CIGWELD Product Transmig 165 Transmig 135 PortaWeld 100 TRANSMIG 165 GS oe TRANSMIG B® 0 CO PORTAWELD 100 /T a8 ES Operating Manual | Welder Process T ype | Part No. Gas/Gasless MIG V Welder | 706555 Gas/Gasless MIG Welder | 710003 Gasless Wire Welder | 710004Transmig 165, Transmig 135, PortaWeld 100 Transmig 165, Transmig 135, PortaWeld 100 ‘Manufacturer and Merchandiser of Quality Consumables and Equipment: CIGWELD Table Of Contents Asse 71 Gower, reson Viera 3072 1. Introduction. wees 2. Electromagnetic Compati lity. 2 crane conan. sos oi Bia © C€ ‘oes S San nes rf nora ipos * Serial mone are nig wi ech individ pis fume an tis description, pus eo manusicare 7. Product Specifications. ‘nt an date of ana 8, Installation Recommendations. * The in fr arfomance itera Asal be H10%-5M6 for wie et pod ‘+ The equipment conforms to all applicable aspects and regulations of the “Low Voltage Directive’ (Directive erode See, ‘Se al eed Been SUSE ed te en eget seo 10, ‘Tronanig 165 © Transndg 136 Controls Indicators aod Feature _— LL. PortaWeld 100. rs ‘National Standard snd Technical Spsxifications ‘12, Basic Welding Technique .. 13. Routine Maintenance & Inspection, 20 Tse otc geo surf ts ance items anon ten 14, Basic Troubleshooting a + 5195p wedng enew nd sect ei rte Tao 3 Perl. aa es AS18661 lawn geet an soil acess rte Tai 16, + as vzS EMC Dee ENS9) ple ne weling pe - rein eins Tables + UL (Une Laratny aing V0 nity sing ral ined tibet a hy +c 741 (85 TOKEN 60974) all slg vies ase asc eee eee eae eee eee onan a +s EEC-2NC Dini ES01 apa a eng einen miss nmin Figures + Extensive product desiga verification is conducted atthe manufacturing facility as part of the routine design and Figure | - Duty cycle curves. a 9 aia pstnte ae fe pects a pies sei Rig arsed nto aaa > ‘the manufacturing process to ensure the manufactured product meets or exceeds ll design specifications. Fig z ig tos ‘s Figure 3- Transm 135 contls ” CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance, ult Figure 5 - MIG Torch angle. 20 spins nd ci enya ne ifons ato elec } Figure 6 = Tansng 165 Circuit ing as Figure 7-Transmig 135 Cie Digg 26 Figure 8 PoraWeld 100 Cc Diagram, 26 Pages PageTransmig 165, Transmig 135, PortaWeld 100 4. Introduction 4.4. Notes, Cautions and Warnings Throughout this manual, notes, cautions, and wamings ae used to highlight important information, Thos highlights are catporsed as follows Nove ‘i operation, pou, or bckgomndHformation sis rues ional empl 0 sal a ‘fen peaton of i sytem cauTion ‘A por, ft properly fle my ns donage te ip “mel i Foot prey le ny eer oh pro ies i peti we 1.2. Important Safety Precautions ‘PERATION AND MAINTENANCE OF WELDING ARC EQUIPMENT CAN BE DANGEROUS ‘AND HAZARDOUS TO YOUR HEALTH, To present pile injury iad, wert ad ol rings sly prcmton an ntractione fefve sng pipent Call yr oo sir yo ey ation Acasesano roves ‘ase ames phe hing the well roses can be dagen ara 305 Sa, + Kesp lms and ges the being ae. Keep your head owt of te wel fe ame «sears respira i eon not adequtoarow al fies ng {The kind of umes am as fom te wsing ae depen ont Knd of mt Bangs Sowing one ca he ere roses Yost be yea Wh cating ‘ch any mens ih my conto orm oft lowing Astimony Beryllium Cobalt Manganese Selenium “Arsenic Cadmium Copper Mercury Silver Barium Chromium Lead Nickel Vanadium “+ Always ead the Material Safety Data Shets(MSD's that shuld be supplied withthe material {you ar using, ‘These MSDS's will give you the information regarding te kind and amount of fiames and gies that may be dangerous to your health + For information on how to test For fumes and gases in your workplace, refer w item I in Subsection 13, Publications in tis manval ‘Use special equipment, suchas water or down daft cuting tables, fo capture fumes and gases + Do not use the welding torch in an area where combustible or explosive gases or materials are located, + Phosgene, a toxic gas, is generated fom the vapours of crite solvents and cleansers Remove all sources ofthese vapours, Transmig 165, Transmig 135, PortaWeld 100 + Refer tothe Vietrian Occupational Heath ad safety (Confined Spaces) Reyulations 1996 and ‘Code of Practice or its equivalent for oer states and/or counties, Atccrcssoce lee Shock can ine oil, The wang ae prose we and poss Nh vlage Seley Th ec ncn case sve fal hk We oper or aes theworiplce «Neve ch any ars nt ae tly "eo" {Weary gloves and clon Tite youl fom he wok peor ter asf te wens epioreace a om ot damaged part + Fu caremste akon hen ewe so damp + slapd maintain equipment accoing fo NEC cde, Wr Rom 4 in Subsea 13 batons «Dicom power spl befor prong ay sev opi 5 cand lo al histone Open Nan A iw anvexerosion ean exis cn becuse by hl slg pus ie welding «bese the sm combustible or Tamale mati in he wea, Any sii ht Cina eoveved se pete «Venta amma or explosive ap ome worl. + onotet orwell onconsine ht my have ed ome ® Provide re wah ven wring anes hfe ry exit * Hyronc sy be omed al taped nr any were en hy ae cat Uniercr whe ings ot le DO NOT ci ani lye ecto o9 8 Scr a ws the ope canbe inane asiae.Teppes yop pat ispnedwiene sex Dhosse "Noise can cause pennanent hering [os Phsms ae processes can cause noise fvels to exceed sae mits You must protet your ears from lod noise Io prevent permanent los of hearing + To protect your hearing ffom load noise, wear proetive earplugs andor earmuffs, Potet “others inthe workplace, + Noise levels should be measured tobe sure the decibels (sound) do not exceed safe levels + For information on how to test for moss, se item | in Subsection 1.3, Publications, inthis manual Baccass ‘Arc Rays can injure your eyes and bum your skin. The welding ae process produces very bright lr violet and infeed ight. These ac rays will damage your ees and burn your skin if you ae ‘ot propery protected, ‘+ To protect your eyes, always wear a welding helmet or shield, Also always wear safety glasses swith ido shield, gogales or oer protective eye west + Wear welding gloves and suitable clothing to proce your skin fom the ate rays nd sparks. + Keep helmet and safety glases in good condition. Replace lenses when etacke, chipped or ny. Protect others inthe work area from hear ays, Use protective booths, crens or shields. 7Transmig 165, Transmig 135, PortaWeld 100 ‘Use the shade of fens as recommended inthe Operating Manual 1.3. Publications Refer ta the fllowving standards or their latest revisions for more information: | OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obiainable fiom the Superintendent of Documents, US. Government Printing Office, Washington, D.C. 20402 2. ANSI Standard 249.1, SAPETY IN WELDING AND CUTTING, obtainable from the ‘American Welding Society, 550 NW. LeJeune Rd, Mian, FL. 33126 NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, US. Goverment Pining Oice, Washington, D.C. 20402 4. ANSI Standard 287.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND PACE PROTECTION, cbtainable ftom American National Standards Intute, 1430 Broadway, New York, NY. 10018 5. ANSI Standard Z4).], STANDARD FOR MEN'S SAFETY-TOE FOOTWEAR, obtainable fiom the American National Standard Insitute, 1430 Broadway, New York, NY. 10018 6, ANSI Standard 249.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obainable from American National Standards Insitute, 1430 Broadway, New York, NY 10018 7. AWS Standaed A60, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable ftom American Welding Society, 580 N:W. LeJeune Rd, Miami FL 33126 8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obiainable from the National Fire Protection Association, Batterymareh Park, Quney, MA 02269 9, NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtinable from the National Fire Protection Assoviation, Baterymarch Park, Quiney, MA 2265, VONFPA Standaed SB, CUTTING AND WELDING PROCESSES, obitinable fiom the ‘National Fire Protection Assoeation, Baterymarch Park, Quincy, MA 02269 H.CGA Pamphlet P-I, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, ‘oblanable from the Compress Gas Association, 1235 Jefferson Davis Highway, Suite 501 Aatngton, VA 22202 128A Stndard WI172, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable fiom he Canadian Standards Associaton, Standards Sales, 178 Rexdale Boulevard, Rexdale (Ontario, Canada MOW IRS TLNWSA booklet, WELDING SAFETY BIBLIOGRAPHY obinable from the National ‘Welding Supply Associaton, 1900 Arch Street, Philadelphia, PA T9103 1M American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable fiom the American Welding Society, 550 NW. Leeune Rd, Miami, FL. 33126 |S.ANSI Standard 7882, PRACTICE FOR RESPIRATORY PROTECTION, obtainable fom “American National Standard Institue, 1430 Broadway, New York, NY 10018 Transmig 165, Transmig 135, PortaWeld 100 2. Electromagnetic Compatibility 24 22 “Epcos for Drogas Copa mr be rural chon ese wld per are we ‘od a doment station, Installation and use - Users Responsibility The vser is responsible for installing and using the welding equipment according to the rmanufiturcr’s instructions. If electromagnetic disturbances are detected then it shall be the responsibilty of the user of the welding equipment fo resolve he situation with the technical assistance othe manufsturer In some eases this remedial action may be as smple as earthing the ‘welding eit, see NOTE I, In other cases it ould involve constructing an electromagnetic seroxn enelosing the Welding power source and the work, complete with assotated input ers In all cases, electromagnetic disturbances shall be reduced tothe point where they are no longer twoublesome. Norer he lng ict may ory note ented Jor safely rene. Changing the earthing amangenents ov onl Ye utr by peson x compton och techn aire h inure allah pall wing ten earn pt hich ay dege ear crete of hr ‘uc Frthr gc gon TEC 97-13 Ave Wading Ein lata al ee eer prpantin. ‘Assessment of Ares Before installing welding equipment, the user shall make an assesment of potential lecttomagnetie problems inthe surrounding ar, The following stl be taken into account ') Other supply cables, contol cables, signalling and telephone cables; above, below and adjacent tothe welding equipment ) Rao and television transmitters and receivers. 4) Computer and othor contol equipment jv) Safety eral equipment, eg, euarding of industrial equipment ¥) Thehealth of people around, e., the use of pacemakers and hearing aids vi) Equipment used for calibration and measurement. vi) The immunity of other equipment in the environment: the user shall ensure that caer equipment being used inthe environment is compatible: this may require additional protection measures. vii) The time of day that welling or ater activities are to be earied out “The size ofthe surouoding ara tobe considered wil depend onthe sracture ofthe building anc ther activites that are taking place. The sutounding area may extend eyo the boundaries of the premises.Transmig 165, Transmig 135, PortaWeld 100 Electromagnetic Compatibility - Methods of Reducing Emissions 341. Mains Supply Welling equipment should be connected to the mains supply secordng tothe manufacturer's recommendations. If intesfrence ocurs, it may be necessary to take atonal precautions such 48 Gilering of the mains supply. Consideration should be given shielding the supply cable of| permanently installed welding equipment in metallic conduit or equivalent. Shielding should be cleetrcally continuous Uoughout its length. The shielding should be connected to the welding povier source so that good electra cont is rsintained between the conduit and the welding ove source enclosu 3.2. Maintenance of Welding Equipment ‘The welding equipment should be routinely maintained according to the manufacuree’s recommendations. Al acces and service doors and eovers shot be closed and yropely fastened ‘when the welding equipment isin operation. The welding equipment should not be modified in any way except for those changes and adjustments covered inthe manufacucr'sinstuctons. panticular, the spark gaps of ae sting and stabilising devices should be adjusted snd mintained scoring othe manufacturers recommendations. 33. Welding Cables ‘The welding cables should be kept as short as posible and shouldbe positioned else together, runing ator close tthe floc evel 3.4. Equipotential Bonding Boning of all metalic components in the welding installation and adjacent to it should be considered, However, Metallic components bonded tothe workpiece will increase the rik that the ‘operator could receive a shock by touching the metallic compenents and the eletode atthe same time. The operator shouldbe insulated from ll such bonded metalic components. 35. Earthing of the Workplece ‘Whore the workpoeei nat bonded 0 anh for electrical safety, nor comecte to earth because of it's size and postion, eg ship's hull or building steelwork a connection Boning the workpiece t0 ath may reduce emissions in some, but not al instances. Care should be taken to prevent the carthing of the workpiece increasing the risk of injury’ t0 users, oF damage to other electrical tsipmnt, Where necessary, the connection of the workpiece to earth should be made by dre ‘snnecton to the workpiece, But in some counties where dre connection isnot permite, the bonding should be achieved by suitable capacitance, selected according to national regulations. 36 Screening and Shielding Selective serening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference, Sercening the entire welding installation may be considered for special applications, aa 42 43 44 Transmig 165, Transmig 135, PortaWeld 100 General Information ‘Transmig 165 “The Transmig 165 ew semi-automatic Gas Mota] Are Welder (GMAW-commonly MIG) with an integrated wire feed unit. The Power Source is designed to meet the broad operating needs of the metal fabrication industry where prodictionefficieney is vita. It is designed to Australian Standard ASII66. “The Transmig 165 gives exellent performance on mild sto, stainless ste, aluminium, silicon ‘bronze and some hard ficing wires with Argon based shielding gases. It also pies excelent results on mild steal using Carbon Dioxide (COs) shielding gas. The Transmig 165 is supplied 3s a complete package ready to weld (apart from gas cylinder and clectode wite) The fllowing insiuctions detail how to correctly setup the machine and give tmuidelines on gaining the best production efficiney from the Power Sours. Please read these ‘structions thoroughly before using your Transm, 168 welder. Transmig 135 “The Transmig 135 isa semi-automatic Gas Metal Are Welder (GMAW-commonly MIG) with at integrated wite feed uni. The PowerSource is designed 1 meet the broad operating needs ofthe professional home weekend Welder. Iti designed to Australian Standard AS3195. “The Transmig 135 gives excellent performance on mild ste, stainless sel, and aluminium wires with Argon based shielding gas. It also ives excelent resuls on mid steel using Carbon Dioxide (CO) shielding gs, “The Transmig 135 is supplied asa complete package ready o weld ineluing s spoo! of 09m islss wire. The following insrvetions detail how to coolly set up the machine and give tuidelineson gaining the best production effciney from the Power Source. Please read tse Instructions thoroughly before using your Transmig 135 welder PortaWeld 100 “The PortaWeld 100 isa semi-automatic Flux Cored Are Welder (FCAW) wih an integrated wire ‘eed unit. The Power Source is designed to meet the broad operating needs ofthe home weekend ‘welder. Its designed to Australian Standard AS3195. “The PortaWeld 100 gives excellent performance on mild stel using gasless fax ered wine “The PomtaWeld 100 is supplied as w complete package ready to weld including a speo of 0m sles wite. The following instractions detail how to correctly set up the machine and give [ptdelines on gtining the best production eficieneyffom the Power Soure. Please rea these instuctons throughly before using your PrtaWeld 100 welder, User Responsibility This equipment wil perform as per the information contained herein when installed, operated, ‘maintained and repaired in acconlance with de instructions provided, This equipment must be checked periodically. Defective equipment (including welding leas) should not be used. Parts that are broken, missing plainly worn, distorted or contaminsted, should be replaced immediate Should such repairs of replacements become necessary, it is recommended tat such repairs be ured out by appropeatly qualified persons approved by CIGWELD. Advice in this repard can be obtained by contacting CIGWELD. ‘This equipment or any ofits pats should not be altered from standard specification without price ‘wren approval of CIGWELD. ‘The user of this equipment shall have the sole responsibility fa ‘ay malfuneton which results from improper se oF unauthorised modification fFem standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately ‘halfed persons approved by CIGWELD.45 46 Transmig 165, Transmig 135, PortaWeld 100 Duty Cycle Duty Cycle isthe amount of are Decrease travel speed Reduce current and voltage and inezease Mig torch travel speed o select lower Penetration shielding gas Tetease weld metal sength correvise design Decrease voltage by reducing the voltage selection switch, B Slow the cooing rate by proheatng part to be welded or cool slowly 7 Cold wold pe ® Faulty exiier unit [A Have an Accredited CIGWELD Service Agent © test then replace the fauly component B Loose welding cable |B Checkall welding cable [C Low Primary Voltage _|C_Contuet supply authority 3 Are does notTavea crip) The MIG tore as bear | —Connest the MIG torch tthe sound that short are connected to the wrong] postive (+) welding terminal exhibits when the voltage polarity onthe | for solid wires and gas wiefeed speed and front panel Shielded Mu cored wires. vollage are adjusted Refer to the electrode wire conrecty ‘manufacturer forthe eorect polarity 4143 Power Source Problems FAULT CAUSE REMEDY T Mains supply volageis [A Primary fuse isBlown. [A Replace primary fase ON. Welding are can not! Broken connection in |B Have an Accredited oe primary ere CIGWELD Service Agent heck primary cicuil, 2 Mains indicator lightis [A Indicatorlightis open [A Have an Accredited rot litbut welding are | cirui CIGWELD Service Agent can be established replace On Switch B Internal A Fuse blown |B Replace Fuse 3 Mains supply volageis | Torch trigger switch Resonnest. (ON ad bat when the torch rigger switch is depressed noting Dappens leads are disconnected. BTransmig 165, Transmig 135, PortaWeld 100 Power Source Problems (continued) FAULT CAUSE REMEDY + Mains sopply voltages [A Hlectode wire stuck in) Check for clogged) kinked ON, no wire feed but gas] conduit liner or contact | MIG Torch conduit or worn Nos from the MIG. tip (burn-back jam, contract tip. Replace faulty “Torch when the torch componeait). trigger switch is B Faultycontrol PCB |B Have an Accredited depressed CIGWELD Service Agent : investigate the ful. 3 Wire feeds when the Poor orno work lad | Clean work clamp area and torch tigger switch is | connection, censure good electrical } depressed but are ea not contact. berestablished 6 torky wire Feed [A Wom ardiny contactup [A Replace B Wom feed rol, B Replace JC Excessive back tension] Reduce brake tension on from wire rel iu. spool hub D Wom, kinked or dry |] D Clean or place conduit liner conduit linge 7 Nogisilow A Gas hoe is ea IA Replace or epain, B Gaspassage contains |B Disconnect gas hose from the impurities, rear of Transnig 168/135, then rise gas pressure and blow out the impurities, IC Gas regulator tuned oft [Turn on. Gas low continues afer | Gas valve has jammed | Have an AccredNed the torch tigger switeh | open duet impurities in| CIGWELD Service Agent has een released, se gas or thegas line. | _repai or eplae gas valve. 15. Circuit Diagrams Figure 6 ransmig 165 Circuit Diayeam Transmig 165, Transmig 135, PortaWeld 100 «+ Figure 8 —PortaWeld 100 Circuit Diagram 36