Tweco VAF4 User Manual

Download

42/115

50 60

Art # A-11251_AB

VAF4

TRANSMIG

WIRE FEEDER

Operating Manual

Revision: AC Issue Date: December 3, 2012 Manual No.: 0-5231

Operating Features:

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.

We have made every effort to provide you with accurate instructions, drawings, and photographs of the product(s) while writing this manual. However errors do occur and we apologize if there are any contained in this manual.

Due to our constant effort to bring you the best products, we may make an improvement that does not get reﬂected in the manual. If you are ever in doubt about what you see or read in this manual with the product you received, then check for a newer version of the manual on our website or contact our customer support for assistance.

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 International, Inc. We are a mainline supplier to major welding industry sectors in the Asia Paciﬁc and emerging global markets including; Manufacturing, Construction, Mining, Automotive, Engineering, Rural and DIY.

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

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

WARNINGS

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

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

Operating Manual Number 0-5231 for:

Cigweld Transmig VAF4 Wirefeeder Part Number W3000700

Published by: CIGWELD Pty. Ltd 71 Gower Street Preston, Victoria, Australia, 3072 +61 3 9474 7400, +61 3 9474 7391

www.cigweld.com.au

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: October 8, 2012 Revision Date: December 3, 2012

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

TABLE OF CONTENTS

SECTION 1: GENErAL INFOrmATION ................................................................... 1-1

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

1.02 Principal Safety Standards .............................................................................. 1-5

1.03 Symbol Chart .................................................................................................. 1-6

1.04 Declaration of Conformity ............................................................................... 1-7

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 Description ..................................................................................................... 2-2

2.05 User Responsibility ......................................................................................... 2-2

2.06 Transportation Methods .................................................................................. 2-2

2.07 Packaged Items .............................................................................................. 2-2

2.08 Speciﬁcations ................................................................................................. 2-3

2.09 Optional Accessories ...................................................................................... 2-3

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 Front Panel Controls, Indicators and Features ................................................ 3-3

3.07 Rear Panel Controls and Features ................................................................... 3-8

3.08 Advanced Features Mode ................................................................................ 3-9

3.09 Wirefeeder Conﬁguration for Different Power Sources ................................. 3-14

3.10 Attaching the MIG Torch (Euro) .................................................................... 3-15

3.11 Installing Handle Assembly ........................................................................... 3-15

3.12 Installing Lifting Eye Kit (Optional) ............................................................... 3-17

3.13 Installing Tweco No. 4 Adaptor (Optional) .................................................... 3-18

3.14 Installing Wire Spool Cover (optional) .......................................................... 3-27

3.15 Installing Welding Wire Spool ....................................................................... 3-30

3.16 Wire Reel Brake ............................................................................................ 3-31

3.17 Inserting Wire into Feed Mechanism ........................................................... 3-31

3.18 Feed Roll Pressure Adjustment ..................................................................... 3-32

3.19 Installing and Changing the Feed Roll / Removing Inlet Guide & Euro Adaptor ....

3-33

3.20 Shielding Gas Regulator Operating Instructions ........................................... 3-34

3.21 Wire Feeder Set Up MIG (GMAW) Welding with Gas Shielded MIG Wire ...... 3-36

3.22 Wire Feeder Set Up MIG (GMAW) Welding with Gasless MIG Wire .............. 3-38

3.23 Prewelding Procedure ................................................................................... 3-41

3.24 Arc Signal Override (SIL_1 #2) ..................................................................... 3-41

3.25 Welding- 2T Operation .................................................................................. 3-42

3.26 Spot Operation .............................................................................................. 3-42

3.27 Welding- 4T Operation .................................................................................. 3-43

3.28 Stitch Operation ............................................................................................ 3-44

3.29 PTC Protection of Power Source Contactor Control Output .......................... 3-45

3.30 Ground Fault Operation ................................................................................. 3-45

3.31 Electronic Motor Protection .......................................................................... 3-45

TABLE OF CONTENTS

SECTION 4: SErvICE....................................................................................... 4-1

4.01 Cleaning The Unit ............................................................................................ 4-1

4.02 Cleaning The Feed Rolls .................................................................................. 4-1

4.03 System Maintenance ....................................................................................... 4-1

4.04 Troubleshooting Guide .................................................................................... 4-1

4.05 Error Codes and Remedies ............................................................................. 4-2

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

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

4.08 Troubleshooting ............................................................................................ 4-10

SECTION 5: pArTS LIST ................................................................................... 5-1

5.01 Equipment Identiﬁcation ................................................................................. 5-1

5.02 How To Use This Parts List ............................................................................. 5-1

5.03 Replacement Parts (without wirefeed plate) ................................................... 5-2

5.04 Replacement Parts- Wirefeed Plate ................................................................. 5-3

AppENDIx 1: CONNECTION DIAGrAm .................................................................. A-1

CIGWELD LImITED WArrANTY ........................................................................ rC-1

TErmS OF WArrANTY – AprIL 2012 ................................................................ rC-2

WArrANTY SCHEDULE – AprIL 2012 ................................................................ rC-3

GLOBAL CUSTOmEr SErvICE CONTACT INFOrmATION ........................................... rC-5

TRANSMIG VAF4

SECTION 1: GENERAL INFORMATION

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 equip ment 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

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

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.

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.

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.

Manual 0-5231 1-1 GENERAL INFORMATION

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.

TRANSMIG VAF4

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

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, ﬂameresistant 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.

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

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

Greater than 400 13

Less than or equal to 150 10

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

Greater than 400 14

Less than or equal to 250 12

250 to 350 13

Less than or equal to 100 10

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

Greater than 350 14

Less than or equal to 300 11

300 to 400 12 400 to 500 13

Greater than 500 14

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

—

Less than or equal to 20 8

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

— —

Safety Spectacles or eye shield

Minimum Shade Number of

Filter(s)

2(5)

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

Table 1-1 Protective Filters

GENERAL INFORMATION 1-2 Manual 0-5231

TRANSMIG VAF4

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

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breath

ing these fumes and gases can be hazardous to your health.

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

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.

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.

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 air-supplied 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. 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.

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

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

3. Remove all ﬂammables within 10M of the welding arc. If this is not possible, tightly cover them with approved covers.

Manual 0-5231 1-3 GENERAL INFORMATION

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

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

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

TRANSMIG VAF4

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.

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.

NOTE

Considerations About Welding And The Effects of Low Frequency Electric and Mag

netic Fields

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

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.)

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.

ABOUT PACEMAKERS:

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

GENERAL INFORMATION 1-4 Manual 0-5231

TRANSMIG VAF4

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 0-5231 1-5 GENERAL INFORMATION

TRANSMIG VAF4

1.03 Symbol Chart

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

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Manual Metal Arc Welding (MMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Welding Torch

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

2 Step Trigger Operation

Press to initiate wirefeed and welding, release to stop.

4 Step Trigger Operation

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

Burnback Time

Disturbance In Ground System

IPM

MPM

Inches Per Minute

Metres Per Minute

115V 15A

Receptacle RatingAuxiliary Power

Voltage Input

Figure 1-1 Symbol Chart

GENERAL INFORMATION 1-6 Manual 0-5231

Art # A-10344_AB

TRANSMIG VAF4

1.04 Declaration of Conformity

Manufacturer: CIGWELD Address: 71 Gower St, Preston Victoria 3072

Australia

Description of equipment: CIGWELD Transmig VAF4 wire feeder 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:

• IEC60974-10applicabletoIndustrialEquipment-genericemissionsandregulations.

• AS1674Safetyinweldingandalliedprocesses.

• IEC60974-5Arcweldingequipment,Wirefeeders.

• (IEC)AS60974.1Arcweldingequipment,Weldingpowersources.

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.

Manual 0-5231 1-7 GENERAL INFORMATION

TRANSMIG VAF4

This page intentionally blank

GENERAL INFORMATION 1-8 Manual 0-5231

TRANSMIG VAF4

SECTION 2: INTRODUCTION

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 word 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

Gives information regarding possible personal injury. Warnings will be enclosed in a box such as this.

CAUTION

Refers to possible equipment damage. Cautions will be shown in bold type.

NOTE

Offers helpful information concerning certain operating procedures. Notes will be shown in italics

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 machine. Equipment which does not have a nameplate attached to the machine is identiﬁed only by the speciﬁcation or part number printed on the shipping container. Record these numbers 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 un-crate the unit.

Manual 0-5231 2-1 INTRODUCTION

TRANSMIG VAF4

2.04 Description

The Transmig VAF4 offers both load and line voltage compensation helping to maintain a constant wire feed speed, even with changes in the input voltage and/or load.

The Transmig VAF4’s sheet metal box totally encloses the solid state control circuitry. A hinged, latched feedhead cover allows quick and easy access to the feedhead featuring quick change feed rolls, and tool-less knobs and clamps for changeover of guides and guns.

The Transmig VAF4 comes with an abundance of standard features including:

• anon/offrockerswitch

• 2circuitbreakersfortotalsystemprotection

• awirefeedspeedcontrol

• apowersourcevoltagecontrol

• aninchswitch

• agaspurgeswitch

• a2T/4T/Spotselectorswitch

• PCboardadjustmentsforenhancedrunincontrol

2.05 User Responsibility

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

2.06 Transportation Methods

• asolidstateelectronicbrakefordynamicbraking

• twoquickchange,gear-drivenfeedrolls

• agasvalvesolenoid

• anisolatedguntriggerforoperatorsafety

• avarietyofadd-onoptionstoconguretheunit

for any wire-welding situation.

The Transmig VAF4 has been designed to comply with CSA NRTL/C, NEMA EW 3, and IEC 60974-1 standards.

The instructions in the next section 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.

WARNING

ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect wire feeder from Power Source before moving the wire feeder.

WARNING

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Lift unit with integrated handle at the top of the unit.

Use handcart or similar device of adequate capacity.

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

2.07 Packaged Items

Transmig VAF4 Wirefeeder (Part No.: W3000700)

•TransmigVAF4Wirefeeder

•OperatingManual

•DriveRoll0.9-1.2mm,V-groovetted

•HandleAssembly

INTRODUCTION 2-2 Manual 0-5231

TRANSMIG VAF4

2.08 Speciﬁcations

Description Transmig VAF4 Wirefeeder

Wirefeeder Part Number W3000700

Wirefeeder Dimensions H 345mm x W 275mm x D 610mm

Wirefeeder Mass 19kg

Input Voltage 42VAC or 115VAC, 350VA

Input Voltage Tolerance ±15%

Input Frequency 50/60 Hz

Gas Solenoid Voltage 24vdc

Maximum Gas Pressure 0.7 Mpa (7 bar)

MIG Welding Output, 40°C, 10

min

Minimum Wire Feed Speed 1.2 - 1.5 MPM (47 - 59 IPM)

Maximum Wire Feed Speed 22.1 - 22.5 MPM (870 - 886 IPM)

Operating Temperature Range 0°C - 40°C

Interconnection Plug 19pin

Solid

Wire Sizes

Aluminium 0.9mm (0.035”) to 1.6mm (1/16”) Flux Cored

450A at 60%

350A at 100%

0.8mm (0.030”) to 1.6mm (1/16”)

0.8mm (0.030”) to 2.0mm (5/64”)

Maximum Wire Spool Weight 60 lb./ 27kg

Table 2-1 Transmig VAF4 Speciﬁcation

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.

2.09 Optional Accessories

Feed Rolls

Wire Size Wire Type Part Number

0.6mm/ 0.8mm Hard 7977729

0.9mm/ 1.2mm* Hard 7977703

1.2mm/ 1.6mm Hard 7977346

0.8mm/ 0.9mm Soft 7977733

1.0mm/ 1.2mm Soft 7977730

1.2mm/ 1.6mm Soft 7977348

0.8mm/ 0.9mm Cored 7977734

1.2mm/ 1.6mm Cored 7977347

1.6mm/ 2.0mm Cored 7977372 Table 2-2 Feed Rolls

NOTE

Two feed rolls are required for each wire size.

NOTE

* indicates ﬁtted as standard.

Manual 0-5231 2-3 INTRODUCTION

TRANSMIG VAF4

Other Accessories

Accessories Part Number Description

TWECO No 4 MIG TORCH

3.6M EURO

TWECO No 4 MIG TORCH

4.5M EURO

TWECO SUPRA XT MIG

TORCH 4.0M EURO

TWECO No 4 MIG TORCH

3.6M Tweco 4

TWECO No 4 MIG TORCH

4.5M Tweco 4

TWECO SUPRA XT MIG

TORCH 4.0M Tweco 4

Interconnect Assy,19P-

19P,2M

Interconnect Assy,19P-

19P,8M

Interconnect Assy,19P-

19P,15M

OTWX412/3545

OTWX415/3545

SE400X4M16

717201

717335

SE4004M16

W4015900

W4015901

W4015902

Euro connection type, length is 3.6 metres, 400 Amps @ 60%, contact tip OTW14/45 (1.2mm)

Euro connection type, length is 4.5 metres, 400 Amps @ 60%, contact tip OTW14/45 (1.2mm)

Euro connection type, length is 4.0 metres, 450 Amps @ 60%, contact tip OTW15H/116 (1.6mm)

Tweco connection type, length is 3.6 metres, 400 Amps @ 60%, contact tip OTW14/45 (1.2mm)

Tweco 4 connection type, length is 4.5 metres, 400 Amps @ 60%, contact tip OTW14/45 (1.2mm)

Tweco connection type, length is 4.0 metres, 450 Amps @ 60%, contact tip OTW15H/116 (1.6mm)

19 pin to 19 pin, 2 metres in length, suitable for Transmig 350i, 450i & 550i

19 pin to 19 pin, 8 metres in length, suitable for Transmig 350i, 450i & 550i

19 pin to 19 pin, 15 metres in length,suitable for Transmig 350i, 450i & 550i

Interconnect Assy,19P-

14P,8M

Adaptor Cable,19P-14P,

0.3M

Spool Cover Assembly W4016300

TWECO No 4 Adaptor

Assembly

Lifting Eye Kit W4016700 Electrically insulated.

Heavy Duty 4 Wheel

Trolley

Mig Pliers WSPLIER

W4016000

W4016001

W4016400

W4000001

19 pin to 14 pin, 8 metres in length,suitable for Transmig 400i, MPM8/255H, MPM8/270K

19 pin to 14 pin, 0.3 metres in length, required for MPM12/400K & MPM20/500P

Suitable for spools up to 300mm diameter. Contains plastic spool cover and all necessary mounting hardware

Tweco No 4 connection, designed for Supra XT MIG torch SE4004M16, Tweco No 4 MIG torch 717201 & 717335. Rated at 450A @ 60%

Heavy duty, large castor wheel trolley for moving the Wirefeeder around the work area.

Speciﬁcally designed for MIG welding applications. Manufactured from drop forged carbon steel. Spring loaded handle. Excellent for trimming MIG wire or holding tips and nozzles.

Measures leg length, root gap, plate

Naka Measurement Gauge 646265

Nozzle Dip 702389

Table 2-3 Options and Accessories

INTRODUCTION 2-4 Manual 0-5231

thickness,convexity, wire and rod diameter and height of welds.

Supplied in 450g tin. Helps to prevent the adhesion of spatter to tips and nozzles.

TRANSMIG VAF4

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 IEC

60974.5.

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.

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

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 wirefeeder 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. The enclosure design of this Wire Feeder meets the

requirements of IP23S as outlined in AS 60529. 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 conditions. For further information please refer to AS 60529.

G. Precautions must be taken against the Wire Feeder

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

3.03 Ventilation

WARNING

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

3.04 Mains Supply Voltage Requirements

CAUTION

This wirefeeder cannot be connected directly to the mains supply. It must be connected to a suitable wirefeeder control socket on a power source.

3.05 Electromagnetic Compatibility

WARNING

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

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 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 Trouble-some.

NOTE

The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorised 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).

Manual 0-5231 3-1 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

B. Assessment of Area

3. Welding Cables

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.

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.

C. Methods of Reducing Electromagnetic Emissions

The welding cables should be kept as short as

possible and should be positioned close together but never coiled and running at or close to the ﬂoor level.

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/grounding of the Work Piece

Where the work piece is not bonded to earth for

electrical safety, nor connected to earth because of its size and position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the work piece to earth should be made by direct connection to the work piece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

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 its 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.

6. Screening and Shielding

Selective screening and shielding of other cables

and equipment in the surrounding area may alleviate problems of interference. Screening the entire welding installation may be considered for special applications.

INSTALLATION, OPERATION AND SETUP 3-2 Manual 0-5231

TRANSMIG VAF4

Amps /

(Wirespeed)

3.06 Front Panel Controls, Indicators and Features

Art # A-11255_AB

Figure 3-1 Front Panel View

WARNING

DO NOT TOUCH the electrode wire while it is being fed through the system. The electrode wire will be at welding voltage potential.

1. POWER Indicator

The red power indicator will be illuminated when the Wirefeeder is turned ON and indicates the presence of power.

2. FAULT Indicator

The yellow fault indicator will be illuminated when any faults are detected. Should a fault condition occur refer to Subsections 3.30, 3.31, 4.05 or 4.08 for further information.

If the Fault indicator is ﬂashing whilst welding refer to Subsection 3.31 as the motor overload protection is active.

3. AMPS Indicator

The red AMPS indicator will be illuminated when the Left Display displays the amperage.

4. IPM Indicator

The red IPM indicator will be illuminated when the Left Display displays WFS in Inches Per Minute (IPM).

5. MPM Indicator

The red MPM indicator will be illuminated when the Left Display displays WFS in Metres Per Minute (MPM).

6. Left Knob

Left Knob

The control knob adjusts Wire Feed Speed (WFS) (which in turn adjusts the output current by turning the amount of MIG wire delivered to the welding arc). The optimum WFS required is dependent on the type of welding application. The value may also be adjusted while a weld is in progress – if this occurs, the left display will brieﬂy

Manual 0-5231 3-3 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

plication. The value may also be adjusted while a weld is in progress – if this occurs, the left display will brieﬂy switch to show the adjusted value as the knob is turned, and will automatically revert back to show the weld current measurements when the knob is not being turned. Turn the left knob either clockwise to increase WFS or counterclockwise to decrease WFS by increments of 0.1MPM. To increment in steps of 1 MPM whilst holding the left knob depressed turn it either clockwise to increase WFS or counterclockwise to decrease WFS.

The Left digital meter display option can be changed either via the Advanced Features Menu (refer to Subsection

3.08)

By simply depressing the Left Amps control knob for 3 seconds whilst welding, then by releasing the knob and then holding it depressed for a further 3 seconds will increment to the next available display option that is shown on the left digital display. i.e. Amps WFS ---- (blank).

Press Left Knob (Amps) and Right Knob (Volts) for 1.2 seconds to enter or exit from the advanced programming mode. Please refer to Subsection 3.08 for Advanced Features Details.

7. Right Knob

Right Knob

The control knob adjusts the output voltage of the power source. The welding voltage is increased by turning the knob clockwise or decreased by turning the knob counter-clockwise. The value may also be adjusted while a weld is in progress – if this occurs, the right display will brieﬂy switch to show the adjusted value as the knob is turned, and will automatically revert back to show the weld voltage measurements when the knob is not being turned. Turn the right knob either clockwise to increase voltage or counterclockwise to decrease voltage by increments of 0.1V. To increment in steps of 1V whilst holding the right knob depressed turn it either clockwise to increase WFS or counterclockwise to decrease WFS.

The Right digital meter display option can be changed either via the Advanced Features Menu (refer to Subsection

3.08)

By simply depressing the Right Amps control knob for 3 seconds whilst welding, then by releasing the knob and then holding it depressed for a further 3 seconds will increment to the next available display option that is shown on the right digital display. i.e. VARC ---- (blank).

Press Left Knob (Amps) and Right Knob (Volts) for 1.2 seconds to enter or exit from the advanced programming mode. In advanced programming mode, turning the knob clockwise to increase and counter-clockwise to decrease the value on right display. Please refer to Subsection 3.08 for Advanced Features Details.

INSTALLATION, OPERATION AND SETUP 3-4 Manual 0-5231

TRANSMIG VAF4

8. Left Digital Display

Left display is a 4- digit display.

In advanced programming mode, this display is used to display advanced features details or simply "----". Please refer to Subsection 3.08 for Advanced Features Details.

When welding, this digital meter will display WFS in Inches Per Minute (IPM) or Metres Per Minute (MPM) and actual welding amperage of the power source; it can also simply display "----" when the VAF4 is connected to a power source without a control signal on pin U of the 19 pin interconnection. The VAF4 uses this signal on pin U of the 19 pin interconnection to display welding amps, if this signal is not present from the power source, set the display to show "----". Press left knob and select the information on left display. At times of non-welding, the digital meter will display a pre-set (preview) WFS value. This value can be adjusted by turning the Left Knob (Control No. 6).

At the completion of welding, the digital meter will hold the last recorded value for a period of approximately 10 seconds. The 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.

The display is also used for providing error messages to the user. Please refer to Subsection 4.05 for Error Codes and Remedies.

9. Right Digital Display

Right display is a 4- digit display.

This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding voltage of the power source or simply "----" when the VAF4 is connected to a power source without a control signal on pin C of the 19 pin interconnection. The VAF4 uses this signal on pin C of the 19 pin interconnection to display welding volts, if this signal is not present from the power source, set the display to show "----". Press right knob and select the information on right display. At times of non-welding, the digital meter will display a pre-set (preview) value of Voltage. This value can be adjusted by turning the Right Knob (Control No 7).

At the completion of welding, the digital meter will hold the last recorded voltage value for a period of approximately 10 seconds in all modes. The voltage 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.

The display is also used for providing error messages to the user and showing other information. Please refer to Subsection 4.05 for Error Codes and Remedies.

10. 2T - 4T- SPOT Trigger Mode Control Button

Press and release the button to change the selected operating mode of the trigger. The selected mode can be “2T”, “4T” or "Spot” operation. The red indicator next to the button will illuminate to identify which mode is selected. In the 4T mode once the weld has been started you can release the trigger and continue welding until the trigger is activated again or the welding arc is broken to stop the welding arc. Please refer to Subsection 3.25 - 3.28 for more details.

Manual 0-5231 3-5 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Note

In Advanced Features Mode Trigger Mode and SCH1-SCH2 can't be changed. In Spot Mode Stitch Mode is not available. Crater is only available in 4T Trigger Mode.

11. SCH 1-SCH 2 Button

This allows the user to save parameter settings in either Schedule 1 (SCH 1) or Schedule 2 (SCH 2) locations. Press the button to select either SCH 1 or SCH 2. The red indicator will illuminate to identify which schedule is selected.

Right Knob

Adjust the wire speed and weld volts, along with parameters such as burnback, pre ﬂow, post ﬂow etc, to the desired setting. Whilst holding the volts knob depressed at the same time press the SCH 1-SCH 2 button for 1.8 seconds to save the schedule. The SCH 1 or SCH 2 LED will ﬂash 3 times to indicate the save has been successful. Note that all adjustable parameters are saved with each schedule.

If the user wishes to load settings saved in either SCH 1 or SCH 2 locations, press and release the SCH 1-SCH 2 button to select either SCH 1 or SCH 2, the red indicator will illuminate to identify which Schedule is selected.

12. INCH Button

After turning the power ON, press this button and hold it to start cold feeding. Left display shows actual WFS and right display shows INCH. If the user wishes to adjust WFS, turn left knob and left display shows preset WFS. 1 second later, it shows actual WFS. Release the button when it feeds the wire to the torch.

13. PURGE Button

This button is used to initiate gas line purge function to ﬁll the gas line with the shielding gas from the connected gas cylinder. Press and hold the button depressed to start gas purge function, at which time a countdown timer will show in left display indicating the number of seconds remaining. You can stop the gas purge any time during the 30 seconds by releasing the button.

14. MIG Torch Adaptor

The MIG Torch adaptor is the connection point for the MIG welding Torch. Connect the MIG Torch by pushing the MIG Torch connector into the brass MIG Torch adaptor ﬁrmly and screwing the plastic MIG Torch nut clockwise to secure in position. To remove the MIG Torch simply reverse these directions.

INSTALLATION, OPERATION AND SETUP 3-6 Manual 0-5231

TRANSMIG VAF4

15. Remote Control Socket

The 8 pin Remote Control Socket is used to connect remote control devices to the welding power source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

1 2

5 6

7 8

Remote Wirespeed in GMAW mode

Figure 3-2 Remote Control Socket

Trigger Switch

Remote Volts in GMAW Mode

Socket Pin

1 Not connected

2 Trigger Switch Input

3 Trigger Switch Input

4 Not connected

5 5k ohm (maximum) connection to 5k ohm remote control potentiometer.

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

7 Wiper arm connection to 5k ohm remote control Wirespeed MIG mode potentiometer.

8 Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.

Function

Table 3-1 Pin Function in Remote Control Socket

NOTE

The remote/ local setting in Advanced Features Menu should be set to remote for the remote wire feeder amperage/voltage controls to be operative.

Manual 0-5231 3-7 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Keyway

3.07 Rear Panel Controls and Features

Art# A-11256

Figure 3-3 Rear Panel View

16. ON/ OFF Switch

Press this switch to turn ON or turn OFF the Wirefeeder.

17. Gas Inlet

Gas inlet allows to connect the shield gas.

18. Control Cable Socket

The control cable connects to the power source at this 19-pin amphenol connector. It contains the signals required to allow the welding power source and the wire feeder to work together as a system.

WARNING

The protective earth ground (pin G) of the control cable is established ONLY when the power source is properly grounded. See the power source owner’s manual for proper grounding methods.

19. Welding Cable Connector

This connector allows to connect welding cable with Wirefeeder. Please make sure that it is secured ﬁrmly, or it will heat and generate arc.

20. 4A Circuit Breaker

This circuit breaker protects the wirefeeder from electrical faults on the 115VAC circuit. In the event of a fault occuring this circuit breaker will trip (pop out). A short cooling period must be allowed before an attempt is made to reset it by pressing it back in. Refer to Subsection 4.08 for further details.

KUNB

HS RD

CPVTJ

EFG

Figure 3-4 Pin Identification

Control Cable

F G H

J K

L M N P R S

Contactor + (Shorted to B to turn ON Power Source)

Contactor- (Shorted to A to turn ON Power Source)

Voltage Feedback ( 1 Volt is 10 Arc Volts)

Not Used 115 VAC Hot 42VAC and 115VAC Neutral Protective Earth Ground Remote Control Maximum Remote Control Signal Not Used Power Source Common Arc Established (= +15 VDC) Power Source Select Line Not Used Not Used 42VAC Live Wire Not Used Current Feedback (1 Volt

is 100 Arc Amps)

Not Used

Function

Table 3-2 Control Cable Pin Functions

21. 8A Circuit Breaker

This circuit breaker protects the wirefeeder from electrical faults on the 42VAC circuit. In the event of a fault occuring this circuit breaker will trip (pop out). A short cooling period must be allowed before an attempt is made to reset it by pressing it back in. Refer to Subsection 4.08 for further details.

INSTALLATION, OPERATION AND SETUP 3-8 Manual 0-5231

TRANSMIG VAF4

3.08 Advanced Features Mode

Enter Advanced Features Mode by pressing both the left knob and right knob at the same time for more than 1.2

seconds.

NOTE

In Advanced Features Mode the Trigger Mode Control Button, SCH 1-SCH 2 button is inactive.

Exit Advanced Features Mode by pressing both the left knob and right knob at the same time for more than 1.2 seconds to Save the Settings and exit advanced features mode. Note if there has been no user input for 30 seconds, the VAF4 will save settings and automatically exit advanced programming mode.

Advanced Feature Left Display

Feature Description

Local / Remote

This is used to select local panel

control on the Wirefeeder, or remote

control from the 8 pin remote

control socket on the front of the

Wirefeeder

Default Local / Remote = Local

If MIG Remote is selected but no remote control device is connected to the 8 pin

control socket then the wirefeed speed will be 1.3MPM (minimum wirespeed) and

Pre Flow

This is used to provide gas to the

weld zone prior to the wire striking

an arc.

Default Pre Flow = 0.1 sec

Run In

(Creep wirefeed speed)

This is used to change Wirespeed to

a percentage of the value set by the

operator. It can improve arc starts

by controlling the wire speed at the

instant the wire touches the base

Default Run In = 70%

metal.

For example if you have 12m/min set speed and have 50% selected for Run-in Speed, the speed of the wire will be 6m/min until the arc is established. Once the arc is established, the speed ramps up to the set speed at the rate set (12m/min)

Right Display

Parameter / Selection

Local / Remote

the voltage will be 14V (minimum volts).

0.0 – 5.0 seconds

30 – 150% of

Wirefeeder Speed

Setting

with Ramp Time described below.

Manual 0-5231 3-9 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Advanced Feature Left Display

Feature Description

Ramp Time

This is used to set the time to ramp

from the creep wire feed speed to

the selected wirefeed speed setting.

Default Ramp Time = 0.2 sec

This is used to adjust the post

gas ﬂow time once the arc has

Default Post Flow = 0.1 sec

This is used to adjust the amount

of MIG wire that protrudes from the

MIG torch after the completion of

MIG welding (commonly referred to

Default Burn Back = 0.15 sec

This is used to ﬁll in the “crater” at

the end of the weld. It only works with 4T mode and the Crater Volts / Crater Wirefeed Speed must be set.

Default Crater = Off

(only if Crater mode is ON)

This sets the reduced volts during

crater operation in 4T at the end of

Default Crater Volts = 70%

An example is if Preview Volts is

set to 26V and crater volts is set to 70% crater volts will be 18.2V. Note minimum crater volts is determined

by minimum preview voltage of

Post Flow

extinguished.

Burn Back

as stick out)

Crater

Crater Volts

the weld.

wirefeeder.

Ramp Time plus Run In is used to optimize arc starting characteristic.

This control is used to dramatically reduce weld porosity at the completion of the

If the Burn Back time is set too long, the MIG wire may burn back to the tip of the

Right Display

Parameter / Selection

0.1 to 1.0 seconds

0.0 – 30 seconds

weld.

0.00 to 1.00 seconds

MIG torch.

Crater Mode ON /

OFF

0 – 100% of

Welding Volts

Setting

INSTALLATION, OPERATION AND SETUP 3-10 Manual 0-5231

TRANSMIG VAF4

Advanced Feature Left Display

Feature Description

Crater Wirefeed Speed

(only if Crater mode is ON)

This sets the reduced wire speed

during crater operation in 4T at the

end of the weld.

Default Crater Wirefeed Speed =

An example is if Preview Wirefeed

speed is set to 14MPM and crater

wirefeed speed is set to 70%

crater wirefeed speed will be

9.8MPM. Note minimum crater

wirefeed speed is determined by

minimum preview wirefeed speed of

This is used to weld two thin plates

together by melting the top &

bottom plates together to form a

nugget between them. The weld time

is set by the Spot Time.

Default Spot Time = 2.0 sec

70%

wirefeeder.

Spot Time

Right Display

Parameter / Selection

0 – 100% of

Welding Wirefeed

Speed Setting

0.1 to 20.0 seconds

Stitch feature is not available in spot mode.

Stitch Mode

This is used to weld two or more

components by stitch or interval

weld together. The weld time is set

by the Stitch Time and the non weld

time is set by the Dwell Time (off

time).

Default Stitch Mode = Off

Stitch Time

(only if Stitch mode is ON)

This sets the “welding on” time in

Stitch mode.

Default Stitch Time = 2.0 sec

Dwell Time

(only if Stitch mode is ON)

This sets the “welding off” time in

Stitch mode.

Default Dwell Time = 0.5 sec

Stitch Mode ON /

OFF

Stitch is only available in 2T or 4T modes.

0.2 to 4.0 seconds

0.1 to 1.0 seconds

Manual 0-5231 3-11 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Advanced Feature Left Display

Feature Description

Wirefeed Speed Units

This allows setting of the Wirefeed

Speed Meter to display in IPM or

Default Wirefeed Speed = MPM

Arc Hours Accumulated Run Time

A Read Only display of the total of

actual arc hours.

Left Display Type

This allows the user to select what

is shown on the LEFT Display when

With some power sources, it may not be possible to display welding

amps on the VAF4 display when

welding, in this case, set the display

to wirefeed speed (WFS) or Blank

Default Left Display = AMPS

Right Display Type

This allows the user to select what is

shown on the RIGHT Display when

With some power sources, it may not be possible to display welding

volts on the VAF4 display when

welding, in this case, set the display

to Blank (BLNK)

Default Left Display = VARC

MPM units.

welding.

(BLNK)

welding.

Right Display

Parameter / Selection

IPM (inches per

minute)

MPM (metres per

minute)

0.0 – 999.9 hours

(It will rollover to 0

once 999.9 hours

have been reached.)

Display AMPS when

welding or

Display WIREFEED

SPEED when

welding or

Display BLANK

when welding

Display ARC VOLTS

when welding or

Display BLANK

when welding

INSTALLATION, OPERATION AND SETUP 3-12 Manual 0-5231

TRANSMIG VAF4

Advanced Feature Left Display

Restore Factory Defaults 1

This resets all the user adjustable

values in this table (except Arc

Hour Accumulated Runtime) to the

Factory Default Values.

Factory Default Setting

Right Display

Feature Description

Parameter / Selection

Restore Factory

Default No / YES

caution

Schedule SCH1 & SCH2 settings will be reset to factory default settings when YES is selected with Restore Factory Defaults.

Exit Advanced Features Mode: by pressing both the left knob and right knob at the same time for more than 1.2 seconds to Save the Settings and exit advanced features mode. Note if there has been no user input for 30 seconds, the VAF4 will save settings and automatically exit advanced programming mode.

Table 3-3 Advanced Features

Factory Default Setting of Non-Schedule: Trigger mode: 2T; Wirefeed speed: 14.0 MPM; Voltage: 26.0V.

Suits Autocraft LW1-6, 0.9mm Hard Wire with Shielding Gas:- 91.9% Ar, 5% CO

, 3.1% O2.

Factory Default Setting of Schedule 1: Wirefeed speed: 11.5 MPM; Voltage: 29.0V. Suits Autocraft LW1-6, 1.2mm Hard Wire with Shielding Gas:- 75 - 80% Ar, 20 - 25% CO

Factory Default Setting of Schedule 2: Wirefeed speed: 9.0 MPM; Voltage: 29.0V. Suits Verti-Cor 3XP, 1.6mm Flux Cored Wire with Shielding Gas:- 75 - 80% Ar, 20 - 25% CO

Advanced Feature Left Display

Feature

Right Display

(Default)

Comments

Description

MIG Control MIG/CNTR LOCL

Pre Flow PRE/FLOW 0.1

Run In RUN/IN 70

Ramp Time RAMP/TIME 0.2

Post Flow POST/FLOW 0.1

Burn Back BURN/BACK 0.15

Crater CRAT OFF Only in 4T Mode

Crater Volts CRAT/ VOLT 70

Crater Wirefeed Speed CRAT/ WFS 70

Spot Time SPOT/TIME 2.0 Only in Spot Mode

Stitch Mode STCH OFF Only in 2T & 4T Modes

Stitch Time STCH/TIME 2.0 Only when Stitch is ON

Dwell Time DWEL/TIME 0.5 Only when Stitch is ON

Wirefeed Speed Units WFS/UNIT MPM

Left Display Type LEFT/DISP AMPS

Right Display Type RGHT/DISP VARC

Table 3-4 Factory Default Setting

Only when in 4T Mode and Crater is ON

Manual 0-5231 3-13 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

3.09 Wirefeeder Conﬁguration for Different Power Sources

WARNING

There are dangerous voltage and power levels inside this product. Turn OFF wirefeeder and disconnect from the power source before removing cover from wirefeeder.

The factory default setting for the wirefeeder is set for the Transmig 350i & Transmig 450i power sources. If a different power source is being used then the user will need to set the Display PCB DIP switch as to Table 3-5 according to the power source being used.

Art # A-11257

DIP Switch

Display PCB

Figure 3-5 DIP Switch on Display PCB

S3S4S5 Vmin Vmax Vsetmin(J&K) Vsetmax(J&K) Welder

S3=Off(0), S4=Off(0), S5=Off(0) 14 50 3.182 11.364 Transmig 550i

S3=On(1), S4=Off(0), S5=Off(0) 10 44 2.273 10 Transmig 500i

Transmig 400i (Refer to

S3=Off(0), S4=On(1), S5=Off(0) 10 36 0 10

S3=On(1), S4=On(1), S5=Off(0) 14 40 3.182 9.091 Transmig 350i & 450i (default)

S3=Off(0), S4=Off(0), S5=On(1) 15 40 0 -4.8

S3=On(1), S4=Off(0), S5=On(1) 15 30 0 5.5 MPM8/270 & MPM8/255

S3=Off(0), S4=On(1), S5=On(1) Spare

S3=On(1), S4=On(1), S5=On(1) 8 50

Section 3.24 to override Arc Establish signal for this welder.

MPM20/500 & MPM12/400 (Refer to Note)

User Type Setting (The Service Manual outlines how to set the wirefeeder for other Power Sources.)

Table 3-5 Voltage Setting

NOTE

When S6=ON(1), calibration functions in Advanced Features Mode is enabled; when S6=OFF(0), calibration functions are disabled.

NOTE

When S1=OFF(0),S2=OFF(0), WFS Setting is applicable for Transmig VAF4 and it ranges from 1.3 MPM to 22.2 MPM.

NOTE

An adaptor cable is required for connection to MPM20/500 or MPM12/400 Engine Drive Power Sources.

INSTALLATION, OPERATION AND SETUP 3-14 Manual 0-5231

TRANSMIG VAF4

3.10 Attaching the MIG Torch (Euro)

Fit the MIG Torch to the power source by pushing the MIG torch connector into the MIG torch adaptor and screwing the plastic torch nut clockwise to secure the MIG torch to the MIG torch adaptor.

MIG Torch Connector

Art # A-11341

MIG Torch Adaptor

Figure 3-6 Attaching MIG Torch (Euro)

3.11 Installing Handle Assembly

WARNING

This handle is not designed to lift wirefeeder by mechanical means. Handle is to be used for Lifting by Hand Only.

For Mechanical Lifting use Lifting Eye Kit W4016700.

The following components are included:

Description Quantity

Handle Assembly 1

Bolt, M10 × 50 (with torque 45~59 N.m.) 2

Flat Washer, M10 (with torque 45~59 N.m.) 4

Spring Washer, M10 (with torque 45~59 N.m.) 2

Nut, M10 (with torque 45~59 N.m.) 2

Table 3-6 Handle Assembly

Manual 0-5231 3-15 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Handle Assembly

Install the handle assembly as below:

Secure the handle assembly to the base assembly with M10 x 50 Bolts, M10 Flat Washers, M10 Spring Wash-

ers and M10 Nuts as shown in Figure 3-7.

Bolt, M10 × 50

Flat Washer, M10

Spring Washer, M10

Nut, M10

Art # A-11471_AB

Figure 3-7 Installing Handle Assembly

warning

Fully tighten all the fasteners with torque 45~59 N.m.

Refer to the ﬁgure below for the assembled handle assembly:

Figure 3-8 Assembled Handle Assembly

Art # A-11472_AB

INSTALLATION, OPERATION AND SETUP 3-16 Manual 0-5231

TRANSMIG VAF4

Bolt, M8 × 40

Lifting Eye

3.12 Installing Lifting Eye Kit (Optional)

The following components are included:

Description Quantity

Lifting Eye 1

Insulator Plate 1

Bolt, M8 × 40 (with torque 45~59 N.m.) 2

Flat Washer (smaller), M8 (with torque 45~59 N.m.) 2

Flat Washer (larger), M8 (with torque 45~59 N.m.) 2

Insulator Washer, M8 (with torque 45~59 N.m.) 2

Spring Washer, M8 (with torque 45~59 N.m.) 2

Nut, M8 (with torque 45~59 N.m.) 2

Table 3-7 Lifting Eye Kit

Install the lifting eye as below:

1. Loosen the M10 x 50 Bolts, M10 Flat Washers, M10 Spring Washers and M10 Nuts with 17mm wrench that secure the handle assembly and remove the handle assembly and ﬁxings from the base assembly. Refer to Figure 3-7.

2. Use 14mm wrench to secure the lifting eye and insulator plate to the base assembly using the M8 x 40 Bolts, M8 Flat Washers, M8 insulator washers, M8 Spring Washers and M8 Nuts as supplied with this kit.

Flat Washer (smaller), M8

Insulator Plate

Art # A-11473_AB

Lifting Eye

Insulator Washer, M8

Flat Washer (larger), M8

Spring Washer, M8

Nut, M8

Figure 3-9 Installing Lifting Eye

WARNING

Fully tighten all the fasteners with torque 45~59 N.m.

Refer to the ﬁgure below for the assembled lifting eye.

Art # A-11474_AB

Figure 3-10 Assembled Lifting Eye

Manual 0-5231 3-17 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

3.13 Installing Tweco No. 4 Adaptor (Optional)

WARNING

There are dangerous voltage and power levels inside this product. Turn OFF wirefeeder and disconnect from the power source before installing kit.

The following components are included in this kit:

Description Quantity

Torch Adaptor, Tweco No. 4 1

Outlet Guide 1

Set Screw, M3 ×8 1

Lock Washer, M10 1

Lock Nut, M10 1

Plastic Flange, Front 1

Flat Washer, M10 1

Spring Washer, M10 1

Hex Bolt, M10 × 15 1

Gas Hose, 220mm 1

Hose Clamp, ø 8.7 2

Wire Tie 2

4 pin- 8 pin Adaptor 1

Thumb Screw 1

Allen Key, 1.5mm 1

Allen Key, 3mm 1

Table 3-8 Tweco No 4 MIG Torch Adaptor Assembly

INSTALLATION, OPERATION AND SETUP 3-18 Manual 0-5231

TRANSMIG VAF4

Earth Wire

Screw

Removing Euro MIG Torch Adaptor

1. Remove the top cover from the base.

a. Open side door to access door earth wire.

b. Disconnect the earth wire from the door and then close the door again.

c. Remove the six screws on the top cover and the four screws on the side of the cover, then remove the

cover. Keep the screws for future use.

Art # A-11519

Figure 3-11 Removing Earth Wire

Star Washer

Screw Hole

Art # A-11520

(Note: For clarity of picture, some screws are not shown.)

Screw

Figure 3-12 Removing the Cover

Manual 0-5231 3-19 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Display PCB

Motor Control PCB

2. Remove the front panel from the base.

a. Disconnect the Cable Assembly from the Motor Control PCB.

b. Disconnect the Earth Wire from the front panel.

c. Remove the two M6 × 16 pan-head screws to disconnect the front panel from the base assembly.

Keep the two screws for future use.

Cable Assembly

Screw

Front Panel

Art # A-11521_AB

Earth Wire

Figure 3-13 Removing Front Panel

3. Loosen the two M5 screws and remove the plastic flange from the front panel. Keep the two screws for future use.

Front Panel

8 Pin Control Socket

Plastic Flange, Euro

Screw，M5

Art # A-11364_AB

Set Screw, M6 × 6

Thumb Screw

Pan- head Screw，M6 × 16

Figure 3-14 Removing Front Panel and Plastic Flange

4. Disconnect the gas hose.

a. Remove the hose clamp over the gas hose.

b. Remove the gas hose from the euro adaptor.

INSTALLATION, OPERATION AND SETUP 3-20 Manual 0-5231

TRANSMIG VAF4

5. Disconnect the welding cable from the Euro adaptor.

a. Loosen the screw from the Euro adaptor. Note that a heat source may be required to loosen the

screw locking compound on the thread.

b. Remove the welding cable.

6. Disconnect the Trigger Wires that connects Euro Adaptor on the Motor Control PCB.

7. Remove the Thumb Screw as shown in Figure 4 then use the 3mm Allen Key supplied to remove the M6 × 6 Set Screw in the wirefeed plate, and remove the Euro adaptor from the wirefeed plate. Keep the two screws for future use.

Screw for Welding Cable

Solenoid

Welding Cable

Motor Control PCB

Trigger Wires

Gas Hose

Trigger Wires

Art # A-11523

Figure 3-15 Removing Euro MIG Torch Adaptor

Manual 0-5231 3-21 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Connecting Gas Hose to Solenoid

1. Place the hose clamp over the solenoid outlet.

2. Push gas hose onto solenoid outlet.

3. Slide the hose clamp over gas hose and tighten it with suitable crimping tool.

Solenoid Outlet

Hose Clamp

Gas Hose

Solenoid

Connected Gas Hose

Art # A-11635

Figure 3-16 Connecting Gas Hose to Solenoid

Connecting Welding Cable to Tweco No. 4 Adaptor

1. Attach the welding cable lug to Tweco No. 4 Torch Adaptor, using the M10 Flat Washer, M10 Spring Washer and M10 x 15 Hex Bolt. Note that M10 x 15 Hex Bolt will need to be adjusted when installing Tweco No. 4 Torch Adaptor.

Torch Adaptor, Tweco No. 4

Welding Cable

Flat Washer, M10

Spring Washer, M10

Hex Bolt, M10 × 15

Torch Adaptor, Tweco No. 4

Welding Cable

Art # A-11366_AB

Art # A-11365_AB

Figure 3-17 Connecting Welding Cable to Tweco No. 4 Torch Adaptor

Connecting Gas Hose to Tweco No. 4 Adaptor

1. Place the hose clamp over gas hose.

2. Push the gas hose onto the Tweco No. 4 Torch Adaptor gas inlet.

3. Slide the hose clamp forward until it sits approximately 5mm from the end of the gas hose.

4. Tighten the hose clamp with a suitable crimping tool.

Torch Adaptor, Tweco No. 4

Hose Clamp

Gas Inlet

Welding Cable

Gas Hose

Art # A-11367_AB

Torch Adaptor, Tweco No. 4

Welding Cable

Gas Hose

Art # A-11368_AB

Figure 3-18 Connecting Gas Hose to Tweco No. 4 Adaptor

INSTALLATION, OPERATION AND SETUP 3-22 Manual 0-5231

TRANSMIG VAF4

Pressure Roll Arm

Lock Washer, M10

Installing Tweco No. 4 Adaptor

1. Remove the feed roll and idler gear as shown. Refer to Subsection 3.19 for more details.

Pressure Adjusting Knob

Feed Roll

Screw

Art # A-11634

Idler Gear

Washer

Thumb Screw

Figure 3-19 Removing Feed Roll and Idler Gear

2. From the front of the Tweco No. 4 Adaptor, slide the outlet guide through. Insert the Tweco No. 4 Adaptor into the body of the feed plate. Note that the Tweco No. 4 Torch Adaptor shall be parallel with the wirefeed plate body. Refer to Figure 3-20.

3. Place the M10 Lock Washer and M10 Lock Nut over the threaded end of the Tweco No. 4 Torch Adaptor.

Make sure the weld cable and the gas hose fit neatly through the internal panel and the gas hose has no

kinks that might restrict gas flow.

Tighten the M10 Lock Nut securely.

4. Install the Feed Roll and Idler Gear.

5. With wires ties supplied replace the wire ties that secure the gas solenoid wires and gas solenoid hose that were removed to allow the euro adaptor trigger wires to be removed.

Push the outlet guide forward, to ensure that it has less than approximately 1mm clearance to the feed

roll. Refer to “D” in Figure 3-20.

Use 1.5mm Allen Key supplied to install the M3 x 8 set screw as shown and tighten, to secure the outlet

guide in place.

Lock Nut, M10

Plane B*

* Note: Plane A (Tweco No. 4 Torch Adaptor) shall be parallel with Plane B (wirefeed plate body).

Art # A-11522_AB

Plane A*

Set Screw, M3 ×8

Figure 3-20

Manual 0-5231 3-23 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

6. Tighten M10 x 15 Hex Bolt securely with 13mm spanner and secure the welding cable to Tweco No. 4 Torch Adaptor.

Art # A-11633

Figure 3-21 Securing Welding Cable

7. Use the 3mm Allen Key supplied to install the M6 × 6 set screw in the wirefeed plate then install Thumb Screw.

Art # A-11342_AB

Set Screw, M6 × 6

Thumb Screw

Figure 3-22

INSTALLATION, OPERATION AND SETUP 3-24 Manual 0-5231

TRANSMIG VAF4

Fitting Plastic Flange to Front Panel

Replace the Front Panel and wiring as outlined in Figures 3-14 and 3-13.

Place the Tweco Plastic Flange supplied on the front panel and secure it with the M5 screws from when the

Euro adaptor front moulding was removed.

Replace the Cover Panel as outlined in Figures 3-12 and 3-11.

Warning

Ensure that when replacing the Front Panel and Cover Panel the earth wires are correctly and securely connected. Also ensure that the cover panel screws have the correct star washers in place.

Warning

Fully tighten all fasteners.

Art # A-11369_AB

Figure 3-23 Fitting Plastic Flange to Front Panel

Plastic Flange, Tweco

Screw, M5

Manual 0-5231 3-25 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Attaching Tweco No. 4 MIG Torch

1. Connect the 4 pin plug with 4 pin - 8 pin adaptor and then insert the adaptor into the 8 pin control socket, and rotate threaded collar fully clockwise to lock the plug into position.

2. Fit the Tweco No. 4 MIG torch to the Wirefeeder by pushing the MIG Torch Connector into the Tweco No. 4 Torch Adaptor and secure it by tightening the Thumb Screw supplied.

Torch Adaptor, Tweco No 4

MIG Torch Connector

8-Pin Control Socket

4-Pin Plug

4 pin- 8 pin Adaptor

Art # A-11343_AB

Thumb Screw

Figure 3-24 Attaching Tweco No 4 MIG Torch

INSTALLATION, OPERATION AND SETUP 3-26 Manual 0-5231

TRANSMIG VAF4

3.14 Installing Wire Spool Cover (optional)

The following components are included in this kit:

Item Description Quantity

1 Bolt, M12 x 30 2 2 Star Washer, M12 2

3 Flat Washer, M12 2

4 Screw, Countersunk, M5 x 12 2

5 Spool Cover Mounting Bracket 1

6 Spool Cover 1

7 Spool Cover Mounting Bracket 1

Table 3-9 Spool Cover Assembly

Art # A-11347

Figure 3-25 Spool Cover Assembly

Manual 0-5231 3-27 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Hexagon Nut

M12 x 30 Bolts;

Spool cover is assembled in the following steps:

1. Remove the spool hub assembly.

a. Remove the clip from the spool hub.

b. Unscrew the 3-lobe screw.

c. Remove the spool hub parts and the spacer in the following sequence. Note that the spacer is not

required when fitting the spool cover.

Friction Washer

Keyed Washer

Flat Washer, small hole

Shaft

Spring Washer

Flat Washer,large hole

Spacer

Hub Wire Reel

Compression Spring

Retaining Clip

3-lobe Screw

Art # A-11514

Figure 3-26 Removing Spool Hub Assembly

2. Assemble the Spool Cover Mounting Brackets, one inside and one outside the spool cover, with the two countersunk screws M5 x 12.

3. Secure the spool cover assembly to the spool support arm with M12 x 30 Bolts, Star Washers, M12, and Flat Washers, M12 as shown in the diagram below.

Star Washers, M12; Flat Washers, M12

Countersunk Screws, M5×12

Spool Cover

Friction Washer

Keyed Washer

Flat Washer, small hole

Art # A-11344

Hub Wire Reel

Compression Spring

3-lobe Screw

Retaining Clip

Spool Cover Mounting Brackets

Figure 3-27 Installing Spool Cover

INSTALLATION, OPERATION AND SETUP 3-28 Manual 0-5231

TRANSMIG VAF4

4. Install the spool hub component parts over the spool hub shaft in the following sequence.

Spool Hub

Spring

3-lobe Screw

Friction Washer

Keyed Washer

Flat Washer

Retaining Clip

Figure 3-28 Spool Hub Assembly

Art # A-11349

Fully tighten all fasteners.

Refer to the figures below for the assembled spool cover:

Figure 3-29a Assembled Spool Cover (door opened)

WARNING

Art # A-11356

Manual 0-5231 3-29 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Screw Hole for

Art # A-11252_AB

Figure 3-29b Assembled Spool Cover

3.15 Installing Welding Wire Spool

Art # A-11348

WARNING

Fully tighten all fasteners.

There are 3 holes on the spool hub support. The top screw hole is for installing a coil of 400mm (30kg) diameter. In this case a 30kg coil holder must be used. The 30kg coil holder is attached to the spool hub in the same way as for a 300mm spool, then the coil is placed over the 30kg coil holder & locked in place. The middle hole is for installing a spool of 300mm diameter (as shown in Figure 3-30). The bottom hole is for installing a spool of 200mm diameter. As delivered from the factory, the unit has the spool hub ﬁtted into the middle (300mm spool) position.

1. Remove the retaining clip from the spool hub.

2. Install the wire spool over the spool hub, locating the hole in the spool, with the alignment pin on the spoolhub.

3. Insert the retaining clip back into the spool hub.

NOTE

Install the welding wire spool so that the wire feeds from the bottom of the spool into the input wire guide.

Alignment Pin

Spool Hub

Wire Spool (300mm)

Retaining Clip

400mm Spool

Screw Hole for 300mm Spool

Retaining clip position for 200mm spool

3-lobe Screw

Screw Hole for 200mm Spool

Figure 3-30 Installing Welding Wire Spool

INSTALLATION, OPERATION AND SETUP 3-30 Manual 0-5231

TRANSMIG VAF4

Wire Spool Hub

3.16 Wire Reel Brake

The wire reel hub incorporates a 3-lobe screw which is adjusted during manufacture for optimum braking.

If it is considered necessary, adjustment can be made by turning the 3-lobe Screw inside the open end of the hub clockwise to tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than 10-20mm after release of the trigger. The electrode wire should be slack without becoming dislodged from wire spool. Please refer to Figure 3-31.

Retaining Clip

3-lobe Screw

Alignment Pin

Art # A-11264_AB

Figure 3-31 Spool Hub Assembly (with spool hub assembly installed)

CAUTION

Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical componentry and possibly an increased incidence of electrode wire Burnback into contact tip.

3.17 Inserting Wire into Feed Mechanism

WARNING

ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power source before proceeding. Do not reattach the input power until told to do so in these instructions.

WARNING

MOVING PARTS can cause injury.

1. Swing the Pressure Adjusting Knobs down and the two Pressure Roll Arms automatically spring up.

2. Make sure the end of the wire is free of any burrs and is straight. Pass the end of wire through the Input Wire Guide and over the Feed Rolls. Make certain the proper groove is being used.

3. Pass the MIG wire over the feed roll groove and out past the MIG Torch Adaptor. Then ﬁt the welding torch as per Subsection 3.10 ensuring the MIG wire passes into the MIG Torch liner of the MIG Torch.

4. Lower the Pressure Roll Arms.

5. Swing the Pressure Adjusting Knobs back into place.

6. Use the Pressure Adjusting Knobs to create a “snug” condition. (Clockwise to tighten and Counter Clockwise to loosen).

7. Turn ON the power supply. Set proper WFS and remove the tip from the welding torch. Depress INCH button until the wire reaches the top of welding torch. Tighten the tip again and ﬁnish inserting wire.

Manual 0-5231 3-31 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Pressure Roll Arm

Pressure Roll

Feed Roll

Pressure Adjusting Knob

Inlet Guide

Figure 3-32 Wire Feeding

Art # A-11253

3.18 Feed Roll Pressure Adjustment

The roll on the swing arm applies pressure to the grooved roll via an adjustable tension device. The pressure adjusting knobs should be set to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping occurs, and inspection of the wire out of the MIG Gun reveals no deformation or wear, the conduit liner should be checked for kinks or clogging from metal ﬂakes. If this is not the cause of slipping, the Feed Roll pressure can be increased by rotating the pressure adjusting knobs clockwise. The use of excessive pressure may cause rapid wear of the Feed Roll, motor shaft and motor bearings.

INSTALLATION, OPERATION AND SETUP 3-32 Manual 0-5231

TRANSMIG VAF4

Pressure Roll Arm

3.19 Installing and Changing the Feed Roll / Removing Inlet Guide & Euro Adaptor

WARNING

MOVING PARTS can cause injury.

Make sure wirefeeder is switched OFF Before changing feedrolls, guides or adaptors.

NOTE

Feed rolls often come with a rust prohibitive coating that needs to be cleaned off before installation.

1. Loosen the Thumb Screw as shown in the ﬁgure below and lift up the ﬁnger guard.

2. Swing the Pressure Adjusting Knob down and the Pressure Roll Arm automatically springs up.

3. Rotate the Screw counter-clockwise and remove the Screw, Washer and Feed Roll.

4. Make the two Positioning Holes on the Feed Roll align at the two Positioning Pins, and install the Feed Roll, Washer and Screw.

5. Tighten the screw clockwise.

6. Lower the Pressure Roll Arm.

7. Swing the Pressure Adjusting Knob back into place.

8. Use the Pressure Adjusting Knobs to create a “snug” condition. (Clockwise to tighten and Counter Clockwise to loosen). Secure the ﬁnger guard with the Set Screw and Thumb Screw.

9. To remove the inlet guide remove the thumb screw as shown in the figure below then use the 3mm allen key to remove the set screw that fixes inlet guide.

10. To remove the Euro torch adaptor remove the thumb screw as shown in the figure below then use the 3mm allen key to remove the set screw that fixes the Euro torch adaptor.

Inlet Guide

Art# A-11254

Note: for clarity of picture, only feed roll at right side shown.

Set Screw （for ﬁxing inlet guide)

Positioning Hole

Pressure Adjusting Knob

Positioning Pin

Feed Roll

Washer

Set Screw (for ﬁxing torch adaptor)

Screw

Thumb Screw

Finger Guard

Thumb Screw

Figure 3-33 Changing Feed Roll (Right Side as Example)

NOTE

All grooved Feed Rolls have their wire size or range stamped on the side of the roll. On rolls with different size grooves, the outer (visible when installed) stamped wire size indicates the groove in use.

Manual 0-5231 3-33 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

WARNING

The welding wire is electrically Hot if it is fed by depressing MIG Gun switch. Electrode contact to work piece will cause an arc with MIG Gun switch depressed.

3.20 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 user's 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 3-34 Fit Regulator to Cylinder

INSTALLATION, OPERATION AND SETUP 3-34 Manual 0-5231

TRANSMIG VAF4

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 igni-

tion. 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 3-35 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 sequence due to back pressure present within shielding gas hose assembly.

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.

Manual 0-5231 3-35 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

GROOVE “B”GROOVE “A”

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.

3.21 Wire Feeder Set Up 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 19 PIN socket on the Power Source as applicable.

NOTE

For Transmig 400i or other power sources ﬁtted with a 14 pin control socket, use interconnection W4016000 to connect to the power source 14 pin control socket.

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.

Art # A-08739

GROOVE “B” SIZE

INSTALLATION, OPERATION AND SETUP 3-36 Manual 0-5231

GROOVE “A” SIZE

TRANSMIG VAF4

E. Fit the electrode wire spool to the wire reel hub. Ensure that the wire reel hub alignment pin engages the mating

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

F MIG Torch Connection (Please refer to Subsection 3.10 & 3.13)

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 gun.

WARNING

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

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

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 gun.

WARNING

If the Gun Trigger is used to feed wire through the gun, 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.

Connection to Transmig 350i, 450i, 550i

Positive Welding Terminal (+)

Negative Welding Terminal (-)

19 Pin Control Socket

Work Lead

VAF4 Wirefeeder

Mig Torch

Figure 3-36 Setup for Wirefeeder with MIG (GMAW) Welding

Manual 0-5231 3-37 INSTALLATION, OPERATION AND SETUP

Art # A-11260

TRANSMIG VAF4

GROOVE “B”GROOVE “A”

3.22 Wire Feeder Set Up 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 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. 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 19 PIN socket on the Power Source as applicable.

NOTE

For Transmig 400i or other power sources ﬁtted with a 14 pin control socket, use interconnection W4016000 to connect to the power source 14 pin control socket.

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

facing outwards.

Art # A-08739

GROOVE “B” SIZE

D. Fit the electrode wire spool to the wire reel hub. Ensure that the wire reel hub alignment pin engages the mating

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

E MIG Torch Connection (Please refer to Subsection 3.10 & 3.13)

GROOVE “A” SIZE

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 gun.

WARNING

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

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

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 gun.

INSTALLATION, OPERATION AND SETUP 3-38 Manual 0-5231

TRANSMIG VAF4

WARNING

If the Gun Trigger is used to feed wire through the gun, 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.

Positive Welding Terminal (+)

Work Lead

19 Pin Control Socket

Art # A-11537

VAF4 Wirefeeder

Mig Torch

Figure 3-37 Setup for Wirefeeder with MIG (GMAW) Welding with Gasless MIG Wire

Manual 0-5231 3-39 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

Negative Welding Terminal (-)

Connection of VAF4 to Transmig 400i for Welding with Gas Shielded MIG Wire

14-pin Control Cable

Negative Welding Terminal (-)

Electrode Lead*

Positive Welding Terminal (+)

Gas

Work Lead*

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

VAF4 Wirefeeder

Mig Torch

Figure 3-37(b) Setup for Wirefeeder with MIG (GMAW) Welding

NOTE

Interconnection Assembly 19 pin to 14 pin, 8m (W4016000) required.

NOTE

Refer to Subsection 3.09 for wirefeeder DIP switch setting required for Transmig 400i power source.

Connection of VAF4 to Engine Drive for Welding with Gas Shielded MIG Wire

Positive Welding Terminal (+)

Art # A-11345

Gas

14-pin Control Cable

Electrode Lead*

Work Lead*

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

VAF4 Wirefeeder

Mig Torch

Figure 3-37(c) Setup for Wirefeeder with MIG (GMAW) Welding

NOTE

Interconnection Assembly 19 pin to 14 pin, 8m (W4016000) required for connection to an MPM8/ 255 or MPM8/ 270 engine-driven welding power source.

An additional adaptor cable W4016001 is required in conjunction with a 19 pin to 14 pin interconnection cable assy (Refer to Table 2-3 for further detail) for connection to MPM12/ 400 or MPM20/ 500 engine-driven welding power source.

WARNING

There are dangerous voltage and power levels inside this product. Turn OFF wirefeeder and disconnect from the power source before removing cover from wirefeeder.

Art # A-11346

NOTE

Refer to Subsection 3.24 and set internal DIP switch SIL_1 # 2 to ON.

INSTALLATION, OPERATION AND SETUP 3-40 Manual 0-5231

TRANSMIG VAF4

3.23 Prewelding Procedure

Follow all installation instructions for the wire feeder, the welding power source, and the welding gun before attempting to operate the Transmig VAF4.

1. Make sure all necessary connections have been made (Refer to Subsection 3.01 of this manual).

2. Turn ON the power source and the wire feeder.

3. All the displays and discrete LED's start self-examination and all the lights on the panel are on for 1 second. Left display shows ﬁrmware information of display PCB "DF X.X" and right display shows hardware information of display PCB "DH X.X". 1.5 seconds later left display shows ﬁrmware information of motor control PCB "PF X.X" and hardware information of motor control PCB "PH X.X".

4. Push the PURGE switch of the feeder and adjust the ﬂow of shield gas.

5. Push the INCH switch of the feeder and adjust the WFS to the desired value by means of WFS control.

WARNING

If the gun switch is depressed, the electrode (welding wire) is electrically “hot”. Do not permit it to touch any metal or a welding arc may be established which may be injurious to someone’s eyes (ﬂash) or skin (burn).

6. Adjust the voltage of the power source to the desired value. The gun switch must be triggered to close power source contactor.

WARNING

In wire welding, the welding wire, wire reel (if used), input guide, feed rolls, output guide, feedhead, and welding gun metal parts are all ELECTRICALLY “HOT”.

3.24 Arc Signal Override (SIL_1 #2)

WARNING

There are dangerous voltage and power levels inside this product. Turn OFF wirefeeder and disconnect from the power source before removing cover from wirefeeder.

This switch on the motor control PCB conﬁgures the wire feeder for the presence of Arc Established signals from a power source. If the power source has an Arc Established, then this switch should be OFF. If the power source does not have these ‘Arc Signals’, then this switch should be ON. This switch allows the 2T / 4T and timer features to work, although they will not be timed from the true start of the arc, but instead from when the gun trigger is pulled.

TRANSMIG 350i, 450i, 500i and 550i have the arc established signal and current feedback signal and SIL_1#2 should be set to OFF. Note that the DIP switch SIL1-#2 is factory default set to OFF.

TRANSMIG 400i, MPM20/500, MPM12/400, MPM8/270 and MPM8/255 do not have these signals, and SIL-1 #2 will need to be set to ON.

Art # A-11268

Motor Control PCB

SIL_1 Switch

Figure 3-38 SIL_1 Switch on Motor Control PCB

Manual 0-5231 3-41 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

3.25 Welding- 2T Operation

Position the welding gun above the workpiece and depress the gun switch trigger. Depressing the gun switch trigger enables the gas valve. When preﬂow ends, wire feed motor and power source are enabled; the welding process begins. To end the weld, release the gun switch trigger which disables the gas valve, wire feed motor, and power source.

Gun Trigger

Arc Established

Gas

Contactor

Wire feed

Preﬂow

Run In %

Ramp

Figure 3-39 Welding- 2T Operation

Art# A-11262

Burnback

Postﬂow

3.26 Spot Operation

Gun Trigger

Arc Established

Gas

Contactor

Wire feed

Spot Time

Art# A-11258_AB

Preﬂow

Run In %

Ramp

Figure 3-40 Spot Operation

Burnback

Postﬂow

INSTALLATION, OPERATION AND SETUP 3-42 Manual 0-5231

TRANSMIG VAF4

3.27 Welding- 4T Operation

Welding- 4T Operation (Crater=ON)

Position the welding gun above the workpiece, depress the gun switch trigger, it enables power source and gas valve, and the wire will begin feeding. Welding arc is established. Release the gun switch trigger and the welding process continues. To end the weld, depress the gun switch trigger again and the welding voltage and welding current turn to preset crater voltage and crater current. Release the gun switch trigger and the welding process ends.

NOTE

In 4T welding (Crater=ON), the user can independently control the amount of crater-ﬁller time by adjusting the amount of time the gun switch is depressed.

Gun Trigger

Arc Established

Gas

Contactor

Art # A-11259

Voltage

Wire feed

Preﬂow

Crater WFS %

Run In %

Ramp

Burnback

Postﬂow

Crater Volts %

Figure 3-41 Welding- 4T Operation (Crater=ON)

Welding- 4T Operation (Crater=OFF)

Art # A-11263_AB

Gun Trigger

Arc Established

Gas

Contactor

Wire feed

Preﬂow

Run In %

Ramp

Postﬂow

Figure 3-42 Welding- 4T Operation (Crater=OFF)

Manual 0-5231 3-43 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

3.28 Stitch Operation

After selecting stitch operation in advanced features menu, select 2T Stitch or 4T Stitch by pressing 2T/ 4T button on front panel.

2T Stitch Operation

Position the welding gun above the workpiece and depress the gun switch trigger. Depressing the gun switch trigger enables the gas valve. When preﬂow ends, wire feed motor and power source are enabled the welding process begins. When Stitch Time is over, arc extinguishes and it will stop feeding. When Dwell Time is over, the welding gun will starting welding again. This process repeats until releasing the gun switch trigger.

Gun Trigger

Dwell time

Arc Established

Gas

Contactor

Art # A-11272_AB

Run In %

StitchTime

Ramp

Postﬂow

Burnback

Wire feed

Preﬂow

Figure 3-43 Welding- 2T Stitch Operation

4T Stitch Operation (Crater=ON)

Position the welding gun above the workpiece and depress the gun switch trigger. Depressing the gun switch trigger enables the gas valve. When preﬂow ends, wire feed motor and power source are enabled the welding process begins. Release the gun switch trigger and the welding process continues. To end the welding, depress the gun switch trigger again and welding current and welding voltage will turn to preset crater voltage and crater current. Release the gun switch trigger and the welding process ends.

Gun Trigger

Dwell time

Arc Established

Gas

Contactor

Voltage

StitchTime

Wire feed

Art # A-11273_AB

Crater Volts %

Preﬂow

Run In %

Ramp

Burnback

Crater WFS %

Burnback

Postﬂow

Figure 3-44 Welding- 4T Stitch Operation (Crater=ON)

4T Stitch Operation (Crater=OFF)

Position the welding gun above the workpiece and depress the gun switch trigger. Depressing the gun switch trigger enables the gas valve. When preﬂow ends, wire feed motor and power source are enabled the welding process begins. When Stitch Time is over, arc extinguishes and it will stop feeding. When Dwell Time is over, the welding gun will starting welding again.

INSTALLATION, OPERATION AND SETUP 3-44 Manual 0-5231

TRANSMIG VAF4

3.29 PTC Protection of Power Source Contactor Control Output

The Power Source Contactor control circuit on the TRANSMIG VAF4 provides a relay closure to the power source through pins A and B of the 19 pin control cable. This allows the welding wire to become electrically ‘HOT’ when the gun switch trigger on the welding gun is pulled. If this relay closure is NOT provided for any reason, the welding wire WILL NOT be electrically ‘HOT’. The wire will feed, but there will be NO arc when the wire touches the work.

The Transmig VAF4 has a thermal, self reset protection device in the A-B contactor circuit to protect the circuitry against a fault or overload condition. This protection device will only allow a maximum steady state current in the range of 180 to 450 milliamps (dependent on ambient temperature) to ﬂow through pins A and B of the 19 pin control cable to the A-B contactor circuit on the Transmig VAF4.

If this acceptable current range is exceeded for any reason, the self-reset protection circuit located on the motor control PCB will be activated effectively disabling the A-B contactor circuit. Once the fault or overload condition has been corrected and the current has returned to an acceptable level, the protection device will automatically reset and normal operation can resume.

NOTE

The protection circuit will remain activated (there will be NO arc when the wire touches the work) as long as the acceptable current range is exceeded.

3.30 Ground Fault Operation

The Transmig VAF4 has been equipped with a ground fault protection circuit. This protection circuit is activated whenever excessive current ﬂow in the protective earth ground is detected. If the ground fault protection circuit is activated, the yellow FAULT indicator on the front of the feeder will ﬂash at a rate of approximately 0.5 second on, 0.5 second off. When a ground fault occurs, the feeder will immediately shut down the feeder, gas valve, and power source contactor. Once the ground fault protection circuit has been set, the wire feeder will not respond to a gun switch closure until the power is reset by turning the feeder off and back on.

NOTE

Before resetting power to the wire feeder after a ground fault occurrence, determine what caused the ground fault and correct the problem before attempting to weld again.

3.31 Electronic Motor Protection

The Transmig VAF4 utilizes an electronic protection circuit to protect the motor against overcurrent caused by excessive load on the motor. This protection will normally trip if the motor stays in current limit for about 10 seconds and during this 10 second period the fault light will ﬂash at a rate of approximately 0.3 second on, 0.3 second off. Once this 10 second timing period completes, the protection circuit will trip which will cause the FAULT indicator LED to light continuously, error code ERR 03 or ERR 04 (refer to Subsection 4.05 Error Code and Remedies) will be displayed and the wirefeeder will shutdown. In order to reset this condition, the power to the wirefeeder must be turned OFF then ON to reset and clear Error Code from display.

NOTE

Should this condition occur, check the wire feeding path, and make sure that there is not any restrictions or binding on the wire, and that the feedrolls aren’t locked by some obstruction.

Manual 0-5231 3-45 INSTALLATION, OPERATION AND SETUP

TRANSMIG VAF4

This page intentionally blank

INSTALLATION, OPERATION AND SETUP 3-46 Manual 0-5231

TRANSMIG VAF4

SECTION 4: SERVICE

4.01 Cleaning The Unit

Periodically, clean the inside of the wire feeder and feedhead assembly by using a vacuum cleaner or clean, dry compressed air of not more than 25 psi (172 kPa) pressure. After cleaning the unit, check all electrical components for loose or faulty connections and correct if necessary.

4.02 Cleaning The Feed Rolls

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

4.03 System Maintenance

The user has been given a visual tool in the feed monitor display. Use the feed monitor display in determining when a new contact tip, liner, and/or wire guide is needed.

4.04 Troubleshooting Guide

NOTE

Refer to the Connection Diagram in the Appendix chapter of this manual for graphical assistance in disassembling and troubleshooting the wire feeder.

Scope

The troubleshooting guide is intended to be used by qualiﬁed service technicians. The troubleshooting guide contains information which can be used to diagnose and correct unsatisfactory operation or failure of the various components of the wire feeder. Each symptom of trouble is followed by a list of probable causes and the procedure necessary to correct the problem.

Safety

To ensure safe operation and service, read this entire manual before attempting to service or repair this machine. The service technician may be asked to check voltage levels while the machine is turned ON. To assure safety, use care and follow all instructions accordingly.

Manual 0-5231 4-1 SERVICE

TRANSMIG VAF4

4.05 Error Codes and Remedies

Error Code

Left

Display

ERR 01-- This protection

ERR 02-- Control cable

ERR 03-- Emergency

ERR 04-- Protective shutdown Motor current exceeds

Right

Display

Description Cause Remedy

Weld current is detected circuit is activated whenever weld current ﬂows in the ground fault protective circuit.

Fault light ﬂashes at a rate of approximately 0.5 second ON, 0.5 second OFF.

connecting Wirefeeder and Power Source not correctly connected.

shutdown

running through the ground

fault protective circuit.

1. 19 pin plug control plug

connection is loose at either

socket on Wirefeeder or

Power Source.

2. Control cable is damaged

or has faulty connection/s.

3. Ensure that the 19 Pin

socket is selected on the

Power Source.

Motor current exceeds

10amps due to seized motor

or clogged liner or ﬁller metal

wire too big for MIG torch

liner or spool hub tension too

tight, etc.

5amps for 10 seconds due to

clogged liner or ﬁller metal

wire too big for MIG torch

liner or spool hub tension too

tight, etc.

1. Look for metallic dust build up between the wirefeed plate assembly/ motor and the Wirefeeder frame and remove the metallic dust build up. Turn OFF Wirefeeder then ON again to clear ERR 01.

2. If ERR 01 appears again with the next weld or metallic dust build up cannot be located then contact your Accredited CIGWELD Service Provider to investigate the fault.

1. Check control cable connections at the Wirefeeder and Power Source are tight.

2. If the Control Cable is damaged then repair or replace cable.

3. Check the Power Source is set to 19 Pin socket mode.

Turn OFF Wirefeeder then check motor / feed mechanism can rotate or replace liner or install correct size liner for ﬁller metal or adjust spool hub tension.

Turn ON Wirefeeder and if ERR 03 appears again with the next weld then contact your Accredited CIGWELD Service Provider to investigate the fault.

Turn OFF Wirefeeder then check motor / feed mechanism can rotate or replace liner or install correct size liner for ﬁller metal or adjust spool hub tension.

Turn ON Wirefeeder and if ERR 04 appears again with the next weld then contact your Accredited CIGWELD Service Provider to investigate the fault.

SERVICE 4-2 Manual 0-5231

TRANSMIG VAF4

Error Code

Left

Display

ERR 05-- Feedback signal of

ERR 06-- Output current of

ERR 07-- Power Source

ERR 08-- Main control PCB

ERR 20-- Display PCB settings

ERR 21-- Welder mode

ERR 22-- Wirefeeder mode

Right

Display

Description Cause Remedy

motor lost

Wirefeeder exceeds allowed maximum value limit

Arc Established signal has not been received within 20 seconds of commencing welding

settings save or read error

save or read error

undeﬁned

Tachometer feedback wiring between Wirefeeder motor and motor control PCB not connected or motor is stalled.

1. Current running through Wirefeeder exceeds 650A for 4 minutes.

2. Welding current signal from Power Source is too high with respect the actual weld current.

Power Source does not provide an Arc Establish signal.

Motor Control PCB Memory IC read/write cycle limit has been exceeded.

Display PCB Memory IC read/ write cycle limit has been exceeded.

Incorrect DIP switch setting. Disconnect Wirefeeder

Disconnect Wirefeeder from Power Source. Check wiring between Wirefeeder motor Tachometer and motor control PCB is correctly connected. Reconnect Wirefeeder to Power Source and if ERR 05 appears again with the next weld then contact your Accredited CIGWELD Service Provider to investigate the fault.

1. Turn OFF Wirefeeder and allow it to cool for 10 minutes then reduce voltage / wirespeed setting to reduce welding current below 650A@40%.

2. Contact your Accredited CIGWELD Service Provider to investigate the fault.

Override the Arc Established signal, refer to Subsection 3.24 or retrigger the wirefeeder.

1. Turn Wirefeeder OFF then ON and check to see if settings can then be saved.

2. Contact your Accredited CIGWELD Service Provider to investigate the fault.

1. Turn Wirefeeder OFF then ON and check to see if settings can then be saved.

2. Contact your Accredited CIGWELD Service Provider to investigate the fault.

from Power Source then check DIP switch setting and set S3S4S5 DIP switch as to Subsection 3.09.

from Power Source then check DIP switch setting and set S1S2 DIP switch as to Subsection 3.09.

Table 4-1 Error Codes and Remedies

Manual 0-5231 4-3 SERVICE

TRANSMIG VAF4

Shielding Gas

NOTE

Once cause of error has been corrected then the power to the Wirefeeder must be turned OFF then ON to reset and clear Error Code from the display.

Please follow Subsection 4.08 for more information regarding troubleshooting.

4.06 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 MIG Torch 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, CO2 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.

Shielding Gas

Molten Weld Metal

Solidiﬁed Weld Metal

Figure 4-1 GMAW Process

GMAW Process

Nozzle

Electrode

Arc

Base Metal

Art # A-8991_AB

Nozzle (Optional)

Flux Cored Electrode

Arc

Base Metal

Art # A-08992_AB

Slag

(Optional)

Molten Metal

Molten Slag

Solidiﬁed Weld Metal

FCAW Process

Figure 4-2 FCAW Process

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 Position of MIG Torch

The MIG Torch should be held at an angle to the weld joint. (See Secondary Adjustment Variables below)

Hold the MIG Torch 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.

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

Do NOT pull the MIG Torch 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 MIG Torch trigger switch is depressed. The wire may therefore be placed on the seam or joint prior to lowering the helmet.

CAUTION

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.

SERVICE 4-4 Manual 0-5231

TRANSMIG VAF4

10° to 20° Longitudinal

Direction of Travel

5° to 15°

Longitudinal

Angle

90°

Transverse

Angle

Direction of

Travel

Art # A-08993

Butt & Horizontal Welds

Figure 4-4 Butt & Horizontal Welds

5° to 15°

Longitudinal Angle

Direction of

Travel

30° to 60°

Transverse Angle

Art # A-08994

Horizontal Fillet Weld

Figure 4-5 Horizontal Fillet Weld

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 20mm. 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 0.6mm to 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:

10°

Longitudinal Angle

30° to 60°

Transverse

Angle

30° to 60°

Transverse Angle

Overhead Weld

Direction of Travel

Vertical Fillet Welds

Art # A-08995

Figure 4-6 Vertical Fillet Weld

5° to 15° Longitudinal Angle

Art # A-08996

Figure 4-7 Overhead Weld

Angle

30° to 60°

Transverse

Angle

• Typeofelectrodewire

• Sizeofelectrodewire

• Typeofgas((notapplicableforFCAWselfshield-

ing wires)

• Gasowrate(notapplicableforFCAWselfshielding wires)

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

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

Manual 0-5231 4-5 SERVICE

increases weld current, Decrease in wire feed speed decreases weld current.

TRANSMIG VAF4

Electrode Stick-Out

Transverse

Gas Nozzle

Tip to

Work Distance

Average Arc Length

Figure 4-8 Electrode Stick-out

Contact Tip (Tube)

Electrode Wire

Actual Stick-out

Art # A-08997_AD

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.

3. Nozzle Angle. This refers to the position of the MIG Torch 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 MIG Torch 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.

Angle

Longitudinal Angle

Axis of Weld

Transverse and Longitudinal Nozzle Axes

Art # A-08998_AB

For practicing MIG welding, secure some pieces of

1.5mm or 2.0mm mild steel plate 150 x 150mm. Use

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 and the welding Voltage Control. The welding current is determined by the Wirespeed control, the current will increase with increased Wirespeed, resulting in a shorter arc. Less wire speed will reduce the current and lengthen the arc. Increasing the welding voltage hardly alters the 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.

Figure 4-9 Transverse and Longitudinal Nozzle Axes

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

Direction of Gun Travel

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

Leading or “Pushing”

Angle

(Forward Pointing)

Nozzle Angle, Right Handed Operator

90°

Trailing or “Pulling”

Angle

(Backward Pointing)

Art # A-08999_AC

the inside of the wirefeed compartment door for setup information.

Figure 4-10 Nozzle Angle, Right Handed Operator

SERVICE 4-6 Manual 0-5231

TRANSMIG VAF4

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

4.07 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.

Problem 1 - 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

Shielding gas cylinder contents and ﬂow

meter.

Gas leaks. Check for gas leaks between the regulator/cylinder connection and in the gas

Internal gas hose in the Power Source. Ensure the hose from the solenoid valve to the MIG Torch adaptor has not

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

Welding dirty, oily, painted, oxidized or

greasy plate.

Distance between the MIG Torch nozzle

and the work piece.

Maintain the MIG Torch in good working

order.

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

hose to the Power Source.

fractured and that it is connected to the MIG Torch adaptor.

Clean contaminates off the work piece.

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

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

nozzle.

Do NOT restrict gas ﬂow by allowing spatter to build up inside the MIG Torch

nozzle.

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

Table 4-2 MIG (GMAW / FCAW) Welding Troubleshooting

Manual 0-5231 4-7 SERVICE

TRANSMIG VAF4

Problem 2 - Inconsistent Wire Feed

WARNING

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

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

FAULT CAUSE

Feed roller driven by motor in the cabinet

slipped.

Wire spool unwound and tangled. Wire spool brake is too loose.

Wire spool brake is too tight.

Worn or incorrect feed roller size

Wire rubbed against the misaligned guides and

reduced wire feed ability.

Liner blocked with swarf

Incorrect or worn contact tip

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

Bent liner This will cause friction between the wire and the liner thus reducing

Use a feed roller matched to the size you are welding.

Replace feed roller if worn.

Misalignment of inlet/outlet guides

Increased amounts of swarf are produced by the wire passing

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

Swarf can also be produced by the wire passing through an

incorrect feed roller groove shape or size.

Swarf is fed into the conduit liner where it accumulates thus

reducing wire feed ability.

The contact tip transfers the weld current to the electrode wire. If

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

When using soft wire such as aluminium it may become jammed in

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

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

wire feed ability

Table 4-3 Wire Feeding Problems

SERVICE 4-8 Manual 0-5231

TRANSMIG VAF4

Basic MIG (GMAW/FCAW) Welding Troubleshooting

FAULT CAUSE REMEDY

Undercut

Welding arc voltage too high.

Incorrect MIG Torch angle

Excessive heat input

Decrease voltage or increase the wire feed speed.

Adjust angle.

Increase the MIG Torch travel speed and/or decrease welding

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

Lack of penetration

Lack of fusion Voltage too low Increase voltage.

Excessive spatter

Irregular weld shape

Weld cracking

Welding current too low

Joint preparation too narrow or

gap too tight

Shielding gas incorrect

Voltage too high

Voltage too low

Incorrect voltage and current

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

Wire is wandering.

Incorrect shielding gas

Insufﬁcient or excessive heat

input

Weld beads too small

Weld penetration narrow and

deep

Excessive weld stresses

Increase welding current by increasing wire feed speed and

increasing voltage.

Increase joint angle or gap.

Change to a gas which gives higher penetration.

Decrease voltage or increase the wirespeed control.

Increase the voltage or decrease wirespeed.

Adjust voltage and current by adjusting the voltage control and

the wirespeed control.

Replace contact tip.

Check shielding gas.

Adjust the wirespeed control or the voltage control.

Decrease travel speed

Reduce current and voltage and increase MIG Torch travel speed

or select a lower penetration shielding gas.

Increase weld metal strength or revise design

Cold weld puddle

Arc does not have a crisp

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

Excessive voltage

Cooling rate too fast

Loose welding cable connection.ACheck all welding cable connections.

Low primary voltage

Fault in power source

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

Decrease voltage.

Slow the cooling rate by preheating part to be welded or cool

slowly.

Contact supply authority.

Have an Accredited CIGWELD Service Provider test then replace

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.

Table 4-4 GMAW (MIG) Welding Problems

Manual 0-5231 4-9 SERVICE

TRANSMIG VAF4

4.08 Troubleshooting

WARNING

ELECTRIC SHOCK can kill.

Follow all safety precautions.

Do not touch live electrical parts.

Turn OFF input power before servicing the machine unless otherwise noted.

Only qualiﬁed technicians are to service the machine.

WARNINGS

PC boards and their components are static sensitive devices.

Use static proof bags.

Use grounded wrist strap.

Only qualiﬁed personnel should test or handle these devices.

Use only genuine replacement parts.

FAULT CAUSE REMEDY

1 Power On Indicator

light is not lit and welding arc cannot be established.

2 Error Code is

displayed and yellow fault indicator is lit when Wirefeeder is turned ON.

Switch on rear panel of Wirefeeder is not turned ON.

Power Source is not turned ON.

19 Pin control cable is not

connected between the power source and Wirefeeder.

Circuit Breaker/s on rear panel is tripped (pops out). Refer to Subsection 3.07 for further detail.

Faulty 19 Pin control cable

connecting power source and Wirefeeder.

Error condition present. Refer to Error Codes and Remedies

Turn switch on rear panel of Wirefeeder to ON.

Turn power source ON and ensure it is in the correct mode of operation.

Connect 19 Pin control cable between the power source and Wirefeeder.

Reset circuit breaker by pushing it in. If it fails to reset have an Accredited CIGWELD Service Provider investigate the fault.

Repair or replace the 19 Pin control

cable.

Table in Subsection 4.05.

3 Power Indicator light

is not lit but welding arc can be established.

4 Power ON Indicator

light is lit but when the torch trigger switch is depressed nothing happens.

SERVICE 4-10 Manual 0-5231

Faulty Indicator light on display PCB.

Torch trigger switch leads are disconnected.

Faulty trigger switch/lead.

Have an Accredited CIGWELD Service Provider investigate the fault.

Re connect Torch trigger switch leads.

Repair or replace torch trigger lead.

TRANSMIG VAF4

FAULT CAUSE REMEDY

5 Power indicator is

ON, no wire feed but gas ﬂows from the MIG Torch when the torch trigger switch is depressed.

6 Wire feeds when the

torch trigger switch is depressed but arc cannot be established.

7 Wirefeed motor

operates but wire does not feed.

Preﬂow is operating.

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

Faulty motor control PCB.

Poor or no work lead contact.

Wirefeeder signal is not initiating the power source which could be caused by a loose 19 pin plug connection.

A fault or overload condition has occurred in pins A & B of the 19 pin interconnection lead control cable and the P.T.C. protection has activated.

Pressure on feed rolls not correctly adjusted.

Incorrect feed rolls used.

Worn feed roll.

Adjust preﬂow time setting. Refer to Section 3.08.

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

Service Provider investigate the fault.

Clean work clamp area and ensure good electrical contact.

Tighten 19 pin plug connection, repair or replace the 19 Pin control cable.

Refer to Subsection 3.29 Protection of Power Source Contactor Output Control. (P.T.C.) or have an Accredited CIGWELD Service Provider investigate the fault.

Adjust pressure on feed rolls so that it will be set to a minimum pressure that will provide satisfactory wire feed without slippage.

Check that feed roll being used matches the wire size and type being used.

Replace feed roll.

8 Jerky wire feed A

B C

9 No gas ﬂow A

10 Gas ﬂow continues

after the torch trigger switch has been released.

11 Wire does not feed

when torch trigger is depressed

12 Wire continues to feed

when torch trigger released

A BWirefeeder in 4T (LATCH) mode

Worn or dirty contact tip. Worn feed roll. Excessive back tension from wire reel hub. Worn, kinked or dirty conduit liner.

Gas hose is cut. Gas passage contains impurities.

Gas regulator turned off.

Empty Cylinder

Postﬂow is operating.

Gas valve has jammed open due to impurities in the gas or the gas line.

Faulty trigger switch / lead. Repair or replace Torch / trigger

Torch trigger leads shorted.

Replace contact tip.

Replace feed roll.

Reduce brake tension on spool hub.

Clean or replace conduit liner.

Replace or repair.

Disconnect gas hose from the rear of Wirefeeder then raise gas pressure and blow out impurities.

Turn on Regulator and adjust to correct pressure.

Replace cylinder.

Adjust postﬂow time setting. Refer to Subsection 3.08.

Have an Accredited CIGWELD Service Provider repair or replace gas valve.

lead.

A BChange to 2T (NORMAL) mode.

Repair or replace Torch / trigger lead.

Manual 0-5231 4-11 SERVICE

TRANSMIG VAF4

FAULT CAUSE REMEDY

13 There is no wire

feed the yellow Fault indicator is lit and ERR 01 is displayed

14 Circuit breaker/s has

tripped on rear panel Refer to Subsection

3.07

15 Wirefeeder is only

displaying 1.3MPM (min) and/or 14V (min) and cannot be adjusted when trigger is depressed.

16 Crater does not

function when 4T Mode is selected and Crater is turned ON and ERR 07 is displayed after 20 seconds.

Earth Fault Protection circuit has operated.

Short circuit on the 42 or 115VAC rear outlets or 14 / 19 pin receptacles.

Internal fault in Wirefeeder.

In Advanced Features the MIG Control function is set to Remote but no remote device is connected to the 8 pin remote socket on the Wirefeeder front panel.

Power Source has not provided an Arc Establish signal to Wirefeeder.

A BRefer to Subsection 4.05 Error

Codes and Remedies ERR 01.

Have an Accredited CIGWELD Service Provider investigate the fault.

Have an Accredited CIGWELD Service Provider check and repair as necessary.

Set MIG Control mode to local

If a remote control device is ﬁtted to the 8 pin remote control socket then the remote control device is faulty. Have an Accredited CIGWELD Service Provider check and repair as necessary.

Override Arc Establish signal, refer to Subsection 3.24.

17 Spot time exceeds

user setting when Spot Mode is selected and ERR 07 is displayed up to after 20 seconds.

18 Stitch does not

function when Stitch is turned on in 2T or 4T Modes and ERR 07 is displayed up to after 20 seconds.

Power Source has not provided an Arc Establish signal to Wirefeeder.

Table 4-5 Troubleshooting

Override Arc Establish signal, refer to Subsection 3.24.

SERVICE 4-12 Manual 0-5231

TRANSMIG VAF4

SECTION 5: PARTS LIST

5.01 Equipment Identiﬁcation

All identiﬁcation numbers as described in the Introduction Chapter must be furnished when ordering parts or making inquiries. This information is found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Speciﬁcation or Assembly numbers.

PART NUMBER

W3000700

5.02 How To Use This Parts List

The Parts List is a combination of an illustration (Figure Number) and a corresponding list of parts which contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All user-serviceable parts are listed except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc. The part descriptions may be indented to show part relationships.

To determine the part number, description, quantity, or application of an item, locate the item in question from the illustration and refer to that item number in the corresponding Parts List.

Manual 0-5231 5-1 PARTS LIST

TRANSMIG VAF4

5.03 Replacement Parts (without wirefeed plate)

Item # Qty Description Part Number

1 1 PCB Display,WF W7005700

2 1 PCB Motor Control,WF W7005701

3 1 Valve,Solenoid,24VDC,WF W7005702

4 1 Circuit Breaker, 8A, WF W7005706

5 1 Circuit Breaker, 4A, WF W7005705

6 1 Switch,ON/OFF, WF W7005704

7 2 Rectiﬁer,Bridge,1000V, 35A, WF W7005703

8 1 Socket, 19 Pin, Male, Panel Mtg W7005715

9 1 Socket Panel, Dinse, Male, 50mm

10 1 SPOOL HUB ASSY W7005609

11 1 Wire Guide, Outlet, 0.8-1.2, WF W7005714

12 1 Adaptor, Euro, WF W7005712

13 1 Handle Kit W7005717

W7005716

Art # A-11261

Figure 5-1 Replacement Parts (without wirefeed plate)

PARTS LIST 5-2 Manual 0-5231

TRANSMIG VAF4

5.04 Replacement Parts- Wirefeed Plate

Item # Qty Description Part Number

14 1 Motor, 42V, WF W7005713

15 1 Wire Drive Assy, 4R, WF W7005707

16 1 Wire Guide, Inlet, 0.8-1.6, WF W7005710

17 1 Wire Guide, Centre, 0.8-1.6, WF W7005711

18 2 Feed Roll Refer to Subsection 2.09

19 2 Idler Gear, 4R W7005708

20 1 Drive Gear, 4R W7005709

Figure 5-2 Replacement Parts- Wirefeed Plate

Art # A-11357

Manual 0-5231 5-3 PARTS LIST

TRANSMIG VAF4

This page intentionally blank

PARTS LIST 5-4 Manual 0-5231

TRANSMIG VAF4

APPENDIX 1: CONNECTION DIAGRAM

EURO ADAPTOR

TORCH TRIGGER

SOLENOID

Art # A-11544

8 PIN SOCKET

MOTOR CONTROL PCB

DISPLAY PCB

19 PIN SOCKET

BASE & REAR PANEL

EARTH

BASE & REAR PANEL

FRONT PANEL

EARTH

CENTRE DIVIDER PANEL

DOOR PANEL

EARTH

Manual 0-5231 A-1 APPENDIX

TRANSMIG VAF4

This page intentionally blank

APPENDIX A-2 Manual 0-5231

CIGWELD LIMITED WARRANTY

LIMITED WARRANTY: CIGWELD, 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.

TERMS OF WARRANTY – APRIL 2012

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

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

Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantable

quality and reasonably ﬁt for the purpose for which they are supplied by CIGWELD.

CIGWELD will repair or, at its option, replace those of the goods which, upon examination, are found by

CIGWELD to be defective in workmanship and/or materials.

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

3. The Warranty in Clause 2;

Is conditional upon:

The Customer notifying CIGWELD or our Accredited Distributor in writing of its claim within seven (7) days

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

Does not apply to:

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

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

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

arrangement with CIGWELD.

Replacement parts or accessories which may affect product safety or performance and which are not

manufactured, distributed or approved by CIGWELD.

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

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

The repair of goods.

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

The payment of the cost of having goods repaired.

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

WARRANTY SCHEDULE – APRIL 2012

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 VAF4 WIREFEEDER

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.

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

WARRANTY PERIOD

PARTS LABOUR

2 Year 2 Year

1 Year 1 Year

A Victor Technologies Company

CIGWELD Terms of Warranty - 2012

Effective 1st January 2012, all warranties against defects (also known as a manufacturer’s

warranty) supplied with goods or services must comply with the mandatory requirements in the new Australian Consumer Law and the Trade Practices (Australian Consumer Law) Amendment Regulations (2010) (No.1).

This Warranty Statement should be read in conjunction with the Warranty Schedule contained in the operating instructions of the product. This schedule contains the warranty period applicable to the product

Any claim under this warranty must be made within the warranty period which commences on the date of purchase of the product. To make a claim under the warranty, take the product (with proof of purchase from a Cigweld Accredited Seller) to the store where you purchased the product or contact Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider.

All costs associated with lodging the warranty claim including the return of goods to Cigweld or our Nominated Accredited Distributor / Accredited Service Provider are the responsibility of the consumer.

This warranty is given. Cigweld Pty Ltd A.B.N. 56007226815 71 Gower Street, Preston Victoria, Australia, 3072 Phone: 1300 654 674 Email: enquiries@cigweld.com.au Website: www.cigweld.com.au

This warranty is provided in addition to other rights and remedies you have under law: Our goods come with guarantees which cannot be excluded under the Australian Consumer Law. You are entitled to replacement or refund for a major failure and to compensation for other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Failures due to incorrect use are not covered by this warranty and consumers are reminded to only use the product in accordance with the Operating Instruction supplied with the product. Additional copies of Operating Instructions are available from Cigweld Customer Care 1300 654 674 or the Website.

CIGWELD Pty Ltd

ABN: 56 007 226 815

71 Gower Street

Preston VIC 3072 Australia

T: +61 3 9474 7400 F: +61 3 9474 7391

enquiries@cigweld.com.au

www.cigweld.com.au

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

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

100 Old Hongjing Rd Minhang District Shanghai, PR, 200052 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.victortechnologies.com

Victor Technologies International

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

Asia Paciﬁc Regional Headquarters

71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX: +61 3 9474 7391 Email: enquiries@cigweld.com.au

www.cigweld.com.au

Tweco VAF4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 1: GENERAL INFORMATION

1.01 Arc Welding Hazards

1.02 Principal Safety Standards

1.03 Symbol Chart

1.04 Declaration of Conformity

SECTION 2: INTRODUCTION

2.01 How to Use This Manual

2.03 Receipt of Equipment

2.04 Description

2.05 User Responsibility

2.06 Transportation Methods

2.07 Packaged Items

2.09 Optional Accessories

SECTION 3: INSTALLATION, OPERATION AND SETUP

3.01 Environment

3.02 Location

3.03 Ventilation

3.04 Mains Supply Voltage Requirements

3.05 Electromagnetic Compatibility

3.06 Front Panel Controls, Indicators and Features

3.07 Rear Panel Controls and Features

3.08 Advanced Features Mode

3.10 Attaching the MIG Torch (Euro)

3.11 Installing Handle Assembly

3.12 Installing Lifting Eye Kit (Optional)

3.13 Installing Tweco No. 4 Adaptor (Optional)

3.14 Installing Wire Spool Cover (optional)

3.15 Installing Welding Wire Spool

3.16 Wire Reel Brake

3.17 Inserting Wire into Feed Mechanism

3.18 Feed Roll Pressure Adjustment

3.19 Installing and Changing the Feed Roll / Removing Inlet Guide & Euro Adaptor

3.20 Shielding Gas Regulator Operating Instructions

3.21 Wire Feeder Set Up MIG (GMAW) Welding with Gas Shielded MIG Wire

3.22 Wire Feeder Set Up MIG (GMAW) Welding with Gasless MIG Wire

3.23 Prewelding Procedure

3.24 Arc Signal Override (SIL_1 #2)

3.25 Welding- 2T Operation

3.26 Spot Operation

3.27 Welding- 4T Operation

3.28 Stitch Operation

3.29 PTC Protection of Power Source Contactor Control Output

3.30 Ground Fault Operation

3.31 Electronic Motor Protection

SECTION 4: SERVICE

4.01 Cleaning The Unit

4.02 Cleaning The Feed Rolls

4.03 System Maintenance

4.04 Troubleshooting Guide

4.05 Error Codes and Remedies

4.06 MIG (GMAW/FCAW) Basic Welding Technique

4.07 MIG (GMAW/FCAW) Welding Troubleshooting

4.08 Troubleshooting

SECTION 5: PARTS LIST

5.02 How To Use This Parts List

5.03 Replacement Parts (without wirefeed plate)

5.04 Replacement Parts- Wirefeed Plate

APPENDIX 1: CONNECTION DIAGRAM

CIGWELD LIMITED WARRANTY

TERMS OF WARRANTY – APRIL 2012

WARRANTY SCHEDULE – APRIL 2012

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION