CIGWELD Transmig 4RXT Operating Manual
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CIGWELD Transmig 4RXT Operating Manual

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OPERATING MANUAL
WIRE FEEDER
OUTPUT CURRENT
GMAW/FCAW
*
450A
60%
Version No: AA | Issue Date: 20-08-2020 | Manual No: 0-5591
*Refer to Specification Table for rating information.

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Summary of Contents for CIGWELD Transmig 4RXT

  • Page 1 OPERATING MANUAL WIRE FEEDER OUTPUT CURRENT GMAW/FCAW 450A Version No: AA | Issue Date: 20-08-2020 | Manual No: 0-5591 *Refer to Specification Table for rating information.
  • Page 2 +1300 654 674, or visit us on the web at www.thermadyne.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 Precau- tions.
  • Page 3 Manufacturer assumes no liability for its use. Operating Manual Number 0-5591 for: WIREFEEDER 4RXT           Part Number W3000420 Published by: CIGWELD Pty Ltd CIGWELD An ESAB Brand 71 Gower Street, Preston, Victoria, Australia, 3072 +61 3 9474 7400 +61 3 9474 7391 www.cigweld.com.au...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ........1-1 1.01 Arc Welding Hazards ..................1-1 1.02 Principal Safety Standards ................1-5 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 ..................
  • Page 6 TABLE OF CONTENTS APPENDIX 1: OPTIONS AND ACCESSORIES ............A-1 APPENDIX 2: 4RXT WIRING SCHEMATIC ............... A-2 CIGWELD - LIMITED WARRANTY TERMS WARRANTY SCHEDULE – TRANSMIG 4RXT...

  • Page 7: Arc Welding Safety Instructions And Warnings

    Transmig 220i OPERATING 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. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
  • Page 8 OPERATING MANUAL 2. Wear approved safety glasses. Side shields recommended. 3. Use protective screens or barriers to protect others WARNING from flash and glare; warn others not to watch the arc. ARC RAYS can burn eyes and skin; NOISE can damage hearing. 4.
  • Page 9 Transmig 220i OPERATING MANUAL 3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. WARNING 4. Be alert that welding sparks and hot materials from FUMES AND GASES can be hazardous to welding can easily go through small cracks and your health.
  • Page 10 OPERATING MANUAL 4. Never allow a welding electrode to touch any The following is a quotation from the General cylinder. Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power 5. Use only correct shielding gas cylinders, Frequency Electric &...

  • Page 11: Principal Safety Standards

    Transmig 220i OPERATING 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 OPERATING MANUAL This Page Intentionally Blank. GENERAL INFORMATION Manual 0-5591...

  • Page 13: Section 2: Introduction

    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 equip- ment identification numbers.

  • Page 14: Symbol Chart

    OPERATING 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 Torch Dangerous Voltage Transformer-Rectifier Purging Of Gas Increase/Decrease...

  • Page 15: Description

    OPERATING MANUAL 2.07 Transportation Methods 2.05 Description WARNING The Transmig 4RXT Wirefeeder is fully compliant to Standard IEC 60974.5.The Transmig 4RXT Wirefeeder ELECTRIC SHOCK can kill. DO NOT TOUCH live when used in conjunction with the Transmig 250i, Trans- electrical parts. Disconnect input power con-...

  • Page 16: Specifications

    10 Pin Optional Interconnection Cable Lengths 8 metre Table 2-1: Transmig 4RXT 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.

  • Page 17: Section 3: Installation Operation And Setup

    Transmig 220i OPERATING MANUAL SECTION 3: INSTALLATION OPERATION AND SETUP 3.01 Environment WARNING These units are designed for use in environments with This equipment should be electrically con- increased hazard of electric shock as outlined in IEC nected by a qualified electrician. 60974.5.
  • Page 18 OPERATING MANUAL B. Assessment of Area 2. Maintenance of Welding Equipment Before installing welding equipment, the user shall make The welding equipment should be routinely an assessment of potential electromagnetic problems maintained according to the manufacturer’s in the surrounding area. The following shall be taken recommendations.

  • Page 19: 4Rxt Wire Feeder Controls, Indicators And Features

    Transmig 220i OPERATING MANUAL 3.06 4RXT Wire Feeder Controls, 1. Left Knob: WFS (Wire Feed Speed) Control Amperage Control Indicators and Features The 4RXT Wirefeeder is designed to be used with the Transmig 350i, 450i, 550i. Select MIG Process and Left Knob Remote 10 pin indicator on the Transmig 350i, 450i, 550i Power Source to enable the controls on the 4RXT...
  • Page 20 OPERATING MANUAL 3. MIG Torch Adaptor (Euro Style) The MIG Torch adaptor is the connection point for the MIG welding Torch. Connect the MIG Torch by push- ing the MIG Torch connector into the brass MIG Torch adaptor firmly and screwing the plastic MIG Torch nut clockwise to secure in position.

  • Page 21: Transmig 250I Power Source Controls, Indicators And Features

    Transmig 220i OPERATING MANUAL 3.07 Transmig 250i Power Source Controls, Indicators and Features NOTE! See Transmig 250i Operator Manual for more information. Power Fault Process LIFT TIG STICK Trigger 2T Normal 4T Latch Amps Volts Advanced Left Knob Right Knob Features Arc Control Wirespeed...
  • Page 22 OPERATING MANUAL 6. Advanced Features Button CONTINUATION OF 250I POWER SOURCE CONTROLS Advanced Features 1. VRD Indicator Gas Purge. WARNING Advanced When the red VRD indicator is on and welding Features is being performed, the presence of dangerous voltage may be present at the electrode. 2.
  • Page 23 Transmig 220i OPERATING MANUAL 15. Negative Welding Output Terminal 10. Right Digital Display The negative welding terminal is used to connect the welding output of the power source to the ap- propriate welding accessory such as the MIG Torch MIG Mode (via the 4RXT polarity lead), or work lead.

  • Page 24: Transmig 350I, 450I, 550I Power Source Controls, Indicators And Features

    OPERATING MANUAL 3.08 Transmig 350i, 450i, 550i Power Source Controls, Indicators and Features A-10627 A-10628 INSTALLATION/ SETUP Manual 0-5591...
  • Page 25 Transmig 220i OPERATING MANUAL A-10629 Figure 3-1: Front Panel and Controls 1. Amperage Control (Wirespeed) The amperage control knob adjusts the amount of welding current delivered by the power source. In MMAW (stick) and GTAW (Lift TIG) modes, the amperage control knob directly adjusts the power inverter to deliver the desired level of output current.
  • Page 26 OPERATING MANUAL When MMAW (Stick) Mode is Selected NOTE! In this mode the multifunction control knob is The preview functionality provided on this used to adjust arc force. Arc force control provides power source is intended to act as a guide only. an adjustable amount of welding force (or “dig”) Some difference may be observed between control.
  • Page 27 Transmig 220i OPERATING MANUAL 6. Local / Remote Button NOTE! The REMOTE button is used to select REMOTE or When operating a 10 pin Wirefeeder in remote LOCAL mode of operation. mode, the maximum output is determined by the settings of the power source (in local The REMOTE button is used only when a remote mode).
  • Page 28 OPERATING MANUAL Both the green and red indicator lights only 9. Trigger Mode Control Button (MIG and LIFT TIG operate in MMAW (stick) mode. Mode only) (Only applicable to 10 pin mode) The green VRD ON light illuminates (red light is Note that this feature on the power source only off) when the VRD is active.
  • Page 29 Transmig 220i OPERATING MANUAL At the completion of welding, the amperage meter To LOAD a program. will hold the last recorded amperage value for a pe- 1. Press the NUMBER button. The display will riod of approximately 10 seconds in all modes. The change to indicate which program is being used.
  • Page 30 OPERATING MANUAL In MIG mode when setting the INDUCTANCE value, the light will illuminate, and the display will read A-10646 INDUCTANCE. The range of adjustment is from 0 to 100. In TIG mode when setting DOWNSLOPE the SEC light will illuminate, and the display will read DOWNSLOPE. The range of adjustment is from 0 to 10 seconds.
  • Page 31 Transmig 220i OPERATING MANUAL Program Number Description Amps Volts A-10635 A-10634 SPOT TIME, adjustable from 0.5 to 5.0 seconds BURN BACK TIME, adjustable from 0.01 to 2.00 seconds PRE FLOW TIME, adjustable from 0.01 to 9.99 seconds POST FLOW TIME, adjustable from 0.01 to 9.99 seconds MMAW (Stick) HOT START CURRENT, adjustable from 10 to 100A CREEP FEED SPEED, adjustable from 0.05 to 20 MPM Wirefeed speed units, change between IPM and MPM...

  • Page 32: Advanced Features Details

    OPERATING MANUAL 3.09 Advanced Features Details See Operating Manual for Transmig 250i for details. 3.10 Wire Feeder Set Up for MIG (GMAW) Welding with Gas Shielded MIG Wire Connection to Transmig 250i The Transmig 250i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Torch that can be used with the 4RXT Wire Feeder.
  • Page 33 Transmig 220i OPERATING MANUAL Connection to Transmig 350i,450i,550i The Transmig 350i, 450i and 550i are supplied with a Tweco air-cooled MIG Torch that can be used with the 4RXT Wire Feeder. The Tweco MIG Torch is designed with an ergonomic handle and fewer parts to cause performance problems.

  • Page 34: Wire Feeder Set Up For Mig (Fcaw) Welding With Gasless Mig Wire

    OPERATING MANUAL 3.11 Wire Feeder Set Up for MIG (FCAW) Welding with Gasless MIG Wire Connection to Transmig 250i The Transmig 250i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Torch that can be used with the 4RXT Wire Feeder.
  • Page 35 Transmig 220i OPERATING MANUAL Transmig 350i,450i,550i Rear View 4RXT Front View 4RXT Control Cable Art# A-14655 10 Pin Control Socket Work Lead Welding Power Cable from Wire Feeder Figure 3-9: Setup for 4RXT Wirefeeder with Gasless MIG Wire WARNING Before connecting the work clamp to the work make sure the mains power supply is switched off. CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.

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

    OPERATING MANUAL 3.12 Attaching the Tweco Professional MIG Torch (Euro) 1. Align the pins on the MIG Torch Cable with the pin holes of the MIG Torch receptacle on the front of the system. Press the MIG Torch in and secure by turning the locking ring to the right (clockwise). Refer to Figure 3-8.

  • Page 37: Installing A Handi Spool (200Mm Diameter)

    Transmig 220i OPERATING MANUAL 3.13 Installing a Handi Spool (200mm diameter) In order to fit a Handi Spool (200mm diameter) assemble parts in the sequence shown in Figure 3-11. Installation of wire spool. 1. Remove spool hub nut by unscrewing in an anticlockwise direction. 2.

  • Page 38: Installing A Standard Spool (300Mm Diameter)

    OPERATING MANUAL 3.14 Installing a Standard Spool (300mm diameter) As delivered from the factory, the unit is set for a 15 kg or 300mm spool. Installation of wire spool. Refer to Figure 3-10. 1. Remove spool hub nut by unscrewing in an anticlockwise direction. 2.

  • Page 39: Inserting Wire Into The Feed Mechanism

    Transmig 220i OPERATING MANUAL 3.15 Inserting Wire into the 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.

  • Page 40: Feed Roller Pressure Adjustment

    OPERATING MANUAL 3.16 Feed Roller Pressure Adjustment 1.2mm (.045”) Stamping NOTE! .045 .045 Before attempting to set the drive roller pressure you must select GMAW mode on the power supply. The roller on the swing arms apply pressure to the grooved roller via an adjustable tension devise.

  • Page 41: Wire Reel Brake

    If it is considered necessary, adjustment can be made by turning the large nut inside the open end of the hub Shielding Gas Regulator not included in the clockwise to tighten the brake. Transmig 4RXT. Pressure NOTE! Adjustment Shielding Gas is not required if the unit is used...
  • Page 42 OPERATING MANUAL User Responsibilities This equipment will perform safely and reliable only when installed, operated, maintained, and repaired in accor- dance 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 43 Transmig 220i OPERATING MANUAL Ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright position. Art # A-14688 Figure 3-20: Attach gas line to proper inlet 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.
  • Page 44 OPERATING MANUAL 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.

  • Page 45: Section 4: Basic Welding Guide

    Transmig 220i OPERATING MANUAL SECTION 4: BASIC WELDING Shielding Gas Nozzle (Optional) (Optional) GUIDE Molten Metal Flux Cored Molten Electrode Slag Slag 4.01 MIG (GMAW/FCAW) Basic Welding Technique Solidified Base Metal Weld Metal Two different welding processes are covered in this section (GMAW and FCAW), with the intention of pro- FCAW Process Art # A-08992_AB...
  • Page 46 OPERATING MANUAL Travel Speed 5° to 15° The speed at which the molten pool travels influences Longitudinal Angle the width of the weld and penetration of the welding run. MIG Welding (GMAW) Variables Direction of 90° Travel Most of the welding done by all processes is on carbon Transverse steel.
  • Page 47 Transmig 220i OPERATING MANUAL 3. Nozzle Angle. This refers to the position of the For practicing MIG welding, secure some pieces of MIG Torch in relation to the joint. The transverse 1.5mm or 2.0mm mild steel plate 150 x 150mm. Use angle is usually one half the included angle be- 0.8mm flux cored gasless wire or a solid wire with tween plates forming the joint.

  • Page 48: Mig (Gmaw/Fcaw) Welding Troubleshooting

    OPERATING MANUAL 4.02 MIG (GMAW/FCAW) Welding Troubleshooting Solving Problems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG Torch. There are two main areas where problems occur with GMAW; Porosity and Inconsistent wire feed. Problem 1 - Porosity When there is a gas problem the result is usually porosity within the weld metal.
  • Page 49 Transmig 220i OPERATING MANUAL 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 Wire spool brake is too tight.
  • Page 50 A Loose welding cable connection. A Check all welding cable connections. B Low primary voltage B Contact supply authority. C Fault in power source C Have an Accredited CIGWELD Service Provider test then replace the faulty component. 8 Arc does not have a crisp The Wirefeeder has been...

  • Page 51: Section 5: Routine Service Requirements

    Replace all exterior broken parts of wirefeeder 6 Months Bring the unit to an authorized CIGWELD Service Provider to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions.

  • Page 52: Cleaning The Feed Rolls

    OPERATING MANUAL 5.02 Cleaning the Feed Rolls Clean the grooves in the drive rolls frequently. This can be done by using a small wire brush. Also wipe off, or clean the grooves on the upper feed roll. After cleaning, tighten the feed roll retaining knobs. CAUTION Do not use compressed air to clean the Welding Power Source.

  • Page 53: Section 6: Key Spare Parts

    Transmig 220i OPERATING MANUAL SECTION 6: KEY SPARE PARTS 6.01 4RXT Wire Feeder Replacement Parts Art # A-14658 Figure 6-1 TRANSMIG 4RXT SPARE PARTS (LEFT SIDE) ITEM PART NUMBER DESCRIPTION W7006950 Spool Hub Assembly 4RXT W7005429 Wire Drive Assembly, (include motor and feed rolls)
  • Page 54 OPERATING MANUAL This Page Intentionally Blank. REPLACEMENT PARTS Manual 0-5591...
  • Page 55 Transmig 220i OPERATING MANUAL APPENDIX 1: OPTIONS AND ACCESSORIES Description Part Number Supra XT torch, 4.0 metre Euro SE400X4M16 Tweco 4, 400A MIG torch, 3.6 metre Euro OTWX412/3545 Table A-1: Options and Accessories Wire Size Wire Type Part Number 0.6mm/0.8mm HARD 7977729 0.9mm/1.2mm...
  • Page 56 OPERATING MANUAL APPENDIX 2: 4RXT WIRING SCHEMATIC Art # A-10509 Figure A-1:4RXT Wiring Schematic APPENDIX Manual 0-5591...
  • Page 57 654 674 for advice on your nearest Service Provider. CIGWELD reserves the right to request documented evidence of date of purchase. CIGWELD or our Accredited Distributor must be notified 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 This warranty is given.
  • Page 58 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.
  • Page 59 Transmig 220i OPERATING MANUAL This Page Intentionally Blank.
  • Page 60 CIGWELD Pty Ltd Singapore Malaysia Indonesia CIGWELD An ESAB Brand ESAB Asia Pacific No. 14 Jalan Teknologi 3/1 JI. Pulogadung No. 45 71 Gower Street, Preston VIC 3072 Australia 38 Joo Koon Circle Selangor Science Park 1 Kawasan Industri Pulogadung...

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