Transmig multi process welding inverter (84 pages)
Summary of Contents for CIGWELD 200i
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200i TRANSMIG MulTI pROceSS weldING INveRTeR Operating Manual Art # A-10419 Revision: AC Issue Date: November 29, 2011 Manual No.: 0-5209 Operating Features:...
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+1300 654 674, or visit us on the web at www.thermadyne.com 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.
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Manufacturer assumes no liability for its use. Welding Power Supply Operating Manual Number 0-5209 for: TRANSMIG 200i Inverter Plant Part Number W1005200 TRANSMIG 200i Inverter Power Source (packed) Part Number W1005201 TRANSMIG 200i Inverter Plant (Asia) Part Number W1005200M...
TRANSMIG 200i 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.
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TRANSMIG 200i 2. Wear approved safety glasses. Side shields recom- mended. 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.
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TRANSMIG 200i 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.
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TRANSMIG 200i 5. Use only correct shielding gas cylinders, a very large volume of scientific findings based on regulators, hoses, and fittings designed for the experiments at the cellular level and from studies specific application; maintain them and associated with animals and people which clearly establish that parts in good condition.
TRANSMIG 200i 1.02 PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.
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.
Use care to avoid damaging the Additional copies of this manual may be purchased by equipment when using bars, hammers, etc., to un- contacting Cigweld at the address and phone number crate the unit. for your location listed in the inside back cover of this manual.
TRANSMIG 200i 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 Welding Gun Frequency Converter- Dangerous Voltage...
TRANSMIG 200i 2.05 Description 2.07 Transporting Methods The Cigweld Transmig 200i is a self contained single This unit is equipped with a handle for carrying phase multi process welding inverter that is capable purposes. of performing GMAW/FCAW (MIG), MMAW (Stick) and GTAW (Lift TIG) welding processes.
Note 3: Generator Requirements at the Maximum Output Duty Cycle. NOTE Transmig 200i Plant Part No. W1005200M (Asia Version) is not fitted with VRD. Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock .
TRANSMIG 200i SECTION 3: INSTALLATION, OPERATION AND SETUP G. The enclosure design of this power source meets 3.01 Environment the requirements of IP23S as outlined in AS60529. These units are designed for use in environments with This provides adequate protection against solid...
TRANSMIG 200i 6. Equipment used for calibration and 3.05 Electromagnetic Compatibility measurement. 7. The time of day that welding or other activities are to be carried out. WARNING 8. The immunity of other equipment in the Extra precautions for Electromagnetic...
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TRANSMIG 200i 4. Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However. Metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.
2. VRD Indicator ON/OFF Lights WARNING VRD is NOT fitted to Transmig 200i (Asia Version) Plant Part No W1005200M. A VRD (voltage reduction device) is a hazard reducing device designed to reduce electric shock hazards present on the output of welding power source when operating in MMAW (stick) mode. Note that the presence of VRD should not be used as a substitute for the use of appropriate safety practices as indicated in section one of this manual.
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TRANSMIG 200i 3. Digital Amps Meter (Left Digital Display) MIG Mode This digital meter is used to display the pre-set (preview) Wirefeed Speed in Meters Per Minute (MPM) in MIG mode and actual welding amperage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Wirefeed Speed.
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TRANSMIG 200i 6. Positive Welding Output Terminal The positive 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), electrode holder lead or work lead.
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TRANSMIG 200i 9. Remote Control Socket The 8 pin Remote Control Socket is used to connect remote control devices to the welding power source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. Negative Trigger Switch...
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TRANSMIG 200i When MMAW (Stick) Mode is Selected In this mode the multifunction control knob is used to adjust arc force. Arc force control provides an adjustable amount of welding force (or “dig”) control. This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit-up in certain situations with particular electrodes.
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TRANSMIG 200i 14. 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.
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TRANSMIG 200i 17. On / Off Switch This Single Phase circuit breaker performs a dual function. It is used to turn the unit on/off and it will also trip in the event of a fault. WARNING When the front digital displays are lit, the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential.
Local / Spool Gun switch (ie in both local and Spool Gun modes). 22. Cooling Fan The Transmig 200i 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.
TRANSMIG 200i 3.08 Installing Spool (300mm diameter) As delivered from the factory, the unit is fitted with a Wire Spool Hub which accepts a Spool of 300mm diameter. Remove the locking pin from the spool hub. Install the wire spool over the spool hub, locating the hole in the spool, with the alignment pin on the spool hub.
TRANSMIG 200i 3.10 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 3-8).
TRANSMIG 200i 3.11 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.
This equipment is designed for use with welding grade (Inert) shielding gases only. NOTE Shielding Gas Regulator not included in the Transmig 200i (Asia Version) Plant Part No W1005200M. 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.
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TRANSMIG 200i 4. DO NOT use the regulator as a control valve. When downstream equipment is not in use for extended periods of time, shut off the gas at the cylinder valve and release the gas from the equipment. 5. OPEN the cylinder valve SLOWLY. Close after use.
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TRANSMIG 200i 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.
TRANSMIG 200i 3.15 Setup for MIG (GMAW) Welding with Gas Shielded Mig Wire A. Select MIG mode with the process selection control. (refer to Section 3.06.13 for further information) B. Connect the Mig torch polarity lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.
TRANSMIG 200i 3.16 Setup for MIG (GMAW) Welding with Gasless Mig Wire A. Select MIG mode with the process selection control (refer to Section 3.06.13 for further information). B. Connect the Mig Torch polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.
TRANSMIG 200i 3.17 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded Mig Wire A. Select MIG mode with the process selection control (refer to Section 3.06.13 for further information). B. Connect the Mig torch polarity lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.
TRANSMIG 200i 3.18 Setup for TIG (GTAW) Welding A. Select Lift TIG mode with the process selection control (refer to Section 3.06.13 for further information). B. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the power source via heavy duty bayonet type terminals.
C. Select STICK mode with the process selection control (refer to Section 3.06.13 for further information). WARNING VRD is NOT fitted to Transmig 200i (Asia Version) Plant Part No W1005200M. WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the mains power supply is switched off.
TRANSMIG 200i SECTION 4: BASIC WELDING GUIDE 4.01 MIG (GMAW/FCAW) Basic Welding Technique Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the very basic concepts in using the Mig mode of welding, where a welding gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
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TRANSMIG 200i Position of MIG Torch The angle of MIG torch to the weld has an effect on the width of the weld. Vertical Push Drag/Pull Art # A-07185_AB Figure 4-3 The welding gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below) Hold the gun so that the welding seam is viewed at all times.
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TRANSMIG 200i Vertical Fillet Welds Art # A-08995 Figure 4-6 Art # A-08996 Overhead Weld Figure 4-7 Distance from the MIG Torch Nozzle to the Work Piece The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20.0mm. This distance may vary depending on the type of joint that is being welded.
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TRANSMIG 200i Secondary Adjustable Variables These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation. They are: 1. Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain at about 10mm stick-out 2.
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TRANSMIG 200i 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.
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Aluminium alloys containing Magnesium. Note that 1.0mm Spool 7kg 722224 a suitable shielding gas is required. Note: Handispool = 200mm diameter, Spool = 300mm diameter. Table 4-1: Cigweld MIG Wire Selection Chart BASIC WELDING GUIDE Manual 0-5209...
TRANSMIG 200i 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...
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TRANSMIG 200i Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE Feed roller driven by motor in the Wire spool brake is too tight. cabinet slipped.
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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...
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.
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TRANSMIG 200i Art # A-07687 Figure 4-11: Flat Position, Down Hand Butt Weld Art # A-07688 Figure 4-12: Flat Position, Gravity Fillet Weld Art # A-07689 Figure 4-13: Horizontal Position, Butt Weld Art # A-07690 Figure 4-14: Horizontal-Vertical (HV) Position...
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TRANSMIG 200i Art# A-07693 Figure 4-17: Overhead Position, Butt Weld Art # A-07694 Figure 4-18: Overhead Position, Fillet Weld Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.
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TRANSMIG 200i 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.
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TRANSMIG 200i Rate of Travel After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead.
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TRANSMIG 200i B. Fillet Welds These are welds of approximately triangular cross-section made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-14. A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles.
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TRANSMIG 200i 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.
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TRANSMIG 200i 3. Overhead Welds Apart from the rather awkward position necessary, overhead welding is not much more difficult that downhand welding. Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch.
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TRANSMIG 200i 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.
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TRANSMIG 200i B. Distribution of Stresses Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 4-30 through 4-33 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it.
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TRANSMIG 200i Art # A-07710 Figure 4-34: Welding Sequence Art # A-07711 Figure 4-35: Step back Sequence Art # A-07712 Figure 4-36: Chain Intermittent Welding Art # A-07713_AB Figure 4-37: Staggered Intermittent Welding BASIC WELDING GUIDE 4-20 Manual 0-5209...
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It 2.5/3.2mm Blisterpack 322217 has better “wetting” action than Castcraft 55. 4.0mm 2.5 kg 611734 Table 4-5: Cigweld Electrode Selection Chart Further information on CIGWELD electrodes can be found at the website www.thermadyne.com. Manual 0-5209 4-21 BASIC WELDING GUIDE...
TRANSMIG 200i 4.04 Stick (MMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE control knob Reduce the ARC FORCE control knob until weld- varying is set at a value that ing current is reasonably constant while prohibit- causes the welding current...
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TRANSMIG 200i 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.
TRANSMIG 200i 4.05 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non- consumable) electrode and the work piece.
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Easier Ceriated 2% steel, copper, alumin- starting, Wider current Grey ium, magnesium and range, Narrower more their alloys concentrated arc. Table 4-9 NOTE The Transmig 200i Inverter is not suited for AC Tig welding. Manual 0-5209 4-25 BASIC WELDING GUIDE...
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Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www. thermadyne.com or contact Cigweld. BASIC WELDING GUIDE...
TRANSMIG 200i 4.06 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.
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9 Arc start is not smooth. A Tungsten electrode is A Select the right size electrode. Refer to too large for the weld- Table 4-7 Cigweld Electrode Selection ing current. Chart. B The wrong electrode B Select the right electrode type. Refer to...
(burn-back jam). contact tip. Replace faulty com- ponents. B Internal fault in power B Have an Accredited CIGWELD source Service Provider investigate the fault. 4 Welding wire continues to A Trigger mode selection...
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.
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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.
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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...
TRANSMIG 200i 5.03 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.
Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. Art # A-10435_AB Figure 5-1: Transmig 200i Volt-Ampere Curves POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-6 Manual 0-5209...
TRANSMIG 200i SECTION 6: KEY SPARE PARTS 6.01 Power Source Art # A-10436 Item Part Number Description W7005600 PCB Power W7005601 PCB Control W7005602 PCB Display W7005607 PCB Spool Gun W7004902 PCB EMC Filter W7005603 Wiredrive Assembly W7004906 Feed Roll Retaining Thumbscrew Feed Roll 0.6/0.8mm V groove (fitted as standard)
WELD whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of CIGWELD is authorized to change this warranty in any way or grant any other warranty.
CIGWELD. 4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supply of goods which are not of a kind ordinarily acquired for personal, domestic or household use or consumption to any one or more of the following (the choice of which shall be at the option of CIGWELD).
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.
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne, China Cigweld, Australia 71 Gower Street RM 102A Preston, Victoria 685 Ding Xi Rd Chang Ning District Australia, 3072 Telephone: 61-3-9474-7400 Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 61-3-9474-7391 Email: cigweldsales@cigweld.com.au Fax: 86-21-69171139 Thermadyne Asia Sdn Bhd...
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