320SP

400SP TRANSMIG
500SP

Service Manual
Version No: 2 Issue Date: October 25, 2005 Manual No.: 0-4773.003
Operating Features:
 CIGWELD
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Cigweld product. We are proud to have
you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call +61-3-9474-7400, or visit us
on the web at www.cigweld.com.au.

This Operating Manual has been designed to instruct you on the correct
use and operation of your CIGWELD product. Your satisfaction with
this product and its safe operation is our ultimate concern. Therefore
please take the time to read the entire manual, especially the Safety
Precautions. They will help you to avoid potential hazards that may
exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

CIGWELD is a Global Brand of Arc Welding Products for Thermadyne

Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through market-

leading, dependable products that have stood the test of time. We pride
ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced

products to achieve a safer working environment for industry
operators.
 WARNINGS

Read and understand this entire Manual and your employer’s safety practices before instaling,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.

Transmig 500SP Automation Power Supply with integrated cooler Spec Number W1000600
Transmig 400SP Automation Power Supply with integrated cooler Spec Number W1000400
Transmig 500SP Power Supply with integrated cooler Spec Number W1000500
Transmig 400SP Power Supply with integrated cooler Spec Number W1000200
Transmig 400SP Power Supply Spec Number W1000300
Transmig 320SP Power Supply Spec Number W1000100
Wirefeeder SP4000G Suits Gas Cooled MIG Torch Spec Number W3000100
Wirefeeder SP4000W Suits Coolant Cooled MIG Torch Spec Number W3000200
Wirefeeder SP4000R Suits Automation Power Supply/Cooled MIG Torch Spec Number W3000300

Published by:
CIGWELD Pty Ltd
71 Gower Street
Preston, Victoria, Australia, 3072

www.cigweld.com.au

©Copyright 2001 by
CIGWELD

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage
caused by any error or omission in this Manual, whether such error results from negligence, accident, or
any other cause.

Publication Date: October 25, 2005

Record the following information for Warranty purposes:

Where Purchased: ____________________________

Purchase Date: ____________________________

Equipment Serial #: ____________________________

This Page Intentionally Blank
 TABLE OF CONTENTS
SECTION 1:
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ........................................................
1.01 Arc Welding Hazards .....................................................................................................
1.02 PRINCIPAL SAFETY STANDARDS .............................................................................
1.03 DECLARATION OF CONFORMITY ..............................................................................
1.04 LIMITED WARRANTY ...................................................................................................

SECTION 2:
INTRODUCTION ..................................................................................................................................
2.01 How To Use This Manual ..............................................................................................
2.02 Equipment Identification ....................................................................................
2.03 Receipt Of Equipment ...................................................................................................
2.04 Symbol Chart .................................................................................................................
2.05 Machine Components ........................................................................................
2.06 Specifications .................................................................................................................

SECTION 3:
INSTALLATION ...................................................................................................................................
3.01 Quick Start Set Up ........................................................................................................
3.02 Recommended Setup for MIG ......................................................................................

SECTION 4:
OPERATION...................................................................................................................

4.01 Welding Controls ...........................................................................................................

4.02 Menu structure ...............................................................................................................
4.03 Special functions ...........................................................................................................
4.04Types of Weld Transfer Modes .....................................................................................
4.05 Holding and Manipulating the Torch ............................................................................
4.06 Basics of Pulsed Arc Welding ......................................................................................
4.07 Synergic Welding ....................................................................................... 4-11
4.08 Conventional Manual MIG Welding .....................................................................4-12
4.09 GTAW Welding ......................................................................................................4-12
4.10 MMAW Welding .....................................................................................................4-13
4.11 Lift TIG welding (optional) ....................................................................................4-13

SECTION 5:
SERVICE ..............................................................................................................................................
5.01 Maintenance ...................................................................................................................
5.02 System Troubleshooting Guide ....................................................................................
5.03 Welding Process Troubleshooting Guide ....................................................................
5.04 Error codes ....................................................................................................................

SECTION 6.0:
PARTS LIST .........................................................................................................................................

APPENDIX 1: GENERAL INFORMATION ............................................................................................A-1

APPENDIX 2: PC-BOARDS & MEASURING POINTS .........................................................................A-3

 TABLE OF CONTENTS

This Page Intentionally Blank

 TRANSMIG 320SP, 400SP, 500SP

SECTION 1:
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE
INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR
SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be
learned through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND
CUTTING. This publication and other guides to what you should learn before operating this equipment are
listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND
REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE

the wire, wire reel, drive roll housing, and

1.01 Arc Welding Hazards a l metal parts touching the welding wire
are electrically live. Incorrectly installed or
improperly grounded equipment is a
hazard.

1. Do not touch live electrical parts.

2 Wear dry, hole-free insulating gloves and body

protection.
3. Insulate yourself from work and ground using dry
insulating mats or covers.
4. Disconnect input power or stop engine before
installing or servicing this equipment. Lock input
power disconnect switch open, or remove line
fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment
according to its Owner’s Manual and national,
state, and local codes.
Touching live electrical parts can cause 6. Turn off all equipment when not in use.
fatal shocks or severe burns. The electrode Disconnect power to equipment if it will be left
and work circuit is electrically live unattended or out of service.
whenever the output is on. The input
power circuit and machine internal circuits
7. Use fully insulated electrode holders. Never dip
are also live when power is on. In holder in water to cool it or lay it down on the
semiautomatic or automatic wire welding, ground or the work surface. Do not touch holders
 connected to two welding machines at the same
time or touch other people with the holder or
electrode.
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.

10.Ground the workpiece to a good electrical (earth)

ground.
11.Do not touch electrode while in contact with the
work (ground) circuit.
12.Use only well-maintained equipment. Repair or
replace damaged parts at once.
TRANSMIG 320SP, 400SP, 500SP
13.In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.
14.Wear a safety harness to prevent falling if working
above floor level.

15.Keep all panels and covers securely in place. FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the

fumes.
2. If inside, ventilate the area and/or use exhaust at the
ARC RAYS can burn eyes and skin; NOISE arc to remove welding fumes and gases.
can damage hearing.
3. If ventilation is poor, use an approved air-supplied
Arc rays from the welding process
respirator.
produce intense heat and strong ultraviolet
rays that can burn eyes and skin. Noise 4. Read the Material Safety Data Sheets (MSDSs) and
from some processes can damage the manufacturer’s instruction for metals, consumables,
hearing. coatings, and cleaners.
5. Work in a confined space only if it is well ventilated,
1. Wear a welding helmet fitted with a proper shade of or while wearing an air-supplied respirator. Shielding
filter (see ANSI Z49.1 listed in Safety Standards) to gases used for welding can displace air causing
protect your face and eyes when welding or watching. injury or death. Be sure the breathing air is safe.
Wear approved safety glasses. Side shields 6. Do not weld in locations near degreasing, cleaning,
recommended. or spraying operations. The heat and rays of the arc
3. Use protective screens or barriers to protect others can react with vapors to form highly toxic and irritating
from flash and glare; warn others not to watch the arc. gases.
4. Wear protective clothing made from durable, flame-
resistant material (wool and leather) and foot
protection.
5. Use approved ear plugs or ear muffs if noise level is
high.

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73

Welding or Cutting Electrode size Metal Thickness Filter Welding or Cutting operation Electrode size Metal Filter
operation or Welding Current shade Thickness or Welding shade
no. Current no.

Torch soldering All 2 Gas metal arc welding

Torch brazing All 2 or 3 Non Ferrous base metal All 11
Oxygen cutting Ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding (TIG) All 12
Medium 1 – 6 in., 25 – 150 mm 4 or 5 Atomic Hydrogen welding All 12
Heavy Over 6 in., 150 mm 5 or 6 Carbon Arc welding All 12
Gas welding Plasma arc Welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Carbon Arc Gouging
Medium 1/8 – 1/2 in., 3 – 12 mm 5 or 6 Light 12
Heavy Over 1/2 in., 12 mm 6 or 8 Heavy 14
Shielded metal-arc welding (stick) electrodes Plasma arc cutting
Under 5/32 in., 4 mm 10 Light Under 300 Amp 9
Under 5/32 to ¼ in., 4 to 6.4mm 12 Medium 300 to 400 Amp 12
Over ¼ in., 6.4 mm 14 Heavy Over 400 Amp 14
 TRANSMIG 320SP, 400SP, 500SP
Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating
is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air-
supplied respirator. The coatings and any metals FLYING SPARKS AND HOT METAL can
containing these elements can give off toxic fumes cause injury.
if welded. Chipping and grinding cause flying metal.
As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles.

Side shields recommended.
2. Wear proper body protection to protect skin.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding
arc. The flying sparks and hot metal, weld
spatter, hot workpiece, and hot equipment
can cause fires and burns. Accidental
contact of electrode or welding wire to
metal objects can cause sparks,
overheating, or fire.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to treat
them carefully.
2. Protect yourself and others from flying sparks and hot metal.
3. Do not weld where flying sparks can strike
flammable material. 1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.
4. Remove all flammables within 35 ft (10.7 m) of
the welding arc. If this is not possible, tightly cover 2. Install and secure cylinders in an upright position
them with approved covers. by chaining them to a stationary support or
equipment cylinder rack to prevent falling or
5. Be alert that welding sparks and hot materials from tipping.
welding can easily go through small cracks and
openings to adjacent areas. 3. Keep cylinders away from any welding or other
electrical circuits.
5. Watch for fire, and keep a fire extinguisher paths and causing electric shock and fire hazards.
nearby. 9. Do not use welder to thaw frozen pipes
10.Remove stick electrode from holder or cut off
6. Be aware that welding on a ceiling, floor, welding wire at contact tip when not in use.
bulkhead, or partition can cause fire on the
hidden side.
7. Do not weld on closed containers such as tanks
or drums.
8. Connect work cable to the work as close to the
welding area as practical to prevent welding
current from traveling long, possibly unknown
4. Never allow a welding electrode to touch any
cylinder.

5. Use only correct shielding gas cylinders,

regulators, hoses, and fittings designed for the
specific application; maintain them and associated
parts in good condition.
6. Turn face away from valve outlet when opening
cylinder valve.
7. Keep protective cap in place over valve except
when cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas
cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
TRANSMIG 320SP, 400SP, 500SP

WARNING

Moving parts, such as fans, rotors, and belts can cut

fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Stop engine before installing or connecting
unit.
3. Have only qualified people remove guards or
Engines produce harmful exhaust gases.
covers for maintenance and troubleshooting
1. Use equipment outside in open, well-ventilated as necessary.
areas.
4. To prevent accidental starting during
2. If used in a closed area, vent engine exhaust servicing, disconnect negative (-) battery
outside and away from any building air intakes. cable from battery.
5. Keep hands, hair, loose clothing, and tools
away from moving parts.
6. Reinstall panels or guards and close doors
when servicing is finished and before starting
engine.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near
any sparks or open flames.
3. Allow engine to cool before fueling. If possible,
check and add fuel to cold engine before beginning
job. Batteries contain acid and generate explosive gases.
4. Do not overfill tank — allow room for fuel to 1. Always wear a face shield when working on a
expand. battery.
5. Do not spill fuel. If fuel is spilled, clean up before 2. Stop engine before disconnecting or connecting
starting engine. battery cables.
3. Do not allow tools to cause sparks when working
 on a battery.
4. Do not use welder to charge batteries or jump
start vehicles.
5. Observe correct polarity (+ and –) on batteries.
 based advice on strategies to minimize or avoid
potential risks.”
To reduce magnetic fields in the workplace, use the
following procedures.

1. Do not remove radiator cap when engine is hot.

Allow engine to cool.
2. Wear gloves and put a rag over cap area when
removing cap.
Allow pressure to escape before completely
removing cap.

The following is a quotation from the General

Conclusions Section of the U.S. Congress, Office of
Technology Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background
Paper, OTA-BP-E-63 (Washington, DC: U.S.
Government Printing Office, May 1989): “...there is
now a very large volume of scientific findings based
on experiments at the cellular level and from studies
with animals and people which clearly establish that
low frequency magnetic fields and interact with, and
produce changes in, biological systems. While most
of this work is of very high quality, the results are
complex. Current scientific understanding does not
yet allow us to interpret the evidence in a single
coherent framework. Even more frustrating, it does
not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-
 TRANSMIG 320SP, 400SP, 500SP
1. Keep cables close together by twisting or
taping them.
2. Arrange cables to one side and away from
the
operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as
far away from body as practical.

.
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.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders,
CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA
Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye
and Face Protection, ANSI Standard Z87.1, from
American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard
51B, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
TRANSMIG 320SP, 400SP, 500SP
1.03 DECLARATION OF CONFORMITY

Manufacturer: CIGWELD
Address: 71 Gower St, Preston
Victoria 3072
Australia

Description of equipment: Welding Equipment (GMAW, MMAW, GTAW, and CAG). CIGWELD TRANSMIG 500SP,
400SP, 320SP and associated accessories.

Serial numbers are unique with each individual piece of equipment and details description, parts
used to manufacture a unit and date of manufacture.
The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive
73/23/EU, as recently changed in Directive 93/68/EU and to the National legislation for the enforcement of the
Directive.
National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements among them
are:
• AS1966-1 applicable to welding equipment and associated accessories.
• AS/NZS 3652-(EMC Directive EN50199) applicable to arc welding equipment - generic emissions and
regulations.
• EN60974-1 applicable to welding equipment and associated accessories.
Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is
incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design
specifications.
CIGWELD has been manufacturing and merchandising an extensive equipment range with superior perfor-
mance, ultra safe operation and world class quality for more than 30 years and will continue to achieve
excellence.
 TRANSMIG 320SP, 400SP, 500SP
1.04 LIMITED WARRANTY
LIMITED WARRANTY: CIGWELD, A Thermadyne Company, hereafter, “CIGWELD” warrants to customers of its
authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material.
Should any failure to conform to this warranty appear within the time period applicable to the CIGWELD products as
stated below, CIGWELD shall, upon notification thereof and substantiation that the product has been stored, installed,
operated, and maintained in accordance with CIGWELD’s specifications, instructions, recommendations and
recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such
defects by suitable repair or replacement, at CIGWELD’s sole option, of any components or parts of the product
determined by CIGWELD to be defective.
CIGWELD MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN
LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: CIGWELD SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL,
INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSI-
NESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELD with
respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from
the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by CIGWELD 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.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES
ARE USED WHICH IN CIGWELD’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY
CIGWELD PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD
TO PURCHASER BY NON-AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the
products to the Purchaser. 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 authorized distributor.
TRANSMIG 320SP, 400SP, 500SP
Terms of Warranty – August 2005

The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply
of goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain
situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including
warranties as to merchantability and fitness for purpose) associated with the supply of goods and ser-
vices. A consumer should seek legal advice as to the nature and extent of these protected interests. In
some circumstances, the supplier of goods and services may legally stipulate that the said conditions,
warranties, guarantees, rights and remedies are limited or entirely excluded. The warranties set out in
Clause 2 shall be additional to any nonexcludable warranties to which the Customer may be entitled pursu-
ant to any statute.
2. Subject to Clause 3. CIGWELD gives the following warranties to the Customer:
Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantable
quality and reasonably fit for the purpose for which they are supplied by CIGWELD.
CIGWELD will repair or, at its option, replace those of the goods which, upon examination, are found by
CIGWELD to be defective in workmanship and/or materials.
CIGWELD reserves the right to request documented evidence of date of purchase.
3. The Warranty in Clause 2;
Is conditional upon:
The Customer notifying CIGWELD or our Accredited Distributor 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. The goods being
used in accordance with the Manufacturer’s Operating Manuals, and under competent supervision.
Does not apply to:
Obsolete goods sold at auction, second-hand goods and prototype goods.
Breakdown or malfunction caused by accident, misuse or normal wear and tear.
Repairs or replacement made other than by CIGWELD or Accredited Service Providers, unless by prior
arrangement with CIGWELD.
Replacement parts or accessories which may affect product safety or performance and which are not
manufactured, distributed or approved by 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 consump-
tion to any one or more of the following (the choice of which shall be at the option of CIGWELD).
The replacement of the goods or the supply of equivalent goods.
The repair of goods.
The payment of cost of replacing the goods or acquiring equivalent goods.
The payment of the cost of having goods repaired.
5. Except as provided in Clauses 2 to 4 above, to the extent permitted by statute, CIGWELD hereby
excludes all liability for any loss, damage, death or injury of any kind whatsoever occasioned to the
Customer in respect of the supply of goods including direct, indirect, consequential or incidental loss,
damage or injury of any kind.
 TRANSMIG 320SP, 400SP, 500SP
W a r r a n t y S c h e d u l e – J u ly 2 0 0 5

These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of sale
from the Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the war-
ranty 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.
MULTI PROCESS EQUIPMENT WARRANTY PERIOD

Transmig 320SP; Transmig 400SP; Transmig 500SP

MULTI PROCESS EQUIPMENT WARRANTY PERIOD

Transmig 320SP; Transmig 400SP; Transmig 500SP
Main Power Magnetics .............................................................................................................. 1 year

_
Original Main Power Rectifier, Control P.C. Boards ...........................................................
1 year
All other circuits and components including, but not limited to, relays, switches, contactors,
solenoids, fans, power switch semi-conductors ........................................................................
WIREFEEDER EQUIPMENT 1

SP4000G; SP4000W; SP4000R

Control P.C. Board .................................................................................................................... 1 year

All other circuits and components including, but not limited to, relays, switches, contactors,
solenoids, fans, power switch semi-conductors ........................................................................ 1 year
ACCESSORIES
Control P.C. Board .................................................................................................................... 1 year
All other circuits and components including, but not limited to, relays, switches, contactors,
solenoids, fans, motors, pumps, power switch semi-conductors ............................................... 1 year
MIG Torch (where fitted) ........................................................................................................... 3 Months
MIG Torch Consumable Items.......................................................................................
Nil

Please note that the information detailed in this statement supersedes any prior published data produced by
CIGWELD.
TRANSMIG 320SP, 400SP, 500SP

This Page Intentionally Blank

 TRANSMIG 320SP, 400SP, 500SP
Include the Owner’s Manual number and equipment
SECTION 2: identification numbers.
INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or
part numbers listed on page i.e.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotations are easily
recognized as follows:

Additional copies of this manual may be purchased

by contacting CIGWELD at the address and phone
number listed in the inside back cover of this manual.
 the invoice to make sure it is complete and inspect
2.02 Equipment Identification the equipment for possible damage due to shipping.
The unit’s identification number (specification or part If there is any damage, notify the carrier immediately
number), model, and serial number usually appear to file a claim. Furnish complete information
on a nameplate attached to the control panel. In some concerning damage claims or shipping errors to the
cases, the nameplate may be attached to the rear location in your area listed in the inside back cover of
panel. Equipment which does not have a control panel this manual.
such as gun and cable assemblies is identified only Include all equipment identification numbers as
by the specification or part number printed on the described above along with a full description of the
shipping container. Record these numbers on the parts in error.
bottom of page i for future reference. Move the equipment to the installation site before un-
crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-
2.03 Receipt Of Equipment
crate the unit.
When you receive the equipment, check it against
TRANSMIG 320SP, 400SP, 500SP
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
 TRANSMIG 320SP, 400SP, 500SP
2.05 Machine Components

No. Machine Component

1 MIG Torch
2 Gas Regulator (not shown)
3 Gas Cylinder (not shown)
4 Gas Cylinder Tray
5 Lifting Points
6 Handle
7 Primary Control Operating Panel
8 Secondary Control Operating Panel
9 Air intake
10 Wheeling Gear
11 Mains On/Off Switch
12 Preview and actual welding current and voltage
13 Work Clamp (not shown)
14 Negative Connection Socket for Work Lead
15 Protective cover, operation panel
18 Red = Hot coolant return
19 Blue = Cool coolant to torch
37 Coolant tank cap
TRANSMIG 320SP, 400SP, 500SP
2.06 Specifications
Power Supply

Power Source Part Numbers 320SP 400SP 500SP

Compact with Integrated Wirefeeder W1000100 – –
Remote Power Source suits Gas Cooled MIG Torch – W1000300 –
Remote Power Source with Integrated Cooler suits
Coolant Cooled MIG Torch – W1000200 W1000500
Remote Automation Power Source with Integrated
Cooler suits Coolant Cooled MIG Torch – W1000400 W1000600
Welding Output
Welding Current Range ( I 2 m i n -I 2 m a x / ) A 5 – 320 5 – 400 5 – 500
Welding MIG Voltage Range (U 2 m i n -U 2 m a x ) V 15.2 – 30 15.2 – 34 15.2 – 39
Nominal DC Open Circuit Voltage (OCV) V 81 81 81
Nominal DC OCV in MMAW/GTAW Mode (VRD ON) V 26 26 26
Voltage/Current Adjustment Continuously Variable Yes Yes Yes
Duty cycle 100% (At 40 °C) A 250 320 400
Duty cycle 60% (At 40 °C) A 270 350 500
Duty cycle at max. current (At 40 °C) 35%@320A 50%@400A 60%@500A
Weldable Wire Steel & Stainless Steel O mm 0.6 – 1.2 0.6 – 1.2 0.6 – 1.6
Weldable Wire Aluminium O mm 1.0 – 1.2 1.0 – 1.6 1.0 – 2.4
Welding Electrodes O mm 2.0 – 6.0 2.0 – 8.0 2.0 – 8.0
Wirefeed Speed m/min 0.1 – 25 n/a n/a
Mains Power
Mains voltage 3~ (50/60 Hz) V 415 415 415
Mains voltage tolerance range % +/- 15 +/- 15 +/- 15
Input power S 1 (100% At 40 °C) kVA 10.7 14.3 19
Input power S 1 (60% At 40 °C) kVA 12.6 16.1 26.1
Input power S1 (max. current) kVA 15.1 19.4 26.1
*Generator Requirement kVA 20 25 30
Current input I1 (100% At 40 °C) A 14.9 20 26.5
Current input I1 (60% At 40 °C) A 17.5 22.5 36.3
Current input I1 (maximum current) A 21 27.1 36.3
Power factor (At I 2 m a x ) cos 0.99 0.99 0.99
**Mains fuse/circuit breaker A 32 32 63
Classification
Protection class (EN 60 529) IP23 IP23 IP23
Insulation class F F F
Cooling method Fan Cooled Fan Cooled Fan Cooled
Noise emission dB (A) <70 <70 <70
Cooling system (Where Fitted)
Standard cooling power (l/min) kW n/a 1.1 1.1
Maximum pressure Pmax (bar) n/a 3.5 3.5
Pump n/a Centrifugal pump Centrifugal pump
Dimensions and weights
Dimension power source (DxWxH) mm 745x340x498 1116x445x855 1116x445x855
Weight of power source kg 35 91.3 100.8
Standard equipment
Wire feed unit Rollers 4 n/a n/a
Wire diameter mm 0.9/1.2 n/a n/a
*Minimum Generator Requirements at the Maximum Output Duty Cycle.
**Motor start fuses or thermal circuit breakers are recommended for this application.
Check local requirements for your situation in this regard.
 TRANSMIG 320SP, 400SP, 500SP
Wire Feeder

Wirefeeder Part Numbers SP4000G SP4000W SP4000R

Wirefeeder suits gas cooled torch – W3000100 –
Wirefeeder suits coolant cooled torch W3000200 – –
Wirefeeder suits Automation Power Source – – W3000300
Welding Output
Weldable Wire Steel & Stainless Steel O mm 0.6 – 1.2 0.6 – 1.2 0.6 – 1.6
Weldable Wire Aluminium O mm 1.0 – 1.2 1.0 – 1.6 1.0 – 2.4
Wirefeed Speed m/min 0.1 – 25 0.1 – 25 0.1 – 25
Wire feed unit Rollers 4 4 4
Wire diameter mm 0.9/1.2 0.9/1.2 0.9/1.2
Dimensions and weights
Size of wire feed case (DxWxH) mm 639x281x498 639x281x498 540x207x178
Weight of wire feed case kg 20.2 20.2 8.5

NOTE
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings,
a l capacities, measurements, dimensions and weights quoted are approximate only. Achievable
capacities and ratings in use and operation will depend upon correct installation, use, applications,
maintenance and service.
TRANSMIG 320SP, 400SP, 500SP

This Page Intentionally Blank

 TRANSMIG 320SP, 400SP, 500SP
SECTION 3: 3.02 Recommended Setup for MIG
INSTALLATION
A. Torch connection

Fit the MIG Torch (17) to the Euro adaptor (16) by

pushing the torch connector into the brass torch
adaptor and screwing the plastic torch nut clockwise
to secure the torch to the torch adaptor. Remove the
contact tip from the torch handset. If a coolant-cooling
system is fitted then connect the coolant connections
(20) of the torch with the sockets (18) and (19).
Connect the red fittings- together and the blue fittings
together.
Red = Hot coolant return (18)
Blue = Cool coolant to torch (19)

3.0 11

1 Quick Start Set Up 1,7'

:191
A. Where equipped, place the gas cylinder on the
power supply cylinder tray and secure with the 10
two safety chains. If unit is not equipped with this
;20!
option, then ensure that the gas cylinder is secured
to a building pillar, wall bracket or otherwise
securely fixed in an upright position.
B. How to connect the work lead
B. Remove screw cap from gas cylinder, if fitted,
and open gas cylinder valve briefly to remove Connect the work lead (22) to the Negative connection
contaminants. (14) and fasten it by turning the connector to the right.
C. Connect gas regulator to gas cylinder. Connect the Work clamp (Opposite end of 22) to the
D. Connect gas hose from power supply to gas workpiece or the welding table.
regulator and open gas cylinder valve.
E. Plug Mains Plug in a suitable socket, refer to
previous WARNING.
F. Connect work lead to Negative connection (–)
and attach Work clamp to workpiece.
G. Fit the correct size feed rollers to wire feeder
then fit the selected welding wire and set the
pressure levers to position 2.
H. Connect torch(central socket, coolant
connections red-blue) and mount contact tip to fit
welding wire selected.
I. Insert welding wire.
J. Turn on main switch.
K. Press push-button and push-button (gas type)
(solenoid valve is activated) and adjust gas amount
on the gas regulator (rule of thumb: wire diameter
x 10 = gas flow).

L. Keep the wire inch switch pressed until the

welding wire protrudes approximately 10 mm out
of the MIG torch nozzle.
TRANSMIG 320SP, 400SP, 500SP
C. Where to connect the Work Clamp F. Insertion of the wire electrode

Fasten the Work clamp (shown as #2 below), near Screw out the contact tip in the MIG torch handset.
the welding location; this avoids stray current flow Open the wire feed compartment lid on the power
through mains earthing system. U_
supply or wirefeed case.
M
The diameter of the wire should correspond to the
diameter of the feedrolls. The wire size is on the face
of the feedrolls. Open the pressure lever (27) and
thread the wire through the inlet guide (28) and the
outlet guide (16).

Connect the Work clamp tightly to the welding bench

or to the workpiece.
D. How to connect at the mains 30.
Insert the plug into a suitable mains socket. The
fuses 27 or circuit breaker should correspond to the
specification data.

Close the lever (30) and fasten the pressure rollers

(27).

E. How to install the wire spool

Open the wire feed compartment lid on the power

supply or wirefeed case and un-screw the nut (26)
from the wire support coil hub (24).
Place wire spool on the hub (24) and ensure that the Switch on power supply at main switch (11), stretch
drive dog-pin (23) engages the mating hole in the torch cable out straight and press the inch switch
wire spool. button ® in the wire feed compartment. Adjust the
pressure at the pressure adjustment screws (27) so
Press then release the inch switch to adjust the the wire-feed rolls drive the wire consistently without
brake (25), the wire spool should not continue to run. slipping. The wire should not be deformed.
 TRANSMIG 320SP, 400SP, 500SP
Adjust the pressure adjustment (27) next to the inlet
H. How to refill the cooling fluid
guide (28) to a lower pressure less than the pressure Only use original MIG/TIG coolant for refill. It provides
adjustment (27) next to the outlet guide (16), this will protection against frost down to -20°C. If using other
ensure that the wire will be located correctly in the coolants, the coolant pump could be damaged.
wire-feed unit. Coolant circulation has to be checked at regular
intervals. Reliable coolant return flow is essential to
Press the inch switch button ® until the wire appears ensure the coolant is not lost and the coolant cooled
approximately 20 mm out of the torch neck. MIG torch is not damaged. Check the level of the
Screw in the contact tip corresponding to the wire coolant every day before operating. The coolant must
diameter and cut off any wire sticking out. be visible when the tank cap (37) is removed.

G. How to connect the gas cylinder

If the Wheeling Kit option has been installed, position a
gas cylinder on the rear tray and lock securely to the
Power Source cylinder bracket with the chains provided.
If this arrangement is not used then ensure that the gas
cylinder is secured to a building pillar, wall bracket or
otherwise securely fixed in an upright position.
Open the gas valve once to blow out possible dirt
particles.
Connect the gas regulator to the gas cylinder valve. MIG/TIG
Coolant 5
Connect the gas hose to the gas regulator. Litre Part No.
W4001400
Open the gas cylinder valve and adjust the gas flow on
the gas regulator while pressing the torch trigger switch.
The quantity will be shown at the flowmeter.
This should be approximately wire diameter x 10 l/min.
TRANSMIG 320SP, 400SP, 500SP
I. How to configure the power supply for
aluminium welding
Change the feedrolls to U groove for aluminium wire.
Change the torch liner to a nylon or teflon liner.
Remove the capillary tube (42) at the central
connection.
Cut the teflon liner close to the end of the feedroll and
pull the brass tube over the teflon liner with the
corresponding length to stabilize it.
Fasten the torch and insert the wire electrode.

(17) Central connection

(38) Nipple for 4.0 mm and 4.7 external diameter
(39) O-ring 3,5 x 1.5 mm to prevent gas outlet

(40) Nut
(41) Nylon or Teflon liner
(42) Support tube. Replaces the outlet guide in the
central connection (16 See Previous Torch
Connection Illustration), for nylon or teflon liners
with 4 mm OD. The 4.7 mm or larger diameter liners
do not require the support tube.
(29) Feedroll
 TRANSMIG 320SP, 400SP, 500SP
For saving user-defined, frequently used welding
SECTION 4: jobs.
OPERATION (46) ”Welding wire diameter” push-button
For diameter selection of the wire to be welded.
The push-button is also used for the “End”
4.01 Welding Controls function, with which you can move back to the
previous menu level.
This section explains the Secondary Control Panel (8)
and Primary Control Panel (7) displays and buttons. (47) “TT Enter” push-button (Tiptronic)
See Section 2.05. For acknowledgement when saving a welding
job.
(48) “Gas type” push-button
414 4 4`51.46-47'48} 40 ' 91,5'1' For selection of the gas to be used. The push-
button is also used for the “increment” (+)
function, e. g., to increase the value of a
secondary parameter.
(49) “Tiptronic” push-button For switching
the Tiptronic mode on or off.
(50) Multi-function display
For indication of all parameter values and
messages.
(51) A and V push-buttons (Enter)
For switching between the individual secondary
parameters. Pressing both push-buttons at the
same time is used for acknowledgement (Enter).
(52) “2 stroke (2T) / 4 stroke (4T)” push-button
For switching between 2T and 4T (Latch)
operation mode. A lit LED indicates the currently
selected operating mode.
(53) “Synergic Power” control knob
(43)“Mode” push-button Sets welding current or material thickness or
For switching between the operation modes wire speed in Normal, Pulse, TwinPulse mode.
OR
Synergic = Synergic non-pulse MIG welding;
“Arc Voltage” control knob Sets welding arc
Pulse = Synergic pulse MIG welding; voltage in GMAW/FCAW mode.
TwinPulse = Synergic TwinPulse pulse MIG
welding; (54) “Digital multifunction” display
Displays the primary parameters such as
MMAW/GTAW = Programmable scratch start welding current, material thickness (in mm),
TIG OR Stick welding with VRD; wire feed speed (in m/min) or arc length trim.
(44) “Material” push-button (55) “Primary parameter” Indicator Lights
For selection of the wire material to be welded. These lights show which primary parameter is
The push-button is also used for the currently displayed in the multifunction display
“Decrementing" (-) function, e. g., to reduce the (54).
value of a secondary parameter.
(56) “Primary parameter” push-button
(45) “TT Save” push-button (Tiptronic) For switching between welding current, material
thickness, wire feed speed and arc length, as
indicated in the digital multifunction display (54).
TRANSMIG 320SP, 400SP, 500SP
(57) “Downslope” push-button
(62) Smart torch push-button
Switches the downslope function on or off. A lit
Has the same function as the “Primary
LED next to the push-button indicates that the
parameter” push-button (56) on the Control
downslope is on.
Panel. In Tiptronic mode this push-button can
(58) “Arc length” control knob be used to switch between job selection and job-
To adjust the arc length in Synergic Pulse, set selection.
TwinPulse mode,
OR
Current / voltage display

"Wire speed/Inductance" control knob. To adjust The actual welding voltage and welding current values
the wire speed or Inductance in GMAW/FCAWl are indicated during welding. After the welding
mode. procedure, the “Hold” LED illuminates and the last
welding voltage and welding current values are
(59) “Arc length” LED indication
indicated. When the operator changes certain welding
Indicates the degree of the trim in Normal, Pulse,
adjustments (e. g. thickness, program, job), the
TwinPulse mode.
“Hold” LED goes out and the preview values for
OR
current and voltage are displayed.
”Wire speed” LED indication Indicates the wire
speed in Manual mode.
When the uppermost centre LED is lit, the
programmed arc length/wire speed remains
unchanged; “0” is indicated in the multifunction
display (54). Turn the rotary control knob (58)
left to shorten the arc length/wire speed; turn
the rotary control knob (58) right to lengthen
the arc length/wire speed

A r t # A -0 6 3 7 7

(60) Smart Torch display

Indicates the welding current or arc length trim;
material thickness or arc length trim; wire feed
speed or arc length trim (Linked to the digital
multifunction display (54)).
In Tiptronic mode, the current job set and the
current job number are displayed.
(61) Smart torch rocker
Changes the welding current, material thickness,
arc length to the arc length (depending on which
value is being displayed on the digital
multifunction display (54)).
In Tiptronic mode, the rocker can be used to
switch between the active jobs or job sets.
 TRANSMIG 320SP, 400SP, 500SP
4.02 Menu structure

Main Level Level 1 Level 2 Remark

Gas pre-flow 0 – 10 sec.; not in MMAW/GTAW electrode mode
Start current 20 % – 200 % of the welding current
Start current time 0 – 10 sec.; not in 4-stroke mode
Twin pulse frequency 0.5 – 5 Hz; only in TwinPulse mode
Twin pulse current
change 5 – 50 % of the welding current; only in TwinPulse mode
Twin pulse relation 20 % – 80 %; only in TwinPulse mode
Welding current Adjustment range depends on the selected material-wire-
gas combination
Downslope 10 – 990 A/sec.; not in electrode mode, only when
downslope = on
Crater fill current 10 % – 200 % of the welding current; not in electrode
mode, only when slope = on or in 4 stroke
Crater Fill time 0 – 10 sec.; not in electrode mode, only for slope = on
Wire burnback time 20 % – 300 % of the programmed value; not in electrode
mode
Gas post-flow 20 % – 200 % of the programmed value; not in electrode
mode
Arc length correction 60 % – 140 % of the programmed value
Inductor effect 20 % – 200 % of the programmed value; only in normal
mode (short arc)
Arc dynamic (Arc Force) 0 % – 100 % of the programmed value; only in electrode
mode
Job selection, indication Set and job name are indicated only in Tiptronic mode
of set and job name upon actuation of the "TT Enter" push-button(47) or the
"Tiptronic" push-button (49)

Edit mode for set Move the cursor with the up and down y push-buttons
and job name (51); change the character with the pushbuttons (48)(+)
and (44)(-)
Extras 1 Machine data Operating system Master Version number, operating system Master
Operating system Process Version number, operating system process
Operating system DMRs Version number, motor assembly
Welding program version Version number, welding programs
Operating hour counter Indication of the welding duration in h, min, sec
Configuration Machine type and the recognized power module (with
max. current ) are indicated alternately
2 Diagnosis Last error message Indication of the last three error messages from the error
memory (0 = last error, 2 = oldest error)
Module temperatures Temperatures of the power modules in °C
Operating voltages Indication of the operating voltages (15 V / 24V) of the
assembly DPMAPRO
Flow rate, cooling unit Indication of the coolant flow rate in l/min
3 Language Selection of the menu language
4 Display contrast Contrast setting of the LCD display
5 Mode cooling 0 normal Cooling unit switches on, as soon as an arc is ignited
system 1 on Cooling unit runs constantly
2 off Cooling unit is deactivated
6 Lock function 0 All free
1 Welding current, mode and Tiptronic on/off free
2 Tiptronic on/off, job selection free
3 All locked except menu selection, gas and pump test
7 Arc length control Voltage Correct arc length with rotary pulse encoder(58)
Wire Correct wire speed with rotary pulse encoder(58)
8 Robot interface Menu item is only visible when the machine is equipped
with a robot interface (further details about
setup/configuration see Robot Interface Operation Manual)
TRANSMIG 320SP, 400SP,
500SP
 TRANSMIG 320SP, 400SP, 500SP
A. Secondary Parameters (Menu Main b. Press the “TT Save” button (45) (Save LED
Level) flashes).
c. Select the target job number with the push-
buttons (44) (-) and (48) (+) or with the smart
torch rocker, and confirm with the “TT Enter”
push-button (47) (if you do not press Enter, the
Save LED goes out after 10 seconds after the
last keystroke and the save operation is
aborted).
d. The Save and Enter LEDs flash briefly to
confirm that programming is terminated.
2. Selecting jobs:
a. Switch the Tiptronic function on by pressing
With and push-buttons you can switch “Tiptronic” (49) (associated LED comes on).
to the secondary parameters. The currently selected b. Select the job number with the smart torch
parameter is indicated in the display (50). The value rocker (alternatively the job number can be
in the square brackets is a standard or suggested selected with the push-buttons (44) (-) and
value. (48) (+)).
Push-button (44) (-) is used to reduce the indicated c. To exit the Tiptronic mode, press “Tiptronic”
parameter and push-button (48) (+) is used to (49) (Tiptronic LED goes out). The parameters
increase the value of the indicated parameter. Pressing are reset to the values that existed before you
the push-button (46) (END) saves the parameter and switched on the Tiptronic mode.
the system switches back to the material-wire-gas
combination display. 3. Setting a job inactive:
B. Extras menu a. Switch the Tiptronic function on by pressing
“Tiptronic” (49) (associated LED comes on).
In addition to the secondary parameters, the Extras
b. Select job number with the smart torch
menu item is also available; it offers the following
rocker (61) or with the push-buttons (44) (-)
functions:
and (48) (+) (an active job is indicated in the
Push-buttons (44) (-) and (48) (+) are used to switch smart torch display (60) and in digital
between the menu items. The different entries of the multifunction display (54) with a decimal point
menu items are called up by pressing the and between the job set and the job number).
push-buttons (51) at the same time. Switching c. Hold the Enter push-button (47) pressed for
between the individual entries is also possible here two seconds (the decimal point in the smart
with the push-buttons (44) (-) and (48) (+). To return, torch display 60 and in the digital display (54)
press push-button (46) (END). goes out).

C. Tiptronic
4. Setting a job active:
a. Switch the Tiptronic function on by pressing
The Tiptronic function provides you with 100 “Tiptronic” (49) (associated LED comes on).
independent jobs (10 job set with 10 jobs each). A
job stores all the settings and corrections on the b. Select the job number with the push-buttons
operating panel. (44) (-) and (48) (+) (with an inactive job, the
The best way to use the Tiptronic function is to as ign decimal point between job set and job number
job numbers to frequently recurring welding tasks or is missing).
save the settings which individual welders use c. Hold the “TT Enter” push-button (47)
specifically for “their” jobs. pressed for two seconds (the decimal point
between the job set and the job number lights
1. Save/Programming jobs:
up).
a. Determine the optimal welding values.
TRANSMIG 320SP, 400SP, 500SP

5. Re-saving/Re-programming jobs: d. The cursor is moved with the &

a. Switch the Tiptronic function on by and push-buttons (51). At the end of the
pressing “Tiptronic” (49) and select a job (see line, the cursor jumps to the respective next
Selecting Jobs). line.

b. Change the settings as required. e. Select a character (number, letter or

speciall character) with push-buttons (44) (-)
c. Press the “TT Save” button (45) (Save LED and (48) (+).
flashes).
f.The edit mode is ended by pressing push-
d. Press “TT Enter” button (47) to confirm. button (46) (END) or by pressing the and
e. The Save and Enter LEDs flash briefly to
confirm that programming is terminated. push-buttons (51) at the same time.
6. Copying jobs: If you press the “Tiptronic” push-button (49) in
a. Switch the Tiptronic function on by edit mode (Tiptronic is switched off), then the
pressing “Tiptronic” (49) and select a job for text entries will not be saved.
copying (see Selecting Jobs). Texts can be programmed both for the job set
b. Press the “TT Save” button (45) (Save LED (upper line in display (50)) as well as for the job
flashes). (bottom line in display (50)).
c. Select the target job number with the push- 4.03 Special functions
buttons (44) (-) and (48) (+) and confirm with A. Gas test
the “TT Enter” pushbutton (47) (if the Enter
push-button is not actuated, the Save LED B. Pressing the ,& push-button (51) and the “Gas
goes out 10 seconds after the last push-button type” pushbutton (48) at the same time activates the
actuation and the saving procedure is
cancelled). If the target job number has not gas test function. The solenoid valve of the system is
been occupied with a job yet, it is indicated by
the display flashing. activated and the gas flow rate can be checked /
d. The Save and Enter LEDs flash briefly to adjusted. The function remains active for 30 seconds
confirm that programming is terminated. and is then ended automatically. By pushing the “Gas
The user-defined job texts are also copied
type” push-button (48) again, the gas test can be
onto the new target job number.
terminated.
7. Assigning descriptive text to a job:
Text can be assigned to each job in order to
identify it more clearly. C. Pump test
Pressing the A push-button (51) and the “Material”
a. Switch on the Tiptronic function with the
pushbutton (44) at the same time activates the pump
“Tiptronic” push-button (49).
test function. The coolant pump is switched on and
b. Select the job number with the push- runs for approximately one minute. By pushing the
buttons (44) (-) and (48) (+). “Material” push-button (44), the pump test can be
terminated.
c. Press the & and push-buttons (51)
D. Resetting Adjustments
at the same time (a flashing cursor appears in
the display (50)) in order to get into the edit Pressing the push-button (51) and the “TT Enter”
mode. pushbutton (47) at the same time resets all secondary
parameters to the Factory set values. When the
Tiptronic mode is active, the settings of the current
job are reset. All adjustment in the Extras menu
(language, display contrast, etc.) remain unchanged.
E. Master Reset
This will erase all Tiptronic jobs / settings. Press
the push-button (51) and the “Mode”
pushbutton (43) at the same time for about 5
seconds. The display will show "Master Reset".
All settings will return to factory settings.
 TRANSMIG 320SP, 400SP, 500SP

E. Code lock function 4.04Types of Weld Transfer Modes

The lock function in menu Extras is secured with a
A. Dip transfer mode (short circuit arc)
code lock. A three-digit code must be entered before
the lock function can be changed. Only after the This type of arc is especially suitable for thin materials
correct code is entered, the lock function can be and positional welding due to a relative cool welding
altered. After leaving the menu, a new code number pool welded with very short arc, low arc voltage and
can be set or the old code number is acknowledged. low current. The surface tension of the welding pooll
Code “000” is the default (factory setting) number. helps to draw the drop into the bath and to reignite
the arc. This cycle is repeated again and again so the
Procedure: short circuit and the arcing period are constantly
1. Switch to menu Extras, lock function alternating.

2. Press button (44) (-) or (48) (+) question

“change parameter ?” is displayed
3. Acknowledge with button & (51)

4. Set three-digit code number with button (44)

(-),(48) (+) or encoder (53)
B. Transitional arc
5. Acknowledge the code number with button
The transitional arc is especially suitable for medium
(51) thickness sheet metals and for vertical-down welding.
The transfer of the electrode to the workpiece takes
6. Set desired lock function number with buttons place partly in short circuit and in free flight. Due to
(44) (-) or (48) (+) fewer short circuits, the welding pool is hotter than at
7. Leave menu with button (46) (END) the short circuit arc. Weldingwith transitional arc
provides higher electrode melt rate and is more
8. If requested, set a new code number with economic than welding at short circuit arc.
buttons (44) (-) ,(48) (+) or encoder (53)
C. Long arc
9. Acknowledge the code number with button Long arcs are typically at a higher ampere range under
(51) carbon dioxide and gases with a high CO2 content. It
is not particularly suitable for positional welding. In
this type of arc large drops are formed which falls into
the welding pool mainly by force of gravity. This
results in occasionally short circuits occurring, which
increases the current at the moment of the short
circuit and high spatter levels when the arc is reignited.
D. Spray arc
The spray arc is not suitable for positional welding,
due to the extremely liquid nature of the welding pool.
The spraying arc forms by welding at the higher range
of ampere using inert gas or mixtures with high argon
content. The most typical characteristic of the spray
arc is the transfer of extremely fine molten metal
droplets across the arc.
TRANSMIG 320SP, 400SP, 500SP
E. Working range at MAG welding Avoid extreme side to side movements as it can cause
the weld pool to dam up in front of the arc. This can
cause lacks of fusion due to the welding pool flowing
Wire Long arc / Transitional Short circuit
diameter Spray arc arc arc
ahead of the welding arc. The side to side motion
should only be used as wide as is necessary to reach
mm A V A V A V
both sides of the joint. If the joint is too wide you
140… 23… 110… 18… 50… 14…
08 should weld two parallel weld beads. When vertical-
180 28 150 22 130 18
180… 24… 130… 18… 70… 16… up welding, the side to side motion should follow the
10
250 30 200 24 160 19
shape of an open triangle.
220… 25… 170… 19… 120… 17…
12 Length of the arc
320 32 250 26 200 20
260… 26… 200… 22… 150… 18… Welding with a longer arc reduces the penetration,
16
320 34 300 28 200 21 the welding bead is wide and flat with increased
Favorable welding characteristics are only possible if voltage spattering. The welding material is transferred with
and current are correctly adjusted. slightly larger drops than welding with a shorter arc.
CO2requires an arc voltage approximately 3 V higher than gas
mixtures with a high argon content.
A longer arc is useful for welding a fillet weld to form
a flat or concave seam. Welding with a shorter arc (at
the same amperage) increases the penetration, the
4.05 Holding and Manipulating the welding bead is narrow and high with reduced
spattering. The welding material is transferred with
Torch smaller droplets.
NOTE

Metal shielded gas welding can be welded

in al positions: horizontal, vertical-down,
vertical-up, overhead and in horizontal-
vertical position.

When horizontal welding, hold the torch vertical to

the workpiece (neutral torch position) or up to 30°
“pushing” the torch. For best depth of penetration
and shielding gas coverage hold the torch in the Length of the wire electrode
neutral position. Please note that if the torch is tilted The distance between the torch and the workpiece
too far, it is possible that air will be sucked into the should be 10 – 12 times the diameter of the wire.
shielded gas and may result in porosity. For verticall Altering the distance of the torch will influence the
or overhead welding a slight pushing motion is re- electrode stick out.
uired. Vertical down welding is most used for thin
materials, hold the torch at the neutral or slightly A longer electrode stick out reduces the amperage
“dragging” position. Some experience is required as
and the penetration.
the welding pool could run ahead of the arc and cause A shorter electrode stick out increases the amperage if
weld defects. There is a danger of lacks of fusion with the wire-feed speed remains the same.
thicker material due to the welding pool being very
liquid from high voltage.
 TRANSMIG 320SP, 400SP, 500SP
Material Transfer

Benefits:
• Controlled, short-circuit-proof material transfer without spatter •
Low thermal transfer due to low primary current
Disadvantages:
• Only shielding gases with low CO2 content can be used
4.06 Basics of Pulsed Arc Welding
A. Current and voltage pulses
Material transfer is achieved by current and voltage pulses controlled at the same rate as the pulse frequency.
The arc power is changed by the ratio between background and pulses current, the pulse duty cycle and the
pulse frequency.
TRANSMIG 320SP, 400SP, 500SP
B. Forces acting during material transfer C. Wire feed speed vD and pulse frequency
fP
The main condition for a controlled material transfer
A number of forces come into play which influences with one drop per pulse is to set a defined drop
the resulting molten metal drop formation and volume. The volume of the melted drop must then be
separation. identical with the volume of the wire electrode fed in
each pulse period. The necessary wire feed speed vD
results from the product of pulse frequency fP and
the wire length “L” melted in each pulse period. From
this relationship you see that a change in wire feed
speed requires a linear change in pulse frequency. A
rise in electrode melt rate by increasing wire feed
speed needs a higher pulse frequency. The objective
drop diameter should be about 1.2 mm with a wire
diameter of 1.2 mm.
D. Primary current
Arc length ionisation must be maintained during the
primary current phase, whose period results from the
selected frequency and pulse period. This requires
currents ranging between 25 and 80 A depending on
wire diameter, material and material thickness. The
primary current can also be used to affect the arc and
material transfer. At a constant ratio of wire feed speed
and pulse frequency, the arc length can be changed
by varying the primary current and the associated
voltage. Reducing the primary current causes a
shorter arc. This can be used to counteract arc
Welding parameters deflection with fillet welds or at high welding rates.
A. Pulse period tP The time of drop separation can be affected by varying
the ratio of primary current to pulse current. Normally
The pulse period for separating the droplet is between
the objective is to separate the drop just after the
1.5 and 3.0 ms depending on wire diameter and the
current pulse in the primary current phase (in the third
pulse current setting IP. pulse current phase).This can be achieved by
If the pulse period is too long, material transfer only increasing the primary current and reducing the pulse
takes place during the pulse phase. current at the same time. Remember that excessively
high primary current will melt the free wire end too
Arc formation and drop rate can be affected by
quickly. This will form very large drops which can
additional pulse stages. lead to spatter during the transition to the welding
B. Pulse voltage UP and pulse current IP
pool.
Since welding with pulsed arc is based on the
temporary utilisation of the pinch effect, the drop-
separating pulse current must always be large enough
to exceed critical current intensity depending on wire
diameter, wire material and shielding gas composition,
etc. If this value is not achieved, material transfer takes
place completely or partially in the short circuit with
possible spatter.
 TRANSMIG 320SP, 400SP, 500SP
E. Pulse MIG applications
4.07 Synergic Welding
The main application for pulse MIG is for precision
MIG welding of aluminium, stainless steel, steel and
other weldable materials.
• Spray transfer welding permitted at lower-than-
normal average weld currents.
• No spatter or undercut in the majority of welding
applications.
• Precise control of welding power, to assure bead
shape and root penetration rivalling TIG welding.
• High energy arc produced, that virtually
eliminates the risk of lack of fusion.
• Improved arc control for out-of-position welding
and more effective welding of thin materials,
with all the advantages of spray transfer.
• Optimised pulse programs for gas/wire
combinations
• TwinPulse® capabilities.
• Exceptional out-of-position welding for non-
ferrous materials, including aluminium.
• Effortless TIG-like weld appearance on
aluminium and stainless steel
• Deeper weld penetration
• Accurate penetration on sheet metal
• Superior welding characteristics on hard-facing
and highalloy steels
• The ability to use larger-than-normal diameter
wires on thin base material, providing a cost
saving on wire
• Spray arc welding vertical up, giving smoother
welds, better control and deeper penetration
• Improved edge wetting in synergic pulse mode
At the lower end of the performance range the pulsed
arc cannot fully replace the dip transfer. The reason
is the continuous arc that occurs in the primary
current phase. This phenomenon does not exist with
the short-circuiting arc. An exception to this is when
welding aluminium and aluminium alloys. Normally,
these materials can only be reliably welded using a
pulsed arc. In the upper performance range, the
pulsed arc is preferable to the sprayer arc, in particular
for welding aluminium materials and high-alloy steels.
TRANSMIG 320SP, 400SP, 500SP
4.08 Conventional Manual MIG
4.09 GTAW Welding
Welding
The following instructions explain how to set up for
The following instructions explain how to set up for GTAW (TIG) welding with VRD on.
conventional manual MIG welding.
 TRANSMIG 320SP, 400SP, 500SP
4.10 MMAW Welding 4.11 Lift TIG welding (optional)
The following Instructions explain how to set up for
MMAW (stick) welding with VRD on.
•

a. Connect TIG torch to socket (14)

b. Connect torch control-plug to socket
c. Connect torch gas hose to gas connector
d. Select TIG mode with mode button (43) t

The following parameters can be set for TIG mode:

-Start current / -time
-Down slope
-End current / -time
TRANSMIG 320SP, 400SP, 500SP

This page intentionally blank

 TRANSMIG 320SP, 400SP, 500SP

SECTION 5:
SERVICE
5.01 Maintenance

Visually check and

Carefully clean the
interior
.
TRANSMIG 320SP, 400SP, 500SP
5.02 System Troubleshooting Guide

Symptom Cause Remedy

Torch too hot Insufficient coolant through flow due to pollution in Flush the coolant hoses of the torch in opposite
coolant direction
Contact tip is not tight or the wrong size for the wire Check it
used
No function when torch Nut of the torch hose is not tight Tighten it
button is pressed No connection of the control cable in the torch hose Check and change if necessary
Overload of the unit and thermal protection operates Allow unit to cool down at no load
Irregular wire feeding Wire electrode is tight at the spool Check and change if necessary
or wire welds to the
contact tip Burr at the wire beginning Cut burr from end of wire
Irregular wire feeding Wrong contact pressure at the wire-feed rolls Adjust it as described in the manual
or no wire feeding Torch defective Check and change if necessary
No intermediate guide or is dirty Install or clean the intermediate guide
Bad quality of welding wire Check and change if necessary
Rust formation on the welding wire Check and change if necessary
Torch liner is dirty inside Disconnect the torch from the machine, unscrew
the contact tip and clean the liner with
compressed air
Torch liner is defective Check and change if necessary
Motor brake adjusted too strong Adjust as described in the manual
Unit switches off Duty cycle overloaded Allow the machine to cool down
Poor cooing of internal unit parts Check the air in and outlet
Cooler, hoses or pump Frozen systems due to low concentration of Contact the nearest service facility
are damaged recommended coolant in re-circulator
Arc or short circuit Spatter built up inside the gas nozzle Remove it with special pliers
between contact tip and
gas nozzle
Unstable arc Wrong diameter contact tip or worn out Change contact tip
The Control Panel is Primary power phase missing Check the unit at another power outlet. Check
completely blank power cable and mains fuses/circuit breakers
No shielded gas Gas cylinder empty Replace it
Defective torch Check and replace it
Gas regulator dirty or defective Check and replace it
Valve of gas cylinder defective Replace the gas cylinder
Shielded gas switches Valve of gas cylinder dirty or does not close Remove torch and gas regulator and clean it
not off with compressed air
Not enough shielded Incorrect setting of shielded gas Adjust as described in the manual
gas Dirty gas regulator Check valve
Torch, gas hose blocked or not air-tight Check and change if necessary
Shielded gas is blown away from draught Avoid draught
Decreased welding Phase missing Check the unit at another power outlet. Check
performance power cable and mains fuses/circuit breakers
Poor Work lead connection Ensure good electrical contact between Work
clamp and workpiece
Work lead not plugged in right Fasten work lead by turning the plug to the right
Defect torch Repair or replace it
Hot plug of work lead Plug was not tightened by turning to the right Check
Higher wire wear out at Wire rolls do not fit the wire diameter Install correct wire rolls
wire-feeding unit Wrong contact pressure at wire feeder Adjust as described in the manual
 TRANSMIG 320SP, 400SP, 500SP
5 . 0 3 Welding Process Troubleshooting Guide

Symptom Cause Remedy

Poor edge wetting on Gas mixture in the cylinder has separated due to lack Place protective cap used for storage and
stainless steel welds of use transport on cylinder then carefully disconnect
the cylinder from the welder and lay it down on
the floor. Carefully roll it back and forth to re-
mix the gas
Wire is contaminated with oil or the wire quality is Contact wire manuafacturer / supplier.
uncertain Keep the wire covered
Work piece is contaminated with grease or oil Degrease with mineral spirits, etc to remove
contaminates
Poor current transfer to the wire at the contact tip Use a copper or brass jump liner in the
conductor tube to improve current transfer to
the wire
Stanless steel weld has Arc length control (58) has been adjusted too high Reduce arc length, control (58)
a dark burnt finish
Dirty aluminum welds Inadequate gas coverage Increase gas flow by 10% and check again.
Shield arc from drafts.
Hold nozzle closer to the work.
Replace the damaged nozzle to center contact
tip in nozzle
Wire is contaminated with oil Contact wire manuafacturer / supplier.
Keep the wire covered
Work piece is contaminated with grease or oil Degrease with mineral spirits, etc to remove
contaminates
Poor current transfer to the wire at the contact tip Use a copper or brass jump liner in the
conductor tube to improve current transfer to
the wire
Weld performance is Incorrect wire / gas combination selected Set the correct gas / wire combination
very poor or high
spatter levels
Poor weld starts Improper work lead connection Reconnect work lead
Contact tip is worn with an oval shape hole or Replace contact tip
contact tip is black
Contact tip is loose Tighten contact tip
Varying arc length Material build-up in torch liner Replace torch liner
when welding Contact tip is worn or damaged Replace contact tip
TRANSMIG 320SP, 400SP, 500SP
5.04 Error codes
When there is a malfunction, an error code is indicated on the digital multifunction display (54) and the corre-
sponding error description appears on the LCD display (50). As long as an error code is indicated, welding
operation will not be possible.

Code Error description Remark Remedy

E00 <noP> (No welding No welding parameters for the selected Choose a different material-wire-gas
program) material-wire-gas combination combination
E01 Thermal overload The system has been overheated Allow the system to cool down in standby;
check the ventilation
E02 Mains over-voltage Mains voltage too high Check mains voltage
E03 Over-current Output current too high Notify an accredited CIGWELD Service Provider
for repair
E04 Air-cooling error Flow rate of air too low Clean the air intake(9); check fan
E05 Faulty cooling circuit No or too little flow rate of coolant Check level of cooling-fluid and coolant filter
E06 Over-voltage Output voltage too high Notify an accredited CIGWELD Service Provider
for repair
E07 EEPROM checksum Adjustment data faulty or not available Switch system off and then on again
error
E08 Wire feed / tacho Current input from feed motor too high No Blow out torch package with compressed air
tacho signal available and check wire feed unit
E09 Error v/a measuring Faulty current / voltage measuring systems Notify an accredited CIGWELD Service Provider
for repair
E10 Torch socket / cable Faulty torch switch cable or torch switch Check torch
socket
E11 Remote control socket Faulty remote control or socket of remote
control Check remote control
E12 Communication process Defective communication CAN-Bus (process) Switch system off and then on again

E13 Error, temperature Thermo sensor not operative Notify an accredited CIGWELD Service Provider
sensor for repair
E14 Supply voltage Internal supply voltage too low Check mains voltages
E16 Over-current protection Allowable maximum power supply of power Notify an accredited CIGWELD Service Provider
1 unit 1 too high for repair
E18 Overload protection Safety switch device for protection of Allow the system to cool down in standby
electrical components
E20 Over-voltage secondary Output voltage too high Notify an accredited CIGWELD Service Provider
for repair
E21 Output voltage / current Power unit delivers voltage / current without Notify an accredited CIGWELD Service Provider
drive for repair
E22 Mains under voltage 1 Mains voltage at power unit 1 too low Check mains voltages
E23 Mains over-voltage Mains voltage too high Check mains voltages
E24 Over-current protection Power supply of power unit 2 too high Notify an accredited CIGWELD Service Provider
2 for repair
E25 Power-module detection Power unit not being recognized or Notify an accredited CIGWELD Service Provider
unallowable combination of power units for repair
E27 No program (DSP) Welding programs faulty or not available Notify an accredited CIGWELD Service Provider
for repair
E30 Mains under-voltage 2 Mains voltage at power unit 2 too low Check mains voltages
E31 Communication error Faulty communication CAN-Bus (master) Switch system off and then on again
 TRANSMIG 320SP, 400SP, 500SP
SECTION 6.0:
PARTS LIST

Cigweld Part Number OEM Part Number Description

W6000000 981.1419.0 Thermal sensor 320/400/500SP
W6000001 665.3008.0 Solenoid valve 24VDC SP
W6000002 650.5160.5 PCB LSW 320/400/500SP
W6000003 650.1242.5 PCB DS20BF 320/400/500SP
W6000004 650.1262.5 PCB DP-UFI 320/400/500SP
W6000005 650.1264.5 PCB DP-MAPRO 320/400/500SP
W6000006 650.1261.5 PCB DMR 320/400/500SP
W6000007 650.5265.5 PCB DK-GLCL 320/400/500SP
W6000008 665.5242.0 Motor 42V 240rpm SP
W6000009 711.2606.0 MOSFET 900V 26A SP
W6000010 709.2000.0 Fuse 4A 320/400/500SP
W6000011 709.0193.0 Fuse 2,5A 320/400/500SP
W6000012 709.0153.0 Fuse 1A 320/400/500SP
W6000013 713.0294.0 Diode BYT231 PIV1000 SP
W6000014 713.0298.0 Diode BYT200 PIV400 SP
W6000100 655.8023.0 Transformer control 320SP
W6000101 657.0103.0 Switch 1/0 20A 320SP
W6000102 650.1281.5 PCB DP-S3NEFI 320SP
W6000103 650.1274.5 PCB DK-S3DRV 320SP
W6000104 665.5727.0 Fan 24V DC Ø150x172x38 320SP
W6000105 658.0244.0 Rectifier 1600V 30A 320/400SP
W6000200 665.8043.5 Power unit 400SP
W6000201 665.6303.0 Filter mains 3PH 32A 4mm 400SP
W6000202 655.8021.0 Transformer control 400SP500SP
W6000203 657.2030.0 Switch 1/0 32A 400/500SP
W6000204 665.5570.0 Pump 400/500SP
W6000205 650.1252.5 PCB PWRUP04D 400/500SP
W6000206 650.1248.5 PCB DS-ERW 400/500SP
W6000207 650.5262.5 PCB DK-DCDRV 400/500SP
W6000208 665.3131.0 Flowmeter 400/500SP
W6000209 665.5725.0 Fan 119x119x38 400/500SP
W6000210 658.1412.0 Rectifier B6 1600V 50A 500SP
W6000211 665.8044.5 Power unit 500SP
W6000212 665.6304.0 Filter mains 3PH 40A 6mm 500SP
 Mechanical Spare Parts

Cigweld Part OEM Part Description Models

Number Number
TBA 620.7110.0 Cover socket central connection (euro)
TBA 620.7111.0 Push rivet 5x7,5 for SF-cover socket
na 620.9101. 7 Inlet guide ID 2,0 MEC
7977487 na Inlet guide 1.6/2.4
7977486 na Inlet guide 0.8/1.6
7977488 na Intermediate guide 0.6/1.6
7977489 na Intermediate guide 1.6/2.4
TBA 665.7030.0 Insert sleeve BEB 50-70-95 (dinse
socket for ground connection)
TBA 604.3673.0 Turn fastener quad Ø 31 mm (from the
side panel)
TBA 620.9003.0 capillar tube 98mm 2,0 Ms (guide tube)
TBA 620.7109.0 Central connection 83,5mm ZF 49mm
MEC (euro adaptor )
TBA 620.9313.0 Wire feed unit VE 42-30 MEFR MEC

705061 na 4R drive conversion kit with flat

pressure roller (recommended for
aluminum wires )
TBA TBA Pressure roller Plain OEM

*Note These fit the bottom drive

roller and top drive after 4R drive
conversion 705061 has been fitted
7977729* na Feed Roll Hard 0.6/0.8mm V-Groove
7977703* na Feed Roll Hard 0.9/1.2 mm V-
Groove
Feed Roll Hard 1.2/1.6 mm V-
7977346* na
Groove
7977733* na Feed Roll Soft 0.8/0.9 mm U-Groove
7977730* na Feed Roll Soft 1.0/1.2 mm U-Groove
7977348* na Feed Roll Soft 1.2/1.6 mm U-Groove
7977734* na Feed Roll Cored 0.8/0.9 mm V-Knurl
7977347* na Feed Roll Cored 1.2/1.6 mm V-Knurl
7977372* na Feed Roll Cored 1.6/2.4 mm V-Knurl
Transmig 320SP Main Schematic
Transmig 320SP Main Schematic Parts List
Pos OEM Part No Description
A 1 650.1281.5 pc-board DP-S3NEFI (E)
A 1 650.1281.9 pc-board DP-S3NEFI (T)
A 2 658.0244.0 rectifier DB 1600V 50A
A 3 650.1274.5 pc-board DK-S3DRV (E)
A 3 650.1274.9 pc-board DK-S3DRV (T)
A 4 650.5160.5 pc-board LSW (E)
A 4 650.5160.9 pc-board LSW (T)
A 5 650.5315.5 pc-board DP-MAPRO VRD (E)
A 5 650.5315.9 pc-board DP-MAPRO VRD (T)
A 6 650.1261.5 pc-board DMR (E)
A 6 650.1261.9 pc-board DMR (T)
A 7 650.1242.5 pc-board DS20BF (E)
A 7 650.1242.9 pc-board DS20BF (T)
A 8 650.1228.5 pc-board DS-VA (E)
A 8 650.1228.9 pc-board DS-VA (T)
A 9 650.6271.5 pc-board PP-90R (E)
A 10 650.5265.5 pc-board DK-GLCL (E)
A 11 713.0298.0 diode BYT200 PIV400
A 12 713.0298.0 diode BYT200 PIV400
A 13 713.0298.0 diode BYT200 PIV400
A 14 650.5316.5 pc-board DP-EMV (E)
A 15 650.5311.5 pc-board DP-UFI-BO (E)
F 1 709.0193.0 fuse 2,5A TR 5x20 (extern cooling system)
F 2 981.1419.0 thermal sensor 23x7x5 LD3,4
F 3 709.2000.0 fuse 4,0A TR 6,3x32mm (control transformer)
F 4 709.2000.0 fuse 4,0A TR 6,3x32mm (control transformer)
L 1 655.7531.0 inductor WA 24000043
M 1 665.5727.0 fan (power unit)
M 2 665.5242.0 wire feed motor 42V 240U/min 73mm T
Q 1 657.0103.0 switch 1/O 20A
S 1 torch switch
S 2 657.8500.0 wire insert switch
T 1 655.8023.0 control transformer WA 31000025 toroidal core
T 2 655.9054.0 transformer WA 13000044
X 1 661.7614.3 mains cable 4x2.5
X 2 665.7032.0 insert sleeve BEB 70-95
X 3 665.7032.0 insert sleeve BEB 70-95
X 4 620.7109.0 central connection
X 6 650.5272.5 socket remote control
X 7 661.3180.1 socket push-pull
X 8 665.2209.0 socket extern cooling system
Y 1 665.3008.0 solenoid valve 24VDC 2x hose connection

(E) : spare part

(T) : replacement
Transmig 400SP Main Schematic
Transmig 400SP Main Schematic Parts List
Po OEM Part No Description
03.0 EMC filter 3PH 32A 4mm²
52.5 pc-board PWRUP04D (E)
52.9 pc-board PWRUP04D (T)
44.0 rectifier DB 1600V 50A
62.5 pc-board DK-DCDRV (E)
pc-board DK-DCDRV (T)
A 4a 650.5262.5 pc-board DK-DCDRV (E)
A 4a 650.5262.9 pc-board DK-DCDRV (T)
A 5 650.5160.5 pc-board LSW (E)
A 5 650.5160.9 pc-board LSW (T)
A 6 650.5315.5 pc-board DP-MAPRO VRD (E)
A 6 650.5315.9 pc-board DP-MAPRO VRD (T)
A 7 650.1261.5 pc-board DMR (E)
A 7 650.1261.9 pc-board DMR (T)
A 8 650.1243.5 pc-board DS22BF (E)
A 8 650.1243.9 pc-board DS22BF (T)
A 10 650.6271.5 pc-board PP-90R (E)
A 11 650.5265.5 pc-board DK-GLCL (E)
A 11a 650.5265.5 pc-board DK-GLCL (E)
A 12 713.0298.0 diode BYT200 PIV400
A 13 713.0298.0 diode BYT200 PIV400
A 14 713.0298.0 diode BYT200 PIV400
A 12a 713.0298.0 diode BYT200 PIV400
A 13a 713.0298.0 diode BYT200 PIV400
A 14a 713.0298.0 diode BYT200 PIV400
A 15 665.8043.5 power unit Cigweld 400SP (E)
A 15 665.8043.9 power unit Cigweld 400SP (T)
A 16 650.5316.5 pc-board DP-EMV (E)
A 17 650.1244.5 pc-board DS21BF (E)
A 17 650.1244.9 pc-board DS21BF (T)
A 18 650.1228.5 pc-board DS-VA (E)
A 18 650.1228.9 pc-board DS-VA (T)
A 19 650.5311.5 pc-board DP-UFI-BO (E)
C 1 704.0881.0 capacitor (at pump)
F 1 709.0153.0 fuse 1,0A TR 5x20 (fan power unit)
F 2 709.0193.0 fuse 2,5A TR 5x20 (pump and fan)
F 3 981.1419.0 thermal sensor 23x7x5 LD3,4 (DC)
F 3a 981.1419.0 thermal sensor 23x7x5 LD3,4 (DC)
F 4 709.2000.0 fuse 4,0A TR 6,3x32mm (control transformer)
F 5 709.2000.0 fuse 4,0A TR 6,3x32mm (control transformer)
F 6 665.3131.0 flowmeter ID2 AD6
L 1 655.7530.0 inductor WA 24000042
M 1 665.5725.0 fan (power unit)
M 2 665.5725.0 fan (power unit)
M 3 665.5570.0 pump
M 4 665.5725.0 fan (cooler)
M 5 665.5725.0 fan (cooler)
M 6 665.5725.0 fan (cooler)
M 7 665.5242.0 wire feed motor 42V 240U/min 73mm T
Q 1 657.2030.0 switch 1/O 32A
S 1 torch switch
S 2 657.8500.0 wire insert switch
T 1 655.8021.0 control transformer WA 31000024 Ringkern
T 2 655.9052.0 transformer WA 13000043
X 1 661.7724.7 mains cable 4x4
X 2 665.7032.0 insert sleeve BEB 70-95
X 3 665.7032.0 insert sleeve BEB 70-95
X 4 620.7109.0 central connection
X 7 661.8914.0 socket CAN
X 9 665.7032.0 insert sleeve BEB 70-95
X 10 665.7130.0 insert plug BKB 50-70 mm²
X 11 661.8877.0 panel socket interpass hose package
X 12 661.8882.0 panel plug interpass hose package
X 13 661.3180.1 socket push-pull
Y 1 665.3008.0 solenoid valve 24VDC 2x hose connection
(E) : spare part
(T) : replacement
Transmig 400SP Automation Main Schematic
Transmig 400SP Automation Main Schematic Parts List
Pos OEM Part No Description
03.0 EMC filter 3PH 32A 4mm²
52.5 pc-board PWRUP04D (E)
52.9 pc-board PWRUP04D (T)
44.0 rectifier DB 1600V 50A
62.5 pc-board DK-DCDRV (E)
pc-board DK-DCDRV (T)
A 4a 650.5262.5 pc-board DK-DCDRV (E)
A 4a 650.5262.9 pc-board DK-DCDRV (T)
A 5 650.5160.5 pc-board LSW (E)
A 5 650.5160.9 pc-board LSW (T)
A 6 650.5315.5 pc-board DP-MAPRO VRD (E)
A 6 650.5315.9 pc-board DP-MAPRO VRD (T)
A 7 650.1261.5 pc-board DMR (E)
A 7 650.1261.9 pc-board DMR (T)
A 10 650.6271.5 pc-board PP-90R (E)
A 11 650.5265.5 pc-board DK-GLCL (E)
A 11a 650.5265.5 pc-board DK-GLCL (E)
A 12 713.0298.0 diode BYT200 PIV400
A 13 713.0298.0 diode BYT200 PIV400
A 14 713.0298.0 diode BYT200 PIV400
A 12a 713.0298.0 diode BYT200 PIV400
A 13a 713.0298.0 diode BYT200 PIV400
A 14a 713.0298.0 diode BYT200 PIV400
A 15 665.8043.5 power unit Cigweld 400SP (E)
A 15 665.8043.9 power unit Cigweld 400SP (T)
A 16 650.5316.5 pc-board DP-EMV (E)
A 19 650.5311.5 pc-board DP-UFI-BO (E)
A 20 650.1247.5 pc-board INT04 (E)
A 20 650.1247.9 pc-board INT04 (T)
A 21 650.1250.5 pc-board Harting adaptor 42p (E)
C 1 704.0881.0 capacitor (at pump)
F 1 709.0153.0 fuse 1,0A TR 5x20 (fan power unit)
F 2 709.0193.0 fuse 2,5A TR 5x20 (pump and fan)
F 3 981.1419.0 thermal sensor 23x7x5 LD3,4 (DC)
F 3a 981.1419.0 thermal sensor 23x7x5 LD3,4 (DC)
F 4 709.2000.0 fuse 4,0A TR 6,3x32mm (control transformer)
F 5 709.2000.0 fuse 4,0A TR 6,3x32mm (control transformer)
F 6 665.3131.0 flowmeter ID2 AD6
L 1 655.7530.0 inductor WA 24000042
M 1 665.5725.0 fan (power unit)
M 2 665.5725.0 fan (power unit)
M 3 665.5570.0 pump
M 4 665.5725.0 fan (cooler)
M 5 665.5725.0 fan (cooler)
M 6 665.5725.0 fan (cooler)
M 7 665.5242.0 wire feed motor 42V 240U/min 73mm T
Q 1 657.2030.0 switch 1/O 32A
S 1 torch switch
S 2 657.8500.0 wire insert switch
S 3 657.8500.0 gas test
T 1 655.8021.0 control transformer WA 31000024 Ringkern
T 2 655.9052.0 transformer WA 13000043
X 1 661.7724.7 mains cable 4x4
X 2 665.7032.0 insert sleeve BEB 70-95
X 3 665.7032.0 insert sleeve BEB 70-95
X 4 620.7109.0 central connection
X 5 661.8914.0 socket CAN
X 9 665.7032.0 insert sleeve BEB 70-95
X 10 665.7130.0 insert plug BKB 50-70 mm²
X 11 661.8877.0 panel socket interpass hose package
X 12 661.8882.0 panel plug interpass hose package
X 13 661.3180.1 socket push-pull
X 14 665.2562.0 socket robot torch
X 15 socket robot interface
Y 1 665.3008.0 solenoid valve 24VDC 2x hose connection
Y 2 665.3008.0 air blast valve

(E) : spare part

(T) : replacement
Transmig 500SP Main Schematic
Transmig 500SP Main Schematic Parts List
Pos OEM Part No Description
A 1 665.6304.0 EMC filter 3PH 40A 6mm²
A 2 650.1252.5 pc-board PWRUP04D (E)
A 2 650.1252.9 pc-board PWRUP04D (T)
A 3 658.0245.0 rectifier DB 1600V 80A
A 4 650.5262.5 pc-board DK-DCDRV (E)
A 4 650.5262.9 pc-board DK-DCDRV (T)
A 4a 650.5262.5 pc-board DK-DCDRV (E)
A 4a 650.5262.9 pc-board DK-DCDRV (T)
A 5 650.5160.5 pc-board LSW (E)
A 5 650.5160.9 pc-board LSW (T)
A 6 650.1264.5 pc-board DP-MAPRO (E)
A 6 650.1264.9 pc-board DP-MAPRO (T)
A 7 650.1261.5 pc-board DMR (E)
A 7 650.1261.9 pc-board DMR (T)
A 8 650.1242.5 pc-board DS20BF (E)
A 8 650.1242.9 pc-board DS20BF (T)
A 9 650.1228.5 pc-board DS-VA (E)
A 9 650.1228.9 pc-board DS-VA (T)
A 10 650.6271.5 pc-board PP-90R (E)
A 11 650.5265.5 pc-board DK-GLCL (E)
A 11a 650.5265.5 pc-board DK-GLCL (E)
A 12 713.0298.0 diode BYT200 PIV400
A 13 713.0298.0 diode BYT200 PIV400
A 14 713.0298.0 diode BYT200 PIV400
A 12a 713.0298.0 diode BYT200 PIV400
A 13a 713.0298.0 diode BYT200 PIV400
A 14a 713.0298.0 diode BYT200 PIV400
A 15 665.8044.5 power unit Cigweld 500SP (E)
A 15 665.8044.9 power unit Cigweld 500SP (T)
A 16 650.1262.5 pc-board DP-UFI (E)
A 17 650.1242.5 pc-board DS20BF (E)
A 17 650.1242.9 pc-board DS20BF (T)
A 18 650.1228.5 pc-board DS-VA (E)
A 18 650.1228.9 pc-board DS-VA (T)
C1 1 704.0881.0 capacitor (at pump)
F 1 709.0153.0 fuse 1,0A TR 5x20 (fan power unit)
F 2 709.0193.0 fuse 2,5A TR 5x20 (pump and fan)
F 3 981.1419.0 thermal sensor 23x7x5 LD3,4 (DC)
F 3a 981.1419.0 thermal sensor 23x7x5 LD3,4 (DC)
F 4 709.2000.0 fuse 4,0A TR 6,3x32mm (control transformer)
F 5 709.2000.0 fuse 4,0A TR 6,3x32mm (control transformer)
F 6 665.3131.0 flowmeter ID2 AD6
L 1 655.7529.0 inductor WA 24000041
M 1 665.5725.0 fan (power unit)
M 2 665.5725.0 fan (power unit)
M 3 665.5570.0 pump
M 4 665.5725.0 fan (cooler)
M 5 665.5725.0 fan (cooler)
M 6 665.5725.0 fan (cooler)
M 7 665.5242.0 wire feed motor 42V 240U/min 73mm T
Q 1 657.2030.0 switch 1/O 32A
S 1 torch switch
S 2 657.8500.0 wire insert switch
T 1 655.8021.0 control transformer WA 31000024 Ringkern
T 2 655.9051.0 transformer WA 13000042
X 1 661.7834.0 mains cable 4x6 CEE 63 4AE
X 2 665.7030.0 insert sleeve BEB 50-70-95
X 3 665.7030.0 insert sleeve BEB 50-70-95
X 4 620.7109.0 central connection
X 5 661.8945.5 socket CAN
X 6 650.5272.5 socket remote control
X 7 661.8914.0 socket CAN
X 8 650.5272.5 socket remote control
X 9 665.7030.0 insert sleeve BEB 50-70-95
X 10 665.7130.0 insert plug BKB 50-70 mm²
X 11 661.8877.0 panel socket interpass hose package
X 12 661.8882.0 panel plug interpass hose package
X 13 661.3180.1 socket push-pull
Y 1 665.3008.0 solenoid valve 24VDC 2x hose connection
(E) : spare part
(T) : replacement
Transmig 500SP Automation Main Schematic
Transmig 500SP Automation Main Schematic Parts List
Pos OEM Part No Description
A 1 665.6304.0 EMC filter 3PH 40A 6mm²
A 2 650.1252.5 pc-board PWRUP04D (E)
A 2 650.1252.9 pc-board PWRUP04D (T)
A 3 658.0245.0 rectifier DB 1600V 80A
A 4 650.5262.5 pc-board DK-DCDRV (E)
A 4 650.5262.9 pc-board DK-DCDRV (T)
A 4a 650.5262.5 pc-board DK-DCDRV (E)
A 4a 650.5262.9 pc-board DK-DCDRV (T)
A 5 650.5160.5 pc-board LSW (E)
A 5 650.5160.9 pc-board LSW (T)
A 6 650.5315.5 pc-board DP-MAPRO VRD (E)
A 6 650.5315.9 pc-board DP-MAPRO VRD (T)
A 7 650.1261.5 pc-board DMR (E)
A 7 650.1261.9 pc-board DMR (T)
A 10 650.6271.5 pc-board PP-90R (E)
A 11 650.5265.5 pc-board DK-GLCL (E)
A 11a 650.5265.5 pc-board DK-GLCL (E)
A 12 713.0298.0 diode BYT200 PIV400
A 13 713.0298.0 diode BYT200 PIV400
A 14 713.0298.0 diode BYT200 PIV400
A 12a 713.0298.0 diode BYT200 PIV400
A 13a 713.0298.0 diode BYT200 PIV400
A 14a 713.0298.0 diode BYT200 PIV400
A 15 665.8044.5 power unit Cigweld 500SP (E)
A 15 665.8044.9 power unit Cigweld 500SP (T)
A 16 650.5316.5 pc-board DP-EMV (E)
A 19 650.5311.5 pc-board DP-UFI-BO (E)
A 20 650.1247.5 pc-board INT04 (E)
A 20 650.1247.9 pc-board INT04 (T)
A 21 650.1250.5 pc-board Harting adaptor 42p (E)
C 1 704.0881.0 capacitor (at pump)
F 1 709.0153.0 fuse 1,0A TR 5x20 (fan power unit)
F 2 709.0193.0 fuse 2,5A TR 5x20 (pump and fan)
F 3 981.1419.0 thermal sensor 23x7x5 LD3,4 (DC)
F 3a 981.1419.0 thermal sensor 23x7x5 LD3,4 (DC)
F 4 709.2000.0 fuse 4,0A TR 6,3x32mm (control transformer)
F 5 709.2000.0 fuse 4,0A TR 6,3x32mm (control transformer)
F 6 665.3131.0 flowmeter ID2 AD6
L 1 655.7529.0 inductor WA 24000041
M 1 665.5725.0 fan (power unit)
M 2 665.5725.0 fan (power unit)
M 3 665.5570.0 pump
M 4 665.5725.0 fan (cooler)
M 5 665.5725.0 fan (cooler)
M 6 665.5725.0 fan (cooler)
M 7 665.5242.0 wire feed motor 42V 240U/min 73mm T
Q 1 657.2030.0 switch 1/O 32A
S 1 torch switch
S 2 657.8500.0 wire insert switch
S 3 657.8500.0 gas test
T 1 655.8021.0 control transformer WA 31000024 Ringkern
T 2 655.9051.0 transformer WA 13000042
X 1 661.7834.5 mains cable 4x6
X 2 665.7032.0 insert sleeve BEB 70-95
X 3 665.7032.0 insert sleeve BEB 70-95
X 4 620.7109.0 central connection
X 5 661.8914.0 socket CAN
X 9 665.7032.0 insert sleeve BEB 70-95
X 10 665.7130.0 insert plug BKB 50-70 mm²
X 11 661.8877.0 panel socket interpass hose package
X 12 661.8882.0 panel plug interpass hose package
X 13 661.3180.1 socket push-pull
X 14 665.2562.0 socket robot torch
X 15 socket robot interface
Y 1 665.3008.0 solenoid valve 24VDC 2x hose connection
Y 2 665.3008.0 air blast valve
Spare Parts List Transmig 320SP
Pos OEM Part No Description
1 602.0908.0 torch holder MIG/MAG
2 602.1642.0 side panel wire feed G16 RAL 2002
3 602.1643.0 side panel inverter G16 RAL 2002
4 604.1001.0 rubberfoot Ø40x46 black
5 604.3032.0 fixed castor 75/40
6 604.3673.0 turn fastener quad Ø 31 mm
7 604.3707.0 endcap handle AD 30
8 604.3714.0 handle tube steel 474mm AD 30
9 604.3716.0 handle tube steel 273mm AD 30
10 604.3721.0 handle right G14
11 604.3722.0 handle left G14
12 606.2027.0 sticker pull mains plug 30 mm blue
13 606.3031.0 sticker Cigweld 160x230 mm
14 608.0468.0 front plate DS-VA-meter
15 608.0483.0 front plate DP20 BF
16 608.0495.0 front plate Cigweld 320SP
17 610.0026.5 cover cap CAN screw.
18 610.1535.0 spacer 8,2x14x43
19 610.1562.0 shaft for display-cover Ø8; l=261
20 610.2530.0 cable gland PG 13,5
21 610.3011.0 motor cover
22 610.3012.0 rubber cover f. display 157mm
23 610.3018.0 plastic cover BF
24 610.3126.0 hinge 40x40 black plastic
25 610.3500.0 gas hose 1.8m R 1/4“i
26 600.3004.0 safety nut M12
27 600.6452.0 hexagon socket head cap screw M10x25
28 600.7115.0 medium washer M10
29 600.7260.0 internal tab washer DIN462 steel DM 22
30 612.5200.0 felt washer 80x20x4
31 612.5205.0 felt washer 40x20x4
32 614.0550.7 knob 23mm black shaft 6,35mm
33 614.0561.0 knob cap 23mm red
34 620.4200.0 spring 3,4 DI 21x30x4,25
35 620.9462.0 stud for wire coil support 103mm
36 620.9700.0 wire coil support
37 620.7109.0 central connection 83,5mm ZF 49mm MEC
38 620.7110.0 cover socket central connection SF-serie
39 620.7111.0 push rivet 5x7,5 for SF-cover socket
40 620.9003.0 capillar tube 98mm 2,0 Ms
41 620.9313.0 wire feed unit VE 42-30 MEFR MEC
42 650.1228.5 pc-board DS-VA (E)
42 650.1228.9 pc-board DS-VA (T)
43 650.1242.5 pc-board DS20BF (E)
43 650.1242.9 pc-board DS20BF (T)
44 650.1261.5 pc-board DMR (E)
44 650.1261.9 pc-board DMR (T)
45 650.1262.5 pc-board DP-UFI (E)
45 650.1262.9 pc-board DP-UFI (T)
46 650.1264.5 pc-board DP-MAPRO (E)
46 650.1264.9 pc-board DP-MAPRO (T)
46 709.0153.0 fuse 1,0A TR 5x20
46 709.0193.0 fuse 2,5A TR 5x20
47 650.1281.5 pc-board DP-S3NEFI (E)
47 650.1281.9 pc-board DP-S3NEFI (T)
48 655.8023.0 control transformer WA 31000025 tor.core
49 657.0103.0 switch 1/0 20A
50 657.8500.0 pushbutton switch S.P. N.C. 20mm grey
51 661.7614.0 mains cable 4x2.5 CEE 16 3AE1RÖ
52 661.8914.5 cable CAN 12pin Bind - 6pin 850mm
53 663.0203.0 insulation socket M9 1/3mm AD 28mm
54 663.2552.0 insulation set VE4 80x170
55 663.0101.0 insulation pin AD20/8,5 LD6,4 H11,2
Pos OEM Part No Description
56 665.3008.0 solenoid valve 24VDC 2x hose
connection
wire feed motor 42V 240U/min 73mm
57 665.5242.0
T
58 665.5727.0 axial fan 24V DC Ø150x172x38
59 665.7030.0 insert sleeve BEB 50-70-95
60 706.9004.0 ferrit ring core AD58 ID40
61 724.0005.0 pcb spacer BHC 9,5mm
62 724.0021.0 pcb spacer M4/9,5mm
63 650.1274.5 pc-board DK-S3DRV (E)
63 650.1274.9 pc-board DK-S3DRV (T)
64 650.5265.5 pc-board DK-GLCL (E)
64 650.5265.9 pc-board DK-GLCL (T)
65 658.0244.0 rectifier DB 1600V 50A
66 711.2606.0 mosfet 900V 26A
67 713.0294.0 diode BYT231 PIV1000
68 713.0298.0 diode BYT200 PIV400
69 981.1419.0 unit thermal sensor 23x7x5 LD3,4
70 650.5160.5 pc-board LSW (E)
70 650.5160.9 pc-board LSW (T)
71 655.9054.0 transformer WA 13000044
72 650.1247.5 pc-board INT04 (E)
72 650.1247.9 pc-board INT04 (T)
73 650.1250.5 pc-board Harting-Adapter42e (E)
73 650.1250.9 pc-board Harting-Adapter42e (T)
74 665.2628.0 socket tray HA 42-pin
74 665.2299.0 socket contact double HA
75 665.2747.0 attachment housing HA 43x93
76 650.5272.5 pc board AMP14-10 (E)
77 650.5309.5 pc-board Sx-WIG-BT (E)
78 650.6271.5 pc-board PP-90R (E)
panel socket 17pin AMPH P.P.
79 661.3180.1
150mm
80 981.1493.0 pc-board DS-ERW remounted
81 665.2209.0 panel socket 8p+PE 4 AMPH
81 665.2265.0 socket contact 8+PE 12A AMPH
82 661.8214.0 cable TIG S3 mobile
quick disconnector DN 2,7 panel
83 612.6019.0
mount
84 655.7531.0 inductor WA 24000043
Spare Parts List Transmig 400SP
Pos OEM Part No Description
1 600.3004.0 safety nut M12
2 600.6452.0 hexagon socket head cap screw M10x25
3 600.7115.0 medium washer M10
4 600.7260.0 internal tab washer DIN462 steel DM 22
5 602.0908.0 torch holder MIG/MAG
6 604.3050.0 swivel castor 125 KU
7 604.3051.0 swivel castor, braked 125 KU
8 604.3052.0 fixed castor 125/KU
9 604.3072.0 wheel 200 x 50
10 604.3506.0 rubber mat 560 x 350 mm
11 604.3602.0 chain gas cylinder 770 mm
12 604.3673.0 turn fastener quad 0 31 mm
13 604.3706.0 handle tube steel 397mm AD 30
14 604.3721.0 handle left G14
15 604.3722.0 handle right G14
16 606.1082.0 sticker mixture ratio anti-freeze liquid
17 606.1096.0 sticker ground/electrode 50 x 25 mm
18 606.2027.0 sticker pull mains plug 30 mm blue
19 606.3031.0 sticker Saprom S 160x230 mm
20 608.0465.0 front plate DS-VA / G14
20 608.0477.0 front plate DS-VA blind / G14
21 608.0478.6 front plate model type S5
22 608.0483.0 front plate DP20 BF
22 608.0491.0 front plate cover BF2x
22 608.0488.0 front plate DP21 BF
22 608.0489.0 front plate DP22 BF
23 610.0026.5 cover cap CAN screw.
24 610.1531.0 spacer 8,2x14x48
24 610.1533.0 spacer 8,2x14x42
24 610.1534.0 spacer 8,2x14x24
25 610.1541.0 spacer 12,5x20x59
26 610.1560.0 shaft for display-cover 08; l=384
27 610.2550.0 cable gland PG 16
28 610.3011.0 motor cover
29 610.3012.0 rubber cover f. display 157mm
30 610.3014.0 plastic cover 332x195x24
31 610.3126.0 hinge 40x40 black plastic
32 610.3500.0 gas hose 1.8m R 1/4“i
33 612.5200.0 felt washer 80x20x4
34 612.5205.0 felt washer 40x20x4
35 612.6010.0 quick disconnector blue
36 612.6012.0 quick disconnector red
37 602.0895.0 side panel left up RAL 2002 GS-G
38 602.0896.0 side panel left down RAL 2002 GS-G
39 614.0550.7 knob 23mm black shaft 6,35mm
40 614.0561.0 knob cap 23mm red
41 620.4200.0 spring 3,4 DI 21x30x4,25
42 620.7109.0 central connection 83,5mm ZF 49mm MEC
43 620.7110.0 cover socket central connection SF-serie
44 620.7111.0 push rivet 5x7,5 for SF-cover socket
45 620.9003.0 capillar tube 98mm 2,0 Ms
46 620.9313.0 wire feed unit VE 42-30 MEFR MEC
47 620.9462.0 stud for wire coil support 103mm
48 620.9700.0 wire coil support
49 650.1228.5 pc-board DS-VA (E)
49 650.1228.9 pc-board DS-VA (T)
50 650.1242.5 pc-board DS20BF (E)
50 650.1242.9 pc-board DS20BF (T)
51 650.1243.5 pc-board DS22BF (E)
51 650.1243.9 pc-board DS22BF (T)
52 650.1244.5 pc-board DS21BF (E)
52 650.1244.9 pc-board DS21BF (T)
53 982.0932.0 cooling system unit G14
 Pos OEM Part No Description
54 602.1470.0 side panel right G14 RAL 2002
55 650.1261.5 pc-board DMR (E)
55 650.1261.9 pc-board DMR (T)
56 650.1262.5 pc-board DP-UFI (E)
56 650.1262.9 pc-board DP-UFI (T)
57 650.1264.5 pc-board DP-MAPRO (E)
57 650.1264.9 pc-board DP-MAPRO (T)
57 709.0153.0 fuse 1,0A TR 5x20
57 709.0193.0 fuse 2,5A TR 5x20
58 650.5272.5 pc board AMP14-10 (E)
58 650.5272.9 pc board AMP14-10 (T)
59 650.6271.5 pc-board PP-90R (E)
60 655.8021.0 control transformer WA 31000024 torrodial.core
61 657.2030.0 switch 1/O 32A
62 657.8500.0 pushbutton switch S.P. N.C. 20mm grey
63 661.3180.1 panel socket 17pin AMPH P.P. 150mm
64 661.7724.0 mains cable 4x4 CEE 32
65 724.0022.0 pcb spacer M4/12.7mm
66 661.8914.5 cable CAN 12pin Bind - 6pin 850mm
67 663.0101.0 insulation pin AD20/8,5 LD6,4 H11,2
68 663.0203.0 insulation socket M9 1/3mm AD 28mm
69 663.2552.0 insulation set VE4 80x170
70 665.3008.0 solenoid valve 24VDC 2x hose connection
71 665.5242.0 wire feed motor 42V 240U/min 73mm T
72 665.7030.0 insert sleeve BEB 50-70-95
73 665.8043.5 power unit Cigweld 400SP (E)
73 665.8043.9 power unit Cigweld 400SP (T)
74 706.9004.0 ferrit ring core AD58 ID40
75 720.5000.0 digital encoder 24imp 360‘ 6,35mm
76 724.0005.0 pcb spacer BHC 9,5mm
77 724.0009.0 pcb spacer M4i/12mm
78 650.1247.5 pc-board INT04 (E)
78 650.1247.9 pc-board INT04 (T)
79 650.1250.5 pc-board Harting-Adapter42e (E)
79 650.1250.9 pc-board Harting-Adapter42e (T)
80 665.2628.0 socket tray HA 42-pin
80 665.2299.0 socket contact double HA
81 665.2747.0 attachment housing HA 43x93
(E) spare part (T) replacement
Spare Parts List Transmig 500SP
Pos OEM Part No Description
1 600.3004.0 safety nut M12
2 600.6452.0 hexagon socket head cap screw M10x25
3 600.7115.0 medium washer M10
4 600.7260.0 internal tab washer DIN462 steel DM 22
5 602.0908.0 torch holder MIG/MAG
6 604.3050.0 swivel castor 125 KU
7 604.3051.0 swivel castor, braked 125 KU
8 604.3052.0 fixed castor 125/KU
9 604.3072.0 wheel 200 x 50
10 604.3506.0 rubber mat 560 x 350 mm
11 604.3602.0 chain gas cylinder 770 mm
12 604.3673.0 turn fastener quad 0 31 mm
13 604.3706.0 handle tube steel 397mm AD 30
14 604.3721.0 handle left G14
15 604.3722.0 handle right G14
16 606.1082.0 sticker mixture ratio anti-freeze liquid
17 606.1096.0 sticker ground/electrode 50 x 25 mm
18 606.2027.0 sticker pull mains plug 30 mm blue
19 606.3031.0 sticker Cigweld 400SP 160x230 mm
20 608.0465.0 front plate DS-VA / G14
20 608.0477.0 front plate DS-VA blind / G14
21 608.0478.7 front plate model type S8
22 608.0483.0 front plate DP20 BF
22 608.0491.0 front plate cover BF2x
22 608.0488.0 front plate DP21 BF
22 608.0489.0 front plate DP22 BF
23 610.0026.5 cover cap CAN screw.
24 610.1531.0 spacer 8,2x14x48
24 610.1533.0 spacer 8,2x14x42
24 610.1534.0 spacer 8,2x14x24
25 610.1541.0 spacer 12,5x20x59
26 610.1560.0 shaft for display-cover 08; l=384
27 610.2560.0 cable gland with spiral top PG 21 KU
27 610.2585.0 cable gland nut PG 21 KU
28 610.3011.0 motor cover
29 610.3012.0 rubber cover f. display 157mm
30 610.3014.0 plastic cover 332x195x24
31 610.3126.0 hinge 40x40 black plastic
32 610.3500.0 gas hose 1.8m R 1/4“i
33 612.5200.0 felt washer 80x20x4
34 612.5205.0 felt washer 40x20x4
35 612.6010.0 quick disconnector blue
36 612.6012.0 quick disconnector red
37 602.0895.0 side panel left up RAL 2002 GS-G
38 602.0896.0 side panel left down RAL 2002 GS-G
39 614.0550.7 knob 23mm black shaft 6,35mm
40 614.0561.0 knob cap 23mm red
41 620.4200.0 spring 3,4 DI 21x30x4,25
42 620.7109.0 central connection 83,5mm ZF 49mm MEC
43 620.7110.0 cover socket central connection SF-serie
44 620.7111.0 push rivet 5x7,5 for SF-cover socket
45 620.9003.0 capillar tube 98mm 2,0 Ms
46 620.9313.0 wire feed unit VE 42-30 MEFR MEC
47 620.9462.0 stud for wire coil support 103mm
48 620.9700.0 wire coil support
49 650.1228.5 pc-board DS-VA (E)
49 650.1228.9 pc-board DS-VA (T)
50 650.1242.5 pc-board DS20BF (E)
50 650.1242.9 pc-board DS20BF (T)
51 650.1243.5 pc-board DS22BF (E)
51 650.1243.9 pc-board DS22BF (T)
52 650.1244.5 pc-board DS21BF (E)
52 650.1244.9 pc-board DS21BF (T)
Pos OEM Part No Description
53 982.0932.0 cooling system unit G14
54 602.1470.0 side panel right G14 RAL 2002
55 650.1261.5 pc-board DMR (E)
55 650.1261.9 pc-board DMR (T)
56 650.1262.5 pc-board DP-UFI (E)
56 650.1262.9 pc-board DP-UFI (T)
57 650.1264.5 pc-board DP-MAPRO (E)
57 650.1264.9 pc-board DP-MAPRO (T)
57 709.0153.0 fuse 1,0A TR 5x20
57 709.0193.0 fuse 2,5A TR 5x20
58 650.5272.5 pc board AMP14-10 (E)
58 650.5272.9 pc board AMP14-10 (T)
59 650.6271.5 pc-board PP-90R (E)
60 655.8021.0 control transformer WA 31000024 tor.core
61 657.2030.0 switch 1/O 32A
62 657.8500.0 pushbutton switch S.P. N.C. 20mm grey
63 661.3180.1 panel socket 17pin AMPH P.P. 150mm
²
64 661.7834.5 mains cable 4x6mm without plug
65 724.0022.0 pcb spacer M4/12.7mm
66 661.8914.5 cable CAN 12pin Bind - 6pin 850mm
67 663.0101.0 insulation pin AD20/8,5 LD6,4 H11,2
68 663.0203.0 insulation socket M9 1/3mm AD 28mm
69 663.2552.0 insulation set VE4 80x170
70 665.3008.0 solenoid valve 24VDC 2x hose connection
71 665.5242.0 wire feed motor 42V 240U/min 73mm T
72 665.7030.0 insert sleeve BEB 50-70-95
73 665.8044.5 power unit Saprom S8 (E)
73 665.8044.9 power unit Saprom S8 (T)
74 706.9004.0 ferrit ring core AD58 ID40
75 720.5000.0 digital encoder 24imp 360‘ 6,35mm
76 724.0005.0 pcb spacer BHC 9,5mm
77 724.0009.0 pcb spacer M4i/12mm
78 650.1247.5 pc-board INT04 (E)
78 650.1247.9 pc-board INT04 (T)
79 650.1250.5 pc-board Harting-Adapter42e (E)
79 650.1250.9 pc-board Harting-Adapter42e (T)
80 665.2628.0 socket tray HA 42-pin
80 665.2299.0 socket contact double HA
81 665.2747.0 attachment housing HA 43x93

(E)spare part
(T)replacement
Spare Parts List Workshop Wirefeeder SP4000

Pos OEM Part No Description

1 602.0908.0 torch holder MIG/MAG
2 604.1001.0 rubberfoot 0140x46 black
3 604.3673.0 turn fastener quad 0 31 mm
4 604.3719.0 handle 180mm
5 604.3721.0 handle right G14
6 604.3722.0 handle left G14
7 608.0468.0 front plate DS-VA-meter
7 608.0469.0 front plate cover DS-VA-meter
8 608.0483.0 front plate DP20 BF
8 608.0488.0 front plate DP21 BF
8 608.0489.0 front plate DP22 BF
8 608.0491.0 front plate cover BF2x
9 610.0026.5 cover cap CAN screw.
10 610.1561.0 shaft for display-cover 018; l=204
11 610.3012.0 rubber cover f. display 157mm
12 610.3013.0 plastic cover BF
13 610.3126.0 hinge 40x40 black plastic
14 612.5200.0 felt washer 80x20x4
15 612.5205.0 felt washer 40x20x4
16 612.6005.0 quick disconnector plug blue
17 612.6006.0 quick disconnector plug red
18 612.6009.0 quick disconnector DN 2,7 G 1/8“a
19 612.6010.0 quick disconnector blue
20 612.6012.0 quick disconnector red
21 614.0550.7 knob 23mm black shaft 6,35mm
21 614.0561.0 knob cap 23mm red
22 620.7109.0 central connection 83,5mm ZF 49mm MEC
22 620.9003.0 capillar tube 98mm 2,0 Ms
23 620.7110.0 cover socket central connection SF-serie
24 620.7111.0 push rivet 5x7,5 for SF-cover socket
25 620.9313.0 wire feed unit VE 42-30 MEFR MEC
26 620.9462.0 stud for wire coil support 103mm
27 620.9700.0 wire coil support
Pos OEM Part No Description
28 622.0005.0 hose connector R1/8 4mm KU
29 622.1225.0 reducing bushing 1/8“i x 1/4“a x 1/8“a
29 622.1330.1 nut R1/4“ MS
30 650.1228.5 pc-board DS-VA (E)
30 650.1228.9 pc-board DS-VA (T)
31 650.1242.5 pc-board DS20BF (E)
31 650.1242.9 pc-board DS20BF (T)
32 650.1243.5 pc-board DS22BF (E)
32 650.1243.9 pc-board DS22BF (T)
33 650.1244.5 pc-board DS21BF (E)
33 650.1244.9 pc-board DS21BF (T)
34 650.1261.5 pc-board DMR (E)
34 650.1261.9 pc-board DMR (T)
35 650.5272.5 pc board AMP14-10 (E)
36 650.6271.5 pc-board PP-90R (E)
37 657.8500.0 pushbutton switch S.P. N.C. 20mm grey
38 661.8882.0 cable 17+PE S AMPH-8pol.Minifi 240mm
39 661.8914.3 cable CAN 12pin Bind - 6pin Mifi 360mm
40 663.2552.0 insulation set VE4 80x170
40 663.0101.0 insulation pin AD20/8,5 LD6,4 H11,2
41 665.3009.0 solenoid valve 24VDC 2xR1/8“ii 2x M4i
42 665.5242.0 wire feed motor 42V 240U/min 73mm T
43 665.7130.0 insert plug BKB 50-70-95
44 724.0005.0 pcb spacer BHC 9,5mm
45 720.5000.0 digital encoder 24imp 360‘ 6,35mm
45 663.0203.0 insulation socket M9 1/3mm AD 28mm
46 600.6452.0 hexagon socket head cap screw M10x25
47 600.7104.0 washer 10.5x30 galvanized
48 600.7260.0 internal tab washer DIN462 steel DM 22
49 600.3004.0 safety nut M12
50 610.1532.0 spacer (IxAxH) 8.2x14x14 Ku
51 608.0492.0 front plate wire feeder K14 water
51 608.0493.0 front plate wire feeder K14 gas
52 610.3011.0 motor cover
53 661.3180.1 panel socket 17pin AMPH P.P. 150mm
54 620.4200.0 spring 3,4 DI 21x30x4,25
55 602.1574.0 side panel right K14 RAL 2002 GS-G
56 602.1575.0 side panel left K14 RAL 2002 GS-G
Spare Parts List Robot Wirefeeder SP4000R
pos OEM Part Number Description
1 602.1590.0 cover 03 RAL 2002 GS-G
2 604.3673.0 turn fastener quad Ø 31 mm
3 610.0026.5 cover cap CAN screw.
4 610.2510.0 cable gland PG 11
5 620.4880.0 hinge 40x32mm brass
6 612.6000.0 quick disconnect DN5 - 1/8
7 612.6005.0 quick disconnect plug blue
8 612.6006.0 quick disconnect plug red
9 612.6009.0 quick disconnect DN 2,7 G 1/8“a
10 612.6010.0 quick disconnect blue
11 612.6012.0 quick disconnect red
12 612.6020.0 mounting adaptor MS 1/8“i - hose 5mm
13 620.7109.0 central connection 83,5mm ZF 49mm MEC
14 620.7110.0 cover socket central connection SF-series
15 620.7111.0 push rivet 5x7,5 for SF-cover socket
16 620.9003.0 capillar tube 98mm 2,0 Ms
17 620.9101.7 inlet guide ID 2,0 MEC
18 620.9313.0 wire feed unit VE 42-30 MEFR MEC
19 650.1261.5 pc-board DMR (E)
19 650.1261.9 pc-board DMR (T)
20 650.5272.5 pc board AMP14-10 (E)
20 650.5272.9 pc board AMP14-10 (T)
21 650.6271.5 pc-board PP-90R (E)
22 657.8500.0 pushbutton switch S.P. N.C. 20mm gray
23 661.3180.1 panel socket 17pin AMPH P.P. 150mm
24 661.8914.3 cable CAN 12pin Bind - 6pin Mifi 360mm
25 665.3009.0 solenoid valve 24VDC 2xR1/8“ii 2x M4i
26 665.5242.0 wire feed motor 42V 240U/min 73mm T
27 665.7130.0 insert plug BKB 50-70-95
28 724.0009.0 pcb spacer M4i/12mm
29 665.2562.0 panel socket 14pin AMPH
Spare Parts List Power Module Cigweld 500SP

Pos OEM Part no Description

1 610.3007.0 ventilation profile 275x172x63
2 650.5160.5 pc-board LSW (E)

2 650.5160.9 pc-board LSW (T)

3 650.1252.5 pc-board PWRUP04D (E)
3 650.1252.9 pc-board PWRUP04D (T)
3 709.2000.0 fuse 4,0A TR 6,3x32mm
4 655.7529.0 inductor WA 24000041
5 655.9051.0 transformer WA 13000042
6 665.5725.0 axial fan 119x119x38
7 665.6304.0 EMC filter 3PH 40A 6mm²
8 724.0007.0 pcb spacer BHC 19,1mm
9 650.5262.5 pc-board DK-DCDRV (E)
9 650.5262.9 pc-board DK-DCDRV (T)
10 650.5265.5 pc-board DK-GLCL (E)
10 650.5265.9 pc-board DK-GLCL (T)
11 658.1412.0 rectifier B6 1600 V 30 A 80x29
12 711.2606.0 mosfet 900V 26A
13 713.0294.0 diode BYT231 PIV1000
14 713.0298.0 diode BYT200 PIV400
15 981.1419.0 unit thermal sensor 23x7x5 LD3,4
APPENDIX 1: GENERAL INFORMATION
SAFETY PRECAUTIONS Requirement
Use and maintenance of welding and cutting machines can be dangerous. Follow the safety precautions in Section 1 of this
manual to avoid injuries. Welding and cutting machines must be used by properly trained personnel. Please review the safety
precautions and regulations on a regular basis to avoid accidents while working with this machine.
Only qualified workers who are knowledgeable and have been trained to work safely with test instruments and equipment on
energized circuits shall be permitted to perform testing work on electrical circuits or equipment where there is danger of injury from
accidental contact with energized parts or improper use of the test instruments and equipment.
Use only original spare parts.
Immediately replace any components that are not in perfect condition. Norms
Please follow the current safety regulations corresponding to your country. Common Logic Functions

Component Function Associated event

Fan (power unit) On Power module temperature over 40°C
Fan (power unit) Off Power module temperature below 40°C
Fan (cooling system) On After detection „welding current on„
Fan (cooling system) Off After welding process, two minutes post-cooling time
Pump On After detection „welding current on„ ,
Pump Off After welding process, two minutes post-cooling time
Settings DIP Switch

If the machine is to be programmed via the serial port, the DIP switches 1-3 has to be set to "ON". In normal operation they has
to be set to "OFF".
If the pc-board is used in a Cigweld Transming 320SP, the DIP switch 4 has to be set to "ON". For the use in a standard 400SP
500SP switch 4 has to be set to "OFF".

DIP switch ON OFF

1 Mode serial programming Mode normal operation
2 Mode serial programming Mode normal operation
3 Mode serial programming Mode normal operation
4 Configuration 320SP Configuration 400SP 500SP
TRANSMIG 320SP, 400SP, 500SP
Appendix 3 Block Diagram SP-Series
 TRANSMIG 320SP, 400SP, 500SP
APPENDIX 2: PC-BOARDS & MEASURING POINTS
Pc-board DP-MAPRO
The pc-board DP-MAPRO is responsible for the welding sequence and is managing the process control of the
SP-Series.
(MAPRO = MAster-PROcess)
Functions
• Logic functions of the welding process
• Generating and monitoring supply voltages •
Driving power-up relays
• Driving power unit/units
• Monitoring control and operating elements (DS20BF, remote control, torch buttons)
• Driving fans
• Driving cooling pump
• Monitoring flow meter
• Monitoring mains- and output voltage •
Generating signal "welding current on"
• Managing communications between PC and machine
• Managing and storage of all welding parameters •
CAN-bus
LED displays

Normal
LED State Designation
1 (green ) Flashing (half freq . o f LED5 ) CPLD-processor ok
2 (red ) Off Digital Signal Processor (DSP) o k
3 (green ) On Supply voltage 3 ,3 V DC o k
4 (red ) Off Micro controller ok
5 (green ) Flashing DSP is working
6 (green ) Flashing Micro controller is working

Malfunction
LED State Designation
1 (green) Never on CPLD-processor is not working
2 (red) On DSP is not working
3 (green) Off Supply voltage 3,3V DC is missing check 18V~ AC of control transformer
X2/1 X2/2
4 (red) On Micro controller is not working
5 (green) Never on DSP is not working
6 (green) Never on Micro controller is not working
TRANSMIG 320SP, 400SP, 500SP

Overview f u s e s DP-MAPRO

Fuse Value [A] Safeguarding

Si 6 1 Fans (power unit)
Si 7 2,5 Cooling pump
 TRANSMIG 320SP, 400SP, 500SP
Description Connectors / Measuring Points
connector pin designation signal
X1 interface primary power unit 1
X1 1 supply primary control
X1 2 supply primary control
X1 3 supply primary control +15V DC
X1 4 gnd for primary control GND
X1 5 inverter PWM-low
X1 6 inverter PWM-high
X1 7 gnd for secondary control GND
X1 8 signal primary shut down 1
X1 9 signal max voltage 1
X1 10 signal min voltage 1
X1 11 analog coding power unit 1
X1 12 temp.sensor primary heatsink 1
X1 13 mains contactor
X1 14 supply current sensor +15V DC
X1 15 current value DK-DCDRV1
X1 16 supply current sensor -15V DC

X2 connector control transformer

X2 1 supply 18V AC 18V AC
X2 2 supply 18V AC 18V AC
X2 3 supply 42V AC 42V AC
X2 4 supply 42V AC 42V AC

X3 connector DS-E
X3 1 gnd for supply GND
X3 2 supply +24V DC
X3 3 clock
X3 4 supply from control transformer (fused) 42V AC
X3 5 supply from control transformer (not fused) 42V AC
X3 6 data
X3 7 strobe
X3 8 n.c.
X3 9 n.c.
X3 10 n.c.

X4 interface primary power unit 2

X4 1 supply primary control
X4 2 supply primary control
X4 3 supply primary control +15V DC
X4 4 gnd for primary control GND
X4 5 inverter PWM-low
X4 6 inverter PWM-high
X4 7 gnd for secondary control GND
X4 8 signal primary shut down 2
X4 9 signal max voltage 2
X4 10 signal min voltage 2
X4 11 analog coding power unit 2
X4 12 temp.sensor primary heatsink 2
X4 13 mains contactor
X4 14 supply current sensor +15V DC
X4 15 current value DK-DCDRV2
X4 16 supply current sensor -15V DC
TRANSMIG 320SP, 400SP, 500SP
X7 connector fan group 1
X7 1 supply fan 230V AC
X7 2 supply fan 230V AC

X8 CAN interface 1
X8 1 supply CAN
X8 2 supply CAN +15V DC
X8 3 CAN low
X8 4 CAN high
X8 5 n.c.
X8 6 n.c.

X9 connector flowrate sensor

X9 1 supply flowrate sensor +15V DC
X9 2 output flowrate sensor
X9 3 gnd for supply GND
X9 4 identification “monitoring off“

X10 connector gas valve

X10 1 supply gas valve +24V DC
X10 2 supply gas valve

X11 connector front panel

X11 1 gnd GND
X11 2 CAN low
X11 3 CAN high
X11 4 n.c.
X11 5 supply +5V DC
X11 6 n.c.
X11 7 n.c.
X11 8 n.c.
X11 9 n.c.
X11 10 gnd GND

X13 connector pump

X13 1 supply pump 230V AC
X13 2 supply pump 230V AC

X14 CAN Interface 2

X14 1 supply CAN
X14 2 supply CAN +15V DC
X14 3 CAN low
X14 4 CAN high
X14 5 n.c.
X14 6 n.c.

X15 connector TIG torch button

X15 1 remote start
X15 2 gnd for remote start

X16 connector VA display

X16 1 gnd GND
X16 2 n.c.
X16 3 n.c.
 contact “welding current on“
TRANS 9
X18 10 contact “welding current on“

X19 connector gas test button

X19 1 gnd GND
X19 2 gas test

X20 CAN Interface 3

X20 1 supply CAN
X20 2 supply CAN +15V DC
X20 3 CAN low
X20 4 CAN high
X20 5 n.c.
X20 6 n.c.

X21 connector JTAG-Interface

X21 1 TMS
X21 2 TRST/
X21 3 TDI
X21 4 gnd GND
X21 5 supply +5V DC
X21 6 n.c.
X21 7 JT TDO
X21 8 gnd GND
X21 9 JT TCK
X21 10 gnd GND
X21 11 JT TCK
X21 12 gnd GND
X21 13 JT_EMU0
X21 14 JT_EMU1

X22 connector JTAG-Interface

X22 1 supply +3,3V DC
X22 2 TDO
X22 3 TDI
X22 4 n.c.
X22 5 n.c.
X22 6 TMS
X22 7 gnd GND
X22 8 TCK

X23 connector serial interface

X23 1 n.c.
X23 2 TX
X23 3 RX
X23 4 DTR
X23 5 gnd GND
X23 6 n.c.
X23 7 RTS
X23 8 n.c.
X23 9 n.c.
TRANSMIG 320SP, 400SP, 500SP
Picture Pc-board DP-
MAPRO
 TRANSMIG 320SP, 400SP, 500SP
Pc-board DMR
The pc-board DMR is the wire feed motor control of the machine.
Functions
• Control and monitoring wire feed motor
• Driving solenoid valve
• Control and monitoring of operating elements (DS20BF, remote control torch buttons) •
Monitoring wire insert button
• Supply pc-board PP90R (Push-Pull)
LED displays

norm al
LED State Designation
1 (red) Off Micro controller ok
2 (green) On Supply voltage 5V ok

Malfunction
LED State Designation
Is lit weak Micro controller not programmed
1 (red)
Flashes Malfunction CAN bus
2 (green) Off Supply voltage 5V not ok
TRANSMIG 320SP, 400SP, 500SP
Description Connectors / Measuring Points

connector pin designation signal

X1 connector torch button
X1 1 torch button
X1 2 torch button

X2 connector front panel

X2 1 gnd GND
X2 2 CAN low
X2 3 CAN high
X2 4 n.c.
X2 5 supply +5V DC
X2 6 n.c.
X2 7 n.c.
X2 8 n.c.
X2 9 n.c.
X2 10 gnd GND
X3 connector VA display
X3 1 gnd GND
X3 2 n.c.
X3 3 n.c.
X3 4 data
X3 5 supply +5V DC
X3 6 load
X3 7 clock
X3 8 flash mode
X3 9 programming voltage +24V DC
X3 10 gnd GND

X4 connector wire insert button

X4 1 gnd GND
X4 2 wire insert button

X5 connector tacho
X5 1 supply +5V DC
X5 2 tacho signal
X5 3 gnd GND
X5 4 tacho on

X6 connector gas valve

X6 1 supply gas valve +24V DC
X6 2 signal gas valve
X7 connector Push-Pull
X7 1 supply Push-Pull relays +24V DC
X7 2 supply Push-Pull motor +70V DC
X7 3 signal Push-Pull relays
X7 4 gnd GND

X8 connector interpass hose

X8 1 gnd GND
X8 2 gnd GND
X8 3 CAN high
X8 4 CAN low
X8 5 supply motor +70V DC
X8 6 supply motor
 TRANSMIG 320SP, 400SP, 500SP

X10/X11 connector Motor

X10 wire feed motor -
X11 wire feed motor +

X12 connector welding voltage

X12 1 torch button (X1/1)
X12 2 welding voltage +
X12 3 torch button (X1/2)

X18 connector remote control socket

X18 1 remote start
X18 2 gnd for remote start GND
X18 3 n.c.
X18 4 n.c.
X18 5 n.c. GND
X18 6 n.c.
X18 7 gnd GND
X18 8 n.c.
X18 9 supply +24V DC
X18 10 signal “welding current on“
Picture Pc-board
TRANSMIG 320SP, 400SP, 500SP
Pc-board DS20BF
The pc-board DS20BF is the front panel with all buttons, rotary impulse encoder and all displays.

Functions

• Operating/Setup the machine

• Display of all welding parameters
• Display error messages
• Display machine parameters (version operating system, actual values etc.)

Picture Pc-board DS20BF

On machines with separated front panels, the pc-boards DS21BF and DS22BF are used.
TRANSMIG 320SP, 400SP, 500SP
Display test
The display has a internal function test. To execute the test press the buttons "-" (TA13) and "manual mode"
(TA4) at the same time. Now the LCD-Display shows "Display Test" and the version number of the operating
system. Press any button to start the first test, where all LEDs and the LCD-Display are turned on and off
alternately. The LCD-Display shows "LEDs on, Backlight off".
Press any button to go to the next test. In this test all buttons are checked, by pressing all 12 buttons one after
another. The button which is to be pressed, is indicated by a lit LED. After that the rotary impulse encoders are
checked. The LCD-Display shows a cursor which can be moved by the rotary impulse encoders. At first the
cursor has to be moved to the left with the left rotary impulse encoder then to the right. After that the cursor
has to be moved to the left and right with the right rotary impulse encoder.
Then the test are completed and the LCD-Display shows "End of Tests" and the machine goes back into normal
mode, which was displayed before the display test was executed.
Pc-board DK-DCDRV / DK-S3DRV
The pc-board DK-DCDRV is managing the primary drive level for power supplies 400SP and 500SP.
The pc-board DK-DCDRV is managing the primary drive level for power supply 320SP.

Functions
• Encoding power unit
• Connection temperature sensor of heat sink
• Supply PC-Board LSW
• Monitoring DC link voltage and supply voltage
• Safety shut-down of power supply
• Pass-through signal powerup relays
• Pass-through signal, "welding current on", (from pc-board LSW)

Encoding Power Unit

Jumper J1 Jumper J2 Setting Machine type

0 0 240 A S5
0 1 270 A S3
1 0 300 A S8
1 1 Reserved
0= contact open

1 = contact closed
If DIP switches are used instead of jumper: 0 = "OFF", 1 = "ON"
 TRANSMIG 320SP, 400SP, 500SP
LED displays

Normal
LED State Designation
1 (red) Off Primary overcurrent shut down
2 (green) On Drive level of low-side is ok
4 (green) On DC link voltage max is ok
5 (green) On Drive level of high-side is ok
6 (green) On DC link voltage min is ok

Malfunction
LED State Reason
1 (red) On Primary current is too high, power unit has been switched off
2 (green) Never on No drive level low-side
4 (green) Off DC link voltage is too high (e.g. mains over voltage)
5 (green) Never on No drive level high-side
6 (green) Off DC link voltage is too low (e.g. mains voltage too low)
TRANSMIG 320SP, 400SP, 500SP
Description connectors/measuring points

connector pin designation signal

X1 interface primary power unit 1
X1 1 supply primary control
X1 2 supply primary control
X1 3 supply primary control +15V DC
X1 4 gnd for primary control gnd
X1 5 inverter PWM-low
X1 6 inverter PWM-high
X1 7 gnd for secondary control gnd
X1 8 signal primary shut down 1
X1 9 signal max voltage 1
X1 10 signal min voltage 1
X1 11 analog coding power unit 1
X1 12 temp.sensor primary heatsink 1
X1 13 mains contactor +24V DC
X1 14 supply current sensor +15V DC
X1 15 current value DK-DCDRV1
X1 16 supply current sensor -15V DC

X2 connector LSW / PRWUP

X2 1 supply LSW +15V DC
X2 2 output LSW
X2 3 supply LSW -15V DC
X2 4 n.c.
X2 5 mains contactor +24V DC
X2 6 gnd gnd

X3 connector temp.sensor
X3 1 gnd gnd
X3 2 temp.sens 10kW at 25°C
or (about +2V DC)
 TRANSMIG 320SP, 400SP, 500SP

Picture pc-board DK-DCDRV

TRANSMIG 320SP, 400SP, 500SP
Pc-board DK-PWRUP / PWRUP04
The pc-board DK-PWRUP is the power up-circuit for the 320SP.
The pc-board DK-PWRUP04 is the powerup-circuit for the 400SP and 500SP.

Functions
• Reducing start-up peak current for capacitors
• Supply and safe guarding of control transformer

Description connectors / measuring points DK-PWRUP

connector pin designation signal

X1 X2 X3 mains output
X1 phase L1 400V AC
X2 phase L2 400V AC
X3 phase L3 400V AC
X4 connector mains relay
X4 1, 3 drive level relay +24V DC
X4 2, 4 gnd gnd
X5 X6 X7 mains input
X5 phase L1 400V AC
X6 phase L2 400V AC
X7 phase L3 400V AC
X10 connector control transformer
X10 1 supply control transformer 400V AC
X10 2 supply control transformer 400V AC

Description connectors / measuring points DK-PWRUP04

connector pin designation signal

X1 X2 X3 mains output
X1 phase L1 400V AC
X2 phase L2 400V AC
X3 phase L3 400V AC
X4 connector mains relay
X4 1, 3 drive level relay +24V DC
X4 2, 4 gnd gnd
X11 X12 mains input
X13
X11 phase L1 400V AC
X12 phase L2 400V AC
X13 phase L3 400V AC
X10 connector control transformer
X10 1 supply control transformer (phase L1) 400V AC
X10 2 supply control transformer (phase L2) 400V AC
 TRANSMIG 320SP, 400SP, 500SP
Picture pc-board DK-PWRUP / DK-PWRUP04

Fuses
Protection of the control transformer via Si1, Si2 : 4A idle each
TRANSMIG 320SP, 400SP, 500SP
Pc-Board DP-S3NEFI
The pc-board DP-S3NEFI is the mains filter and power up circuit for the Transmig 320SP.

Functions

• Mains filter
• Reducing start-up peak current for capacitors
• Supply and safeguarding for control transformer
Descriptions connectors / measuring points

connector pin designation signal

LP1,2,3 mains input
LP1 mains phase L1 400V AC
LP2 mains phase L2 400V AC
LP3 mains phase L3 400V AC

X4 connector mains relay

X4 1,3 mains relay +24V DC
X4 2,4 gnd gnd

X10 connector control transformer

X10 1 supply control transformer (phase L1) 400V AC
X10 2 supply control transformer (phase L2) 400V AC

LP4,5,6 mains output

LP4 mains phase L1 400V AC
LP5 mains phase L2 400V AC
LP6 mains phase L3 400V AC

Picture pc-board DP-S3NEFI

 TRANSMIG 320SP, 400SP, 500SP
Pc-board DK-GLCL

The pc-board DK-GLCL is for wiring the secondary rectifier diodes.

Functions
• Wiring
• Pulse smoothing

Picture pc-board DK-GLCL

TRANSMIG 320SP, 400SP, 500SP
Pc-board DP-UFI-BO Functions
• Witing welding sockets
• Providing output voltage

Description connectors / measuring points

connector pin designation signal

X1 connector
X1 1 “+“ welding voltage (in MMA mode) + 80V DC
X1 2 “-“ welding voltage

X2, X3 connector
X2 “-“ welding voltage
X3 “+“ welding voltage (in MMA mode) +80V DC

Picture pc-board DP-UFI-BO

 TRANSMIG 320SP, 400SP, 500SP
Pc-board DP-EMV

Functions
• EMC filter

Description connectors / measuring points

connector pin designation signal
X2, X3 connector
X2 “-“ welding voltage
X3 “+“ welding voltage (in MMA mode) +80V DC

Picture pc-board DP-EMV

4
TRANSMIG 320SP, 400SP, 500SP
Pc-board LSW

The pc-board LSW is a potential free current sensor. Functions

• Measuring welding current
Description connectors / measuring points
connector pin designation signal
X1 connector
X1 1 supply +15V DC
X1 2 sensor output
X1 3 supply -15V DC

Picture pc-board LSW

 TRANSMIG 320SP, 400SP, 500SP
PC-Board DS-VA
The pc-board DS-VA is the digital volt and ampere display.
Functions
• Display nominal and actual values of welding voltage and welding current •
Hold-function of the last welding values LED displays:
Normal
LED State Designation
41 (green) On Hold-function active

Description connectors / measuring points

connector pin designation signal

X1 connector VA display
X1 1 gnd gnd
X1 2 data
X1 3 gnd gnd
X1 4 data
X1 5 supply +5V DC
X1 6 load
X1 7 clock
X1 8 gnd gnd
X1 9 clock
X1 10 gnd gnd

Picture Pc-board DS-VA:

TRANSMIG 320SP, 400SP, 500SP
PC-Board DS-ERW
The pc-board DS-ERW is the extension pc-board for machines with additional wire feeder.
Functions
• Switching between wire feeder 1 and wire feeder
• Driving gas valve
• Driving water valve
LED displays:
Normal
LED State Designation
Off Wire feed unit 1 active
1 (green)
On Wire feed unit 2 active

Description connectors / measuring points

connector pin designation signal

X1 connector optional interface
X1 1 gnd gnd
X1 2 supply +24V DC
X1 3 clock
X1 4 supply 42V AC
X1 5 supply 42V AC
X1 6 data
X1 7 strobe
X1 8 n.c.
X1 9 n.c.
X1 10 n.c.

X2 connector to DP-MAPRO
X2 1 gnd gnd
X2 2 gnd gnd
X2 3 CAN high
X2 4 CAN low
X2 5 wire feeder case active
X2 6 supply motor +70V DC
X2 7 supply motor
X2 8 supply +24V DC
 TRANSMIG 320SP, 400SP, 500SP

X3 connector wire feeder 1

X3 1 gnd gnd
X3 2 gnd gnd
X3 3 CAN high
X3 4 CAN low
X3 5 wire feeder case active
X3 6 supply motor +70V DC
X3 7 supply motor
X3 8 supply +24V DC

X4 connector wire feeder 2

X4 1 gnd gnd
X4 2 gnd gnd
X4 3 CAN high
X4 4 CAN low
X4 5 wire feeder case active
X4 6 supply motor +70V DC
X4 7 supply motor
X4 8 supply +24V DC

X5 connector gas valve 1

X5 1 signal gas valve
X5 2 supply +24V DC

X6 connector gas valve 2

X6 1 signal gas valve
X6 2 supply +24V DC

X7 connector water valve 1

X7 1 signal water valve 42V AC
X7 2 supply 42V AC

X8 connector water valve 2

X8 1 signal water valve 42V AC
X8 2 supply 42V AC
TRANSMIG 320SP, 400SP, 500SP
Picture pc-board DS-ERW
APPENDIX 4 :Installing the Cigweld Setup Program
Contents
Installing the Cigweld Setup program 1
Programming (flashing) an Operating System and Updating 3
characteristics via CAN Port
Special welding programs 6
Programming (flashing) an Operating System via serial Port 7
Flashing the V/S-Master / Robotic interface INT04 via serial Port 7
Flashing the V/S-Process via serial Port 8
Annex A1 Installation LPT-CAN-Dongle 10
Annex A2 Installation USB-CAN-Dongle 10
Annex A3 Installation CAN-driver for Windows 9x/Me/NT/2000/XP 13
Annex A4 Troubleshooting 17
Installing the Cigweld-Install program

The procedure described below assumes the following:

The driver software for the CAN port (CAN dongle) must be installed in the PC. If not, please install
the CAN dongle first. Refer to Annex A1 of this guideline for instructions on how to do this.
If an older version of CIGWELD-Install was installed previously, please uninstall that version first.

For the installation the Windows Installer 2.0 is needed. It is already included in Windows
XP, in Windows NT/2000 the program InstMsiW.exe must be installed and in Windows
95/98/Me the program InstMsiA.exe must be installed first. Both programs are in the folder
Microsoft on the Cigweld-Install-CD.
• If the Microsoft Installer is
already installed, the msi files
are displayed with the
following icon:

• Log on as Administrator
under Windows NT/2000/XP.
• Doubleclick the Cigweld-
Install2.msi icon. Newer
versions get higher version –
numbers as shown in the
picture.
• Click on Next to continue the
installation.
• Don’t change the Installation
folder and select the
Everyone option.
• Click on Next to continue
the installation.
 • Clicking on Next, all
necessary files are being
copied to the folder
C:\Program Files\CIGWELD
and shortcuts are created on
the desktop and in the
Startmenu.

• The progress of the flash

operation is displayed as an
increasing blue bar.

• Click on Close to complete

the installation.
Important note: Only one
program that uses the CAN port
should be open at a time (
CIGWELD-Install...). If two or more
of these programs are open at the
same time, problems with the CAN
port may occur.
Programming (flashing) an Operating System and Updating characteristics via CAN Port

• note: flashing an operating system and update welding characteristics via CAN port, can be
made in one step.
!! caution !! please backup existing Tiptronic jobs before any flash operation (use VJob-Tool or
SJob- Tool).
• connect the PC to the welding machine by the CAN-Dongle. If the welding machine is not
equiped with an external CAN port, a CAN adapter cable (661.8914.3) is needed to make the
connection directly to an internal CAN port of the machine.
• switch on the machine and the PC.
• doubleclick the icon CIGWELD-Install on the Windows desktop or click on
Start\Programs\CIGWELD\CIGWELD-Install.
• The program
CIGWELD-Install
automatically checks the
connection to the
machine at startup and
displays all found
devices with their
version numbers. Only
devices which are
correctly programmed
and which are able to be
updated via CAN port,
are displayed.

• If no CAN connection
can be established
between PC and
machine, an error
message is displayed.
After confirming the
error message an empty
device window is shown,
which means that no
devices have been found.
If there are Devices
which are not displayed
but definitely exist in the
machine can only be pro-
grammed via serial port
(see Programming
(flashing) an Operating
System via serial Port).
• Clicking on the button repeat search, the program searches for existing devices again.
• Devices, which ought to
be flashed must be
selected first. Clicking on
button next, the program
continues to the next
screen.

• Clicking on search file a

dialogbox appears, to
specify an operating
system file, to be flashed
into the machine (see
actual release
information). Size and
date of the file are shown
in the status field. To
start the flash operation
click on next.
• The progress of the flash
operation is displayed in
the status field.
• If more then one device
were selected, the
program switches to the
next screen to choose the
file to flash for the next
device.

• If the checkbox Auto-

Mode is activated, the
file which was chosen at
the previous flash
operation, is used.
Therefore it is not
necessary to specify the
file again.

• The program CIGWELD-Install automatically checks the version number of the selected
files. If someone tries to overwrite an operating system or characteristics with an older
version, a warning message is shown.
 • By activating the
checkbox Master Reset
all parameters are reset to
default values and all
Tiptronic jobs are deleted
after flashing. The
operating hour counter
and the error memory
remain unchanged.
• Finally all devices with
their version numbers are
displayed. The program
is terminated by clicking
on finish.

Special Welding Programs

• To transfer special welding programs

select the device entry S Welding
Programs
• click on Next

• Clicking on search file a dialogbox

appears, to select a welding program
file, to be transfered to the machine.
Size and date of the file are shown in
the status field. To start the flash
operation click on Next.
 • Use the up and down buttons next to
the program number to select a
program cell for the special program.
Every program number is checked if
the cell is clear of occupied.
• Click on Next

• If the Next button is clicked although

a program cell is occupied, a warning
is displayed.

• Click on Yes to overwrite the existing

program cell
• Click on No to go back.
• To delete a program cell, select the
file Delete.wld over the Search file
button, which is an empty “dummy“
file.
• Click on Next to overwrite the
existing program with the “dummy“.
• To delete all special welding
programs, activate the checkbox
Delete User Welding Programs.

Programming (flashing) an Operating System via serial Port

• important: it is not possible to update the welding characteristics via the serial COM-port.
Update the charateristics as described in chapter "Programming (flashing) via CAN
interface and updating characteristics".
• important: If a flash procedure has failed (error during data transfer) the pc-boards can only
be reprogrammed at the factory.
Programming (flashing) the V/S Master / robotic interface INT04 via serial port

• remove the right side panel (V series) resp. left side panel (S series) of the machine.
• connect the serial COM port of the computer with the COM port of the pc-board MAPRO
resp. pc-board INT04, using a serial SUB-D cable (9 pin).
• to flash the V-Master, the jumpers J2, J3 and J4 on the old version of pc-board MAPRO must
not be set, on the new version of the pc-board MAPRO, the DIP switches S1-1 to S1-3 has to
be set to “OFF“. Do not change the DIP switch S1-4, it’s for the identification of V-mobile.
• to flash the S-Master, set the DIP switches S1-1 to S1-3 on pc-board MAPRO to OFF. Do not
change the DIP switch S1-4, it’s for the identification of S-mobile.
• switch on the machine and the computer.
• start the ComFlash program.
• click on Search File... and choose the
file to be flashed (vMaster.m23 for V
series, sMaster.m14 for S series,
RobIntf.m21 for the robotic
interface). Date and size of the file are
shown in the status line. Click on
Flash to start the progamming
procedure.
• The program ComFlash checks at
first the serial connection to the pc-
board. If no connection could be
established, an error message is
displayed.
• if the connection is ok, the program
starts the flash procedure , the
progress is displayed in the status line.

• After a successful update Program

Flash completed is displayed.
• end the program with ALT + F4 , turn
off the machine and remove the serial
cable.
Programming (flashing) the V/S Process via serial port

• remove the right side panel (V series) resp. left side panel (S series) of the machine.
• connect the serial COM port of the computer with the COM port of the pc-board MAPRO,
using a serial SUB-D cable (9 pin).
• to flash the V-Process : on the old version of the pc-board MAPRO the jumpers J2, J3 and J4
must be set, on the new version of the pc-board MAPRO the DIP switches S1-1 to S1-3 must
be set to “ON“. Do not change DIP switch S1-4.
• to flash the S-Process, set the DIP switches S1-1 to S1-3 on pc-board MAPRO to ON. Do not
change the DIP switch S1-4.
• !! caution !! mark the flat ribbon cables, which cable was connected to which connector
• before flashing the V-Process, all flat ribbon cables of X2, X3, X4 and X5 on pc-board
MAPRO must be disconnected.
• before flashing the S-Process, all flat ribbon cables of X1 and X4 on pc-board MAPRO must
be disconnected.
• switch on the machine and the computer.
• depending on which COM port of the computer is used, start the program V-Flash Com1 or
V-Flash Com2 (V series) resp. S-Flash Com1 or S-Flash Com2 (S series).
• the program checks the serial connection. If no connection could be established, an error
message is displayed:

if the connection is ok, the program starts the flash procedure , the progress is displayed in the
window.

• after a successful flash procedure, Finished! is displayed in the window.

 • close the program with ALT + F4.
• turn off the power source.
• V series : remove jumper J2, J3 and J4
• S series : set DIP switches S1-1 to S1-3 on pc-board MAPRO to OFF. Do not change the DIP
switch S1-4.
• remove serial cable
• re-connect the flat ribbon cables on pc-board MAPRO.
• !! caution !! do not permute the flat ribbon cables !

Annex A1 Installation LPT-CAN-Dongle

These steps are only necessary if the LPT-CAN-Dongle is installed for the first time.

The CAN interface is ready after a successful installation of the CAN-Dongle and CAN driver
software:
• connect the Dongle to the parallel LPT port when the computer is in off-state and the power
supply of the Dongle with the adapter cable to the keyboard connector. Do not connect the
LPT-Dongle when the computer is on, resp. do not disconnect the dongle from the
computer if it’s still on.
• turn on the computer and enter the BIOS setup mode (check user manual of the computer).
• select the parallel port LPT1 (Onboard Devices or Peripheral Setup).
• check the operation mode of the LPT port. It must run in ECP mode, not ECP/EPP, EPP resp.
bi-directional. If it’s not in ECP mode, change it to ECP.
• go back to the main menu.
• leave the BIOS setup by selecting Save and Exit menu item.
• after the computer has rebooted install the CAN driver software as described in Annex A3.
Annex A2 Installation USB-CAN-Dongle

These steps are only necessary if the USB-CAN-Dongle is installed for the first time.

The CAN interface is ready after a successful installation of the CAN-Dongle and CAN driver
software:
• start Windows 98/ME/2000/XP. Windows NT does not support USB-devices ! put the USB-
plug of the Dongle into a free USB-socket of the computer.
• a windows appears starting
the installation procedure
(example for Windows
2000):
• the hardware-assistant starts
automatically. click on
Weiter (next).

• select Nach einem

passenden Treiber für das
Gerät suchen (empfohlen)
and click on Weiter (next).
 • select Diskettenlaufwerke
(floppy disk drive) insert the
driver disk into the floppy
disk drive and click on
Weiter (next).

• After the assistant has found

the driver, click on Weiter
(next).

• click on Fertig stellen

(finish), to end the
installation.
• Then install the CAN driver
software as described in
Annex A3

Remove USB hardware

• In Windows 2000/XP the
symbol for removing USB
hardware is located in the
right corner of the toolbar:

• doubleclick this symbol and

select PCAN_USB-Device in
the list of hardware
components.

• CLICK ON Deaktivieren (deactivate) and then on OK.

• after deactivation a message appears, that the device can be removed safely. Unplug the
dongle an click on OK.
• to remove the USB-CAN-Dongle in Windows 98, check that the red LED at the USB-CAN-
Dongle is not blinking. A blinking LED indicates data transfer between computer and
machine. If the CAN dongle is disconnected while the LED is blinking, the Windows
operating system could crash.

Important:
Windows is binding the driver to the used USB port. If the CAN-Dongle is used at other ports, the
driver must be installed for every single port like described in this annex.
Annex A3 CAN driver Installation for Windows 9x/Me/NT/2000/XP

These steps are only necessary when the CAN driver software is installed for the first time. In
Windows NT/2000/XP it is necessary to log on as Administrator in order to install the driver
software.

• close all running programs

before the installation.
• start the programm
Pcandrv.exe with
doubleclick.
• click on Next to continue the
installation.

• accept the license agreement

by clicking on Yes.

• takeover the preset

installation-
path.
• click Next to continue.

• click Next to continue.

• the installation progress is
displayed during the process.
• click on Finish to end the
installation.
• to restart the system click on
OK.

• after the system has rebooted, the CAN dongle must be registered in the control panel.
• click on Start/Settings/Control Panel/PCAN2-CAN-Hardware.
• if previous CAN driver have
been installed, do not use the
old icon :

• only use the new icon :

• In some Windows 95 versions it may happen, that the icon PCAN2-CAN-Hardware is

installed, but not displayed in the control panel. In this case contact CIGWELD directly for a
Windows 95 driver.
• activate the USB radio
button.
• the USB-CAN-Dongle is
automatically displayed and
registered.
• click on OK to close the
window.
• the installation is finished.

• in case of a LPT-CAN-
Dongle, click on the radio
button Peakcan (non Plug-
and-Play).
• if the LPT-CAN-Dongle is
not displayed automatically,
the resource informations has
to be set manually.
• look up the hardware resources
of the printer port via the
control panel
(I/O adress and IRQ). The
standard I/O adress of the
printer port is 0378 with
IRQ 7.

• in Windows 2000 and XP the

IRQ of the parallel ports has to
be activated first.
• choose ressource-method
assign interrupt to every
port. Click on OK. The used
IRQ is now displayed in the
ressource window.

• the CAN hardware can now be

added.
• click on Add... in the PCAN2-
CAN-hardware window, then
choose PEAK Dongle-CAN
with the right I/O adress and
IRQ and click on OK.

• the installation is now finished. Click on OK to close the window.

Annex A4 Troubleshooting

If no CAN connection can be estabished

to the machine, even after a successfully
installed driver, check the net-
configuration with Start/Program
Files/Pcan/NetConfig.
• The CIGWELD-Net must be
attached to the PEAK-CAN-
Dongle not to Internal.
• If the CIGWELD-Net is attached
to Internal, re-attach it to the
PEAK-CAN-Dongle by drag-
and-drop. Save this configuration
when ending the program.
• If the CIGWELD-Net doesn’t appear at all, start the CIGWELDInstall program and terminate
it again. By starting the CIGWELD Install program the CIGWELD-Net is set up
automatically.
• Be sure to log on as Administrator under Windows NT/2000/XP in order to make any
changes!
Robot Interface Manual INT04

Operation Manual Robot Interface INT04

Robot Interface INT04
The Robot interface INT04 is for connection between the series V, S, C2603-C4503 and M3030 to the robot
control. There are different analog and digital in- outputs available to allow an individual adaptation
between welding power source and robot control.
Configuration of the INT04 is possible via:
• DIP switches at the pc-board itself
• The control panel of the power source
• A PC with CAN interface

The INT04 works as a participant of the internal CAN-Bus. Commands coming over the INT04 interface are
converted into CAN-Bus messages and vice versa : actual values and status signals coming from the internal
CAN-Bus (e.g. „welding current on“) are put out to the INT04 interface.

The INT04 is potentially separated to the machine. The analog and digital inputs are not potentially seperated
against each other.

All inputs and outputs are available at the 42 pin Harting socket at the rear side of the welding power
source. Additional signals and functions (like gas monitoring) can be connected optionally.

Digital Inputs

The 18 digital inputs are designed for a voltage of +24V DC. For some of the digital inputs, LEDs are
showing the state of the inputs (see “Overview LEDs Robot interface INT04” on page 4).

Digital Outputs

The two digital outputs are designed as potential free relays contact. The power rating of the contacts ist
max. 1A at 48V. The state of the digital outputs are displayed on the pc-board INT04 with two LEDs (see
“Overview LEDs Robot interface INT04” on page 4).
Analog inputs
The eight analog inputs are designed for a voltage of 0 to +10V DC. Programming the analog in-puts
(assignment to welding parameters) is made with a PC with CAN interface (see PC Program RobotTool) or
directly at the power source over the front panel (menu Extras, Robot Interface). The selectable range of a
welding parameter corresponds to the range which is selectable at the front panel. The settings can be
monitored at the displays of the welding machine.
The factory default-assignment is:

Harting socket
input S-Series V-Series
Pin no.
A1 23 welding current welding current I1
A2 24 arc lenght second current I2
A3 25 start current welding time I1
A4 26 downslope welding time I2
A5 27 start current time AC frequency
A6 28 end current AC balance (+)
A7 29 end current time start current
A8 30 Twinpuls frequency end current IE

Parameter selection
The DIP switch (S1) on the pc-board INT04is used to determine, which parameter is set from ex-tern or
set at the front panel of the welding machine. When activating the signal „set extern“, all parameters
whose related DIP switch is set to „On“, can only be adjusted over the robot interface INT04. All input
signals for the other parameters whose related DIP switches are set to „off“, are ignored. The described
parameter selection can also be made with a PC using the program „RobotTool“. As soon as the parameter
selection is altered with the program, the settings of the DIP switch S1 are no longer valid. Any change of
the DIP switch itself reactivates set DIP switch settings again. A lit LED close to the DIP switch (LED 15
„DIPAKTIV“) indicates whether the settings of the DIP switch is valid or not.
If the signal „Job setting“ is used, the DIP switch S1 and consequently all analog inputs are without
function. In this mode all parameters stored in the welding job are used.

Overview DIP switch S1:

switch no. ON OFF
1..8 analog input 1..8 active, parameter is analog input not active, actual setting of
adjustable only via the INT04 interface the front panel is valid for the particular
parameter
9 program selection external (only S- Program selection via front panel
Series)
10 operating mode selection external operating mode selection via front panel
Picture Robot Interface INT04

Overview Connectors Robot interface INT04

Connector Description
X1 CAN connector
X2 Internal programming connector
X3 Flat ribbon connector to 42 pin Harting socket (digital and analog inputs)
X4 Flat ribbon connector to 42 pin Harting socket (digital in- and outputs)

Overview LED’s Robot interface INT04

LED Designation State Meaning

1 CAN-Bus status blinking CAN-Bus disturbed
on Robot interface not programmed (see manual CIGWELD
Install 909.0410.0 : Flashing units via CAN)
off CAN-Bus
2 Supply voltage +5V DC on +5V supply ok
+5V supply not ok
3 signal „welding current on“ (I>0 on signal „welding current on“ is active (relay Re1 = on,
contact closed)
off signal „welding current on“ is not active (relay Re1 = off,
contact open)
4 signal „power source ok on signal „power source ok
off (relay Re2 = on, contact closed)
5 digital input X4/18 on input is triggered (+24V DC)
Harting socket pin 10 off input is triggered (+24V DC)
LED Designation State Meaning
6 digital input X4/17 on input is triggered (+24V DC)
Harting socket Pin 9 off input is not triggered (0V)
7 digital inputX4/16 on input is triggered (+24V DC)
Harting socket Pin 8 off input is not triggered (0V)
8 digital input X4/15 on input is triggered (+24V DC)
Harting socket Pin 7 off input is not triggered (0V)
9 digital input X4/14 on input is triggered (+24V DC)
Harting socket Pin 6 off input is not triggered (0V)
10 digital input X4/13 on input is triggered (+24V DC)
Harting socket Pin 5 off input is not triggered (0V)
11 digital input X4/12 on input is triggered (+24V DC)
Harting socket Pin 4 off input is not triggered (0V)
12 digital input X4/11 on input is triggered (+24V DC)
Harting socket Pin 3 off input is not triggered (0V)
13 digital input X4/10 on input is triggered (+24V DC)
Harting socket Pin 2 off input is not triggered (0V)
14 digital input X4/9 on input is triggered (+24V DC)
Harting socket Pin 1 off input is not triggered (0V)
15 DIP switch S1 active on actual setting of the DIP switch is valid
off software settings (Robot Tool) are valid

Picture 42 pin Harting socket

8
1
2
Harting type designation description v s c signal functiom
Pin No
1-7 d. i. job- / program no. These digital inputs are used to select a job no. (at Saprom S also program no.). The X X X +24V DC bit = 1
job no. has to beset into binary code (see “Conversion decimal-binary” on page 12). 0V bit = 0
only at Saprom S: when none of the inputs are set (program no. 0), a program selec-
tion can be made at the front panel of the welding machine.
8 d. i. job select The Tiptronic mode is activated with this signal. A valid job no. has to be set at the X X X +24V DC Tiptronic mode on
inputs 1-7 in binary code(see “Conversion decimal-binary” on page 12). 0V Tiptronic mode off
If the signal is not set, the signals at the digital inputs 1-7 are interpreted as welding
program no. (only at Saprom S and only when DIP switch 9 „program select“ is “ON“)
9 d. i. welding on Start signal of the welding machine. This signal corresponds with a pressed torch but- X X X +24V DC machine starts welding
ton. At C- and S-series the wire feed unit 1 is activated. 0V machine stops welding
10 d. i. welding on 2 Start signal of the welding machine. This signal corresponds with a pressed torch but- X X +24V DC machine starts welding
ton. At C- and S-series the wire feed unit 2 is activated. (wire feed unit 2)
0V machine stops welding
welding mode AC2 Welding mode AC2 is activated: alternating current welding (noise reduced). The alter- X +24V DC AC2 mode on
nating current is not that rectangular like AC1 but smoother. 0V AC2 mode off
12,13 d. o. power source ok potential free output (relay contact): if the power source is operable the contact is clo- X X X 0 il between machine is operable
sed, otherwise the contact is open (in case of an error or during initialisation after the 12 and 13
machine is switched on)
oobd between machine is operable
12 and 13
13,14 d. o. welding current on potential free output (relay contact): if welding current flows (arc is ignited) the contact X X X 0 11 between „welding current on“ is active
is closed, if no welding current (no arc) the contact is open 13 and 14 (contact closed)

oobd between „welding current on“ is not active

13 and 14 (contact open)
15 d. i. set extern By setting this signal, all inputs which are declared as “external“ are valid. That means X X +24V DC external mode (“robot mode“)
the machine switches from “normal manual mode“ to “robot mode“. 0V internal mode (“normal manual mode“)
When activated, all parameters which are set as „external“ can’t be changed over the
front panel, but the actual values of the welding parameters are still displayed.
it is necessary, that valid values are present at the inputs at least 100ms before
and after setting the signal.
16 d. i. setup mode By setting this signal, the welding procedure can be started without starting the power X X +24V DC setup mode is active
source (“currentless welding“). The signal “welding current on“ is simulated by the 0V setup mode is not active
INT04. The signals “set extern“, “setup mode“ and “welding on“ must be active .
Course corrections can be made in this mode.
17 d. i. slope The downslope is activated with this signal. X X +24V DC Slope is active
DIP switch 10 (operating mode selection) must be in “ON“ position 0V Slope is not active
Hartin Type Designation Description V S C Signal Function
g Pin
18 d. i. mode pulse This signal activates the pulse welding mode (pluse welding mode = pulse-shaped X
welding current). If the signal is not set, the machine operates in normal welding mode
(short circuit arc)
0V normal welding mode
DIP switch 10 (operating mode selection) must be in “ON“ position
This signal activates the pulse welding mode (welding current alternates between wel- X
ding current I1 and second current I2). If the signal is not set, the machine operates in
normal welding mode
0V normal welding mode
DIP switch 10 (operating mode selection) must be in “ON“ position
d. i. This signal activates the twinpulse welding mode (twinpuls mode = pulse-shaped wel-
19 Twinpulse mode ding current with two alternating energy levels). The signal “mode pluse“ must be set. X
DIP switch 10 (operating mode selection) must be in “ON“ position
0V Twinpulse not active
Welding mode AC1 is activated (rectangular shaped alternating current).
welding mode AC1 DIP switch 10 (operating mode selection) must be in “ON“ position X
d. i. This signal activates the wire feeder and corresponds with pressing the wire insert but-
20 wire feed ton. The signal “set extern“ is not necessary. X
d. i. This signal is for checking the gas supply (solenoid valve opens) and corresponds with
21 gas test pressing the gas test button. The signal “set extern“ is not necessary. X X
a. i. control voltage 0-10V for the welding current

24 a. i. second current I2 control voltage 0-10V for the second current I2 X

The function of this control voltage depends on the user mode set in the machine: 0V automatic mode: 5%
automatic or manual. in automatic mode the second current is set as a percentage of
the welding current (5%-200%), in manual mode the second current is set directly in
10V DC automatic mode: 200%
amps. (min. - max.).
manual mode: max. current of p.s.
arc lenght / wire speed control voltage 0-10V for the correction of the arc length / wire speed X
The function of this control voltage depends on the setting in menu „Extras, arc length
correction“.
voltage : the programmed arc length given by the characteristic is corrected by the 10V DC 140% of the programmed value
control voltage
wire : the programmed wire feed speed given by the characteristic is corrected
by the control voltage

25 a. i. pulse welding time I1 control voltage 0-10V for the pulse welding time I1 X
The function of this control voltage depends on the user mode set in the machine: 0V automatic mode: 0,2 Hz
automatic or manual. in automatic mode the pulse frequency is set by the control
voltage (0,2 - 2000 Hz), in manual mode the pulse welding time is set in ms
10V DC automatic mode: 2000 Hz
(0,2 - 5000 ms). The machine must operate in pulse mode.
manual mode: 5000 ms
control voltage 0-10V for the start current
start current the start current is set as a percentage of the welding current. X
 Hartin Type Designation Description V S C Signal Function
g pin
No
26 a. i. pulse welding time I2 control voltage 0-10V for pulse welding time I2 X 0V
The function of this control voltage depends on the user mode set in the machine: automatic mode: 1%
automatic or manual. in automatic mode the control voltage sets the duty cycle (1% -
99%), in manual mode the pulse welding time is set in ms (0,2 - 5000 ms)
The machine must operate in pulse mode. 10V DC automatic mode: 99%
manual mode: 5000 ms
control voltage 0-10V for the downslope
downslope The operating mode slope must be active. X
a. i. control voltage 0-10V fur die AC-Frequenz
27 AC frequency The machine must operate in AC1 or AC2 mode. X
control voltage 0-10V for the start current time

a. i. control voltage 0-10V for the AC balance

28 AC-Balance The machine must operate in AC1 or AC2 mode. X 0V 10% pos. part of AC wave

10V DC 90% pos. part of AC wave

control voltage 0-10V for the final current
final current The final current is set as a percentage of the welding current. X
The operating mode slope must be active.
10V DC 100% of welding current
29 a. i. start current control voltage 0-10V for the start current X
The function of this control voltage depends on the user mode set in the machine: 0V automatic mode: 5%
automatic or manual. in automatic mode the control voltage sets the start current as a
percentage of the welding current (5% - 200%), in manual mode the start current is set
10V DC automatic mode: 200%
directly in amps. (min. max.).
manual mode: max. current of p.s.
control voltage 0-10V for the final current time
final current time The operating mode slope must be active. X
30 a. i. final current IE control voltage 0-10V for the final current IE X
The function of this control voltage depends on the user mode set in the machine: 0V automatic mode: 5%
automatic or manual. in automatic mode the control voltage sets the final current as a
percentage of the welding current (5% - 150%), in manual mode the final current is set
10V DC automatic mode: 150%
directly in amps. (min. max.).
manual mode: max. current of p.s.
control voltage 0-10V for the twinpulse frequency
twinpulse frequency The operating mode twinpulse must be active. X
d. i. : digital input
d. o. : digital output
a. i. : analog input
Other Analog Parameters

machine
designation description signal function
V S
pre gas time control voltage 0-10V for the pre gas time X 0V 0,1 sec.
10V DC 10 sec.
X 0V 0 sec.
10V DC 10 sec.
start current time control voltage 0-10V for the start current time X 0V 0 sec.
10V DC 10 sec.
upslope control voltage 0-10V for the upslope X 0V 0,1% (10 A/sec.)
The operating mode slope must be active. 10V DC 99% (990 A/sec.)
spot welding time control voltage 0-10V for the spot welding time X 0V 0,1 sec.
The operating mode spot welding must be active. 10V DC 10 sec.
downslope control voltage 0-10V for the downslope X 0V 0,1% (10 A/sec.)
The operating mode slope must be active. 10V DC 99% (990 A/sec.)
final current time control voltage 0-10V for the final current time X 0V 0 sec.
10V DC 10 sec.
gas post time control voltage 0-10V for the gas post time X 0V 50%
10V DC 200%
X 0V 20%
10V DC 200%
ignition current control voltage 0-10V for the ignition current X 0V 50%
10V DC 200%
arc shape control voltage 0-10V for the arc shape (calotte forming) X 0V 50%
The operating mode AC1 or AC2 must be active. 10V DC 200%
positive ignition current control voltage 0-10V for the positive ignition current X 0V 50%
10V DC 200%
twinpulse current change control voltage 0-10V for the twinpulse current change X 0V 5% of welding current
The operating mode twinpulse must be active. 10V DC 50% of welding current
twinpulse relation control voltage 0-10V for the twinpulse relation X 0V 20%
The operating mode twinpulse must be active. 10V DC 80%
wire burnback time control voltage 0-10V for the wire burnback time X 0V 20% of programmed value
10V DC 300% of programmed value
inductor effect control voltage 0-10V for the inductor effect X 0V 20% of programmed value
10V DC 200% of programmed value
coarse step pulsing control voltage 0-10V for the coarse step pulsing X 0 - 0,5V step 0 : (full range)
To achieve a more precise setting of the pulse parameters, the control voltage works as a coarse step preselecting cetain 0,5V - 1,5V step 1 : 0,2 - 2 Hz / 0,2 - 1ms
ranges for the pulse frequency resp. pulse welding times. The actual frequency/welding time has to be set with the control
voltages at the inputs 25/26. 1,5V - 2,5V step 2 : 2 - 5 Hz / 1 - 3ms
2,5V - 3,5V step 3 : 5 - 12,5 Hz / 3 - 7,5ms
3,5V - 4,5V step 4 : 12,5 - 30 Hz / 7,5 - 20ms
4,5V - 5,5V step 5 : 30 - 75 Hz / 20 - 50ms
5,5V - 6,5V step 6 : 75 - 200 Hz / 50 - 125ms
6,5V - 7,5V step 7 : 200 - 500 Hz / 125 - 300ms
7,5V - 8,5V step 8 : 500 - 1000 Hz / 300 - 750ms
8,5V - 10V step 9 : 1 - 1,5 kHz / 750 - 2000ms
Configuration at front panel menu
The INT04 can also be programmed at the front panel in menu “Extras, Robot Interface“ (only S-
and V-series). The eight analog inputs can be enabled or disabled. So it is not necessary to open the
machine and set the DIP switches. There is a special feature at Saprom S: if there are not enough
digital outputs available at the robot control to select a welding program, it is possible to select three
different pre-defined welding pro-grams with only two digital outputs. Those welding programs can
be set at menu items „ProgIn1“ to „ProgIn3“. The selection of these welding programs is made over
the digital inputs 1 and 2 (pin 1 and 2).
menu item pin no. setting description
Opt01(AnalogIn1) 23 On analog input is enabled (corresponds with DIP switch 1 set to „ON„)
Off analog input is disabled
Opt02(AnalogIn2) 24 On analog input is enabled (corresponds with DIP switch 2 set to „ON„)
Off analog input is disabled
Opt03(AnalogIn3) 25 On analog input is enabled (corresponds with DIP switch 3 set to „ON„)
Off analog input is disabled
Opt04(AnalogIn4) 26 On analog input is enabled (corresponds with DIP switch 4 set to „ON„)
Off analog input is disabled
Opt05(AnalogIn5) 27 On analog input is enabled (corresponds with DIP switch 5 set to „ON„)
Off analog input is disabled
Opt06(AnalogIn6) 28 On analog input is enabled (corresponds with DIP switch 6 set to „ON„)
Off analog input is disabled
Opt07(AnalogIn7) 29 On analog input is enabled (corresponds with DIP switch 7 set to „ON„)
Off analog input is disabled
Opt08(AnalogIn8) 30 On analog input is enabled (corresponds with DIP switch 8 set to „ON„)
Off analog input is disabled
Opt09(ProgSelect) On program selection is enabled (corresponds with DIP switch 9 set to „ON„)
Off program selection is disabled
Opt10(OperMode) On operating mode selection is enabled (corresponds with DIP switch 10 set to „ON„)
Off operating mode selection is disabled
Opt11(Setextern) On „robot mode„ is active (corresponds with the signal „set extern„)
Off „manual hand mode„ is active
Opt12(Job+Analog) On When using job selection (tiptronic mode) it is possible during the welding, to change
enabled parameters over the analog inputs. For example during the welding process the
welding current can be altered with the control voltage at the analog input 1
[Opt01(AnalogIn1) must be set to „ON„]
Off normal tiptronic mode, all welding parameters are stored in the job and can’t be changed
over the analog inputs.
ProgIn1 = Prog (0-99) Assignment of a welding program (only Saprom S)
welding program no. (0-99) set as program 1
ProgIn2 = Prog (0-99) Assignment of a welding program (only Saprom S)
welding program no. (0-99) set as program 2
ProgIn3 = Prog (0-99) Assignment of a welding program (only Saprom S)
welding program no. (0-99) set as program 3
Installation Software RobotTool
Insert the Installation floppy disk/CD RobotTool into your disk drive A, resp. CD-drive, click
on Start and execute, type in the command printed on the disk label and click on OK.
Follow the instructions given by the program which installs the software. A new icon
RobotTool is created on the Windows desktop.

Program description
The software RobotTool is for control and monitoring the interface INT04. It is expected, that
a CAN-interface is already installed and working. If not, please install a CAN-interface first. For
instructions see Operation Manual MT 900 or CIGWELD Install.
Start the software by double-clicking the icon
on the Windows desktop.

The actual states of the digital inputs are shown

in the upper part of the program window.
In the lower part of the program window, diffe-
rent parameters/inputs can be enabled or
disabled by clicking on the buttons 1-10. A clik-
ked button means enabled a released button
means disabled.
When starting the software the settings of the
DIP switch S1 is displayed. Any change of the
buttons 1-10 deactivates the DIP switch set-
tings, an the software settings are valid. The
software settings are saved when the machine
is turned off and are restored when the machine
is switched on again. Any change of the DIP
switches deactivates the software settings and
then only the DIP switch settings are valid.
In the right part of the program window, all
levels of the analog inputs are displayed as sliders and their actual value.
 The version of the operating system of the robot interface is displayed in the status line
below.
With the Drop-Down lists next to the buttons 1..8, any parameter can be assigned to the
eight analog inputs. Those assignments are also saved permanently into the machine. Assi-
gning one parameter to several inputs is not possible.
When assigning the parameters, notice that some parameters are only useable in certain
operating modes (e.g.: “twinpulse frequency“ on S-series is only available when the twinpulse
mode is active).

Conversion decimal-binary
decimal binary decimal binary decimal binary
0 0000000 34 0100010 67 1000011
1 0000001 35 0100011 68 1000100
2 0000010 36 0100100 69 1000101
3 0000011 37 0100101 70 1000110
4 0000100 38 0100110 71 1000111
5 0000101 39 0100111 72 1001000
6 0000110 40 0101000 73 1001001
7 0000111 41 0101001 74 1001010
8 0001000 42 0101010 75 1001011
9 0001001 43 0101011 76 1001100
10 0001010 44 0101100 77 1001101
11 0001011 45 0101101 78 1001110
12 0001100 46 0101110 79 1001111
13 0001101 47 0101111 80 1010000
14 0001110 48 0110000 81 1010001
15 0001111 49 0110001 82 1010010
16 0010000 50 0110010 83 1010011
17 0010001 51 0110011 84 1010100
18 0010010 52 0110100 85 1010101
19 0010011 53 0110101 86 1010110
20 0010100 54 0110110 87 1010111
21 0010101 55 0110111 88 1011000
22 0010110 56 0111000 89 1011001
23 0010111 57 0111001 90 1011010
24 0011000 58 0111010 91 1011011
25 0011001 59 0111011 92 1011100
26 0011010 60 0111100 93 1011101
27 0011011 61 0111101 94 1011110
28 0011100 62 0111110 95 1011111
29 0011101 63 0111111 96 1100000
30 0011110 64 1000000 97 1100001
31 0011111 65 1000001 98 1100010
32 0100000 66 1000010 99 1100011
33 0100001
Frimware Operating System Programming

Please ensure that the different versions of the operating systems match to each other, when updating a machine.

The actual version numbers are printed in bold numbers in the table below. Operating systems which haven’t

changed, needn’t to be updated. The actual versions of the operating systems can be displayed at the front panel or

via the Cigweld-Install Software.

Valid combinations Master-/Process-/Display/INT04/DMR -operating system – welding programs

operating system welding S-Series

Master Process Display INT04 DMR programs Release
1 250703 00
1 290803 02 1 060803 00 1 150803 00 1.00 - 1.02
1 020903 00
1 221003 03 1 281003 03 1 300103 00 1 281003 03 1.03
1 171103 04 1 131103 04 1 141103 04 1.04
1 270104 05 1 270104 05 1 280803 01 1 270104 05 1.05
1 080304 06 1 080304 06 1 290103 00 1 080304 06 1.06
1 070404 07 1 070404 07 1 211003 01 1 070404 07 1.07
1 200404 08 1 200404 08 1 200404 08 1.08
1 310304 01
1 190504 09 1 190504 09 1.09
1 250504 09 1 010604 09 1 060904 10 1.10
1 181104 11 1 021104 11 1 031104 11 1.11
1 161204 12 1 161204 12 3 240804 01 1 160604 02 1 161204 12 1.12
1 270105 13 1 310105 13 1 270105 13 1.13

It is possible to update both - systems and welding programs - at once via CAN-interface on the machines of the

Transmig Series with the Cigweld-Install. It is not necessary to open the machine. Cigweld-Install shows at the start

the number of the versions of the different pc-boards. A detailed description can be found in the user manual "PC-

Software Cigweld-Install" (909.0410.1-03).

 User Manual

PC-Software Job-Tool
Brief description of the job managing program
SJobTool.exe
The program SJobTool.exe is used for managing and editing welding jobs of the S-
Series.

Hard- and software requirements

- MS-Windows 95, NT 4.0 or higher is required

- CAN-Bus driverpakage must be installed
- CAN-Bus connection beween Peak-CAN-Dongle at parallel port of your PC and the
welding power source (optional CAN socket or via an adapter at 6 pin Minifit socket
on pc-board DP-MAPRO).

Program description

Transfering parameters from PC to Machine and vice versa

With the upload controls: in the toolbar, all jobs, the actual job-set or the actual
job can be sent from the PC to the welding machine. Clicking on the download controls:
all jobs, the actual job-set or the actual job is transfered from the machine to
the PC.
Click to send all jobs to the Saprom.
Click to send the actual job-set to the Saprom.
Click to send the actual job to the Saprom.

Click to read all jobs of the Saprom.

Click to read the actual job-set of the Saprom.
Click to read the actual job of the Saprom.
In case of an electrically interfered CAN-connection between the PC and welding
machine, the controls in the toolbar are inactive (grey). When the machine is in MMA
mode or during a welding process it is not possible to transfer any data, that means the
machine must be in standby to send or receive data.

With a working CAN-connection the version number of the operating system and the
operating hour counter can be displayed by clicking on the control: in the toolbar.
Additionally the version number of the operating system is displayed in the status-bar or
in case of a bad CAN-connection, an error message is shown in the status-bar.

Managing Jobs
On the left side of the dialog window a tree-structure is shown, containing the 10 job-
sets with each 10 jobs. The last entry in the tree-structure „Current settings„ represent
the actual settings of the machine regardless if the tiptronic mode is active or not. Even
if a valid job is altered and not jet saved.
The selected job is shown in the upper area of the dialog window in form of „Job x-x„.
Only if the checkbox „Valid„ is selected, the job is useable in the machine. If the
checkbox „Active„ is selected, the job is selectable via up/down-torch switches or
up/down switches of a remote control. If the checkbox „Active„ is not selected, the job
can only be selected with the digital encoder at the front panel of the machine.
An valid job is marked with a decimal point in the display (shown as „1-.0„).
Any name can be given to a job or a job-set which is stored in the machine and
displayed in the display. The name can be edited by reclicking a selected job or job-set.
A maximum of 23 characters can be used for one name and may contain space and
special characters.

Mode Selection
In the upper right rectangle „Operating mode„ all modes are visible and selectable: 2-
stroke/4-stroke/spot welding, Normal/Pulse/Twinpulse as well as Slopes. MMA mode is
not available when in tiptronic mode.

Editing Job Parameters

On the right side of the dialog window the job parameters are shown and with the
scrollbar you can move up and down to access all parameters. With the associated
slider a coarse adjustment can be preformed to the value of the parameter. A finetuning
can be made with the cursor-controls (right beside the slider).
Selection of material, wire, gas combination
In the „Program„ area the material, wire, gas combination can be selected for the job.
The program number is shown on the right side of the combination. Program number
„0„ will be displayed if an invalid combination has been set.

Copying, Moving and Erasing Jobs

A selected job can be copied to another job no. using the menu „Job„ - „copy...„. The
name of the job is also copied to the new job number. Even the last entry of the tree
structure „Current settings„ can be handled and copied like a job.
The menu function „Job„ - „Move...„ is similar to the copy function. The selected job is
moved to a new job no. and the old job no. is erased.
The menu function „Job„ - „Delete„ erases a selected job, that means the job name is
erased and all job settings and parameters are reset to default values.

Service Tool
Using menu „Extras„ - „Service tool...„ or clicking on in the toolbar, a dialogbox
appears to configure the key switch lock function and displaying diagnosis informations
of the machine.
When opening the window, the data is displayed and can be altered if neccessary. Click
on „Apply„ to send the changed parameter to the machine. Clicking on „Ok„, the
changed parameter are also send to the machine and the dialog windows is closed.
Click on „Cancel„ to close the window without any change.

Parameter description:
- „Current lock level„ is equal to th parameter Lock function of the machine (menu
Extras, lock function). If a machine is equipped with a key switch and the switch is
activated, it sets the machine to the specified lock level.
- „Key switch on = lock level„ defines which lock level is valid when the key switch is
activated (preset: lock level 2)

In middle area of the dialog window the Master Operating system version and the actual
operating hour counter is displayed.
In the lower part of the window the last five error messages are displayed including the
operating hour counter of the time the error occured. (0) ist the latest error, (4) is the
oldest error.

Language selection
The language in which the job parameter are displayed can be set using the menu
„Extras„ - „Language...„. The language setting is stored for the next use of the program.
Smart Torch Spare Parts
Power Master Schematic
Installation of Push Pull

Change of digital Push Pull

Thermal Arc - SP-Series
Overview parts

5
4

3 1

POS article-no name quantity

1 600.2999.0 locknut Ripp M4 4
2 600.5800.0 slotted pan head screw ST 2.9x9.5 4
3 650.5340.1 pc-board DMR4Q 150(S) 1
4 661.3138.0 Minifit-connection 2pol B/B 300mm 1
5 661.3180.2 socket 17+PE AMPH Dig.P.P.150mm 1
Technical Instruction

Attention: before opening the housing 2. Puncture the panel sticker at the
disconnect from the mains! marked place.
1. unsrew cover (right side) 3. Cut the panel sticker according to
(6 x crosshead screw). the round gap in the metal
housing.

4. Plug in the socket (5) from outside 7. Disconnect all plug-in connections
(cables first). off the pc-board.
5. Fix the socket (5) with the screws And do name/mark them!
(2). Attention: danger of wrong polarity!
6. Connect the minifit-connection (4) 8. take of pc-board (6) from the
with the cable of the socket (5). spacers.
Info: The two left cables of the socket
are not needed (see arrow).
Overview

9. Open housing (left site). 11. Fix pc-board (3) with the screws
4
(1) at the metal sheet.
10. Take the spacers (7) of the sheet.

Info: The spacers (7) are not needed

any more.

14. Screw housing plate (right side)

again to the machine.

12. Connect all plugs like named to the

pc-board.
13. Connect minifit (4) to the
pc-board (3).
TIG OPTION

Activating / deactivating TIG-Option for SP Series

1Button „-“ (minus)

2Button „END“
3Button „+“ (plus)
4Button „up“
5Button „down“
6Rotary impulse encoder left

Activating TIG-option:
• switch to menu Extras, lock function
• pressing button 1 (minus) or 3 (plus) question,”change parameter ?“ is
displayed
• acknowledge with button 4 (up)
• set three-digit code number “660“ with button 1 (minus), 3 (plus) or encoder 6
• acknowledge the code number with button 5 (down) !

Deactivating TIG-option:
• switch to menu Extras, lock function
• pressing button 1 (minus) or 3 (plus) question „change parameter ?“ is
displayed
• acknowledge with button 4 (up)
• set three-digit code number “661“ with button 1 (minus), 3 (plus) or encoder 6
• acknowledge the code number with button 5 (down) !

For the TIG option you need an additional gas valve, gas hose, gas connector and two connection cable sets.
No interface board is needed.
In detail that is: (with OEM part no.)
665.3009.0 gas valve (mounted at the back side of the machine)
661.8874.5 connection cable gas valve (to pc-board DP-MAPRO X10)
661.8214.5 connection cable TIG torch control socket (this is the 5 pin control socket in the front, to pc-board DP-
MAPRO X15)

612.6019.0 gas connector (this is the gas connector for the TIG torch in the front)
610.3505.0 external gas hose
610.3580.0 internal gas hose
622.1221.1 reducing bushing R1/4'a x R1/8'a / long
622.0005.0 hose connector R1/8 4mm KU
612.0150.0 sealing ring R 1/8" alu

The 5 pin socket is a standard TIG control socket. Pins 1 and 2 are connected to the start-button of the torch.

You press the torch button and ignite by contacting the tip of the needle to the welding material shortly.

After hardware setup you need to activate the TIG function via the front panel.

After activating the TIG function, you can select the TIG mode using the mode button at the front panel.
Here some additional pictures from a 500SP:
500SP
Semi Conductor Device Data
Torque Setting(s)

All power semi conductors and mounting screws should be tightened with a torque wrench to
1.5 Nm.
Global Customer Service Contact Information

Cigweld, Australia Thermadyne Asia Pacific Pte Ltd

71 Gower Street 5 Shenton Way

Preston, Victoria #37-02 / 38-02 UIC Building

Australia, 3072 Singapore 068808

Telephone: 61-3-9474-7400 Telephone: 65-6832-8066

Fax: 61-3-9474-7510 Fax : 65+ 6763 5812

Thermadyne Victor Brasil Thermadyne, China

Avenida Brasil RM 102A

13629-Cordovil 685 Ding Xi Rd

Rio de Janeiro, Brazil 21012-351 Chang Ning District

Telephone: 55-21-2485-8998 Fax: Shanghai, PR, 200052

55-21-2-485-8735 Telephone: 86-21-69171135

Fax: 86-21-69171139

Thermadyne Chile Thermadyne Asia Sdn Bhd

Piloto Lazo #90 Lot 151, Jalan Industri 3/5A

Cerrillos Rawang Integrated Industrial Park - Jln Batu Arang

Santiago, Chile 7278-654 48000 Rawang Selangor Darul Ehsan

Telephone: 56-2-557-2465 West Malaysia

Fax: 56-2-557-5349 Telephone: 603+ 6092 2988

Fax : 603+ 6092 1085

Thermadyne USA
Thermadyne Europe
82 Benning Street
Europe Building
West Lebanon, NH 03784 USA
Chorley North Industrial Park
Telephone: (603) 298-5711
Chorley, Lancashire England,
800-752-7621
PR6 7Bx Telephone: 44-
Fax: 800-221-4401
1257-261755 Fax: 44-1257-
Email: sales@thermalarc.com
224800
Corporate Headquarters 16052
Swingley Rigdge Road Suite 300 St.
Louis MO 63017 USA Telephone:
(636) 728-3000 800-526-2106 Voice
Mail Email:
cigweldsales@cigweld.com.au
www.cigweld.com.au