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OPERATING MANUAL
TRANSMIG 180
MIG WELDING PLANT
Part Number 705180
719322
Issue 5
Nov 06, 96
CIGWELD
CONTENTS
Transmig 180
Page 1. INTRODUCTION 1.1 Safety 1.2 Protective Filter Lenses 1.3 Welding Protection 1.4 User Responsibility 1.5 Duty Cycle 2. SPECIFICATIONS 2.1 Power Source Specifications 2.2 MIG Torch Specifications 2.3 Wire Drive Specifications 2.4 Plant Contents 2.5 Optional Accessories 3. INSTALLATION RECOMMENDATIONS 3.1 Environment 3.2 Location 3.3 Ventilation 3.4 Mains Supply Voltage Requirements 3.5 Alternative Mains Supply Voltage Connection 4. WIRE SPOOL HUB ADJUSTMENT 4.1 Standard 300mm Spool Set-up 4.2 Handi 200mm Spool Set-up 4.3 Mini 100mm Spool Set-up 5. SET UP FOR TRANSMIG 180 6. POWER SOURCE CONTROLS, INDICATORS AND FEATURES 6.1 POWER ON Light 6.2 Voltage Control Switch 6.3 OVER TEMPERATURE Light 6.4 Wirespeed Control 6.5 Burnback Adjustment 6.6 Polarity Reversal Terminals 6.7 Thermal Overload.... 6.8 Whefeeder Driver Roller Pressure Adjustment 6.9 Wire Spool Brake 7. TWECO MIG TORCH (717579) 7.1 Introduction 7.2 MIG Torch Components 7.3 MIG Torch Consumable Parts · 1
1
1 2 2 2 3 3 3 4
4 4
5 5 5 5 5 6 6
6
7 7 7 9
9 9
9
9
10 TM ^ TM
11
H " 12
12
Page i
Transmig 180
CONTENTS
7.4 Installing A New Wire Conduit 7.5 MIG Torch Maintenance 8. BASIC WELDING TECHNIQUE 8.1 Setting of the Power Source & Wirefeeder 8.2 Position of MIG Torch 8.3 Distance from the MIG Torch Nozzle to the Work Piece 8.4 MIG Torch Travel Speed 8.5 Electrode Wire Size Selection 9. ROUTINE MAINTENANCE & INSPECTION 10. BASIC TROUBLESHOOTING 10.1 Solving Problems Beyond the Welding Terminals 10.7 Welding Problems 10.3 Power Source Problems 10.4 Key Spare Parts 11. Transmig 180 Volt/Amp curves 12. TRANSMIG 180 CIRCUIT DIAGRAMS 12.1 Power Source 12.2 Control PCB Page 13 14 14 14 14 14 14 14 15 15 15 17 18 19 20 20 20 21
Page ii
Transmig 180
TABLES
Page Table 1 - Filter lens size verses welding current Table 2 - MIG Torch components Table 3 - MIG Torch gas Table 4 - MIG Torch contact tips Table 5 - MIG Torch nozzles Table 6 - MIG Torch conduit liners diffusers 2 12 12 12 13 13
FIGURES
Page Figure 1 - Transmig 180 duty cycle curve Figure 2 - Contactor adjustment (wire 7) Figure 3 - Input terminal block adjustment (wire 7A) Figure 4 - Standard 300mm spool set-up Figure 5 - Handi 200mm spool set-up Figure 6 - Mini 100mm spool set-up Figure 7 - MIG Torch and polarity connections Figure 8 MIG Torch breakdown Figure 9 - MIG Torch angle Figure 10 - Transmig 180 Volt/Amp curves 2 6 6 6 7 7 8 11 14 20
Page iii
Transmig 180
1. INTRODUCTION
The Transmig 180 is a semi-automatic Gas Metal Arc Welder (GMAW-commonly MIG) with an integrated wire feed system. The plant is designed to meet the broad operating needs of the light metal fabricators, automotive repairers, light rural workshops and home workshops where excellent arc characteristics are vital. This product is designed and manufactured in Australia to Australian Standard AS1966.1-1985. The Transmig 180 gives excellent performance on mild steel, stainless steel, aluminium, silicon bronze and some hard facing wires with Argon based shielding gases. It also gives excellent results on mild steel using carbon dioxide (C0 ) shielding gas.
2
This product is supplied as a complete package ready to weld (apart from gas cylinder and electrode wire). The following instructions explain how to correctly set up the Power Source and provide guidelines on gaining the best production efficiency from the plant. Please read these instructions thoroughly before using your Transmig 180 welder. 1.1 Safety The following basic safety rules should always be followed: i) ii) iii) Ensure the Power Source is correctly installed, if necessary, by a qualified electrician Ensure the Power Source is earthed correctly (electrically) in accordance with local regulations. Excessive heat in the welding cables may cause fire. Never weld with poor electrical connections, damaged welding cables or exceed the welding cable current rating as this will produce excessive heat and may cause a fire. Always wear the correct protective clothing for protection from sparks, molten particles and arc rays. When welding in confined spaces, always ensure adequate ventilation and constant observation of the operator. Keep combustible materials away from the welding area. Have a suitable fire extinguisher handy. Never watch the welding arc with naked eyes. Always use and wear a welding mask fitted with the correct filter lens. For more complete safety advice please read the safety literature included with the equipment before starting to weld.
iv) v) vi) vii)
viii) Do not stand on damp ground when welding. ix)
1.2
Protective Filter Lenses Protective filter lenses are provided to reduce the intensity of radiation entering the eye thus filtering out harmful infra-red, ultra-violet radiation and a percentage of the visible light. Such filter lenses are incorporated within face shields. To prevent damage to the filter lenses from molten or hard particles an additional hard clear glass or special plastic external cover lens should be used. This cover lens should always be kept in place and replaced before the damage impairs your vision while welding.
Page 1
1.3
Welding Protection It is recommended to use a welding helmet, conforming to Australian Standards AS/NZS1337-1992 when electric arc welding. Use a welding helmet in serviceable condition with the correct filter lens fitted as per Table 1.
A p p r o x i m a t e r a n g e of welding c u r r e n t Up to 150 150-250 250-300 300-350 Over 350
Filter lens r e q u i r e d for MIG Shade 10 Shade 11 Shade 12 Shade 13 Shade 14
1.4
Table 1 - Filter lens size verses welding current User Responsibility This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment (including welding leads) should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by CIGWELD. Advice in this regard can be obtained by contacting CIGWELD. This equipment or any of its parts should not be altered from standard specification without prior written approval of CIGWELD. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorised modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by CIGWELD.
1.5
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. The area to the left of the curve is the safe operating area for this product. In Australia a duty cycle period of 5 minutes is specified in Australian Standard AS 1966 Part 1-1990. To explain the 5 Welding Current (amps) minute duty cycle period the following example is used. Suppose Figure 1 - Transmig 180 duty cycle curve a welding Power Source is designed to operate at 30% duty cycle, 140 amperes at 20.5 load volts. This means that it has been designed and built to provide the rated amperage (140 A) at the rated load voltage (20.5V), 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.
Duty Cycle (percentage)
180
Page 2
Transmig 180
2. SPECIFICATIONS
2.1 Power Source Specifications
Plant Assembly part number Plant Mass Plant Dimensions (packed) Power Source Dimensions (less MIG Torch) Open Circuit Voltage Range Welding Arc Voltage Range Output Current Range Rated Output Duty Cycle 100% Duty Cycle Output Rating Duty Cycle Period Number of Output Voltage Settings Electrode Wire Size Range Wire Speed Range Wire Spool Size Diameter Burnback Time Range Operating Temperature Range Number of Phases Frequency Mains Supply Voltage (Primary Input Voltage) V Rated Input Current @ 75A output (100% Duty Cycle) Rated kVA @ 75A output (100% Duty Cycle) Maximum Input Current @ 180A output Generator Requirements at 180A output Recommended Outlet Size Supply VA @ no load Supply Watts @ no load Supply VA @ 180A output Supply Watts @ 180A output Power Source Efficiency @ 180 A output Power Factor @ 180A output + Recommended Fuse Size 220V 9.7A 2.1WA 29.3A 6.5kVA 15A 400VA 250W 6.5kVA 5.7kW 61% 0.88 25A (23 SWG) 705180 60kg H 625mm x W 345mm x D 560mm H 470mm x W 460mm x D 800mm 18.5 to 36.0V DC 13 to 21V DC 25 to 180A DC 180A @ 18% 140A @ 30% 75ADC 5 or 10 minutes 8 0 . 6 - 0 . 9 H a r d / 0 . 9 - 1.2 Soft 1.0 to 15.0 metres/minute 100mm / 200mm / 300mm 0.0 to 0.5 seconds 0°C to 40°C (32°F to 104°F)
1
50 / 60Hz 240V 8.9A 2.1kVA 26.9A 6.5kVA 15A 400VA 250W 6.5kVA 5.7kW 61% 0.88 20A (24 SWG)
V +
The Rated Input Current should be used for the determination of cable size & supply requirements. Motor start fuses or thermal circuit breakers (not magnetic 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. MIG Torch Specifications
Torch Part Number Torch Type Torch Cable Length 717579 TWECO 180 A (Eliminator Consumables) 3.0 metres (10 ft)
2.2
Page 3
2.3
Wire Drive Specifications
Motor Supply Voltage Motor Supply VA Control Supply Voltage Control Supply VA Minimum Wire Speed Maximum Wire Speed Wire Diameter Mild Steel: Stainless Steel: Aluminium: Flux Cored: 24V AC 120VA 24V AC 30VA 1 metre per minute (40 inches per minute) 15 metre per minute (590 inches per minute) 0.6mm 0.6mm 0.9mm 0.8mm (.024"), (.024"), (.035"), (.030"), 0.8mm 0.8mm 1.0mm 0.9mm (.030"), (.030"), (.040"), (.035"), 0.9mm 0.9mm 1.2mm 1.2mm (.035") (.035") (.045") (.045")
Wire Spool Size
3
100mm or 200mm or 300mm
lant Contents
Part N u m b e r 705197 705195GRY 705260GRY 703625 719322 705174 301526 717579 705366 7977036 705368 Wheeling Kit Cylinder Carrier Cylinder Bracket Cylinder Chain Operating Instructions 3 Metre Work Lead (fitted) Regulator / Flowmeter TWECO MIG Torch 180A Handi spool hub Feed Roller 0.6/0.8 Hard Torch accessory kit (for 200mm spool adaptation) (fitted) Description
2.5
Optional Accessories
Part N u m b e r 705252 7977036 7977660 7977037 Handle Feed roll, 0.6/0.8 Hard Wire Feed roll, 0.9/1.2 Hard Wire Feed roll, 1.0/1.2 Hard Wir Description Part Number 7977731 7977264 7977732 704277 Description Feed roll, 0.8/0.9 Soft Wire Feed roll, 1.0/1.2 Soft Wire Feed roll, 0.8/0.9 Flux cored Feed roll, 1.0/1.2 Flux cored
Page 4
Transmig 180
3. INSTALLATION RECOMMENDATIONS
3.1 Environment The Transmig 180 is NOT designed for use in environments with increased hazard of electric shock as denned 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) iii) b) 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 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.
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 this product is 65mm.
3.3
Ventilation Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated. 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 to malfunction. Too high a supply voltage will cause components to overheat and possibly fail. The Transmig 180 is supplied with a 15A input lead (and 15A plug) to connect to a 15A power outlet and is factory set for 240V operation
3.4
CAUTION 1:
CIGWELD advises that you should avoid the use of extension leads as this can reduce the Mains supply voltage below 10% of the rated Mains supply voltage. Refer to section 3.5 for the instructions to convert your Transmig 180 to 220V operation.
Page 5
3.5
Alternative Mains Supply Voltage Connection The Transmig 180 can be rewired to operate on a Mains supply voltage of 220V. CIGWELD advises that a qualified electrical tradesperson rewire your Transmig 180 for 220V operation.
WARNING 1: a) b) c) d)
Disconnect the Transmig 180 from the Mains supply voltage. Disconnect wire No 7 from terminal L3 then reconnect it to terminal L2 on the contactor. Refer to Figure 2. Disconnect wire No 7A from the 240V position on the input terminal block then reconnect wire No 7A to the 220V position on the input terminal block terminal. Refer to Figure 3. The Transmig 180 is now ready for 220V Mains supply voltage.
Figure 2 - Contactor adjustment (wire 7)
Figure 3 - Input terminal block adjustment (wire 7A)
4. WIRE SPOOL HUB ADJUSTMENT
4.1 Standard 300mm Spool Set-up
Steel flat washer 16mm ID \ Steel flat washer 16mm ID \
Friction washer (7976411)
Wire spool hub (702337)
Nut 5/8" BSW
(7958040)
Figure 4 - Standard 300mm spool set-up
Page 6
Transmig 180
4.2 Handi 200mm Spool Set-up
Steel flat washer 16mm ID
Spring (7976405)
Friction washer (7976411 Wire spool hub (705366)
Nut 5/8" BSW (7958040)
Figure 5 - Handi 200mm spool set-up 4.3 Mini 100mm Spool Set-up
Nut 5/8" BSW (7958040)
Steel flat washer 16mm ID
Figure 6 - Mini 100mm spool set-up
5. SETUP FOR TRANSMIG 180
a) Remove all packaging materials. Ensure airflow through the vent holes in the base are not restricted. CAUTION 2: b)
Position a gas cylinder on the carrier 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/Flowmeter to the gas cylinder. Connect the gas hose from the rear of the Power Source to the Flowmeter outlet. A dual groove feed roller is supplied as standard with the plant. This can accommodate 0.6mm and 0.8mm diameter hard wires. Select the roller required with the chosen wire size marked face outwards. Adjust wire hub assembly to suit either standard, handi or mini spool size chosen; refer to section 4 on page 6. The Transmig 180 is factory fitted with the standard spool hub which is suitable for 300mm spools. Fit the electrode wire spool to the wire spool hub located behind wire compartment door. For either the standard or handi spool sizes, ensure that the drive dog-pin engages into the spool mating hole. Push the 'R' clip into place to retain the wire spool securely. The wire should feed from the bottom of the spool.
c) d) e)
f) NOTE 1: g)
Page 7
h) i) j) k) I)
Fit the TWECO MIG Torch to the wire drive assembly in the wire compartment. Refer to Figure 9. Connect both black Torch trigger leads to the Torch trigger terminals. Refer to Figure 9. Remove the contact tip from the MIG Torch. Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide, between the rollers then into the MIG Torch. Lower the pressure lever and with the MIG Torch lead reasonably straight, feed the wire through the MIG Torch. Fit the appropriate contact tip.
m) Fit the internal gas hose onto the gas nipple in the MIG Torch. CAUTION 3: The electrode wire will be at welding voltage potential whilst it is being fed through the system.
Positive Welding Terminal
Negative Welding Terminal
Work Lead
Torch Lead Connect two black leads from the MIG Torch to the two way terminal
Voltage Control Selection
Wire Speed Control
MIG Torch Secure torch lead (using a supplied: M6*10mm screw, star washer, flat washer ) to achieve a sound electrical connection to the MIG Torch Connect the gas hose onto the MIG Torch gas connection
Secure screw to fix the MIG Torch into position. Do not overtighten as this will result in the insert pulling out of the feed plate.
Figure 7 - MIG Torch and polarity connections
Page 8
Transmig 180
6. POWER SOURCE CONTROLS, INDICATORS AND FEATURES
Power On Light
Voltage Control Switch
Thermal Overload Light Wirespeed Control
Burnback Adjustment Access Hole
6.1
POWER ON Light The POWER ON light is provided to indicate when the Power Source is connected to the Mains supply voltage. When the light is lit, the Power Source is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential.
·
CAUTION 4:
6.2
Voltage Control Switch The Voltage Control switch sets the voltage level to the welding terminals with the voltage increasing as it is rotated in the clockwise direction The Voltage Control switch MUST NOT BE TURNED during welding.
CAUTION 5: 6.3
OVER TEMPERATURE Light The OVER TEMPERATURE light will flash to indicate that the transformer or rectifier have exceeded their temperature rating (normally caused by exceeding the Power Source duty cycle) and welding current is interrupted. When this happens, allow the internal components of the Power Source to cool by leaving the Mains supply voltage ON for 10 to 15 minutes. The Power Source is ready for operation when the OVER TEMPERA TURE indicator stays extinguished.
6.4
Wirespeed Control The Wirespeed Control knob controls the welding current via the electrode wire feed rate (i.e. the speed of the wire feed motor).
Page 9
6.5
Burnback Adjustment The Burnback time can be adjusted by placing a flat bladed screw driver into the Burnback Adjustment access hole and engaging the Burnback trim potentiometer. Rotating in the anti clockwise direction increases Burnback time while the clockwise direction decreases Burnback time. Polarity Reversal Terminals The Polarity Reversal Terminals are located in the wire spool compartment. The electrode wire welding voltage polarity is selected by connecting the Torch Polarity Lead and the work lead to the Polarity Reversal Terminals. Connect the Torch Polarity Lead to the positive welding terminal (+) when using steel, stainless steel or aluminium electrode wire. Refer to Figure 9. Alternatively connect the Torch Polarity Lead to the negative welding terminal (-) when using gasless electrode wire. If in doubt, consult the manufacturer of the electrode wire for the correct polarity.
6.6
CAUTION 6:
Welding current flows to the MIG Torch via the output terminal/lug connection. It is essential that the bolt is secured tightly to achieve a sound electrical connection. Loose welding terminal connections can cause overheating and result in the terminal being fused beyond repair.
6.7
Thermal Overload The critical components for thermal protection are the transformer and rectifier stack. Both are fitted with a thermal overload cutout device. The OVER TEMPERATURE indicator will flash to indicate that the transformer or rectifier have exceeded their temperature rating (normally caused by exceeding the Power Source duty cycle) and welding current is interrupted. If the overload operates, as indicated by the OVER TEMPERATURE indicator, then the Power Source should be left to cool with the fan operating for approximately 10 to 15 minutes before resuming welding. If the Power Source is operated within its duty cycle, then the thermal overload feature will not operate and there will be no danger of transformer, damage. Refer to section 1.5 for an explanation of duty cycle and section 2 for the Power Source Specifications.
6.8
Wirefeeder Driver Roller Pressure Adjustment The moveable roller applies pressure to the grooved roller via a 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 conduit liner should be checked for kinks and clogging by metal flakes and swarf. Refer to CAUTION 7. If this is not the cause of slipping, the feedroll pressure can be increased by rotating the adjustable spring screw clockwise. The use of excessive pressure may cause rapid wear of the feed roller, motor shaft and motor bearings. Genuine TWECO contact tips and lines should be used use inferior materials that can cause wire feed problems. Many non-genuine liners
NOTE 2:
Page 10
Transmig 180
6.9 Wire Spool Brake The wire spool hub incorporates a friction brake that is set 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 spool hub. Clockwise rotation will tighten the brake. Correct adjustment will result in the spool circumference continuing no further than 20mm after release of the Torch trigger switch. The wire should be slack without becoming dislodged from the spool. 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.
CAUTION 7:
7. TWECO MIG TORCH (717579)
7.1 Introduction The TWECO 180A gun fitted to the Transmig 180 offers robust construction, unparalleled reliability and easy replacement of consumable parts. The TWECO 180A MIG Torch has an operating capacity in excess of the capacity of the Transmig 180 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.
Figure 8 MIG Torch breakdown
Page 11
7.2
MIG Torch Components
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Part No. EL22I50P EL16T35 EL52 OTW90810 OTW90814 Nozzle Description (refer to Table 5) Contact tip (refer to Table 4) Gas diffuser (refer to Table 3) Conductor tube Gun Hanger 2.8mm Push on terminal Trigger Assembly Trigger Screw Handle Cap Cable Assembly Set Screw Conduit Assembly Hex Key l l l l l l
1
Qty l l l l l
--
717523 OTW94D/1 OTW35/80A/1 OTW9080C OTW44C 717524 OTW44/25
Table 2 - MIG Torch components 7.3 MIG Torch Consumable Parts * denotes parts that are supplied as standard with MIG Torch 717579. Gas Diffusers
Part No. Part No.
NOTE 3: a)
* EL52 (slide on nozzles) b) Contact Tips
STANDARD W i r e Size (mm) Part No.
EL52CT (screw on nozzles)
Table 3 - MIG Torch gas diffusers
TAPERED Wire Size (mm) Part N o .
0.6 0.8 0.9 1.0 1.2 1.2 Alum
not available EL1630 EL1635 EL1640 EL1645 EL16A364
0.6 0.8 0.9 1.0 1.2 1.2 Alum
EL16T23 EL16T30 * EL16T35 EL16T40 EL16T45 EL16AT364
Table 4 - MIG Torch contact tips
Page 12
Transmig 180
c) Nozzles
B o r e Size (mm) Part No. Bore Size (mm) Part N o .
9.5 9.5 12.7 12.7 12.7 15.9 15.9 15.9 19.1 19.1 15.9
-
EL22A37 EL22A37F EL22A50 EL22A50F *EL22I50P EL22A62 EL22A62F EL22I62P EL22A75 EL22A75F EL22I62FAS (Spot Nozzle)
9.5 9.5 12.7 12.7 12.7 15.9 15.9 15.9 19.1 19.1 CT = Coarse Thread F = Flush Tip
EL22CT37 EL22CT37F EL22CT50 EL22CT50F EL22CT50P EL22CT62 EL22CT62F EL22CT62P EL22CT75 EL22CT75F P=Protruding Tip
Table 5 - MIG Torch nozzles d) Conduits
HARD & SOFT ELECTRODE WIRES W i r e Size (mm) Part No. 717524 717524 * 717524 717524
0.6 0.8 0.9 1.0 1.2
OTW45/40
Table 6 - MIG Torch conduit liners 7.4 Installing A New Wire Conduit a) Be sure the MIG Torch cable is arranged in a straight line, free from twists, when installing or removing a wire conduit liner. Remove the old conduit liner by first removing the MIG Torches nozzle, contact tip and gas diffuser. Then loosen Allen screw in the connector plug and pull the old wire conduit liner out of the cable assembly from the connector plug end. To install a new wire 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. When the wire conduit liner stop meets the end of the connector plug and the new raw end extends through the end of the conductor tube, the Allen screw in the connector plug must be securely tightened onto the conduit liner to prevent its backward movement. 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 to a length of 35mm to 36mm past the conductor tube. The trimmed end which seats in the Gas Diffuser must be filed and reamed smooth on the inside and outside radii so wire feed will not be obstructed
b)
c)
IMPORTANT 1:
Page 13
d) e) CAUTION 8:
Replace Gas Diffuser, Contact Tip, and Nozzle. Tighten the Allen screw in the conductor tube. 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.
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.
8.
BASIC WELDING TECHNIQUE
8.1 Setting of the Power Source & Wirefeeder The setting of the Transmig 180 requires some practice by the operator, the welding plant having two control settings that have to balance. These are the Wirespeed control and the Voltage Control switch. 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 welding current level, but lengthens the arc. By decreasing the voltage, a shorter arc is obtained with little change in welding current. When changing the electrode wire diameters, different control settings are required. electrode wire needs more Wirespeed to achieve the same current level. A thinner
A satisfactory weld cannot be obtained if the Wirespeed and Voltage Control Switch settings are not adjusted to suit the electrode wire diameter and 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 electrode 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 9. Figure 9 - MIG Torch angle Distance from the MIG Torch Nozzle to the Work Piece The electrode stick out from the MIG Torch nozzle should be between 2.0mm to 5.0mm. distance may vary depending on the type of joint that is being welded. MIG Torch Travel Speed Speed at which a weld travels influences the width of the weld and penetration of the welding run. 8.5 Electrode Wire Size Selection The choice of electrode wire size in conjunction with shielding gas used depends on: · Thickness · Type of the of metal to be joint welded · The deposition rate required · The bead profile desired
8.3
This
8.4
· Capacity of the wire feed unit and power source · The position of welding · The amount of penetration required · Cost of electrode wire
Page 14
Transmig 180
9. ROUTINE MAINTENANCE & INSPECTION
The only routine maintenance required for the Transmig 180 is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment. CAUTION 9: Disconnect the Transmig 180 from the Mains supply voltage before disassembling. Special maintenance is not necessary for the control unit parts in the Power Source. If these parts are damaged for any reason, replacement is recommended. CAUTION 10: Do not blow air into the Power Source during cleaning. Blowing air into the Power Source can cause metal particles to interfere with sensitive electronic components and cause damage to the Power Source.
To clean the Power Source, disconnect if from the Mains supply voltage then open the enclosure and use a vacuum cleaner to remove any accumulated dust. The Power Source should also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used. Troubleshooting and repairing the Transmig 180 should be carried out only by those who are familiar with electrical equipment. CAUTION 11: Do not attempt to diagnose or repair unless you have had training in electronic measurement and troubleshooting techniques.
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. If major components are faulty, then the Power Source 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. The two main problem areas with GMAW are: 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 that 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. - Check for gas leaks between the regulator/cylinder connection and in the gas hose to the Power Source.
2. Gas leaks.
3. Internal gas hose in the Power Source. - Ensure the hose from the solenoid valve to the MIG Torch has not fractured and the hose is connected to the MIG Torch gas nipple. 4. Welding in a windy environment. - Shield the weld area from the wind or increase the gas flow.
Page 15
5. Welding dirty, oily, painted, oxidised or greasy plate. 6. Distance between the MIG Torch nozzle and the work piece. 7. Maintain the MIG Torch in good working order.
Clean contaminates off the plate Keep the distance between the MIG Torch nozzle and the work piece to a minimum. Refer to section 8.3 on page 14. - Ensure that the gas holes are not blocked and gas is exiting out of the MIG Torch nozzle. Refer to CAUTION 12. Do not restrict gas flow by allowing spatter to build up inside the MIG Torch nozzle. Check that the MIG Torch O-rings are not damaged.
CAUTION 12: Disengage the drive roll when testing for gas flow by ear. b) Inconsistent wire feed Wire feeding problems can be reduced by checking the following points. 1. Wire spool brake is too tight. 2. Wire spool brake is too loose. 3. Worn or incorrect feed roller size. Feed roller driven by motor in the cabinet will slip. Wire spool can unwind and tangle. 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. Wire will rub against the mis-aligned guides and reduces wire feedability. Increased amounts of swarf is produced by the 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 liner where it accumulates thus reducing wire feedability. 6. Incorrect or worn contact tip The contact tip transfers the weld current to the wire. If the hole in the contact tip is too large then arcing may occur inside the contact tip resulting in the electrode 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. Contact tip designed for soft wires should be used. Page 16
4. Mis-alignment of inlet/outlet guides. 5. Liner blocked with swarf
Transmig 180
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 welding arc. - This will cause friction between the wire and the liner thus reducing wire feedability
8. Bent liner
10.2 Welding Problems
FAULT 1 Undercut A CAUSE Welding arc voltage too high. A REMEDY Reduce voltage by reducing the voltage selection switch position or increasing the Wirespeed. Adjust angle Increase the MIG Torch travel speed and/or reduce welding current by reducing the voltage selection switch position or reducing the Wirespeed. Increase welding current by increasing wire speed control and increasing voltage selection switch position. Increase joint angle or gap Change to a gas which gives higher penetration Increase voltage by increasing voltage selection switch position. A Lower the voltage by reducing the voltage selection switch or increase the Wirespeed control. Raise voltage by increasing the voltage selection switch or reduce Wirespeed control. Adjust voltage and current by adjusting the voltage selection switch and the Wirespeed control. Replace contact tip Check the type of shielding gas being used. Adjust the Wirespeed control or the voltage selection switch. Decrease the MIG Torch travel speed Reduce current and voltage and increase the MIG Torch travel speed or select a lower penetration shielding gas. Increase weld metal strength or revise design
B C
Incorrect Torch angle Excessive heat input
B C
2
Lack of penetration
A
Welding current too low
A
B C 3 4 Lack of fusion Excessive spatter A
Joint preparation too narrow or gap too tight Shielding gas incorrect Voltage too low Voltage too high
B C
B
Voltage too low
B
5
Irregular weld shape
A
Incorrect voltage and current A settings. Convex, voltage too low. Concave, voltage too high. Wire is wandering Incorrect shielding gas Insufficient or excessive heat input Weld beads too small B C D A
B C D 6 Weld cracking A B
Weld penetration narrow and B deep
C
Excessive weld stresses
C
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Welding Problems (continued)
FAULT D E 7 Cold weld puddle A CAUSE Excessive voltage Cooling rate loo fast Faulty rectifier unit D E A REMEDY Decrease voltage by reducing the voltage selection switch. Slow the cooling rate by preheating part to be welded or cool slowly. Have an Accredited CIGWELD Service Agent to test then replace the faulty component. Check all welding cable connections. Contact supply authority Connect the MIG Torch to the positive (+) welding terminal for solid wires and gas shielded flux cored wires. Increase the burnback time. Refer to section 6.5 on page 10.
B C 8 Arc does not have a crisp sound (that short arc exhibits) when the Wirespeed and voltage are adjusted correctly. Electrode wire freezes onto the work piece when the torch trigger switch is released. Electrode wire is burning back onto the contact tip when the torch trigger switch is released.
Loose welding cable connection. Low Primary Voltage The MIG Torch has been connected to the wrong voltage polarity in the wire spool compartment. The burnback time is too low.
B C
9
10
The burnback time is too high.
Decrease the burnback time. Refer to section 6.5 on page 10.
10.3 Power Source Problems
FAULT 1 Mains supply voltage is ON. Indicator light is not lit and welding arc can not be established. Mains indicator light is not lit but welding arc can be , established. Mains supply voltage is ON and Indicator light is lit but when the Torch trigger switch is depressed nothing happens. Mains supply voltage is ON, no wire feed but gas flows from the MIG Torch when the Torch trigger switch is depressed. Wire feeds when the Torch trigger switch is depressed but arc can not be established. Mains supply voltage is ON and contactor in the Power Source operates but wire does not feed when the Torch trigger switch is depressed. A A B CAUSE A Primary fuse is blown. Broken connection in primary B circuit. Indicator light has malfunctioned. Torch trigger switch leads are not connected to the torch trigger terminals. REMEDY Replace primary fuse. Have an Accredited CIGWELD Service Agent check primary circuit Have an Accredited CIGWELD Service Agent replace Indicator light. Connect the trigger switch leads to the torch trigger terminals
2
3
4
Electrode wire stuck in conduit liner or contact tip (burn-back jam). Faulty Control PCB Poor or no work lead connection. MIG Torch has been damaged internally, torch trigger wires are making contact with welding power cable.
A
Check for clogged / kinked MIG Torch conduit liner or worn contract tip. Replace faulty component(s). Have an Accredited CIGWELD Service Agent investigate the fault. Clean work clamp area and ensure good electrical contact. Have an Accredited CIGWELD Service Agent repair Torch & replace Control PCB.
B
B
5
6
Page 18
Transmig 180
Power Source Problems (continued)
FAULT 7 Jerky wire feed A B C D 8 No gas flow A B CAUSE Worn or dirty contact tip Worn feed roll. Excessive back tension from wire reel hub. C Reduce brake tension on spool hub Clean or replace conduit liner Replace or repair. Disconnect gas hose from the rear of the Power Source then raise gas pressure and blow out impurities. Turn on. Have an Accredited CIGWELD Service Agent repair or replace gas valve. Worn, kinked or dirty conduit D liner Gas hose is cut. Gas passage contains impurities. Gas regulator turned off. Gas valve has jammed open due to impurities in the gas or the gas line. A B A B Replace Replace REMEDY
C 9 Gas flow continues after the Torch trigger switch has been released.
C
10.4 Key Spare Parts
Part Number 704888 717579 301526 705197 703299 705260GRY 705366 7977675 7977676 7977683 7977768 7977769 705363 7977752 7977759 705182GRY 705190PKD 7977745 7977774 7977740 7977765 705195GRY 703625 7976759 7977743 Handle MIG Torch Reg 500A arg 55LPM 2GA Wheeling kit MIG180 Hose assy Bracket CYL chain Handi spool hub (for 200mm spool adaptation) Hinge pin type a Hinge type a Latch slide Hinge pin type b Hinge type b Base MIG 180 Contactor Thermostat 150C (transformer) Panel centre grey MIG 180 Transformer/Inductor MIG 180 Rectifier 250A Capacitor lOOOOOuF 40V Fan motor 240v aux24v Impellor 180mm & retaining clip Cylinder carrier Cylinder chain Rear Wheel Front Swivel Wheel Description Part Number 7977155 7977156 7977714 7976411 702337 7976405 7958040 OTWAK1P 705415 705416 7977739 7977738 704279 KK281 VB1358 7976741 705173 7976667 7977680 705I98PKD 7977709 705174 705364 705365 705317 Description Fuse holder 3 AG Fuse bayonet cap 3 AG Connector term 2way 6.3mm Washer friction Hub wire reel (300mm spool) Spring Nut nyloc 5/8 BSW Lockpin no4 MIG TCH Control Loom MIG 180 Power Loom MIG180 Switch ROT 32A 8pos Wire drive assy Liner outlet 1.6mm Solenoid valve Supply lead Clamp cable Hose gas internal MIG 180 Clip hose ID 11.5 Light 240V red 41series Control PCB Transmig 180 Wirespeed knob Lead work Panel fixed blue MIG180 Door blue MIG180 Aux Transformer 220/240-24/5A
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11. Transmig 180 Volt/Amp curves
Welding Current
Figure 10 - Transmig 180 Volt/Amp curves
12. TRANSMIG 180 CIRCUIT DIAGRAMS
12.1 Power Source
Page 20
Transmig 180
12.2 Control PCB
Page 21
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Manufacturer and Supplier of Welding Consumables and Equipment
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