key Spare Parts .................................................................................................................................... 31
Page 2 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330
CONTENTS
Page
TABLES
DOC No: MIGTRN0001 Page 5 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330
FIGURES
Page
Page 6 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330
1. INTRODUCTION
The Transmig 210, 250, 310 and 330 are semi-automatic Gas Metal Arc Welder (GMAW-commonly
MIG) with either integrated or separate wire feed unit. These products are designed to meet the broad operating needs of the metal fabrication industry where production efficiency is vital. They are designed and manufactured in Australia to Australian Standard AS1966.1-1985.
The Transmig range gives excellent performance on mild steel, stainless steel, aluminium, silicon bronze and some hard facing wires with the Argon based of shielding gases. The Transmig range also gives excellent results on mild steel using CO
2
(carbon dioxide) shielding gas.
The Transmig Plants are supplied as a complete welding package (apart from gas cylinder and electrode wire). The following instructions detail how to correctly set up your new Transmig and give guidelines on gaining the best production efficiency. Please read these instructions thoroughly before using your
Transmig.
1.1 Duty Cycle
The rated duty cycle of a welding Power
Source is the operating time it may be used at its rated output current without exceeding the temperature limits of the insulation of the component parts. In
Australia a duty cycle period of 5 minutes is specified in Australian
Standard AS 1966
Part 1-1985. To explain the 5 minute
100
90
80
70
60
50
40
30
20
10
0
Safe
Operating
Region
Welding Current (amp)
Figure 1 - Transmig duty cycle curves duty cycle period the following example is used. Suppose a welding Power Source is designed to operate at 30% duty cycle, 250 amperes at 26 volts. This means that it has been designed and built to provide the rated amperage (250A) at the rated voltage (26V), for 1.5 minutes out of every 5 minute period (30% of 5 minutes is 1.5 minutes). During the other 3.5 minutes of the 5 minute period the Power Source must idle and be allowed to cool. The thermal cut-out will operate if the duty cycle is exceeded.
CAUTION 1: The above times are not accumulative.
DOC No: MIGTRN0001 Page 7 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330
2. SPECIFICATIONS
2.1 Transmig 210 and Transmig 250 Specifications
Transmig 210 Transmig 250
Compact Remote Compact Remote
Plant Assembly part number 704830 704831 704833 704834
Plant Mass 77Kg 107Kg 78Kg 108Kg
Plant Dimensions 860mm x 490mm x 845mm 860mm x 490mm x 845mm
Power Source part number 704832 704808 704835 704809
Power Source Mass 60Kg 58.5Kg 61Kg 59.5Kg
Power Source Dimensions 640 x 310 x 732 640 x 310 x 732
Number of Phases Single Phase Single Phase
Frequency 50 / 60 Hz 50 / 60 Hz
Open Circuit Voltage Range 18.9 to 34.2V 19 to 43V
Output Current Range 25 to 210A 30 to 250A
Rated Output for 15A Outlet at 240V
210A @ 25%
148A @ 50%
105A @ 100%
184A @ 25%
130A @ 50%
92A @ 100%
µ Rated Output for 20A Outlet at 240V
210A @ 36%
164A @ 60%
127A @ 100%
¾
Ù Rated Output for 25A Outlet at 240V ¾
250A @ 25%
180A @ 50%
127A @ 100%
Duty Cycle Period 5 minutes or 10 minutes 5 minutes or 10 minutes
Number of Output Voltage Values 16 16
Wire Size Range 0.6 - 0.9 Hard / 0.9 - 1.2 Soft 0.6 - 0.9 Hard / 0.9 - 1.2 Soft
Operating Temperature Range 0°C to 40°C 0°C to 40°C
Primary input voltage 200V 220V 240V 200V 220V 240V
Ñ Rated Input Current (output of 127A) 25A 23A 21A 30A 27A 25A
Rated kVA (output of 127A) 5kVA 5kVA 5kVA 6kVA 6kVA 6kVA
Maximum Input Current 42A 38A 35A 52A 47A 43A
Generator Requirements 8.5kVA 8.5kVA 8.5kVA 10kVA 10kVA 10kVA
Rated Outlet @ Max Duty Cycle 25A 23A 20A 30A 27A 25A
ª Fuse Size @ Max Duty Cycle 50A 50A 40A 60A 60A 50A
Ñ The Rated Input Current should be used for the determination of cable size & supply requirements.
ª Motor start fuses or motor start thermal circuit breakers are recommended for this application.
Australian Standard AS3000 (Clause 2.4.3.4) permits the use of a fuse or circuit breaker rated at two times the rated input current.
µ To achieve this rating, the 15 Amp plug and primary supply lead (as supplied) must be replaced with a 20 Amp plug & lead. This must be carried out by a qualified electrical tradesperson.
Page 8 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330
Ù To achieve this rating, the 15 Amp plug and primary supply lead (as supplied) must be replaced with a 25 Amp plug & lead. This must be carried out by a qualified electrical tradesperson.
2.2 Transmig 310 and Transmig 330 Specifications
Transmig 310 Transmig 330
Plant Assembly part number 704836 704839
Plant Mass 87Kg 117Kg
Plant Dimensions 860mm x 490mm x 845mm 860mm x 490mm x 845mm
Power Source part number 704838 705085
Power Source Mass 71Kg 70Kg
Power Source Dimensions 640 x 310 x 732 640 x 310 x 732
Number of Phases Three Phase Three Phase
Frequency 50 / 60 Hz 50 / 60 Hz
Open Circuit Voltage Range 17.5 to 41.2V 17.5 to 41.2V
Output Current Range 25 to 310A 25 to 330A
Rated Output Duty Cycle
310A @ 30%
220A @ 60%
170A @ 100%
330A @ 30%
228A @ 60%
177A @ 100%
Duty Cycle Period 5 minutes or 10 minutes 5 minutes or 10 minutes
Number of Output Voltage Values 24 24
Wire Size Range 0.6 - 1.2 Hard / 0.9 - 1.2 Soft 0.6 - 1.2 Hard / 0.9 - 1.2 Soft
Operating Temperature Range 0°C to 40°C 0°C to 40°C
Primary input voltage 220V 380V 415V 220V 380V 415V
Ñ Rated Input Current for output current at 100% duty cycle.
21A 12A 11A 21A 12A 11A
Rated kVA for output current at
100% duty cycle.
8kVA 8kVA 8kVA 8kVA 8kVA 8kVA
Maximum Input Current 36A 21A 19A 38A 22A 20A
Generator Requirements 13.7kVA 13.7kVA 13.7kVA 14.4kVA 14.4kVA 14.4kVA
Rated Outlet @ Max Duty Cycle 25A 15A 15A 25A 15A 15A
ª Fuse Size @ Max Duty Cycle 50A 30A 20A 50A 30A 20A
Ñ The Rated Input Current should be used for the determination of cable size & supply requirements.
ª Motor start fuses or motor start thermal circuit breakers are recommended for this application.
Australian Standard AS3000 (Clause 2.4.3.4) permits the use of a fuse or circuit breaker rated at two times the rated input current.
2.3 MIG Torch Specifications
Torch Part Number 717578
Torch Type TWECO 250A (Eliminator Consumables)
Torch Cable Length 3.6 metre
DOC No: MIGTRN0001 Page 9 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330
2.4 Wirefeeder Specifications
Wirefeeder
704975
(Transmig 210 & 250 Remote)
704841
(Transmig 330)
Mass 21Kg 23Kg
Dimensions 600 x 245 x 475
Motor Supply Voltage 36V AC
Motor Supply VA 180VA
Control Supply Voltage 24V AC
Control Supply VA 30VA
Minimum Wire Speed One metre per minute
Maximum Wire Speed 17 metres per minute
Wire Diameter: Mild Steel 0.6, 0.8, 0.9
Stainless Steel 0.8, 0.9
Aluminium 0.9, 1.0, 1.2
Flux Cored 0.8, 0.9, 1.2
Operating Temperature Range 0°C to 40°C
Wire Spool Size 15Kg Maximum
Spot Time Range 0 to 2.5 Seconds
Stitch ‘ON‘ Time 0 to 2.5 Seconds
Stitch ‘OFF‘ Time 0 to 2.5 Seconds
Burnback Time Range 0 to 0.15 Seconds
2.5 Plant Contents
Transmig 210 Transmig 250 Transmig 310 Transmig 330
Compact Remote Compact Remote Compact Remote
Wheeling Kit
4 4 4 4 4 4
Roll on Cylinder Carrier
4 4 4 4 4 4
Power Source
4 4 4 4 4 4
Operating Instructions
4 4 4 4 4 4
3 Metre Work Lead
8 Metre Work Lead
4
¾
¾
4
4
¾
¾
4
4
¾
¾
4
2R Wirefeeder (8 metre) ¾
4
¾
4
¾
4
Regulator / Flowmeter
4 4 4 4 4 4
TWECO MIG torch 250A
4 4 4 4 4 4
Feed Roller 0.6/0.8 Hard
4 4 4 4 4 4
Feed Roller 0.9/1.2 Hard
4 4 4 4 4 4
Page 10 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330
2.6 Optional Accessories
Part Description Transmig 210 Transmig 250 Transmig 310 Transmig 330
Number Compact Remote Compact Remote Compact Remote
705103 Digital Meter Kit
4 4 4 4 4
Standard
704914 Wirefeeder Swivel Base ¾ 4 ¾ 4 ¾ 4
704913 Wirefeeder Trolley ¾ 4 ¾ 4 ¾ 4
704917 110Volt Aux Supply Kit
4 4 4 4 4 4
ELC2123035 250A Eliminator torch (3.6M)
(fits Transmig adaptor)
4 4 4 4 4 4
ELC4123545 450A Eliminator torch (3.6M)
(fits Transmig adaptor)
4 4 4 4 4 4
704343 Torch trigger lead to suit
Eliminator torch
4 4 4 4 4 4
704099 Work lead (3m)
4 4 4 4 ¾ ¾
705163 Work lead (3m) ¾ ¾ ¾ ¾ 4 4
704829 Work lead (8m)
4 4 4 4 ¾ ¾
704828 Work lead (8m) ¾ ¾ ¾ ¾ 4 4
704912 8 M Interconnection Extension ¾ 4 ¾ 4 ¾ ¾
704465 8 M Interconnection Extension ¾ ¾ ¾ ¾ ¾ 4
717162 TWECO No.2 torch (3.6M)
(adaptor 704915 required)
4 4 4 4 4 4
717201 TWECO No.4 torch (3.6M)
(adaptor 704915 required)
4 4 4 4 4 4
704915 TWECO No.2 & 4 Adaptor
4 4 4 4 4 4
7977036 Feed roll, 0.6/0.8 Hard Wire
4 4 4 4 4 4
7977660 Feed roll, 0.9/1.2 Hard Wire
4 4 4 4 4 4
7977037 Feed roll, 1.0/1.2 Hard Wire
4 4 4 4 4 4
7977731 Feed roll, 0.8/0.9 Soft Wire
4 4 4 4 4 4
7977264 Feed roll, 1.0/1.2 Soft Wire
4 4 4 4 4 4
7977732 Feed roll, 0.8/0.9 Flux cored
4 4 4 4 4 4
704277 Feed roll, 1.0/1.2 Flux cored
4 4 4 4 4 4
ELC94L Eliminator Torch trigger lock
4 4 4 4 4 4
705000 MIG pliers (size No 1)
4 4 4 4 4 4
705001 MIG pliers (size No 2)
4 4 4 4 4 4
646265 Weld measurement gauge
4 4 4 4 4 4
705277 Auxiliary transformer kit
240/36/24V
705278 Auxiliary transformer kit 240-
220-200/36/24V
705126 Auxiliary transformer kit 415-
380-220/36/24V
4 4
¾ ¾
¾ ¾ ¾ ¾
4 4
¾ ¾ ¾ ¾
¾ ¾
4 4
DOC No: MIGTRN0001 Page 11 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330
3. INSTALLATION RECOMMENDATIONS
3.1 Environment
The Transmigs are NOT designed for use in environments with increased hazard of electric shock as defined in AS3195-1990.
a) Examples of environments with increased hazard of electric shock are i) 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; ii) In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator, or iii) In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accessories.
b) Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.
3.2 Location
Be sure to locate the Power Source according to the following guidelines: a) In areas, free from moisture and dust.
b) Ambient temperature 0 ° C to 40 ° C.
c) In areas, free from oil, steam and corrosive gases.
d) In areas, not subjected to abnormal vibration or shock.
e) In areas, not exposed to direct sunlight or rain.
f) Place at a distance of 30cm or more from walls or similar that could restrict natural air flow for cooling.
g) The minimum ground clearance for these products is 140mm.
3.3 Ventilation
Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.
3.4 Mains Supply Voltage Requirements
The Mains supply voltage should be within ± 10% of the rated Mains supply voltage. Too low a voltage may cause poor welding performance or the wirefeeder malfunction. Too high a supply voltage will cause components to overheat and possibly fail.
The Transmig is supplied with an input lead to which an appropriate plug should be fitted.
Install a power outlet for each Power Source and fit fuses as per Transmig 210 and Transmig 250
Specifications or Transmig 310 and Transmig 330 Specifications.
WARNING 1: CIGWELD advises that your Transmig be electrically connected by a qualified electrical tradesperson.
Refer to Table 1 for the ratings of the Mains supply leads that are supplied with the various Transmig
Power Sources.
Page 12 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330
Transmig
Mains
Supply Lead
Size
210 1.5mm
2
250 1.5mm
2
310 1mm
2
330 1mm
2
Lead
Current
Rating
Lead
Length
Machine
Voltage
Setting
Duty Cycle
16 Amps 3 metre 240 Volt 210A @ 25%
16 Amps 3 metre 240 Volt 184A @ 25%
12 Amps 3.7 metre 415/440 Volt 310A @ 30%
12 Amps 3.7 metre 415/440 Volt 330A @ 30%
Table 1 - Factory fitted Mains supply leads fitted to the Transmig Power Sources
CAUTION 2: The Transmig Mains supply leads should be replaced with leads as specified in Table
2 when the Transmigs Mains supply voltage is changed or when it is plugged into a higher rated Mains outlet.
3.5 Alternative Mains Supply Voltage Requirements
The Power Sources are suitable for the following Mains supply voltages:
Mains Supply
Voltage Setting
Mains Supply
Lead Size
Mains
Outlet Size
Fuse Size Machines
Duty Cycle
200 Volt 4mm
2
Export Model
Only
220 Volt 4mm
2
Export Model
Only
Transmig 210 240 Volt 2.5mm
2
200 Volt 6mm
2
Transmig 250 220 Volt 6mm
2
See Figure 2 240 Volt 4mm
2
220 Volt 2.5mm
2
Transmig 310 380 Volt 1.5mm
2
See Figure 3 415/440 Volt 1mm
2
220 Volt 2.5mm
2
Transmig 330 380 Volt 1.5mm
2
See Figure 3 415/440 Volt 1mm
2
25 Amp ª 50 Amp
25 Amp ª 50 Amp 210A @ 36%
20 Amp ª 40 Amp
30 Amp ª 60 Amp
30 Amp ª 60 Amp 250A @ 25%
25 Amp ª 50 Amp
20 Amp ª 40 Amp
15 Amp ª 20 Amp 310A @ 30%
15 Amp ª 20 Amp
20 Amp ª 40 Amp
15 Amp ª 20 Amp 330A @ 30%
15 Amp ª 20 Amp
Table 2 - Mains supply lead sizes for alternative Mains supply voltages
Figure 2 - Voltage settings for Transmig 210/250 Figure 3 - Voltage settings for Transmig 310/330
DOC No: MIGTRN0001 Page 13 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330
4. SET UP FOR COMPACT TRANSMIGS
Refer to Figure 4 for the plant setup of a compact Transmig.
a) Remove all packaging materials.
b) Fit the fixed and swivel wheels to the Power Source.
WARNING 2: To obtain adequate air flow and cooling for the Power Source components, the four wheels must be fitted. Alternatively, the Power Source may be raised
140mm from the floor using supports that do not restrict airflow.
c) Connect the work lead to the negative welding terminal (-) [positive welding terminal (+) for flux cored wire].
d) Connect the TORCH lead to the positive welding terminal (+) [negative welding terminal
(-) for flux cored wire].
e) Position a gas cylinder on the rear tray and lock securely to the Power Source cylinder bracket with the chain provided. If this arrangement is not used then ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright position.
f) Fit the gas Regulator/Flowmeter to the gas cylinder.
g) Connect the gas hose from the rear of the Power
Source to the Flowmeter outlet.
h) Two dual groove feed rollers are supplied as standard with the plant. These can accommodate
0.6, 0.8, 0.9 and 1.2 diameter hard wires. Select the roller required with the chosen wire size marking facing outwards.
i) Fit the electrode wire spool to the wire reel hub located behind the wire compartment door.
Ensure that the drive dog-pin engages the mating hole in the wire spool. Push the 'R' clip into place to retain the wire spool securely. The wire should feed from the bottom of the spool.
j) Fit the TWECO MIG torch to the wire feed unit by releasing the torch locking screw in the brass torch adaptor and pushing in the torch fitting until the plastic torch casing meets the brass adaptor.
Tighten the torch locking screw securely. Also ensure that the adjacent black knurled screw in the
Figure 4 - Compact Transmig Setup wire feeder casting is securely tightened. Remove the contact tip from the torch.
k) Connect the two black torch trigger leads to the torch trigger terminals.
l) Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide, between the rollers, through the outlet guide and into the torch.
m) Lower the pressure lever and with the torch lead reasonably straight, feed the wire through the torch. Fit the appropriate contact tip.
CAUTION 3: The electrode wire will be at welding voltage potential whilst it is being fed through the system.
Page 14 of 31 DOC No: MIGTRN0001
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Transmig 210, 250, 310, 330
5. SET UP FOR REMOTE TRANSMIG WITH WIREFEEDER
Refer to Figure 5 for the plant setup of a remote Transmig with wirefeeder.
5.1 Power Source Connections a) Remove all packaging materials.
b) Fit the fixed and swivel wheels to the Power Source. Refer to WARNING 2.
c) Connect the work lead to the negative welding terminal (-) [positive welding terminal (+) for flux cored wire].
d) Position a gas cylinder on the rear tray and lock securely to the Power Source cylinder bracket with the chain provided. If this arrangement is not used then ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright position.
e) Fit the gas regulator and Flowmeter to the gas cylinder.
5.2 Wirefeeder Connections a) Connect the welding power cable to the positive welding terminal (+) [negative welding terminal (-) for flux cored wire].
b) Connect the control cable to the front of the
Power Source of the Transmig 210 remote or
Transmig 250 remote or Transmig 330.
c) Connect the gas hose from the rear of the wire feeder unit to the Flowmeter outlet.
d) Two dual groove feed rollers are supplied as standard with the plant. These can accommodate 0.6, 0.8, 0.9, 1.0 and 1.2
diameter hard wires. Select the roller required with the chosen wire size marking facing outwards.
e) Fit the electrode wire spool to the wire reel hub located behind the wire compartment door. Ensure that the drive dog-pin engages the mating hole in the wire spool. Push the
'R' clip into place to retain the wire spool securely. The wire should feed from the bottom of the spool.
Figure 5 - Remote Transmig Setup f) Fit the torch to the wire feed unit by releasing the torch locking screw in the brass torch adaptor and pushing in the torch fitting until the plastic torch casing meets the brass adaptor. Tighten the torch locking screw securely. Also ensure that the adjacent black knurled screw in the wire feeder casting is securely tightened. Remove the contact tip from the torch.
g) Connect the torch trigger lead to the torch trigger terminals.
h) Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide, between the rollers, through the outlet guide and into the torch.
i) Lower the pressure lever and with the torch lead reasonably straight, feed the wire through the torch. Fit the appropriate contact tip. Refer to CAUTION 3.
DOC No: MIGTRN0001 Page 15 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330
6. Power Source / 2R Wirefeeder Controls, Indicators and Features
Optional Meter
(standard on the Transmig 330)
Indicator Light
Optional Meter
(standard on the Transmig 330)
Ammeter/Voltmeter
Switch
On/Off & Coarse
Voltage Control Switch
Fine Voltage
Control Switch
Wirespeed Control
Dwell Timer Control
Spot Timer Control
Mode Selector
Switch
Brass Torch Adaptor
Positive Welding
Current Terminal
Indicator Light
On/Off & Coarse
Voltage Control Switch
Fine Voltage
Control Switch
Negative Welding
Current Terminal
Wirefeeder Control
Socket
Positive Welding
Current Terminal
Torch Polarity Lead
Negative Welding
Current Terminal
Figure 6 - Compact Transmig controls Figure 7 - Remote Transmig controls
Wirespeed
Control
Spot Timer
Control
Dwell Timer
Control
Mode Selector
Switch
Brass Torch
Adaptor
Gas Hose
Power Cable
Control Cable
Figure 8 - Wirefeeder controls
6.1 Indicator Light
The indicator light is provided to indicate when the Transmig is connected to the Mains supply voltage.
WARNING 3: When the light is lit, the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential.
6.2 Standby/Coarse Voltage Control Switch and Fine Voltage Control Switch
The Coarse Voltage Control switch turns off the fan and auxiliary power in the STANDBY position.
It sets the voltage level to the welding terminals in the remaining positions, increasing the voltage as it is rotated in the clockwise direction. The Fine Voltage Control switch increases the voltage (in smaller increments than the Coarse switch) as it is rotated in the clockwise direction.
WARNING 4: The Coarse & Fine Voltage Control switches MUST NOT BE SWITCHED during the welding process.
Page 16 of 31 DOC No: MIGTRN0001
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Transmig 210, 250, 310, 330
6.3 Digital Ammeter and Voltmeter (Standard for Transmig 330 Only)
Where fitted an average reading ammeter and voltmeter is provided to allow accurate monitoring
(5% tolerance) of welding current and voltage. Refer to section 9.1 on page 25 for the Improved
Current Accuracy Calibration Procedure for the Digital Meter.
The Digital Meter will display both welding current and voltage. To toggle between the current and voltage readings depress the push button switch mounted below the meters display. See Figure 9 for an example of current and voltage displays.
Value displayed for 157 Amp Value displayed for 23.4 Volts
Figure 9 - Examples of the digital read outs
6.4 Torch Polarity Lead (Compact Models Only)
This lead selects the welding voltage polarity of the electrode wire. Plug it into the positive welding terminal ( + ) when using steel, stainless steel or aluminium electrode wire. Plug the Torch Polarity
Lead into the negative welding terminal ( - ) when using gasless electrode wire. If in doubt, consult the manufacturer of the electrode wire for the correct polarity.
6.5 Positive and Negative Welding Terminals
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.
WARNING 5: Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.
6.6 Wirefeeder Control Socket (Remote Wirefeeder Models Only)
This socket accepts the male plug on the control cable from the Wirefeeder. The male plug should be fully inserted into the control socket then locked into position by turning the retaining ring on the male plug in a clockwise direction.
6.7 Thermal Overload
The critical component for thermal protection is the rectifier stack, which is fitted with a thermal overload cutout device. If the overload operates then the machine should be left to cool for approximately 15 minutes before resuming welding. There will be no danger of transformer damage if the Power Source is operated within its duty cycle, refer to section 1.1 for an explain of duty cycle and section 2 for the Power Source specifications.
DOC No: MIGTRN0001 Page 17 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330
6.8 Choice of Inductance Setting (Transmig 210 & 250 Only)
The Transmig 210 & 250 have two inductance taps. These inductance terminals are the positive welding terminals. Inductance selection can effect the spatter level and penetration characteristics of the weld. The correct choice depends upon the shielding gas, transfer mode and the material type.
High Inductance Symbol
Used for:
1. CO
2
shielded welding.
2. Dip transfer with Æ 1.2mm wires (CO
2
or mixed gas).
3. Gives a hotter weld in DIP transfer.
Low Inductance Symbol
Used for:
1. Spray transfer
2. Aluminium and Flux Cored wires.
3. Gives a cooler weld in DIP transfer.
CAUTION 4: If in doubt, use the high inductance setting.
6.9 Wirespeed Control (Compact Models & 2R Wirefeeder Only)
The Wirespeed Control knob controls the welding current via the electrode wire feed rate. ie the speed of the wire feed motor.
6.10 Spot Timer (Compact Models & 2R Wirefeeder Only)
With the MODE SELECTOR switch is switched to the SPOT position, the SPOT TIME knob controls the duration of a single spot weld.
With the MODE SELECTOR switch is switched to the STITCH position, the SPOT TIME knob controls the welding or 'ON' time whilst stitch welding.
6.11 Dwell Timer (Compact Models & 2R Wirefeeder Only)
The DWELL TIME knob controls the interval or 'OFF' time whilst stitch welding.
6.12 Mode Selector Switch (Compact Models & 2R Wirefeeder Only)
The Mode Selector switch selects the method of welding mode.
a) SPOT This mode of welding is used to weld two plates together at a desired location by melting the top & bottom plates together to form a nugget between them. The spot time period is set by the SPOT TIME control knob. Refer to CAUTION 5.
CAUTION 5: A spot nozzle (P/N EL22I62FAS) should be used on the MIG torch to obtain consistent spot welds.
b) CONTINUOUS This mode of welding is used to weld two or more components together with a continuous weld.
c) STITCH This mode of welding is used to weld two or more components together with a stitch weld. The SPOT TIME knob controls the welding or 'ON' time whilst the DWELL TIME knob controls the interval or 'OFF' time for stitch welding.
6.13 Burnback Control (Compact Models & 2R Wirefeeder Only)
The amount of electrode wire that is burnt back out of the weld pool, when the torch trigger switch is released, can be adjusted by the potentiometer shaft that is located inside the wire spool cavity compartment above the wire feed motor.
Page 18 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330
6.14 Wirefeeder Driver Roller Pressure Adjustment (Compact Models & 2R
Wirefeeder Only)
The moveable roller applies pressure to the grooved roller via screw adjustable spring pressure. The adjustable spring screw should be adjusted to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn-back jam, the correct feed roll groove size is used, the feed roll groove is not worn, the conduit liner should be checked for kinks and clogging by metal flakes and swarf. If this is not the cause of slipping, the feedroll pressure can be increased by rotating the adjustable spring screw clockwise. Excessive pressure may cause rapid wear of the feed roller, motor shaft and motor bearings. Refer to CAUTION 7.
6.15 Wire Reel Brake (Compact Models & 2R Wirefeeder Only)
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 large nut inside the open end of the wire reel hub. Clockwise rotation will tighten the brake. Correct adjustment will result in the reel circumference continuing no further than 20mm after release of the Torch trigger switch. The electrode wire should be slack without becoming dislodged from the reel.
CAUTION 6: Excessive tension on the brake will cause rapid wear of mechanical wire feed parts, overheating of electrical componentry and possibly an increased incidence of wire Burnback into the contact tip.
7. TWECO MIG TORCH (P/N 717578 where supplied)
7.1 Introduction
The TWECO 250A gun fitted to the Transmig offers robust construction, unparalleled reliability and easy replacement of consumable parts. The TWECO 250A has an operating capacity in excess of the capacity of the Transmigs and can be expected to give trouble free service.
TWECO MIG Torches may be fitted to many different types of MIG welding plants so that your whole shop can be converted to TWECO. Not only will this give greater reliability (and hence greater productivity), but it will reduce stockholdings of consumable parts. See your CIGWELD distributor for details.
CAUTION 7: Genuine TWECO contact tips and lines should be used. Many non-genuine liners use inferior materials which can cause wire feed problems.
7.2 Torch Consumable Parts
NOTE 1: * denotes parts that are supplied as standard with MIG torch 717578.
a) Gas Diffusers
Part No. Part No.
* EL52 (slide on nozzles) EL52CT (screw on nozzles)
Table 3 - MIG torch gas diffusers
DOC No: MIGTRN0001 Page 19 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330 b) Contact Tips
STANDARD TAPERED
Wire Size
(mm)
Part No. Wire Size (mm) Part No.
0.6 not available 0.6 EL16T23
0.8 EL1630 0.8 EL16T30
0.9 * EL1635 0.9 EL16T35
1.0 EL1640 1.0 EL16T40
1.2 EL1645 1.2 EL16T45
1.2 Alum EL16A364 1.2 Alum EL16AT364
Table 4 - MIG torch contact tips c) Nozzles
Bore Size
(mm)
Part No. Bore Size (mm) Part No.
9.5 EL22A37 9.5 EL22CT37
9.5 EL22A37F 9.5 EL22CT37F
12.7 EL22A50 12.7 EL22CT50
12.7 EL22A50F 12.7 EL22CT50F
12.7 EL22I50P 12.7 EL22CT50P
15.9 EL22A62 15.9 EL22CT62
15.9 EL22A62F 15.9 EL22CT62F
15.9 * EL22I62P 15.9 EL22CT62P
19.1 EL22A75 19.1 EL22CT75
19.1 EL22A75F 19.1 EL22CT75F
15.9 EL22I62FAS (Spot Nozzle) CT = Coarse Thread
F = Flush Tip
Table 5 - MIG torch nozzles
P=Protruding Tip d) Conduit liners
HARD ELECTRODE WIRE SOFT ELECTRODE WIRE
Wire Size Part No. Wire Size (mm) Part No.
0.6 OTW42/23 0.6 Alum not available
0.8 OTW42/3035 0.8 Alum not available
0.9 * OTW42/3035 0.9 Alum OTW42N/3545
1.0 OTW42/4045 or OTW44/3545 1.0 Alum or
1.2 OTW42/4045 or OTW44/3545 1.2 Alum OTW44N/3545
Table 6 - MIG torch conduit liners
Page 20 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330
7.3 MIG Torch Components
Refer to Figure 10 for a pictorial representation of the components listed in Table 7.
5
6
22 23
8 9
4
3
7
2
1
14
13
10
11
12
18 17 15
Figure 10 - Exploded view of MIG torch
Item Part No. Description Qty
1 ¾ Nozzle (refer to Table 5 ) 1
2 ¾ Contact tip (refer to Table 4 ) 1
3 ¾ Gas diffuser (refer to Table 3 ) 1
4 WM6345 Conductor tube 1
5 OTW45B O-Ring, Gun Handle 1
6 OTW90721H Handle kit (includes items 7, 22 & 23) 1
7 Insert & screw (refer to item 6) 2
8 n/a Handle cap 1
9 n/a Support 1
10 ELC94 Trigger Lever 1
11 ELC94B Trigger blades 1
12 ¾ Butt Splice (insulated crimp link 1.5mm
2
) 2
13 ELC1042 Cap screw 1
14 OTW9072110 Cable assembly 1
15 OTW224 O-Ring, Connector Plug 2
16 OTW44C Set screw 8/32 UNC 1
17 OTW350174 Connector plug 1
18 ¾ Conduit liner (refer to Table 6 ) 1
22 ¾ Gun hanger (refer to item 6) 1
23 ¾ Hanger screw (refer to item 6) 1
24 ELC94L Locking Trigger (not shown) (option)
Table 7 - MIG Torch components
DOC No: MIGTRN0001 Page 21 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330
7.4 Installing A New Conduit Liner a) Be sure the MIG Torch cable is arranged in a straight line, free from twists, when installing or removing a conduit liner. Remove the old conduit liner by first removing the MIG
Torches nozzle, contact tip and gas diffuser. Then loosen set screws (8/32 UNC) in the conductor tube and connector plug and pull the old conduit liner out of the cable assembly from the connector plug end.
b) To install a new conduit liner, first inspect the o-ring gas seal on the conduit liner for cuts or damage. Start from the connector plug end of the assembly and begin pushing the conduit liner through the connector plug, cable assembly and into the gun. If the conduit liner should lodge along the way, gently whip or work the cable assembly to aid forward movement.
c) When the conduit liner stop meets the end of the connector plug and the new raw end extends through the end to the conductor tube, the Allen screw in the connector plug must be securely tightened onto the conduit liner to prevent its backward movement.
IMPORTANT 1: When the conduit liner is fully inserted into the cable assembly and the conduit liner stop is firmly against the Connector Plug, the "raw end" of the conduit liner will protrude out of the open end of the gun conductor tube. Trim the conduit liner as shown in Figure 11. The trimmed end which seats in the Gas
Diffuser must be filed and reamed smooth on the inside and outside radii so the electrode wire will not be obstructed.
d) Replace Gas Diffuser, Contact Tip, and Nozzle.
e) Tighten the Allen screw in the conductor tube.
WARNING 6: Do not over tighten the conductor tube screw as this action will result in the distortion of the conduit liner and will lead to wire feedability problems.
Conductor tube
Conduit
34 mm
(1.34")
Figure 11 - Conduit liner trim length
7.5 MIG Torch Maintenance
Remove dust and metallic particles from the torch conduit liner by forcing clean, dry compressed air into the conduit liner once a week. This will minimise wire feeding problems.
Page 22 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330
8. BASIC WELDING TECHNIQUE
8.1 Setting of the Power Source & Wirefeeder
The setting of the Transmig requires some practice by the operator, the welding plant having two control settings that have to balance. These are the Wirespeed control and the welding Voltage
Control switches. The welding current is determined by the Wirespeed control, the current will increase with increased Wirespeed, resulting in a shorter arc. Less wire speed will reduce the current and lengthen the arc. Increasing the welding voltage hardly alters the current level, but lengthens the arc. By decreasing the voltage, a shorter arc is obtained with a little change in current level.
When changing to a different electrode wire diameter, different control settings are required. A thinner electrode wire needs more Wirespeed to achieve the same current level.
A satisfactory weld cannot be obtained if the Wirespeed and Voltage control switch settings are not adjusted to suit the electrode wire diameter and the dimensions of the work piece.
If the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If, however, the welding voltage is too high, large drops will form on the end of the wire, causing spatter. The correct setting of voltage and Wirespeed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound.
8.2 Position of MIG Torch
The angle of MIG torch to the weld has an effect on the width of the weld run. Refer to Figure 12.
8.3 Distance from the MIG Torch Nozzle to the Work
Piece
Figure 12 - MIG Torch angle
The electrode wire stick out from the MIG Torch nozzle should be between 2.0mm to 5.0mm. This distance may vary depending on the type of joint that is being welded.
8.4 Travel Speed
Speed at which a weld travels influences the width of the weld and penetration of the welding run.
8.5 Stitch Welding Operation
Stitch welding is normally used to bridge excessive gaps between panels or when welding very thin material to prevent heat build up and distortion. Set the controls as follows for stitch welding: a) Coarse & Fine Voltage Control Switches and Wirespeed Control
Set these controls to obtain the desired welding conditions for the wire and material being welded.
b) Mode Selector Switch
Set the MODE SELECTOR switch to STITCH. c) Spot Time
Adjust the SPOT TIME control knob for the desired weld or 'ON' time whilst stitch welding.
d) Dwell Time
Adjust the DWELL TIME control knob for the desired interval or 'OFF' time whilst stitch welding.
DOC No: MIGTRN0001 Page 23 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330
8.6 Spot Welding Operation
Fit a spot welding nozzle to the MIG Torch for consistent spot welding operations. The Transmigs will operate effectively using 0.8mm electrode wire when spot welding. Penetration depth is limited when using 0.6mm electrode wire for spot welding. Set the controls as follows for spot welding: a) Coarse & Fine Voltage Control Switches and Wirespeed Control
Select higher Voltage Control switch positions and set the Wirespeed Control between 9 to 15 m/min for maximum penetration.
b) Mode Selector Switch
Set the MODE SELECTOR switch to SPOT. c) Spot Time
Adjust the SPOT TIME control knob for the desired weld or 'ON' time for spot welding.
d) Dwell Time
The DWELL TIME control knob has no affect in this mode of operation.
9. ROUTINE MAINTENANCE & INSPECTION
The only routine maintenance required for the Transmig is a thorough cleaning and inspection. For operating environments with high levels of air born metallic dust particles clean out the Power
Source/Wirefeeder once a week. For operating environments with low levels of air born metallic dust particles clean out the Power Source/Wirefeeder once every six months.
WARNING 7: Disconnect the Transmig from the Mains supply voltage before disassembling.
Special maintenance is not necessary for the control unit parts in the Power Source / Wirefeeder. If these parts are damaged for any reason, replacement is recommended.
CAUTION 8: Do not blow air into the Power Source / Wirefeeder during cleaning. Blowing air into the Power Source / Wirefeeder can cause metal particles to interfere with sensitive electronic components and cause damage to the Power Source /
Wirefeeder.
To clean the Power Source / Wirefeeder, disconnect the Power Source from the Mains supply voltage, remove the covers and use a vacuum cleaner to remove any accumulated dust. The Power Source /
Wirefeeder should also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used.
Troubleshooting and repairing the Transmig should be carried out only by those who are familiar with electrical equipment.
WARNING 8: Do not attempt to diagnose or repair unless you have had training in electronic measurement and troubleshooting techniques.
Page 24 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330
9.1 Improved Current Accuracy Calibration Procedure for the Digital Meter
CAUTION 9: This calibration procedure should be carried out by a qualified electrical tradesperson.
The following procedure will give a current measurement accuracy of better than the factory standard of approximately 5%.
a) Equipment Required:
Transmig
210
Transmig
250
Transmig
310
Transmig
330
DC Ammeter
(certified up to ±1% accuracy)
LOAD RESISTANCE of
0.1
W
Output Connecting Leads
250A 300A 400A 400A
5kW 8kW 12kW 12kW
4 4 4 4 b) Procedure: i) With the Transmig switched off, connect the LOAD RESISTANCE and DC
AMMETER to the output terminals.
ii) Open the wirefeeder compartment door or remove the lefthand side cover (when viewing the Transmig from the front) from the Power Source.
iii) Select maximum voltage switch positions Coarse 4 Fine 4 (MIG 210/250)
Coarse 4 Fine 6 (MIG 310/330) iv) Switch the Mains supply voltage to the Transmig ON.
v) Ensure the DIGITAL METER is selected to read current.
vi) Short circuit the TORCH TRIGGER terminals to energise output welding terminals.
CAUTION 10: Do not allow the Transmig to remain ON under load for more than ONE minute!
vii) Determine the output current as given by the DC AMMETER.
viii) Adjust SHUNT CAL. potentiometer on DIGITAL METER to read identically with
DC AMMETER.
ix) Open circuit the TORCH TRIGGER terminals to deactivate output welding terminals.
x) Select minimum voltage switch positions Coarse 1 Fine 1 xi) Short circuit the TORCH TRIGGER terminals to energise output welding terminals.
Refer to CAUTION 10.
xii) Determine output current as given by the DC AMMETER.
xiii) Confirm the minimum DIGITAL METER reading is within ±2% of DC AMMETER.
xiv) If the above is not met, offset the SHUNT CAL. potentiometer such that both the minimum and maximum values are within ±2%.
xv) The improved accuracy for DIGITAL METER is now complete.
xvi) Where fitted, position the meter cover over the hexagonal brass spacers taking care not to trap loom wiring.
xvii) Fit the M3 flat washers and M3x10 screws through the meter cover and into the hexagonal brass spacers.
DOC No: MIGTRN0001 Page 25 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330 xviii) Close wire-feeder compartment or replace side panel.
10. BASIC TROUBLESHOOTING
The basic level of troubleshooting is that which can be performed without special equipment or knowledge, and without removing the covers from the Power Source / Wirefeeder.
If major components are faulty, then the Power Source / Wirefeeder should be returned to an Accredited
CIGWELD Service Agent for repair.
10.1 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: a) Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal.
Contaminants range from no gas around the welding arc to dirt on the work piece surface.
Porosity can be reduced by checking the following points.
1. Gas cylinder contents and flow meter. - Ensure that the gas cylinder is not empty and the flow meter is correctly adjusted to 15 litres per minute.
2. Gas leaks. - Check for gas leaks between the regulator/cylinder connection and in the gas hose to the Power
Source.
3. Internal gas hose in the Power Source. - Ensure the hose from the solenoid valve to the torch adaptor has not fractured and that it is connected to the torch adaptor.
4. Welding in a windy environment. - Shield the weld area from the wind or increase the gas flow.
5. Welding dirty, oily, painted, oxidised or greasy plate.
- Clean contaminates off the work piece.
6. Distance between the MIG torch nozzle and the work piece.
7. Maintain the MIG torch in good working order.
- Keep the distance between the MIG torch nozzle and the work piece to a minimum. Refer to section
8.3 on page 23.
- Ensure that the gas holes are not blocked and gas is exiting out of the torch nozzle. Refer to
CAUTION 11.
Do not restrict gas flow by allowing spatter to build up inside the torch nozzle.
Check that the MIG torch O-rings are not damaged.
CAUTION 11: Disengage the drive roll when testing for gas flow by ear.
Page 26 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330 b) Inconsistent wire feed
Wire feeding problems can be reduced by checking the following points.
1. Wire spool brake is too tight - Feed roller driven by motor in the cabinet will slip.
2. Wire spool brake is too loose - Wire spool can unwind and tangle.
3. Worn or incorrect feed roller size - Use 'U' groove drive feed roller matched to the aluminium wire size you are welding.
Use 'V' groove drive feed roller matched to the steel wire size you are welding.
Use ‘knurled V’ groove drive feed roller matched to the flux cored wire size you are welding.
4. Mis-alignment of inlet/outlet guides - Wire will rub against the mis-aligned guides and reduces wire feedability.
5. Liner blocked with swarf - Increased amounts of swarf is produced by the electrode wire passing through the feed roller when excessive pressure is applied to the pressure roller adjuster.
Swarf can also be produced by the wire passing through an incorrect feed roller groove shape or size.
Swarf is fed into the conduit liner where it accumulates thus reducing wire feedability.
6. Incorrect or worn contact tip - The contact tip transfers the weld current to the electrode wire. If the hole in the contact tip is too large then arcing may occur inside the contact tip resulting in the wire jamming in the contact tip.
When using soft wire such as aluminium it may become jammed in the contact tip due to expansion of the wire when heated. A contact tip designed for soft wires should be used.
7. Poor work lead contact to work piece - If the work lead has a poor electrical contact to the work piece then the connection point will heat up and result in a reduction of power at the arc.
8. Bent liner - This will cause friction between the wire and the liner thus reducing wire feedability
DOC No: MIGTRN0001 Page 27 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330
10.2 Welding Problems
FAULT CAUSE REMEDY
1 Undercut A Welding arc voltage too high.
A Reduce voltage by reducing the
Voltage Control switches positions or turn the Wirespeed control knob clockwise.
B Incorrect torch angle B Adjust angle
C Excessive heat input C Increase the torch travel speed or reduce welding current by reducing the Voltage Control switches positions and turn the
Wirespeed control knob anticlockwise.
2 Lack of penetration A Welding current too low A Increase welding current by increasing turn the Wirespeed control knob clockwise and increasing Voltage Control switch positions.
B Joint preparation too narrow or gap too tight
B Increase joint angle or gap
C Shielding gas incorrect C Change to a gas which gives higher penetration
3 Lack of fusion Arc voltage to low Increase Arc voltage by increasing the Voltage Control switches position.
4 Excessive spatter A Arc voltage too high A Lower voltage by reducing the
Voltage Control switches positions or turn the Wirespeed control knob clockwise.
B Arc voltage too low B Raise voltage by increasing the
Voltage Control switches or turn the Wirespeed control knob anticlockwise.
5 Irregular weld shape A Incorrect voltage and current settings. Convex,
Arc voltage too low
Concave, voltage too high.
A Adjust voltage and current by adjusting the Voltage Control switches positions and the
Wirespeed control knob.
B Wire is wandering B Replace contact tip
C Incorrect shielding gas C Check gas selection
D Insufficient or excessive heat input
D Adjust the Wirespeed control knob or the Voltage Control switches.
6 Arc does not have a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly.
The MIG torch has been connected to the wrong voltage polarity on the front panel.
Connect the MIG torch to the positive welding terminal (+) for solid wires and gas shielded flux cored wires.
Page 28 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330
Welding Problems (continued)
FAULT CAUSE REMEDY
7 Weld cracking A Weld beads too small A Decrease torch travel speed
B Weld penetration narrow and deep
B Reduce current and voltage and increase the MIG Torch travel speed or select a lower penetration shielding gas.
C Excessive weld stresses C Increase weld metal strength or revise design
D Excessive voltage D Decrease voltage by reducing the
Voltage Control switches.
E Cooling rate too fast E Slow the cooling rate by preheating part to be welded or cool slowly.
8 Cold weld puddle A Faulty rectifier unit A Have an Accredited CIGWELD
Service Agent test then replace the faulty component.
B Loss of a phase in the
Mains supply voltage.
B Check mains power
C Loose welding cable connection.
C Check all welding cable connections.
D Low Mains supply voltage D Contact supply authority
10.3 Power Source Problems
FAULT CAUSE REMEDY
1 Indicator light is ON but welding arc can not be established.
Coarse Voltage Control switch is in the STANDBY position.
Switch the Coarse Voltage
Control switch to a welding setting.
2 Mains supply voltage is
ON. Indicator light is not lit and welding arc can not be established.
A
B
Primary fuse is blown.
Broken connection in primary circuit.
A
B
Replace primary fuse.
Have an Accredited CIGWELD
Service Agent check primary circuit.
3 Mains indicator light is not lit but welding arc can be established.
4 Mains supply voltage is
ON and Indicator light is lit but when the torch trigger switch is depressed nothing happens.
5 Mains supply voltage is
ON, no wire feed but gas flows from the MIG Torch when the torch trigger switch is depressed.
Burnt out Indicator light. Have an Accredited CIGWELD
Torch trigger switch leads are disconnected.
A Electrode wire stuck in conduit liner or contact tip
(burn-back jam).
Service Agent replace Indicator light.
Reconnect.
A Check for clogged / kinked MIG
Torch conduit liner or worn contract tip. Replace faulty components.
B Faulty control PCB B Have an Accredited CIGWELD
Service Agent investigate the fault.
DOC No: MIGTRN0001 Page 29 of 31
Issue No: 2 Date: 14/09/98
Transmig 210, 250, 310, 330
Power Source Problems (continued)
FAULT CAUSE REMEDY
6 Wire feeds when the torch trigger switch is depressed but arc can not be established.
Poor or no work lead contact.
Clean work clamp area and ensure good electrical contact.
7 Mains supply voltage is
ON and contactor in the
Power Source operates but wire does not feed when the torch trigger switch is depressed.
TWECO Torch has been damaged internally, trigger wires are making contact with welding power cable.
Have an Accredited CIGWELD
Service Agent repair torch & replace PCB.
8 Jerky wire feed A Worn or dirty contact tip A Replace
B Worn feed roll. B Replace
C Excessive back tension from wire reel hub.
C Reduce brake tension on spool hub
D Worn, kinked or dirty conduit liner
D Clean or replace conduit liner
9 No gas flow A Gas hose is cut. A Replace or repair.
B Gas passage contains impurities.
B Disconnect gas hose from the rear of Power Source or wirefeeder then raise gas pressure and blow out impurities.
C Gas regulator turned off. C Turn on.
10 Gas flow continues after the torch trigger switch has been released.
Gas valve has jammed open due to impurities in the gas or the gas line.
Have an Accredited CIGWELD
Service Agent repair or replace gas valve.
Page 30 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Transmig 210, 250, 310, 330
10.4 Key Spare Parts
Description Transmig 210 Transmig 250 Transmig 310 Transmig 330
Main Transformer 705164 705165 704983 705166
Auxiliary Transformer 705275 705278 705126 705126
Rectifier 7977657 7977657 7977658 7977658
Capacitor 22000
µ
F 63V 7977178 7977178 ¾ ¾
Control PCB (704882) 705150 705150 705150 705150
Contactor 7977752 7977752 7977752 7977752
Wirespeed Knob 7977709 7977709 7977709 7977709
Spot & Dwell Knob 7977708 7977708 7977708 7977708
Wirespeed Potentiometer 704807 704807 704807 704807
Spot & Dwell Potentiometer 704806 704806 704806 704806
Coarse Voltage Switch 7977677 7977678 7977667 7977667
Fine Voltage Switch 7977665 7977666 7977668 7977668
Solenoid Valve KK281 KK281 KK281 KK281
Wire Reel Lock Pin OTWAK1P OTWAK1P OTWAK1P OTWAK1P
Wire Reel Hub 702337 702337 702337 702337
Indicator Light 7977680 7977680 7977681 7977681
Welding Current Terminals 7977159 7977159 704460 704460
Work Lead Plug 705152 705152 704461 704461
Wire Drive Assembly 7977659 7977659 7977659 7977659
Wire Drive Motor 7977693 7977693 7977693 7977693
Two roll wire drive system 7977684 7977684 7977684 7977684
Fan Motor 7976341 7976341 7977679 7977679
Fan Impellor 7977288 7977288 7977288 7977288
Swivel Wheel 7977566 7977566 7977566 7977566
Fixed Wheel 7977567 7977567 7977567 7977567
7 Pin Control Plug 7977162 7977162 7977162 7977162
7 Pin Plug Cable Clamp 703255 703255 703255 703255
7 Pin Control Socket 7977163 7977163 7977163 7977163
Roll on cylinder carrier 704961 704961 704961 704961
Cylinder bracket 704692 704692 704692 704692
Cylinder chain 703625 703625 703625 703625
Front wheel bracket 704960 704960 704960 704960
Wirefeeder to suit Remote Power
Source only
704975 704975 ¾ 704841
Regulator/Flowmeter 301526 301526 301526 301526
MIG Torch 250A 717578 717578 717578 717578
DOC No: MIGTRN0001 Page 31 of 31
Issue No: 2 Date: 14/09/98
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Key Features
- Compact and portable design for easy maneuverability
- Digital display for precise voltage and amperage settings
- Inductance control for adjusting the arc characteristics
- Spot and stitch welding modes for specialized applications
- Thermal overload protection for enhanced safety
- Compatible with various shielding gases for welding different metals