Tweco 400i User Manual

Download

400 i

TRANSMIG

INVERTER ARC WELDER

Operating Manual

Revision: AA Issue Date: July 18, 2008 Manual No.: 0-4959 Operating Features:

GMAW FCAW

GTAWMMAW

PHASE

50 60

CC CV

415

INVERTER

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new CIGWELD product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and accredited service network. To locate your nearest distributor or service provider call +61-3-9474-7400, or visit us on the web at www.cigweld.com.au.

This Operating Manual has been designed to instruct you on the correct use and operation of your CIGWELD product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

CIGWELD is a Market Leading Brand of Arc Equipment, Gas Equipment and Filler Metals for Thermadyne Industries Inc. We are a mainline supplier to major welding industry sectors in the Asia Pacific and emerging global markets including; Manufacturing, Construction, Mining, Automotive, Engineering, Rural and DIY.

We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced products to achieve a safer working environment for industry operators.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Transmig 400 i Inverter Arc Welder Operating Manual Number 0-4959 for: Part Number 710014

Published by: Thermadyne Industries Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermadyne.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this manual, whether such error results from negligence, accident, or any other cause.

Publication Date: July 18, 2008

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS .................................... 1-1

1.01 Arc Welding Hazards ...................................................................................... 1-1

1.02 PRINCIPAL SAFETY STANDARDS .................................................................. 1-5

1.03 DECLARATION OF CONFORMITY ................................................................... 1-6

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identification ................................................................................. 2-1

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 Symbol Chart ................................................................................................. 2-2

2.05 Description ..................................................................................................... 2-3

2.06 Functional Block Diagrams ............................................................................. 2-4

2.07 Transporting Methods .................................................................................... 2-4

2.08 Specifications ................................................................................................. 2-5

SECTION 3:

INSTALLATION ...................................................................................... 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location ......................................................................................................... 3-1

3.03 Electrical Input Connections ........................................................................... 3-1

3.04 Mains Supply Voltage Requirements .............................................................. 3-2

3.05 High Frequency Introduction .......................................................................... 3-3

3.06 High Frequency Interference .......................................................................... 3-3

3.07 Duty Cycle ...................................................................................................... 3-4

SECTION 4:

OPERATION........................................................................................... 4-1

4.01 Transmig 400 i Controls ................................................................................. 4-1

4.02 Weld Process Selection .................................................................................. 4-3

4.03 Weld Parameter Descriptions ......................................................................... 4-3

4.04 Front Panel Weld Parameter Descriptions ...................................................... 4-5

4.05 Weld Parameters ............................................................................................ 4-6

4.06 Power Source Features ................................................................................... 4-6

4.07 Set-up for MMAW (STICK) and GTAW (TIG) .................................................. 4-8

4.08 Set-up for GMAW/FCAW (MIG) ...................................................................... 4-9

4.09 Sequence Of Operation ................................................................................. 4-10

4.10 Stick Welding ............................................................................................... 4-11

4.11 LIFT TIG Welding .......................................................................................... 4-11

4.12 MIG Welding ................................................................................................ 4-11

4.13 Save-Load Operation .................................................................................... 4-12

TABLE OF CONTENTS

SECTION 5:

BASIC WELDING GUIDE ............................................................................ 5-1

5.01 Basic TIG Welding Guide ................................................................................ 5-1

5.01.1 Electrode Polarity ................................................................................ 5-1

5.01.2 Tungsten Electrode Current Ranges .................................................... 5-1

5.01.3 Tungsten Electrode Types .................................................................... 5-1

5.01.4 Guide for Selecting Filler Wire Diameter .............................................. 5-2

5.01.5 Shielding Gas Selection ....................................................................... 5-2

5.01.6 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe ....... 5-2

5.01.7 Welding Parameters for Steel .............................................................. 5-3

5.02 Basic STICK Welding Guide ............................................................................ 5-4

5.02.1 Electrode Polarity ................................................................................ 5-4

5.02.2 Effects of Stick Welding Various Materials .......................................... 5-4

5.03 Basic MIG Welding Guide ............................................................................... 5-5

5.03.1 Setting of the Power Source ................................................................ 5-5

5.03.2 Position of MIG Torch ......................................................................... 5-5

5.03.3 Travel Speed ........................................................................................ 5-5

5.03.4 Electrode Wire Size Selection .............................................................. 5-5

5.03.5 Deposition Rate Comparison ............................................................... 5-5

TABLE OF CONTENTS (continued)

SECTION 6:

SERVICE .............................................................................................. 6-1

6.01 Routine Maintenance ...................................................................................... 6-1

6.02 Maintenance Diagram ..................................................................................... 6-2

6.03 Basic Troubleshooting .................................................................................... 6-3

6.04 Solving MIG Problems beyond the Welding Terminals ................................... 6-3

6.05 MIG Welding Problems ................................................................................. 6-5

6.06 TIG Welding Problems ................................................................................... 6-6

6.07 Stick Welding Problems ................................................................................. 6-8

6.08 Power Source Problems ............................................................................... 6-11

6.09 Power Source Error Codes ........................................................................... 6-12

6.10 Voltage Reduction Device (VRD) .................................................................. 6-14

APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1

APPENDIX 2: TRANSMIG 400 i INTERCONNECT DIAGRAM.......................................... A-2

CIGWELD LIMITED WARRANTY

Terms of Warranty – January 2008

Warranty Schedule – January 2008

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

TRANSMIG 400 i

SECTION 1:

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the Australian Standard AS1674.2-2007 entitled: Safety in welding and allied processes Part 2: Electrical. This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION,

MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly spliced cables.

9. Do not wrap cables around your body.

10.Ground the workpiece to a good electrical (earth) ground.

11.Do not touch electrode while in contact with the work (ground) circuit.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

July 18, 2008

12.Use only well-maintained equipment. Repair or replace damaged parts at once.

13.In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

14.Wear a safety harness to prevent falling if working above floor level.

15.Keep all panels and covers securely in place.

1-1

TRANSMIG 400 i

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage hearing.

Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73

Welding or Cutting

operation

Torch soldering All 2

Torch brazing All 2 or 3 Non Ferrous base metal All 11

Oxygen cutting

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding (TIG) Medium 1 – 6 in., 25 – 150 mm 4 or 5 Atomic Hydrogen welding

Heavy Over 6 in., 150 mm 5 or 6 Carbon Arc welding

Light Under 1/8 in., 3 mm 4 or 5 Carbon Arc Gouging

Medium 1/8 – 1/2 in., 3 – 12 mm 5 or 6 Light 12

Heavy Over 1/2 in., 12 mm 6 or 8 Heavy 14

Shielded metal-arc welding (stick) electrodes

1-2

Electrode size Metal Thickness

or Welding Current

Ga s welding

Under 5/32 in., 4 mm 10 Light Under 300 Amp 9 Under 5/32 to ¼ in., 4 to 6.4mm

Over ¼ in., 6.4 mm

Filter

shade

no.

Welding or Cutting opera tion Electrode size Metal

Thickness or Welding

Current

Gas metal arc welding

Ferrous base metal

Plasma arc Welding

Plasma arc cutting

Medium 300 to 400 Amp 12

Heavy Over 40 0 Amp 14

All 1 2

July 18, 2008

Filter

shade

no.

TRANSMIG 400 i

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

10.Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields recommended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

July 18, 2008

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

1-3

TRANSMIG 400 i

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open flames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

1-4

July 18, 2008

WARNING

TRANSMIG 400 i

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hot and under pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals know to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety code Sec. 25249.5 et seq.)

NOTE

Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear sciencebased advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from body as practical.

ABOUT PACEMAKERS:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

1.02 PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safety in welding and allied processes Part 2: Electrical, AS1674.2-2007 from SAI Global Limited, www.saiglobal.com

July 18, 2008

1-5

TRANSMIG 400 i

1.03 DECLARATION OF CONFORMITY

Manufacturer: CIGWELD Address: 71 Gower St, Preston

Victoria 3072

Australia

Description of equipment: Welding Equipment (GMAW, MMAW, GTAW). Including, but not limited to CIGWELD Transtig 200 Pi, Transtig 200 AC/DC, Transarc 300 Si, Transtig 300 Pi, Transtig 300 AC/DC, Transmig 400 i and associated accessories.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive 73/23/EU, as recently changed in Directive 93/68/EU and to the National legislation for the enforcement of the Directive.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements among them are:

• AS/NZS 3652-(EMC Directive EN50199) applicable to arc welding equipment - generic emissions and

regulations.

• EN60974-1 applicable to welding equipment and associated accessories.

• AS60974.1 applicable to welding equipment and associated accessories.

Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance, ultra safe operation and world class quality for more than 30 years and will continue to achieve excellence.

1-6

July 18, 2008

TRANSMIG 400 i

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part numbers listed on page i.

To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

WARNING

A WARNING gives information regarding possible personal injury.

2.02 Equipment Identification

The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel. Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers on the bottom of page i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.

Include all equipment identification numbers as described above along with a full description of the parts in error.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

Additional copies of this manual may be purchased by contacting Cigweld at the address and phone number for your location listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Cigweld web site listed below and clicking on the Literature Library link:

http://www.cigweld.com.au

Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to uncrate the unit.

July 18, 2008

2-1

TRANSMIG 400 i

2.04 Symbol Chart

Note that only some of these symbols will appear on your model.

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

2 Step Trigger Operation

Press to initiate wirefeed and welding, release to stop.

4 Step Trigger Operation

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

Burnback Time

Disturbance In Ground System

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

2-2

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04937

July 18, 2008

2.05 Description

The Cigweld Transmig 400 i is a self contained threephase DC arc welding power source with Constant Current (CC) and Constant Voltage (CV) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, lift arc starter for use with Gas Tungsten Arc Welding (GTAW), and Control and Hot Start for Shielded Metal Arc Welding (SMAW) processes. The power source is totally enclosed in an impact resistant, flame resistant and nonconductive plastic case.

NOTE

(V)

OCV

18V

TRANSMIG 400 i

160A

400A5A (A)

420A

Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source. Curves of other settings will fall between the curves shown.

STICK Process

(V)

OCV

10V

400A25A (A)

LIFT-TIG Process

(V)

OCV

July 18, 2008

36V

10V

5A (A)

400A

480A

MIG Process

Figure 2-1: Transmig 400 i Volt-Ampere Curves

2-3

TRANSMIG 400 i

2.06 Functional Block Diagrams

Figure 2-2 illustrates the functional block diagram of the Transmig 400 i power source.

Input

Power

Main Circuit Switch

Filter

Down

Transformers

AC115V,AC24V

(T3)

Over Current Protect

14PIN

Receptacle

(CON1)

Input

Diode

Capacitor

DC Power Primary Voltage

Sensor

To each control circuit

+/-15VDC +18VDC +24VDC +5VDC

Thermal Detector

IGBT

Inverter

Trouble

Sensing

Circuit

Drive

Circuit

Main

Transformers

(T1)

Thermal

Sensor

Circuit

Primary

Circuit

Sensor

Current

Adjustment

Circuit

Output

Diodes Thermal Detector

Stick Mode

VRD

Sensing

Circuit

Sequence

Control

Reference

Adjustment &

Mode Select Switch

Panel Circuit Board

Output

Inductor

Figure 2-2: Transmig 400 i Functional Block Diagram

Lift Tig Mode Output Short

Sensing

Circuit

Fan Control

Hall Current Transformer

Output

Voltage

Detect Circuit

Circuit

Art # A-08566

(HCT1)

Fan

2.07 Transporting Methods

These units are equipped with a handle for carrying purposes.

WARNING

ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source.

WARNING

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Lift unit with handle on top of case.

Use handcart or similar device of adequate capacity.

If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

2-4

July 18, 2008

2.08 Specifications

Power Source Part Number 710014 Cooling Fan Cooled Welder Type Inverter Power Source Welding Power Source Mass 25kg Dimensions H 420mm x W 210mm x D 450mm Manufactured to Australian Standard AS 60974.1-2006 Number of Phases 3 Nominal Supply Voltage 415V ±15% Nominal Supply Frequency 50Hz Open Circuit Voltage 65V Welding Current Range 5 - 400 Amps Effective Input Current (I1eff) 16.7 Amps Maximum Input Current (I1max) 33.4 Amps Three Phase Generator Requirement 24.0 KVA

Welding Output, 40 (quoted figures refer to MMAW output)

Welding Output 40 (Quoted figures refer to GTAW output)

Welding Output 40 (Quoted figures refer to GMAW output) Protection Class IP23S

Parameter Transmig 400i

C, 10 min.

400A @ 25%, 36.0V 300A @ 60%, 32.0V

200A @ 100%, 28.0V

C, 10 min.

400A @ 25%, 26.0V 300A @ 60%, 22.0V

200A @ 100%, 18.0V

C, 10 min.

400A @ 25%, 34.0V 300A @ 60%, 29.0V

200A @ 100%, 24.0V

TRANSMIG 400 i

Table 2-1: Specifications

Cigweld continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifications due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components, installation location and conditions and local power grid supply conditions.

July 18, 2008

2-5

TRANSMIG 400 i

THIS PAGE LEFT INTENTIONALLY BLANK

2-6

July 18, 2008

SECTION 3:

INSTALLATION

TRANSMIG 400 i

3.01 Environment

The Transmig 400 i is designed for use in hazardous environments. Examples of environments with increased hazardous environments are:

a. 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;

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

c. In wet or damp hot locations where humidity or

perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories.

Environments with hazardous environments do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.

3.03 Electrical Input Connections

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.

DO NOT TOUCH live electrical parts.

SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

3.02 Location

Be sure to locate the welder according to the following guidelines:

· In areas, free from moisture and dust.

· Ambient temperature between 0 degrees C to 40 degrees 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 12” (304.79mm) or more from walls or similar that could restrict natural airflow for cooling.

WARNING

Cigweld advises that this equipment be electrically connected by a qualified electrician.

July 18, 2008

3-1

TRANSMIG 400 i

3.04 Mains Supply Voltage Requirements

The Mains supply voltage should be within ± 15% of the rated Mains supply voltage. Too low a voltage may cause the fuse or circuit breaker to rupture due to the increased primary current. Too high a supply voltage will cause the Power Source to fail.

415V Mains Current Circuit Requirements for the Transmig 400 i

The Welding Power Source must be:

• Correctly installed, if necessary, by a qualified electrician.

• Correctly earthed (electrically) in accordance with local regulations.

• Connected to the correct size 415V Mains Current Circuit as per the Specifications

WARNING

CIGWELD advises that this equipment be electrically connected by a qualified electrical tradesperson.

The following 415V Mains Current Circuit recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment:

Model Minimum 240V Mains

Current Circuit Size

Transmig 400 i 33.4 Amps

Table 3-1: 415V Mains Current Circuit Size to Achieve Maximum Current

3-2

July 18, 2008

TRANSMIG 400 i

3.05 High Frequency Introduction

The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation. The following information is intended as a guide for personnel installing high frequency welding machines.

WARNING: EXPLOSIVES

The high frequency section of this machine has an output similar to a radio transmitter. The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing.

WARNING: COMPUTERS

It is also possible that operation close to computer installations may cause computer malfunction.

3.06 High Frequency Interference

Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following ways:

1. Direct Radiation: Radiation from the machine can

occur if the case is metal and is not properly grounded. It can occur through apertures such as open access panels. The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properly grounded.

2. Transmission via the Supply Lead: Without

adequate shielding and filtering, high frequency energy may be fed to the wiring within the installation (mains) by direct coupling. The energy is then transmitted by both radiation and conduction. Adequate shielding and filtering is provided in the Power Source.

3. Radiation from Welding Leads: Radiated

interference from welding leads, although pronounced in the vicinity of the leads, diminishes rapidly with distance. Keeping leads as short as possible will minimize this type of interference. Looping and suspending of leads should be avoided where possible.

4. Re-radiation from Unearthed Metallic Objects:

A major factor contributing to interference is reradiation from unearthed metallic objects close to the welding leads. Effective grounding of such objects will prevent re-radiation in most cases.

July 18, 2008

3-3

TRANSMIG 400 i

3.07 Duty Cycle

The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases. If the welding amperes are increased beyond the rated output, the duty cycle will decrease.

WARNING

Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature.

CAUTION

Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty.

NOTE

Due to variations that can occur in manufactured products, claimed performance, 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, applications, maintenance and service.

3-4

July 18, 2008

4.01 Transmig 400 i Controls

TRANSMIG 400 i

SECTION 4:

OPERATION

Figure 4-1: Transmig 400 i Power Source

1. Control Knob: This control sets the selected weld

parameter, rotating it clockwise increases the parameter that is indicated on the digital meter. Pushing the knob inward displays the actual welding voltage.

2 . Remote Control Socket: The 14 pin Remote

Control Socket is used to connect remote current control devices to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Art # A-07653_AB

ABC

DE F H I JKLMNG

BK I

CL NH

DMG

Art A-08355_AB

Socket

Torch Switch Input (24V) to (connect

pins A & B to turn on welding current).

Torch Switch Input (0V) to energize

weld

B current (connect pins A & B to turn on

welding current). 5k ohm (maximum) connection to 5k

ohm remote control potentiometer. Zero ohm (minimum) connection to 5k

ohm remote control potentiometer. Wiper arm connection to 5k ohm

remote control potentiometer.

G Mains Earth.

Function

Figure 4-2: 14-Pin Socket Receptacle

July 18, 2008

5k ohms

Front view of 14 Socket Receptacle

F,H,I,J,

K,L

Not Used.

OK to move current detect signal for robotics applications. OK to move current detect signal for robotics applications.

Table 4-1: Socket Pin Functions

4-1

TRANSMIG 400 i

3. Positive Terminal: Welding current flows from the Power Source via heavy duty Dinse type terminal. It is

essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

4. Negative Terminal: Welding current flows from the Power Source via heavy duty Dinse type terminal. It

is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.

5. ON/OFF Switch: This switch connects the Primary supply voltage to the inverter when in the ON position. This

enables the Power Supply.

WARNING

When the welder is connected to the Primary supply voltage, the internal electrical components may be at 240V potential with respect to earth.

6. Input Cable: The input cable connects the Primary supply voltage to the equipment.

7. 24VAC Remote Device C/B: Push to reset. Controls the 24VAC power source for the wire feeders controlled

through the Remote Control Sockets.

8. 115VAC Remote Device C/B: Push to reset. Controls the 115VAC power source for the wire feeders controlled

through the Remote Control Sockets.

4-2

July 18, 2008

4.02 Weld Process Selection

TRANSMIG 400 i

Weld Parameter

STICK

WELD (V)

INDUCTANCE

HOT START

WELD (A)

Weld Mode

MIG

LIFT

TIG

  

        

ARC CONTROL

  

Table 4-3: Weld Process selection versus Weld Mode for Transmig 400 i

4.03 Weld Parameter Descriptions

WELD (V):

This parameter sets the MIG weld arc voltage in MIG mode.

INDUCT ANCE

Description

Weld voltage MIG Mode.

Inductance control in MIG Mode.

Start current in amps is added to the WELD (A).

WELD (A) current for STICK or LIFT TIG.

Adjusts percentage increase in welding current and is proportional to arc length (arc voltage).

This parameter sets the INDUCTANCE when MIG welding. It controls the dynamic properties of the arc in dip transfer welding mode. When this parameter is set to 0%, i.e. minimum inductance, the arc has a fast response with a resulting crisp arc noise and coarse spatter. When this parameter is set to 100%, i.e. maximum inductance, the arc has a slow response with a resulting soft arc and fine spatter.

NOTE

As the INDUCTANCE is increased, the WELD (V) may need to be adjusted to achieve the desired weld characteristic.

HOT ST ART

This parameter operates in STICK mode and improves the start characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the WELD current. e.g. HOT START current = 150 amps when Weld Current = 100 amps & HOT START = 50A

WELD (A)

This parameter sets the STICK & Lift TIG weld current.

July 18, 2008

4-3

TRANSMIG 400 i

ARC CONTROL

This parameter operates in STICK mode only and is used to adjust percentage increase in welding current and is proportional to arc length (arc voltage). This control provides an adjustable amount of arc control (or dig). This feature can be particularly beneficial in providing the operator with the ability to compensate for variability in joint fit up in certain situations with particular electrodes, e.g. cellulose and hydrogen controlled electrodes. In all welding processes, the amount of penetration obtained is dependent on the welding current; i.e. the greater the penetration, the greater the current.

Arc Force Position

Minimum (0) 0A Soft arc, Low spatter, Low

Medium (20%) 32A Normal arc, Improved fusion

Maximum (100%) 160A Hard arc, Deep penetration

Current Increase when Arc

Voltage is less than 18V

Effect on Welding Performance

penetration

characteristics,

Normal penetration

Table 4-4: Arc Control Parameters

In general, having the ARC CONTROL set at 100% (maximum) allows greater penetration control to be achieved. With the ARC CONTROL set at 0% (minimum) the Power Source has a constant current characteristic. In other words, varying the arc length does not significantly affect the welding current. When the ARC CONTROL set to 100%, it is possible to control the welding current by varying the arc length. This is very useful for controlling penetration on root runs and side wall wash on vertical up fillet welds.

Root Runs

During root runs the weld pool forms a "keyhole" shape. If too much weld current is used, the hole blows out and the weld collapses. If too little weld current is used, the hole closes up and penetration is lost. The size of the hole also determines the arc length; i.e. as the hole gets bigger, the arc gets longer.

If arc force is used, the increase in the arc length causes the weld current to decrease until the hole starts to close up but if the hole closes up to much then the arc length decreases which causes the weld current to increase. Too little or too much arc force makes this process unstable. The operator must adjust the arc force until a happy medium is reached.

Vertical Up Welding

When welding vertical up with arc force on, the operator can control the amount of current by changing arc length, i.e. voltage. Weld metal is deposited by "digging" the electrode into the side of the base metal joint and then increasing the arc length with a flicking motion, to allow the weld pool to freeze, before digging the electrode into the other side of the base metal joint.

Without arc force, increasing the arc length does not decrease the weld current sufficiently and the operator has to manually decrease the current via a remote current control to freeze the weld pool. This welding current reduction also reduces the penetration.

The arc force allows the weld pool to freeze during the "flick" phase without decreasing the amount of weld current available during the "dig" phase thus maximizing penetration.

4-4

July 18, 2008

4.04 Front Panel Weld Parameter Descriptions

TRANSMIG 400 i

Parameter Description

ARC CONTROL

HOT START

DC (A)

DC (V)

Art # A-08421

Figure 4-3: Transmig 400 i Front Panel

Parameter Description

This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability.

This parameter operates in STICK weld mode and is used to improve the start characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the current.

Weld Current (Amperage) - when lit parameter knob sets the STICK and TIG WELD current.

Weld Voltage (Volt) – when lit parameter knob sets the MIG voltage.

Table 4-4: Transmig 400 i Front Panel Parameter Description

(WELD)

Contactor ON/OFF

Operation

PANEL/REMOTE

INDUCTANCE

Contactor operation in MIG Mode only.

Selects in operation: Panel or Remote.

This parameter, similar to the ARC CONTROL in STICK mode, allows for the adjustment of the dynamic property of the arc. As the inductance is increased the output voltage may need to be adjusted to achieve the desired weld characteristics.

The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs into the Transmig 400 i memory. The Save/Load buttons must be depressed for 3 seconds to store settings.

July 18, 2008

4-5

TRANSMIG 400 i

4.05 Weld Parameters

Weld

Parameter

WELD (V)

MIG

INDUCTANCE

HOT START

WELD (A)

TIG or STICK

ARC CONTROL

Parameter Range Factory

10.0 to 36.0V DC 17.0V 0.1V

0 to 100% 10% 1%

0 to 70A 20A 1A

5 to 400A DC 80A 1A

0 to 100% 10% 1%

4.06 Power Source Features

Feature Description

Digital Control

Setting

Incremental

Unit

STICK

     

        

• All welding parameters are adjustable

Weld Mode

MIG

LIFT

TIG

Touch Panel Switches Front Control Cover Digital Meter Volt & Ammeter

Intelligent Fan Control

ON/OFF Switch

Voltage Reduction Device (VRD) (shipped activated, field-capable)

• Touch switches eliminate mechanical damage

• Protects front panel controls

• Displays selected weld parameter value

• Displays average weld current when welding

• Displays average weld current for 20 seconds after weld

has been completed

• A selected weld parameter value can be adjusted at any

time even while welding

• The intelligent cooling system is designed to reduce

dust and foreign material build-up, while providing optimum cooling.

• Fan speed reduces approximately 30 seconds after

machine is turned on

• Fan speed increases when internal components reaches

operating temperature

• Primary voltage Supply ON/OFF switch located on rear

panel

Reduces the OCV when the power supply is not in use. Eliminates the need for add on voltage reducers and has no effect on arc starting.

• VRD fully complies to AS 60974.1

• When Stick mode is selected the green VRD light is

ON when not welding and red when welding.

• When in TIG modes VRD is OFF.

4-6

July 18, 2008

TRANSMIG 400 i

Control Knob

Self Diagnosis Using Error Codes

Save/Load Function

• For the selected weld parameter, rotating the knob

clockwise increases the parameter.

• Rotating the knob counter-clockwise decreases the

parameter.

• A selected weld parameter value can be adjusted at any

time even while welding.

• Pushing the knob in sets the selected parameter then

displays the next parameter.

• An error code is displayed on the Digital Meter when a

problem occurs with Mains supply voltage or internal component problems.

• A total number of 5 programs can be saved into the 400 i

memory.

SAVE

the Current Weld Parameters into Memory

• Press and HOLD the

sound and Digital Meter display will show a number 1.

• Select a memory location by rotating the control knob,

1 to 5 is displayed on the meter.

After selecting the desired memory location (i.e. 1 to 5), press the right scroll button and the machine will give a beep to confirm the weld parameters are loaded onto the control panel.

LOAD

(retrieve) a Program to Control Panel

• Press and HOLD the

sound and Digital Meter display will show a number 1.

• Select a memory location by rotating the control knob,

1 to 5 is displayed on the meter.

After selecting the desired memory location (i.e. 1 to 5), press the right scroll button and the machine will give a beep to confirm the weld parameters are loaded onto the control panel.

SAVE

button for 3 seconds. Beep will

LOAD

button for 3 seconds. Beep will

July 18, 2008

4-7

TRANSMIG 400 i

4.07 Set-up for MMAW (STICK) and GTAW (TIG)

Conventional operating procedures apply when using the welding power source, i.e. connect work lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the welding power source will withstand short-term overload without adverse effects. The welding current range values should be used as a guide only. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between different classes of electrodes, welding current at any one setting would vary according to the type of electrode in use. The operator should use the welding current range values as a guide, then finally adjust the current setting to suit the application.

Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the primary power supply is switched off.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear or sides of the welding power source.

WARNING

Art # A-08545

Figure 4-4: Transmig 400 i MMAW/GTAW Set-up

4-8

July 18, 2008

TRANSMIG 400 i

4.08 Set-up for GMAW/FCAW (MIG)

MIG welding with the Transmig 400 i requires the integration of a constant voltage (CV) wire feeder. Shielding gas will also usually be required in most cases except for some flux cored welding operations (FCAW). When setting up for flux cored welding, contact the welding wire manufacturer for lead polarity recommendations.

Refer to Figure 4-5 for a typical MIG welding configuration and connect your equipment accordingly.

NOTE

Consult the wire feeder manual on how to adjust the wire feed speed and connect the MIG gun.

Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the primary power supply is switched off.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear or sides of the welding power source.

Transmig 400 i

Gas

14-Pin Control Cable

WARNING

Constant Speed Wire Feeder MIG Gun

Electrode Lead *

Work Lead * Workpiece

* These leads may need to be reversed when using ﬂux core welding wire. Contact the welding wire manufacturer for details.

Figure 4-5: Transmig 400 i GMAW (MIG) Set-up

July 18, 2008

4-9

TRANSMIG 400 i

4.09 Sequence Of Operation

NOTE:

Parameter Buttons are used to select the parameters to be set. The LED's show which function is being adjusted on the weld sequence graph. Refer to Symbols Table located in the front of the manual for Symbol descriptions.

Art # A-08422

Figure 4-6: Transmig 400 i Front Panel

1. Contactor Function: Pressing this buttons enables Contactor functions. This function is operable in MIG

mode only. It is used to enable the output such that a voltage sensing wirefeeder i.e. Transmig VS 212 can be connected.

2. Remote Functions: Pressing this buttons enables remote current functions.

3. Digital LED Displays: Welding amperage, Voltage and parameter values are displayed in this window.

Internal warnings such as over temperature, low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen.

4. Save/Load Buttons: By using the Save & Load buttons the operator can easily save up to 5 welding

parameter programs. The Save/Load buttons must be depressed for 3 seconds to store settings.

5. Control Knob: Allows the operator to adjust the output amperage/voltage within the entire range of the

power source, also used to set each parameter value.

6. Process Button: This button selects between STICK, Lift TIG, and MIG modes. MIG modes include MS for

mild steel and SS for stainless steel.

7. Parameter Button: This button select between HOT START, WELD CURRENT, and ARC CONTROL while in

STICK and Lift TIG modes and selects between WELD VOLTAGE and INDUCTANCE CONTROL while in MIG mode. This button is also used in conjunction with the Save/Load buttons to save and load welding programs.

4-10

July 18, 2008

TRANSMIG 400 i

4.10 Stick Welding

• Connect work lead to negative terminal.

• Connect electrode lead to positive terminal.

• Switch machine on.

• Set weld current.

• Set Contactor.

• Connect remote control device if required.

Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

• Set HOT START.

• Set ARC CONTROL.

• Set WELD current.

Commence welding.

4.11 LIFT TIG Welding

• Connect work lead to positive terminal.

• Connect TIG torch to negative terminal.

• Switch machine on.

• Set weld current.

• Connect remote control device if required.

Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

Commence welding.

4.12 MIG Welding

• Connect work lead to negative terminal.

This lead may need to be reversed when using flux cored welding wire. Contact the welding wire manufacturer for details.

• Connect electrode lead to positive terminal.

This lead may need to be reversed when using flux cored welding wire. Contact the welding wire manufacturer for details.

• Switch machine on.

• Set weld voltage.

• Set Inductance.

• Connect Wire feeder.

• Set wire feed speed (IPM).

Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

Commence welding.

July 18, 2008

4-11

TRANSMIG 400 i

4.13 Save-Load Operation

A total number of 5 programs can be saved into the Transmig 400 i memory.

SAVE the Current Weld Parameters into Memory

• Press and HOLD the SAVE button for 3 seconds. Beep will sound and Digital Meter display will show a

number 1.

• Select a memory location by rotating the control knob, 1 to 5 is displayed on the meter.

• After selecting the desired memory location (i.e. 1 to 5), press the right scroll button and the machine will

give a beep to confirm the weld parameters from the control panel are saved. The Save/Load buttons must be depressed for 3 seconds to store settings.

LOAD (retrieve) a Program to Control Panel

• Press and HOLD the LOAD button for 3 seconds. Beep will sound and Digital Meter display will show a

number 1.

• Select a memory location by rotating the control knob, 1 to 5 is displayed on the meter.

• After selecting the desired memory location (i.e. 1 to 5), press the right scroll button and the machine will

give a beep to confirm the weld parameters are loaded onto the control panel. The Save/Load buttons must be depressed for 3 seconds to store settings.

4-12

July 18, 2008

TRANSMIG 400 i

SECTION 5:

BASIC WELDING GUIDE

5.01 Basic TIG Welding Guide

5.01.1 Electrode Polarity

Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece.

5.01.2 Tungsten Electrode Current Ranges

Electrode Diameter AC Current (Amps) DC Current (Amps)

0.040” (1.0mm) 30 – 70 30 – 60

1/16” (1.6mm) 60 – 95 60 – 115

3/32” (2.4mm) 125 – 150 100 – 165

1/8” (3.2mm) 130 – 225 135 – 200

5/32” (4.0mm) 190 – 280 190 – 280

3/16” (4.8mm) 250 – 340 250 – 340

5.01.3 Tungsten Electrode Types

Electrode Type

(Ground Finish)

Thoriated 2%

Zirconated 1%

Ceriated 2%

Welding Application Features

DC welding of mild steel, stainless steel and copper.

High quality AC welding of aluminium, magnesium and their alloys.

AC & DC welding of mild steel, stainless steel, copper, aluminium, magnesium and their alloys

Excellent arc starting, Long life, High current carrying capacity.

Self cleaning, Long life, Maintains balled end, High current carrying capacity.

Longer life, More stable arc, Easier starting, Wider current range, Narrower more concentrated arc.

Color Code

Red

White

Grey

July 18, 2008

5-1

TRANSMIG 400 i

5.01.4 Guide for Selecting Filler Wire Diameter

Filler Wire Diameter

1/16” (1.6 mm) 30 - 95 20 - 90

3/32” (2.4 mm) 125 - 160 65 - 115

1/8” (3.2 mm) 180 - 240 100 - 165

3/16” (4.8 mm) 220 - 320 200 - 350

AC Current Range

(Amps)

DC Current Range

(Amps)

NOTE 1

The filler wire diameter specified in the above table is a guide only, other diameter wires may be used according to the welding application.

5.01.5 Shielding Gas Selection

Alloy Shielding Gas

Aluminum & alloys Welding Argon

Carbon Steel Welding Argon

Stainless Steel Welding Argon

Copper Welding Argon

5.01.6 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe

Electrode Type &

Diameter

Thoriated 2%

3/32” (2.4 mm)

Thoriated 2%

3/32” (2.4 mm)

Thoriated 2%

3/32” (2.4 mm)

Current Range DC

Amperes

120 - 170 Yes

100 - 160 Yes

90 - 130 No

Filler Rod for

Root Pass

Joint Preparation

5-2

July 18, 2008

5.01.7 Welding Parameters for Steel

TRANSMIG 400 i

Base Metal

Thickness

0.040”

1.0mm

0.045”

1.2mm

1/16”

1.6mm

1/8”

3.2mm

3/16”

4.8mm

¼”

6.4mm

DC Current for

Mild Steel

35-45 20-30 Butt/Corner 40-50 25-35

45-55 30-45 Butt/Corner 50-60 35-50

60-70 40-60 Butt/Corner 70-90 50-70

80-100 65-85 Butt/Corner 90-115 90-110

115-135 100-125 Butt/Corner 140-165 125-150

160-175 135-160 Butt/Corner 170-200 160-180

DC Current for

Stainless

Steel

Tungsten Electrode Diameter

0.040”

1.0mm

0.040”

1.0mm

1/16”

1.6mm

1/16”

1.6mm

3/32”

2.4mm

1/8”

3.2mm

Filler Rod

Diameter

(if required)

1/16”

1.6mm

1/16”

1.6mm

1/16”

1.6mm

3/32”

2.4mm

1/8”

3.2mm

5/32”

4.0mm

Argon Gas

Flow Rate

Liters/min

5-7

Joint Type

Lap/ Fillet

July 18, 2008

5-3

TRANSMIG 400 i

5.02 Basic STICK Welding Guide

Cast Iron

5.02.1 Electrode Polarity

Stick electrodes are generally connected to the '+' terminal and the work lead to the '-' terminal but if in doubt consult the electrode manufacturers literature.

5.02.2 Effects of Stick Welding Various Materials

High tensile and alloy steels

The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.

Manganese steels

The effect on manganese steel of slow cooling from high temperatures is to make it brittle. For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.

Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the porosity caused by gas held in this type of iron.

Copper and alloys

The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections necessary to give proper fusion of weld and base metal.

Types of Electrodes

Arc Welding electrodes are classified into a number of groups depending on their applications (refer to table below). There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for welding large diameter pipes, etc. The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be encountered; are all easy to use and all will work on even the most basic of welding machines.

Metals being joined Electrode Comments

Mild steel 6013 Ideal electrodes for all general

purpose work. Features include out standing operator appeal, easy arc starting and low spatter.

Mild steel 7014 All positional electrodes for use on

mild and galvanized steel furniture, plates, fences, gates, pipes and tanks etc. Especially suitable for verticaldown welding.

Cast iron 99% Nickel

Stainless steel 318L-16 High corrosion resistance. Ideal for

Copper, Bronze, Brass, etc.

High Alloy Steels, Dissimilar Metals, Crack Resistance. All Hard-To-Weld Jobs.

Bronze

5.7 ERCUSI-A

312-16 It will weld most problematical jobs

Suitable for joining all cast irons except white cast iron.

dairy work, etc. on stainless steels.

Easy to use electrode for marine fittings, water taps and valves, water trough float arms, etc. Also for joining copper to steel and for bronze overlays on steel shafts.

such as springs, shafts, broken joins mild steel to stainless and alloy steels. Not suitable for Aluminium.

5-4

July 18, 2008

5.03 Basic MIG Welding Guide

TRANSMIG 400 i

5.03.4 Electrode Wire Size Selection

5.03.1 Setting of the Power Source

The setting of the Transmig 400 i requires some practice by the operator, the welding Power Source/Wirefeeder having two control settings that have to balance. These are the Wirespeed control and the Voltage Control. 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 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 switch settings are not adjusted to suit the electrode wire diameter and dimensions of the workpiece.

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.

5.03.2 Position of MIG Torch

The angle of MIG torch to the weld has an effect on the width of the weld run.

The choice of electrode wire size in conjunction with shielding gas used depends on:

• The position of welding

• Thickness of the metal to be welded

• The deposition rate required

• Capacity of the wire feed unit and power source

• The bead profile desired

• The amount of penetration required

• Type of joint

• Cost of the electrode wire

Weld metal deposition rate is proportional to current density. Current density is defined as the current per cross sectional area of the electrode wire and is normally expressed as amps per mm2. An example is tabled below.

)

Deposition

Rate

(lb/hour)

Electrode

Wire Size

0.035”

(0.9mm)

0.034”

(1.2mm)

Current (Amps)

200 380 6.3

200 177 6.0

Current

Density

(Amps/mm

5.03.5 Deposition Rate Comparison

This demonstrates that where the upper limit of current is limited by machine capacity and duty cycle, higher deposition rates and therefore greater productivity will be achieved by using smaller electrode wire. The TRANSMIG 400 i is a particularly efficient MIG welder with the 0.9mm steel wire in spray transfer mode. The savings from decreased welding time will more than cover the small cost penalty of the smaller electrode wire sizes. 0.035" wire cost approximately 10% more than 0.045", but is deposited approximately 15% faster. Higher current density (or smaller diameter wire) also gives deeper penetration as shown.

5.03.3 Travel Speed

Speed at which a weld travels influences the width of the weld and penetration of the welding run.

July 18, 2008

Wire penetration comparison using the same

current (200A) for both electrodes

5-5

TRANSMIG 400 i

THIS PAGE LEFT INTENTIONALLY BLANK

5-6

July 18, 2008

TRANSMIG 400 i

SECTION 6:

SERVICE

6.01 Routine Maintenance

The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

WARNING

Disconnect primary power at the source before opening the enclosure. Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge.

To clean the unit, open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should also be wiped clean, if necessary; with solvents that are recommended for cleaning electrical apparatus.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

July 18, 2008

6-1

TRANSMIG 400 i

6.02 Maintenance Diagram

Warning! Disconnect input power before maintaining.

Maintain mo

Visual check of regulator and pressure

Visually inspect the torch body and consumables

re often if used under severe conditions

Each Use

Visual check of torch Consumable parts

Weekly

Visually inspect the cables and leads. Replace as needed

3 Months

Art # A-07681_AC

Replace all broken parts

Clean exterior of power supply

6 Months

Bring the unit to an authorized CIGWELD Service Provider to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions.

6-2

July 18, 2008

TRANSMIG 400 i

6.03 Basic Troubleshooting

WARNING

There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an Accredited Cigweld Service Provider and you have had training in power measurements and troubleshooting techniques.

If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Cigweld Service Provider for repair.

The basic level of troubleshooting is that which can be performed without special equipment or knowledge.

6.04 Solving MIG 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:

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 25 cubic feet per hour.

2. Gas leaks. Check for gas leaks between the regulator/cylinder

connection and in the gas hose to the Wire Feeder.

3. Internal gas hose in the Wire Feeder. Ensure the hose from the solenoid valve to the MIG torch

adapter has not fractured and that it is connected to the MIG torch adapter.

4. Welding in a windy environment. Shield the weld area from the wind or increase the gas

flow.

5. Welding dirty, oily, painted, oxidized or

greasy plate.

6. Distance between the MIG torch nozzle

and the work piece.

7. Maintain the MIG torch in good

working order.

Do not restrict gas flow by allowing spatter to build up

Check that the MIG torch O-rings are not damaged.

Clean contaminates off the plate.

Keep the distance between the MIG torch nozzle and the work piece to a minimum.

Ensure that the gas holes are not blocked and gas is exiting out of the torch nozzle.

inside the MIG torch nozzle.

July 18, 2008

WARNING

Disengage the drive roll when testing for gas flow by ear.

6-3

TRANSMIG 400 i

Inconsistent Wire Feed

Checking the following points can reduce wire-feeding problems:

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. Misalignment of inlet/outlet guides. Wire will rub against the misaligned guides and

reduces wire feedability.

5. Liner blocked with wire debris. Wire debris is produced by the wire passing

through the feed roller, if excessive pressure is applied to the pressure roller adjuster.

Wire debris can also be produced by the wire passing through an incorrect feed roller groove shape or size.

Wire debris 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

electrode wire. If the hole in the contact tip is to large then arcing may occur inside the contact tip resulting in the electrode wire jamming in the contact tip.

When using soft electrode 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 electrode 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.

6-4

July 18, 2008

6.05 MIG Welding Problems

TRANSMIG 400 i

Description

1 Undercut. A Welding arc voltage too high. A

B Incorrect torch angle. B Adjust angle. C Excessive heat input. C

2 Lack of penetration. A Welding current too low. A

C Shielding gas incorrect. C Change to a gas which gives

3 Lack of fusion. Voltage too low. Increase

4 Excessive spatter. A Voltage too high. A

B Voltage too low. B

Irregular weld shape.

B Wire is wandering. B Replace contact tip. C Incorrect shielding gas. C Check shielding gas. D Insufficient or excessive heat input. D

6 Weld cracking. A Weld beads too small. A Decrease travel speed.

B Weld penetration narrow and deep. B Reduce current and voltage and increase MIG

C Excessive weld stresses. C Increase weld metal strength or

D Excessive voltage. D

E Cooling rate too fast. E Slow the cooling rate by preheating part to be

7 Cold weld puddle. A Loose welding cable connection. A Check all welding cable connections.

8 Arc does not have

the crisp sound that comes when the wirefeed speed and voltage are adjusted correctly.

Joint preparation too narrow or gap too tight.

Incorrect voltage and current settings. Convex, voltage too low. Concave, voltage too high.

B Low Primary Voltage. B Contact supply authority.

C Faulty rectifier unit. C Have an accredited Cigweld Service Provider

The MIG torch has been connected to the wrong voltage polarity on the front panel.

Possible Cause

Remedy

Reduce feed speed.

Increase the torch travel speed and/or reduce welding current by reducing the control or reducing the wire feed speed.

Increase welding current by increasing wire feed speed and increasing

B Increase joint angle or gap.

higher penetration.

WELD (V)

Lower the voltage by reducing the control or increase wirespeed control.

Raise the voltage by increasing the control or reduce wirespeed control.

Adjust voltage and current by adjusting the

WELD (V)

Adjust the wirespeed control or the voltage selection switches.

torch travel speed or select a lower penetration shielding gas.

revise design. Decrease voltage by reducing the

WELD (V)

welded or cool slowly.

to test then replace the faulty component.

Connect the MIG torch to the positive (+) welding terminal for solid wires and gas shielded flux cored wires. Refer to the electrode wire manufacturer for the correct polarity.

control and the wirespeed control.

control.

control or increase the wire

WELD (V)

control.

WELD (V)

July 18, 2008

6-5

TRANSMIG 400 i

6.06 TIG Welding Problems

Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique.

Description Possible Cause Remedy

1 Excessive bead build-up or poor

penetration or poor fusion at edges of weld

2 Weld bead too wide and flat or

undercut at edges of weld or excessive burn through

3 Weld bead too small or insufficient

penetration or ripples in bead are widely spaced apart

4 Weld bead too wide or excessive

bead build-up or excessive penetration in butt joint

5 Uneven leg length in fillet joint Wrong placement of filler

6 Electrode melts when arc is struck Electrode is connected to

7 Dirty weld pool A Electrode contaminated

8 Electrode melts or oxidizes when

an arc is struck

9 Poor weld finish Inadequate shielding gas Increase gas flow or

Welding current is too low Increase weld current

and/or faulty joint preparation

Welding current is too high Decrease weld current

Travel speed too fast Reduce travel speed

Travel speed too slow Increase travel speed

Re-position filler rod

rod

Connect the electrode to

the '+' terminal

through contact with work piece or filler rod material

B Gas contaminated with air B Check gas lines for cuts

A No gas flowing to welding

region

B Torch is clogged with dust B Clean torch C Gas hose is cut C Replace gas hose D Gas passage contains

impurities

E Gas regulator turned off E Turn on F Torch valve is turned off F Turn on G The electrode is too small

for the welding current

the '-' terminal

A Clean the electrode by

grinding off the contaminates

and loose fitting or change gas cylinder

A Check the gas lines for

kinks or breaks and gas cylinder contents

D Disconnect gas hose from

torch then raise gas pressure and blow out impurities

G Increase electrode

diameter or reduce the welding current

check gas line for gas flow problems

6-6

July 18, 2008

Possible CauseDescription Remedy

10 Arc flutters during TIG welding A Tungsten electrode is too

large for the welding current

B Absence of oxides in the

weld pool

11 Welding arc cannot be established A Work clamp is not

connected to the work piece or the work/torch leads are not connected to the right terminals

B Torch lead is disconnected B Connect it to the '-'

C Gas flow incorrectly set,

cylinder empty or the torch valve is off

12 Arc start is not smooth A Tungsten electrode is too

large for the welding current

B The wrong electrode is

being used for the welding job

C Gas flow rate is too high C Select the correct rate for

D Incorrect shielding gas is

being used

E Poor work clamp

connection to work piece

TRANSMIG 400 i

A Select the right size

electrode. Refer to Basic TIG Welding Guide

B Refer to Basic TIG

Welding Guide for ways to reduce arc flutter

A Connect the work clamp

to the work piece or connect the work/torch leads to the right welding terminals

terminal

C Select the right flow rate,

change cylinders or turn torch valve on

A Select the right size

electrode. Refer to Basic TIG Welding Guide

B Select the right size

electrode. Refer to Basic TIG Welding Guide

the welding job. Refer to Basic TIG Welding Guide

D Select the right shielding

gas. Refer to Basic TIG Welding Guide

E Improve connection to

work piece

July 18, 2008

6-7

TRANSMIG 400 i

6.07 Stick Welding Problems

1 Gas pockets or voids in weld metal

(Porosity)

2 Crack occurring in weld metal soon

after solidification commences

3 A gap is left by failure of the weld

metal to fill the root of the weld

Possible CauseDescription Remedy

A Electrodes are damp A Dry electrodes before use

B Welding current is too high B Reduce welding current C Surface impurities such as

C Clean joint before welding

oil, grease, paint, etc

A Rigidity of joint A Redesign to relieve weld

joint of severe stresses or use crack resistance electrodes

B Insufficient throat thickness B Travel slightly slower to

alloy greater build-up in throat

C Cooling rate is too high C Preheat plate and cool

slowly

A Welding current is too low A Increase welding current

B Electrode too large for joint B Use smaller diameter

electrode C Insufficient gap C Allow wider gap D Incorrect sequence D Use correct build-up

sequence

Art # A-05866_AB

Incorrect Sequence

Insufﬁcient Gap

Figure 5-1: Example of Insufficient Gap or Incorrect Sequence

6-8

July 18, 2008

4 Portions of the weld run do not

fuse to the surface of the metal or edge of the joint

TRANSMIG 400 i

Possible CauseDescription Remedy

A Small electrodes used on

heavy cold plate

B Welding current is too low B Increase welding current C Wrong electrode angle C Adjust angle so the

D Travel speed of electrode is

too high

E Scale or dirt on joint surface E Clean surface before

Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high

A Use larger electrodes and

preheat the plate

welding arc is directed more into the base metal

D Reduce travel speed of

electrode

welding

Art # A-05867_AB

Lack of side fusion, scale dirt, small electrode, amperage too low

Figure 5-2: Example of Lack of Fusion

Lack of inter-run fusion

Lack of root fusion

July 18, 2008

6-9

TRANSMIG 400 i

6.07 Stick Welding Problems (con't)

5 Non-metallic particles are trapped

in the weld metal (slag inclusion)

A Non-metallic particles may

be trapped in undercut from previous run

B Joint preparation too

restricted

C Irregular deposits allow slag

to be trapped

D Lack of penetration with

slag trapped beneath weld bead

E Rust or mill scale is

preventing full fusion

F Wrong electrode for position

in which welding is done

Possible CauseDescription Remedy

A If bad undercut is

present, clean slag out

and cover with a run from

a smaller diameter

electrode

B Allow for adequate

penetration and room for

cleaning out the slag

C If very bad, chip or grind

out irregularities

D Use smaller electrode with

sufficient current to give

adequate penetration. Use

suitable tools to remove

all slag from corners

E Clean joint before welding

F Use electrodes designed

for position in which

welding is done,

otherwise proper control

of slag is difficult

Not cleaned, or incorrect electrode

Figure 5-3: Examples of Slag Inclusion

Art # A-05868

Slag trapped in undercut

Slag trapped in root

6-10

July 18, 2008

6.08 Power Source Problems

1 The welding arc cannot be

established

2 Maximum output welding

current cannot be achieved with nominal Mains supply voltage

3 Welding current reduces

when welding

TRANSMIG 400 i

Possible CauseDescription Remedy

A The Primary supply voltage

has not been switched ON

B The Welding Power Source

switch is switched OFF

C Loose connections

internally

Defective control circuit Have an Accredited

Poor work lead connection to the work piece

A Switch ON the Primary

supply voltage

B Switch ON the Welding

Power Source

C Have an Accredited

Cigweld Service Provider repair the connection

Cigweld Service Provider inspect then repair the welder Ensure that the work lead has a positive electrical connection to the work piece

July 18, 2008

6-11

TRANSMIG 400 i

6.09 Power Source Error Codes

Description Possible Cause Remedy Remarks

1 E01 error code displayed

Temperature sensor TH1 (protects IGBTs) is greater than 80ºC for about 1 second.

2 E02 error code displayed

Temperature sensor TH2 (protects secondary diodes) is greater than 80ºC for about 1 second.

3 E03 error code displayed

Primary (input) current too high.

4 E04 error code displayed

Output voltage exceeds the secondary voltage specification.

5 E11 error code displayed

Over Primary supply (input) voltage at primary capacitors is exceeded for one second.

6 E12 error code displayed

Under mains supply (input) voltage primary capacitors is reduced for one second.

The Welding Power Source’s duty cycle has been exceeded.

Fan ceases to operate.

Air flow is restricted by vents being blocked.

The Welding Power Source’s duty cycle has been exceeded.

Fan ceases to operate.

Air flow is restricted by vents being blocked.

Primary current is too high because welding arc is too long.

Mains supply voltage is more than 10% below nominal voltage.

TIG torch cable

and/or work lead are too long or leads are coiled.

Primary supply

voltage is greater than the nominal voltage plus 10%.

Mains supply

voltage is down to a dangerously low level.

Let Power Source cool down then keep within its duty cycle. Have an accredited

Cigweld Service Provider investigate.

Unblock vents then let Power Source cool down.

Let Power Source cool down then keep within its duty cycle. Have an accredited

Cigweld Service Provider investigate.

Unblock vents then let Power Source cool down.

Reduce length of welding arc.

Have an accredited Cigweld Service Provider or a qualified electrician check for low Mains voltage.

Reduce the length of

the TIG torch cable and/or work lead or un-coiled leads.

Have an accredited

Cigweld Service Provider or a qualified electrician check the Primary voltage.

Have an accredited

Cigweld Service Provideror a qualified electrician check the Mains voltage.

Weld current ceases. Buzzer sounds constantly. Fan operates at max speed. E01 resets when TH1 decreases to 70ºC for about 30 seconds.

Weld current ceases. Buzzer sounds constantly. Fan operates at max speed. E02 resets when TH1 decreases to 70ºC for about 30 seconds.

Weld current ceases. Buzzer sounds constantly. Switch machine OFF then ON to reset E03 error.

Weld current ceases. Buzzer sounds constantly. Switch machine off then on to reset E04 error.

Weld current ceases. Buzzer sounds constantly. Error code E11 automatically will reset when the voltage reduces.

Weld current ceases. Buzzer sounds constantly. Error code E12 automatically will reset when the voltage increases.

6-12

July 18, 2008

TRANSMIG 400 i

Description Possible Cause Remedy Remarks

7 E14 error code displayed

Under mains supply (input) voltage warning primary capacitors is reduced for one second.

8 E81 error code displayed

Wrong Primary supply (input) voltage connected.

9 E82 error code displayed

Link switch plug not connected.

10 E83 error code displayed

CPU checks mains supply (input) voltage when the ON/OFF switch on rear panel of machine is turned ON.

11 E85 error code displayed

Pre-charge abnormality.

Mains supply

voltage is less than the nominal operating voltage less 10%.

When 3 phase

machine is first turned ON with the wrong Primary supply (input) voltage connected.

Link switch plug

not connected.

The Primary supply

(input) voltage fluctuates and is not stable.

Due to malfunction

inside the Welding Power Source, primary capacitors are not charging correctly.

Have an accredited

Cigweld Service Provider or a qualified electrician check the Mains voltage.

Have an accredited

Cigweld Service Provider or a qualified electrician check the Mains voltage.

Have an accredited

Cigweld Service Provider check connector plug on input PCB.

Have an accredited

Cigweld Service Provider check connector plug on input PCB and the Mains voltage.

Have an Accredited

Cigweld Service Provider service the machine.

Weld current available. Buzzer sounds intermittently. Error code E14 automatically will reset when the voltage increases.

No weld current is available. Buzzer sounds constantly. Switch machine OFF.

No weld current is available. Buzzer sounds constantly. Switch machine OFF then ON to reset E83 error.

No weld current is available. Buzzer sounds constantly. Switch machine OFF then ON to reset E85 error.

12 E93 error code displayed

Memory chip (EEPROM) on control PCB can not read/write weld parameters.

13 E94 error code displayed

Temperature sensor TH1 for IGBTs or sensor TH2 for secondary diodes are open circuit.

14 E99 error code displayed

Mains supply (input) voltage has been turned OFF but control circuit has power from the primary capacitors.

Memory chip

(EEPROM) error.

The Welding Power

Source’s temperature sensors have malfunctioned.

Main ON/OFF switch on machine has been turned OFF.

Mains supply (input) voltage has been turned OFF.

Have an accredited

Cigweld Service Provider check the control PCB.

Have an accredited

Cigweld Service Provider check or replace the temperature sensors.

Turn ON/OFF Switch ON.

Have an accredited Cigweld Service Provider or a qualified electrician check the Mains voltage and fuses.

Weld current ceases. Buzzer sounds constantly. Switch machine OFF.

Weld current ceases. Buzzer sounds constantly. Must switch machine OFF then ON to reset E99 error.

July 18, 2008

6-13

TRANSMIG 400 i

6.10 Voltage Reduction Device (VRD)

1. VRD Specification:

Description Transtig 400 i Notes

VRD Open Circuit Voltage 15.3 to 19.8V Open circuit voltage between welding

terminals

VRD Resistance 148 to 193 ohms The required resistance between welding

terminals to turn ON the welding power

VRD Turn OFF Time 0.2 to 0.3 seconds The time taken to turn OFF the welding

power once the welding current has stopped

2. VRD Maintenance:

Routine inspection and testing (power source):

An inspection of the power source, an insulation resistance test and an earth resistance test shall be carried out.

a) For transportable equipment, at least once every 3 months; and

b) For fixed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record of the periodic tests.

NOTE

A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated.

In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests should also be conducted by an accredited Cigweld service agent.

Description Required Parameters

VRD Open Circuit

Voltage

VRD Turn ON

Resistance

VRD Turn OFF

Time

Less than 20V; at Vin=415V

Less than 200 ohms

Less than 0.3 seconds

Periodic Tests

If this equipment is used in a hazardous location or environments with a high risk of electrocution then the above tests should be carried out prior to entering this location.

6-14

July 18, 2008

TRANSMIG 400 i

APPENDIX 1: OPTIONS AND ACCESSORIES

Description Part No. Details

17 Series air cooled TIG torch

(suitable for TransTig 200Pi)

26 Series air cooled TIG torch 538720401 TIG torch with 4 metre cable & remote

200 Amp lead set, 5 metre 646323 1 x 5m work lead; 1 x 5m electrode holder

400 Amp lead set, 8 metre 646325 1 x 8m work lead; 1 x 8m electrode holder

Slide controller

Hand pendant

Foot controller

CIGWELD COMET argon regulator 301527 Regulator only CIGWELD COMET argon flowmeter

0-15 lpm 301710 Flowmeter only

CIGWELD COMET argon flowmeter

10-40 lpm 301711 Flowmeter only

CIGWELD COMET argon

regulator/flowmeter 301526 Regulator/flowmeter only

VAF-4 Wirefeeder (for 400i ONLY) 705700 VAF-4 wirefeeder, 8m interconnection,

VS212 Voltage sensing wirefeeder W3512006 VS212 wirefeeder, operating manual Tweco® 4 MIG Torch 717201 MIG torch with 3.6m cable, T4 connection ArcMaster Pro Auto-darkening

Helmet, 9-13 – blue

ArcMaster Pro Auto-darkening

Helmet, 9-13 – blue with graphic

ArcMaster Pro Auto-darkening

Helmet, 9-13 – black with graphic

518710402 TIG torch with 4 metre cable & remote

current control

OTD 10/4013 200Pi, 200AC/DC slider only OTD 10/2004 300Pi, 300AC/DC, 400i slider only OTD 10/4014 200Pi, 200AC/DC hand pendant only OTD 10/2005 300Pi, 300AC/DC, 400i hand pendant only OTD 10/4016 200Pi, 200AC/DC OTD 10/2007 300Pi, 300AC/DC, 400i

operating manual

454294 Welding helmet, 2 x spare cover lenses,

product bag, operating manual

454295 Welding helmet, 2 x spare cover lenses,

product bag, operating manual

454296

Welding helmet, 2 x spare cover lenses,

product bag, operating manual

July 18, 2008

A-1

TRANSMIG 400 i

APPENDIX 2: TRANSMIG 400 i INTERCONNECT DIAGRAM

TB1

L101

L104 L107

Ground

SIDE CHASSIS

FAN1

115V

24V

PCB22

CE Filter

Circuit Board

[WK-5022]

CN1

234 5

L108

L103

REAR

PANEL

1 2 3 4

1 2

CN33

1 2

CN18

L106

Circuit Board

[WK-4917]

1 2 3 4 5 6

CN11

S R

PCB21

Filter

CN1

CN2

CN1

CN31 CN30

Conect Circuit Board

CN131 CN130

1 2 3

CN20

1 2

CN20

1 2

CN3

L111 L112

L102

R(3)

S(4)

K(7 G(6

(1)

(0)

T(5)

L109

(2)

400V

24V

115V

MCB2

2 345

CN32 CN32

CN3

1 2 3 4

MCB1

24V

115V

PCB4

Detect

Circuit Board

CN4

[WK-4819]

CN5 CN6 CN4

CN30CN31

PCB5

[WK-5696]

CN130CN131

CN132 CN132

CN27 CN27

CN1

234 567 1 2

CN18 CN18

PCB2

Circuit Board

[WK-5597]

1 2 3

CN2

4 5

CN1

2 3

CN7

CN1CN6CN5

PCB3

Control Souce

Circuit Board

[WK-5548]

PCB7

Filter Circuit Board

[WK-5689]

Link

CON1

PCB8

CN1

CN2

PCB9

CN1

CN2

CN21

C G

E C

G E

C G

E C

G E

C G

E C

G E

C G

E C

G E

C G

E C

G E

C G

E C

G E

Q10

Q11

Q12

2 3 4 5 6

G4 E4

G3 E3

UB1

G7 E7

G8 E8

CN22

TB10 TB11 TB12

TB5 TB6 TB7

1 2 3

1 2 3 4

1 2 3

1 2 3 4

C CE E

PCB10

IGBT Gate

Circuit Board

[WK-5479]

CN1

CN2

C CE E

PCB11

IGBT Gate

Circuit Board

[WK-5479]

CN1

CN2

TB13 TB14 TB15

PCB1

C CE E

UB3

Mai n

TB2

TB3

TB4

TB1

Circuit Board

[WK- 5493]

TB1

G1 E1

G2 E2

TB2

TB3

TB4

TB18 TB19 TB20

IGBT Gate

Circuit Board

[WK-5479]

1 2 3

1 2 3 4

C CE E

IGBT Gate

Circuit Board

[WK-5479]

3 4

CT1 CT2

2 3 4

2 3 4 5 6

CN20

CT3 CT4

2 3 4 5 6

CN7

C G

E C

G E

C G

E C

G E

C G

E C

G E

C G

E C

G E

C G

E C

G E

C G

E C

G E

3 456

CN23

Q13

Q14

Q15

Q16

Q17

Q18

Q19

Q20

Q21

Q22

Q23

Q24

PCB6

Control

Circuit Board

[WK-6163]

CN3 CN3

CN13

CN15

123 4

D E H FJ CKG BI LA NM

CN16

234

CN2

3 456

CN19

A-2

July 18, 2008

UB2

UB4

TB7

TB21

TB8

TB17

TB16

TB22

CT3

CT1

CT3

PCB14

TRANS Board

[WK-5594]

CT2

CT4

TB35

TB33

TB34

TB30

TB32

TB31

AC4

PCB15

DIODE Snubber

Circuit Board

[WK-6131]

AC2 AC1

UB2UB1

UB4UB3

TH2 TH1

2 3

CN9

2 3 4 CN8

FCH1

SH.DET+

RY+15V /RY_ON

1 2 3

SH.DET-

PCB23

Output Voltage

De te ct Circ u it Bo a rd

[WK-6164]

CN2

123 4

-15

+15

GND

HCT1

2 3 4 5

PCB20

Filter Circuit Board

CN3

[WK-5499]

VT+

1 2 3

CN1

TRANSMIG 400 i

TO1

VT+

L110

CN1

S+15

123

CN3

Ground

SIDE CHASSIS

TO2

SGND

+Output Terminal

-Output

Terminal

2 3 4 5

S+15

CN8

1 2

SGND

2 3 4 5 6 789

SH.DET-

AC4

CN9

SH.DET+

AC2

L113

Ground

CON1

3 4

CN33

5 6

1 2 3

CN21

1 2 3

CN1

SIDE CH A SSIS

1 2 3 4 5 6

+15

-15 IS

GND

Ground

SIDE CH A SSIS

CN2

FRONT PANEL

PCB12

Panel

Circuit Board

[WK-5527]

CN1 2 3 4

PCB13

Encoder Board

[WK-5528]

CN1

1 2 3 4

Art # A-08550

July 18, 2008

A-3

TRANSMIG 400 i

THIS PAGE LEFT INTENTIONALLY BLANK

A-4

July 18, 2008

CIGWELD LIMITED WARRANTY

LIMITED WARRANTY: CIGWELD, A Thermadyne Company, hereafter, “CIGWELD” warrants to customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the CIGWELD products as stated below, CIGWELD shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with CIGWELD’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at CIGWELD’s sole option, of any components or parts of the product determined by CIGWELD to be defective.

CIGWELD MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: CIGWELD SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELD with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by CIGWELD whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of CIGWELD is authorized to change this warranty in any way or grant any other warranty.

PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN CIGWELD’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY CIGWELD PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date CIGWELD delivered the product to the authorized distributor.

Terms of Warranty – January 2008

1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply of goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including warranties as to merchantability and fitness for purpose) associated with the supply of goods and services. A consumer should seek legal advice as to the nature and extent of these protected interests. In some circumstances, the supplier of goods and services may legally stipulate that the said conditions, warranties, guarantees, rights and remedies are limited or entirely excluded. The warranties set out in Clause 2 shall be additional to any nonexcludable warranties to which the Customer may be entitled pursuant to any statute.

2. Subject to Clause 3. CIGWELD gives the following warranties to the Customer:

Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantable quality and reasonably fit for the purpose for which they are supplied by CIGWELD.

CIGWELD will repair or, at its option, replace those of the goods which, upon examination, are found by CIGWELD to be defective in workmanship and/or materials.

CIGWELD reserves the right to request documented evidence of date of purchase.

3. The Warranty in Clause 2;

Is conditional upon:

The Customer notifying CIGWELD or our Accredited Distributor in writing of its claim within seven (7) days of becoming aware of the basis thereof, and at its own expense returning the goods which are the subject of the claim to CIGWELD or nominated Accredited Distributor/Accredited Service Provider. The goods being used in accordance with the Manufacturer’s Operating Manuals, and under competent supervision.

Does not apply to:

Obsolete goods sold at auction, second-hand goods and prototype goods.

Breakdown or malfunction caused by accident, misuse or normal wear and tear.

Repairs or replacement made other than by CIGWELD or Accredited Service Providers, unless by prior arrangement with CIGWELD.

Replacement parts or accessories which may affect product safety or performance and which are not manufactured, distributed or approved by CIGWELD.

4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supply of goods which are not of a kind ordinarily acquired for personal, domestic or household use or consumption to any one or more of the following (the choice of which shall be at the option of CIGWELD).

The replacement of the goods or the supply of equivalent goods.

The repair of goods.

The payment of cost of replacing the goods or acquiring equivalent goods.

The payment of the cost of having goods repaired.

5. Except as provided in Clauses 2 to 4 above, to the extent permitted by statute, CIGWELD hereby excludes all liability for any loss, damage, death or injury of any kind whatsoever occasioned to the Customer in respect of the supply of goods including direct, indirect, consequential or incidental loss, damage or injury of any kind.

Warranty Schedule – January 2008

These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of sale from the Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date CIGWELD delivered the product to the Accredited Distributor. Unless otherwise stated the warranty period includes parts and labour. CIGWELD reserves the right to request documented evidence of date of purchase.

CIGWELD PROFESSIONAL INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR Transtig 200 Pi, Transtig 200 AC/DC, Transarc 300 Si, Transtig 300 Pi, Transtig 300 AC/DC, Transmig 400 i

Origin al Main Power Mag netics ................................................................................................................ 3 years 2 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors...................... 2 years 2 years

All other circuits and components including, but not limited to, relays, switches, contactors,

soleno ids, fans, electric motors.................................................................................................. 1 year 1 year

Please note that the information detailed in this statement supersedes any prior published data produced by CIGWELD.

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510

Thermadyne Italy

OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne,Utama Indonesia

Kawasan Industri Jababeka JI Jababeka VI Blok P No. 3 Cikarang - Bekasi, 17550 Indonesia Tel: +62 21 893 6071 Fax: +62 21 893 6067 / 6068 http://www.thermadyne.com

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

Asia Paciﬁc Regional Headquarters

71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX: Email: cigweldsales@cigweld.com.au

+61 3 9474 7488

www.cigweld.com.au

Tweco 400i User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Arc Welding Hazards

1.02 PRINCIPAL SAFETY STANDARDS

1.03 DECLARATION OF CONFORMITY

2.01 How To Use This Manual

2.02 Equipment Identification

2.03 Receipt Of Equipment

2.04 Symbol Chart

2.05 Description

2.08 Specifications

3.01 Environment

3.03 Electrical Input Connections

3.02 Location

3.04 Mains Supply Voltage Requirements

3.05 High Frequency Introduction

3.06 High Frequency Interference

3.07 Duty Cycle

4.02 Weld Process Selection

4.03 Weld Parameter Descriptions

4.04 Front Panel Weld Parameter Descriptions

4.05 Weld Parameters

4.06 Power Source Features

4.07 Set-up for MMAW (STICK) and GTAW (TIG)

4.13 Save-Load Operation

5.01 Basic TIG Welding Guide

5.01.1 Electrode Polarity

5.01.2 Tungsten Electrode Current Ranges

5.01.3 Tungsten Electrode Types

5.01.4 Guide for Selecting Filler Wire Diameter

5.01.5 Shielding Gas Selection

5.01.6 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe

5.01.7 Welding Parameters for Steel

5.02 Basic STICK Welding Guide

5.02.1 Electrode Polarity

5.02.2 Effects of Stick Welding Various Materials

5.03 Basic MIG Welding Guide

5.03.4 Electrode Wire Size Selection

5.03.1 Setting of the Power Source

5.03.2 Position of MIG Torch

5.03.5 Deposition Rate Comparison

5.03.3 Travel Speed

6.01 Routine Maintenance

6.02 Maintenance Diagram

6.03 Basic Troubleshooting

6.04 Solving MIG Problems beyond the Welding Terminals

6.05 MIG Welding Problems

6.06 TIG Welding Problems

6.07 Stick Welding Problems

6.09 Power Source Error Codes

6.10 Voltage Reduction Device (VRD)

APPENDIX 1: OPTIONS AND ACCESSORIES

CIGWELD LIMITED WARRANTY