Tweco 550i User Manual

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Page 1

350i

TRANSMIG

450i

550i

MULTI PROCESS WELDING INVERTER

Operating Manual

Revision: AE Issue Date: May 7, 2013 Manual No.: 0-5205 Operating Features:

A-10625

Page 2

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 world-wide service network. To locate your nearest distributor or accredited service provider call +1300 654 674, 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 the Market Leading Brand of Arc Welding Products for Victor Technologies. 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.

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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.

Welding Power Supply Operating Manual Number 0-5205 for:

TRANSMIG 350i Plant Part Number W1005350 TRANSMIG 350i Power Source (packed) Part Number W1005352

TRANSMIG 450i Plant with 4RT wirefeeder Part Number W1005450 TRANSMIG 450i Pro Plant with VAF4 wirefeeder Part Number W1005451 TRANSMIG 450i Power Source (packed) Part Number W1005452

TRANSMIG 550i Plant Part Number W1005550 TRANSMIG 550i Power Source (packed) Part Number W1005552

Published by: CIGWELD Pty Ltd 71 Gower Street Preston, Victoria, Australia, 3072

www.cigweld.com.au

A 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: November 21, 2011 Revision AE Date: May 7, 2013

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

Page 4

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 User Responsibility ......................................................................................... 2-3

2.07 Transporting Methods ..................................................................................... 2-3

2.08 Packaged Items .............................................................................................. 2-4

2.09 Duty Cycle ....................................................................................................... 2-5

2.10 Speciﬁcations ................................................................................................. 2-6

2.11 Gouging Speciﬁcations (Transmig 550i only) ................................................. 2-7

2.12 Optional Accessories ...................................................................................... 2-8

SECTION 3:

INSTALLATION, OPERATION AND SETUP ........................................................ 3-1

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

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

3.03 Ventilation ....................................................................................................... 3-1

3.04 Mains Supply Voltage Requirements .............................................................. 3-1

3.05 Electromagnetic Compatibility ........................................................................ 3-1

3.06 Transmig 350i, 450i, 550i Power Source Controls, Indicators and Features .. 3-3

3.07 Shielding Gas Regulator Operating Instructions ........................................... 3-15

3.08 Setup for MIG (GMAW) Welding with Gas Shielded Mig Wire ...................... 3-17

3.09 Setup for MIG (GMAW) Welding with Gasless Mig Wire .............................. 3-20

3.10 Setup for TIG (GTAW) Welding With Gas Shielding ...................................... 3-22

3.11 Setup for STICK (MMAW) Welding ............................................................. 3-23

3.12 Setup for GOUGING (Transmig 550i only) .................................................... 3-24

SECTION 4:

BASIC WELDING GUIDE ............................................................................ 4-1

4.01 MIG (GMAW/FCAW) Basic Welding Technique ............................................... 4-1

4.02 MIG (GMAW/FCAW) Welding Troubleshooting ............................................... 4-7

4.03 Stick (MMAW) Basic Welding Technique ...................................................... 4-10

4.04 Stick (MMAW) Welding Troubleshooting ...................................................... 4-21

4.05 TIG (GTAW) Basic Welding Technique .......................................................... 4-23

4.06 TIG (GTAW) Welding Problems ..................................................................... 4-25

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TABLE OF CONTENTS

SECTION 5:

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS .................... 5-1

5.01 Power Source / Wirefeeder Problems ............................................................. 5-1

5.02 Routine Service and Calibration Requirements ............................................... 5-2

5.03 Cleaning the Welding Power Source ............................................................... 5-4

5.04 Cleaning the Feed Rolls ................................................................................... 5-4

SECTION 6:

KEY SPARE PARTS ................................................................................... 6-1

6.01 Power Source ................................................................................................. 6-1

SECTION 7:

VOLT/AMPERE CURVES ............................................................................. 7-1

7.01 Volt/Amp Curves ............................................................................................. 7-1

SECTION 8: CIRCUIT DIAGRAM .......................................................................... 8-1

8.01 Circuit Diagram ..................................................................................................... 8-1

CIGWELD - LIMITED WARRANTY TERMS

TERMS OF WARRANTY – JULY 2011

WARRANTY SCHEDULE – JULY 2011

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

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TRANSMIG 350i, 450i, 550i

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.

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.

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.

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.

Manual 0-5205 1-1 GENERAL INFORMATION

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TRANSMIG 350i, 450i, 550i

2. Wear approved safety glasses. Side shields recommended.

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.

1. Use a Welding Helmet or Welding Faceshield ﬁtted with a proper shade of ﬁlter (see ANSI Z49.1 and AS 1674 listed in Safety Standards) to protect your face and eyes when welding or watching.

Recommended Protective Filters for Electric Welding

Description of Process

Manual Metal Arc Welding - covered electrodes (MMAW)

Gas Metal Arc Welding (GMAW) (MIG) other than Aluminium and Stainless Steel

Gas Metal Arc Welding (GMAW) (MIG) Aluminium and Stainless Steel

Gas Tungsten Arc Welding (GTAW) (TIG)

Flux-cored Arc Welding (FCAW) -with or without shielding gas.

Air - Arc Gouging Less than or equal to 400 12

Plasma - Arc Cutting

Plasma - Arc Spraying

Plasma - Arc Welding

Submerged - Arc Welding

Resistance Welding

Approximate Range of

Welding Current in Amps

Less than or equal to 100 8

Greater than 400 13

Less than or equal to 150 10

Greater than 400 14

Less than or equal to 250 12

Less than or equal to 100 10

Greater than 350 14

Less than or equal to 300 11

Greater than 500 14

Less than or equal to 20 8

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.

6. Never wear contact lenses while welding.

Minimum Shade Number of

Filter(s)

100 to 200 10 200 to 300 11 300 to 400 12

150 to 250 11 250 to 300 12 300 to 400 13

250 to 350 13

100 to 200 11 200 to 250 12 250 to 350 13

300 to 400 12 400 to 500 13

50 to 100 10 100 to 400 12 400 to 800 14

—

20 to 100 10 100 to 400 12 400 to 800 14

—

Safety Spectacles or eye

2(5)

shield

Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.

GENERAL INFORMATION 1-2 Manual 0-5205

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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.

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 vapours to form highly toxic and irritating gases.

TRANSMIG 350i, 450i, 550i

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 travelling 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.

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.

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 con

tact 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.

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.

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

Manual 0-5205 1-3 GENERAL INFORMATION

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

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TRANSMIG 350i, 450i, 550i

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

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.

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.

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 science-based advice on strategies to minimize or avoid potential risks.”

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

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

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

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

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

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.

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

ABOUT PACEMAKERS:

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

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

GENERAL INFORMATION 1-4 Manual 0-5205

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TRANSMIG 350i, 450i, 550i

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 1: Fire Precautions, AS 1674.1-1997 from SAI Global Limited, www.saiglobal.com.

Safety in welding and allied processes Part 2: Electrical, AS 1674.2-2007 from SAI Global Limited, www. saiglobal.com.

Filters for eye protectors - Filters for protection against radiation generated in welding and allied operations AS/NZS 1338.1:1992 from SAI Global Limited, www.saiglobal.com.

Manual 0-5205 1-5 GENERAL INFORMATION

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TRANSMIG 350i, 450i, 550i

1.03 DECLARATION OF CONFORMITY

Manufacturer and Merchandiser of Quality Consumables and Equipment : CIGWELD Address: 71 Gower St, Preston Victoria 3072 Australia

Description of equipment: Welding Equipment: TRANSMIG 350i, 450i, 550i MULTI PROCESS INVERTER Power Source 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 60974.10/IEC 60974-10 EMC Directive applicable to arc welding equipment - generic emissions and regulations.

* AS 60974.1/IEC 60974-1 applicable to welding equipment and associated accessories.

* AS 1674 Safety in welding and allied processes

* 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.

GENERAL INFORMATION 1-6 Manual 0-5205

Page 13

SECTION 2:

INTRODUCTION

TRANSMIG 350i, 450i, 550i

2.01 How To Use This Manual

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.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information con cerning 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.

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.

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

Manual 0-5205 2-1 INTRODUCTION

Page 14

TRANSMIG 350i, 450i, 550i

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Te mperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Dangerous Voltage

Off

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Receptacle RatingAuxiliary Power

Art # A-04937

115V 15A

IPM

MPM

Fuse

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld Mode

Press to initiate wirefeed and welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Disturbance In Ground System

Welding Gun

Burnback Time

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

4 Step Trigger Operation

2 Step Trigger Operation

2.04 Symbol Chart

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

INTRODUCTION 2-2 Manual 0-5205

Page 15

TRANSMIG 350i, 450i, 550i

2.05 Description

The Cigweld Transmig 350i, 450i and 550i are three phase multi process welding inverters that are capable of performing GMAW/FCAW (MIG), MMAW (Stick) and GTAW (Lift TIG) welding processes. The unit is equipped with an integrated voltage reduction device (VRD applicable in stick mode only), digital voltage and amperage meters, and a host of other features in order to fully satisfy the broad operating needs of the modern welding professional. The unit is also fully compliant to Australian Standard AS 60974.1 and IEC 60974.1.

The Transmig 350i, 450i and 550i provide excellent welding performance across a broad range of applications when used with the correct welding consumables and procedures. The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efﬁciency and quality from the Power Source. Please read these instructions thoroughly before using the unit.

2.06 User Responsibility

2.07 Transporting Methods

This unit is 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 or lifting lug 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.

This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment (including welding leads) should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualiﬁed persons approved by CIGWELD. Advice in this regard can be obtained by contacting an Accredited CIGWELD Distributor.

This equipment or any of its parts should not be altered from standard speciﬁcation without prior written approval of CIGWELD. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualiﬁed persons approved by CIGWELD.

Manual 0-5205 2-3 INTRODUCTION

Page 16

TRANSMIG 350i, 450i, 550i

2.08 Packaged Items

Transmig 350i Plant (Part No. W1005350)

• Transmig 350i Inverter Power Source

• Transmig 4RT wirefeeder with 8m interconnec-

tion lead ﬁtted

• Tweco Professional No.4 Mig Torch

• Comet Professional Argon regulator/owmeter

• Feed roll: 0.9/1.2mm V groove (tted)

• Electrode holder with 5m lead

• Work clamp with 5m lead

•Trolley

• Operating Manual

Transmig 350i Power Source (Part No. W1005352)

• Transmig 350i inverter Power Source

• Operating Manual

Transmig 550i Plant (Part No. W1005550)

• Transmig 550i Inverter Power Source

• Transmig VA4000 wirefeeder with 15m intercon-

nection lead

• Tweco Professional Supra XT Mig Torch

• Comet Professional Argon regulator/owmeter

• Feed roll: 1.3/1.6mm V groove (tted)

• Electrode holder with 8m lead

• Work clamp with 8m lead

•Trolley

• Operating Manual

Transmig 550i Power Source (Part No. W1005552)

• Transmig 550i inverter Power Source

• Operating Manual

Transmig 450i Plant (Part No. W1005450)

• Transmig 450i Inverter Power Source

• Transmig 4RT wirefeeder with 8m interconnec-

tion lead ﬁtted

• Tweco Professional Supra XT Mig Torch

• Comet Professional Argon regulator/owmeter

• Feed roll: 0.9/1.2mm V groove (tted)

• Electrode holder with 8m lead

• Work clamp with 8m lead

•Trolley

• Operating Manual

Transmig 450i Pro Plant (Part No. W1005451)

• Transmig 450i Inverter Power Source

• Transmig VAF-4 wirefeeder with 8m interconnec-

tion lead ﬁtted

• Tweco Professional Supra XT Mig Torch

• Comet Professional Argon regulator/owmeter

• Feed roll: 0.9/1.2mm V groove (tted)

• Electrode holder with 8m lead

• Work clamp with 8m lead

•Trolley

• Operating Manual

Transmig 450i Power Source (Part No. W1005452)

• Transmig 450i inverter Power Source

• Operating Manual

INTRODUCTION 2-4 Manual 0-5205

Page 17

TRANSMIG 350i, 450i, 550i

Duty Cycle (PERCENTAGE)

2.09 Duty Cycle

The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 60% duty cycle, 550 amperes at 41.5 volts. This means that it has been designed and built to provide the rated amperage (550A) for 6 minutes, i.e. arc welding time, out of every 10 minute period (60% of 10 minutes is 6minutes). During the other 4minutes of the 10 minute period the Welding Power Source must idle and allowed to cool. The thermal cut out will operate if the duty cycle is exceeded.

100

TRANSMIG

350i

TRANSMIG

450i

TRANSMIG

550i

SAFE OPERATING REGION

(MIG, STICK & TIG )

25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550

Welding Current (AMPS)

Figure 2-1: Transmig 350i, 450i, 550i Duty Cycle

A-10626

Manual 0-5205 2-5 INTRODUCTION

Page 18

TRANSMIG 350i, 450i, 550i

2.10 Speciﬁcations

Description TRANSMIG 350i TRANSMIG 450i TRANSMIG 550i

Plant Part Number W1005350

Power Source (Packed)Part Number W1005352 W1005452 W1005552

Power Source Mass 72 kg 72 kg 72 kg

Power Source Dimensions H 580mm x W 350mm x D 640mm

Cooling Fan Cooled Welder Type Multi Process Inverter Power Source

Applicable Standards AS 60974.1-2006 / IEC 60974-1

Number of Phases 3

Nominal Supply Voltage 415V +/- 15% Nominal Supply Frequency 50/60Hz

W1005450 W1005451

W1005550

Welding Current Range (MIG Mode)

Effective Input Current (I 1eff) (note1)

Maximum Input Current (I1max) 25A 35A 47A

Three Phase Generator Requirement (note 3)

MIG (GMAW) Welding Output, 40ºC, 10 min.

STICK (MMAW) Welding Output, 40ºC, 10 min.

TIG (GTAW) Welding Output, 40ºC, 10 min.

Gouging (CAG)

Welding Output, 40ºC, 3 min.

Note: Gouging is speciﬁed over a 3 minute duty cycle period only.

40 – 350A 40 – 450A 40 – 550A

18A 25A 32A

18kVA 25kVA 35kVA

350A @ 60%, 31.5V

270A @ 100%, 27.5V

350A @ 60%, 34.0V

270A @ 100%, 30.8V

350A @ 60%, 24.0V

270A @ 100%, 20.8V

Not Available Not Available

450A @ 60%, 36.5V

350A @ 100%, 31.5V

450A @ 60%, 38.0V

350A @ 100%, 34.0V

450A @ 60%, 28.0V

350A @ 100%, 24.0V

550A @ 60%, 41.5V

420A @ 100%, 35.0V

550A @ 60%, 42.0V

420A @ 100%, 36.8V

550A @ 60%, 32.0V

420A @ 100%, 26.8V

6.5mm Carbon 400A@63%

8.0mm Carbon 450A@54%

9.5mm Carbon 550A@35%

Open circuit voltage (VRD inactive) 84V 84V 84V

Protection Class IP23S IP23S IP23S

Table 2-1: Power Source Speciﬁcation

Note 1: The Effective Input Current should be used for the determination of cable size & supply requirements.

Note 2: Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your situation in this regard.

Note 3: Generator Requirements at the Maximum Output Duty Cycle.

INTRODUCTION 2-6 Manual 0-5205

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TRANSMIG 350i, 450i, 550i

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. In the interest of continuous improvement, CIGWELD Pty, Ltd reserves the right to change the speciﬁcations or design of any of its products without prior notice.

2.11 Gouging Speciﬁcations (Transmig 550i only)

Gouging is a process where a copper coated carbon electrode is used to rapidly remove material from the workpiece.

The arc voltage is much higher during Gouging, than in Stick, or Mig welding. This means, that for the same output current, we have much higher arc volts during Gouging, and therefore much higher output power. It is because of this extra output power, that we need to rate the power source differently for gouging, than we do for welding.

Also as we are drawing a much higher output power from the power source during Gouging, in order to keep the power source's internal temperatures within acceptable limits, the Duty Cycle for Gouging is speciﬁed over a 3 minute duty cycle period, instead of the normal 10 minute duty cycle period speciﬁed for the welding processes.

Refer to Section 3.12 for how to set up for gouging.

Carbon electrodes have a range of speciﬁed operating current. Here are the normal sizes that would be in use with a power source of this size, and the power source capability when used with these carbon electrode sizes

Electrode Size Amps Duty Cycle

6.5mm 300A 90% 400A 63%

8.0mm 350A 70% 450A 54%

9.5mm 450A 50% 550A 35%

Table 2-2: Electrode Size

Figure 2-2: Gouging Current (AMPS)

Manual 0-5205 2-7 INTRODUCTION

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TRANSMIG 350i, 450i, 550i

As an example, if we were Gouging with an 8mm electrode at 400A, we can see from the graph that we can expect 400A at 57% duty cycle. For a 3 minute duty cycle period, this means our arc time is 57% of 3 minutes, which is 1 minute & 40 seconds, during the other 1 minute & 20 seconds the machine must be allowed to cool.

NOTE

Gouging is speciﬁed for a 3 minute duty cycle period only.

2.12 Optional Accessories

Part Number Description

717201 TWECO #4 Mig Torch, 3.6 metre Tweco connection 717335 TWECO #4 Mig Torch, 4.5 metre Tweco connection SE4004M16 TWECO Supra XT Mig Torch (4.0M) Tweco connection 717211 TWECO #5 torch, 3.6 metre Tweco connection 717212 TWECO #5 torch, 4.5 metre Tweco connection W4015500 Heavy Duty Transmig Trolley with inbuilt cylinder carrier W4015600 Heavy Duty Transmig Roll Cage W4014602 Tig Torch 26V, Flex neck, 4m lead, gas valve, 3m gas hose, 10 pin

connector and accessory kit. 706954 TRANSMIG VA4000 wirefeeder, 19 pin, 110VAC 706965 TRANSMIG VAF-4 wirefeeder, 19 pin, 110VAC WSPLIER MIG Pliers 646265 Weld measurement gauge W7005358 10 Pin Control Plug 7977877 19 Pin Control Plug

Table 2-3: Optional Accessories

INTRODUCTION 2-8 Manual 0-5205

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TRANSMIG 350i, 450i, 550i

SECTION 3:

INSTALLATION, OPERATION AND SETUP

3.01 Environment

These units are designed for use in environments with increased hazard of electric shock as outlined in

AS 60974.1 and AS 1674.2.

A. Examples of environments with increased hazard

of electric shock are:

1. 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;

2. 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

3. In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accessories

conditions. For further information please refer to AS 60529.

H. Precautions must be taken against the power

source toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use.

3.03 Ventilation

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.

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 poor welding performance. Too high a supply voltage will cause components to overheat and possibly fail.

The Welding Power Source must be:

B. Environments with increased hazard of electric

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

3.02 Location

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

A. In areas, free from moisture and dust.

B. Ambient temperature between 0° C to 40° C.

C. In areas, free from oil, steam and corrosive gases.

D. In areas, not subjected to abnormal vibration or

shock.

E. In areas, not exposed to direct sunlight or rain.

F. Place at a distance of 300mm or more from walls

or similar that could restrict natural air ﬂow for cooling.

• Correctly installed, if necessary, by a qualied

electrician.

• Correctly earthed (electrically) in accordance

with local regulations.

• Connected to the correct size power point and

fuse as per the Speciﬁcations on page 2-5.

WARNING

Any electrical work must be carried out by a qualiﬁed Electrical Tradesperson.

3.05 Electromagnetic Compatibility

WARNING

Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation.

G. The enclosure design of this power source meets

the requirements of IP23S as outlined in AS60529. This provides adequate protection against solid objects (greater than 12mm), and direct protection from vertical drops. Under no circumstances should the unit be operated or connected in a micro environment that will exceed the stated

Manual 0-5205 3-1

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the

welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the

INSTALLATION, OPERATION AND SETUP

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TRANSMIG 350i, 450i, 550i

manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see NOTE below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work, complete with associated input ﬁlters. In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer troublesome.

NOTE

The welding circuit may or may nor be earthed for safety reasons. Changing the earthing arrangements should only be au

thorised by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC 60974-13 Arc Welding Equipment - Installation and use (under preparation).

B. Assessment of Area

Before installing welding equipment, the user shall

make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account

1. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the welding equipment.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial equipment.

C. Methods of Reducing Electromagnetic Emissions

1. Mains Supply

Welding equipment should be connected to the

mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as ﬁltering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout it’s length. The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure.

2. Maintenance of Welding Equipment

The welding equipment should be routinely

maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modiﬁed in any way except for those changes and adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilising devices should be adjusted and maintained according to the manufacturer’s recommendations.

3. Welding Cables

The welding cables should be kept as short

as possible and should be positioned close together, running at or close to the ﬂoor level.

5. The health of people around, e.g. the use of pacemakers and hearing aids.

6. Equipment used for calibration and measurement.

7. The time of day that welding or other activities are to be carried out.

8. The immunity of other equipment in the environment: the user shall ensure that other equipment being used in the environment is compatible: this may require additional protection measures.

The size of the surrounding area to be considered

will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

INSTALLATION, OPERATION AND SETUP

3-2 Manual 0-5205

4. Equipotential Bonding

Bonding of all metallic components in the

welding installation and adjacent to it should be considered. However. Metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

5. Earthing of the Workpiece

Where the workpiece is not bonded to earth

for electrical safety, nor connected to earth because of it’s size and position, e.g. ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be

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TRANSMIG 350i, 450i, 550i

taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

6. Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may allevi-

ate problems of interference. Screening the entire welding installation may be considered for special applications.

3.06 Transmig 350i, 450i, 550i Power Source Controls, Indicators and Features

A-10627

A-10628

Manual 0-5205 3-3

INSTALLATION, OPERATION AND SETUP

Page 24

TRANSMIG 350i, 450i, 550i

A-10629

Figure 3-1: Front Panel and Controls

1. Amperage Control (Wirespeed)

The amperage control knob adjusts the amount of welding current delivered by the power source.

In MMAW (stick) and GTAW (Lift TIG) modes, the amperage control knob directly adjusts the power inverter to deliver the desired level of output current.

In 10 PIN GMAW/FCAW modes (MIG), the amperage knob adjusts the speed of the 10 pin remote traveller wire feed motor (which in turn adjusts the output current by varying the amount of MIG wire delivered to the welding arc). The optimum wire speed required will be dependent on the welding application.

In 19PIN GMAW/FCAW modes (MIG), the amperage knob is inactive as the wirefeeder speed is adjusted using the control located on the wirefeeder only.

NOTE

The preview functionality provided on this power source is intended to act as a guide only. Some difference may be observed between preview values and actual welding values due to factors includ ing the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate.

INSTALLATION, OPERATION AND SETUP

3-4 Manual 0-5205

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TRANSMIG 350i, 450i, 550i

2. Voltage Control

The voltage control knob adjusts the amount of welding voltage delivered by the power source.

In MMAW (stick) and GTAW (Lift TIG) modes, the voltage control knob is inactive.

In 10 PIN and 19 PIN GMAW/FCAW modes (MIG), the voltage knob directly adjusts the power inverter to deliver the desired level of output voltage.

NOTE

3. Multifunction Control

The multifunction control knob is used to adjust three main parameters depending on the welding mode selected.

When GMAW/FCAW (MIG) Mode is Selected

In this mode the control knob is used to adjust the adjust the intensity of the welding arc.

Lower arc control settings make the arc softer with less weld spatter. Higher arc control settings give a stronger driving arc which can increase weld penetration.

When MMAW (Stick) Mode is Selected

In this mode the multifunction control knob is used to adjust arc force. Arc force control provides an adjustable amount of welding force (or “dig”) control. This feature can be particularly beneﬁcial in providing the operator the ability to compensate for variability in joint ﬁt-up in certain situations with particular electrodes. In general increasing the arc force control toward ‘10’ (maximum arc force) allows greater penetration control to be achieved. Arc force is increased by turning the control knob clockwise or decreased by turning the knob anti-clockwise.

When GTAW (Lift Tig) Mode is Selected

In this mode the multifunction control knob is used to adjust down slope. Down slope allows the user to select the ramp down time at the completion of the weld. The main function of down slope is to allow the welding current to be gradually reduced over a pre-set time frame such that the welding pool is given time to cool sufﬁciently.

Note that when in 2T normal mode (refer item 14), the unit will enter down slope mode as soon as the trigger switch is released (ie if the multifunction control knob is set to 5, the unit will ramp down from the present welding current to zero over 5 seconds). If no down slope time is selected then the welding output will cease immediately. If the unit is set to 4T latch mode, to enter down slope mode the trigger must be held in for the selected time period (ie press and release trigger to commence welding, then press and hold trigger again to enter down slope mode). Should the trigger be released during the down slope phase (4T only), the output will cease immediately.

4. Purge Button

This button will purge the shielding gas when pressed.

The PURGE button is active in 10 PIN GMAW/FCAW (Mig) mode only.

Press and hold the PURGE button to purge the gas line in the Wirefeeder (Active in 10 Pin mode only).

Manual 0-5205 3-5

INSTALLATION, OPERATION AND SETUP

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TRANSMIG 350i, 450i, 550i

5. Inch Button

The INCH button is active in 10 PIN GMAW/FCAW mode (MIG) only.

Press and hold the INCH button to inch the wire in the Wirefeeder (Active in 10 Pin mode only).

6. Local / Remote Button

The REMOTE button is used to select REMOTE or LOCAL mode of operation.

The REMOTE button is used only when a remote control device (such as a TIG torch with remote current control, or a Wirefeeder) is ﬁtted to the unit via the remote control socket (items 5 & 6). When the REMOTE button is in the remote position, the unit will detect a remote device and work accordingly

When in the local mode, the unit will not detect the remote device and will operate from the power source controls only. Note that the trigger will operate at all times on the remote control socket irrespective of the position of the local remote switch (ie in both local and remote modes).

Should a remote device be connected and the remote/local switch set to remote, the maximum setting of the power source will be determined by the respective front panel control, irrespective of the remote control device setting. As an example, if the output current on the power source front panel is set to 50% and the remote control device is set to 100%, the maximum achievable output from the unit will be 50%.

Should 100% output be required, the respective front panel control must be set to 100%, in which case the remote device will then be able to control between 0-100% output.

7. 10 PIN / 19 PIN Remote Button

The REMOTE button is used to select 10 PIN, 19 PIN, mode of operation when the REMOTE button ( item

13) is in REMOTE mode.

When in 10 PIN Remote mode, the 10 PIN control socket is active and remote voltage or current / wirespeed controls will be active.

The 10 PIN Remote mode is only available in GMAW/FCAW (Mig) and GTAW (Lift Tig) modes only.

When in 19 PIN Remote mode, the 19 PIN control socket is active and remote voltage controls will be active.

The 19 PIN Remote mode is only available in GMAW/FCAW (Mig) mode only.

NOTE

When operating a 10 pin Wirefeeder in remote mode, the maximum output is determined by the settings of the power source (in local mode). This is done such that the maximum output available at the wirefeeder can be restricted to a preset level. This preset level must be selected whilst the machine is in local mode.

As an example, should 0-100% output control be required at the wirefeeder, the power source should be set to local mode, and both the amps (wirespeed) and volts controls set to 100% (maximum). the wirefeeder will then be able to control between 0-100% of output [both amps(wire speed) and volts].

Should 50% output be required at the wirefeeder controls, the power source should be set to local mode, and both the amps (wirespeed) and volts set to 50% (mid point). The wirefeeder will then be able to control between 0-50% of output [both amps(wirespeed and volts)]

NOTE

When a 19 pin wirefeeder in used, 100% output for both amps (wirespeed) and volts is available at the wirefeeder at all times regardless of the amps (wirespeed) and volts control settings at the power source (The power source display will show a series of dashes when in 19 pin remote mode). The wirefeeder can adjust both amps (wirespeed) and volts between 0-100%.

NOTE

Welding Setup Program Storage (10 programs) applies to Mig 10 pin only, Stick and Lift Tig modes.

INSTALLATION, OPERATION AND SETUP

3-6 Manual 0-5205

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TRANSMIG 350i, 450i, 550i

8. Process Selection Button

The process selection control is used to select the desired welding mode. Three modes are available, GMAW/FCAW (MIG), GTAW (Lift TIG) and MMAW (Stick) and Gouging (Transmig 550i only) modes. Refer to section 3.15 or 3.16 for FCAW/GMAW (MIG) set up details, section 3.17 for GTAW (Lift TIG) set-up details or section 3.18 for MMAW (stick) set-up details.

Note that when the unit is powered off the mode selection control will automatically default to MIG mode.

This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work piece during power up.

9. Trigger Mode Control Button (MIG and LIFT TIG Mode only) (Only applicable to 10 pin mode)

Note that this feature on the power source only applies to devices connected to the 10 pin control socket. In the case of wirefeeders connected to the 19 pin socket the function is controlled from that independant wirefeeder only.

The trigger mode control is used to switch the functionality of the of the torch trigger between 2T (normal),

4T (latch mode) and SPOT (spot mode)

2T Normal Mode

In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold the torch trigger to activate the power source (weld). Release the torch trigger switch to cease welding.

4T Latch Mode

This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator can press and release the torch trigger and the output will remain active. To deactivate the power source, the trigger switch must again be depressed and realised, thus eliminating the need for the operator to hold the torch trigger.

Note that when operating in GTAW (LIFT TIG mode), the power source will remain activated until the selected down slope time has elapsed (refer Item 10).

SPOT Mode

This mode of welding is similar to 2T mode, except the welding output will be active only for a preset amount of time. This mainly used for tacking at the start of a job setup. Press and hold the torch trigger to activate the power source (weld). After the SPOT time has elapsed and welding output has ceased, release the torch trigger switch.

10. VRD ON/OFF Indicator Lights

A VRD (voltage reduction device) is a hazard reducing device designed to reduce electric shock hazards present on the output of welding power source when operating in MMAW (stick) mode. Note that the presence of VRD should not be used as a substitute for the use of appropriate safety practices as indicated in section one of this manual.

Both the green and red indicator lights only operate in MMAW (stick) mode.

The green VRD ON light illuminates (red light is off) when the VRD is active. Under this condition the open circuit voltage of the unit is limited to below 35V DC, thus reducing the potential of serious electric shock (such as when changing electrodes).

The red VRD OFF light illuminates (green light is off) when the VRD is inactive. Under this condition the output voltage of the unit will be at welding potential which in some cases may exceed 35V DC.

The VRD incorporated within the TRANSMIG 350i, 450i and 550i is fully standards compliant to AS

60974.1 / IEC 60974-1.

Manual 0-5205 3-7

INSTALLATION, OPERATION AND SETUP

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TRANSMIG 350i, 450i, 550i

11. Thermal Overload Indicator Light (Fault)

This welding power source is protected by a self resetting thermostat. The indicator will illuminate if the duty cycle of the power source has been exceeded. Should the thermal overload indicator illuminate the output of the power source will be disabled. Once the power source cools down this light will go OFF and the over temperature condition will automatically reset. Note that the mains power switch should remain in the on position such that the fan continues to operate thus allowing the unit to cool sufﬁciently. Do not switch the unit off should a thermal overload condition be present.

12. Program Storage Buttons and Display

This welding power source is able to store 10 machine setups in memory for MIG (10 pin only), Stick and Lift Tig modes. This memory is retained even if mains supply power is turned off. Button status, Amps, Volts, and Wirespeed are stored in memory for quick change between commonly used welding setups.

The memory will store machine setups in all three operating modes, GMAW/FCAW (MIG) (10 Pin only), GTAW (Lift TIG) and MMAW (Stick).

To STORE a program.

Press the number button. The display will change to indicate

which program number location is being used.

Press and Hold the SAVE button. The number on the display

will ﬂash for 3 seconds.

During this time the current machine setup will be saved in the

numbered program location as selected.

To LOAD a program.

Press the NUMBER button. The display will change to indicate which program is being used.

Press the LOAD button. The PROGRAM light will illuminate. During this time the machine setup will be loaded into the numbered program location and locked in. To

unlock this press the load button again and the program light will go off.

At any time after a SAVE or LOAD has been performed, manual adjustment of Volts, Amps, Wirespeed or any button press will return the unit to manual operating mode.

13. Digital Ammeter / Wirefeed Speed / Spot time meter

The digital amperage meter is used to display both the pre-set current (Stick and TIG modes only) and actual output current (all modes) of the power source. It is also used to display Wirefeed speed and SPOT time.

At times of non-welding, the amperage meter will display a pre-set

(preview) value in both MMAW (Stick) and GTAW (LIFT TIG) modes.

This value can be adjusted by varying the amperage control (item 8)

and the AMPS light will illuminate to indicate AMPS are being displayed.

In 10 PIN GMAW/FCAW (MIG) mode, the amperage meter will preview

550

IPM MPM AMPS SEC

A-10630

A-10631_AB

wirefeed speed. The IPM (inches per minute) or MPM (metres per minute)

light will illuminate to indicate which wirespeed scale is being used.

In 19 PIN GMAW/FCAW (MIG) mode, the amperage meter will read zero. When welding, the amperage meter will display actual welding current in all modes.

At the completion of welding, the amperage meter will hold the last recorded amperage value for a period of approximately 10 seconds in all modes. The amperage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode.

INSTALLATION, OPERATION AND SETUP

3-8 Manual 0-5205

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TRANSMIG 350i, 450i, 550i

NOTE

14. Digital Voltmeter / Inductance meter (MIG) / Downslope (TIG) / Arc Force (Stick)

The digital volt meter is used to display both the pre-set voltage (MIG mode only) and actual output voltage (all modes) of the power source. It is also used to display inductance and down slope time.

At times of non-welding, the VOLT meter will display a pre-set (preview)

value in GMAW (MIG) mode.

This value can be adjusted by varying the volts control (item 9)

32.0

and the VOLTS light will illuminate to indicate VOLTS are being

displayed. When welding, the volt meter will display actual welding voltage in all modes.

At the completion of welding, the volt meter will hold the last recorded voltage value for a period of approximately 10 seconds in all modes. The volt meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding voltage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode.

In MIG mode when setting the INDUCTANCE value, the read INDUCTANCE. The range of adjustment is from 0 to 100.

In TIG mode when setting DOWNSLOPE the SEC light will illuminate, and the display will read DOWNSLOPE. The range of adjustment is from 0 to 10 seconds.

In Stick mode when setting the ARCFORCE the display will read ARCFORCE. The range of adjustment is from 0 to 100.

Arc force control provides an adjustable amount of welding force (or "dig") control. This feature can be particularly beneﬁcial in providing the operator the ability to compensate for variability in joint ﬁt-up in certain situations with particular electrodes. In general increasing the arc force control toward "100" (maximum arc force) allows greater penetration control to be achieved. Arc force is increased by turning the control knob clockwise or decreased by turning the knob anti-clockwise.

light will illuminate, and the display will

VOLTSSEC

A-10632_AB

NOTE

Manual 0-5205 3-9

INSTALLATION, OPERATION AND SETUP

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TRANSMIG 350i, 450i, 550i

Amps

A-10634

Volts

A-10635

15. Advanced Features

The TRANSMIG 350i, 450i and 550i have a series of Advanced features that allow the control of multiple parameters.

These are accessed by pressing the AMPS and VOLTS knobs at the same time.

Once in the Advanced Features mode, turn the AMP control to select the Parameter, and turn the VOLTS control to adjust the value.

Figure 3-2: Advanced Features

Program Number Description

P01 P02 P03 P04 P05 P06 P07 P08

SPOT TIME, adjustable from 0.5 to 5.0 seconds

BURN BACK TIME, adjustable from 0.01 to 2.00 seconds

PRE FLOW TIME, adjustable from 0.01 to 9.99 seconds

POST FLOW TIME, adjustable from 0.01 to 9.99 seconds

MMAW (Stick) HOT START CURRENT, adjustable from 10 to 100A

CREEP FEED SPEED, adjustable from 0.05 to 20 MPM

Wirefeed speed units, change between IPM and MPM

Displays Software revision

Table 3-1: Advanced Features

A-10633

INSTALLATION, OPERATION AND SETUP

3-10 Manual 0-5205

Page 31

TRANSMIG 350i, 450i, 550i

16. Fan as Needed

The TRANSMIG 350i, 450i and 550i are ﬁtted with a fan as needed feature. Fan as needed automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimise the amount of contaminants such as dust that are drawn into the power source.

Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required.

17. Main Three Phase Power On / Off Switch

This Three Phase circuit breaker performs a dual function.

It is used to turn the unit on/off and it will also trip in the event of a major fault condition.

Lift the cover for access to the circuit breaker.

WARNING

When the front digital displays are lit, the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential

18. Positive Welding Terminal

Welding current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

19. Negative Welding Terminal

CAUTION

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

Manual 0-5205 3-11

INSTALLATION, OPERATION AND SETUP

Page 32

TRANSMIG 350i, 450i, 550i

20. 10 Pin Control Socket

The 10 pin receptacle is used to connect a Wirefeeder or other suitable remote control device to the weld-

ing Power Source circuitry:

To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. The socket

information is included in the event the supplied cable is not suitable and it is necessary to wire a plug or cable to interface with the 10 pin receptacle

Socket

A-10636

Part Number / Description

A Remote Voltage Control Potentiometer Wiper B Motor Negative C Motor Positive D Contactor + (Contact closure is provided between socket

pins D and G to energise the contactor)

E Remote Voltage & Wirespeed Control Potentiometers Maximum

F Remote Wirespeed Control Potentiometer Wiper G Contactor Negative, Solenoid Negative H Remote Voltage & Wirespeed Control Potentiometers Minimum

I Solenoid Positive

J Not used

Table 3-2: 10 Pin Interconnection Control Plug conﬁguration

INSTALLATION, OPERATION AND SETUP

3-12 Manual 0-5205

Page 33

TRANSMIG 350i, 450i, 550i

21. 19 Pin Wirefeeder Control Socket

The WIREFEEDER 19 pin receptacle is used to connect a Wirefeeder to the welding Power Source circuitry. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. The socket information is included in the event the supplied cable is not suitable and it is necessary to wire a plug or cable to interface with the WIREFEEDER 19 pin receptacle.

A-10637

Socket Pin Part Number / Description

A Contactor + (Contact closure is provided between socket

pins A and B to energise the contactor)

B Contactor - (Contact closure is provided between socket

pins A and B to energise the contactor) C Voltage feedback (1V=10V output voltage) D Not used E Input Supply 110VAC 4A with respect to Socket F (circuit common)

F 42VAC and 110VAC common G Chassis Ground (Mains Earth) H Remote Voltage Control Potentiometers Maximum

J Remote Voltage Control Potentiometer Wiper K Remote Voltage Control Potentiometers Minimum L Control circuit common

M Arc Established = +15V DC

N Power Source Select Line (0V = wirefeeder enabled) P Not used R Not used S Input Supply 42VAC 8A with respect to Socket F (circuit common) T Not used U Current feedback (1V=100A output current) V Not used

Table 3-3: 19 Pin Interconnection Control Plug conﬁguration

WARNING

The Protective Earth Ground pin G of the control cable is established only when the power source is properly grounded

Manual 0-5205 3-13

INSTALLATION, OPERATION AND SETUP

Page 34

TRANSMIG 350i, 450i, 550i

22. Control Circuit Breakers

A-10638

Figure 3-3: Circuit Breakers

These Circuit Breakers protects the unit from electrical faults.

The SOLENOID 4A and MOTOR 5A circuit breakers are for Wirefeeders connected to the 10 pin control socket. The 42VAC 8A and 110VAC 4A circuit breakers are for Wirefeeders connected to the 19 pin control socket. The Fan 3A circuit breaker protects the fan circuit in the event of a fault.

NOTE

If a circuit breaker trips, a short cooling period must be allowed before an attempt is made to reset the unit by pressing the circuit breaker reset button. In the event that the circuit breaker will not reset have an Accredited Cigweld Service provider investigate the fault.

23. Restore Factory Default Settings

The Transmig 350i, 450i and 550i can have Factory Default Settings Restored .This function is accessed by pressing the AMPS and INDUCTANCE knobs at the same time for two seconds (2s). The VOLTS and AMPS led's will ﬂash 3 times to indicate a Factory Reset has been completed.

INSTALLATION, OPERATION AND SETUP

A-10973

Figure 3-4: Restore Factory Default Settings

3-14 Manual 0-5205

Page 35

TRANSMIG 350i, 450i, 550i

3.07 Shielding Gas Regulator Operating Instructions

WARNING

This equipment is designed for use with welding grade (Inert) shielding gases only.

Shielding Gas Regulator Safety

This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.

If the equipment is improperly used, hazardous conditions are created that may cause accidents. It is the users responsibility to prevent such conditions. Before handing or using the equipment, understand and comply at all times with the safe practices prescribed in this instruction.

SPECIFIC PROCEDURES for the use of regulators are listed below.

1. NEVER subject the regulator to inlet pressure greater than its rated inlet pressure.

2. NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition. NEVER loosen a connection or attempt to remove any part of a regulator until the gas pressure has been relieved. Under pressure, gas can dangerously propel a loose part.

3. DO NOT remove the regulator from a cylinder without ﬁrst closing the cylinder valve and releasing gas in the regulator high and low pressure chambers.

4. DO NOT use the regulator as a control valve. When downstream equipment is not in use for extended periods of time, shut off the gas at the cylinder valve and release the gas from the equipment.

5. OPEN the cylinder valve SLOWLY. Close after use.

User Responsibilities

This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in accordance with the instructions provided. Equipment must be checked periodically and repaired, replaced, or reset as necessary for continued safe and reliable performance. Defective equipment should not be used. Parts that are broken, missing, obviously worn, distorted, or contaminated should be replaced immediately.

The user of this equipment will generally have the sole responsibility for any malfunction, which results from improper use, faulty maintenance, or by repair by anyone other than an accredited repairer.

CAUTION

Match regulator to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas.

Art: A-05087

Figure 3-5: Fit Regulator to Cylinder

Manual 0-5205 3-15

INSTALLATION, OPERATION AND SETUP

Page 36

TRANSMIG 350i, 450i, 550i

Installation

1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog oriﬁces and damage seats before connecting the regulator.

Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of

ignition. Wipe with a clean lint free cloth.

2. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking agree and that the regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas.

3. Connect the regulator inlet connection to cylinder or pipeline and tighten it ﬁrmly but not excessively, with a suitable spanner.

4. Connect and tighten the outlet hose ﬁrmly and attach down-stream equipment.

5. To protect sensitive down-stream equipment a separate safety device may be necessary if the regulator is not ﬁtted with a pressure relief device.

Operation

With the regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows:

1. Stand to one side of regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal regulator parts.

2. With valves on downstream equipment closed, adjust regulator to approximate working pressure. It is recommended that testing for leaks at the regulator connection points be carried out using a suitable leak detection solution or soapy water.

3. Purge air or other unwanted welding grade shielding gas from equipment connected to the regulator by individually opening then closing the equipment control valves. Complete purging may take up to ten seconds or more, depending upon the length and size of the hose being purged.

Adjusting Flow Rate

Art: A-05088_AB

Figure 3-6: Adjust Flow Rate

With the regulator ready for operation, adjust working ﬂow rate as follows:

1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required ﬂow rate.

NOTE

It may be necessary to re-check the shielding gas regulator ﬂow rate following the ﬁrst weld se quence due to back pressure present within shielding gas hose assembly.

INSTALLATION, OPERATION AND SETUP

3-16 Manual 0-5205

Page 37

TRANSMIG 350i, 450i, 550i

2. To reduce ﬂow rate, allow the welding grade shielding gas to discharge from regulator by opening the downstream valve. Bleed welding grade shielding gas into a well ventilated area and away from any ignition source. Turn adjusting screw counterclockwise, until the required ﬂow rate is indicated on the gauge. Close downstream valve.

Shutdown

Close cylinder valve whenever the regulator is not in use. To shut down for extended periods (more than 30 minutes).

1. Close cylinder or upstream valve tightly.

2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from any ignition source.

3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.

4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove regulators.

3.08 Setup for MIG (GMAW) Welding with Gas Shielded Mig Wire

POWER SOURCE CONNECTIONS

A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source.

B. Connect the work lead to the negative welding terminal (-) [positive welding terminal(+) for ﬂux cored

electrode wire]. If in doubt, consult the electrode wire manufacturer. Welding current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

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

WARNING

Before connecting the work clamp to the work piece make sure the mains power supply is switched off.

Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping.

C. Position a gas cylinder on the rear tray of the Power Source and lock securely to the Power Source cylinder

bracket with the chain provided. If this arrangement is not used or the Power Source is not ﬁtted with a gas cylinder tray then ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely ﬁxed in an upright position.

D. Select MIG mode with the process selection control button.

WIREFEEDER CONNECTIONS

A. Connect the welding power cable from the Wirefeeder's interconnection cables to the positive welding

terminal (+) [negative welding terminal (-) for ﬂux cored electrode wire]. If in doubt, consult the electrode wire manufacturer. Welding current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

B. Connect the control cable from the Wirefeeder to the 10 PIN or 19 PIN socket on the Power Source as

applicable.

Manual 0-5205 3-17

INSTALLATION, OPERATION AND SETUP

Page 38

TRANSMIG 350i, 450i, 550i

C. Fit the gas regulator and ﬂowmeter to the gas cylinder then connect the gas hose from the rear of the

Wirefeeder to the ﬂowmeter outlet.

D. Dual groove feed rollers are supplied as standard. Select the roller required with the chosen wire size

marking facing outwards.

GROOVE “B”GROOVE “A”

Art # A-08739

GROOVE “B” SIZE

E. Fit the electrode wire spool to the wire reel hub. Ensure that the drive dog-pin engages the mating hole

in the wire spool. Push the 'R' clip into place to retain the wire spool securely. The electrode wire should feed from the bottom of the spool.

F MIG Torch, EURO MIG Torch Connection

Fit the MIG Torch to the Wirefeeder by pushing the torch connector into the brass torch adaptor and screw-

ing the plastic torch nut clockwise to secure the torch to the torch adaptor. Remove the contact tip from the torch handset.

TWECO style Torch Connection

Fit the MIG Torch to the Wirefeeder by pushing the torch connector into the brass torch adaptor and screw-

ing the hand nut clockwise to secure the torch to the torch adaptor. Remove the contact tip from the torch handset. Attach the wirefeeder trigger wires to the MIG Torch.

G Lift up the wire feeder pressure levers and pass the electrode wire through the inlet guide, between the

rollers, through the centre guide, between the rollers, through the outlet guide and into the MIG torch.

DO NOT WEAR GLOVES WHILE THREADING THE WIRE OR CHANGING THE WIRE SPOOL.

GROOVE “A” SIZE

WARNING

H. Lower the pressure levers and with the torch lead reasonably straight, feed the electrode wire through the

torch. Fit the appropriate contact tip, eg a 0.9mm tip for 0.9mm wire.

I Press the INCH button to feed the wire through the torch. (Only applicable to wirefeeders connected to the

10 pin socket. Wirefeeders connected to the 19 pin socket can only be inched from the wirefeeder itself if that function is available.)

WARNING

If the Torch Trigger is used to feed wire through the torch, the electrode wire will be at welding voltage potential whilst it is being fed through the wirefeeder system.

WARNING

Before connecting the work clamp to the work piece make sure the mains power supply is switched off.

NOTE

Welding Setup Program Storage (10 programs) applies to MIG (10 pin only), Stick and Lift Tig modes.

INSTALLATION, OPERATION AND SETUP

3-18 Manual 0-5205

Page 39

Mig Torch

Positive Welding Terminal (+)

TRANSMIG 350i, 450i, 550i

Work Lead

Powered Wirefeeder (19 Pin)

Negative Welding Terminal (-)

19 Pin Control Socket

A-10639

Figure 3-7: Setup for Mig Welding with Gas Shielded Mig Wire

Manual 0-5205 3-19

INSTALLATION, OPERATION AND SETUP

Page 40

TRANSMIG 350i, 450i, 550i

3.09 Setup for MIG (GMAW) Welding with Gasless Mig Wire

POWER SOURCE CONNECTIONS

A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source.

B. Connect the work lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufac-

turer. Welding current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

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

WARNING

Before connecting the work clamp to the work piece make sure the mains power supply is switched off.

C. Select MIG mode with the process selection control button.

WIREFEEDER CONNECTIONS

A. Connect the welding power cable from the Wirefeeder's interconnection cables to the negative welding

terminal (-). If in doubt, consult the electrode wire manufacturer. Welding current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

B. Connect the control cable from the Wirefeeder to the 10 PIN or 19 PIN socket on the Power Source as

applicable.

C. Dual groove feed rollers are supplied as standard. Select the roller required with the chosen wire size

marking facing outwards.

GROOVE “B”GROOVE “A”

Art # A-08739

GROOVE “B” SIZE

D. Fit the electrode wire spool to the wire reel hub. Ensure that the drive dog-pin engages the mating hole

in the wire spool. Push the 'R' clip into place to retain the wire spool securely. The electrode wire should feed from the bottom of the spool.

E. MIG Torch, EURO MIG Torch Connection

Fit the MIG Torch to the Wirefeeder by pushing the torch connector into the brass torch adaptor and screw-

ing the plastic torch nut clockwise to secure the torch to the torch adaptor. Remove the contact tip from the torch handset.

GROOVE “A” SIZE

TWECO style Torch Connection

Fit the MIG Torch to the Wirefeeder by pushing the torch connector into the brass torch adaptor and screw-

ing the hand nut clockwise to secure the torch to the torch adaptor. Remove the contact tip from the torch handset. Attach the wirefeeder trigger wires to the MIG Torch.

F. Lift up the wire feeder pressure levers and pass the electrode wire through the inlet guide, between the

rollers, through the centre guide, between the rollers, through the outlet guide and into the MIG torch.

INSTALLATION, OPERATION AND SETUP

3-20 Manual 0-5205

Page 41

TRANSMIG 350i, 450i, 550i

WARNING

DO NOT WEAR GLOVES WHILE THREADING THE WIRE OR CHANGING THE WIRE SPOOL.

G. Lower the pressure levers and with the torch lead reasonably straight, feed the electrode wire through the

torch. Fit the appropriate contact tip, eg a 0.9mm tip for 0.9mm wire.

H Press the INCH button to feed the wire through the torch. (Only applicable to wirefeeders connected to the

10 pin socket. Wirefeeders connected to the 19 pin socket can only be inched from the wirefeeder itself if that function is available.)

WARNING

If the Torch Trigger is used to feed wire through the torch, the electrode wire will be at welding voltage potential whilst it is being fed through the wirefeeder system.

WARNING

Before connecting the work clamp to the work piece make sure the mains power supply is switched off.

NOTE

Welding Setup Program Storage (10 programs) applies to MIG (10 pin only), Stick and Lift Tig modes.

Figure 3-8: Setup for Mig Welding with Gasless Mig Wire

Manual 0-5205 3-21

A-10794

INSTALLATION, OPERATION AND SETUP

Page 42

TRANSMIG 350i, 450i, 550i

3.10 Setup for TIG (GTAW) Welding With Gas Shielding

A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source.

B. Connect the work lead to the positive welding terminal (+).Welding current ﬂows from the Power Source

via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the optional TIG Torch (refer to table 2-2 optional accessories) to the negative welding terminal

(-).Welding current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

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

WARNING

Before connecting the work clamp to the work piece make sure the mains power supply is switched off.

Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping.

D. Position a gas cylinder on the rear tray of the Power Source and lock securely to the Power Source cylinder

E. Select LIFT TIG mode with the process selection control button.

F. Connect the TIG Torch trigger switch / remote control to the 10 PIN socket on the Power Source as ap-

plicable. The TIG Torch will require a trigger switch to operate in LIFT TIG mode.

G. Fit the gas regulator and ﬂowmeter to the gas cylinder then connect the gas hose from the TIG Torch to

the Flowmeter outlet. The Power Source is not ﬁtted with a shielding gas solenoid to control the gas ﬂow in LIFT TIG mode, therefore the TIG Torch will require a gas valve.

Work Lead

INSTALLATION, OPERATION AND SETUP

Positive Welding Terminal (+)

Negative Welding Terminal (-)

10 Pin Control Socket

Tig Torch

A-10640_AB

Figure 3-9: Setup for TIG (GTAW) Welding with Gas Shielding

3-22 Manual 0-5205

Page 43

TRANSMIG 350i, 450i, 550i

3.11 Setup for STICK (MMAW) Welding

A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source.

B. Connect the Electrode Holder to the positive welding terminal (+). If in doubt, consult the electrode manu-

facturer. Welding current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer.

CAUTION

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

WARNING

Before connecting the work clamp to the workpiece make sure the mains power supply is switched off.

D. Select STICK mode with the process selection control button

Positive Welding Terminal (+)

Electrode Holder

A-10641

Negative Welding Terminal (-)

Work Lead

Figure 3-10: Setup for Manual Arc Welding.

Manual 0-5205 3-23

INSTALLATION, OPERATION AND SETUP

Page 44

TRANSMIG 350i, 450i, 550i

A-10795

3.12 Setup for GOUGING (Transmig 550i only)

A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source.

B. Connect the Carbon Arc Gouging Torch to the positive welding terminal (+). If in doubt, consult the car-

bon electrode manufacturer. Welding current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer.

D. Connect the air hose from the Carbon Arc Gouging Torch to a Filtered, Industrial, Compressed air outlet

and set pressure to the Carbon Arc Gouging Torch manufacturers speciﬁcation.

E. Select STICK / GOUGING mode with the process selection control button (Transmig 550i only).

CAUTION

Refer to Section 2.10 & 2.11 for Gouging Ratings and Duty Cycle Period.

WARNING

Before connecting the work clamp to the workpiece make sure the mains power supply is

switched off.

INSTALLATION, OPERATION AND SETUP

Figure 3-11: Setup for Gouging

3-24 Manual 0-5205

Page 45

TRANSMIG 350i, 450i, 550i

Art # A-8991_AB

Shielding Gas

Molten Weld Metal

Solidiﬁed Weld Metal

Nozzle

Electrode

Arc

Base Metal

GMAW Process

Art # A-08992_AB

Molten Slag

Nozzle (Optional)

FCAW Process

Flux Cored Electrode

Arc

Shielding Gas (Optional)

Slag

Molten Metal

Base Metal

Solidiﬁed Weld Metal

SECTION 4:

BASIC WELDING GUIDE

4.01 MIG (GMAW/FCAW) Basic Welding Technique

Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the very basic concepts in using the Mig mode of welding, where a welding gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.

GAS METAL ARC WELDING (GMAW): This process, also known as MIG welding, CO

welding, Micro Wire

Welding, short arc welding, dip transfer welding, wire welding etc., is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a solid continuous, consumable electrode and the work. Shielding is obtained from an externally supplied welding grade shielding gas or welding grade shielding gas mixture. The process is normally applied semi automatically; however the process may be operated automatically and can be machine operated. The process can be used to weld thin and fairly thick steels, and some non-ferrous metals in all positions.

Figure 4-1

FLUX CORED ARC WELDING (FCAW): This is an electric arc welding process which fuses together the parts to

be welded by heating them with an arc between a continuous ﬂux ﬁlled electrode wire and the work. Shielding is obtained through decomposition of the ﬂux within the tubular wire. Additional shielding may or may not be obtained from an externally supplied gas or gas mixture. The process is normally applied semi automatically; however the process may be applied automatically or by machine. It is commonly used to weld large diameter electrodes in the ﬂat and horizontal position and small electrode diameters in all positions. The process is used to a lesser degree for welding stainless steel and for overlay work.

Figure 4-2

Manual 0-5205 4-1 BASIC WELDING GUIDE

Page 46

TRANSMIG 350i, 450i, 550i

Butt & Horizontal Welds

Direction of

Travel

5° to 15°

Longitudinal

Angle

90°

Transverse

Angle

Art # A-08993

Horizontal Fillet Weld

Direction of

Travel

5° to 15°

Longitudinal Angle

30° to 60°

Transverse Angle

Art # A-08994

Position of MIG Torch

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

Push

Vertical

Drag/Pull

Art # A-07185_AB

Figure 4-3

The welding gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below)

Hold the gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper ﬁlter lenses and use the proper safety equipment.

CAUTION

Do not pull the welding gun back when the arc is established. This will create excessive wire extension (stick-out) and make a very poor weld.

The electrode wire is not energized until the gun trigger switch is depressed. The wire may therefore be placed on the seam or joint prior to lowering the helmet.

BASIC WELDING GUIDE 4-2 Manual 0-5205

Figure 4-4

Figure 4-5

Page 47

Vertical Fillet Welds

Art # A-08995

30° to 60° Transverse

Angle

30° to 60° Transverse

Angle

Direction of Travel

10°

Longitudinal Angle

10° to 20° Longitudinal

Angle

Figure 4-6

Overhead Weld

Art # A-08996

30° to 60°

Transverse Angle

Direction of Travel

5° to 15° Longitudinal Angle

TRANSMIG 350i, 450i, 550i

Figure 4-7

Distance from the MIG Torch Nozzle to the Work Piece

The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20.0mm. This distance may vary depending on the type of joint that is being welded.

Travel Speed

The speed at which the molten pool travels inﬂuences the width of the weld and penetration of the welding run.

MIG Welding (GMAW) Variables

Most of the welding done by all processes is on carbon steel. The items below describe the welding variables in short-arc welding of 24gauge (0.024”, 0.6mm) to ¼” (6.4mm) mild sheet or plate. The applied techniques and end results in the GMAW process are controlled by these variables.

Preselected Variables

Preselected variables depend upon the type of material being welded, the thickness of the material, the welding position, the deposition rate and the mechanical properties. These variables are:

• Type of electrode wire

• Size of electrode wire

• Type of gas (not applicable to self shielding wires FCAW)

• Gas ﬂow rate (not applicable to self shielding wires FCAW)

Primary Adjustable Variables

These control the process after preselected variables have been found. They control the penetration, bead width, bead height, arc stability, deposition rate and weld soundness. They are:

• Arc Voltage

• Welding current (wire feed speed)

• Travel speed

Manual 0-5205 4-3 BASIC WELDING GUIDE

Page 48

TRANSMIG 350i, 450i, 550i

Electrode Stick-Out

Transverse and Longitudinal Nozzle Axes

Art # A-08998_AB

Longitudinal Angle

Axis of Weld

Transverse Angle

Art # A-08999_AC

Nozzle Angle, Right Handed Operator

Direction of Gun Travel

Leading or “Pushing”

Angle

(Forward Pointing)

Trailing or “Pulling”

Angle

(Backward Pointing)

90°

Secondary Adjustable Variables

These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation. They are:

1. Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain at about 10mm stick-out

2. Wire Feed Speed. Increase in wire feed speed increases weld current, Decrease in wire feed speed decreases weld current.

Gas Nozzle

Tip to

Work Distance

Average Arc Length

Contact Tip (Tube)

Electrode Wire

Actual Stick-out

Art # A-08997_AD

Figure 4-8

3. Nozzle Angle. This refers to the position of the welding gun in relation to the joint. The transverse angle is usually one half the included angle between plates forming the joint. The longitudinal angle is the angle between the centre line of the welding gun and a line perpendicular to the axis of the weld. The longitudinal angle is generally called the Nozzle Angle and can be either trailing (pulling) or leading (pushing). Whether the operator is left handed or right handed has to be considered to realize the effects of each angle in relation to the direction of travel.

BASIC WELDING GUIDE 4-4 Manual 0-5205

Figure 4-9

Figure 4-10

Page 49

TRANSMIG 350i, 450i, 550i

Establishing the Arc and Making Weld Beads

Before attempting to weld on a ﬁnished piece of work, it is recommended that practice welds be made on a sample metal of the same material as that of the ﬁnished piece.

The easiest welding procedure for the beginner to experiment with MIG welding is the ﬂat position. The equipment is capable of ﬂat, vertical and overhead positions.

For practicing MIG welding, secure some pieces of 16 or 18 gauge (0.06” 1.5mm or 0.08” 2.0mm) mild steel plate 6” x 6” (150 x 150mm). Use 0.030” (0.8mm) ﬂux cored gasless wire or a solid wire with shielding gas.

Setting of the Power Source

Power source and Wirefeeder setting requires some practice by the operator, as the welding plant has two control settings that have to balance. These are the Wirespeed control (refer to section 3.06.4) and the welding Voltage Control (refer to section 3.06.10). The welding current is determined by the Wirespeed control, the current will increase with increased Wirespeed, resulting in a shorter arc. Less wire speed will reduce the current and lengthen the arc. Increasing the welding voltage hardly alters the current level, but lengthens the arc. By decreasing the voltage, a shorter arc is obtained with a little change in current level.

When changing to a different electrode wire diameter, different control settings are required. A thinner electrode wire needs more Wirespeed to achieve the same current level.

A satisfactory weld cannot be obtained if the Wirespeed and Voltage settings are not adjusted to suit the electrode wire diameter and the dimensions of the work piece.

If the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If, however, the welding voltage is too high, large drops will form on the end of the wire, causing spatter. The correct setting of voltage and Wirespeed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound. Refer to the Weld Guide located on the inside of the wirefeed compartment door for setup information.

Electrode Wire Size Selection

The choice of Electrode wire size and shielding gas used depends on the following

• Thickness of the metal to be welded

• Type of joint

• Capacity of the wire feed unit and Power Source

• The amount of penetration required

• The deposition rate required

• The bead prole desired

• The position of welding

• Cost of the wire

Manual 0-5205 4-5 BASIC WELDING GUIDE

Page 50

TRANSMIG 350i, 450i, 550i

ransmig

MULTI PROCESS WELDING INVERTER

350

550

Cigweld Welding Wire Selection Chart

Description

Shield-Cor 11

Verti-Cor 3XP

Autocraft LW1-6

Diameter

1.2mm

1.6mm

1.2mm

1.6mm

0.8mm

0.9mm

1.0mm

1.2mm

1.6mm

Pack

Spool 15kg

Handispool

Spool 15kg

15kg

Spool

Spool 15kg

5kg

Part Number

720923

720925

720919

720921

720114

720161

720090

720094

720096

720095

Application

Shield-Cor 11 is an all positional self-shielded flux cored wire recommended for the general purpose single or multi-pass lap, fillet and butt welding of mild and galvanised steels.

Verti-Cor 3XP is an all positional rutile type flux cored wire for welding a wide range of mild and medium strength steels. Verti-Cor 3XP is for use with Argon+20 to 25% CO shielding gases.

General purpose solid welding wire suitable for the all positional Gas Metal Arc Welding (GWAW) of mild and low alloy steels, used in general fabrication and for welding of light to medium gauge sheet and tubular steel sections. Note that a suitable shielding gas is required.

2 or 100% CO type

Autocraft 316LSi Solid Stainless Steel Mig Wire

Autocraft AL5356 Solid Aluminium Mig Wire

Note Handispool = 200mm diameter, Spool = 300mm diameter.

0.8mm

0.9mm

1.0mm

1.2mm

0.9mm

1.0mm

1.2mm

Handispool 5kg

Handispool

Spool 15kg

Spool

Spool 7kg

Handispool 2kg

Spool

Spool 7kg

5kg

15kg

7kg

720288

720283

721286

722386

721287

722226

723224

722224

722227

General purpose all positional stainless steel wire providing excellent results when used with correct shielding gas. Suitable for the general welding of a wide range of stainless steels (300 & 400 series). Note that a suitable shielding gas is required.

Excellent general purpose Aluminium Mig wire suitable for the welding of a wide range of wrought and cast Aluminium alloys containing Magnesium. Note that a suitable shielding gas is required.

BASIC WELDING GUIDE 4-6 Manual 0-5205

Page 51

TRANSMIG 350i, 450i, 550i

4.02 MIG (GMAW/FCAW) Welding Troubleshooting

Solving Problems Beyond the Welding Terminals

The general approach to ﬁx Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG torch. There are two main areas where problems occur with GMAW, Porosity and Inconsistent wire feed

Solving Problems Beyond the Welding Terminals - 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.

FAULT CAUSE

1 Shielding gas cylinder contents

and ﬂow meter.

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

3 Internal gas hose in the Power

Source.

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

5 Welding dirty, oily, painted,

oxidised or greasy plate.

6 Distance between the MIG torch

nozzle and the work piece.

7 Maintain the MIG torch in good

working order.

Table 4-1: Solving Problems beyond the Welding Terminals-Porosity

Ensure that the shielding gas cylinder is not empty and the ﬂow meter is correctly adjusted to 15 litres per minute.

tion and in the gas hose to the Power Source.

Ensure the hose from the solenoid valve to the torch adaptor has not fractured and that it is connected to the torch adaptor.

Clean contaminates off the work piece.

Keep the distance between the MIG torch nozzle and the work piece to a minimum. Refer to section 2.03

A Ensure that the gas holes are not blocked and gas is exiting

out of the torch nozzle.

B Do not restrict gas ﬂow by allowing spatter to build up inside

the torch nozzle.

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

WARNING

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

Manual 0-5205 4-7 BASIC WELDING GUIDE

Page 52

TRANSMIG 350i, 450i, 550i

Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed

Wire feeding problems can be reduced by checking the following points.

FAULT CAUSE

1 Feed roller driven by motor in the

cabinet slipped.

2 Wire spool unwinded and tangled. Wire spool brake is too loose.

3 Worn or incorrect feed roller size A Use a feed roller matched to the size you are welding.

4 Wire rubbed against the mis-aligned

guides and reduced wire feedability.

5 Liner blocked with swarf A Increased amounts of swarf are produced by the wire

6 Incorrect or worn contact tip A The contact tip transfers the weld current to the elec-

Wire spool brake is too tight.

B Replace feed roller if worn.

Mis-alignment of inlet/outlet guides

passing through the feed roller when excessive pressure is applied to the pressure roller adjuster.

B Swarf can also be produced by the wire passing

through an incorrect feed roller groove shape or size.

C Swarf is fed into the conduit liner where it accumu-

lates thus reducing wire feedability.

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

B When using soft wire such as aluminium it may

become jammed in the contact tip due to expansion of the wire when heated. A contact tip designed for soft wires should be used.

7 Poor work lead contact to work piece If the work lead has a poor electrical contact to the

work piece then the connection point will heat up and result in a reduction of power at the arc.

8 Bent liner This will cause friction between the wire and the liner

thus reducing wire feedability

Table 4-2: Wire Feeding Problems

BASIC WELDING GUIDE 4-8 Manual 0-5205

Page 53

Basic GMAW (MIG) Welding Troubleshooting

FAULT CAUSE REMEDY

TRANSMIG 350i, 450i, 550i

1 Undercut A Welding arc voltage too

high.

B Incorrect torch angle B Adjust angle.

C Excessive heat input C Increase the torch travel speed and/or decrease

2 Lack of penetration A Welding current too low A Increase welding current by increasing wire feed

B Joint preparation too

narrow or gap too tight

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

3 Lack of fusion Voltage too low Increase voltage.

4 Excessive spatter A Voltage too high A Decrease voltage or increase the wirespeed

B Voltage too low B Increase the voltage or decrease wirespeed.

5 Irregular weld shape A Incorrect voltage and

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

A Decrease voltage or increase the wire feed speed.

welding current by decreasing the voltage or decreasing the wire feed speed.

speed and increasing voltage.

B Increase joint angle or gap.

control.

A Adjust voltage and current by adjusting the voltage

control and the wirespeed control.

B Wire is wandering. B Replace contact tip.

C Incorrect shielding gas C Check shielding gas.

D Insufﬁcient or excessive

heat input

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

B Weld penetration narrow

and deep

C Excessive weld stresses C Increase weld metal strength or revise design

D Excessive voltage D Decrease voltage.

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

7 Cold weld puddle A Loose welding cable

connection.

B Low primary voltage B Contact supply authority.

C Fault in power source C Have an Accredited CIGWELD Service Provider to

D Adjust the wirespeed control or the voltage

control.

B Reduce current and voltage and increase Mig torch

travel speed or select a lower penetration shielding gas.

welded or cool slowly.

A Check all welding cable connections.

test then replace the faulty component.

8 Arc does not have

a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly.

Manual 0-5205 4-9 BASIC WELDING GUIDE

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

Table 4-3: GMAW (MIG) Welding Problems

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.

Page 54

TRANSMIG 350i, 450i, 550i

4.03 Stick (MMAW) Basic Welding Technique

Size of Electrode

The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufﬁcient current (amperage) to run the smaller size electrodes.

For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A little practice will soon establish the most suitable electrode for a given application.

Storage of Electrodes

Always store electrodes in a dry place and in their original containers.

Electrode Polarity

Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited CIGWELD Distributor.

Effects of Arc Welding Various Materials

A. 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 may result. 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.

Hydrogen controlled Electrodes must be used for this application. Use Ferrocraft 61 or 16TXP for normal

strength (500 MPa) steels, and Alloycraft range for higher strength steels.

B. Austenitic manganese steels

The effect on manganese steel of slow cooling from high temperatures is to embrittle it. 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. Suitable Electrode types are Cobalarc Austex or Cobalarc Mangcraft.

C. Cast Iron

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 whiteheart malleable, due to the porosity caused by gas held in this type of iron. Suitable Electrode types are Castcraft 55 or Castcraft 100.

D. 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. Suitable Electrode types are Bronzecraft AC-DC electrodes.

Arc Welding Practice

The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally enough, different types of electrodes would be used for different metals as described in the preceding section.

Welding Position

The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in ﬂat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these. Some of the common types of welds are shown in Figures 4-15 through 4-22.

BASIC WELDING GUIDE 4-10 Manual 0-5205

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TRANSMIG 350i, 450i, 550i

Art # A-07688

Art # A-07689

Art # A-07690

Art # A-07687

Figure 4-11: Flat Position, Down Hand Butt Weld

Figure 4-12: Flat Position, Gravity Fillet Weld

Figure 4-13: Horizontal Position, Butt Weld

Figure 4-14: Horizontal-Vertical (HV) Position

Art A-07691

Figure 4-15: Vertical Position, Butt Weld

Art # A-07692

Figure 4-16: Vertical Position, Fillet Weld

Manual 0-5205 4-11 BASIC WELDING GUIDE

Page 56

TRANSMIG 350i, 450i, 550i

Gap varies from

1.6mm (1/16”) to 4.8mm (3/16”) depending on plate thickness

Joint

Open Square Butt

1.6mm (1/16” ) max

1.6mm (1/16”)

Single Vee Butt Joint

Not less than

70°

Double Vee Butt Joint

1.6mm (1/16”)

Lap Joint

Tee Joints

(Fillet both sides of the

joint)

Edge Joint

Fillet Joint

Corner Weld

Plug Weld Plug Weld

Not less than

70°

Single Vee Butt Joint

Not less than

45°

1.6mm (1/16”) max

Art # A-07695_AE

Art# A-07693

Figure 4-17: Overhead Position, Butt Weld

Art # A-07694

Figure 4-18: Overhead Position, Fillet Weld

Joint Preparations

In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.

In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in Figure 4-19.

Figure 4-19: Typical Joint Designs for Arc Welding

BASIC WELDING GUIDE 4-12 Manual 0-5205

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TRANSMIG 350i, 450i, 550i

Art # A-07696_AB

20°

1.6 mm (1/16”)

Arc Welding Technique - A Word to Beginners

For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode. Clean any paint, loose scale or grease off the plate and set it ﬁrmly on the work bench so that welding can be carried out in the downhand position. Make sure that the work clamp is making good electrical contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a poor circuit will probably result.

The Welder

Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body will soon make you feel tired. Relax and you will ﬁnd that the job becomes much easier. You can add much to your peace of mind by wearing a leather apron and gauntlets. You won't be worrying then about being burnt or sparks setting alight to your clothes.

Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down. If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight off your hand. Be sure the insulation on your cable and electrode holder is not faulty, otherwise you are risking an electric shock.

Striking the Arc

Practice this on a piece of scrap plate before going on to more exacting work. You may at ﬁrst experience difﬁculty due to the tip of the electrode "sticking" to the work piece. This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it. This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck. As soon as the arc is established, maintain a 1.6mm to 3.2mm gap between the burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.

Another difﬁculty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the arc is broken again. A little practice will soon remedy both of these faults.

Figure 4-20: Striking an Arc

Arc Length

The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will ﬁnd that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs. The weld bead is ﬂattened and spatter increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidiﬁed in. If this should happen, give the electrode a quick twist back over the weld to detach it. Contact or "touch-weld" electrodes such as Ferrocraft 21 do not stick in this way, and make welding much easier.

Rate of Travel

After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.

Manual 0-5205 4-13 BASIC WELDING GUIDE

Page 58

TRANSMIG 350i, 450i, 550i

Art # A-07697_AB

Tack Weld

20°-30°

Electrode

Tack Weld

Art # A-07698

If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. If the travel is too slow, the weld metal piles up and the bead will be too large.

Making Welded Joints

Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.

A. Butt Welds

Set up two plates with their edges parallel, as shown in Figure 4-21, allowing 1.6mm to 2.4mm gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment. Plates thicker than 6.0mm should have their mating edges bevelled to form a 70º to 90º included angle. This allows full penetration of the weld metal to the root. Using a 3.2mm Ferrocraft 21 electrode at 100 amps, deposit a run of weld metal on the bottom of the joint.

Do not weave the electrode, but maintain a steady rate of travel along the joint sufﬁcient to produce a well-formed bead. At ﬁrst you may notice a tendency for undercut to form, but keeping the arc length short, the angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help eliminate this. The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc. To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.

Figure 4-21: Butt Weld

Figure 4-22: Weld Build up Sequence

Heavy plate will require several runs to complete the joint. After completing the ﬁrst run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run. Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4-22. The width of weave should not be more than three times the core wire diameter of the electrode. When the joint is completely ﬁlled, the back is either machined, ground or gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld.

BASIC WELDING GUIDE 4-14 Manual 0-5205

Page 59

TRANSMIG 350i, 450i, 550i

Art # A-07699_AB

45° from vertical

60° - 70° from line of weld

Art # A-07700_AB

B. Fillet Welds

These are welds of approximately triangular cross-section made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-14.

A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. Using a 3.2mm Ferrocraft 21 electrode at 100 amps, position angle iron with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) ﬁllet. Strike the arc and immediately bring the electrode to a position perpendicular to the line of the ﬁllet and about 45º from the vertical. Some electrodes require to be sloped about 20º away from the perpendicular position to prevent slag from running ahead of the weld. Refer to Figure 4-23. Do not attempt to build up much larger than 6.4mm width with a 3.2mm electrode, otherwise the weld metal tends to sag towards the base, and undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 4-24. Weaving in HV ﬁllet welds is undesirable.

Figure 4-23: Electrode Position for HV Fillet Weld

Figure 4-24: Multi-runs in HV Fillet Weld

C. Vertical Welds

1. Vertical Up

Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm

Ferrocraft 21 electrode and set the current at 100 amps. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the ﬁllet. The electrode needs to be about 10º from the horizontal to enable a good bead to be deposited. Refer Figure 4-25. Use a short arc, and do not attempt to weave on the ﬁrst run. When the ﬁrst run has been completed de-slag the weld deposit and begin the second run at the bottom. This time a slight weaving motion is necessary to cover the ﬁrst run and obtain good fusion at the edges. At the completion of each side motion, pause for a moment to allow weld metal to build up at the edges, otherwise undercut will form and too much metal will accumulate in the centre of the weld. Figure 4-26 illustrates multi-run technique and Figure 4-27 shows the effects of pausing at the edge of weave and of weaving too rapidly.

Manual 0-5205 4-15 BASIC WELDING GUIDE

Page 60

TRANSMIG 350i, 450i, 550i

Art # A-07701

Figure 4-25: Single Run Vertical Fillet Weld

Art # A-07702

Figure 4-26: Multi Run Vertical Fillet Weld

Art # A-07703

Figure 4-27: Examples of Vertical Fillet Welds

2. Vertical Down

The Ferrocraft 21 electrode makes welding in this position particularly easy. Use a 3.2mm electrode at

100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should point upwards at an angle of about 45º.

3. Overhead Welds

Apart from the rather awkward position necessary, overhead welding is not much more difﬁcult that

downhand welding. Set up a specimen for overhead welding by ﬁrst tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch. The electrode is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-28). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique

is not advisable for overhead llet welds. Use a 3.2mm Ferrocraft 12XP electrode at 100 amps, and

deposit the ﬁrst run by simply drawing the electrode along at a steady rate. You will notice that the weld deposit is rather convex, due to the effect of gravity before the metal freezes.

BASIC WELDING GUIDE 4-16 Manual 0-5205

Page 61

TRANSMIG 350i, 450i, 550i

Art # A-07705_AB

Hot

Weld

Upsetting

Expansion with compression

Cool

Art # A-07704

Figure 4-28: Overhead Fillet Weld

Distortion

Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur. The study of distortion is so complex that only a brief outline can be attempted hear.

The Cause of Distortion

Distortion is caused by:

A. Contraction of Weld Metal:

Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In a welded joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore, cooling causes the weld metal to ﬂow plastically, that is, the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint. If the restraint is very great, as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still remain stresses "Locked-up" in the structure. If the joint material is relatively weak, for example, a butt joint in 2.0mm sheet, the contracting weld metal may cause the sheet to become distorted.

B. Expansion and Contraction of Parent Metal in the Fusion Zone:

While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions. It is able to do this freely at right angles to the surface of the plate (i.e., "through the weld", but when it attempts to expand "across the weld" or "along the weld", it meets considerable resistance, and to fulﬁl the desire for continued expansion, it has to deform plastically, that is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by expanding, pushes against the cooler, harder metal further away, and tends to bulge (or is "upset". When the weld area begins to cool, the "upset" metal attempts to contract as much as it expanded, but, because it has been "upset" it does not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal. Several things can then happen.

The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful contraction stresses (distortion), or the weld may crack, in any case, there will remain "lockedup" stresses in the job. Figures 4-29 and 4- 30 illustrate how distortion is created.

Figure 4-29: Parent Metal Expansion

Manual 0-5205 4-17 BASIC WELDING GUIDE

Page 62

TRANSMIG 350i, 450i, 550i

Art # A-07706_AC

Weld

Permanent Upset

Contraction with tension

Art # A-07708

PreheatPreheat

Dotted lines show effect if no preheat is used

Weld

Figure 4-30: Parent Metal Contraction

Overcoming Distortion Effects

There are several methods of minimizing distortion effects.

A. Peening

This is done by hammering the weld while it is still hot. The weld metal is ﬂattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer.

B. Distribution of Stresses

Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 4-30 through 4-33 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion.

C. Restraint of Parts

Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and tack welds are methods employed with this in view.

D. Presetting

It is possible in some cases to tell from past experience or to ﬁnd by trial and error (or less frequently, to calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the components to be welded, constructional stresses can be made to pull the parts into correct alignment. A simple example is shown in Figure 4-31.

E. Preheating

Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure 4-32 shows a simple application. By removing the heating source from b and c as soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.

Art # A-07707

BASIC WELDING GUIDE 4-18 Manual 0-5205

Figure 4-31: Principle of Presetting

Figure 4-32: Reduction of Distortion by Preheating

Page 63

Art # A-07709

Art # A-07710_AB

Block Sequence. The spaces between the welds are ﬁlled in when the welds are cool.

Art # A-07711_AB

Art # A-07713_AB

Figure 4-33: Examples of Distortion

TRANSMIG 350i, 450i, 550i

Figure 4-34: Welding Sequence

Figure 4-35: Step back Sequence

Art # A-07712

Figure 4-36: Chain Intermittent Welding

Figure 4-37: Staggered Intermittent Welding

Manual 0-5205 4-19 BASIC WELDING GUIDE

Page 64

TRANSMIG 350i, 450i, 550i

Electrode Selection Chart (Further information on CIGWELD electrodes can be found at the website www.cigweld.com.au.)

CIGWELD Electrode Selection Chart

Description Diameter Pack Part No. Application

Satincraft 13

Ferrocraft

12XP

WeldSkill GP

Ferrocraft 16

Twincoat

Satincrome

308L-17

Satincrome

309Mo-17

Satincrome

316L-17

Weldall

Castcraft 55

Castcraft 100

2.5mm

3.2mm

4.0mm

2.0mm

2.5mm

3.2mm

4.0mm

2.0mm

2.5mm

3.2mm

4.0mm

2.5mm

3.2mm

4.0mm

2.5mm

3.2mm

4.0mm

2.5mm

3.2mm

4.0mm

2.0mm

2.5mm

3.2mm

2.5/3.2mm

4.0mm

2.5mm

3.2mm

2.5/3.2mm

4.0mm

3.2mm

4.0mm

2.5mm

3.2mm

2.5/3.2mm

4.0mm

1kg

2.5kg 1kg

2.5kg 5kg 1kg

2.5kg 1kg

2.5kg 5kg

1 kg

2.5 kg 1 kg

2.5 kg 5 kg 1 kg

2.5 kg 5 kg 5 kg

2.5kg 5 kg

2.5kg 5 kg 5 kg

2.5 kg

2.5 kg 2,5 kg

2.5 kg

Blisterpack

2.5 kg

Blisterpack

2.5 kg

Blisterpack

2.5 kg

322135 612182 322136 612183 611184 322128 612231 322129 612232 322138 612233 611234

WEG1020 WEG2520 WEG1025 WEG2525 WEG5025 WEG1032 WEG2532 WEG5032 WEG5040

612752 611752 612753 611753 611754

611602 611603 611604

611692 611693 611694

611661 611662 611663 322215 611664

611702 611703 322216 611704

611723 611724

611732 611733 322217 611734

General purpose electrode suitable for all positional welding and galvanised steel.

General purpose, Xtra performance electrode

recommended for all positional (inc. Vertical down) welding of mild and galvanised steel.

User-friendly GP electrode for welding thin section mild and galvanised steels. Excellent for vertical down ﬁllet welding applications.

Hydrogen Controlled type offering exceptional AC/DC performance in all welding positions.

Stainless Steel type for 19Cr/10Ni stainless grades including 201, 202, 301, 302, 303, 304, 304L, 305, 308, etc

Stainless Steel type for 309 and 309L grades. It is also suitable for welding of dissimilar welding of other 300 series stainless steels.

Stainless Steel type for welding of matching Mo bearing grades, 316 and 316L.

High alloy stainless steel type for welding of unknown steels, repair of die or tool steels and for joining dissimilar steels. (Not recommended for cast iron).

For repair and maintenance welding of S.G. cast iron, meehanite and other cast irons. It produces high strength weld than Castcraft 100.

Soft, Ductile Nickel type electrode for repair and maintenance welding of a wide range of cast irons. It has better “wetting” action than Castcraft 55.

Table 4-4: Cigweld Electrode Selection Chart

BASIC WELDING GUIDE 4-20 Manual 0-5205

Page 65

4.04 Stick (MMAW) Welding Troubleshooting

FAULT CAUSE REMEDY

TRANSMIG 350i, 450i, 550i

1 Welding current

varying

2 A gap is left by

failure of the weld metal to ﬁll the root of the weld.

3 Non-metallic par-

ticles are trapped in the weld metal.

ARC FORCE control knob is set at a value that causes the welding current to vary excessively with the arc length.

A Welding current too low A Increase welding current.

B Electrode too large for

joint.

C Insufﬁcient gap. C Allow wider gap.

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.

Reduce the ARC FORCE control knob until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece when you “dig” the electrode into the workpiece.

B Use smaller diameter electrode.

A If a bad undercut is present clean slag bout and

cover with a run from a smaller gauge 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 comers.

4 A groove has been

formed in the base metal adjacent to the toe of a weld and has not been ﬁlled by the weld metal (undercut).

E Rust or mill scale is pre-

venting full fusion.

F Wrong electrode for posi-

tion in which welding is done.

Figure 1-Example of insufﬁcient gap or incorrect sequence

A Welding current is too

high.

B Welding arc is too long. B Reduce the length of the welding arc.

C Angle of the electrode is

incorrect.

D Joint preparation does not

allow correct electrode angle.

E Clean joint before welding.

F Use electrodes designed for position in which

welding is done, otherwise proper control of slag is difﬁcult.

A Reduce welding current.

C Electrode should not be inclined less than 45° to

the vertical face.

D Allow more room in joint for manipulation of the

electrode.

E Electrode too large for

joint.

F Insufﬁcient deposit time at

edge of weave.

G Power source is set for

MIG (GMAW) welding.

Manual 0-5205 4-21 BASIC WELDING GUIDE

E Use smaller gauge electrode.

F Pause for a moment at edge of weave to allow

weld metal buildup.

G Set power source to STICK (MMAW) mode.

Page 66

TRANSMIG 350i, 450i, 550i

5 Portions of the

weld run do not fuse to the surface of the metal or edge of the joint.

6 Gas pockets or

voids in weld metal (porosity)

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 welding arc is directed more

D Travel speed of electrode

is too high.

E Scale or dirt on joint

surface.

Figure 2: Example of Lack of Fusion

A High levels of sulphur in

steel.

B Electrodes are damp. B Dry electrodes before use.

A Use larger electrodes and preheat the plate.

into the base metal.

D Reduce travel speed of electrode.

E Clean surface before welding.

A Use an electrode that is designed for high sul-

phur steels.

7 Crack occurring in

weld metal soon after solidiﬁcation commences

C Welding current is too

high.

D Surface impurities such as

oil, grease, paint, etc.

E Welding in a windy envi-

ronment.

F Electrode damaged ie ﬂux

coating incomplete.

A Rigidity of joint. A Redesign to relieve weld joint of severe stresses

B Insufﬁcient throat thick-

ness.

C Weld current is too high. C Decrease welding current.

C Reduce welding current.

D Clean joint before welding.

E Shield the weld area from the wind.

F Discard damaged electrodes and only use elec-

trodes with a complete ﬂux coating.

or use crack resistance electrodes.

B Travel slightly slower to allow greater build up in

throat.

Table 4-5: Welding Problems MMAW (Stick)

BASIC WELDING GUIDE 4-22 Manual 0-5205

Figure 3: Example of Slag Inclusion

Page 67

TRANSMIG 350i, 450i, 550i

Welds Made With or Without

Addition of Filler Metal

Work Piece

Can Be Any Commercial

Metal

Gas Cup Either Ceramic, High-lmpact or

Water Cooled

Metal

Inert Gas Shields Electrode and Weld Puddle

Tungsten Electrode

Non-Consumable

A-09658_AB

4.05 TIG (GTAW) Basic Welding Technique

Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (nonconsumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based. A ﬁller metal may also be added manually in some circumstances depending on the welding application.

Figure 4-38: TIG Welding Application Shot

Tungsten Electrode Current Ranges

Electrode Diameter DC Current (Amps)

0.040” (1.0mm) 30-60

1/16” (1.6mm) 60-115

3/32” (2.4mm) 100-165

1/8” (3.2mm) 135-200

5/32” (4.0mm) 190-280

3/16” (4.8mm) 250-340

Table 4-6: Current Ranges for Various Tungsten Electrode Sizes

Guide for Selecting Filler Wire Diameter

Filler Wire Diameter DC Current Range (Amps)

1/16” (1.6mm) 20-90

3/32” (2.4mm) 65-115

1/8” (3.2mm) 100-165

3/16” (4.8mm) 200-350

Table 4-7: Filler Wire Selection Guide

Manual 0-5205 4-23 BASIC WELDING GUIDE

Page 68

TRANSMIG 350i, 450i, 550i

Tungsten Electrode Types

Electrode Type

(Ground Finish)

Thoriated 2%

Zirconated 1%

Ceriated 2%

Welding Application Features Colour Code

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.

Table 4-8

NOTE

The Transmig 350i, 450i, 550i Inverter is not suited for AC Tig welding.

Red

White

Grey

TIG Welding Filler Rods

Comweld

Rod

LW1

LW1-6

Supersteel

CrMo1 CrMo2

308L 309L 316L

Aust Std AWS Std Part No.

R4 R6 R2

RB2 RB3

R308L R309L R316L

ER70S-4 ER70S-6 ER70S-2

ER80S-B2 ER90S-B3

ER308L ER309L ER316L

1.6mm

321411 321417 321370

— —

321406 321403 321400

Part No.

2.4mm

— — —

321379 321383

321407 321404 321401

Table 4-9

Part No.

3.2mm

— — —

— —

— — —

Type/Application

For mild-medium strength steels. Pipes, tubing, roll cages, etc.

For welding of high strength Cr-Mo steels used at elevated temperatures.

For stainless steels. Stainless pipes, tubing, architectural uses, etc.

BASIC WELDING GUIDE 4-24 Manual 0-5205

Page 69

TRANSMIG 350i, 450i, 550i

Base Metal

Thickness

0.040”

1.0mm

0.045”

1.2mm

1/16”

1.6mm

1/8”

3.2mm

3/16”

4.8mm

1/4”

6.4mm

TIG Welding is generally regarded as a specialised process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www. cigweld.com or contact Cigweld.

DC Current

for Mild

Steel

35-45 40-50

45-55 50-60

60-70 70-90

80-100 90-115

115-135 140-165

160-175 170-200

DC Current

for Stainless

Steel

20-30 25-35

30-45 35-50

40-60 50-70

65-85

90-110

100-125 125-150

135-160 160-180

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 Table 4-10

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 Litres/min

5-7 Butt/Corner

7 Butt/Corner

10 Butt/Corner

Joint Type

Lap/Fillet

Manual 0-5205 4-25 BASIC WELDING GUIDE

Page 70

TRANSMIG 350i, 450i, 550i

4.06 TIG (GTAW) Welding Problems

FAULT CAUSE REMEDY

1 Excessive beard 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

6 Electrode melts or oxidises

when an arc is struck.

Welding current is too low

Welding current is too high

Travel speed too fast Reduce travel speed.

Travel speed too slow Increase travel speed.

Wrong placement of ﬁller rod

A Torch lead connected

to positive welding terminal.

Increase weld current and/or faulty joint preparation.

Decrease weld current.

Re-position ﬁller rod.

A Connect torch lead to negative welding

terminal.

B No gas ﬂowing to weld-

ing region.

C Torch is clogged with

dust or dirt.

D Gas hose is cut. D Replace gas hose.

E Gas passage contains

impurities.

F Gas regulator turned

off.

G Torch valve is turned

off.

H The electrode is too

small for the welding current.

I Power source is set for

MIG welding.

B Check the gas lines for kinks or breaks

and gas cylinder contents.

C Clean torch.

E Disconnect gas hose from the rear of

Power Source then raise gas pressure and blow out impurities.

F Turn on.

G Turn on.

H Increase electrode diameter or reduce the

welding current.

I Set Power Source to Lift TIG mode.

BASIC WELDING GUIDE 4-26 Manual 0-5205

Page 71

TRANSMIG 350i, 450i, 550i

7 Dirty weld pool A Electrode contaminated

by contact with work piece or ﬁller rod material.

B Work piece surface has

foreign material on it.

C Gas contaminated with

air.

8 Poor weld ﬁnish Inadequate shielding

gas.

9 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.

A Clean the electrode by grinding off the

contaminates.

B Clean surface.

C Check gas lines for cuts and loose ﬁtting

or change gas cylinder.

Increase gas ﬂow or check gas line for gas ﬂow problems.

A Select the right size electrode. Refer to

Table 4-6 Cigweld Electrode Selection Chart.

B Select the right electrode type. Refer to

Table 4-8 Cigweld Electrode Selection Chart.

C Select the right rate for the welding job.

Refer to Table 4-10.

10 Arc ﬂutters during TIG

welding.

D Incorrect shielding gas

is being used.

E Poor work clamp con-

nection to work piece.

Tungsten electrode is too large for the welding current.

Table 4-11: GTAW (TIG) Welding Problems

D Select the right shielding gas.

E Improve connection to work piece.

Select the right size electrode. Refer to Table 4-6 Cigweld Electrode Selection Chart.

Manual 0-5205 4-27 BASIC WELDING GUIDE

Page 72

TRANSMIG 350i, 450i, 550i

BASIC WELDING GUIDE 4-28 Manual 0-5205

Page 73

SECTION 5:

POWER SOURCE PROBLEMS AND ROUTINE SERVICE

REQUIREMENTS

5.01 Power Source / Wirefeeder Problems

FAULT CAUSE REMEDY

TRANSMIG 350i, 450i, 550i

Mains supply voltage is

ON, power indicator is illuminated however unit will not commence welding when the torch trigger switch is depressed.

Mains supply voltage is

ON. Indicator light is not lit and welding arc cannot be established.

Fault Indicator is illuminated

and unit will not commence welding when the torch trigger switch is depressed.

Wirefeeder will not feed wire

in MIG mode.

Power source is not in the correct mode of operation.

Faulty torch trigger.

A BPrimary fuse is blown.

Broken connection in primary circuit.

Duty cycle of power source has been exceeded.

Electrode wire stuck in conduit liner or contact tip (burn-back jam).

Internal fault in power source

Set the power source to the correct mode of operation with the process selection switch.

Repair or replace torch trigger switch/lead.

A BReplace primary fuse.

Have an Accredited CIGWELD Service Agent check primary circuit.

Leave the power source switched ON and allow it to cool. Note that fault indicator must be extinguished prior to commencement of welding.

Check for clogged / kinked MIG torch conduit liner or worn contact tip. Replace faulty components. Have an Accredited CIGWELD

Service Provider investigate the fault.

Wire continues to feed when

torch trigger released

Wire feeds when the

torch trigger switch is depressed but arc cannot be established.

Inconsistent wire feed A

Wire does not feed when

torch trigger depressed

TIG electrode melts when

arc is struck.

Arc ﬂutters during TIG

welding.

Trigger mode selection is in 4T (LATCH) mode(10 Pin socket only)

Torch trigger leads shorted

Poor or no work lead contact. Clean work clamp area and

Worn or dirty contact tip

Worn feed roll.

Excessive back tension from wire reel hub.

Worn, kinked or dirty conduit liner

Faulty trigger switch / lead Repair or replace Torch /

TIG torch is connected to the (+) VE terminal.

Tungsten electrode is too large for the welding current.

Change to 2T (NORMAL) mode

Repair or replace Torch / trigger lead

ensure good electrical contact.

Replace contact tip

Replace feed roll

Reduce brake tension on spool hub

Clean or replace conduit liner

trigger lead

Connect the TIG torch to the (-) VE terminal.

Select the correct size of tungsten

electrode.

Manual 0-5205 5-1 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS

Page 74

TRANSMIG 350i, 450i, 550i

5.02 Routine Service and Calibration Requirements

WARNING

There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do not attempt to open or repair unless you are an accredited CIGWELD Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.

Routine Inspection, Testing & Maintenance

The inspection and testing of the power source and associated accessories shall be carried out in accordance with Section 5 of AS 1674.2 - 2007: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Cigweld's original speciﬁcations.

If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in AS 1674.2 - 2007, then the above tests should be carried out prior to entering this location.

A. Testing Schedule

1. For transportable equipment, at least once every 3 months; and

2. For ﬁxed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, including the date of the most recent inspection.

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

B. Insulation Resistance

Minimum insulation resistance for in-service Cigweld Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 6-1below. Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.

Components to be Tested

Input circuit (including any connected control circuits) to welding circuit (including any connected control circuits)

All circuits to exposed conductive parts

Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage exceeding extra low voltage

Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage not exceeding extra low voltage

Minimum Insulation

Resistance (MΩ)

2.5

Separate welding circuit to separate welding circuit

Table 5-2: Minimum Insulation Resistance Requirements: Cigweld Inverter Power Sources

C. Earthing

The resistance shall not exceed 1Ω between any metal of a power source where such metal is required to be earthed, and -

1. The earth terminal of a ﬁxed power source; or

2. The earth terminal of the associated plug of a transportable power source

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-2 Manual 0-5205

Page 75

TRANSMIG 350i, 450i, 550i

Note that due to the dangers of stray output currents damaging ﬁxed wiring, the integrity of ﬁxed wiring supplying Cigweld welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below -

1. For outlets/wiring and associated accessories supplying transportable equipment - at least once every 3 months; and

2. For outlets/wiring and associated accessories supplying ﬁxed equipment - at least once every 12 months.

D. Voltage Reduction Device (VRD)

Units ﬁtted with VRD's, shall have the periodic tests outlined in Table 6-2 below conducted by an accredited CIGWELD service provider. Testing shall be conducted at intervals as outlined below -

1. For transportable equipment, at least once every 3 months; and

2. For ﬁxed equipment, at least once every 12 months.

Description Required Parameters

VRD Open Circuit Voltage Less than 35V; at nominal input voltage

VRD Turn OFF Resistance Less than 200 ohms

VRD Turn ON Time Less than 0.3 seconds

Table 5-3: VRD Periodic Tests

E. General Maintenance Checks

Welding equipment should be regularly checked by an accredited Cigweld Service Provider to ensure that:

1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly connected and in good condition.

2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short circuit.

3. The Welding System is clean internally, especially from metal ﬁling, slag, and loose material.

F. Accessories

Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable condition. All unsafe accessories shall not be used.

G. Repairs

If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited Cigweld Service Provider.

Power Source Calibration

A. Schedule

Output testing of all Cigweld Inverter Power Sources and applicable accessories shall be conducted at regular intervals to ensure they fall within speciﬁed levels. Calibration intervals shall be as outlined below -

1. For transportable equipment, at least once every 3 months; and

2. For ﬁxed equipment, at least once every 12 months.

Manual 0-5205 5-3 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS

Page 76

TRANSMIG 350i, 450i, 550i

B. Calibration Requirements

Where applicable, the tests outlined in Table 6-3 below shall be conducted by an accredited CIGWELD service agent.

Testing Requirements

Output current (A) to be checked to ensure it falls within applicable Cigweld power source speciﬁcations

Output Voltage (V) to be checked to ensure it falls within applicable Cigweld power source speciﬁcations

Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required Cigweld power source / wire feeder speciﬁcations

Accuracy of digital meters to be checked to ensure it falls within applicable Cigweld power source speciﬁcations

Table 5-4: Calibration Parameters

Periodic calibration of other parameters such as timing functions are not required unless a speciﬁc fault has been identiﬁed.

C. Calibration Equipment

All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question. Only test equipment with valid calibration certiﬁcates (NATA certiﬁed laboratories) shall be utilized.

5.03 Cleaning the Welding Power Source

WARNING

There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualiﬁed electrical tradesperson. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.

To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated dirt, metal ﬁlings, slag and loose material. Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current.

5.04 Cleaning the Feed Rolls

Clean the grooves in the drive rolls frequently. This can be done by using a small wire brush. Also wipe off, or clean the grooves on the upper feed roll. After cleaning, tighten the feed roll retaining knobs.

CAUTION

Do not use compressed air to clean the Welding Power Source. Compressed air can force metal particles to lodge between live electrical parts and earthed metal parts within the Welding Power Source. This may result in arcing between this parts and their eventual failure.

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-4 Manual 0-5205

Page 77

6.01 Power Source

TRANSMIG 350i, 450i, 550i

SECTION 6:

KEY SPARE PARTS

A-10642

Figure 6-1

Item Part Number Description

1 W7005202 PCB, main control 550i 1 W7005208 PCB, main control 450i 1 W7005209 PCB, main control 350i 2 W7005210 Filter, EMC (all models) 3 W7005206 PCB, display (all models) 4 W7005205 PCB, Filter EMC (all models) 5 W7005207 PCB, diode snubber (all models) 6 W7005211 Auxiliary transformer T2 (all models) 7 W7005212 Auxiliary transformer T3 (all models) 8 W7005213 Capacitor, Silver (all models)

9 W7005214 Diode, Welding (all models) 10 W7005215 Inverter transformer 550i 10 W7005216 Inverter transformer 450i 10 W7005217 Inverter transformer 350i Power Source Part No. W1005352 10 W7005230 Inverter transformer 350i Power Source Part No. W1005359 11 W7005218 Inductor (all models)

Table 6-1 Key Spare Parts

Manual 0-5205 6-1 KEY SPARE PARTS

Page 78

TRANSMIG 350i, 450i, 550i

A-10643_AB

Item

Part

Number

Description

12 W7005219 Sensor, Hall Effect (all models) 13 W7005201 PCB, IGBT driver (all models) 14 W7005203 PCB, IGBT snubber (all models) except 350i Power Source Part No. W1005359 14 W7005228 PCB, IGBT snubber 350i Power Source Part No. W1005359 15 W7005204 PCB, current transformer (all models)except 350i Power Source Part No. W1005359 15 W7005229 PCB, current transformer 350i Power Source Part No. W1005359 16 W7005220 Relay, Solid State (all models) 17 W7005221 Fan, 230V Transmig (all models) 18 W7005222 IGBT (all models) 19 W7005223 Input rectiﬁer bridge (all models) 20 W7005224 Capacitor, Poly, 20uF (all models) 21 W7005225 Capacitor, Poly, 5uF (all models) 22 W7005226 Welding Current DINSE Terminal (all models) 23 W7005227

Varistor 550V 25Dia

Table 6-2 Key Spare Parts

KEY SPARE PARTS 6-2 Manual 0-5205

Page 79

7.01 Volt/Amp Curves

Output Voltage

MIN MAX

SECTION 7:

VOLT/AMPERE CURVES

MMAW (Stick)

MAX ARC FORCE

TRANSMIG 350i, 450i,550i

TRANSMIG 550i

TRANSMIG 450i

TRANSMIG 350i

MIN ARC FORCE

Output Voltage

100 200 300 400

Welding Current (amps)

MIN

100 200 300 400

Welding Current (amps)

Output Voltage

100 200 300 400

Welding Current (amps)

MIN

GTAW (Lift Tig)

GMAW (Mig)

MAX

500 600

MAX

500 600

TRANSMIG 550i

TRANSMIG 450i

TRANSMIG 350i

TRANSMIG 550i

TRANSMIG 450i

TRANSMIG 350i

A-10644

Table 7-1 Volt/Amp Curves

Manual 0-5205 7-1 VOLT/AMP CURVES

Page 80

TRANSMIG 350i, 450i, 550i

VOLT/AMP CURVES 7-2 Manual 0-5205

Page 81

SECTION 8: CIRCUIT DIAGRAM

8.01 CIRCUIT DIAGRAM

WELDING TERMINALS

POSITIVE

C11

C12

CT2

HALL EFFECT

RA4

NEGATIVE

TRANSMIG 350i, 450i, 550i

BCD

EFG

10 PIN

CB4

HIJ

CB5

CB3

X4-E

CDE

FGHJKLMNPRS

19 PIN

X4-F

CB6

X4-S

TUV

C10

Q2A

W7005203

Q1A

RA1

Q2B

Q1B

4 X 20UF

W7005207

C2 C3

20UF 20UF

RA3

5UF

1X12-1

1X12-3

3X3-1

W7005206

3X1

1X6

1X11-7

1X11-6

1X11-5

1X11-4

1X11-3

1X11-2

3X3-2

DISPLAY BOARD

3X2

1X7

1X4-1

1X4-4

1X4-2

1X4-5

1X4-3

1X4-6

1X2-6

1X2-5

1X2-1

1X2-3

1X2-2

1X2-4

1X5-2

1X5-1

1X2-7

1X5-3

1X2-8

1X5-9

1X5-4

1X5-5

1X5-6

1X5-7

1X5-8

W7005202

MAIN CONTROL BOARD

X4-F

X4-S

X4-E

RA2

CT1

W7005204

IGBT SNUBBER

2X3-1

2X3-2

2X2-4

W7005201

2X2-3

IGBT DRIVE

POSITIVE

G1 E1 G2 E2 G3 E3 G4 E4

2X1-1

2X1-3

2X1-2

NEGATIVE

19V

INPUT

RECTIFIER

W7005205

EMC FILTER

CB1

C13

CB2

19V

121310V

RLY1

1X13-1

1X13-2

1X13-3

1X3-1

1X3-4

1X3-5

19V

1X3-3

19V

3442V

TS1

1X1-4 & 5

1X1-1 & 2

1X1-6 & 7

1X1-8

1X1-9

T3 2

34V

5626V

FAN 230VAC

A-10647_AC

Manual 0-5205 8-1 CIRCUIT DIAGRAM

Page 82

TRANSMIG 350i, 450i, 550i

CIRCUIT DIAGRAM 8-1 Manual 0-52052

Page 83

CIGWELD - LIMITED WARRANTY TERMS

LIMITED WARRANTY: CIGWELD Pty Ltd, A Victor Technologies 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.

Page 84

TERMS OF WARRANTY – JULY 2011

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.

Page 85

WARRANTY SCHEDULE – JULY 2011

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.

TRANSMIG 350i, 450i, 550i POWER SOURCE

Original main power magnetics. 3 Years 2 Years Original main power rectiﬁers, printed circuit boards and power switch

semiconductors. All other circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans and electric motors.

ACCESSORIES WARRANTY PERIOD

MIG torch, electrode holder lead and work lead. 3 Months MIG torch consumable items. NIL

Gas regulator/ﬂowmeter (excluding seat assembly, pressure gauges, elastomer seals and “O” rings).

Regulator seat assemblies and pressure gauges. 6 Months Elastomer seals and “O” rings used in the equipment. 3 Months

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

Note: For Wirefeeder Warranty information refer to the relevant Wirefeeder Operating Manual.

WARRANTY

PERIOD

2 Years 2 Years

1 Year 1 Year

1 Year

LABOUR

Page 86

Page 87

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Asia Paciﬁc Regional Headquarters

71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX:

+61 3 9474 7391

Email: enquiries@cigweld.com.au

www.cigweld.com.au

Cigweld, Australia

71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7391 Email: cigweldsales@cigweld.com.au

Victor Technologies USA

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

Victor Technologies Canada

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

Victor Technologies, China

No 100 Lao Hongjing Rd Minhang District Shanghai, PR, 200235 Telephone: 86-21-64072626 Fax: 86-21-64483032

Victor Technologies 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

Victor Technologies Italy

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

Victor Technologies Europe

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

PT. Victor Technologies Utama Indonesia

Jl. Angsana II Blok AE No. 28 Delta Silicon I, Cikarang - Sukaresmi Bekasi, 17550 Indonesia Tel: +62 21 8990 6095 Fax: +62 21 8990 6096 / 1867 http://www.Victor Technologies.com

Victor Technologies International

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

Page 88

Asia Paciﬁc Regional Headquarters

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

+61 3 9474 7391

www.cigweld.com.au

Tweco 550i 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

2.03 Receipt Of Equipment

2.04 Symbol Chart

2.05 Description

2.06 User Responsibility

2.07 Transporting Methods

2.08 Packaged Items

2.09 Duty Cycle

3.01 Environment

3.03 Ventilation

3.04 Mains Supply Voltage Requirements

3.02 Location

3.05 Electromagnetic Compatibility

3.07 Shielding Gas Regulator Operating Instructions

3.08 Setup for MIG (GMAW) Welding with Gas Shielded Mig Wire

4.01 MIG (GMAW/FCAW) Basic Welding Technique

4.02 MIG (GMAW/FCAW) Welding Troubleshooting

4.03 Stick (MMAW) Basic Welding Technique

4.04 Stick (MMAW) Welding Troubleshooting

4.05 TIG (GTAW) Basic Welding Technique

4.06 TIG (GTAW) Welding Problems

5.02 Routine Service and Calibration Requirements

5.03 Cleaning the Welding Power Source

5.04 Cleaning the Feed Rolls

CIGWELD - LIMITED WARRANTY TERMS

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION