CIGWELD Transmig 355i Operating Manual
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CIGWELD Transmig 355i Operating Manual

Multi process welding inverter
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MULTI PROCESS
AUTO PROCESS
OUTPUT CURRENT
.
AUTO
*
355A
3 1
IN
SET
DC
O
m
MIG STICK TIG
MIG
Version No: AB | Issue Date: 04-02-2021 | Manual No: 0-5586
*Refer to Specification Table for rating information.
COMPATIBLE WITH
INPUT SUPPLY
SAFETY DEVICE
SPOOL & PUSHPULL
415V 3 ph
GUN (OPTIONAL)
OPERATING MANUAL
MULTI PROCESS WELDING INVERTER
4 ROLL WIRE DRIVE
SPOOLS UP TO 300mm

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Summary of Contents for CIGWELD Transmig 355i

  • Page 1 OPERATING MANUAL MULTI PROCESS WELDING INVERTER MULTI PROCESS AUTO PROCESS COMPATIBLE WITH 4 ROLL WIRE DRIVE OUTPUT CURRENT INPUT SUPPLY SAFETY DEVICE AUTO 355A SPOOL & PUSHPULL MIG STICK TIG SPOOLS UP TO 300mm 415V 3 ph GUN (OPTIONAL) Version No: AB | Issue Date: 04-02-2021 | Manual No: 0-5586 *Refer to Specification Table for rating information.
  • Page 2 OPERATING MANUAL REGISTER YOUR WARRANTY ONLINE FOR YOUR CHANCE TO GREAT PRIZES http://warranties.cigweld.com.au Check out our online registration for the most up to date competitions and promotions PROTECT YOUR INVESTMENT Please register your warranty online immediately after purchase for complete warranty coverage and to guarantee your proof of purchase.
  • Page 3 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 4 While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. Operating Manual Number 0-5586 for: Transmig 355i Compact Plant Part Number: W1003511 Transmig 355i Remote Plant Part Number: W1003510...
  • Page 5 Name, address, and telephone No: Cigweld Pty Ltd 71 Gower Street Preston, Victoria, Australia, 3072 Phone: +61 3 9474 7400; www.cigweld.com.au The following has been used in the design: AS 1674.2:2007 Safety in welding and allied processes, Part 2: Electrical AS 60974.1:2020...

  • Page 6: Table Of Contents

    Electromagnetic Compatibility ................ 3-2 SECTION 4: OPERATION ................... 4-1 4.01 Overview ......................4-1 4.02 Transmig 355i Power Source Controls, Indicators and Features ..... 4-1 4.03 Advanced Features Details ................4-9 SECTION 5: MIG (GMAW) WELDING ................5-1 5.01 Shielding Gas Regulator/Flowmeter Operating Instructions ......5-1 5.02...
  • Page 7 Power Source Problems ................. 8-4 SECTION 9: KEY SPARE PARTS ................... 9-1 9.01 Tweco Fusion 400 Mig Torch ................9-1 9.02 Power Source ....................9-2 APPENDIX: TRANSMIG 355i CIRCUIT DIAGRAM ............A-1 CIGWELD – LIMITED WARRANTY TERMS WARRANTY SCHEDULE – TRANSMIG 355i...
  • Page 8 This Page Intentionally Blank.

  • Page 9: 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 10 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 11 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 12 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 13: Principal Safety Standards

    Transmig 220i OPERATING MANUAL 1.02 Principal Safety Standards 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.
  • Page 14 OPERATING MANUAL This Page Intentionally Blank. GENERAL INFORMATION Manual 0-5586...

  • Page 15: 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 equipment identification numbers.

  • Page 16: Symbol Chart

    OPERATING MANUAL 2.04 Symbol Chart Note that only some of these symbols will appear on your model. Single Phase Wire Feed Function Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier Purging Of Gas Increase/Decrease...

  • Page 17: Description

    ELECTRIC SHOCK can kill. DO NOT TOUCH live elec- results across MIG, STICK and TIG. trical parts. Disconnect input power conductors The Transmig 355i is loaded with advanced features from de-energized supply line before moving the to get the best out of your welding performance while welding power source.

  • Page 18: Duty Cycle

    (60% of 10 minutes is 6 minutes). During the other 4 minutes of the 10 minute period the Welding Power Source must idle and allowed to cool. The thermal cut out will operate if the duty cycle is exceeded. Figure 2-1: Transmig 355i Duty Cycle INTRODUCTION...

  • Page 19: Specifications

    275A @ 100%, 27.8V STICK (MMAW) Welding 355A @ 60%, 34.2V Output, 40ºC, 10 min. 275A @ 100%, 31V TIG (GTAW) Welding Output, 355A @ 60%, 24.2V 40ºC, 10 min. 275A @ 100%, 21V Table 2-1: Transmig 355i Specification Manual 0-5586 INTRODUCTION...
  • Page 20 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 21: Optional Accessories

    CIGWELD TBi Push-Pull Gun, 12m 185P001002 CIGWELD TBi Push-Pull Gun Neck, 40 degree 590P958000 CIGWELD TBi Synchroniser Box W4011360 CIGWELD TBi Push-Pull Gun 8m and Sync Box 646779 Twistlock Electrode Holder Lead, 400A, 5m W4013801 TIG Torch 17V with 4m lead (200A@20%) W4013800...
  • Page 22 BG57Y04/R Back Cap – Short for 17, 26 & 18 TIG Torches (pkt of 2) Table 2-3 TIG Tungsten Electrodes Cigweld Tungsten Electrodes suitable for AC & DC TIG Welding Part Number Description 699859 3T Rare Earth Tungsten Electrode 1.6mm x 175mm AC/DC Purple Band (Pkt of 2) 699860 3T Rare Earth Tungsten Electrode 2.4mm x 175mm AC/DC Purple Band (Pkt of 2)
  • Page 23 WeldSkill Welding Curtain – Dark Green, 1.74m x 1.74m 646777 WeldSkill Welding Curtain – Red, 1.74m x 1.74m 646776 Welding Curtain Frame, 1.8m x 1.8m 646778 Welding Blanket, 1.8m x 1.8m Note: CIGWELD Electrodes see Page 7-13. Table 2-5 Manual 0-5586 INTRODUCTION...
  • Page 24 OPERATING MANUAL This Page Intentionally Blank INTRODUCTION 2-10 Manual 0-5586...

  • Page 25: Installation

    Transmig 220i OPERATING MANUAL SECTION 3: INSTALLATION This provides adequate protection against solid 3.01 Environment objects (greater than 12mm), and direct protection These units are designed for use in environments with from vertical drops. Under no circumstances increased hazard of electric shock as outlined in AS should the unit be operated or connected in a 60974.1 and AS 1674.2.

  • Page 26: Electromagnetic Compatibility

    OPERATING MANUAL 6. Equipment used for calibration and 3.05 Electromagnetic Compatibility measurement. WARNING 7. The time of day that welding or other activities Extra precautions for Electromagnetic Compat- are to be carried out. ibility may be required when this Welding Power 8.
  • Page 27 Transmig 220i OPERATING 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 28 OPERATING MANUAL This Page Intentionally Blank INSTALLATION Manual 0-5586...

  • Page 29: 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 355i Power Source Controls, Indicators and Features INPUT 415V AC...
  • Page 30 OPERATING 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. VRD Indicator ON/OFF Lights A VRD (voltage reduction device) is a hazard reducing device designed to reduce electric shock hazards present on the output of welding power source when operating in MMAW (stick) mode.
  • Page 31 Transmig 220i OPERATING MANUAL 5. Digital Voltage Meter (Right Digital Display) MIG Mode This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding voltage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Voltage.
  • Page 32 OPERATING MANUAL In Manual MIG Mode, the setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications. NOTE! In Auto MIG mode adjusting the Wire Feed Speed Control may also Synergically adjust the voltage value. In Auto MIG mode pressing the Volts Control Knob will select Heat Control function which by turning the Voltage Control knob clockwise increases the voltage by 0.1V increments and the maximum value is +5V.
  • Page 33 Transmig 220i OPERATING MANUAL 12. Process Selection Control - Auto MIG,Manual MIG,STICK &LIFT TIG The process selection control is used to select the desired welding mode. Four modes are available, AUTO MIG, MANUAL MIG (GMAW / FCAW (MIG)), GTAW (Lift TIG) and MMAW (Stick) modes. Refer to sections 5.13-5.17 for FCAW/GMAW (MIG) set up details, Section 6.02 for GTAW (TIG) set-up details or Section 7.01 for MMAW (stick) set-up details.
  • Page 34 OPERATING MANUAL 18. Negative Welding Output Terminal The negative welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the MIG torch (via the MIG torch polarity lead), TIG torch or work lead.
  • Page 35 Transmig 220i OPERATING MANUAL NOTE! When using a TIG Torch with Remote Current Control via the 8 pin socket that in order to achieve full TIG current range via the torch remote control the wirefeeder 10 pin control plug must be removed from the 10 pin socket of the power source. NOTE! When using the spool gun in the 355i, the INTERNAL SWITCH in wirefeed compartment should be set to <1>...
  • Page 36 25. Cooling Fan The Transmig 355i is fitted with a fan as needed feature. Fan as needed automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimise the amount of contaminants such as dust that are drawn into the power source.

  • Page 37: Advanced Features Details

    Transmig 220i OPERATING MANUAL 4.03 Advanced Features Details NOTE! The "R/L" settings will revert to the factory default setting each time the weld process is changed. A setting other than the default will only be remembered while in that process. If the Power Source is in Advanced Features mode and the Weld Process (Control No.
  • Page 38 OPERATING MANUAL Right Display (Factory Function Left Display Limits Comments Default Values) Lower arc control settings make the arc softer with less weld spatter. Higher arc control Inductance 01-10 settings give a stronger stiffer arc which can increase weld penetration. The time difference between turning the wire Burn Back 0.05 S...
  • Page 39 Transmig 220i OPERATING MANUAL This parameter operates in Crater Filler ON only and is used to set the time for the weld current to ramp down, after the torch trigger switch has Down Slope 0.1-4S been pressed, to crater current. This control is used to eliminate the crater that can form at the completion of a weld.
  • Page 40 OPERATING MANUAL LIFT TIG Mode Advanced Features Menu Map Left Knob Right Knob Press Advanced Menu - LIFT Advanced Menu - TIG Options or Range LIFT TIG Mode 0-5 S Press Advanced Button Press Advanced Button Press to Exit to Welding Mode to Exit to Welding Mode Left Knob Selection Right Knob Selection...
  • Page 41 Transmig 220i OPERATING MANUAL STICK Mode Advanced Features Left Knob Right Knob Press Advanced Menu - LIFT Advanced Menu - TIG Options or Range LIFT TIG Mode 10-100 A 0-100 % Press Advanced Button Press Advanced Button Press to Exit to Welding Mode to Exit to Welding Mode Left Knob Selection Right Knob Selection...
  • Page 42 OPERATING MANUAL Restore Factory Default Settings The Transmig 355i can have Factory Default Settings restored. This function is accessed by pressing the Advanced FEATURE and MEMORY buttons at the same time for three seconds (3s). The VOLTS and AMPS LEDs will flash 3 times displaying “SYS RST” to indicate a Factory Reset has been completed.

  • Page 43: Mig (Gmaw) Welding

    Transmig 220i OPERATING 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 44 OPERATING 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 45 Transmig 220i OPERATING 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 46: Optional Wire Feeder Controls, Indicators And Features

    5.02 Optional Wire Feeder Controls, Indicators and Features The optional 4RX Wirefeeder is designed to be used with the Transmig 355i. Select MIG Process and REMOTE 10P in Advanced Features to enable the controls on this wirefeeder. Set Internal Switch to <1>Local / 4RX / Spool Gun position.

  • Page 47: Optional Wire Feeder Setup Mig (Gmaw) Welding With Gas Shielded Mig Wire

    Check with wire manufacturer for recommended polarity. NOTE! The Transmig 355i Remote Plant Part No W1003510 comes supplied with an 8m Interconnection Lead. There are three option length Interconnection Leads available for the 4RX Wirefeeder refer to Optional Accessories Table 2-2 on Page 2-7.

  • Page 48: Optional Wire Feeder Setup Mig (Fcaw) Welding With Gasless Mig Wire

    355i. Check with wire manufacturer for recommended polarity. NOTE! The Transmig 355i Remote Plant Part No. W1003510 comes supplied with an 8m Interconnection Lead. There are three option length Interconnection Leads available for the 4RX Wirefeeder, refer to Optional Accessories Table 2-2 on Page 2-7.

  • Page 49: Assembly And Fitting Of Optional Welding Trolley

    Transmig 220i OPERATING MANUAL 5.05 Assembly and Fitting of Optional Welding Trolley Assemble the Welding Trolley according to Figure 5-5. Read all steps before beginning and ensure all hardware is tightened properly. 1. Refer to the Trolley Assembly Instructions included with the Trolley Kit. Art # A-14705 Figure 5-6: Welding Trolley Assembly 2.
  • Page 50 OPERATING MANUAL Warning: If Cylinder is fitted to the Trolley it must be fitted in the correct position and secured firmly in the upright position using the Chain provided to prevent it from falling or tipping. Art # A-14706 Figure 5-7: Welding Trolley and Welding Equipment MIG (GMAW) WELDING Manual 0-5586...

  • Page 51: Attaching The Tweco Professional Fusion Mig Torch (Euro)

    Transmig 220i OPERATING MANUAL 5.06 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. 3P 41 5 V Art # A-14707 Figure 5-8: Attaching MIG Torch...

  • Page 52: Installing Handispool (200Mm Diameter)

    OPERATING MANUAL 5.08 Installing Handispool (200mm diameter) Remove the locking pin from the spool hub. Install the Handi Spool over the spool hub, locating the hole in the Handi Spool, with the alignment pin on the Spool Hub. Insert the locking pin back into the spool hub, in the “rear” position, as shown, ensuring the wire spool is firmly secured in position.

  • Page 53: Inserting Wire Into The Wire Feed Mechanism

    Transmig 220i OPERATING MANUAL 5.09 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 5-11).

  • Page 54: Feed Roller Pressure Adjustment

    OPERATING MANUAL 5.10 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 55: Wire Reel Brake

    Transmig 220i OPERATING MANUAL 5.12 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking. If it is considered necessary, adjustment can be made by turning the Thumb Screw inside the open end of the hub clockwise to tighten the brake.

  • Page 56: Setup For Auto Set (Synergic) Mig (Gmaw) Welding With Gas Shielded Mig Wire

    5.01) then connect the shielding gas hose from the shielding gas regulator / flowmeter outlet to the quick connect Shielding Gas Inlet fitting gas on the rear of the Transmig 355i Power Source. Ensure that the shielding gas hose connection is sufficiently tight at the regulator connection and the quick connect fitting "locks"...
  • Page 57 Transmig 220i OPERATING MANUAL L. Select Plate (Material) Thickness. I. Select MIG Auto Set mode. Figure 5-20: Select Plate (Material) Thickness Figure 5-17: Select MIG Auto Set Mode Press left knob to switch between the wirefeed speed and plate thicknesss, and then the left J.

  • Page 58: Setup For Manual Mig (Gmaw) Welding With Gas Shielded Mig Wire

    OPERATING MANUAL Press the Voltage Control Knob, and the Heat Control value or pre-set volts will be displayed in the right display in turn. Note: when switching from pre-set volts to Heat Control value display, the Heat Control value will remain for 5s and then return to pre-set volts if there is no more adjustment;...
  • Page 59 Transmig 220i OPERATING MANUAL 3P 41 5 V Shielding Gas Hose Shielding Gas Hose Art # A-1 Shielding Gas Hose Fitted Negative Welding with Quick Connect Terminal (-) MIG Torch MIG Torch Polarity Lead Positive Welding Art # A-14714 Terminal (+) Work Lead Figure 5-23: Setup for Manual MIG (GMAW) Welding with Gas Shielded MIG Wire Manual 0-5586...

  • Page 60: Setup For Manual Mig (Fcaw) Welding With Gasless Mig Wire

    OPERATING MANUAL 5.15 Setup for Manual MIG (FCAW) Welding with Gasless MIG Wire A. Fit the MIG Torch to the Power Source. (Refer to Section 5.06 the Tweco Professional Fusion MIG Torch). B. Connect the Mig Torch polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.
  • Page 61 Transmig 220i OPERATING MANUAL 3P 415 V MIG Torch Negative Welding Positive Welding Terminal (-) Terminal (+) MIG Polarity Lead Work Lead Art # A-14715 Figure 5-24: Setup for MIG (GMAW) Welding with Gasless Mig Wire Manual 0-5586 5-19 MIG (GMAW) WELDING...

  • Page 62: Setup For Spool Gun Mig (Gmaw) Welding With Gas Shielded Mig Wire

    Shielding Gas Inlet fitting gas on the rear of the Transmig 355i Power Source. Ensure that the shielding gas hose connection is sufficiently tight at the regulator connection and the quick connect fitting "locks"...
  • Page 63 Transmig 220i OPERATING MANUAL 3P 415 V Shielding Gas Hose Fitted with Quick Connect Positive Welding Remote Control Terminal (+) Socket Spool Gun Negative Welding Terminal (-) Art # A-14716 MIG polarity lead Work Lead Figure 5-25: Setup for Spool Gun Welding with Gas Shielded Mig Wire Manual 0-5586 5-21 MIG (GMAW) WELDING...

  • Page 64: Setup For Push Pull Gun Mig (Gmaw) Welding With Gas Shielded Mig Wire

    Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source. CAUTION Please keep control leads of Push-Pull Gun and Synchroniser Box away from hot torch end or door panel of Transmig 355i and Transmig 4RX remote wirefeeder.
  • Page 65 Transmig 220i OPERATING MANUAL 3 P 41 5V Shielding Gas Hose Fitted with Quick Connect Positive Welding Remote Control Terminal (+) Socket Push/pull Gun Negative Welding Terminal (-) Art # A-14723 MIG polarity lead Work Lead Synchroniser Box Figure 5-26: Setup for PUSH PULL GUN MIG (GMAW) Welding with Gas Shielded Mig Wire Manual 0-5586 5-23 MIG (GMAW) WELDING...

  • Page 66: Mig (Gmaw/Fcaw) Basic Welding Technique

    OPERATING MANUAL 5.18 MIG (GMAW/FCAW) Basic Welding Technique Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the very basic concepts in using the Mig mode of welding, where a welding gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
  • Page 67 Transmig 220i OPERATING MANUAL 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 5-29 The welding gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below) Hold the gun so that the welding seam is viewed at all times.
  • Page 68 OPERATING MANUAL Direction of Travel 30° to 60° Transverse Angle 5° to 15° Longitudinal Angle Art # A-08996 Overhead Weld Figure 5-33 Distance from the MIG Torch Nozzle to the Work Piece The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20.0mm. This distance may vary depending on the type of joint that is being welded.
  • Page 69 Transmig 220i OPERATING MANUAL 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.
  • Page 70 OPERATING MANUAL 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.

  • Page 71: Cigweld Mig Wire Selection Chart

    1.6mm 15kg 720913 producing a low hydrogen level of H4. (PLW) NOTE: HANDISPOOL = 200MM DIAMETER, SPOOL = 300MM DIAMETER Table 5-1: Cigweld MIG Wire Selection Chart Manual 0-5586 5-29 MIG (GMAW) WELDING...

  • Page 72: Mig (Gmaw/Fcaw) Welding Troubleshooting

    OPERATING MANUAL 5.20 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 73 Transmig 220i OPERATING 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 74 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 75: Tig (Gtaw) Welding

    Transmig 220i OPERATING MANUAL SECTION 6: TIG (GTAW) WELDING 6.01 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.
  • Page 76 OPERATING 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 77 Transmig 220i OPERATING MANUAL 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.

  • Page 78: Setup For Tig (Gtaw) Welding

    OPERATING 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 79 Transmig 220i OPERATING MANUAL 3P 41 5V Remote Positive Welding Control Terminal (+) Work Lead Connect to shielding gas regulator/flowmeter Negative Welding Terminal (-) Note: This 8 pin connection plug is for Art # A-14717 TIG torch trigger connection and remote TIG torch current TIG Torch control if applicable.

  • Page 80: Tig (Gtaw) Basic Welding Technique

    OPERATING 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 81 DC TIG welding Electrodes. Non Radioactive to improve health and safety for operator and environment. Table 6-3 NOTE! The Transmig 355i Inverter is not suited for AC Tig welding. TIG Welding Filler Rods Comweld Aust Std AWS Std Part No.

  • Page 82: Tig (Gtaw) Welding Problems

    OPERATING MANUAL 6.04 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive bead build up or Welding current is too Increase weld current and/or faulty joint poor penetration or poor preparation. fusion at edges of weld. 2 Weld bead too wide and Welding current is too Decrease weld current.
  • Page 83 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 84 OPERATING MANUAL This Page Intentionally Blank TIG (GTAW) WELDING 6-10 Manual 0-5586...

  • Page 85: Manual Arc (Mmaw) Welding

    Transmig 220i OPERATING MANUAL SECTION 7: MANUAL ARC (MMAW) WELDING 7.01 Setup for STICK (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 type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

  • Page 86: 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 87 Transmig 220i OPERATING 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 88 OPERATING 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 89 Transmig 220i OPERATING 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 90 OPERATING 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 91 Transmig 220i OPERATING 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 92 OPERATING 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 93 Transmig 220i OPERATING 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 94 OPERATING 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 95 Transmig 220i OPERATING 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. The effect of peening is relatively shallow, and is not advisable on the last layer.
  • Page 96 OPERATING 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 97: Electrode Selection Chart

    It 2.5/3.2mm 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 0-5586 7-13 MANUAL ARC (MMAW) WELDING...

  • Page 98: Stick (Mmaw) Welding Troubleshooting

    OPERATING 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 work piece when you “dig”...
  • Page 99 Transmig 220i OPERATING MANUAL FAULT CAUSE REMEDY 4 A groove has been A Welding current is too A Reduce welding current. formed in the base high. metal adjacent to B Welding arc is too long. B Reduce the length of the welding arc. the toe of a weld C Angle of the electrode is C Electrode should not be inclined less than 45°...
  • Page 100 OPERATING MANUAL FAULT CAUSE REMEDY Slag trapped in undercut Not cleaned, or incorrect electrode Slag trapped in root Art # A-05868_AC Figure 3: Example of Slag Inclusion Table 7-2: Welding Problems MMAW (Stick) MANUAL ARC (MMAW) WELDING 7-16 Manual 0-5586...

  • Page 101: Routine Service Requirements And Power Source Problems

    There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do not attempt to open or repair unless you are an accredited CIGWELD Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.
  • Page 102 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 103: Cleaning The Welding Power Source

    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 104: Power Source Problems

    8 Pin control socket of the front of tion in plug. the Transmig 355i Power Source. Repair or replace if faulty. D Faulty TIG Torch Trigger. D Repair or replace TIG Torch Trigger switch/lead.
  • Page 105 D Empty gas cylinder. D Replace gas cylinder. 10 Gas flow continues after Gas valve has jammed open Have an accredited CIGWELD the torch trigger switch has due to impurities in the gas service provider repair or replace been released (MIG mode).
  • Page 106 B Check front and rear Panel Air Louvers are clean and not blocked by any dirt or obstacles. If damaged they should be replaced by an Accredited Cigweld Service Provider. C Check that the fan is running normally during welding.

  • Page 107: Key Spare Parts

    Transmig 220i OPERATING MANUAL SECTION 9: KEY SPARE PARTS 9.01 Tweco Fusion 400 Mig Torch MIG Torch Part No: OTWF412X3545, 3.6 metre Art # A-14719 Figure 9-1 TWECO FUSION MIG TORCH PARTS ITEM PART NO. DESCRIPTION 717309 Nozzle 24AT/37/SS Tweco 4, TWE4 Adjustable 10mm Recess Tip OTW24A/50 Adjustable Nozzle 13mm OTW24A/62...

  • Page 108: Power Source

    OPERATING MANUAL 9.02 Power Source Art # A-14720_AB Figure 9-2 KEY SPARE PARTS Manual 0-5586...
  • Page 109 Transmig 220i OPERATING MANUAL TRANSMIG 355i POWER SOURCE SPARE PARTS Item Part Number Description W7006650 Current Sensor, Primary W7006651 Current Transformer W7006652 Fan W7006658 Dinse Socket 50mm² W7006659 Control Socket 10 Pin W7006660 Control Socket 8 Pin W7006661 Adaptor, Euro...
  • Page 110 OPERATING MANUAL This page intentionally blank KEY SPARE PARTS Manual 0-5586...

  • Page 111: Appendix: Transmig 355I Circuit Diagram

    Transmig 220i OPERATING MANUAL APPENDIX: TRANSMIG 355i CIRCUIT DIAGRAM Manual 0-5550 APPENDIX...
  • Page 112 OPERATING MANUAL This Page Intentionally Blank APPENDIX Manual 0-5550...

  • Page 113: Cigweld - Limited Warranty Terms

    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 114 * 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 115 Transmig 220i OPERATING MANUAL This Page Intentionally Blank...
  • Page 116 CIGWELD Pty Ltd CIGWELD An ESAB Brand Singapore Malaysia Indonesia 71 Gower Street, Preston VIC 3072 Australia ESAB Asia Pacific No. 14 Jalan Teknologi 3/1 JI. Pulogadung No. 45 38 Joo Koon Circle Selangor Science Park 1 Kawasan Industri Pulogadung...

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