CIGWELD TRANSMIG 180 Manuel utilisateur

OPERATINGMANUAL

TRANSMIG180

MIGWELDINGPLANT

PartNumber705180

719322

Issue5 Nov06,96

CIGWELD

Transmig

180

CONTENTS Page

1.INTRODUCTION1

1.1Safety1

1.2ProtectiveFilterLenses1

1.3WeldingProtection2

1.4UserResponsibility2

1.5DutyCycle2

2.SPECIFICATIONS3

2.1PowerSourceSpecifications3

2.2MIGTorchSpecifications3

2.3WireDriveSpecifications4

2.4PlantContents4

2.5OptionalAccessories4

3.INSTALLATIONRECOMMENDATIONS5

3.1Environment5

3.2Location5

3.3Ventilation5

3.4MainsSupplyVoltageRequirements5

3.5AlternativeMainsSupplyVoltageConnection6

4.WIRESPOOLHUBADJUSTMENT6

4.1Standard300mmSpoolSet-up6

4.2Handi200mmSpoolSet-up7

4.3Mini100mmSpoolSet-up7

5.SETUPFORTRANSMIG1807

6.POWERSOURCECONTROLS,INDICATORSANDFEATURES9

6.1POWER ONLight9

6.2VoltageControlSwitch9

6.3OVER TEMPERATURE Light9

6.4WirespeedControl9

6.5BurnbackAdjustment10

6.6PolarityReversalTerminals™

6.7ThermalOverload....^

6.8WhefeederDriverRollerPressureAdjustment• ™

6.9WireSpoolBrake11

7.TWECOMIGTORCH(717579)H

7.1Introduction"

7.2MIGTorchComponents12

7.3MIGTorchConsumableParts12

Pagei

Transmig180

CONTENTS Page

7.4InstallingA NewWireConduit13

7.5MIGTorchMaintenance14

8.BASICWELDINGTECHNIQUE14

8.1SettingofthePowerSource& Wirefeeder14

8.2PositionofMIGTorch14

8.3DistancefromtheMIGTorchNozzletotheWorkPiece14

8.4MIGTorchTravelSpeed14

8.5ElectrodeWireSizeSelection14

9.ROUTINEMAINTENANCE& INSPECTION15

10.BASICTROUBLESHOOTING15

10.1SolvingProblemsBeyondtheWeldingTerminals15

10.7WeldingProblems17

10.3PowerSourceProblems18

10.4KeySpareParts19

11.Transmig180Volt/Ampcurves20

12.TRANSMIG180CIRCUITDIAGRAMS20

12.1PowerSource20

12.2ControlPCB21

Pageii

Transmig180

TABLES

Page

Table1 - Filterlenssizeversesweldingcurrent2

Table2 - MIGTorchcomponents12

Table3 - MIGTorchgasdiffusers12

Table4 - MIGTorchcontacttips12

Table5 - MIGTorchnozzles13

Table6 - MIGTorchconduitliners13

FIGURES

Page

Figure1 - Transmig180dutycyclecurve2

Figure2 - Contactoradjustment(wire7)6

Figure3 - Inputterminalblockadjustment(wire7A)6

Figure4 - Standard300mmspoolset-up6

Figure5 - Handi200mmspoolset-up7

Figure6 - Mini100mmspoolset-up7

Figure7 - MIGTorchandpolarityconnections8

Figure8 MIGTorchbreakdown11

Figure9 - MIGTorchangle14

Figure10- Transmig180Volt/Ampcurves20

Pageiii

Transmig180

Page1

1.INTRODUCTION

TheTransmig180isa semi-automaticGasMetalArcWelder(GMAW-commonlyMIG)withan

integratedwirefeedsystem.Theplantisdesignedtomeetthebroadoperatingneedsofthelightmetal

fabricators,automotiverepairers,lightruralworkshopsandhomeworkshopswhereexcellentarc

characteristicsarevital.ThisproductisdesignedandmanufacturedinAustraliatoAustralianStandard

AS1966.1-1985.

TheTransmig180givesexcellentperformanceonmildsteel,stainlesssteel,aluminium,siliconbronzeand

somehardfacingwireswithArgonbasedshieldinggases.Italsogivesexcellentresultsonmildsteelusing

carbondioxide(C02)shieldinggas.

Thisproductissuppliedasa completepackagereadytoweld(apartfromgascylinderandelectrodewire).

ThefollowinginstructionsexplainhowtocorrectlysetupthePowerSourceandprovideguidelineson

gainingthebestproductionefficiencyfromtheplant.Pleasereadtheseinstructionsthoroughlybefore

usingyourTransmig180welder.

1.1Safety

Thefollowingbasicsafetyrulesshouldalwaysbefollowed:

i)EnsurethePowerSourceiscorrectlyinstalled,ifnecessary,bya qualifiedelectrician

ii)EnsurethePowerSourceisearthedcorrectly(electrically)inaccordancewithlocal

regulations.

iii)Excessiveheatintheweldingcablesmaycausefire.Neverweldwithpoorelectrical

connections,damagedweldingcablesorexceedtheweldingcablecurrentratingas

thiswillproduceexcessiveheatandmaycausea fire.

iv)Alwayswearthecorrectprotectiveclothingforprotectionfromsparks,molten

particlesandarcrays.

v)Whenweldinginconfinedspaces,alwaysensureadequateventilationandconstant

observationoftheoperator.

vi)Keepcombustiblematerialsawayfromtheweldingarea.Havea suitablefire

extinguisherhandy.

vii)Neverwatchtheweldingarcwithnakedeyes.Alwaysuseandweara weldingmask

fittedwiththecorrectfilterlens.

viii)Donotstandondampgroundwhenwelding.

ix)Formorecompletesafetyadvicepleasereadthesafetyliteratureincludedwiththe

equipmentbeforestartingtoweld.

1.2ProtectiveFilterLenses

Protectivefilterlensesareprovidedtoreducetheintensityofradiationenteringtheeyethusfiltering

outharmfulinfra-red,ultra-violetradiationanda percentageofthevisiblelight.Suchfilterlensesare

incorporatedwithinfaceshields.Topreventdamagetothefilterlensesfrommoltenorhardparticles

anadditionalhardclearglassorspecialplasticexternalcoverlensshouldbeused.Thiscoverlens

shouldalwaysbekeptinplaceandreplacedbeforethedamageimpairsyourvisionwhilewelding.

1.3WeldingProtection

Itisrecommendedtousea weldinghelmet,

conformingtoAustralianStandards

AS/NZS1337-1992whenelectricarc

welding.Usea weldinghelmetin

serviceableconditionwiththecorrectfilter

lensfittedasperTable1.

1.5

Approximaterangeof

weldingcurrent

Filterlensrequired

forMIG

Upto150 Shade10

150-250 Shade11

250-300 Shade12

300-350 Shade13

Over350 Shade14

1.4UserResponsibility

Thisequipmentwillperformaspertheinformationcontainedhereinwheninstalled,operated,

maintainedandrepairedinaccordancewiththeinstructionsprovided.Thisequipmentmustbe

checkedperiodically.Defectiveequipment(includingweldingleads)shouldnotbeused.Partsthat

arebroken,missing,plainlyworn,distortedorcontaminated,shouldbereplacedimmediately.

Shouldsuchrepairsorreplacementsbecomenecessary,itisrecommendedthatsuchrepairsbe

carriedoutbyappropriatelyqualifiedpersonsapprovedbyCIGWELD.Adviceinthisregardcanbe

obtainedbycontactingCIGWELD.

Thisequipmentoranyofitspartsshouldnotbealteredfromstandardspecificationwithoutprior

writtenapprovalofCIGWELD.Theuserofthisequipmentshallhavethesoleresponsibilityforany

malfunctionwhichresultsfromimproperuseorunauthorisedmodificationfromstandard

specification,faultymaintenance,damageorimproperrepairbyanyoneotherthanappropriately

qualifiedpersonsapprovedbyCIGWELD.

DutyCycle

Therateddutycycleofa welding

PowerSourceistheoperatingtimeit

maybeusedatitsratedoutput

currentwithoutexceedingthe

temperaturelimitsoftheinsulationof

thecomponentparts.Theareatothe

leftofthecurveisthesafeoperating

areaforthisproduct.InAustraliaa

dutycycleperiodof5 minutesis

specifiedinAustralianStandardAS

1966Part1-1990.Toexplainthe5

minute dutycycleperiodthe

followingexampleisused.Suppose

aweldingPowerSourceisdesignedtooperateat30%dutycycle,140amperesat20.5loadvolts.

Thismeansthatithasbeendesignedandbuilttoprovidetheratedamperage(140A)attherated

loadvoltage(20.5V),for1.5minutesoutofevery5 minuteperiod(30%of5 minutesis1.5

minutes).Duringtheother3.5minutesofthe5 minuteperiodthePowerSourcemustidleandbe

allowedtocool.Thethermalcut-outwilloperateifthedutycycleisexceeded.

DutyCycle(percentage)

WeldingCurrent(amps)

180

Page2

Table1 - Filterlenssizeversesweldingcurrent

Figure1 - Transmig180dutycyclecurve

Transmig180

PlantAssemblypartnumber 705180

PlantMass 60kg

PlantDimensions(packed) H625mmx W 345mmx D 560mm

PowerSourceDimensions(lessMIGTorch) H470mmx W 460mmx D 800mm

OpenCircuitVoltageRange 18.5to36.0VDC

WeldingArcVoltageRange 13to21VDC

OutputCurrentRange 25to180ADC

RatedOutputDutyCycle 180A

@18%

140A@ 30%

100%DutyCycleOutputRating 75ADC

DutyCyclePeriod 5or10minutes

NumberofOutputVoltageSettings 8

ElectrodeWireSizeRange 0.6-0.9Hard/0.9-1.2Soft

WireSpeedRange 1.0to15.0metres/minute

WireSpoolSizeDiameter 100mm/ 200mm/ 300mm

BurnbackTimeRange 0.0to0.5seconds

OperatingTemperatureRange 0°Cto40°C(32°Fto104°F)

NumberofPhases 1

Frequency 50/ 60Hz

MainsSupplyVoltage(PrimaryInputVoltage) 220V 240V

VRatedInputCurrent@ 75Aoutput(100%DutyCycle) 9.7A 8.9A

RatedkVA@ 75Aoutput(100%DutyCycle) 2.1WA 2.1kVA

MaximumInputCurrent@ 180Aoutput 29.3A 26.9A

GeneratorRequirementsat180Aoutput 6.5kVA 6.5kVA

RecommendedOutletSize 15A 15A

SupplyVA@ noload 400VA 400VA

SupplyWatts@ noload 250W 250W

SupplyVA@ 180Aoutput 6.5kVA 6.5kVA

SupplyWatts@ 180Aoutput 5.7kW 5.7kW

PowerSourceEfficiency@ 180A output

61% 61%

PowerFactor@ 180Aoutput 0.88 0.88

+RecommendedFuseSize 25A(23SWG) 20A(24SWG)

VTheRatedInputCurrentshouldbeusedforthedeterminationofcablesize& supply

requirements.

+Motorstartfusesorthermalcircuitbreakers(notmagneticcircuitbreakers)arerecommended

forthisapplication.AustralianStandardAS3000(Clause2.4.3.4)permitstheuseofa fuseor

circuitbreakerratedattwotimestheratedinputcurrent.

2.2MIGTorchSpecifications

TorchPartNumber 717579

TorchType TWECO180A (EliminatorConsumables)

TorchCableLength 3.0metres(10ft)

Page3

2.SPECIFICATIONS

2.1PowerSourceSpecifications

2.3WireDriveSpecifications

MotorSupplyVoltage 24VAC

MotorSupplyVA 120VA

ControlSupplyVoltage 24VAC

ControlSupplyVA 30VA

MinimumWireSpeed 1metreperminute(40inchesperminute)

MaximumWireSpeed 15metreperminute(590inchesperminute)

WireDiameter MildSteel:0.6mm(.024"),0.8mm(.030"),0.9mm(.035")

StainlessSteel:0.6mm(.024"),0.8mm(.030"),0.9mm(.035")

Aluminium:0.9mm(.035"),1.0mm(.040"),1.2mm(.045")

FluxCored:0.8mm(.030"),0.9mm(.035"),1.2mm(.045")

WireSpoolSize 100mmor200mmor300mm

3lantContents

PartNumber Description

705197 WheelingKit

705195GRY CylinderCarrier

705260GRY CylinderBracket

703625 CylinderChain

719322 OperatingInstructions

705174 3MetreWorkLead(fitted)

301526 Regulator/ Flowmeter

717579 TWECOMIGTorch180A

705366 Handispoolhub (for200mmspooladaptation)

7977036 FeedRoller0.6/0.8Hard (fitted)

705368 Torchaccessorykit

2.5OptionalAccessories

PartNumber Description

705252 Handle

7977036 Feedroll,0.6/0.8HardWire

7977660 Feedroll,0.9/1.2HardWire

7977037 Feedroll,1.0/1.2HardWir

PartNumber Description

7977731 Feedroll,0.8/0.9SoftWire

7977264 Feedroll,1.0/1.2SoftWire

7977732 Feedroll,0.8/0.9Fluxcored

704277 Feedroll,1.0/1.2Fluxcored

Page4

Transmig180

3.INSTALLATIONRECOMMENDATIONS

3.1Environment

TheTransmig180isNOTdesignedforuseinenvironmentswithincreasedhazardofelectricshock

asdennedinAS3195-1990.

a)Examplesofenvironmentswithincreasedhazardofelectricshockare-

i)Inlocationsinwhichfreedomofmovementisrestricted,sothattheoperatoris

forcedtoperformtheworkina cramped(kneeling,sittingorlying)positionwith

physicalcontactwithconductiveparts;

ii)Inlocationswhicharefullyorpartiallylimitedbyconductiveelements,andinwhich

thereisa highriskofunavoidableoraccidentalcontactbytheoperator,or

iii)Inwetordamphotlocationswherehumidityorperspirationconsiderablereducesthe

skinresistanceofthehumanbodyandtheinsulationpropertiesofaccessories.

b)Environmentswithincreasedhazardofelectricshockdonotincludeplaceswhere

electricallyconductivepartsinthenearvicinityoftheoperator,whichcancauseincreased

hazard,havebeeninsulated.

3.2Location

BesuretolocatethePowerSourceaccordingtothefollowingguidelines:

a)Inareas,freefrommoistureanddust.

b)Ambienttemperature0°Cto40°C.

c)Inareas,freefromoil,steamandcorrosivegases.

d)Inareas,notsubjectedtoabnormalvibrationorshock.

e)Inareas,notexposedtodirectsunlightorrain.

f)Placeata distanceof30cmormorefromwallsorsimilarthatcouldrestrictnaturalairflow

forcooling.

g)Theminimumgroundclearanceforthisproductis65mm.

3.3Ventilation

Sincetheinhalationofweldingfumescanbeharmful,ensurethattheweldingareaiseffectively

ventilated.

3.4MainsSupplyVoltageRequirements

TheMainssupplyvoltageshouldbewithin± 10%oftheratedMainssupplyvoltage.Toolowa

voltagemaycausepoorweldingperformanceorthewirefeedertomalfunction.Toohigha supply

voltagewillcausecomponentstooverheatandpossiblyfail.

TheTransmig180issuppliedwitha 15Ainputlead(and15Aplug)toconnecttoa 15Apower

outletandisfactorysetfor240Voperation

CAUTION 1: CIGWELD advises that you should avoid the use of extension leads as this can

reduce the Mains supply voltage below 10% of the rated Mains supply voltage.

Refertosection3.5fortheinstructionstoconvertyourTransmig180to220Voperation.

Page5

3.5AlternativeMainsSupplyVoltageConnection

TheTransmig180canberewiredtooperateona Mainssupplyvoltageof220V.

WARNING 1: CIGWELD advises that a qualified electrical tradesperson rewire your Transmig

180 for 220V operation.

a)DisconnecttheTransmig180fromtheMainssupplyvoltage.

b)DisconnectwireNo7 fromterminalL3thenreconnectittoterminalL2onthecontactor.

RefertoFigure2.

c)DisconnectwireNo7Afromthe240Vpositionontheinputterminalblockthenreconnect

wireNo7Atothe220Vpositionontheinputterminalblockterminal.RefertoFigure3.

d)TheTransmig180isnowreadyfor220VMainssupplyvoltage.

Figure2 - Contactoradjustment(wire7)Figure3 - Inputterminalblockadjustment(wire7A)

4.WIRESPOOLHUBADJUSTMENT

4.1Standard300mmSpoolSet-up

Steelflatwasher16mmID

Steelflatwasher16mmID\

Frictionwasher

(7976411) Wirespoolhub

(702337)

Nut5/8"BSW

(7958040)

Figure4 - Standard300mmspoolset-up

Page6

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