ESAB Transmig 305S & 405S User manual

 MUREX® OperatinsyENRONLAl
Transmig 3055 & 405S
Please ensure that this
Instruction Manual is made
available to the user of
the equipment
№ J
MUREX®
Contents
Warnings
Page
Safety...
Introduction & Controls
Installation
Specification
Circuit Diagram
Circuit Description.
© © ~N Oo N 4 Q
Maintenance
Spare Parts
11-14
MUREX>
“1 WARNING
This welding equipment has been designed, manufactured and tested to tbe
© vom standards to ensure long and trouble free life. However, regular :
maintenance is an essential part of keeping the machine operating in a reliable
and safe manner and your EE is gene to sh maintenance instructions whe
are contained in this manual. ; i
in general, all welding su mont should be thoroughly inspental. sested and |
L. serviced at least annually. More frequent checking will be иной when the
— equipment is heavily used.
‘Wear and tear, particularly in electro mechanical and ‚moving components. : are |
| gradual processes. Caught in time, repair costs are small and the benefits in Ci
. performance reliability and safety ¢ are significant; Left alone, they can put ihe
; equipment, and you, at risk. E |
— Have this e TT Ро and maintained by an approved service ii
— centre. an
ARC WELDING AND CUTTING CAN N BE INJURIOUS TO YOURSELF AND OTHERS. uu
TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER'S SAFETY
PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS! HAZARD DATA.
iti ELECTRIC SHOCK - Can Kill
n ‘Install and earth the welding à in acvordenes with. applicable standards.
. Do not touch: live electrical parts or electrodes with bare skin, wet Ве or wet clothing.
Insulate yourself from earth and work.
i . Ensure your working position is secure.
FUMES AND GASES - Can be Dangerous to Health
on Keep your head out of the fumes. : ЕЕ
EM Use ventilation, extraction at the arc, or both, to ken fumes and gases from your oreathing 2 zone and st
the general area.
i ARC RAYS - Can injure Eyes and Burn pen
= Protect your eyes and me Use the fi welding screen rand fiter tens and wear ee
clothing.
— Protect bystanders with suitable s screens or curtains.
NOISE~ Excessive noise can damage hearing :
M Protect your ears. Use ear defondars or other hearing ne.
5 E Warn bystanders of the risks.
READ AND UNDERSTAND THE INSTRUCTION MANUAL
BEFORE INSTALLING OR OPERATING AND SEE WMA PUBLICATION 237
‘The arc welder at work’ AVAILABLE FROM THE MANUFACTURER.
PROTECT YOURSELF AND OTHERS
Bt el ch
MUREX¢D
4
SAFETY
In any arc welding or gouging operation, it is the
responsibility of the user to observe certain safety rules to
ensure his personal safety and to protect those working
near him.
Read all safety articles relevant to arc welding published
by the WMA. Pay particular attention to any CAUTION or
WARNING Notes included in this manual. CAUTION
indicates possible equipment damage. WARNING indicates
possible hazard to life.
IN WARNING N
/ The ON/OFF sul, on this equipment does not es
the unit from the mains electrical supply. AC POWER
| IS PRESENT ON THE ON/OFF SWITCH TERMINALS.
The On/Off lamp is an indication that the supply is
switched on and does not imply that the unit is isolated
from the supply. BEFORE REMOVING THE COVERS
FOR MAINTENANCE, ISOLATE THE UNIT FROM
THE MAINS ELEC TRICAL SUPPLY. |
1. Electrical
/\ Treat electricity with respect. Even the open circuit voltage
of this equipment can be dangerous. Adjustments to the
torch or replacement of torch parts should be undertaken
with the mains supply isolated from the unit.
If damaged torch cables or torch components are found,
the unit must be disconnected from the mains and
defective parts must be replaced using only Murex spare
parts.
/N Do not work on live circuits or cables. Disconnect the main
power supply. before checking the machine or performing
any maintenance operation.
/\ Be sure the case of the welding machine is properly
connected to a good electrical earth.
/N Have the wiring for the welding machine installed by a
qualified electrician. All connections must be made
according to specifications in force and to general safety
standards.
/\ Do not stand in water or on damp floors while using an arc
welder or cutter. Do not use in the rain.
/\ Do not operate with worn or poorly connected cables.
Inspect all cables frequently for insulation failure, exposed
wires and loose connections. |
A Do not overioad cables or continue to operate with
overheating cables. Cables which are too small for the
current carried will overheat, causing rapid deterioration of
the insulation.
/\ Pay attention that live parts of the torch do not touch any
metal which is connected to the earth cable. Fix an
insulated hook to hang the torch on when it is not in use.
1. Ventilation
Do not weld or cut on containers which have held
combustible or flammable materials, or materials which
give off flammable or toxic vapours when heated, without
proper cleaning.
/\ Locate the welding/cutting operation far enough from any
vapour-type degreaser using trichlorethylene or other
chlorinated hydrocarbons as solvents. The ultraviolet light
from the arc can decompose these vapours into toxic
gases at a considerable distance from the arc, even though
the concentration of the gases is low enough to be
undetectable by smell.
/\ Be sure to provide adequate ventilation for removal and
dilution of fume and gases. Fume exhaust facilities near the
arc, or a ventilated helmet should be used when cutting in
confined spaces or on toxic material.
2. Glare
/N Never look at the arc without wearing eye protection.
Always use the proper protective clothing, filter glasses,
and gloves. Be careful to avoid exposed skin areas. Do not
use cracked or defective helmets or shields.
/N Never strike an arc when there is someone near who is not
protected from the strong light of the arc.
/A Wam bystanders who are not aware of the dangers of ultra-
violet light.
3. General
AN Take care when lifting the unit. |
/\ Ensure that cylinders are secured by chains.
/\ Locate the unit so that there is adequate air flow to the
ventilation louvres.
A Always dress correctly to protect against glare, radiation
and spatter.
4. Fire
/N Ensure that the correct type of fire extinguisher is available
in the welding area.
/N Do not weld near flammable materials or liquids, in or near
explosive atmospheres, or on pipes carrying explosive
gases.
5. Vehicle Electrics
/\ When working on motor vehicles, remove the battery and
any circuitry which may be damaged by the arc.
/\ Whilst welding be aware of the possibility of ‘hidden wires’
behind panels or bulkheads.
GENERAL
The Transmig 305S and Transmig
4058 (TM 3058 a TM 4055) are
constant voltage characteristic
welding power supply units designed
for use in MIG/MAG dip transfer and
spray transfer modes.
Inductance output sockets (XS2 A, B
a C) are provided for these
techniques (see below).
In addition to the welding output,
these units provide 42 volts and
contactor control circuit outputs to a
wire feed unit (socket on rear panel).
Both units can be used in conjunction
with the Transmatic 2 x 2, 4 x 4 and 4
x 4HD Feed Units. Details of
interconnections to these feeders are
given at the front of the Parts List
under ‘Optional Extras’.
A 42 volts a.c. outlet is supplied on a
terminal block inside the unit to
supply a CO. Heater if required (see
installation, page 6).
A water cooler may be fitted to the
unit by mounting it on the cylinder
carrier plate on the back panel.
CONTROLS
Ammeter
MUREX
Under welding conditions
indicates welding current
Voltmeter
Indicates actual welding
voltage.
Press-to-read OCV
switch
-VE Welding power
Minimum Inductance
For short arc welding of thin
materials root runs, aluminium
and cored wires.
-VE Welding power
Medium Inductance -
Used for short arc welding,
gives slightly increased heat
input.
220 volts a.c. is provided on a
terminal block inside the unit to
power the cooler (see installation,
page 6).
A thermostatically controlled cooling
fan is mounted inside the rear panel.
This fan normally runs at reduced
power but if the temperature rises,
the fan speed increases. Once the
power source has cooled down, the
fan returns to a low speed. The fan
draws air in via the louvres in the
front and side panels, and expels
through the rear, cooling the rectifiers
and other components. To operate
efficiently these louvres must be kept
free from obstruction.
Reduced air flow may cause a
thermal overload (over-heating).
A thermostat protects he unit from
thermal overload. This thermostat is
mounted on the rectifier assembly
(see Parts List) and disables the
control circuit in the event of
overheating. Should the overload
lamp light (see below) cease welding,
keep the mains switched on leaving
the fan running to minimise the
Overload Lamp
5
cooling time, and leave the unit to
cool. Investigate the cause of
overheating (ventilation, fan failure
etc.).
Circuit breakers on the rear panel,
protect the circuits from excess
current overload. They are reset by
pushing in the buttons.
WARNING
Persistent operation of the ecu:
breakers must be investigated.
Under no conditions should (hey
be held on artic oe
device etc.)
A Voltmeter and Ammeter mounted
on the front panel indicate actual
welding voltage and welding current
values.
The ‘Press to read’ button activates
the welding output voltage allowing
the O.C.V. (Open Circuit voltage) to
be checked.
The Voltage Selection switches
provide coarse and fine control of
output voltage.
ON/OFF Lamp
Indicates welding power
is switched on.
ON/OFF switch
Note: This switch does not
isolate the unit from the
mains supply.
-Fine' output Control
‘Coarse’ output Control
+VE Welding power
output socket
Positive polarity output to
wire feed unit.
Also duplicated on the rear
panel.
-VE Welding power
Maximum Inductance
Used for spray arc welding
of thick materials.
6
INSTALLATION
~ WARNING -
Installs tion should only be Me
by a qualified electrician or Hand
individual.
Correct installation is important for the
reliable and safe ing. of the
equipment. Before continuing carry out
the following checks:
1. Having unpacked the power source,
inspect for evidence of damage or
missing parts. Notify the carrier or Murex
immediately.
2. Check the air louvres in the front and
rear panels for any packing materials that
might obstruct the air flow.
3. Position the equipment in a safe area.
Leave at lest 0.5m clearance around the
unit to allow air to circulate freely. The
position should be free from dust, fumes
and heat. See SAFETY at the front of this
manual.
Connection to Mains Supply
WARNING
i Before “making electrical input l
£ connections: to the unit, use ‘machinery :
lockout procedures’. If the connection is
to be made from a mains disconnect
Switch, the switch should be padiocked
‘in the off position. If the connection is
: made from a fuse box, remove the fuses
from the box and padlock the cover in
the closed position. if locking facilities
are not available, attach a red tag to the
‘mains disconnect switch (or fuse) to
warn others that the circuit is e
I worked mn :
Placing the machine unit oar switoh |
in the "Off" position does not shut off a |
the power within the equipment.
Clamp the input cable firmly
MAINS CABLE INPUT
Connect the mains input cable to TB XT1
D
A
TERMINAL BOARD XT2 MAINS VOLTAGE SELECTION
400 - 415V
AUXILIARY TRANSFORMER MAINS VOLTAGE SELECTION
230V, 50Hz 400 - 415V, 50Hz 500V, 50Hz
OUGLOLGUÉ
onojonone
01 02 03 04 05 01 02 03 04 05 01 02 03 04 05
030 037 029 030 037 029 030 037 029
The Murex Transmig 3055 or 4055 power
source requires industrial 3 phase mains
power of the proper voltage, 230, 400,
415 or 500V, see SPECIFICATION
section, page 7.
WARNING
From the factory the machine is set for
415V use and the fitted primary cable
is suitable for à use with 400V or 4157
supplies only.
Fitting Optional Extras
Terminal Boards XT3 and XT5 provide a
means of connection to the various
auxiliary supplies available.
WARNING
Ensure suitable strain reliefs are fitted
when routing cables through the rear
panel. ER A
42V and 220V a.c. auxiliaries are
protected by resettable circuit breakers
and accessible on the rear panel.
WARNING > a
The 2207 a.c. auxiliary is not isolated
from the incoming mains and is for use
with vetar torch ane pooling units
on |
TBXT5 & TBXT3 AUXILIARY SUPPLIES
42\
1
|
|
i
nj
17
à à
\ ¥
A 11
11 |
— =} à x
i
== |
7 ; + I
CO, Fo 7 | Water
Heater *: ях Cooler
Connect to auxiliary supplies as required
taking care to clamp the cables (as
shown)
. MUREX>
Transmig 3058 8: 4055
Technical Notes
INPUT
Phase:
Frequency:
Max current at 420V:
Max kVA
Fuse rating 420V supply:
Nominal Voltage:
TM 3055
3
50/60Hz
18A
13kVA
20A
230/400 - 415/500V 50Hz
220/440 - 460/550V 60Hz
Rating specification:
Ambient temperature:
Insulation class:
Max temperature rise:
Weight:
40 Switch Positions
SPECIFICATION
495mm ==] т
w
6 ()%
1: t 2
0 0
A E
| 790mm
| Cr) ed —
ES — y 0 — |
о | =) — — — —
== Z— — 7m —
me — NA A
— —— — — —
ZZ =
— TA
=— — = |
ОС Ц,
127mm
a | X
OUTPUT
TM4055 TM305S
3 Open Circuit voltage: 39V max.
50/60Hz Current range: 60A:15V
28A 300A:30V
20kVA Rated output: 100% 250A/27V
35A 60% 300A/30V
Permitted max current: 300A
Control:
Inductance Taps: 3
OTHER DATA
IEC 974-1
40°C
H
140°C
TM3055 TM4055
160Kg 200Kg
Due to variations which can occur in manufactured products, claimed perfor-
mance voltages, ratings, all capacities, measurements, dimensions and
weights quoted are approximate only. Achievable capacities and ratings in
use and operation will depend upon correct installation, use, application,
maintenance and service. | |
TM405S
46V max
60A:17V
400A:36V
320A/30V
400A/34V
400A
3
230V 220-230V
50HZ 60HZ
| |
029— 74 | 02
1 03 | 18
037 , 18 03
S10) TCI
400-4 15V 440-460V
SCHZ 60HZ
| 4
02 | 02 |
| È
| 037 Pa 18
037 Т ' Т 18 03 1
90— Tc TC]
500V 550V
50HZ 60HZ
029 per 02 |
! | |
i I
$ i
| 037 i 18
OST ' 77018 030 '
90— TE TCI
Fan mote 3
ONLY,
e EAE RE 5 =
I
i
i
I
I
I
|
h
I
e
ХТ |
XT |
XT I
Ё
8
Bi OZ
y | = BLUE
gf ul |
pe ep 2 = ALacik C3
3 = BROWN
TCI ===
X52.-C
X52.-B
X52.-A
X51.G
XS! .B
XSI.F
X51. A
CIRCUIT DESCRIPTION
Welding Supply
The mains input is applied to Terminal Block TBXT2 and
is connected to the primary of transformer TM1 when
contactor KM1 closes.
It can be seen that, with the 230 volt links only in position
as shown (see also pages 6 and 8). TM1 primary is
connected as a delta winding for a fixed, 3 phase voltage
of 230 volts.
With the 400-415/500V links in position (230V links
removed), the primary is star wired and the links add or
remove lower sections of the primary winding as
necessary.
NOTE
When selecting the input voltage, the one es on
the Auxiliary Transformer mn must also me set. fe
pages 6 and 8). |
Fine and coarse settings are achieved by switching in or
out sections of the primary winding, resulting in changes
to the transformation ratio of the transformer, and hence
the value of secondary output. The table opposite shows
the switch contacts for various settings.
The output from TM1 is rectified by diodes V1-V3 (pos.)
and V4-V6 (neg.). Shunt RS1 ‘senses’ the output current
which is displayed by the ammeter A. R1/C2 are transient
suppressors and voltmeter V measures the output voltage
across terminals XS2+ and XS2-.
Inductance L1 has three tappings (XS2-A, XS2-B and
XS2-C) for use in various welding modes - see page 5.
The output voltage is taken to pins C and G of the control
socket XS1.
Auxiliary Supplies
Switch OF1 connects mains supply voltage to the primary
of Auxiliary Transformer TCH.
NOTE
The connections on ne terminal block must be
changed to match the mains dés st see ages.
6 and 8. e
220V for the Fan M (via TBXT4) and Water Cooler ve
TBXT3) is taken from the primary of TC1. The fan is
powered via capacitor C3. If the temperature rises above
a set limit, thermostat ST2 or ST3 will cause KM? to
energise, and the fan will speed up until ST2 or ST3 re-
sets.
The Water Cooler supply is protected by circuit breakers
FU3 and FU4.
The 42V control voltage from TC1 secondary lights lamp
НЫ.
NOTE
This lamp indicates control voltage ON/OFF and cv
not signify isolation from the mains supply i.e. Mains
Supply is still connnected to transformer TM1 primary
and mains voltage selection blocks.
mures
9
42 volts is taken to TB XT5 to power an external CO:
Heater, this output is protected by circuit breaker FU1.
Control
When the torch switch is pressed, it completes a 42V
circuit to main contactor KM1 via a thermostat ST1 and
welding power is switched on by contacts KM1.
It can be seen that a thermal overload (ST1) will result in
KM1 becoming de-energised, resulting in welding power
being shut down until the unit cools and ST1 resets.
OF2 is a ‘Press-to-read’ button which energises the main
contactor, allowing the open circuit volts to be read
locally.
SA1
6 7 9 10 13 15 14 19 21
1 |X X|X X|X X
2 |X| |X|X| |X| |X|X| EXI |XIX
3 XIX| Ix] |XIX| IX] XIX! [X
4 XXIX X | X|X XIX|X
SA2 т | а
1
2
3
4
5
6
7
8
9
—
o
FINE (SA2) & COARSE (SA1) SWITCH CONTACTS
X = Contacts Closed
MUREX¢D
10
MAINTENANCE
Insulation and Continuity Test
Yearly (or after a long period of
storage)
Carry out insulation resistance and
continuity test as follows:-
1. Switch off and isolate the main
supply.
2. Using an insulation/resistance
tester (e.g. Megger) set on the ohms
range, check for earth continuity
between the mains lead earth terminal
and all earthed components. A
reading of zero ohms should be
obtained. A simple bulb and battery
may be used if a megger or similar is
not available. The bulb should glow
brightly if continuity is satisfactory.
3. Manually hold on contactor KM1
or short circuits its contacts.
4. Wire together the L1, L2 and L3
terminals (or the cable ends) to form a
‘common junction’.
5. Turn the ON/OFF switch to the
‘ON’ position.
6. Wire together the (-) and (+) output
sockets.
7. Using a 500V insulation tester (e.g.
megger) check for an insulation
resistance of at least 2m ohms
between:
a. The input terminals ‘common
junction’ and the output terminals.
b. The input terminals and pin F of
XS1 (42V connections).
8. Remove all shorting links, release
the contactor, reconnect to the mains
supply and test the equipment before
use.
Overload Protection
The overload protection thermostat is
mounted on the diode bridge and will
interrupt the welding current when the
rectifier is overloaded. The current will
automatically be reset when the unit is
adequately cooled down.
If the unit shuts off, keep the mains
switched on leaving the fan running to
minimise the cooling time. =
Schedule Maintenance
Daily
1. Check all welding and electrical
cable for signs of cracking or general
deterioration.
2. Check that all electrical and gas
connections are in good physical
condition.
3. Check the torch for damage.
Replace any suspect part(s).
ALWAYS CHECK THE WELDING
AREA DAILY FOR POSSIBLE
SAFETY HAZARDS, IF IN DOUBT
CONSULT YOUR SAFETY OFFICER.
Six-Monthly
1. Switch off the unit and disconnect
from the mains electrical supply.
2. Remove the top and side covers
(retain the fixing screws).
3. Using a soft brush, remove any
dust or dirt from the interior of the
unit. If compressed air is used to
clean the unit the pressure must not
exceed 2kg/cm? (30Ib/in?), and the air
must be dry. |
SUITABLE EYE AND MOUTH
PROTECTION SHOULD BE WORN
4. Check the security of all
components and connections.
5. Carry out an insulation and
continuity test as detailed above.
6. Refit the covers.
MUREX4S
Transmig 3058 8 4055
Parts List
11
OPTIONAL EXTRAS
Interconnections
2 metre (TM 305S & TM 405S to TIM 2x2 & IM4x4 1413660
(ТМ 3055 & ТМ 4055) 1409320
Work Return Cable and Clamp
12
(12)
Fig. A. - Front View
TM 3055 - Part No. 1414704
TM 405S - Part No. 1414706
CCT TM 3058 TM 40558
Item Ref Part No Part No Description
1 - 156654881 156654881 Pivot post
2 - - - Top plate (Note 1)
3 - - - | Handle complete (Note 1)
4 HL2 192576004 192576004 Overload lamp
5 HL1 192576004 192576004 ON/OFF lamp
6 OF1 320746001 320746001 ON/OFF switch
- - 1411688 1411688 Knob for item 6 |
7 SA? 320751002 320751002 Fine voltage switch - 10 position
8 SA1 1411690 1411690 Coarse voltage switch - 4 position
9 - - - Side panel Left (Note 1)
9a - - - Side panel Right (Note 1)
10 XS2 17242 17242 Dinse socket
- - 1380441 1380441 Dinse plugs for item 10
11 - 1409223 1409223 Swivel castors
12 - 1409222 1409222 Fixed castors
13 - - - Front panel (Note 1)
14 OF2 1411698 1411698 Voltage switch
15 V 1407165 1407165 Voltmeter 60V
16 A 1407166 1407166 Ammeter
Note 1: Please note that these items must be ordered on a special order form and may be on
extended delivery (contact MUREX WELDING PRODUCTS for details).
N
Back Panel
Fig. B. - Right Hand Side View
CCT TM 3058 TM 4058
ltem Ref Part No Part No Description
16 FU1, FU3, FU4 193586101 193586101 Circuit breaker 5A
- FU2 193586102 193586102 Circuit breaker 10A
17 XS1 538500108 538500108 42V Control socket
- - 1411740 1411740 Plug for item 17
18 TMT 469278880 469278881 Main transformer
19 V1-V3 1413834“ 1413848 35 Diode bridge (Positive)
- - 321468003 321468003 Diode (Red) |
20 RS1 1411723 1411723 Shunt
21 ST2, ST3 369904001 369904001 Thermostat (Fan)
22 ST 319445001 319445001 Thermostat
23 KM2 193296101 193296101 Contactor (Fan)
24 C3 1414037 1414037 Capacitor (Fan speed)
25 XT2 | 1413837 1413837 Mains selection block
- XT3, XT5 1411732 1411732 Terminal block 220V & 42V
26 C1 191085103 191085103 Capacitor (Fan start)
27 XT4 523104102 523104102 Terminal block (Fan)
28 - 191309112 191309112 Input cable clamp
29 M 162430001 162430001 Fan
30 - - - Rear panel (Note 1)
31 - 17242 17242 Dinse socket
- - 1380441 1380441 Plug for item 31
Note 1: Please note that these items must be ordered on a special order form and may be on
extended delivery (contact MUREX WELDING PRODUCTS for details).
14
3 i 4e 1-0 ослы
: : : >! В
OCEAN
i » LEE e er A dE oi
©)
CCT TM 3058 TM 4058
Item Ref Part No Part No Description
| 31 - : - Base plate (Note 1)
32 L1 469255883 469255883 Inductor complete
33 - - - Cylinder carrier (Note 1)
34 - - - Cylinder support plate (Note 1)
34a - 321173001 321173001 Chain
35 ХТ 162781002 162781002 Mains connection block
36 TCH 319469001 319469001 Auxiliary transformer
37 KM1 193297101 193297101 Contactor
38 C2 046006704 046006704 Capacitor
38a R1 191093146 191093146 Resistor
39 V4-6 1413829 x 1413830 y Diode bridge negative
39a - 321468004 - 321468004 Diode (black)
40 R2 320007001 320007001 _ Resistor
Note 1: Please note that these items must be ordered on a special order form and may be on
extended delivery (contact MUREX WELDING PRODUCTS for details).
MUREXD
—
Murex Welding Products Limited |
Hertford Road, Waltham Cross, -
Herts. EN8 7RP. England Pt. No. 100490
Printed in England
Telephone: Lea Valley (0992) 710000
Telex: 25743 | Issue 2
FRINTWORKS 10/83