CIGWELD Transmig 165ST Service Manual
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CIGWELD Transmig 165ST Service Manual

Multi process welding inverter
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Transmig 165
Transmig 165
OUTPUT CURRENT
INPUT SUPPLY
INT. WIRE FEEDER
165A
DC
240V 15A
SPOOLS UP TO 200mm
Version No: AA | Issue Date: October 2015 | Manual No: 0-5442
ST
ST
SAFETY DEVICE
SERVICE MANUAL
MULTI PROCESS WELDING INVERTER

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  • Page 1 SERVICE MANUAL Transmig 165 Transmig 165 MULTI PROCESS WELDING INVERTER OUTPUT CURRENT INPUT SUPPLY INT. WIRE FEEDER SAFETY DEVICE 165A 240V 15A SPOOLS UP TO 200mm Version No: AA | Issue Date: October 2015 | Manual No: 0-5442...
  • Page 2 YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. CIGWELD is a Market Leading Brand of Arc Welding Products for ESAB. 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.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. Service Manual Number 0-5442 for: Cigweld Transmig 165ST Inverter Plant Part Number W1005165 Published by: CIGWELD Pty Ltd CIGWELD An ESAB Brand...

  • Page 4: Table Of Contents

    Volt-Ampere Curves ..................3-4 SECTION 4: OPERATION ................... 4-1 4.01 Overview ......................4-1 4.02 Transmig 165ST Power Source Controls, Indicators and Features ....4-1 SECTION 5: MIG (GMAW) WELDING ................5-1 5.01 Shielding Gas Regulator/Flowmeter Operating Instructions ......5-1 5.02 Attaching the Tweco Professional Fusion MIG Torch (Euro) ......
  • Page 5 Setup for Manual Arc (MMAW) Welding ............7-1 7.02 Stick (MMAW) Basic Welding Technique ............7-2 7.03 CIGWELD Electrode Selection Chart ............. 7-13 7.04 Stick (MMAW) Welding Troubleshooting ............7-15 SECTION 8: ROUTINE SERVICE REQUIREMENTS AND POWER SOURCE PROBLEMS ....8-1 8.01...
  • Page 6 Installing Main Control Panel and Clear Cover Sheet ........12-5 12.05 Installing Case ....................12-7 SECTION 13: KEY SPARE PARTS ..................13-1 13.01 Tweco Fusion 150 MIG Torch ................ 13-1 13.02 Power Source ....................13-2 CIGWELD - LIMITED WARRANTY TERMS WARRANTY SCHEDULE – TRANSMIG 165ST...

  • Page 7: Arc Welding Safety Instructions And Warnings

    Transmig 165 Transmig 165 SERVICE MANUAL SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS.
  • Page 8 Transmig 165 Transmig 165 SERVICE MANUAL 2. Wear approved safety glasses. Side shields recommended. 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the WARNING arc. ARC RAYS can burn eyes and skin; NOISE 4.
  • Page 9 Transmig 165 Transmig 165 SERVICE MANUAL 2. Do not weld where flying sparks can strike flammable material. 3. Remove all flammables within 35 ft (10.7 m) of the WARNING welding arc. If this is not possible, tightly cover FUMES AND GASES can be hazardous to them with approved covers.
  • Page 10 Transmig 165 Transmig 165 SERVICE MANUAL 3. Keep cylinders away from any welding or other NOTE electrical circuits. Considerations About Welding And The Effects of Low Frequency Electric and 4. Never allow a welding electrode to touch any Magnetic Fields cylinder.

  • Page 11: Principal Safety Standards

    Transmig 165 Transmig 165 SERVICE MANUAL 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.

  • Page 12: Declaration Of Conformity

    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.

  • Page 13: Servicing Hazards

    Transmig 165 Transmig 165 SERVICE MANUAL 1.04 Servicing Hazards • Use proper static-proof bags and boxes to store, move, or ship PC boards. WARNING WARNING The symbols shown below are used throughout this manual to call attention to FIRE OR EXPLOSION hazard. and identify possible hazards.
  • Page 14 Transmig 165 Transmig 165 SERVICE MANUAL WARNING FALLING UNIT can cause injury. • Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. • Use equipment of adequate capacity to lift and support unit. •...

  • Page 15: Emf Information

    Transmig 165 Transmig 165 SERVICE MANUAL 1.05 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.”...
  • Page 16 Transmig 165 Transmig 165 SERVICE MANUAL Notes GENERAL INFORMATION 1-10 Manual 0-5442...

  • Page 17: Introduction

    Use care to avoid damaging the Additional copies of this manual may be purchased by equipment when using bars, hammers, etc., to unpack contacting Cigweld at the address and phone number the unit. for your location listed in the inside back cover of this manual.

  • Page 18: Symbol Chart

    Transmig 165 Transmig 165 SERVICE MANUAL 2.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier...

  • Page 19: Description

    SERVICE MANUAL 2.07 Transporting Methods 2.05 Description This unit is equipped with a handle for carrying The Cigweld Transmig 165ST is a self contained purposes. single phase multi process welding inverter that is capable of performing GMAW/FCAW (MIG), MMAW (Stick) and GTAW (Lift TIG) welding processes. The...

  • Page 20: Duty Cycle

    (15% of 10 minutes is 1.5 minutes). During the other 8.5 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool. MIG (GMAW) & TIG (GTAW) Safe Opera ng Region S ck (MMA) Welding Current (amps) Art # A-12899 Figure 2-1: Transmig 165ST Duty Cycle INTRODUCTION Manual 0-5442...

  • Page 21: Specifications

    Transmig 165 Transmig 165 SERVICE MANUAL 2.10 Specifications Description Transmig 165ST Transmig 165ST Plant Part Number W1005165 Power Source Dimensions H410mm x W210mm x D450mm Power Source Mass 14.6kg Cooling Fan Cooled Welder Type Multi Process Inverter Power Source Australian Standard...

  • Page 22: Options And Accessories

    Minimum Generator Recommendation at the Maximum Output Duty Cycle. Due to large variations in performance and specifications of different brands and types of generators, CIGWELD cannot guarantee full welding output power or duty cycle on every brand or type of generator.

  • Page 23: Installation

    Transmig 165 Transmig 165 SERVICE MANUAL SECTION 3: INSTALLATION G. The enclosure design of this power source meets 3.01 Environment the requirements of IP23S as outlined in AS60529. This provides adequate protection against solid These units are designed for use in environments with objects (greater than 12mm), and direct protection increased hazard of electric shock as outlined in AS from vertical drops.

  • Page 24: Electromagnetic Compatibility

    Transmig 165 Transmig 165 SERVICE MANUAL 5. The health of people around, e.g. the use of 3.05 Electromagnetic Compatibility pacemakers and hearing aids. 6. Equipment used for calibration and measurement. WARNING 7. The time of day that welding or other activities Extra precautions for Electromagnetic are to be carried out.
  • Page 25 Transmig 165 Transmig 165 SERVICE MANUAL 3. Welding Cables The welding cables should be kept as short as possible and should be positioned close together, running at or close to the floor level. 4. Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However.

  • Page 26: Volt-Ampere Curves

    Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. 240VAC Input MIG Max Lift TIG Max Stick Max AMPS Art # A-13004 Figure 3-1: Transmig 165ST Volt-Ampere Curves INSTALLATION Manual 0-5442...

  • Page 27: Operation

    The operator should use the welding current range values as a guide, then finally adjust the current setting to suit the application. 4.02 Transmig 165ST Power Source Controls, Indicators and Features Art # A-12901 Art # A-12900...
  • Page 28 Transmig 165 Transmig 165 SERVICE MANUAL 1. Power Indicator The power indicator is illuminated when the correct mains power is applied to the power source and when the ON/OFF switch located on the rear panel is in the ON position. 2.
  • Page 29 Transmig 165 Transmig 165 SERVICE MANUAL 6. MIG Torch Polarity Lead The polarity lead is used to connect the MIG torch to the appropriate positive or negative output terminal (allowing polarity reversal for different welding applications). In general, the polarity lead should be connected in to the positive welding terminal (+) when using steel, stainless steel or aluminium electrode wire.
  • Page 30 Transmig 165 Transmig 165 SERVICE MANUAL 10. Trigger Mode Control (MIG Mode only) The trigger mode control is used to switch the functionality of the of the torch trigger between 2T (normal) and 4T (latch mode) 2T Normal Mode In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold the torch trigger to activate the power source (weld).
  • Page 31 SERVICE MANUAL 16. Fan on Demand The Transmig 165ST is fitted with a fan on demand feature. Fan on demand automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimise the amount of contaminants such as dust that are drawn into the power source.
  • Page 32 Transmig 165 Transmig 165 SERVICE MANUAL Notes OPERATION Manual 0-5442...

  • Page 33: Mig (Gmaw) Welding

    Transmig 165 Transmig 165 SERVICE MANUAL SECTION 5: MIG (GMAW) WELDING 5.01 Shielding Gas Regulator/Flowmeter Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Regulator/Flowmeter Safety This regulator/flowmeter is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.
  • Page 34 Transmig 165 Transmig 165 SERVICE MANUAL 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.
  • Page 35 Transmig 165 Transmig 165 SERVICE MANUAL Operation With the regulator/flowmeter connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows: 1. Stand to one side of regulator/flowmeter and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal regulator/flowmeter parts.

  • Page 36: Attaching The Tweco Professional Fusion Mig Torch (Euro)

    Transmig 165 Transmig 165 SERVICE MANUAL 5.02 Attaching the Tweco Professional Fusion 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 Adaptor MIG Torch Connector Art # A-12903...

  • Page 37: Installing Handispool (200Mm Diameter)

    Transmig 165 Transmig 165 SERVICE MANUAL 5.04 Installing Handispool (200mm diameter) As delivered from the factory, the unit is set for a Handispool (200mm diameter). In order to re-fit a 200mm spool assemble parts in the sequence shown below in Figure 5-5. Adjustment of the nut with nylon insert will control the Mig Wire Spool Brake.

  • Page 38: Inserting Wire Into The Wire Feed Mechanism

    Transmig 165 Transmig 165 SERVICE MANUAL 5.05 Inserting Wire into the Wire Feed Mechanism Release the tension from the pressure roller by turning the adjustable wire drive tension screw in an anti- clockwise direction. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm (Figure 5-6).

  • Page 39: Feed Roller Pressure Adjustment

    Transmig 165 Transmig 165 SERVICE MANUAL 5.06 Feed Roller Pressure Adjustment The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit liner should be checked for kinks and clogging by metal flakes and swarf.

  • Page 40: Wire Reel Brake

    Transmig 165 Transmig 165 SERVICE MANUAL 5.08 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking. If it is considered necessary, adjustment can be made by turning the large nut inside the open end of the hub clockwise to tighten the brake.
  • Page 41 Transmig 165 Transmig 165 SERVICE MANUAL I. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer. Welding current flows from the Power Source via Dinse terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. J.

  • Page 42: Setup For Mig (Gmaw) Welding With Gasless Mig Wire

    Transmig 165 Transmig 165 SERVICE MANUAL 5.10 Setup for MIG (GMAW) Welding with Gasless MIG Wire A. Fit the MIG Torch to the Power Source. (Refer to section 5.02 Attaching the Tweco Fusion MIG Torch). B. Connect the Mig Torch polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.

  • Page 43: Mig (Gmaw/Fcaw) Basic Welding Technique

    Transmig 165 Transmig 165 SERVICE MANUAL 240VAC, 15A Mains Supply Positive Welding Terminal (+) MIG Torch Negative Welding Terminal (-) MIG Gun Polarity Lead Art # A-12911 Work Lead Figure 5-12: Setup for Mig Welding with Gasless Mig Wire 5.11 MIG (GMAW/FCAW) Basic Welding Technique Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the very basic concepts in using the Mig mode of welding, where a welding gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert...
  • Page 44 Transmig 165 Transmig 165 SERVICE MANUAL Shielding Gas Nozzle (Optional) (Optional) Molten Metal Flux Cored Molten Electrode Slag Slag Solidified Base Metal Weld Metal FCAW Process Art # A-08992_AB Figure 5-14 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...
  • Page 45 Transmig 165 Transmig 165 SERVICE MANUAL 5° to 15° Longitudinal Angle 30° to 60° Transverse Angle Direction of Travel Art # A-08994 Figure 5-17 Horizontal Fillet Weld 10° to 20° Longitudinal Angle 10° Longitudinal Angle 30° to 60° 30° to 60° Transverse Transverse Angle...
  • Page 46 Transmig 165 Transmig 165 SERVICE MANUAL 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) •...
  • Page 47 Transmig 165 Transmig 165 SERVICE MANUAL Direction of Gun Travel 90° Leading or “Pushing” Trailing or “Pulling” Angle Angle (Forward Pointing) (Backward Pointing) Nozzle Angle, Right Handed Operator Art # A-08999_AC Figure 5-22 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.

  • Page 48: Cigweld Mig Wire Selection Chart

    Transmig 165 Transmig 165 SERVICE MANUAL 5.12 CIGWELD MIG Wire Selection Chart Table 5-1: Cigweld MIG Wire Selection Chart MIG (GMAW) WELDING 5-16 Manual 0-5442...

  • Page 49: Mig (Gmaw/Fcaw) Welding Troubleshooting

    Transmig 165 Transmig 165 SERVICE MANUAL 5.13 MIG (GMAW/FCAW) Welding Troubleshooting Solving Problems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG torch. There are two main areas where problems occur with GMAW, Porosity and Inconsistent wire feed Solving Problems Beyond the Welding Terminals - Porosity When there is a gas problem the result is usually porosity within the weld metal.
  • Page 50 Transmig 165 Transmig 165 SERVICE MANUAL Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1 Feed roller driven by motor in the Wire spool brake is too tight. cabinet slipped.
  • Page 51 B Low primary voltage B Contact supply authority. C Fault in power source C Have an Accredited CIGWELD Service Provider to test then replace the faulty component. 8 Arc does not have The MIG torch has been Connect the MIG torch to the positive (+) welding...

  • Page 52: Leak Testing The System

    Transmig 165 Transmig 165 SERVICE MANUAL 5.14 Leak Testing the System Leak test the system before putting into operation. 1. Be sure that there is a valve in the downstream equipment to turn off the gas flow. 2. With the cylinder valve open, adjust the regulator to deliver the maximum required delivery flow rate. 3.

  • Page 53: Tig (Gtaw) Welding

    Transmig 165 Transmig 165 SERVICE MANUAL SECTION 6: TIG (GTAW) WELDING 6.01 Shielding Gas Regulator/Flowmeter Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Regulator/Flowmeter Safety This regulator/flowmeter is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.
  • Page 54 Transmig 165 Transmig 165 SERVICE MANUAL 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.
  • Page 55 Transmig 165 Transmig 165 SERVICE MANUAL Operation With the regulator/flowmeter connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows: 1. Stand to one side of regulator/flowmeter and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal regulator/flowmeter parts.

  • Page 56: Setup For Tig (Gtaw) Welding

    Transmig 165 Transmig 165 SERVICE MANUAL 6.02 Setup for TIG (GTAW) Welding A. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the power source via Dinse terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
  • Page 57 Transmig 165 Transmig 165 SERVICE MANUAL 240VAC, 15A Mains Supply Refer to the WARNING on page 6-4 regarding securing the gas cylinder. Positive welding terminal (+) Connect to shielding gas regulator/flowmeter MIG Torch Negative welding polarity lead terminal (-) not connected Art # A-12912_AB Work lead TIG Torch...

  • Page 58: Tig (Gtaw) Basic Welding Technique

    Transmig 165 Transmig 165 SERVICE MANUAL 6.03 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non- consumable) electrode and the work piece.
  • Page 59 TIG Welding is generally regarded as a specialised process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Manual. For further information please refer to www.cigweld. com.au or contact Cigweld.

  • Page 60: Tig (Gtaw) Welding Problems

    Transmig 165 Transmig 165 SERVICE MANUAL 6.04 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive beard build up Welding current is too Increase weld current and/or faulty joint or poor penetration or poor preparation. fusion at edges of weld. 2 Weld bead too wide and Welding current is too Decrease weld current.
  • Page 61 9 Arc start is not smooth. A Tungsten electrode A Select the right size electrode. Refer to is too large for the Table 6-1 Cigweld Electrode Selection welding current. Chart. B The wrong electrode B Select the right electrode type. Refer to...

  • Page 62: Leak Testing The System

    Transmig 165 Transmig 165 SERVICE MANUAL 6.05 Leak Testing the System Leak test the system before putting into operation. 1. Be sure that there is a valve in the downstream equipment to turn off the gas flow. 2. With the cylinder valve open, adjust the regulator to deliver the maximum required delivery flow rate. 3.

  • Page 63: Manual Arc (Mmaw) Welding

    Transmig 165 Transmig 165 SERVICE MANUAL SECTION 7: MANUAL ARC (MMAW) WELDING 7.01 Setup for Manual Arc (MMAW) Welding A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via Dinse terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

  • Page 64: Stick (Mmaw) Basic Welding Technique

    Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited CIGWELD Distributor. Effects of Arc Welding Various Materials A.
  • Page 65 Transmig 165 Transmig 165 SERVICE MANUAL Art # A-07687 Figure 7-2: Flat Position, Down Hand Butt Weld Art # A-07688 Figure 7-3: Flat Position, Gravity Fillet Weld Art # A-07689 Figure 7-4: Horizontal Position, Butt Weld Art # A-07690 Figure 7-5: Horizontal-Vertical (HV) Position Art A-07691 Figure 7-6: Vertical Position, Butt Weld Art # A-07692...
  • Page 66 Transmig 165 Transmig 165 SERVICE MANUAL Art# A-07693 Figure 7-8: Overhead Position, Butt Weld Art # A-07694 Figure 7-9: Overhead Position, Fillet Weld Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.
  • Page 67 Transmig 165 Transmig 165 SERVICE MANUAL Arc Welding Technique - A Word to Beginners For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position.
  • Page 68 Transmig 165 Transmig 165 SERVICE MANUAL Arc Length The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will find that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs.
  • Page 69 Transmig 165 Transmig 165 SERVICE MANUAL Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run.
  • Page 70 Transmig 165 Transmig 165 SERVICE MANUAL C. Vertical Welds 1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm Ferrocraft 21 electrode and set the current at 100 amps. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet.
  • Page 71 Transmig 165 Transmig 165 SERVICE MANUAL 2. Vertical Down The Ferrocraft 21 electrode makes welding in this position particularly easy. Use a 3.2mm electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag.
  • Page 72 Transmig 165 Transmig 165 SERVICE MANUAL Distortion Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur.
  • Page 73 Transmig 165 Transmig 165 SERVICE MANUAL Overcoming Distortion Effects There are several methods of minimizing distortion effects. A. Peening This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of this the tensile stresses are reduced a little.
  • Page 74 Transmig 165 Transmig 165 SERVICE MANUAL Art # A-07709 Figure 7-24: Examples of Distortion Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool. Figure 7-25: Welding Sequence Art # A-07711_AB Figure 7-26: Step back Sequence Art # A-07712 Figure 7-27: Chain Intermittent Welding Art # A-07713_AB...

  • Page 75: Cigweld Electrode Selection Chart

    Satincrome Stainless Steel type for welding of matching Mo bearing 3.2mm 2.5 kg 611663 316L-17 grades, 316 and 316L. 2.5/3.2mm Blisterpack 322215 4.0mm 2.5 kg 611664 Cigweld Electrode Selection Chart continued over page Manual 0-5442 7-13 MANUAL ARC (MMAW) WELDING...
  • Page 76 It Blisterpack Blisterpack 322217 has better “wetting” action than Castcraft 55. 4.0mm 2.5 kg 611734 Table 7-1: Cigweld Electrode Selection Chart Further information on CIGWELD electrodes can be found at the website www.cigweld.com.au MANUAL ARC (MMAW) WELDING 7-14 Manual 0-5442...

  • Page 77: Stick (Mmaw) Welding Troubleshooting

    Transmig 165 Transmig 165 SERVICE MANUAL 7.04 Stick (MMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE control knob Reduce the ARC FORCE control knob until varying is set at a value that welding current is reasonably constant while causes the welding current prohibiting the electrode from sticking to the to vary excessively with...
  • Page 78 Transmig 165 Transmig 165 SERVICE MANUAL 5 Portions of the A Small electrodes used on A Use larger electrodes and preheat the plate. weld run do not heavy cold plate. fuse to the surface B Welding current is too low. B Increase welding current. of the metal or C Wrong electrode angle.

  • Page 79: Routine Service Requirements And Power Source Problems

    The inspection and testing of the power source and associated accessories shall be carried out in accordance with Section 5 of AS 1674.2 - 2007: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Cigweld's original specifications.
  • Page 80 2. The earth terminal of the associated plug of a transportable power source Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying Cigweld welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below - 1.
  • Page 81 Output current (A) to be checked to ensure it falls within applicable Cigweld power source specifications Output Voltage (V) to be checked to ensure it falls within applicable Cigweld power source specifications Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required Cigweld power source / wire feeder specifications...

  • Page 82: Cleaning The Welding Power Source

    Transmig 165 Transmig 165 SERVICE MANUAL 8.02 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.

  • Page 83: Theory Of Operation

    Transmig 165 Transmig 165 SERVICE MANUAL SECTION 9: THEORY OF OPERATION Inverter Design What does the word inverter mean? The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the incoming AC to DC, and then the transistors create a higher frequency AC. The higher frequency AC then goes on to a much smaller main transformer than in a conventional power supply.
  • Page 84 Transmig 165 Transmig 165 SERVICE MANUAL Notes THEORY OF OPERATION Manual 0-5442...

  • Page 85: Troubleshooting

    Transmig 165 Transmig 165 SERVICE MANUAL SECTION 10: TROUBLESHOOTING 10.01 Basic Troubleshooting-Power Source Faults The following table is a guide for analysing problems and making repairs to the Power Source. Fault Possible Cause Remedy There is no weld The main Power Switch is set to OFF Set main Power Switch to ON output and all front Line fuse is blown...

  • Page 86: Checking Unit Before Applying Power

    Transmig 165 Transmig 165 SERVICE MANUAL The following table is a guide for analysing problems and making repairs to the Power Source Fault Possible Cause Remedy Wirefeed motor operates Internal wiring fault Check solenoid wiring header when the torch trigger is plugged securely into switch is depressed but Control board.

  • Page 87: Tools Needed For Troubleshooting And Servicing

    Transmig 165 Transmig 165 SERVICE MANUAL 10.03 Tools Needed for Troubleshooting and Servicing Art # A-09849 10.04 Case Removal Read and follow safety information in Section 10.02 before proceeding. 1. Cover Remove Screws Loosen Screws Front & Rear Art # A-13005 a) Remove the two top screws from the front &...

  • Page 88: Clear Cover Sheet Removal

    Transmig 165 Transmig 165 SERVICE MANUAL 10.05 Clear Cover Sheet Removal Read and follow safety information in Section 10.02 before proceeding. 1. Clear protective sheet Take out clear protective sheet. Art # A-13006 10.06 Visually Inspect Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning or arcing of PCB, transformers, switches, or rectifier when a failure occurs.

  • Page 89: Preliminary Check Of The Main Inverter Board

    Transmig 165 Transmig 165 SERVICE MANUAL 10.08 Preliminary check of the main inverter board Read and follow safety information in Section 10.02 before proceeding. A-09988 Output Diode Testing Multimeter Lead Placement Diode Voltage Positive meter lead to testpoint 5 Left Output Diodes 0.2 –...
  • Page 90 Transmig 165 Transmig 165 SERVICE MANUAL IGBT Testing Multimeter Lead Placement Impedance IGBT 1 Positive meter lead to testpoint 17 150 to 350 Ω Negative meter lead to testpoint 9 Positive meter lead to testpoint 18 IGBT 2 150 to 350 Ω Negative meter lead to testpoint 11 Positive meter lead to testpoint 19 IGBT 3...

  • Page 91: Check Main On / Off Switch

    Transmig 165 Transmig 165 SERVICE MANUAL 10.09 Check main On / Off Switch Art # A-13007 Power Switch Testing Multimeter Lead Placement Impedance Switch ON Positive meter lead to testpoint 23 0 to 1 Ω Negative meter lead to testpoint 24 Switch ON Positive meter lead to testpoint 25 0 to 1 Ω...

  • Page 92: Dc Bus Voltage Measurement

    Transmig 165 Transmig 165 SERVICE MANUAL 10.11 DC Bus voltage measurement Apply voltage to the Power Source. There are extremely dangerous voltage and power levels present inside these Power Sources. Do not attempt to diagnose or repair unless you have had training in power electronics measure- ment and troubleshooting techniques.

  • Page 93: Pcb Connectors

    Transmig 165 Transmig 165 SERVICE MANUAL 10.12 PCB Connectors Inverter PCB QF/FJ NTCS CIN2 CIN1 OUT+ OUT- T19-1 T18-1 T17-1 T16-1 T15-1 T14-1 T13-1 T20-1 COUT1 COUT2 R103 R101 R102 R100 C101 C100 A-09990 IN Header Pin Pin function Signal +15V 15 VDC IGBT 1 pwm drive signal, 15V p-p square wave...
  • Page 94 Transmig 165 Transmig 165 SERVICE MANUAL DY2 Header Pin Pin function signal +24V 24 VDC 0 VDC -24V -24 VDC Table 10-15 DY2 Header pin function (connects to SOURCE header on control PCB) DY1 Header Pin Pin function signal +24V (solenoid positive) 24 VDC No connection +24V (solenoid positive)
  • Page 95 Transmig 165 Transmig 165 SERVICE MANUAL PWM Header Pin Pin function Signal 0VDC 0 VDC Motor pwm drive signal 5 VDC pk Table 10-20 PWM Header pin function (connects to PWM header on inverter PCB) QF/DY Header Pin Pin function Signal +24V (VRD positive, South Pacific Version Only) 24 VDC...
  • Page 96 Transmig 165 Transmig 165 SERVICE MANUAL IGBT OT Header Pin Pin function signal Igbt thermostat (0VDC when thermostat closed) 0 VDC Table 10-28 IGBT OT Header pin function (connects to igbt thermostat) NTCS Header Pin Pin function Signal +24V 24 VDC 0 VDC Table 10-29 NTCS Header pin function (connects to NTCS header on inverter PCB) MB Header Pin...
  • Page 97 Transmig 165 Transmig 165 SERVICE MANUAL Front Panel Control PCB Art # A-13008 Amps Inductance Volts / Downslope / Arcforce J1 Header Pin Pin function Signal Not Used Not Used Not Used 2T/4T pushbutton (0V when button pushed) 0VDC Not Used Stick mode (used for remote / local) Not Used MODE pushbutton (0V when button pushed)

  • Page 98: Dip Switch Settings, Control Pcb

    Function 165ST Calibration Mode Used for calibrating wirefeed speed, Amps / Volts meters. 165ST Operating Mode Transmig 165ST Normal Operating Mode. Not Design for 165ST DO NOT USE. This configuration is for an export model. Not Design for 165ST DO NOT USE. This configuration is for an export model.

  • Page 99: Calibration

    Transmig 165 Transmig 165 SERVICE MANUAL 10.14 Calibration Calibration Imax Imin Art # A-12984 Vmin Set SW0-1 to ON, SW0-1 to ON, SW0-3 to ON, SW0-4 to OFF to allow calibration of output volts & amps, and calibration of wire feed speed. Output Current Calibration Select STICK mode on the front panel.
  • Page 100 Transmig 165 Transmig 165 SERVICE MANUAL Wire Speed Calibration NOTE: these adjustments are on the wiring side of the main inverter module circuit board. W05 MAX SPEED W0 2 MIN SPEED U0 2 pin 6 E U0 1 pin 1 F U0 1 pin 2 G U0 1 pin 3 0V for wiredrive circuit (R017)
  • Page 101 Transmig 165 Transmig 165 SERVICE MANUAL Wire Speed Testpoint Waveforms Testpoint A waveform :The PWM wave from digital control PCB (5V/div) Testpoint B waveform :The PWM set point from 6P of U02 (5V/div) Testpoint C waveform :The drive PWM from SG3524 11P (5V/div) Testpoint D waveform :The MOSFET gate drive PWM (5V/div) Testpoint E &...

  • Page 102: Main Circuit Description

    Transmig 165 Transmig 165 SERVICE MANUAL 10.15 Main Circuit Description Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two minutes for capacitors to discharge after disconnection from mains supply voltage. TROUBLESHOOTING 10-18 Manual 0-5442...
  • Page 103 Transmig 165 Transmig 165 SERVICE MANUAL The mains supply voltage is connected via a double pole switch to the input rectifier Q1 through an EMC filter. Over- voltage protection is provided by varistor CY1. The rectifier output charges the main capacitor bank (C16, C17, C18, C19, C22 and C23) to high voltage. Inrush cur- rent limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds.

  • Page 104: Circuit Diagram

    Transmig 165 Transmig 165 SERVICE MANUAL 10.16 Circuit Diagram TROUBLESHOOTING 10-20 Manual 0-5442...

  • Page 105: Disassembly Procedure

    Transmig 165 Transmig 165 SERVICE MANUAL SECTION 11: DISASSEMBLY PROCEDURE 11.01 Safety Precautions for Disassembly Read and follow safety information in Section 10.02 before proceeding. Unplug unit before beginning Disassembly procedure. Manual 0-5442 11-1 DISASSEMBLY PROCEDURE...

  • Page 106: Control Board Removal

    Transmig 165 Transmig 165 SERVICE MANUAL 11.02 Control Board Removal Read and follow safety information in Section 10.02 before proceeding with disassembly Remove case (refer to 10.04) before remove control board. Refer to graphics on page 11-3. 1. M4 Screw. Remove 4 screws from Control panel. 2 Disconnect DRIVE harness from DRIVE connector.
  • Page 107 Transmig 165 Transmig 165 SERVICE MANUAL A-09963 WVIN QF/DY IGBT OT SOURCE NTCS FUNs DRIVE A-10018 Manual 0-5442 11-3 DISASSEMBLY PROCEDURE...

  • Page 108: Front Panel Assembly Removal

    Transmig 165 Transmig 165 SERVICE MANUAL 11.03 Front Panel Assembly Removal Read and follow safety information in Section 10.02 before proceeding with disassembly 1. Screws on front panel 2 Negative output terminal bolts. Unscrew Negative output terminal bolts. 3. Torch cable bolts. Unscrew torch cable terminal bolts. 4.

  • Page 109: Front Panel (Operator Interface) Circuit Board Pcb3 Removal

    Transmig 165 Transmig 165 SERVICE MANUAL 11.04 Front Panel (Operator Interface) Circuit Board PCB3 Removal Read and follow safety information in Section 10.02 before proceeding with disassembly 1. Remove Control Panel screw (4). 2. Front Panel PCB. Art # A-13014 Manual 0-5442 11-5 DISASSEMBLY PROCEDURE...

  • Page 110: Back Panel Removal

    Transmig 165 Transmig 165 SERVICE MANUAL 11.05 Back Panel Removal Read and follow safety information in Section 10.02 before proceeding with disassembly 1. ON/OFF switch. Ground wire screw. Disconnect Input cord ground wire from Main Power PCB1 using a 150mm adjustable wrench. 2.

  • Page 111: Power Switch S1 And Power Cord Removal

    Transmig 165 Transmig 165 SERVICE MANUAL 11.06 Power Switch S1 and Power Cord Removal Read and follow safety information in Section 10.02 before proceeding with disassembly 1. Gas hose is fixed to the gas inlet nipple using a metal gas line hose clamp (gas hose has been remove in picture).

  • Page 112: Base Panel Removal

    Transmig 165 Transmig 165 SERVICE MANUAL 11.07 Base Panel Removal Read and follow safety information in Section 10.02 before proceeding with disassembly 1. Remove Wire Feeder Screws. 2. Remove Main PCB assembly Screws. 3. Remove Central Panel Screws. A-10007 DISASSEMBLY PROCEDURE 11-8 Manual 0-5442...

  • Page 113: Assembly Procedures

    Transmig 165 Transmig 165 SERVICE MANUAL SECTION 12: ASSEMBLY PROCEDURES 12.01 Installing Base Board 1. Main Power PCB assembly 2. Install main PCB assembly screws 3. Install central Panel Screws. 4. Install wire feeder. A-10009 A-10008 Manual 0-5442 12-1 ASSEMBLY PROCEDURE...

  • Page 114: Installing Back Panel

    Transmig 165 Transmig 165 SERVICE MANUAL 12.02 Installing Back Panel 1. Install gas inlet nipple then fix the gas hose to the nipple using a gas hose line clamp. 2. Install ON/OFF switch 3. Install wire cord and 2 screws. 4.
  • Page 115 Transmig 165 Transmig 165 SERVICE MANUAL A-10011 A-10012 Manual 0-5442 12-3 ASSEMBLY PROCEDURE...

  • Page 116: Installing Front Panel

    Transmig 165 Transmig 165 SERVICE MANUAL 12.03 Installing Front Panel 1. Reinstall output terminals on front panel with 27mm wrench. 2. Place front panel PCB assembly into front panel and install screws. A-10013 Art # A-13010 3. Reconnect torch polarity cable to the torch connector. 4.

  • Page 117: Installing Main Control Panel And Clear Cover Sheet

    Transmig 165 Transmig 165 SERVICE MANUAL 12.04 Installing Main Control Panel and Clear Cover Sheet Refer to diagram on page 12-6. 1. Install 4 screws. 2 Plug harness into DRIVE connector. 3. Plug harness into SOURCE connector. 4. Plug harness into CR connector. 5.
  • Page 118 Transmig 165 Transmig 165 SERVICE MANUAL Art # A-13011 ASSEMBLY PROCEDURE 12-6 Manual 0-5442...

  • Page 119: Installing Case

    Transmig 165 Transmig 165 SERVICE MANUAL 12.05 Installing Case 1. Install Case. 2. Install Ground Screw, which connects the ground wire to the cover. 3. Install Screws. Tighten screws. Install Screws Tighten Screws Front & Rear Art # A-13012 A-09960 Manual 0-5442 12-7 ASSEMBLY PROCEDURE...
  • Page 120 Transmig 165 Transmig 165 SERVICE MANUAL Notes ASSEMBLY PROCEDURE 12-8 Manual 0-5442...

  • Page 121: Key Spare Parts

    Transmig 165 Transmig 165 SERVICE MANUAL SECTION 13: KEY SPARE PARTS 13.01 Tweco Fusion 150 MIG Torch MIG Torch Part No: OTWF112X3035, 3.6 metre A-09659_AB Figure 13-1 TWECO FUSION 150 MIG TORCH PARTS ITEM PART NO. DESCRIPTION OTW22/50 Nozzle 13mm OTW22/62 Nozzle 16mm OTW14/23...

  • Page 122: Power Source

    Transmig 165 Transmig 165 SERVICE MANUAL 13.02 Power Source Art # A-12914 Figure 13-2 TRANSMIG 165ST POWER SOURCE SPARE PARTS ITEM PART NUMBER DESCRIPTION W7004900 PCB Power W7004939 PCB Control W7004902 PCB EMC Filter W7004935 PCB Front Panel W7004905 Wiredrive Assembly...

  • Page 123: Cigweld - Limited Warranty Terms

    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 Ac- credited Seller) to the store where you purchased the product or contact Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider.
  • Page 124 * No employee, agent, or representative of CIGWELD is authorized to change this warranty in any way or grant any other warranty, and CIGWELD shall not be bound by any such attempt. Correction of non- conformities, in the manner and time provided herein, constitutes fulfilment of CIGWELD’s obligations to purchaser with respect to the product.
  • Page 125 Transmig 165 Transmig 165 SERVICE MANUAL This Page Intentionally Blank...
  • Page 126 CIGWELD Pty Ltd Malaysia Indonesia CIGWELD An ESAB Brand Lot 151, Jalan Industri 3/5A JL Akasia II Blok A-05 No. 10A 71 Gower Street, Preston VIC 3072 Australia Rawang Integrated Industrial Park, Delta Silicon - Lippo Cikarang Customer Care Jln Batu Arang...

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