Operating Manual

Operating Manual
TRANSMIG 210 Compact Power Source
Remote Power Source
704832
704808
TRANSMIG 250 Compact Power Source
Remote Power Source
704833
704809
2R TRANSMIG 210/250 Wirefeeder
704975
TRANSMIG 310 Compact Power Source
704836
TRANSMIG 330 Remote Power Source
705085
2R TRANSMIG 330 Wirefeeder
MIGTRN0001
Issue 2 14/09/98
704841
OperatingManual
Transmig 210, 250, 310, 330
CONTENTS
Page
1. INTRODUCTION .................................................................................................................. 7
1.1 Duty Cycle................................................................................................................................................ 7
2. SPECIFICATIONS ................................................................................................................ 8
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. INSTALLATION RECOMMENDATIONS ....................................................................... 12
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
4. SET UP FOR COMPACT TRANSMIGS ........................................................................... 14
5. SET UP FOR REMOTE TRANSMIG WITH WIREFEEDER ......................................... 15
5.1 Power Source Connections ...................................................................................................................... 15
5.2 Wirefeeder Connections........................................................................................................................... 15
6. Power Source / 2R Wirefeeder Controls, Indicators and Features ..................................... 16
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. TWECO MIG TORCH (P/N 717578 where supplied) ........................................................ 19
7.1 Introduction ............................................................................................................................................ 19
7.2 Torch Consumable Parts ......................................................................................................................... 19
DOC No: MIGTRN0001
Issue No: 2
Page 1 of 31
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. BASIC WELDING TECHNIQUE .......................................................................................23
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. ROUTINE MAINTENANCE & INSPECTION..................................................................24
9.1 Improved Current Accuracy Calibration Procedure for the Digital Meter.................................................. 25
10. BASIC TROUBLESHOOTING.........................................................................................26
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
Date: 14/09/98
DOC No: MIGTRN0001
Issue No: 2
Transmig 210, 250, 310, 330
CONTENTS
Page
TABLES
Table 1 - Factory fitted Mains supply leads fitted to the Transmig Power Sources ..................................13
Table 2 - Mains supply lead sizes for alternative Mains supply voltages ..................................................13
Table 3 - MIG torch gas diffusers ..........................................................................................................19
Table 4 - MIG torch contact tips............................................................................................................20
Table 5 - MIG torch nozzles ..................................................................................................................20
Table 6 - MIG torch conduit liners.........................................................................................................20
Table 7 - MIG Torch components..........................................................................................................21
DOC No: MIGTRN0001
Issue No: 2
Page 5 of 31
Date: 14/09/98
Transmig 210, 250, 310, 330
FIGURES
Page
Figure 1 - Transmig duty cycle curves ..................................................................................................... 7
Figure 2 - Voltage settings for Transmig 210/250 .................................................................................. 13
Figure 3 - Voltage settings for Transmig 310/330 .................................................................................. 13
Figure 4 - Compact Transmig Setup ...................................................................................................... 14
Figure 5 - Remote Transmig Setup ........................................................................................................ 15
Figure 6 - Compact Transmig controls................................................................................................... 16
Figure 7 - Remote Transmig controls..................................................................................................... 16
Figure 8 - Wirefeeder controls............................................................................................................... 16
Figure 9 - Examples of the digital read outs ........................................................................................... 17
Figure 10 - Exploded view of MIG torch............................................................................................... 21
Figure 11 - Conduit liner trim length...................................................................................................... 22
Figure 12 - MIG Torch angle................................................................................................................. 23
Page 6 of 31
Date: 14/09/98
DOC No: MIGTRN0001
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 CO2 (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.
CAUTION 1:
Transmig 330
320
330
Transmig 310
300
280
260
Transmig 250
250
240
220
210
200
180
160
140
120
100
80
60
40
The above times are not accumulative.
DOC No: MIGTRN0001
Issue No: 2
20
0
Transmig 210
Duty Cycle (percentage)
1.1 Duty Cycle
The rated duty cycle
100
of a welding Power
90
Source
is
the
80
operating time it may
70
be used at its rated
60
output current withSafe
50
out exceeding the
temperature limits of
Operating
40
the insulation of the
30
Region
component parts. In
20
Australia a duty cycle
10
period of 5 minutes is
0
specified in Australian
Standard AS 1966
Welding Current (amp)
Part 1-1985.
To
Figure 1 - Transmig duty cycle curves
explain the 5 minute
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.
Page 7 of 31
Date: 14/09/98
Transmig 210, 250, 310, 330
2. SPECIFICATIONS
2.1 Transmig 210 and Transmig 250 Specifications
Transmig 210
Plant Assembly part number
Plant Mass
Plant Dimensions
Power Source part number
Power Source Mass
Transmig 250
Compact
Remote
Compact
Remote
704830
704831
704833
704834
77Kg
107Kg
78Kg
108Kg
860mm x 490mm x 845mm
860mm x 490mm x 845mm
704832
704808
704835
704809
60Kg
58.5Kg
61Kg
59.5Kg
Power Source Dimensions
640 x 310 x 732
640 x 310 x 732
Single Phase
Single Phase
50 / 60 Hz
50 / 60 Hz
18.9 to 34.2V
19 to 43V
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%
5 minutes or 10 minutes
5 minutes or 10 minutes
16
16
0.6 - 0.9 Hard / 0.9 - 1.2 Soft
0.6 - 0.9 Hard / 0.9 - 1.2 Soft
0°C to 40°C
0°C to 40°C
Number of Phases
Frequency
Open Circuit Voltage Range
Output Current Range
Duty Cycle Period
Number of Output Voltage Values
Wire Size Range
Operating Temperature Range
Primary input voltage
200V
220V
240V
200V
220V
240V
25A
23A
21A
30A
27A
25A
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
25A
23A
20A
30A
27A
25A
50A
50A
40A
60A
60A
50A
Ñ Rated Input Current (output of 127A)
Rated kVA (output of 127A)
Rated Outlet @ Max Duty Cycle
ª Fuse Size @ Max Duty Cycle
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
Date: 14/09/98
DOC No: MIGTRN0001
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
704836
704839
87Kg
117Kg
860mm x 490mm x 845mm
860mm x 490mm x 845mm
704838
705085
71Kg
70Kg
640 x 310 x 732
640 x 310 x 732
Three Phase
Three Phase
50 / 60 Hz
50 / 60 Hz
17.5 to 41.2V
17.5 to 41.2V
25 to 310A
25 to 330A
310A @ 30%
220A @ 60%
170A @ 100%
330A @ 30%
228A @ 60%
177A @ 100%
5 minutes or 10 minutes
5 minutes or 10 minutes
24
24
0.6 - 1.2 Hard / 0.9 - 1.2 Soft
0.6 - 1.2 Hard / 0.9 - 1.2 Soft
0°C to 40°C
0°C to 40°C
Plant Assembly part number
Plant Mass
Plant Dimensions
Power Source part number
Power Source Mass
Power Source Dimensions
Number of Phases
Frequency
Open Circuit Voltage Range
Output Current Range
Rated Output Duty Cycle
Duty Cycle Period
Number of Output Voltage Values
Wire Size Range
Operating Temperature Range
Primary input voltage
Ñ Rated Input Current for output current
at 100% duty cycle.
Rated kVA for output current at
100% duty cycle.
Maximum Input Current
Generator Requirements
Rated Outlet @ Max Duty Cycle
ª Fuse Size @ Max Duty Cycle
220V
380V
415V
220V
380V
415V
21A
12A
11A
21A
12A
11A
8kVA
8kVA
8kVA
8kVA
8kVA
8kVA
36A
21A
19A
38A
22A
20A
13.7kVA 13.7kVA 13.7kVA 14.4kVA 14.4kVA 14.4kVA
25A
15A
15A
25A
15A
15A
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
Torch Type
Torch Cable Length
DOC No: MIGTRN0001
Issue No: 2
717578
TWECO 250A (Eliminator Consumables)
3.6 metre
Page 9 of 31
Date: 14/09/98
Transmig 210, 250, 310, 330
2.4 Wirefeeder Specifications
Wirefeeder
704975
704841
(Transmig 210 & 250 Remote)
(Transmig 330)
21Kg
23Kg
Mass
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
Stainless Steel
Aluminium
Flux Cored
Operating Temperature Range
0.6, 0.8, 0.9
0.8, 0.9
0.9, 1.0, 1.2
0.8, 0.9, 1.2
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
Compact Remote Compact Remote
4
4
4
4
3 Metre Work Lead
4
4
4
4
4
8 Metre Work Lead
Transmig 330
Compact
Remote
4
4
4
4
4
4
4
4
¾
4
4
4
4
4
¾
4
4
4
4
4
¾
4
¾
4
¾
4
2R Wirefeeder (8 metre)
¾
4
¾
4
¾
4
Regulator / Flowmeter
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
Wheeling Kit
Roll on Cylinder Carrier
Power Source
Operating Instructions
TWECO MIG torch 250A
Feed Roller 0.6/0.8 Hard
Feed Roller 0.9/1.2 Hard
Page 10 of 31
Date: 14/09/98
Transmig 310
¾
DOC No: MIGTRN0001
Issue No: 2
Transmig 210, 250, 310, 330
2.6 Optional Accessories
Part
Number
Description
Transmig 210
Transmig 250
Transmig 310 Transmig 330
Compact Remote Compact Remote
Compact
Remote
705103
Digital Meter Kit
4
704914
Wirefeeder Swivel Base
¾
704913
Wirefeeder Trolley
¾
704917
110Volt Aux Supply Kit
ELC2123035 250A Eliminator torch (3.6M)
(fits Transmig adaptor)
ELC4123545 450A Eliminator torch (3.6M)
(fits Transmig adaptor)
4
4
4
4
4
4
4
4
4
Standard
¾
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
¾
¾
¾
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
717162
TWECO No.2 torch (3.6M)
(adaptor 704915 required)
4
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
7977036
Feed roll, 0.6/0.8 Hard Wire
7977660
Feed roll, 0.9/1.2 Hard Wire
7977037
Feed roll, 1.0/1.2 Hard Wire
7977731
Feed roll, 0.8/0.9 Soft Wire
7977264
Feed roll, 1.0/1.2 Soft Wire
7977732
Feed roll, 0.8/0.9 Flux cored
704277
Feed roll, 1.0/1.2 Flux cored
ELC94L
Eliminator Torch trigger lock
705000
MIG pliers (size No 1)
705001
MIG pliers (size No 2)
646265
Weld measurement gauge
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
705277
Auxiliary transformer kit
240/36/24V
4
4
¾
¾
¾
¾
705278
Auxiliary transformer kit 240220-200/36/24V
¾
¾
4
4
¾
¾
705126
Auxiliary transformer kit 415380-220/36/24V
¾
¾
¾
¾
4
4
DOC No: MIGTRN0001
Issue No: 2
Page 11 of 31
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)
b)
c)
d)
e)
f)
g)
In areas, free from moisture and dust.
Ambient temperature 0°C to 40°C.
In areas, free from oil, steam and corrosive gases.
In areas, not subjected to abnormal vibration or shock.
In areas, not exposed to direct sunlight or rain.
Place at a distance of 30cm or more from walls or similar that could restrict natural air flow
for cooling.
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
Date: 14/09/98
DOC No: MIGTRN0001
Issue No: 2
Transmig 210, 250, 310, 330
Mains
Supply Lead
Size
1.5mm2
Transmig
210
2
Lead
Current
Rating
16 Amps
Lead
Length
3 metre
Machine
Voltage
Setting
240 Volt
210A @ 25%
Duty Cycle
250
1.5mm
16 Amps
3 metre
240 Volt
184A @ 25%
310
2
12 Amps
3.7 metre
415/440 Volt
310A @ 30%
2
12 Amps
3.7 metre
415/440 Volt
330A @ 30%
1mm
330
1mm
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 Mains Supply
Mains
Fuse Size
Voltage Setting
Lead Size
Outlet Size
Machines
Duty Cycle
Export Model
Only
200 Volt
4mm2
25 Amp
ª 50 Amp
Export Model
Only
220 Volt
4mm2
25 Amp
ª 50 Amp 210A @ 36%
Transmig 210
240 Volt
2.5mm2
20 Amp
ª 40 Amp
200 Volt
6mm2
30 Amp
ª 60 Amp
220 Volt
6mm2
30 Amp
ª 60 Amp 250A @ 25%
240 Volt
2
Transmig 250
See Figure 2
220 Volt
Transmig 310
See Figure 3
Transmig 330
See Figure 3
380 Volt
25 Amp
ª 50 Amp
2
20 Amp
ª 40 Amp
2
1.5mm
15 Amp
ª 20 Amp 310A @ 30%
2
4mm
2.5mm
415/440 Volt
1mm
15 Amp
ª 20 Amp
220 Volt
2.5mm2
20 Amp
ª 40 Amp
380 Volt
1.5mm2
15 Amp
ª 20 Amp 330A @ 30%
15 Amp
ª 20 Amp
415/440 Volt
2
1mm
Table 2 - Mains supply lead sizes for alternative Mains supply voltages
Figure 2 - Voltage settings for Transmig 210/250
DOC No: MIGTRN0001
Issue No: 2
Figure 3 - Voltage settings for Transmig 310/330
Page 13 of 31
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
Figure 4 - Compact Transmig Setup
ensure that the adjacent black knurled screw in the
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
Date: 14/09/98
DOC No: MIGTRN0001
Issue No: 2
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)
b)
c)
d)
e)
Remove all packaging materials.
Fit the fixed and swivel wheels to the Power Source. Refer to WARNING 2.
Connect the work lead to the negative welding terminal (-) [positive welding terminal (+)
for flux cored wire].
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.
Fit the gas regulator and Flowmeter to the gas cylinder.
5.2 Wirefeeder Connections
a)
b)
c)
d)
e)
f)
g)
h)
i)
Connect the welding power cable to the
positive welding terminal (+) [negative
welding terminal (-) for flux cored wire].
Connect the control cable to the front of the
Power Source of the Transmig 210 remote or
Transmig 250 remote or Transmig 330.
Connect the gas hose from the rear of the
wire feeder unit to the Flowmeter outlet.
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.
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
Figure 5 - Remote Transmig Setup
securely. The wire should feed from the
bottom of the spool.
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.
Connect the torch trigger lead to the torch trigger terminals.
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.
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
Issue No: 2
Page 15 of 31
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)
Ammeter/Voltmeter
Switch
Optional Meter
(standard on the Transmig 330)
Indicator Light
On/Off & Coarse
Voltage Control Switch
Fine Voltage
Control Switch
Indicator Light
On/Off & Coarse
Voltage Control Switch
Wirespeed Control
Fine Voltage
Control Switch
Dwell Timer Control
Spot Timer Control
Negative Welding
Current Terminal
Mode Selector
Switch
Wirefeeder Control
Socket
Brass Torch Adaptor
Positive Welding
Current Terminal
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
Power Cable
Control Cable
Gas Hose
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:
Page 16 of 31
Date: 14/09/98
The Coarse & Fine Voltage Control switches MUST NOT BE SWITCHED
during the welding process.
DOC No: MIGTRN0001
Issue No: 2
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
Issue No: 2
Page 17 of 31
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. CO2 shielded welding.
2. Dip transfer with Æ1.2mm wires (CO2 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
Date: 14/09/98
DOC No: MIGTRN0001
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:
a)
* denotes parts that are supplied as standard with MIG torch 717578.
Gas Diffusers
Part No.
Part No.
* EL52 (slide on nozzles)
EL52CT (screw on nozzles)
Table 3 - MIG torch gas diffusers
DOC No: MIGTRN0001
Issue No: 2
Page 19 of 31
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
P=Protruding Tip
Table 5 - MIG torch nozzles
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
Date: 14/09/98
DOC No: MIGTRN0001
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.
22
6
5
23
89
4
3
14
7
2
1
13
10
11
18
12
17 16 15
Figure 10 - Exploded view of MIG torch
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
22
23
24
¾
¾
¾
WM6345
OTW45B
OTW90721H
n/a
n/a
ELC94
ELC94B
¾
ELC1042
OTW9072110
OTW224
OTW44C
OTW350174
¾
¾
¾
ELC94L
Description
(refer to Table 5)
(refer to Table 4)
(refer to Table 3)
Nozzle
Contact tip
Gas diffuser
Conductor tube
O-Ring, Gun Handle
Handle kit (includes items 7, 22 & 23)
Insert & screw (refer to item 6)
Handle cap
Support
Trigger Lever
Trigger blades
Butt Splice (insulated crimp link 1.5mm2 )
Cap screw
Cable assembly
O-Ring, Connector Plug
Set screw 8/32 UNC
Connector plug
Conduit liner
(refer to Table 6)
Gun hanger
(refer to item 6)
Hanger screw
(refer to item 6)
Locking Trigger (not shown) (option)
Qty
1
1
1
1
1
1
2
1
1
1
1
2
1
1
2
1
1
1
1
1

Table 7 - MIG Torch components
DOC No: MIGTRN0001
Issue No: 2
Page 21 of 31
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
Date: 14/09/98
DOC No: MIGTRN0001
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
Issue No: 2
Page 23 of 31
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:
Page 24 of 31
Date: 14/09/98
Do not attempt to diagnose or repair unless you have had training in electronic
measurement and troubleshooting techniques.
DOC No: MIGTRN0001
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)
b)
Equipment Required:
Transmig
210
Transmig
250
Transmig
310
Transmig
330
DC Ammeter
(certified up to ±1%
accuracy)
250A
300A
400A
400A
LOAD RESISTANCE of
0.1W
5kW
8kW
12kW
12kW
Output Connecting Leads
4
4
4
4
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:
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
Do not allow the Transmig to remain ON under load for more than ONE
minute!
Determine the output current as given by the DC AMMETER.
Adjust SHUNT CAL. potentiometer on DIGITAL METER to read identically with
DC AMMETER.
Open circuit the TORCH TRIGGER terminals to deactivate output welding
terminals.
Select minimum voltage switch positions
Coarse 1
Fine 1
Short circuit the TORCH TRIGGER terminals to energise output welding terminals.
Refer to CAUTION 10.
Determine output current as given by the DC AMMETER.
Confirm the minimum DIGITAL METER reading is within ±2% of DC AMMETER.
If the above is not met, offset the SHUNT CAL. potentiometer such that both the
minimum and maximum values are within ±2%.
The improved accuracy for DIGITAL METER is now complete.
Where fitted, position the meter cover over the hexagonal brass spacers taking care
not to trap loom wiring.
Fit the M3 flat washers and M3x10 screws through the meter cover and into the
hexagonal brass spacers.
DOC No: MIGTRN0001
Issue No: 2
Page 25 of 31
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.
- Keep the distance between the MIG torch nozzle
and the work piece to a minimum. Refer to section
8.3 on page 23.
7. Maintain the MIG torch in good working
order.
- 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:
Page 26 of 31
Date: 14/09/98
Disengage the drive roll when testing for gas flow by ear.
DOC No: MIGTRN0001
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
Issue No: 2
Page 27 of 31
Date: 14/09/98
Transmig 210, 250, 310, 330
10.2 Welding Problems
FAULT
1
2
Lack of penetration
3
Lack of fusion
4
Excessive spatter
5
6
Page 28 of 31
Date: 14/09/98
Undercut
Irregular weld shape
Arc does not have a crisp
sound that short arc
exhibits when the wirefeed
speed and voltage are
adjusted correctly.
CAUSE
REMEDY
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.
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
Arc voltage to low
Increase Arc voltage by
increasing the Voltage Control
switches position.
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.
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.
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.
DOC No: MIGTRN0001
Issue No: 2
Transmig 210, 250, 310, 330
Welding Problems (continued)
FAULT
7
8
Weld cracking
Cold weld puddle
CAUSE
REMEDY
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.
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
Coarse Voltage Control
switch is in the STANDBY
position.
1
Indicator light is ON but
welding arc can not be
established.
2
A Primary fuse is blown.
Mains supply voltage is
ON. Indicator light is not lit B Broken connection in
and welding arc can not be
primary circuit.
established.
Switch the Coarse Voltage
Control switch to a welding
setting.
A Replace primary fuse.
B Have an Accredited CIGWELD
Service Agent check primary
circuit.
3
Mains indicator light is not
lit but welding arc can be
established.
Burnt out Indicator light.
Have an Accredited CIGWELD
Service Agent replace Indicator
light.
4
Mains supply voltage is
ON and Indicator light is lit
but when the torch trigger
switch is depressed nothing
happens.
Torch trigger switch leads
are disconnected.
Reconnect.
5
A Electrode wire stuck in
Mains supply voltage is
conduit liner or contact tip
ON, no wire feed but gas
(burn-back jam).
flows from the MIG Torch
when the torch trigger
switch is depressed.
B Faulty control PCB
DOC No: MIGTRN0001
Issue No: 2
REMEDY
A Check for clogged / kinked MIG
Torch conduit liner or worn
contract tip. Replace faulty
components.
B Have an Accredited CIGWELD
Service Agent investigate the
fault.
Page 29 of 31
Date: 14/09/98
Transmig 210, 250, 310, 330
Power Source Problems (continued)
FAULT
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
9
No gas flow
10 Gas flow continues after
the torch trigger switch has
been released.
Page 30 of 31
Date: 14/09/98
CAUSE
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
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.
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.
DOC No: MIGTRN0001
Issue No: 2
Transmig 210, 250, 310, 330
10.4 Key Spare Parts
Description
Main Transformer
Transmig 210
705164
Transmig 250
705165
Transmig 310
704983
Transmig 330
705166
Auxiliary Transformer
705275
705278
705126
705126
Rectifier
7977657
7977657
7977658
7977658
Capacitor 22000µF 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
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
Wire Reel Lock Pin
DOC No: MIGTRN0001
Issue No: 2
Page 31 of 31
Date: 14/09/98

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