250i
TRANSMIG
MULTI PROCESS WELDING
INVERTER
2RT
WIRE FEEDER (OPTIONAL)
Operating Manual
Revision: AD Issue Date: October 12, 2011 Manual No.: 0-5187
Operating Features:
250
240
PFC
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
+1300 654 674, or visit us on the web at www.thermadyne.com
This Operating Manual has been designed to instruct you on the correct
use and operation of your CIGWELD product. Your satisfaction with this
product and its safe operation is our ultimate concern. 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.
We have made every effort to provide you with accurate instructions,
drawings, and photographs of the product(s) while writing this manual.
However errors do occur and we apologize if there are any contained in
this manual.
Due to our constant effort to bring you the best products, we may make
an improvement that does not get reflected in the manual. If you are ever
in doubt about what you see or read in this manual with the product you
received, then check for a newer version of the manual on our website
or contact our customer support for assistance.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
CIGWELD is the Market Leading Brand of Arc Welding Products for
Thermadyne Industries Inc. We are a mainline supplier to major welding
industry sectors in the Asia Pacific and emerging global markets including; Manufacturing, Construction, Mining, Automotive, Engineering,
Rural and DIY.
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 installing,
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.
Operating Manual Number 0-5187 for:
Cigweld Transmig 250i Inverter Plant (South Pacific) Part Number W1003250
Cigweld Transmig 250i Inverter Power Source (South Pacific) Part Number W1003251
Cigweld Transmig 250i Inverter Plant (Asia) Part Number W1003250M
Cigweld Transmig 2RT Wirefeeder (Optional - All Regions) Part Number W3000500
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermadyne.com
Copyright 2011 by
Thermadyne Industries, Inc.
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: August 19, 2011
Revision Date: October 12, 2011
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
TABLE OF CONTENTS
SECTION 1:
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ......................................... 1-1
1.01 Arc Welding Hazards .............................................................................................. 1-1
1.02 Principal Safety Standards ...................................................................................... 1-5
1.03 Declaration of Conformity ....................................................................................... 1-6
SECTION 2: INTRODUCTION
2.01 How to Use This Manual ......................................................................................... 2-1
2.02 Equipment Identification ......................................................................................... 2-1
2.03 Receipt of Equipment ............................................................................................. 2-1
2.04 Symbol Chart .......................................................................................................... 2-2
2.05 Description ............................................................................................................. 2-3
2.06 User Responsibility ................................................................................................. 2-3
2.07 Transportation Methods .......................................................................................... 2-3
2.08 Packaged Items ...................................................................................................... 2-4
2.09 Duty Cycle .............................................................................................................. 2-5
2.10 Specifications ......................................................................................................... 2-6
SECTION 3: INSTALLATION OPERATION AND SETUP
3.01 Environment ........................................................................................................... 3-1
3.02 Location .................................................................................................................. 3-1
3.03 Ventilation ............................................................................................................... 3-1
3.04 Mains Supply Voltage Requirements ...................................................................... 3-1
3.05 Electromagnetic Compatibility ................................................................................ 3-3
3.06 Power Source Controls, Indicators and Features .................................................... 3-4
3.07 Advanced Features Details .................................................................................... 3-10
3.08 Optional Wire Feeder Controls, Indicators and Features ....................................... 3-15
3.09 Optional Wire Feeder Set Up MIG (GMAW) Welding with Gas Shielded MIG Wire 3-16
3.10 Optional Wire Feeder Set-up for MIG (FCAW) Welding with Gasless MIG Wire .... 3-17
3.11 Fitting of Optional Roll Cage ................................................................................. 3-18
3.12 Assembly and Fitting of Optional Welding Trolley ................................................. 3-20
3.13 Attaching the Tweco Professional MIG Torch (Euro)............................................. 3-22
3.14 Installing a Handispool (200mm diameter)........................................................... 3-23
3.15 Installing a Standard Spool (300mm diameter) .................................................... 3-24
3.16 Inserting Wire into the Feed Mechanism ............................................................. 3-25
3.17 Feed Roller Pressure Adjustment.......................................................................... 3-26
3.18 Feed Roller Alignment........................................................................................... 3-26
3.19 Changing the Feed Roll ......................................................................................... 3-27
3.20 Input And Output Wire Guide Installation ............................................................. 3-28
3.21 Wire Reel Brake .................................................................................................... 3-29
3.22 Shielding Gas Regulator Operating Instructions ................................................... 3-29
3.23 Set-up MIG (GMAW) Welding with Gas Shielded MIG Wire ................................. 3-33
3.24 Set-up for MIG (FCAW) Welding with Gasless MIG Wire ...................................... 3-34
3.25 Set-up for LIFT TIG (GTAW) Welding .................................................................... 3-35
3.26 Set-up for Metal Manual Metal Arc Welding (MMAW) .......................................... 3-36
................................................................................. 2-1
..................................................... 3-1
SECTION 4:
BASIC WELDING GUIDE
4.01 MIG (GMAW/FCAW) Basic Welding Technique ....................................................... 4-1
4.02 MIG (GMAW/FCAW) Welding Troubleshooting ....................................................... 4-4
4.03 Stick (MMAW) Basic Welding Technique ................................................................ 4-7
4.04 Stick (MMAW) Welding Troubleshooting .............................................................. 4-16
4.05 TIG (GTAW) Basic Welding Technique .................................................................. 4-18
4.06 TIG (GTAW) Welding Problems ............................................................................ 4-21
TABLE OF CONTENTS
................................................................................ 4-1
SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS
5.01 Power Source Problems ......................................................................................... 5-1
5.02 Routine Service and Calibration Requirements ....................................................... 5-3
5.03 Cleaning the Welding Power Source ....................................................................... 5-6
5.04 Cleaning the Feed Rolls .......................................................................................... 5-7
SECTION 6: KEY SPARE PARTS
.............................................................................. 6-1
6.01 Tweco Fusion 250 Mig Torch .................................................................................. 6-1
6.02 Transmig 250i Power Source .................................................................................. 6-2
APPENDIX 1: OPTIONS AND ACCESSORIES
APPENDIX 2: TRANSMIG 250i CIRCUIT DIAGRAM
CIGWELD LIMITED WARRANTY
............................................................................ RC-2
TERMS OF WARRANTY – APRIL 2010
WARRANTY SCHEDULE – APRIL 2010
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
............................................................... A-1
........................................................ A-2
.................................................................... RC-3
.................................................................... RC-4
.............................................. RC-5
............... 5-1
This page intentionally blank
TRANSMIG 250i
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SECTION 1:
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. Do NOT LOSE THESE INSTRUCTIONS.
READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
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 Australian Standard AS1674.2-2007 entitled: Safety in welding and allied processes
Part 2: Electrical. 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.
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and
work circuit is electrically live whenever the
output is on. The input power circuit and machine internal circuits are also live when power
is ON. In semiautomatic or automatic wire
welding, the wire, wire reel, drive roll housing,
and all 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.
6. Turn OFF all equipment when not in use. Disconnect
power to equipment if it will be left unattended or out
of service.
7. Use fully insulated electrode holders. Never dip holder
in water to cool it or lay it down on the 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.
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.
Manual 0-5187 1-1 GENERAL INFORMATION
TRANSMIG 250i
2. Wear approved safety glasses. Side shields recommended.
WARNING
ARC RAYS can burn eyes and skin; NOISE can
damage hearing.
Arc rays from the welding process produce
intense heat and strong ultraviolet rays that
can burn eyes and skin. Noise from some
processes can damage hearing.
1. Use a Welding Helmet or Welding Faceshield fitted
with a proper shade of filter (see ANSI Z49.1 and AS
1674 listed in Safety Standards) to protect your face
and eyes when welding or watching.
Recommended Protective Filters for Electric Welding
Description of Process
Manual Metal Arc Welding - covered
electrodes (MMAW)
Gas Metal Arc Welding (GMAW)
(MIG) other than Aluminium and
Stainless Steel
Gas Metal Arc Welding (GMAW)
(MIG) Aluminium and Stainless Steel
Gas Tungsten Arc Welding (GTAW)
(TIG)
Flux-cored Arc Welding (FCAW) -with
or without shielding gas.
Air - Arc Gouging Less than or equal to 400 12
Plasma - Arc Cutting
Plasma - Arc Spraying
Plasma - Arc Welding
Submerged - Arc Welding
Resistance Welding
Approximate Range of
Welding Current in Amps
Less than or equal to 100 8
100 to 200 10
200 to 300 11
300 to 400 12
Greater than 400 13
Less than or equal to 150 10
150 to 250 11
250 to 300 12
300 to 400 13
Greater than 400 14
Less than or equal to 250 12
250 to 350 13
Less than or equal to 100 10
100 to 200 11
200 to 250 12
250 to 350 13
Greater than 350 14
Less than or equal to 300 11
300 to 400 12
400 to 500 13
Greater than 500 14
50 to 100 10
100 to 400 12
400 to 800 14
Less than or equal to 20 8
20 to 100 10
100 to 400 12
400 to 800 14
3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flameresistant material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is
high.
6. Never wear contact lenses while welding.
Minimum Shade Number of
Filter(s)
—
—
—
Safety Spectacles or eye shield
15
2(5)
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.
GENERAL INFORMATION 1-2 Manual 0-5187
WARNING
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 breathe the
fumes.
2. If inside, ventilate the area and/or use exhaust at the
arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables,
coatings, and cleaners.
5. Work in a confined space only if it is well ventilated,
or while wearing an air-supplied respirator. Shielding
gases used for welding can displace air causing injury
or death. Be sure the breathing air is safe.
6. DO NOT weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc can
react with vapours to form highly toxic and irritating
gases.
TRANSMIG 250i
3. Remove all flammables within 10M of the welding arc.
If this is not possible, tightly cover them with approved
covers.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, 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
travelling long, possibly unknown paths and causing
electric shock and fire hazards.
9. Do NOT use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding
wire at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can cause
injury.
Chipping and grinding cause flying metal. As
welds cool, they can throw off slag.
7. 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 containing these
elements can give off toxic fumes if welded.
WARNING
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.
1. Protect yourself and others from flying sparks and hot
metal.
2. Do NOT weld where flying sparks can strike flammable
material.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
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.
1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by
chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
Manual 0-5187 1-3 GENERAL INFORMATION
TRANSMIG 250i
!
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.
WARNING
MOVING PARTS can cause injury.
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.
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-based advice on strategies
to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following procedures.
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.
3. Have only qualified people remove guards or covers
for maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect negative (-) battery 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.
WARNING
This product, when used for welding or cutting, produces fumes or gases which contain
chemicals know to the State of California to
cause birth defects and, in some cases, cancer.
(California Health & Safety code Sec. 25249.5
et seq.)
NOTE
Considerations About Welding And The Effects
of Low Frequency Electric and Magnetic Fields
ABOUT PACEMAKERS:
The above procedures are among those
also normally recommended for pacemaker
wearers. Consult your doctor for complete
information.
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of
Technology Assessment, Biological Effects of Power
GENERAL INFORMATION 1-4 Manual 0-5187
TRANSMIG 250i
1.02 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402.
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.
Safety in welding and allied processes Part 1: Fire Precautions, AS 1674.1-1997 from SAI Global Limited, www.
saiglobal.com.
Safety in welding and allied processes Part 2: Electrical, AS 1674.2-2007 from SAI Global Limited, www.saiglobal.com.
Filters for eye protectors - Filters for protection against radiation generated in welding and allied operations AS/NZS
1338.1:1992 from SAI Global Limited, www.saiglobal.com.
Manual 0-5187 1-5 GENERAL INFORMATION
TRANSMIG 250i
1.03 Declaration of Conformity
Manufacturer: CIGWELD
Address: 71 Gower St, Preston
Victoria 3072
Australia
Description of equipment: Welding Equipment (GMAW, FCAW, GTAW, MMAW) including, but not limited to CIGWELD
Transmig 250i Multi Process Welding Inverter, CIGWELD Transmig 2RT wire feeder 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:
• IEC60974-10applicabletoIndustrialEquipment-genericemissionsandregulations.
• AS1674Safetyinweldingandalliedprocesses.
• AS60974.1/IEC60974-1applicabletoweldingequipmentandassociatedaccessories.
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 performance, ultra
safe operation and world class quality for more than 30 years and will continue to achieve excellence.
GENERAL INFORMATION 1-6 Manual 0-5187
INTRODUCTION TRANSMIG 250i
!
SECTION 2: INTRODUCTION
2.01 How to Use This Manual
This Operating Manual usually applies to the part numbers
listed on page i. To ensure safe operation, read the entire
manual, including the chapter on safety instructions and
warnings. Throughout this manual, the word WARNING,
CAUTION and NOTE may appear. Pay particular attention
to the information provided under these headings. These
special annotations are easily recognized as follows:
WARNING
Gives information regarding possible personal
injury. Warnings will be enclosed in a box
such as this.
CAUTION
Refers to possible equipment damage. Cautions will be shown in bold type.
NOTE
Offers helpful information concerning certain
operating procedures. Notes will be shown
in italics
2.02 Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear on
a nameplate attached to the machine. Equipment which
does not have a nameplate attached to the machine is
identified only by the specification or part number printed
on the shipping container. Record these numbers for
future reference.
2.03 Receipt of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any
damage, notify the carrier immediately to file a claim.
Furnish complete information concerning damage claims
or shipping errors to the location in your area listed in the
inside back cover of this manual.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.
Additional copies of this manual may be purchased by
contacting CIGWELD at the address and phone number
for your location listed in the inside back cover of this
manual. Include the Owner’s Manual number and equipment identification numbers.
Manual 0-5187 2-1 INTRODUCTION
TRANSMIG 250i INTRODUCTION
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
X
%
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Remote
Duty Cycle
Percentage
Panel/Local
Manual Metal
Arc Welding (MMAW)
Gas Metal Arc
Welding (GMAW)
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Welding Torch
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
t2
Preflow Time
Postflow Time
t1
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
Burnback Time
t
Disturbance In
Ground System
IPM
MPM
Inches Per Minute
Meters Per Minute
115V 15A
INTRODUCTION 2-2 Manual 0-5187
Receptacle RatingAuxiliary Power
Voltage Input
V
Figure 2-1 Symbol chart
Art # A-10344
INTRODUCTION TRANSMIG 250i
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!
2.05 Description
The Cigweld Transmig 250i is a self contained single phase
multi process welding inverter that is capable of performing GMAW/FCAW (MIG), MMAW (Stick) and GTAW (Lift
TIG) welding processes. The Transmig 250i is equipped
with an integrated wire feed unit, voltage reduction device (VRD) for STICK (MMAW) welding, digital volt age
/ amperage meters, power factor correction (PFC) with
energy saving technology and a host of other features to
satisfy the broad operating needs of the modern welding
professional.
An optional Wirefeeder can also be connected to the
Transmig 250i to extend the welding radius from 3.6m
to 11.6m from the Power Source.
The Transmig 250i and 2RT Wirefeeder are fully compliant
to Australian Standard AS 60974.1 and IEC 60974.1. The
Transmig 250i MIG provides excellent welding performance across a broad range of applications when used
with the correct welding consumables and procedures.
The following instructions detail how to correctly and
safely set up the machine and give guidelines on gaining
the best efficiency and quality from the Power Source.
Please read these instructions thoroughly before using
the unit.
2.07 Transportation Methods
WARNING
ELECTRIC SHOCK can kill. DO NOT TOUCH
live electrical parts. Disconnect input power
conductors from de-energized supply line
before moving the welding power source.
WARNING
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Lift unit with integrated hand holds at the front and rear
of the unit.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a proper
skid before transporting.
2.06 User Responsibility
This equipment will perform as per the information contained herein when installed, operated, maintained and
repaired in accordance with the instructions provided.
This equipment must be checked periodically. Defective
equipment (including welding leads) should not be used.
Parts that are broken, missing, plainly worn, distorted or
contaminated, should be replaced immediately. Should
such repairs or replacements become necessary, it is
recommended that such repairs be carried out by appropriately qualified persons approved by CIGWELD. Advice
in this regard can be obtained by contacting an Accredited
CIGWELD Distributor.
This equipment or any of its parts should not be altered
from standard specification without prior written approval
of CIGWELD. The user of this equipment shall have the
sole responsibility for any malfunction which results from
improper use or unauthorized modification from standard
specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons
approved by CIGWELD.
Manual 0-5187 2-3 INTRODUCTION
TRANSMIG 250i INTRODUCTION
2.08 Packaged Items
Transmig 250i Plant -
South Pacific (Part No. W1003250)
•Transmig250iInverterPowerSource
•MIGTorch,TwecoFusion250A,3.6M,Euro,STD
•Regulator/FlowMeter-COMET250ARG55LPM2GA
•Leadset,250A,4M,50D
•GasHose,3M
•OperatingManual
•DriveRoll'V'Knurled1.2mm
•DriveRoll'U'Groove1.2mm
•DriveRoll'V'Groove0.6-0.9mm
•DriveRoll'V'Groove0.9-1.2mm,Fitted
•PressureRoll0.6-1.2mmSolidWire,Fitted
•Contacttips:0.8mm,0.9mmFitted,1.0mm,1.2mm
•OutletGuide0.9-1.2mm,Fitted
•OutletGuide0.6mm
Transmig 250i MIG Plant -
Asia (Part number W1003250M)
•Transmig250iInverterPowerSource
•MIGTorch,TwecoFusion250A,3.6M,Euro,STD
•Leadset,250A,4M,50D
•GasHose,3M,Female3/8BSP
•OperatingManual
•DriveRoll'V'Knurled1.2mm
•DriveRoll'U'Groove1.2mm
•DriveRoll'V'Groove0.6-0.9mm
•DriveRoll'V'Groove0.9-1.2mm,Fitted
•PressureRoll0.6-1.2mmSolidWire,Fitted
•Contacttips:0.8mm,0.9mmFitted,1.0mm,1.2mm
•OutletGuide0.9-1.2mm,Fitted
•OutletGuide0.6mm
Transmig 2RT Wirefeeder (Optional)
(Part No. W3000500)
Transmig 250i Power Source -
South Pacific (Part No. W1003251)
•Transmig250iInverterPowerSource
•GasHose,3M
•OperatingManual
•DriveRollVGroove0.9-1.2mm,Fitted
•PressureRoll0.6-1.2mmSolidWire,Fitted
•OutletGuide(0.9-1.2mm),Fitted
•Transmig2RTWirefeeder
•8MInterconnectionLead,Fitted
•OperatingManual
•DriveRoll0.9-1.2mm,Fitted
•PressureRoll0.6-1.2mmSolidWire,Fitted
•OutletGuide0.9-1.2mm,Fitted
•ShieldingGasAdapter
INTRODUCTION 2-4 Manual 0-5187
INTRODUCTION TRANSMIG 250i
2.09 Duty Cycle
The rated duty cycle of a Welding Power Source is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute
duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 40%
duty cycle, 250 amperes at 26.5 volts. This means that it has been designed and built to provide the rated amperage
(250A) for 4 minutes, i.e. arc welding time, out of every 10 minute period (40% of 10 minutes is 4 minutes). During
the other 6 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool.
With Factory Installed Input Lead and Plug
100
90
80
70
60
50
40
30
Duty Cycle (percentage)
20
10
0
0
Safe
Operating
Region
25 50 75
Stick (MMAW)
100
125 150 225 250
175
TIG (GTAW)
MIG (GMAW)
200
Welding Current (amps)
Art # A-10315
Figure 2-2: Transmig 250i Duty Cycle with Factory Fitted Supply Lead and Plug
With Upgraded Supply Lead and Plug
100
90
80
70
60
50
40
30
Duty Cycle (percentage)
20
10
0
0
25 50 75
Safe
Operating
Region
100
Stick (MMAW)
125 150 225 250
175
Welding Current Max (amps)
Figure 2-3: Transmig 250i Duty Cycle with Upgraded Supply Lead and Plug
TIG (GTAW)
MIG (GMAW)
200
Art # A-10316
Manual 0-5187 2-5 INTRODUCTION
TRANSMIG 250i INTRODUCTION
2.10 Specifications
Description TRANSMIG 250i MULTI PROCESS WELDING INVERTER
Power Source Dimensions H 440mm x W 260mm x D 600mm
Power Source Mass 29.5kg
Cooling Fan Cooled
Welder Type Multi Process Inverter Power Source
Australian Standard AS 60974.1-2006 / IEC60974.1
Number of Phases Single Phase
Nominal Supply Voltage 240VAC ± 15%
Nominal Supply Frequency 50/60Hz
Open Circuit Voltage 72 VDC
MIG Voltage Range 14-30 VDC
Wirefeeder Speed Range 1.7-17.8 MPM
Protection Class IP23S
Supply Lead & Plug Rating "15 Amps (2.5mm²)
Ratings Below Applies to the
Factory Fitted Supply Lead & Plug"
Welding Current Range (MIG Mode) 20-190 Amps 20-300 Amps
Welding Current Range (LIFT TIG Mode) 5-235 Amps 5-300 Amps
Welding Current Range (STICK Mode) 20-170 Amps 20-230 Amps
Effective Input Current (I1eff) 15 Amps 22.4 Amps
Maximum Input Current (I1max) 23.7 Amps 34.7 Amps
Single Phase Generator Requirement 6 kVA 10 kVA
MIG (GMAW) Welding Output, 40°C, 10 min. 190A @ 40%, 23.5V
165A @ 60%, 22.3V
135A @ 100%, 20.8V
STICK (MMAW) Welding Output, 40°C, 10 min. 170A @ 40%, 26.8V
145A @ 60%, 25.8V
115A @ 100%, 24.6V
TIG (GTAW) Welding Output, 40°C, 10 min. 235A @ 40%, 19.4V
200A @ 60%, 18V
150A @ 100%, 16V
[Ratings Below Applies to an Upgraded
4mm² Supply Lead & Plug Fitted]"
"25 Amps ( 4mm²)
250A @ 40%,26.5V
200A @ 60%, 24V
150A @ 100%, 21.5V
230A @ 40%,29.2V
200A @ 60%, 28V
150A @ 100%, 26V
250A @ 40%,20V
200A @ 60%, 18V
150A @ 100%, 16V
Table 2-1: Transmig 250i Specification
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all
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.
INTRODUCTION 2-6 Manual 0-5187
NOTE
INSTALLATION/SETUP TRANSMIG 250i
!
SECTION 3: INSTALLATION OPERATION AND SETUP
3.01 Environment
These units are designed for use in environments with
increased hazard of electric shock as outlined in AS
60974.1 and AS 1674.2. Note the Transmig 250i Plant Part
No. W1003250M (Asia Version) has the VRD turned OFF.
Additional safety precautions may be required when using
unit in an environment with increased hazard of electric
shock. Please refer to relevant local standards for further
information prior to using in such areas.
A. Examples of environments with increased hazard of
electric shock are:
1. In locations in which freedom of movement is
restricted, so that the operator is forced to perform
the work in a cramped (kneeling, sitting or lying)
position with physical contact with conductive
parts.
2. In locations which are fully or partially limited by
conductive elements, and in which there is a high
risk of unavoidable or accidental contact by the
operator.
G. The enclosure design of this power source meets the
requirements of IP23S as outlined in AS60529. This
provides adequate protection against solid objects
(greater than 12mm), and direct protection from vertical drops. Under no circumstances should the unit be
operated or connected in a micro environment that will
exceed the stated conditions. For further information
please refer to AS 60529.
H. Precautions must be taken against the power source
toppling over. The power source must be located on
a suitable horizontal surface in the upright position
when in use.
WARNING
This equipment should be electrically
connected by a qualified electrician.
3.03 Ventilation
3. In wet or damp hot locations where humidity
or perspiration considerably reduces the skin
resistance of the human body and the insulation
properties of accessories.
B. Environments with increased hazard of electric shock
do not include places where electrically conductive parts in
the near vicinity of the operator, which can cause increased
hazard, have been insulated.
3.02 Location
Be sure to locate the welder according to the following
guidelines:
A. In areas, free from moisture and dust.
B. Ambient temperature between 0° C to 40° C.
C. In areas, free from oil, steam and corrosive gases.
D. In areas, not subjected to abnormal vibration or shock.
E. In areas, not exposed to direct sunlight or rain.
F. Place at a distance of 300mm or more from walls or
similar that could restrict natural air flow for cooling.
WARNING
Since the inhalation of welding fumes can
be harmful, ensure that the welding area is
effectively ventilated.
3.04 Mains Supply Voltage
Requirements
The Mains supply voltage
should be within ± 15% of the rated Mains supply voltage. Too low of a supply voltage may cause poor welding
performance or wirefeeder malfunction. Too high of a
supply voltage will cause components to overheat and
possibly fail.
Manual 0-5187 3-1 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
WARNING
The Transmig 250i must be electrically connected by a qualified electrical trades-person. Damage to the
PCA (Power Control Assembly) could occur if 276 VAC or higher is applied to the Primary Power Cable
50/60 Hz
Single Phase
Yes
Yes 4.0mm² 240/25A 25A 40% @ 250A 40% @ 250A 40% @ 230A
Primary Supply
Lead Size
2.5mm² (Factory
Fitted)
Table 3-1: Input Power Source Leads for Transmig 250i
Minimum
Primary Current
Circuit Size
(Vin/Iin)
240/15A 15A 40% @ 190A 40% @ 235A 40% @ 170A
Minimum
Plug Size
Current & Duty Cycle
MIG LIFT TIG STICK
WARNING
ELECTRIC SHOCK
TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging
procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting
OFF and red-tagging circuit breaker or other disconnecting device.
Electrical Input Requirements
Operate the welding power source from a single-phase 50/60 Hz, AC power source. The Welding Power Source must be:
can kill;
SIGNIFICANT DC VOLTAGE
is present after removal of input power. DO NOT
•Correctlyinstalled,ifnecessary,byaqualiedelectrician.
•Correctlyearthed(electrically)inaccordancewithlocalregulations.
•Connectedtothecorrectsizepowerpoint,fuzeandprimarysupplyleadbasedonTable3-1.
•Connectedwithacustomer-suppliedgroundingcabletothegroundingstudonthetop-rearofthepowersourceas
required by applicable Local and National Codes or local authority having jurisdiction. Grounding stud is identified
with this symbol:
WARNING
Any electrical work must be carried out by a qualified Electrical Tradesperson.
INSTALLATION/SETUP 3-2 Manual 0-5187
INSTALLATION/SETUP TRANSMIG 250i
!
3.05 Electromagnetic Compatibility
WARNING
Extra precautions for Electromagnetic
Compatibility may be required when this
Welding Power Source is used in a domestic
situation.
A. Installation and Use - Users Responsibility
The user is responsible for installing and using the welding
equipment according to the manufacturer’s instructions.
If electromagnetic disturbances are detected then it shall
be the responsibility of the user of the welding equipment
to resolve the situation with the technical assistance of
the manufacturer. In some cases this remedial action
may be as simple as earthing the welding circuit, see
NOTE below. In other cases it could involve constructing
an electromagnetic screen enclosing the Welding Power
Source and the work, complete with associated input
filters. In all cases, electromagnetic disturbances shall be
reduced to the point where they are no longer Troublesome.
NOTE
The welding circuit may or may nor be earthed
for safety reasons. Changing the earthing arrangements should only be authorised by a
person who is competent to assess whether
the changes will increase the risk of injury,
e.g. by allowing parallel welding current return
paths which may damage the earth circuits of
other equipment. Further guidance is given in
IEC 60974-13 Arc Welding Equipment - Installation and use (under preparation).
B. Assessment of Area
Before installing welding equipment, the user shall make
an assessment of potential electromagnetic problems in
the surrounding area. The following shall be taken into
account.
1. Other supply cables, control cables, signalling and
telephone cables; above, below and adjacent to the
welding equipment.
5. The health of people around, e.g. the use of pacemakers and hearing aids.
6. Equipment used for calibration and measurement.
7. The time of day that welding or other activities are to
be carried out.
8. The immunity of other equipment in the environment:
the user shall ensure that other equipment being used
in the environment is compatible: this may require
additional protection measures.
The size of the surrounding area to be considered will
depend on the structure of the building and other activities
that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
C. Methods of Reducing Electromagnetic Emissions
1. Mains Supply
Welding equipment should be connected to the
mains supply according to the manufacturer’s
recommendations. If interference occurs, it may be
necessary to take additional precautions such as
filtering of the mains supply. Consideration should
be given to shielding the supply cable of permanently
installed welding equipment in metallic conduit or
equivalent. Shielding should be electrically continuous
throughout its length. The shielding should be
connected to the Welding Power Source so that good
electrical contact is maintained between the conduit
and the Welding Power Source enclosure.
2. Maintenance of Welding Equipment
The welding equipment should be routinely maintained
according to the manufacturer’s recommendations. All
access and service doors and covers should be closed
and properly fastened when the welding equipment
is in operation. The welding equipment should not
be modified in any way except for those changes
and adjustments covered in the manufacturer’s
instructions.
3. Welding Cables
The welding cables should be kept as short as possible
and should be positioned close together but never
coiled and running at or close to the floor level.
2. Radio and television transmitters and receivers.
3. Computer and other control equipment.
4. Safety critical equipment, e.g. guarding of industrial
equipment.
Manual 0-5187 3-3 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
4. Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered. However,
metallic components bonded to the work piece will increase the risk that the operator could receive a shock by
touching the metallic components and the electrode at the same time. The operator should be insulated from all
such bonded metallic components.
5. Earthing/grounding of the Work Piece
Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and
position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions
in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk
of injury to users, or damage to other electrical equipment. Where necessary, the connection of the work piece to
earth should be made by direct connection to the work piece, but in some countries where direct connection is not
permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
6. Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems
of interference. Screening the entire welding installation may be considered for special applications.
3.06 Power Source Controls, Indicators and Features
ON OFF
Amps
Left Knob Right Knob
Wirespeed
7
1
Arc Control
Push For Inductance
9 10
Power
2
Volts
Fault
3
4
Process
Trigger
8
MIG
LIFT TIG
STICK
2T Normal
4T Latch
Advanced
Features
5
6
Art # A-10123
INSTALLATION/SETUP 3-4 Manual 0-5187
Figure 3-1: Transmig Control Panel
INSTALLATION/SETUP TRANSMIG 250i
12
11
14
+
16
-
Art # A-10319
13
15
Figure 3-2: Transmig Front Connections
WARNING
DO NOT TOUCH the electrode wire while it is
being fed through the system. The electrode
wire will be at welding voltage potential.
2. Power Indicator
The green power indicator will be illuminated when the
welder is turned ON and indicates the presence of power.
3. Fault Indicator
The yellow fault indicator will be illuminated when any
of the faults are detected. ALL Faults will illuminate the
indicator
4. Weld Process Selection Button
LIFT TIG
1. VRD Indicator
ON OFF
A VRD (voltage reduction device) is designed to reduce
electric shock hazards present on the output of welding
power source when operating in STICK mode. Note that
the presence of VRD should not be used as a substitute
for the use of appropriate safety practices as indicated in
section one of this manual.
Both the green and red indicator lights only operate in
STICK mode.
The green VRD ON light illuminates (red light is OFF)
when the VRD is active. Under this condition the open
circuit voltage of the unit is limited to below 35V DC, thus
reducing the potential of serious electric shock (such as
when changing electrodes).
The red VRD OFF light illuminates (green light is OFF)
when the VRD is inactive. Under this condition the output
voltage of the unit will be at welding potential which in
some cases may exceed 35V DC.
WARNING
When the red VRD indicator is on and welding
is being performed, the presence of dangerous
voltage may be present at the electrode.
Press and release this button to change the selected weld
process mode from MIG to LIFT TIG to STICK. The weld
process will change to the next process in the sequence
each time the button is pressed and released. The red
indicators next to the button will illuminate to identify MIG
or LIFT TIG or STICK process mode.
. WARNING
When the Power light is lit, the machine is
connected to the Mains supply voltage and
the internal electrical components are at Mains
voltage potential.
5. 2T - 4T Trigger Latch Button
Press and release the button to change the selected operating mode of the trigger. The selected mode can be
either “2T” (unlatched) or “4T” (latched) operation. The
red indicator next to the button will illuminate to identify
which mode is selected (2T or 4T). In the 4T mode once
the weld has been started you can release the trigger and
continue welding until the trigger is activated again or the
welding arc is broken to stop the welding arc.
Manual 0-5187 3-5 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
6. Advanced Features Button
Press and release the Advanced Features button to enter
or exit from the advanced programming mode. To exit,
simply press and release the button again. Any changes
made are saved. The advanced programming menu items
are described in detail for each welding mode in Section
3.07.
Gas Purge.
In addition, the Advanced Features Button is used to initiate a 30 second gas line purge function to fill the gas line
with the shielding gas from the connected gas cylinder.
To start the gas purge function, simply press and hold the
button for approximately two (2) seconds. Once the Gas
purge function has started, a countdown timer will show
in the left alpha-numeric display indicating the number
of seconds remaining before the purge will be automatically terminated. You can stop the Gas purge any time
during the 30 seconds by quickly pressing and releasing
the button again.
revert back to showing the weld current measurements
when the knob is not being turned.
8. Right Knob: Multifunction Control - MIG Voltage /
Arc Control (Inductance) & STICK Arc Force
Right Knob
Arc Control
Push For Inductance
MIG Voltage Control
In this mode the control knob is used to adjust the output voltage of the power source. The welding voltage is
increased by turning the knob clockwise or decreased
by turning the knob anti-clockwise. The optimum voltage level required is dependent on the type of welding
application. The setup chart on the inside of the wire
feed compartment door provides a brief summary of the
required output settings for a basic range of MIG welding
applications. The value may also be adjusted while a weld
is in progress – if this occurs, the left display will briefly
switch to show the adjusted value as the knob is turned,
and will automatically revert back to showing the weld
current measurements when the knob is not being turned.
Right Knob
7. Left Knob: Amperage Control (Wirespeed)
Left Knob
The amperage control knob adjusts the amount of welding
current delivered by the power source. In STICK and LIFT
TIG modes, the amperage control knob directly adjusts the
power inverter to deliver the desired level of output current. In MIG mode, the amperage knob adjusts the speed
of the wire feed motor (which in turn adjusts the output
current by varying the amount of MIG wire delivered to
the welding arc). The optimum wire speed required is
dependent on the type of welding application. The setup
chart on the inside of the wire feed compartment door
provides a brief summary of the required output settings
for a basic range of MIG welding applications. The value
may also be adjusted while a weld is in progress – if this
occurs, the left display will briefly switch to show the adjusted value as the knob is turned, and will automatically
Arc Control
Push For Inductance
MIG Arc Control (Inductance)
The arc control operates in MIG mode only and is used
to adjust the intensity of the welding arc. To access the
Arc Control function, push inward on the right knob and
hold it for approximately 2 seconds. This feature can be
accessed and adjusted during welding.
When STICK Mode is Selected
In this mode the multifunction control knob is used to
adjust arc force. Arc force control provides an adjustable
amount of welding force (or “dig”) control. This feature
can be particularly beneficial in providing the operator the
ability to compensate for variability in joint fit-up in certain
situations with particular electrodes. In general increasing
the arc force control toward ‘100%’ (maximum arc force)
allows greater penetration control to be achieved. Arc
force is increased by turning the control knob clockwise
or decreased by turning the knob anti-clockwise. This
feature can be accessed and adjusted during welding.
INSTALLATION/SETUP 3-6 Manual 0-5187
INSTALLATION/SETUP TRANSMIG 250i
To access the Arc Control function, push inward on the right knob and hold it for approximately 2 seconds. This feature
can be accessed and adjusted during welding.
The left display will change to show the Arc Control parameter name that is in effect for the current MIG or STICK
Modes and the right display will show its present value. Use the right knob to change the value. When the desired
value is selected, press inward again on the knob without turning it and release it to exit the Arc Control function and
save the value.
Weld Modes Arc Control Function Left Display Right Display Limits
MIG Inductance INDU 25% (default) 0 – 100 %
STICK Arc Force ARC- / FRCE 50% (default) 0 – 100%
Table 3-2
9. Left Digital Display
MIG Mode
This digital meter is used to display the pre-set (preview) Wirefeed Speed in Metres Per Minute (MPM) in MIG mode
and actual welding amperage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Wirefeed Speed. This value can be adjusted by varying the Left Knob (Control No 7).
STICK and LIFT TIG Modes
The digital meter is used to display the pre-set (preview) amperage in STICK / LIFT TIG modes and actual welding
amperage of the power source when welding. At times of non-welding, the amperage meter will display a pre-set
(preview) value in both STICK and LIFT TIG modes. This value can be adjusted by varying the Left Knob (Control No 7).
When welding, this digital meter will display actual welding amperage in all modes.
At the completion of welding, the digital meter will hold the last recorded amperage value for a period of approximately
10 seconds in all modes. The amperage meter will hold the value until; (1) any of the front panel controls are adjusted
in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the
unit will return to preview mode.
The display is also used for providing error messages to the user and showing other information, which will be explained in Section 5.
10. Right Digital Display
MIG Mode
This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding voltage of the power
source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Voltage. This
value can be adjusted by varying the Right Knob (Control No 8).
STICK and LIFT TIG Modes
This digital meter is used to display the Welding Output Terminal Voltage in STICK / LIFT TIG modes during non-welding
or welding. This value can not be adjusted by varying the Right Knob (Control No 8).
When welding, this digital meter will display actual welding voltage in all modes.
At the completion of welding, the digital meter will hold the last recorded voltage value for a period of approximately
10 seconds in all modes. The voltage meter will hold the value until; (1) any of the front panel controls are adjusted in
Manual 0-5187 3-7 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
ode
Remote Volts in
(+)24V DC
(-)
M
which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage
will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit
will return to preview mode.
The display is also used for providing error messages to the user and showing other information, which will be explained in Section 5.
11. MIG Torch Adaptor (Euro Style)
The MIG Torch adaptor is the connection point for the MIG welding Torch. Connect the MIG Torch by pushing the
MIG Torch connector into the brass MIG Torch adaptor firmly and screwing the plastic MIG Torch nut clockwise
to secure in position. To remove the MIG Torch simply reverse these directions.
12. Remote Control Socket
The 8 pin Remote Control Socket is used to connect remote control devices to the welding power source. To make
connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
1
5
8
A-09594_AB
2
1
2
3
4
6
7
3
4
5
6
7
8
Remote Wirespeed in GMAW m
Trigger Switch
W
V
GMAW Mode
Figure 3-3: Remote Control Socket
Socket Pin
Function
1 Not connected
2
3
4
5
6
7
8
Trigger Switch Input
Trigger Switch Input
Not connected
5k ohm (maximum) connection to 5k ohm remote control potentiometer.
Zero ohm (minimum) connection to 5k ohm remote control potentiometer.
Wiper arm connection to 5k ohm remote control Wirespeed MIG mode potentiometer. Wiper
arm connection to 5k ohm remote control Amps LIFT TIG mode potentiometer.
Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.
Table 3-3
NOTE
The remote local setting on the control panel should be set to remote for the remote wire feeder amperage/
voltage controls to be operative.
INSTALLATION/SETUP 3-8 Manual 0-5187
INSTALLATION/SETUP TRANSMIG 250i
13. 10 Pin Accessories Socket
The 10 pin Accessories Socket is used to connect remote devices such as 2RT wirefeeder to the welding power
source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
J
1
1
Peripheral
Resistor
3
+
M
-
Motor
24V
G
H
Art # A-10320
I
D
F
E
D
J
I
C
B
A
G
E
F
H
Trigger
1
2
Wirespeed
Potentiometer
3 3
+
Solenoid
Valve
-
1
2
Voltage
Potentiometer
A
C
B
Figure 3-4: Remote Control Socket
Socket Pin
Function
A Voltage Pot. Wiper
B
C
D
E
F
G
H
I
J
Wire Feed Motor (-)
Wire Feed Motor (+)
Torch Trigger Switch
Wire Speed Pot. & Voltage Pot. (+) CW 10K ohm
Wiper Arm Speed Pot.
Torch Trigger Switch & Solenoid (-)
Wire Speed Pot. & Voltage Pot. (-) ACW
Solenoid (+)
Peripheral Program Resistor
Table 3-4
14. Positive Welding Output Terminal
The positive welding terminal is used to connect the welding output of the power source to the appropriate welding
accessory such as the MIG Torch (via the MIG Torch polarity lead), electrode holder lead or work lead. Positive
welding current flows from the power source via this heavy duty bayonet type terminal. It is essential, however,
that the male plug is inserted and turned securely to achieve a sound electrical connection.
Loose welding terminal connections can cause overheating and result in the male plug being fused in the
bayonet terminal.
Manual 0-5187 3-9 INSTALLATION/SETUP
CAUTION
TRANSMIG 250i INSTALLATION/SETUP
LIFT TIG
Left Knob
Push For Inductance
Arc Cont rol
Right Knob
15. Negative Welding Output Terminal
The negative welding terminal is used to connect the
welding output of the power source to the appropriate
welding accessory such as the MIG Torch (via the MIG
Torch polarity lead), TIG torch or work lead. Negative
welding current fl ows to the power source via this
heavy duty bayonet type terminal. It is essential,
however, that the male plug is inserted and turned
securely to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause
overheating and result in the male plug being
fused in the bayonet terminal.
16. MIG Torch Polarity Lead
The polarity lead is used to connect the MIG Torch to
the appropriate positive or negative output terminal
(allowing polarity reversal for different welding applications). In general, the polarity lead should be
connected in to the positive welding terminal (+) when
using steel, stainless steel or aluminium electrode
wire. When using gasless wire, the polarity lead is
generally connected to the negative welding terminal (-). If in doubt, consult the manufacturer of the
electrode wire for the correct polarity. It is essential,
however, that the male plug is inserted and turned
securely to achieve a sound electrical connection.
General Operation
Select the weld process (Control No 4)
you wish to view Advanced Features
for.
Then press and release the Advanced Features button (Control No 6) to enter or exit
from the Advanced Features programming
function of the welder.
The Advanced Features menu items are viewed by turning
the left knob (Control No 7) to move forward or backward
through the list. The function names in the menu will be
displayed in abbreviated form in the left alpha-numeric
display. In the case of two part names or abbreviations,
the left display will alternately fl ash the fi rst part of the
function name and then the second part, followed by a
brief “blank” interval. For each function, the right alphanumeric display will show its present value.
CAUTION
Loose welding terminal connections can cause
overheating and result in the male plug being
fused in the bayonet terminal.
3.07 Advanced Features Details
NOTE
The "LOCL/ REMT" settings will revert to the
factory default setting each time the weld
process is changed. A setting other than the
default will only be remembered while in that
process.
INSTALLATION/SETUP 3-10 Manual 0-5187
To change the value of that parameter, simply turn the
right knob (Control No 8) to change it. If the setting has
been changed from its previous value the welder will save
the new value when the left knob is turned to view the
next parameter, or if the user activates a control to cause
the welder to exit Advanced Features mode as described
earlier. Once the beginning or end of the menu list is
reached, additional turning of the left knob in that direction
will not result in any change of the displayed parameter.
The Advanced Features control functions are in order with
the user’s process steps when setting up to operate the
welder in the selected welding process modes (MIG, LIFT
TIG, STICK). The menu functions shown in Advanced
Features Mode are mostly dependent on the currently
selected weld process mode of the machine.
INSTALLATION/SETUP TRANSMIG 250i
LIFT TIG
If the welder is in Advanced Features mode and the Weld Process Selection button (Control No 4) is pressed, the
welder will exit Advanced Features mode, saving any change made, and change to the next weld process function in
the sequence: MIG, TIG, stick. If you wish to view the Advanced Features for the next process you will need to enter
the Advanced Features function again.
Right Knob
Arc Control
Push For Inductance
If the welder is in Advanced Features mode and the right knob (Control No 8) is pressed for one (1) second (to enter
Arc Control Function) the welder will exit Advanced Features mode, saving any change made, and enter the Arc Control
Function for the currently selected weld process.
NOTE
The "LOCL/REMT" settings will revert to the factory default setting each time the weld process is changed.
A setting other than the default will only be remembered while in that process.
MIG (GMAW/FCAW)Mode Advanced Features Menu Map
Left Display Right Display
Advanced Menu – MIG
Mode
MIG / CNTL
PRE- / FLOW
RUN- / IN
POST / FLOW
BURN / BACK
WIRE / SHRP
SPOT
*SPOT / TIME
STCH
*STCH / TIME
DWEL / TIME
ARC- / TYPE
Wire Feed Speed
HR
FACT / DFLT
Advanced Menu - MIG
Options or Range
LOCL REMT
0.1 - 5.0 S
30 - 150%
0.0 - 30.0 S
0.00 - 1.00 S
ON OFF
ON OFF
0.1-20.0 S
ON OFF
0.2 - 4.0 S
0.1 - 1.0 S
AUTO CV
MPM IPMWFS- / UNIT
0.0 - 9999.9
NO YES
Press Advanced Button
to Exit to Welding Mode
Left Knob Selection
* SPOT TIME and STCH TIME are only active when SPOT or STCH are “ON”.
Note “SPOT” and “STCH” are MUTUALLY EXCLUSIVE functions. If the user enables either function and the system
detects that the OTHER function is already ON, the system will automatically turn the OTHER conflicting function OFF.
Left Display: Where (2) items shown, e.g. RUN- / IN, the display will alternate (flash) between the (2) items
Manual 0-5187 3-11 INSTALLATION/SETUP
Press Advanced Button
to Exit to Welding Mode
Right Knob Selection
Figure 3-5 MIG Advanced Menu
Art # A-10321
TRANSMIG 250i INSTALLATION/SETUP
Right Display
Function Left Display
MIG Operator
Controls
Pre Flow (MIG
Setting)
MIG/CNTL LOCL LOCL - REMT
PRE-/FLOW 0.1 S 0.0 – 5 S
Run In RUN/IN 70% 30 – 150 %
Post Flow (MIG
Setting)
POST/FLOW 0.5 S 0.0 – 30 S
Burn Back BURN/BACK 0.15 S 0.00 – 1.00 S
Wire Sharp WIRE/SHRP ON OFF – ON
Spot SPOT OFF OFF – ON
Spot Time
(Only shown/
SPOT/TIME 2.0 S 0.1 – 20.0 S
enabled if
Spot=ON)
Stitch STCH OFF OFF – ON
Stitch Time
(Only shown/
STCH/TIME 2.0 S 0.2 – 4.0 S
enabled if
Stitch=ON)
Dwell Time
(Only shown/
DWEL/TIME 0.5 S 0.1 – 1.0 S
enabled if
Stitch=ON)
Arc Type ARC-/TYPE AUTO AUTO – CV-M
Wire Feed Speed
Units
WFS/UNIT MPM MPM – IPM
(Factory De-
fault Values)
Limits Comments
LOCL = Local control of the Wirespeed
and Voltage with the machines controls.
REMT = Remote control of the Wirespeed and
Voltage with an accessory device.
Shielding gas flows for the time specified before
an arc is initiated.
Wirespeed runs as a percentage of preview wirespeed until an arc is struck.
Shielding gas flows for the time specified after
an arc has extinguished.
The time difference between turning the wire feed
OFF before the voltage is turned OFF.
Wire Sharp adds a burst of current at the end of
a weld to remove the ball at the end of the wire.
This improves the restart of the next weld.
Spot is used to weld two thin plates together at
a desired location by melting the top & bottom
plates together to form a nugget between them.
The weld time is set by the Spot Time.
Spot Time is the time used for the Spot weld
mode.
Stitch is used to weld two or more components
by stitch or interval weld together.
The weld time is set by the Stitch Time and the
non weld time is set by the Dwell Time.
Stitch Time is the time used for the weld time in
Stitch weld mode.
Dwell Time is the time used for the non weld time
in Stitch weld mode.
Auto is an optimized arc control for dip transfer
welding with minimal spatter on mild steel with
mixed shielding gases. CV-M is the traditional
constant-voltage arc control for all other welding.
MPM provides preview wirespeed in Metres
Per Minute.
IPM provides preview wirespeed in Inches Per
Minute.
INSTALLATION/SETUP 3-12 Manual 0-5187
INSTALLATION/SETUP TRANSMIG 250i
Right Display
Function Left Display
Arc Hour Accumulated Run-
HR 0.0 0.0 – 9999.9
time
Restore Factory
Defaults
FACT/DFLT NO NO – YES
The "LOCL/REMT" settings will revert to the factory default setting each time the weld process is changed.
A setting other than the default will only be remembered while in that process.
LIFT TIG Mode Advanced Features Menu Map
Left Display Right Display
(Factory De-
fault Values)
Limits Comments
Provides Arc On Hours that the power source has
welded. The number displayed is in hours and
read only. It will rollover to 0 once 10,000 hours
have been reached.
When YES is selected all the user adjustable values in this table (except Arc Hour Accumulated
Runtime) are reset to the Factory Default Values.
NOTE
Left Display: Where (2) items shown, e.g. RUN- / IN, the display will alternate (flash) between the (2) items
Function Left Display
TIG Operator
Controls
Pre Flow (TIG
Setting)
Post Flow (TIG
Setting)
TIG/CNTL LOCL LOCL - REMT
PRE-/FLOW 0.1 S 0.0 – 5 S
POST/FLOW 10.0 S 0.0 – 30 S
Advanced Menu -
LIFT TIG Mode
TIG / CNTL
PRE- / FLOW
POST / FLOW
DOWN / SLPE
HR
FACT / DFLT
Press Advanced Button
to Exit to Welding Mode
Left Knob Selection Right Knob Selection
Advanced Menu - LIFT
TIG Options or Range
LOCL REMT
0.0 - 5.0 S
0.0 - 30.0 S
0.0 - 30.0 S
0.0 - 9999.9
NO YES
Press Advanced Button
to Exit to Welding Mode
Figure 3-6: LIFT TIG Advanced Menu
"Right Display
(Factory De-
Limits Comments
fault Values)"
Art # A-10322
LOCL = Local control of the Amps with the
machines controls
REMT = Remote control of the Amps with an
accessory device
Shielding gas flows for the time specified before
an arc is initiated
Shielding gas flows for the time specified after
an arc has extinguished
Manual 0-5187 3-13 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
"Right Display
Function Left Display
(Factory De-
fault Values)"
Limits Comments
In “2T” (unlatched), the unit will enter down slope
mode as soon as the trigger switch is released (ie
if Down Slope is set to 5.0 S, the unit will ramp
down from the present welding current to zero
over 5 seconds).
Down Slope DOWN/SLPE 0.0 S 0.0 – 30 S
trigger switch must be held in for the selected
time period (ie press and release trigger switch to
commence welding, then press and hold trigger
switch again to enter down slope mode). Should
the trigger switch be released during the down
slope time, the output will cease immediately in
"4T" only.
In "4T" (latched), to enter down slope mode the
Arc Hour Accumulated Runtime
Restore Factory
Defaults
HR 0.0 0.0 – 9999.9
FACT/DFLT NO NO – YES
Provides Arc On Hours that the power source has
welded. The number displayed is in hours and
read only. It will rollover to 0 once 10,000 hours
have been reached.
When YES is selected all the user adjustable values in this table (except Arc Hour Accumulated
Runtime) are reset to the Factory Default Values.
NOTE
The "LOCL/REMT" settings will revert to the factory default setting each time the weld process is changed.
A setting other than the default will only be remembered while in that process.
STICK Mode Advanced Features
Left Display Right Display
Advanced Menu - STICK
Mode
STCK / CNTL
HOT- / START
HS / TIME
HS / AMPS
HR
FACT / DFLT
Press Advanced Button
to Exit to Welding Mode
Advanced Menu - STICK
Options or Range
LOCL REMT
ON OFF
0.0 - 2.0 S
75 - 200 %
0.0 - 9999.9
NO YES
Press Advanced Button
to Exit to Welding Mode
Left Knob Selection
Left Display: Where (2) items shown, e.g. HOT- / STRT, the display will alternate (flash) between the (2) items
INSTALLATION/SETUP 3-14 Manual 0-5187
Right Knob Selection
Figure 3-7: Stick Advanced Menu
Art # A-10323
INSTALLATION/SETUP TRANSMIG 250i
Right Display
Function Left Display
Stick Operator
Controls
STCK/CNTL LOCL LOCL - REMT
Hot Start HOT/STRT ON OFF – ON
Hot Start Time TIME/HS 0.5 S 0.0 - 2.0 S
Hot Start Amps AMPS/HS 140% 75 – 200%
Arc Hour Accumulated Run-
HR 0.0 0.0 – 9999.9
time
Restore Factory
Defaults
FACT/DFLT NO NO – YES
(Factory De-
fault Values)
Limits Comments
LOCL = Local control of the Amps with the
machines controls
REMT = Remote control of the Amps with an
accessory device
Hot Start is used to improve the start characteristics for stick electrodes, e.g. low hydrogen
electrodes.
Hot Start Time is the time that the Hot Start
Amps is applied.
Hot Start Amps sets the peak start current, e.g.
100A at 140% = 140A
Provides Arc On Hours that the power source
has welded. The number displayed is in hours
and read only. It will rollover to 0 once 10,000
hours have been reached.
When YES is selected all the user adjustable values in this table (except Arc Hour Accumulated
Runtime) are reset to the Factory Default Values.
3.08 Optional Wire Feeder Controls, Indicators and Features
The optional 2RT Wirefeeder is designed to be used with the Transmig 250i. Select MIG Process and REMT in Advanced Features to enable the controls on this wirefeeder. There are two controls on the 2RT.
1. The Left Knob controls Wirespeed in this wirefeeder. It adjusts the preview wire speed display in the power source.
2. The Right Knob controls the Volts in the power source. It adjusts the preview volts display in the power source.
Description Transmig 2RT Wirefeeder
Wirefeeder Plant Part Number W3000500
Wirefeeder Plant Dimensions H 453mm x W 238mm x D 553mm
Wirefeeder Plant Mass 25kg
Wire Feed Motor Voltage 24 VDC
Gas Solenoid Voltage 24 VDC
Minimum Wire Speed 1.2 MPM
Maximum Wire Speed 17.8 MPM
Operating Temperature Range 0°C - 40°C
Interconnection Plug 10 Pin
Interconnection Length 8 metre
Manual 0-5187 3-15 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
Wirespeed
WFS Control
Volts
Right Knob
Left Knob
Volts Control
Euro Connector
Art # A-10324
8 Pin Remote
Connector
Figure 3-8: 2RT Front Panel Controls
The Tweco professional MIG Torch will connect to the 2RT just as it does to the 250i power source. The electrode
Polarity setting is done at the power source. See section 3.23 and 3-24.
3.09 Optional Wire Feeder Set Up MIG (GMAW) Welding with Gas Shielded MIG Wire
The Transmig 250i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Torch. The Fusion MIG Torch is designed
with an ergonomic handle and fewer parts to reduce performance problems. The Fusion MIG Torch uses standard
readily available Tweco consumable parts.
When using a Gas Shielded wire with the 2RT Wire Feeder, you need to have an external gas source attached to the 2RT.
For most Gas Shielded wire, connect the Work Lead to the negative - terminal on the front of the 250i and connect
the Welding Power Cable from the back of the 2RT to the positive + terminal on the front of the 250i. Check with wire
manufacturer for recommended polarity.
The 2RT Wire Feeder is fitted with an 8M interconnection cable assembly to connect from the back of the 2RT to the
front of the 250i welding power source.
Connect the MIG Torch to the front of the 2RT as you would to the front of the 250i in Sections 3.23 and 3.24.
Front View 2RT
Rear View 2RT
Front View 250i
Gas Hose
Control Cable
+
Art # 10335
-
Work Lead
Welding Power Cable
from Wire Feeder
Figure 3-9: Setup for 2RT Wirefeeder
WARNING
Before connecting the work clamp to the work make sure the mains power supply is switched OFF.
INSTALLATION/SETUP 3-16 Manual 0-5187
INSTALLATION/SETUP TRANSMIG 250i
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the
terminal.
Remove any packaging material prior to use. DO NOT block the air vents at the front or rear of the Welding
Power Source.
NOTE
Depending on the type of wire you will be using the Welding Power Cable may need to be switched. Follow
the wire manufacturers recommendation.
NOTE
Spool hub and feed plate set up and operation are the same as the 250i which can be reviewed later in this
section starting at 3.14.
3.10 Optional Wire Feeder Set-up for MIG (FCAW) Welding with Gasless MIG Wire
The Transmig 250i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Torch. The Fusion MIG Torch is designed
with an ergonomic handle and fewer parts to reduce performance problems. The Fusion MIG Torch uses standard
readily available Tweco consumable parts.
When using a gasless flux cored wire, you do not need to have an external gas source attached to the 2RT. If an external
gas source is connected, then make sure it is turned OFF.
For most Self Shielded Flux Cored Wire, connect the Work Lead to the positive + terminal on the front of the 250i
and connect the MIG Torch polarity lead from the back of the 2RT to the negative - terminal on the front of the 250i.
The 2RT Wire Feeder is fitted with an 8M interconnection cable assembly to connect from the back of the 2RT to the
front of the 250i welding power source.
Front View 2RT
Work Lead
Rear View 2RT
Control Cable
Welding Power Cable
from Wire Feeder
Front View 250i
+
-
Art # 10350_AB
Figure 3-28: MIG Torch Polarity Negative
Before connecting the work clamp to the work make sure the mains power supply is switched OFF.
Manual 0-5187 3-17 INSTALLATION/SETUP
WARNING
TRANSMIG 250i INSTALLATION/SETUP
of the 3 studs
Front
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the
terminal.
Remove any packaging material prior to use. Do NOT block the air vents at the front or rear of the Welding
Power Source.
NOTE
Depending on the type of wire you will be using the Welding Power Cable may need to be switched. Follow
the wire manufacturers recommendation.
NOTE
Spool hub and feed plate set up and operation are the same as the 250i which can be reviewed later in this
section starting at 3.14.
3.11 Fitting of Optional Roll Cage
1. Assemble the Roll Cage according to Figure 3-11. Ensure that all hardware is properly tightened and will not
come apart with the power source attached.
NOTE
You will need to wait to attach the front roll bar until after the welder has been mounted.
Art # A-10336
These holes are not used
Rear
Rear
Note the orientation
Do not attach front yet
Front
Figure 3-11: Roll Cage Assembly
2. Disconnect power from the power source.
3. Remove the top centre screw in the cover and open the side cover to the wire spool so you can see the 3 holes
that will need to align with the mounting studs from the roll cage.
4. Carefully lift the unit and maneuver into place aligning the 3 studs with the 3 holes in the bottom of the power
source.
INSTALLATION/SETUP 3-18 Manual 0-5187
INSTALLATION/SETUP TRANSMIG 250i
2nd
1st
3 Nuts
Front
3 Studs
These holes are not used
Art # A-10337
Figure 3-12: Mounting Welder to Roll Cage.
5. First, use the 3 nuts (included) and secure the power source to the roll cage. Second, attach the front roll bar
and secure all hardware now. When you are done it should look like the first part of Figure 3-13.
6. Attach the Cross Bar to the front and rear roll bars with hardware shown and the bracket with the screw from
the top of the welder cover removed earlier. See Figure 3-13.
Cross Bar
Art # A-10325
Manual 0-5187 3-19 INSTALLATION/SETUP
Figure 3-13: Roll Cage Cross Bar Fitted
TRANSMIG 250i INSTALLATION/SETUP
3.12 Assembly and Fitting of Optional Welding Trolley
Assemble the Welding Trolley according to Figure 3-14. Read all steps before beginning and ensure all hardware is
tightened properly.
1. Attach the front base section to the upright rear section with the 3 screws provided.
NOTE
If attached, the optional roll cage must be removed before mounting to the Welding Trolley as the same
mounting holes are used for both.
Rubber Mat
Chain
4 screws
provided
3 screws
provided
Art # A-10326
Screw from top
of 250i
3 screws provided
to secure 250i
Figure 3-14: Welding Trolley Assembly
2. Mount the 250i power source to the bottom tray aligning the 3 holes in the bottom of the power source with
the 3 holes in the base. Secure with the 3 screws provided.
3. Temporarily remove the top center screw in the 250i case. Attach the top tray using four screws provided ensuring the tab on the front of the tray captures the hand hold on the front of the 250i power source. Re-install the
screw through the hole in the centre of the top tray into the top of the 250i case. Ensure that all fixing screws
are in place and tightened.
4. Place rubber mat on the top tray and then place the 2RT Wire Feeder on that.
5. Position a gas cylinder on the rear tray of the Trolley and lock securely to the Trolley cylinder bracket with the
chain 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.
6. Attach Gas Regulator and hose per instructions found in sub Section 3-22.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary
support to prevent falling or tipping.
INSTALLATION/SETUP 3-20 Manual 0-5187
!
WARNING
INSTALLATION/SETUP TRANSMIG 250i
Secure the welding grade
shielding gas cylinder in
an upright position by
chaining it to a suitable
stationary support to
prevent falling or tipping.
Art # A-10327
Figure 3-15: Welding Trolley and Welding Equipment
Rear Hand Grip
Front Hand Grip
Art # A-10407
Figure 3-16: Location of Hand Grips
Manual 0-5187 3-21 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
3.13 Attaching the Tweco Professional MIG Torch (Euro)
1. Align the pins on the MIG Torch Cable with the pin holes of the MIG Torch receptacle on the front of the system
above the positive(+) dinse type receptacle. Press the MIG Torch in and secure by turning the locking ring to
the right (clockwise).Refer to Figure 3-17.
Attach MIG Torch. Turn
locking ring to the right
Art # A-10338
Figure 3-17: Mount MIG Torch Cable to Adapter Socket
2. If equipped, align the keyways of the MIG Torch Switch connector pigtail with the 8 pin receptacle to the right
of the MIG Torch cable and plug them together. Secure by turning the locking ring to the right (clockwise ).
Refer to Figure 3-17.
NOTE
When disconnecting the MIG Torch trigger switch leads from the machine, DO NOT pull on the wires.
Loosen the locking ring and gently pull the plug out of the socket.
INSTALLATION/SETUP 3-22 Manual 0-5187
INSTALLATION/SETUP TRANSMIG 250i
3.14 Installing a Handispool (200mm diameter)
In order to fit a Handispool (200mm diameter) assemble parts in the sequence shown in Figure 3-18.
Installation of wire spool.
1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.
2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool
rotates counter clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the
wire spool.
3. Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool.
NOTE
The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to section 3.21
CAUTION
Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the
end of the wire firmly and don’t let go of it.
Wire Spool
Hub Nut
Flat Washer
Large Hole
Flat Washer
Small Hole
200mm
Wire Spool
Spring
Fibre Washer
Retaining Clip
Use inner holes on
Spool Hub
Keyed Washer
Pin
Spool Hub
Figure 3-18: 200mm Handispool Installation
A-10340
Manual 0-5187 3-23 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
3.15 Installing a Standard Spool (300mm diameter)
As delivered from the factory, the unit is set for a 15 kg or 300mm spool.
Installation of wire spool. Refer to Figure 3-19.
1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.
2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool
rotates counter clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the
wire spool.
3. Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool.
NOTE
The Wire Wheel Brake has been pre-adjusted at the factory. However if adjustment is required, refer to
Section 3.21
CAUTION
Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the
end of the wire firmly and don’t let go of it.
Wire Spool
Hub Nut
Flat Washer
Small Hole
300mm
Wire Spool
Flat Washer
Large Hole
Spring
Retaining Clip
Use outer holes
Keyed Washer
Spool Hub
Fibre Washer
Pin
Figure 3-19: Standard 300mm Spool Installation
A-10340
INSTALLATION/SETUP 3-24 Manual 0-5187
INSTALLATION/SETUP TRANSMIG 250i
3.16 Inserting Wire into the Feed Mechanism
WARNING
ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power source before
proceeding. DO NOT reattach the input power until told to do so in these instructions.
1. Loosen the Spring Pressure Adjusting Knob if needed and swing it down (First part of Figure. 3-20)
2. Move the Pressure (top) Roller Arm by swinging it to the right. (Second part of Figure. 3-20)
3. Make sure the end of the wire is free of any burrs and is straight. Pass the end of wire through the Inlet Wire
Guide and over the Feedroll. Make certain the proper groove is being used. (Second part of Figure. 3-20)
4. Pass the MIG wire over the drive roll groove, through the outlet guide and out past the MIG Torch Adaptor.
Then fit the MIG Torch as per Section 3.13 ensuring the MIG wire passes into the MIG Torch liner of the MIG
Torch.)
5. Close the Pressure Roller Arm. (Figure. 3-21)
6. Swing the Spring Pressure Adjusting Knob back into place. (Figure. 3-21)
7. Use the Spring Pressure Adjusting Knob to create a “snug” condition. (Clockwise to tighten and Counter
Clockwise to loosen). (Figure. 3-21)
8. Figure 3-23 shows the result with wire installed. Continue to the next section for proper setting of tension.
1
Art # A-10030
2
3
4
Figure 3-20: Opening Pressure Arm and Inserting Wire
5
7
6
Figure 3-21: Closing Pressure Arm and Adjusting Tension
Manual 0-5187 3-25 INSTALLATION/SETUP
Art # A-10031
TRANSMIG 250i INSTALLATION/SETUP
3.17 Feed Roller Pressure Adjustment
NOTE
Before attempting to set the drive roller pressure you must select GMAW mode on the front panel. See
earlier in section 3 for information on how to select this feature. Once selected it will allow the activation
of the drive roll when the trigger on the MIG Torch is activated.
The roller on the swing arm applies pressure to the grooved roller via an adjustable tension devise. The Tension Adjuster should be set to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping occurs,
and inspection of the wire out of the MIG Torch reveals no deformation or wear, the conduit liner should be checked
for kinks or clogging from metal flakes. If this is not the cause of slipping, the feedroll pressure can be increased by
rotating the Tension Adjusting knob clockwise. The use of excessive pressure may cause rapid wear of the feed roller,
motor shaft and motor bearings.
NOTE
Genuine TWECO contact tips and liners should be used. Many non-genuine liners use inferior materials
which can cause wire feed problems.
3.18 Feed Roller Alignment
The bottom Feed Roll is adjustable in and out to provide for best alignment of wire as it feeds into the outlet guide. To
adjust the roll do the following and refer to Figure 3-22, Note, the welding wire is not shown in order to more clearly
see the groove in the feed roll.
1. Place a wrench on the adjusting bolt (number 2) and hold in place while you loosen the locking screw (number
1) with a hex wrench
2. With the locking screw loosened, turn the adjusting bolt right or left to align the feed roll (number 3) so the
groove is aligned with the outlet guide (number 4).
3. With the feed roll aligned, place a wrench on the adjusting bolt and hold it in place while tightening the locking
screw with the hex wrench. If the adjusting bolt moves before the locking screw is secured then the alignment
will change.
3
1
4
2
Art # A-10415
Figure 3-22: Top View of Feed Plate with Pressure Arm Open
It may not be possible to align with both the inlet and outlet guide at the same time. The outlet guide is the
one that needs to be aligned to for best wire feeding.
INSTALLATION/SETUP 3-26 Manual 0-5187
NOTE
INSTALLATION/SETUP TRANSMIG 250i
3.19 Changing the Feed Roll
NOTE
Feedrolls often come with a rust prohibitive coating that needs to be cleaned off before installation.
A Feedroll consists of two different sized grooves. As delivered from the factory the drive roll is installed for 0.9mm
/ 1.2mm.
The stamped marking on the feedroll refers to the groove furthest from the stamped marking. When mounted, that
will be the groove closest to the motor and the one to thread.
To ensure proper wire feed, the groove closest to the motor must match the electrode wire size being used.
1.2mm (.045”) Stamping
.045
1.2
1.2mm (.045”) Groove
Art: A-10345
The size that is visible when
fitting the feedroll is the groove
size in use.
.045
1.2
Figure 3-23: Feedroll Example
NOTE
All grooved feed rolls have their wire size or range stamped on the side of the roll. On rolls with different
size grooves, the outer (visible when installed) stamped wire size indicates the groove in use.
Refer to feed roll kit in the Appendix for the proper selection and ordering of feed roll kits. Kit includes drive rolls, an
input wire guide and an output wire guide for a specific wire type and size.
Feed rolls are removed by twisting the feed roll retainer cap and aligning the retaining knob splines/tabs with the drive
gear splines. Feedrolls are installed by putting the feedroll onto the drive gear splines and twisting the feedroll retainer
cap so that the splines/tabs rest against the face of the feedroll where they will click into place.
Installation of all styles of feed rolls for the Transmig 250i are identical.
The welding wire is electrically Hot if it is fed by depressing MIG Torch switch. Electrode contact to work
piece will cause an arc with MIG Torch switch depressed.
Manual 0-5187 3-27 INSTALLATION/SETUP
NOTE
WARNING
TRANSMIG 250i INSTALLATION/SETUP
3.20 Input And Output Wire Guide Installation
NOTE
0.9mm / 1.2mm feed rolls and guides are installed from the factory. Other sizes need to be purchased
separately.
Input Wire Guide - Install (the shorter one) by loosening the input guide lockscrew and inserting the guide into the hole
in the feedhead assembly. Adjust the guide so that it is clear of the feed rolls and tighten the input guide lockscrew.
NOTE
Before tightening the input and output guide lockscrews, install the drive roll to help in the alignment of
the wire guides.
Output Wire Guide - With the MIG Torch removed, loosen the adapter nut. This will aid with alignment. Install the
output wire guide (the longer one) by inserting the conical end part way into the Euro Adapter from the front of the
machine. Now install the MIG Torch pressing the output guide further in until the tip of the guide is as close to the
feed rolls as practical. Secure the MIG Torch. Tighten the adapter lock nut then tighten the output guide lockscrew.
NOTE
Gently strike the electrode on the work piece to generate a welding arc, and slowly move along the work
piece while holding a consistent arc length above base metal.
Input Guide Lockscrew
Output Guide Lockscrew
Input Wire Guide
Figure 3-24: Wire Guide Installation
MIG Torch
Adapter Lock
Nut
Art # A-10346
Output Wire Guide
INSTALLATION/SETUP 3-28 Manual 0-5187
INSTALLATION/SETUP TRANSMIG 250i
3.21 Wire Reel Brake
The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking. If it is
considered necessary, adjustment can be made by turning the tri-lobe nut inside the open end of the wire reel hub.
Clockwise rotation will tighten the brake. (Refer to Figure 3-25).
Wheel Brake adjusting tri-lobe nut
Pressure Adjustment
Knob
Art # A-10032
Figure 3-25: Wire Installed
CAUTION
Excessive tension on the brake will cause rapid wear of mechanical wire feed parts, over heating of electrical
componentry and possibly an increased incidence of wire Burnback into the contact tip.
NOTE
Correct adjustment will result in the wire reel circumference continuing no further than 20mm after release
of the MIG Torch trigger switch. The wire should be slack without becoming dislodged from the reel.
3.22 Shielding Gas Regulator Operating Instructions
!
WARNING
This equipment is designed for use with welding grade (Inert) shielding gases only.
NOTE
Shielding Gas Regulator not included in the Transmig 250i (Asia Version) Plant Part No W1003250M.
Shielding Gas is not required if the unit is used with self shielded FCAW (flux cored arc welding) wires
Manual 0-5187 3-29 INSTALLATION/SETUP
NOTE
TRANSMIG 250i INSTALLATION/SETUP
Shielding Gas Regulator Safety
This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure
required for the equipment using it.
If the equipment is improperly used, hazardous conditions are created that may cause accidents. It is the users
responsibility to prevent such conditions. Before handing or using the equipment, understand and comply at all
times with the safe practices prescribed in this instruction.
SPECIFIC PROCEDURES for the use of regulators are listed below.
1. NEVER subject the regulator to inlet pressure greater than its rated inlet pressure.
2. NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition. NEVER loosen
a connection or attempt to remove any part of a regulator until the gas pressure has been relieved. Under
pressure, gas can dangerously propel a loose part.
3. Do NOT remove the regulator from a cylinder without first closing the cylinder valve and releasing gas in the
regulator high and low pressure chambers.
4. Do NOT use the regulator as a control valve. When downstream equipment is not in use for extended periods
of time, shut OFF the gas at the cylinder valve and release the gas from the equipment.
5. OPEN the cylinder valve SLOWLY. Close after use.
User Responsibilities
This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in accordance
with the instructions provided. Equipment must be checked periodically and repaired, replaced, or reset as necessary
for continued safe and reliable performance. Defective equipment should not be used. Parts that are broken, missing,
obviously worn, distorted, or contaminated should be replaced immediately.
The user of this equipment will generally have the sole responsibility for any malfunction, which results from improper
use, faulty maintenance, or by repair by anyone other than an accredited repairer.
CAUTION
Match regulator to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to a
cylinder containing any other gas.
LOW PRESSURE
GAUGE (DELIVERY)
OUTLET
CONNECTION
HIGH PRESSURE
GAUGE (SUPPLY)
PRESSURE
ADJUSTING
SCREW
INSTALLATION/SETUP 3-30 Manual 0-5187
INLET
Art # A-10108
CONNECTION
Figure 3-26: Adjusting Flow Rate
INSTALLATION/SETUP TRANSMIG 250i
NOTE
The regulator/flow meters used with argon based and carbon dioxide shielding gases are different. The
regulator/flow meter supplied is for argon based shielding gases. If carbon dioxide is to be used a suitable
carbon dioxide regulator/flow meter will need to be fitted.
NOTE
All valves downstream of the regulator must be opened to obtain a true flow rate reading on the outlet
gauge. (Welding power source must be triggered) Close the valves after the pressure has been set.
Installation
1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices and
damage seats before connecting the regulator.
Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition.
Wipe with a clean lint free cloth.
2. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking agree and
that the regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed for a particular gas
or gases to a cylinder containing any other gas.
3. Connect the regulator inlet connection to cylinder or pipeline and tighten it firmly but not excessively, with a
suitable spanner.
4. Attach supplied gas line between the regulator output and the desired input at the rear of the power source.
MIG Spool Torch and TIG in the bottom fitting and regular MIG Torch in the top fitting.
Ensure that the gas
cylinder is secured to
a building pillar, wall
bracket or otherwise
securely fixed in an
upright position.
Art # A-10239
Figure 3-27: Attach gas line to proper inlet
5. To protect sensitive down-stream equipment a separate safety device may be necessary if the regulator is not
fitted with a pressure relief device.
Operation
With the regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as
follows:
1. Stand to one side of regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge
may damage internal regulator parts.
2. With valves on downstream equipment closed, adjust regulator to approximate working pressure. It is recommended that testing for leaks at the regulator connection points be carried out using a suitable leak detection
solution or soapy water.
Manual 0-5187 3-31 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
3. Purge air or other unwanted welding grade shielding gas from equipment connected to the regulator by individually opening then closing the equipment control valves. Complete purging may take up to ten seconds or
more, depending upon the length and size of the hose being purged.
Adjusting Flow Rate
Art: A-05088_AB
Figure 3-28: Adjust Flow Rate
With the regulator ready for operation, adjust working flow rate as follows:
1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow
rate.
NOTE
It may be necessary to re-check the shielding gas regulator flow rate following the first weld sequence due
to back pressure present within shielding gas hose assembly.
2. To reduce flow rate, allow the welding grade shielding gas to discharge from regulator by opening the downstream valve. Bleed welding grade shielding gas into a well ventilated area and away from any ignition source.
Turn adjusting screw counterclockwise, until the required flow rate is indicated on the gauge. Close downstream
valve.
3. Adjust regulator pressure adjusting screw to the required flow rate, indicated on gauge dial. (Refer to Figure
3-28)
The gas flow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas flow rates may
cause turbulence and weld porosity.
Argon or argon based gas flow rates:
- Workshop welding: 10-15 LPM
- Outdoor welding: 15-20 LPM
Shutdown
Close cylinder valve whenever the regulator is not in use. To shut down for extended periods (more than 30 minutes).
1. Close cylinder or upstream valve tightly.
2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from any
ignition source.
3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.
4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove regulators.
INSTALLATION/SETUP 3-32 Manual 0-5187
INSTALLATION/SETUP TRANSMIG 250i
3.23 Set-up MIG (GMAW) Welding with Gas Shielded MIG Wire
The Transmig 250i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Torch. The Fusion MIG Torch is designed
with an ergonomic handle and fewer parts to cause performance problems. The Fusion MIG Torch uses standard
readily available Tweco consumable parts.
When using a non shielded wire, you need to have an external gas source attached to the unit.
For most Non Shielded Wire, connect the Work Lead to the negative - terminal and connect the MIG Torch polarity
lead to the positive + terminal. If in doubt, consult the MIG electrode wire manufacturer.
Ensure that the gas
cylinder is secured to
a building pillar, wall
bracket or otherwise
securely fixed in an
upright position.
Connect MIG Torch Polarity
Terminal to +/Positive
(Dinse® type 50mm)
+
-
Negative Output
Terminal
(Dinse® type 50mm)
Art # A-10282
Figure 3-29: MIG Torch Polarity Positive
1. Turn the Main ON/OFF switch OFF (located on the rear panel).
2. Check that the MIG wire size, contact tip, MIG Torch liner and drive roll groove are all the same size before
fitting the MIG wire into the Power Source.
3. Connect the MIG Torch Polarity Lead to the positive welding terminal (+). If in doubt, consult the MIG electrode
wire manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is
essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
4. Fit the MIG wire spool and MIG Torch to the Power Source. (Refer to section 3.14 to 3.21 ).
5. Connect the work lead to the negative welding terminal (-). If in doubt, consult the MIG electrode wire manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential,
however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
6. Fit the welding grade shielding gas regulator/flow gauge to the shielding gas cylinder (refer to Section 3.22)
then connect the shielding gas hose from the rear of the power source to the regulator/flow gauge outlet.
7. Turn the Main ON/OFF switch ON (located on the rear panel).
8. Select MIG mode with the process selection control. (Refer to Section 3.06.4 for further information)
9. Remove the MIG Torch nozzle and contact tip.
10. Depress MIG Torch trigger to feed the MIG wire out through the MIG Torch gas diffuser then fit the contact
tip on the MIG wire and securely fasten it to the MIG Torch then Fit the nozzle in place.
Manual 0-5187 3-33 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
11. Refer to the Weld Guide located on the inside of the wire feed compartment door for further information on
Voltage/Wirespeed settings.
WARNING
Before connecting the work clamp to the work make sure the mains power supply is switched OFF.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary
support to prevent falling or tipping.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the
terminal.
Remove any packaging material prior to use. DO NOT block the air vents at the front or rear of the Welding
Power Source.
NOTE
Depending on the type of wire you will be using the MIG Torch polarity may need to be switched. Follow
the wire manufacturers recommendation.
3.24 Set-up for MIG (FCAW) Welding with Gasless MIG Wire
The Transmig 250i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Torch. The Fusion MIG Torch is designed
with an ergonomic handle and fewer parts to cause performance problems. The Fusion MIG Torch uses standard
readily available Tweco consumable parts.
When using a gasless flux cored wire, you do not need to have an external gas source attached to the unit. If one is,
then make sure it is turned OFF.
For most Self Shielded Flux Cored Wire, connect the Work Lead to the positive + terminal and connect the MIG Torch
polarity lead to the negative - terminal.
Connect MIG Torch Polarity
Terminal to -/Negative
®
(Dinse
+
-
type 50mm)
Positive Output
Terminal
®
(Dinse
type 50mm)
Figure 3-30: MIG Torch Polarity Negative
INSTALLATION/SETUP 3-34 Manual 0-5187
Art # A-10283
INSTALLATION/SETUP TRANSMIG 250i
1. Turn the Main ON/OFF switch OFF (located on the
rear panel).
2. Check that the MIG wire size, contact tip, MIG Torch
liner and drive roll groove are all the same size
before fitting the MIG wire into the Power Source.
3. Connect the MIG Torch Polarity Lead to the negative welding terminal (-). If in doubt, consult the
MIG electrode wire manufacturer. Welding current flows from the Power Source via heavy duty
bayonet type terminals. It is essential, however,
that the male plug is inserted and turned securely
to achieve a sound electrical connection.
4. Fit the MIG (FCAW) wire spool and MIG Torch to
the Power Source. (Refer to section 3.13 to 3.21 ).
5. Connect the work lead to the positive welding terminal (+). If in doubt, consult the MIG electrode
wire manufacturer. Welding current flows from
the Power Source via heavy duty bayonet type
terminals. It is essential, however, that the male
plug is inserted and turned securely to achieve a
sound electrical connection.
6. If gasless MIG (FCAW) wire is fitted then shielding
gas is not required for welding. Otherwise fit the
welding grade shielding gas regulator/flow gauge
to the shielding gas cylinder (refer to Section
3.22) then connect the shielding gas hose from
the rear of the power source to the regulator/flow
gauge outlet.
7. Turn the Main ON/OFF switch ON (located on the
rear panel).
8. Select MIG mode with the process selection control.
(Refer to Section 3.06.4 for further information)
CAUTION
Loose welding terminal connections can cause
overheating and result in the male plug being
fused in the terminal.
Remove any packaging material prior to use.
DO NOT block the air vents at the front or rear
of the Welding Power Source.
NOTE
Depending on the type of wire you will be
using the MIG Torch polarity may need to
be switched. Follow the wire manufacturers
recommendation.
3.25 Set-up for LIFT TIG (GTAW) Welding
!
WARNING
Before any welding is to begin, be sure to
wear all appropriate and recommended safety
equipment.
NOTE
The following steps will assume that you have
already set up the proper shielding gas as
outlined in Sub Section 3.22.
NOTE
The following set up is known as Straight
Polarity or DC Electrode Negative. This is
commonly used for DC TIG welding on most
materials such as steel and stainless steel.
9. Remove the MIG Torch nozzle and contact tip.
10. Depress MIG Torch trigger to feed the MIG wire
out through the MIG Torch gas diffuser then fit the
contact tip on the MIG wire and securely fasten
it to the MIG Torch then Fit the nozzle in place.
11. Refer to the Weld Guide located on the inside of
the wire feed compartment door for further information on Voltage/Wirespeed settings.
Before connecting the work clamp to the
work make sure the mains power supply is
switched OFF.
Manual 0-5187 3-35 INSTALLATION/SETUP
WARNING
1. Switch the ON/OFF Switch (located on the rear
panel) to OFF.
2. Connect the work lead cable to the positive output
terminal, and the TIG Torch cable to the negative
output terminal. Refer to Figure 3-32.
3. Connect the gas line/hose to the proper shielding
gas source. Refer to Figure 3-32.
4. Be sure the gas valve on the TIG Torch is closed,
and slowly open the Argon Cylinder Valve to the fully
open position.
5. Connect the work lead clamp to your work piece.
TRANSMIG 250i INSTALLATION/SETUP
A-00503_AB
6. The tungsten must be ground to a blunt point (similar to a pencil) in order to achieve optimum welding results.
See illustration. It is critical to grind the tungsten electrode in the direction the grinding wheel is turning. Grind
at a 30 degree angle and never to a sharp point.
2 to 2-1/2 Times
Electrode Diameter
Electrode
Figure 3-31: Electrode sharpening
7. Install the tungsten with approximately 3.2mm to 6.4mm sticking out from the gas cup, ensuring you have
correct sized collet.
8. Tighten the back cap.
9. Turn the switch to the “ON” position. The power L.E.D. light should illuminate.
10. Set the welding process to LIFT TIG.
11. Set the Weld Current Control Knob to the desired amperage.
Art # A-10284
Ensure that the gas
cylinder is secured to
a building pillar, wall
bracket or otherwise
securely fixed in an
+
-
Negative Output
Terminal
(Dinse® type 50mm)
upright position.
Figure 3-32: Setup for LIFT TIG (GTAW) Welding
12. You are now ready to begin LIFT TIG Welding.
3.26 Set-up for Metal Manual Metal Arc Welding (MMAW)
!
WARNING
Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
The following set up is known as DC Electrode Positive or reverse polarity. Please consult with the stick
electrode manufacturer for specific polarity recommendations.
1. Switch the ON/OFF Switch (located on the rear panel) to OFF.
2. Attach the stick and work leads as shown in Figure 3-33.
INSTALLATION/SETUP 3-36 Manual 0-5187
NOTE
INSTALLATION/SETUP TRANSMIG 250i
Art # A-10285
+
-
Negative Output
Terminal
(Dinse® type 50mm)
Figure 3-33: Setup for STICK Welding reverse polarity shown.
3. Set the welding process to STICK.
4. Set the Weld Current Control Knob to the desired amperage.
5. Install a stick electrode in the electrode holder.
6. You are now ready to begin Stick Welding.
NOTE
Gently strike the electrode on the work piece to generate a welding arc, and slowly move along the work
piece while holding a consistent arc length above base metal.
Manual 0-5187 3-37 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
Notes
INSTALLATION/SETUP 3-38 Manual 0-5187
BASIC WELDING TRANSMIG 250I
Shielding Gas
SECTION 4:
BASIC WELDING GUIDE
4.01 MIG (GMAW/FCAW) Basic Welding
Technique
Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing
the very basic concepts in using the Mig mode of welding, where a MIG Torch is hand held, and the electrode
(welding wire) is fed into a weld puddle, and the arc is
shielded by an inert welding grade shielding gas or inert
welding grade shielding gas mixture.
GAS METAL ARC WELDING (GMAW): This process, also
known as MIG welding, CO
short arc welding, dip transfer welding, wire welding etc.,
is an electric arc welding process which fuses together the
parts to be welded by heating them with an arc between
a solid continuous, consumable electrode and the work.
Shielding is obtained from an externally supplied welding
grade shielding gas or welding grade shielding gas mixture. The process is normally applied semi automatically;
however the process may be operated automatically and
can be machine operated. The process can be used to
weld thin and fairly thick steels, and some non-ferrous
metals in all positions.
Shielding Gas
Molten Weld Metal
Solidified
Weld Metal
welding, Micro Wire Welding,
2
Nozzle
Electrode
Arc
Base Metal
Nozzle
(Optional)
Flux Cored
Electrode
Arc
Base Metal
Art # A-08992_AB
Slag
(Optional)
Molten Metal
Molten
Slag
Solidified
Weld Metal
FCAW Process
Figure 4-2
Position of MIG Torch
The angle of MIG Torch to the weld has an effect on the
width of the weld.
Push
Vertical
Drag/Pull
Art # A-07185_AB
Figure 4-3
The MIG Torch should be held at an angle to the weld joint.
(See Secondary Adjustment Variables below)
Hold the MIG Torch so that the welding seam is viewed
at all times. Always wear the welding helmet with proper
filter lenses and use the proper safety equipment.
GMAW Process
Figure 4-1
FLUX CORED ARC WELDING (FCAW): This is an electric
arc welding process which fuses together the parts to be
welded by heating them with an arc between a continuous flux filled electrode wire and the work. Shielding is
obtained through decomposition of the flux within the
tubular wire. Additional shielding may or may not be obtained from an externally supplied gas or gas mixture. The
process is normally applied semi automatically; however
the process may be applied automatically or by machine. It
is commonly used to weld large diameter electrodes in the
flat and horizontal position and small electrode diameters
in all positions. The process is used to a lesser degree for
welding stainless steel and for overlay work.
Manual 0-5187 4-1 BASIC WELDING
Art # A-8991_AB
CAUTION
Do NOT pull the MIG Torch back when the
arc is established. This will create excessive
wire extension (stick-out) and make a very
poor weld.
The electrode wire is not energized until the MIG Torch
trigger switch is depressed. The wire may therefore be
placed on the seam or joint prior to lowering the helmet.
TRANSMIG 250I BASIC WELDING
Travel Speed
The speed at which the molten pool travels influences
the width of the weld and penetration of the welding run.
MIG Welding (GMAW) Variables
Most of the welding done by all processes is on carbon
steel. The items below describe the welding variables in
Art # A-08993
Butt & Horizontal Welds
Figure 4-4
short-arc welding of 0.6mm to 6.4mm) mild sheet or
plate. The applied techniques and end results in the GMAW
process are controlled by these variables.
Preselected Variables
Preselected variables depend upon the type of material
being welded, the thickness of the material, the welding
position, the deposition rate and the mechanical properties. These variables are:
•
Type of electrode wire
Horizontal Fillet Weld
Figure 4-5
Vertical Fillet Welds
Figure 4-6
Art # A-08994
Art # A-08995
• Size of electrode wire
• Type of gas ((not applicable for FCAW self shielding
wires)
Gas flow rate (not applicable for FCAW self shielding
•
wires)
Primary Adjustable Variables
These control the process after preselected variables have
been found. They control the penetration, bead width, bead
height, arc stability, deposition rate and weld soundness.
They are:
•
Arc Voltage
• Welding current (wire feed speed)
• Travel speed
Secondary Adjustable Variables
These variables cause changes in primary adjustable
variables which in turn cause the desired change in the
bead formation. They are:
1. Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire).
Maintain at about 10mm stick-out
Art # A-08996
Overhead Weld
Figure 4-7
Distance from the MIG Torch Nozzle to the Work Piece
The electrode wire stick out from the MIG Torch nozzle
should be between 10mm to 20mm. This distance may
vary depending on the type of joint that is being welded.
BASIC WELDING 4-2 Manual 0-5187
2. Wire Feed Speed. Increase in wire feed speed
increases weld current, Decrease in wire feed
speed decreases weld current.
BASIC WELDING TRANSMIG 250I
Electrode Stick-Out
Transverse
Establishing the Arc and Making Weld Beads
Gas Nozzle
Tip to
Work Distance
Contact Tip (Tube)
Electrode Wire
Actual Stick-out
Before attempting to weld on a finished piece of work, it
is recommended that practice welds be made on a sample
metal of the same material as that of the finished piece.
Average Arc Length
Art # A-08997_AD
Figure 4-8
3. Nozzle Angle. This refers to the position of the MIG
Torch in relation to the joint. The transverse angle
is usually one half the included angle between
plates forming the joint. The longitudinal angle
is the angle between the centre line of the MIG
Torch and a line perpendicular to the axis of the
weld. The longitudinal angle is generally called the
Nozzle Angle and can be either trailing (pulling)
or leading (pushing). Whether the operator is left
handed or right handed has to be considered to
realize the effects of each angle in relation to the
direction of travel.
Angle
Longitudinal
Angle
The easiest welding procedure for the beginner to experiment with MIG welding is the flat position. The equipment
is capable of flat, vertical and overhead positions.
For practicing MIG welding, secure some pieces of 1.5mm
or 2.0mm mild steel plate 150 x 150mm. Use 0.8mm flux
cored gasless wire or a solid wire with shielding gas.
Setting of the Power Source
Power source and Wirefeeder setting requires some practice by the operator, as the welding plant has two control
settings that have to balance. These are the Wirespeed
control (refer to section 3.06.4) and the welding Voltage
Control (refer to section 3.06.10). The welding current
is determined by the Wirespeed control, the current will
increase with increased Wirespeed, resulting in a shorter
arc. Less wire speed will reduce the current and lengthen
the arc. Increasing the welding voltage hardly alters the
current level, but lengthens the arc. By decreasing the
voltage, a shorter arc is obtained with a little change in
current level.
When changing to a different electrode wire diameter, different control settings are required. A thinner electrode
wire needs more Wirespeed to achieve the same current
level.
A satisfactory weld cannot be obtained if the Wirespeed
Axis of Weld
and Voltage settings are not adjusted to suit the electrode
wire diameter and the dimensions of the work piece.
Transverse and Longitudinal
Nozzle Axes
Figure 4-9
Art # A-08998_AB
If the Wirespeed is too high for the welding voltage,
“stubbing” will occur as the wire dips into the molten
pool and does not melt. Welding in these conditions
normally produces a poor weld due to lack of fusion. If,
however, the welding voltage is too high, large drops will
form on the end of the wire, causing spatter. The correct setting of voltage and Wirespeed can be seen in the
shape of the weld deposit and heard by a smooth regular
arc sound. Refer to the Weld Guide located on the inside
of the wirefeed compartment door for setup information.
Nozzle Angle, Right Handed Operator
Art # A-08999_AB
Figure 4-10
Manual 0-5187 4-3 BASIC WELDING
TRANSMIG 250I BASIC WELDING
Electrode Wire Size Selection
The choice of Electrode wire size and shielding gas used depends on the following
• Thicknessofthemetaltobewelded
• Typeofjoint
• CapacityofthewirefeedunitandPowerSource
• Theamountofpenetrationrequired
• Thedepositionraterequired
• Thebeadproledesired
• Thepositionofwelding
• Costofthewire
4.02 MIG (GMAW/FCAW) Welding Troubleshooting
Solving Problems Beyond the Welding Terminals
The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through
to the MIG Torch. There are two main areas where problems occur with GMAW; Porosity and Inconsistent wire feed.
Problem 1 - Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some
contaminant within the moulten weld pool which is in the process of escaping during solidification of the moulten
metal. Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be
reduced by checking the following points.
FAULT CAUSE
1 Shielding gas cylinder contents
and flow meter.
2 Gas leaks. Check for gas leaks between the regulator/cylinder connec-
3 Internal gas hose in the Power
Source.
4 Welding in a windy environment. Shield the weld area from the wind or increase the gas flow.
5 Welding dirty, oily, painted,
oxidized or greasy plate.
6 Distance between the MIG Torch
nozzle and the work piece.
7 Maintain the MIG Torch in good
working order.
Ensure that the shielding gas cylinder is not empty and the
flow meter is correctly adjusted to 15 liters per minute.
tion and in the gas hose to the Power Source.
Ensure the hose from the solenoid valve to the MIG Torch
adaptor has not fractured and that it is connected to the MIG
Torch adaptor.
Clean contaminates off the work piece.
Keep the distance between the MIG Torch nozzle and the work
piece to a minimum.
A Ensure that the gas holes are not blocked and gas is exiting
out of the torch nozzle.
Table 4-1: MIG (GMAW / FCAW) Welding Troubleshooting
BASIC WELDING 4-4 Manual 0-5187
B Do NOT restrict gas flow by allowing spatter to build up inside
the MIG Torch nozzle.
C Check that the MIG Torch O-rings are not damaged.
BASIC WELDING TRANSMIG 250I
!
Problem 2 - Inconsistent Wire Feed
WARNING
Disengage the feed roll when testing for gas flow by ear.
Wire feeding problems can be reduced by checking the following points.
FAULT CAUSE
1 Feed roller driven by motor in the
cabinet slipped.
2 Wire spool unwound and tangled. Wire spool brake is too loose.
3 Worn or incorrect feed roller size A Use a feed roller matched to the size you are welding.
4 Wire rubbed against the misaligned
guides and reduced wire feed ability.
5 Liner blocked with swarf A Increased amounts of swarf are produced by the wire
6 Incorrect or worn contact tip A The contact tip transfers the weld current to the elec-
Wire spool brake is too tight.
B Replace feed roller if worn.
Misalignment of inlet/outlet guides
passing through the feed roller when excessive pressure is applied to the pressure roller adjuster.
B Swarf can also be produced by the wire passing
through an incorrect feed roller groove shape or size.
C Swarf is fed into the conduit liner where it accumu-
lates thus reducing wire feed ability.
trode wire. If the hole in the contact tip is too large
then arcing may occur inside the contact tip resulting
in the wire jamming in the contact tip
B When using soft wire such as aluminium it may
become jammed in the contact tip due to expansion of
the wire when heated. A contact tip designed for soft
wires should be used.
7 Poor work lead contact to work piece If the work lead has a poor electrical contact to the
work piece then the connection point will heat up and
result in a reduction of power at the arc.
8 Bent liner This will cause friction between the wire and the liner
thus reducing wire feed ability
Table 4-2: Wire Feeding Problems
Manual 0-5187 4-5 BASIC WELDING
TRANSMIG 250I BASIC WELDING
Basic MIG (GMAW/FCAW) Welding Troubleshooting
FAULT CAUSE REMEDY
1 Undercut A Welding arc voltage too
A Decrease voltage or increase the wire feed speed.
high.
B Incorrect MIG Torch angle B Adjust angle.
C Excessive heat input C Increase the MIG Torch travel speed and/or decrease
welding current by decreasing the voltage or
decreasing the wire feed speed.
2 Lack of penetration A Welding current too low A Increase welding current by increasing wire feed
speed and increasing voltage.
B Joint preparation too nar-
B Increase joint angle or gap.
row or gap too tight
C Shielding gas incorrect C Change to a gas which gives higher penetration.
3 Lack of fusion Voltage too low Increase voltage.
4 Excessive spatter A Voltage too high A Decrease voltage or increase the wirespeed control.
B Voltage too low B Increase the voltage or decrease wirespeed.
5 Irregular weld shape A Incorrect voltage and
current settings. Convex,
A Adjust voltage and current by adjusting the voltage
control and the wirespeed control.
voltage too low. Concave,
voltage too high.
B Wire is wandering. B Replace contact tip.
C Incorrect shielding gas C Check shielding gas.
D Insufficient or excessive
D Adjust the wirespeed control or the voltage control.
heat input
6 Weld cracking A Weld beads too small A Decrease travel speed
B Weld penetration narrow
and deep
B Reduce current and voltage and increase MIG Torch
travel speed or select a lower penetration shielding
gas.
C Excessive weld stresses C Increase weld metal strength or revise design
D Excessive voltage D Decrease voltage.
E Cooling rate too fast E Slow the cooling rate by preheating part to be welded
or cool slowly.
7 Cold weld puddle A Loose welding cable con-
A Check all welding cable connections.
nection.
B Low primary voltage B Contact supply authority.
C Fault in power source C Have an Accredited CIGWELD Service Provider test
then replace the faulty component.
8 Arc does not have
a crisp sound that
short arc exhibits
when the wirefeed
The MIG Torch has been
connected to the wrong
voltage polarity on the
front panel.
Connect the MIG torch to the positive (+) welding
terminal for solid wires and gas shielded flux cored
wires. Refer to the electrode wire manufacturer for
the correct polarity.
speed and voltage are
adjusted correctly.
Table 4-3: GMAW (MIG) Welding Problems
BASIC WELDING 4-6 Manual 0-5187
BASIC WELDING TRANSMIG 250I
Art # A-07688
Art # A-07689
4.03 Stick (MMAW) Basic Welding
Technique
Size of Electrode
The electrode size is determined by the thickness of metals being joined and can also be governed by the type of
welding machine available. Small welding machines will
only provide sufficient current (amperage) to run the
smaller size electrodes.
For thin sections, it is necessary to use smaller electrodes
otherwise the arc may burn holes through the job. A little
practice will soon establish the most suitable electrode
for a given application.
Storage of Electrodes
C. Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness,
generally cracks when attempts are made to weld
it. Trouble may also be experienced when welding
white-heart malleable, due to the porosity caused by
gas held in this type of iron. Suitable Electrode types
are Castcraft 55 or Castcraft 100.
D. Copper and alloys
The most important factor is the high rate of heat
conductivity of copper, making preheating of heavy
sections necessary to give proper fusion of weld and
base metal. Suitable Electrode types are Bronzecraft
AC-DC electrodes.
Always store electrodes in a dry place and in their original
containers.
Electrode Polarity
Electrodes are generally connected to the ELECTRODE
HOLDER with the Electrode Holder connected positive
polarity. The WORK LEAD is connected negative polarity
and is connected to the work piece. If in doubt consult the
electrode data sheet or your nearest Accredited CIGWELD
Distributor.
Effects of Arc Welding Various Materials
A. High tensile and alloy steels
The two most prominent effects of welding these
steels are the formation of a hardened zone in the
weld area, and, if suitable precautions are not taken,
the occurrence in this zone of under-bead cracks
may result. Hardened zone and under-bead cracks in
the weld area may be reduced by using the correct
electrodes, preheating, using higher current settings,
using larger electrodes sizes, short runs for larger
electrode deposits or tempering in a furnace.
Arc Welding Practice
The techniques used for arc welding are almost identical
regardless of what types of metals are being joined. Naturally enough, different types of electrodes would be used
for different metals as described in the preceding section.
Welding Position
The electrodes dealt with in this publication can be used
in most positions, i.e. they are suitable for welding in
flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions
intermediate between these. Some of the common types
of welds are shown in Figures 4-15 through 4-22.
Art # A-07687
Figure 4-11: Flat Position, Down Hand Butt Weld
Hydrogen controlled Electrodes must be used for this
application. Use Ferrocraft 61 or 16TXP for normal
strength (500 MPa) steels, and Alloycraft range for
higher strength steels.
B. Austenitic manganese steels
The effect on manganese steel of slow cooling from
high temperatures is to embrittle it. For this reason it
is absolutely essential to keep manganese steel cool
during welding by quenching after each weld or skip
welding to distribute the heat. Suitable Electrode types
are Cobalarc Austex or Cobalarc Mangcraft.
Manual 0-5187 4-7 BASIC WELDING
Figure 4-12: Flat Position, Gravity Fillet Weld
Figure 4-13: Horizontal Position, Butt Weld
TRANSMIG 250I BASIC WELDING
Art # A-07690
Joint Preparations
In many cases, it will be possible to weld steel sections
without any special preparation. For heavier sections and
for repair work on castings, etc., it will be necessary to
cut or grind an angle between the pieces being joined
to ensure proper penetration of the weld metal and to
Figure 4-14: Horizontal-Vertical (HV) Position
Art A-07691
Figure 4-15: Vertical Position, Butt Weld
produce sound joints.
In general, surfaces being welded should be clean and free
of rust, scale, dirt, grease, etc. Slag should be removed
from oxy-cut surfaces. Typical joint designs are shown
in Figure 4-19.
Art # A-07692
Figure 4-16: Vertical Position, Fillet Weld
Art# A-07693
Figure 4-17: Overhead Position, Butt Weld
Art # A-07694
Figure 4-18: Overhead Position, Fillet Weld
BASIC WELDING 4-8 Manual 0-5187
BASIC WELDING TRANSMIG 250I
(
Open Square Butt
Joint
Gap varies from
1.6mm to 4.8mm
depending on plate thickness
Single Vee Butt Joint
Lap Joint
Fillet Joint
Corner Weld
Not less than
45°
Single Vee Butt Joint
Double Vee Butt Joint
Tee Joints
Fillet both sides of the
joint)
Edge Joint
1.6mm
1.6mm
Not less than
70°
Not less than
70°
1.6mm max
1.6mm max
Plug Weld Plug Weld
Art # A-10347
Figure 4-19: Typical Joint Designs for Arc Welding
Arc Welding Technique - A Word to Beginners
For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate.
Use mild steel plate about 6.0mm thick and a 3.2mm electrode. Clean any paint, loose scale or grease off the plate
and set it firmly on the work bench so that welding can be carried out in the downhand position. Make sure that the
work clamp is making good electrical contact with the work, either directly or through the work table. For light gauge
material, always clamp the work lead directly to the job, otherwise a poor circuit will probably result.
The Welder
Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much work as
possiblesittingdown.Don'tholdyourbodytense.Atautattitudeofmindandatensedbodywillsoonmakeyoufeel
tired. Relax and you will find that the job becomes much easier. You can add much to your peace of mind by wearing
aleatherapronandgauntlets.Youwon'tbeworryingthenaboutbeingburntorsparkssettingalighttoyourclothes.
Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead
should be clear of any obstruction so that you can move your arm freely along as the electrode burns down. If the lead
is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight off your hand. Be sure
the insulation on your cable and electrode holder is not faulty, otherwise you are risking an electric shock.
Manual 0-5187 4-9 BASIC WELDING
TRANSMIG 250I BASIC WELDING
20°-30°
Striking the Arc
Practice this on a piece of scrap plate before going on to
more exacting work. You may at first experience difficulty
due to the tip of the electrode "sticking" to the work piece.
This is caused by making too heavy a contact with the
work and failing to withdraw the electrode quickly enough.
A low amperage will accentuate it. This freezing-on of the
tip may be overcome by scratching the electrode along
the plate surface in the same way as a match is struck.
As soon as the arc is established, maintain a 1.6mm to
3.2mm gap between the burning electrode end and the
parent metal. Draw the electrode slowly along as it melts
down.
Another difficulty you may meet is the tendency, after the
arc is struck, to withdraw the electrode so far that the arc
is broken again. A little practice will soon remedy both
of these faults.
20°
Art # A-10348
1.6 mm
Figure 4-20: Striking an Arc
Arc Length
The securing of an arc length necessary to produce a neat
weld soon becomes almost automatic. You will find that a
long arc produces more heat. A very long arc produces a
crackling or spluttering noise and the weld metal comes
across in large, irregular blobs. The weld bead is flattened
and spatter increases. A short arc is essential if a high
quality weld is to be obtained although if it is too short
there is the danger of it being blanketed by slag and the
electrode tip being solidified in. If this should happen, give
the electrode a quick twist back over the weld to detach it.
Contact or "touch-weld" electrodes such as Ferrocraft 21
do not stick in this way, and make welding much easier.
If the travel is too fast, the bead will be narrow and strung
out and may even be broken up into individual globules.
If the travel is too slow, the weld metal piles up and the
bead will be too large.
Making Welded Joints
Having attained some skill in the handling of an electrode,
you will be ready to go on to make up welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown in
Figure 4-21, allowing 1.6mm to 2.4mm gap between
them and tack weld at both ends. This is to prevent
contraction stresses from the cooling weld metal
pulling the plates out of alignment. Plates thicker
than 6.0mm should have their mating edges bevelled
to form a 70º to 90º included angle. This allows full
penetration of the weld metal to the root. Using a
3.2mm Ferrocraft 21 electrode at 100 amps, deposit
a run of weld metal on the bottom of the joint.
Do not weave the electrode, but maintain a steady
rate of travel along the joint sufficient to produce a
well-formed bead. At first you may notice a tendency
for undercut to form, but keeping the arc length short,
the angle of the electrode at about 20º from vertical,
and the rate of travel not too fast, will help eliminate
this. The electrode needs to be moved along fast
enough to prevent the slag pool from getting ahead
of the arc. To complete the joint in thin plate, turn the
job over, clean the slag out of the back and deposit
a similar weld.
Electrode
Tack Weld
Tack Weld
Figure 4-21: Butt Weld
Rate of Travel
After the arc is struck, your next concern is to maintain
it, and this requires moving the electrode tip towards the
molten pool at the same rate as it is melting away. At the
same time, the electrode has to move along the plate to
form a bead. The electrode is directed at the weld pool at
about 20º from the vertical. The rate of travel has to be
adjusted so that a well-formed bead is produced.
BASIC WELDING 4-10 Manual 0-5187
Art # A-07698
Figure 4-22: Weld Build up Sequence
BASIC WELDING TRANSMIG 250I
Heavy plate will require several runs to complete the
joint. After completing the first run, chip the slag out
and clean the weld with a wire brush. It is important
to do this to prevent slag being trapped by the second
run. Subsequent runs are then deposited using either
a weave technique or single beads laid down in the
sequence shown in Figure 4-22. The width of weave
should not be more than three times the core wire
diameter of the electrode. When the joint is completely
filled, the back is either machined, ground or gouged
out to remove slag which may be trapped in the root,
and to prepare a suitable joint for depositing the
backing run. If a backing bar is used, it is not usually
necessary to remove this, since it serves a similar
purpose to the backing run in securing proper fusion
at the root of the weld.
B. Fillet Welds
These are welds of approximately triangular crosssection made by depositing metal in the corner of two
faces meeting at right angles. Refer to Figure 4-14.
A piece of angle iron is a suitable specimen with which
to begin, or two lengths of strip steel may be tacked
together at right angles. Using a 3.2mm Ferrocraft 21
electrode at 100 amps, position angle iron with one
leg horizontal and the other vertical. This is known
as a horizontal-vertical (HV) fillet. Strike the arc and
immediately bring the electrode to a position perpendicular to the line of the fillet and about 45º from the
vertical. Some electrodes require to be sloped about
20º away from the perpendicular position to prevent
slag from running ahead of the weld. Refer to Figure
4-23. Do not attempt to build up much larger than
6.4mm width with a 3.2mm electrode, otherwise
the weld metal tends to sag towards the base, and
undercut forms on the vertical leg. Multi-runs can be
made as shown in Figure 4-24. Weaving in HV fillet
welds is undesirable.
6
3
1
5
2
4
Figure 4-24: Multi-runs in HV Fillet Weld
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron to your
work bench in an upright position. Use a 3.2mm
Ferrocraft 21 electrode and set the current at
100 amps. Make yourself comfortable on a seat
in front of the job and strike the arc in the corner
of the fillet. The electrode needs to be about 10º
from the horizontal to enable a good bead to be
deposited. Refer Figure 4-25. Use a short arc, and
do not attempt to weave on the first run. When
the first run has been completed de-slag the weld
deposit and begin the second run at the bottom.
This time a slight weaving motion is necessary
to cover the first run and obtain good fusion at
the edges. At the completion of each side motion,
pause for a moment to allow weld metal to build
up at the edges, otherwise undercut will form and
too much metal will accumulate in the centre of the
weld. Figure 4-26 illustrates multi-run technique
and Figure 4-27 shows the effects of pausing at
the edge of weave and of weaving too rapidly.
Art # A-07701
Art # A-07700_AB
45° from
vertical
60° - 70° from line
of weld
Figure 4-23: Electrode Position for HV Fillet Weld
Manual 0-5187 4-11 BASIC WELDING
Figure 4-25: Single Run Vertical Fillet Weld
Art # A-07699_AB
TRANSMIG 250I BASIC WELDING
Art # A-07702
Figure 4-28: Overhead Fillet Weld
Art # A-07704
Figure 4-26: Multi Run Vertical Fillet Weld
Art # A-07703
Figure 4-27: Examples of Vertical Fillet Welds
2. Vertical Down
The Ferrocraft 21 electrode makes welding in this
position particularly easy. Use a 3.2mm electrode
at 100 amps. The tip of the electrode is held in light
contact with the work and the speed of downward
travel is regulated so that the tip of the electrode
just keeps ahead of the slag. The electrode should
point upwards at an angle of about 45º.
3. Overhead Welds
Apart from the rather awkward position necessary,
overhead welding is not much more difficult that
downhand welding. Set up a specimen for overhead welding by first tacking a length of angle
iron at right angles to another piece of angle iron
or a length of waste pipe. Then tack this to the
work bench or hold in a vice so that the specimen
is positioned in the overhead position as shown
in the sketch. The electrode is held at 45º to the
horizontal and tilted 10º in the line of travel (Figure
4-28). The tip of the electrode may be touched
lightly on the metal, which helps to give a steady
run. A weave technique is not advisable for overhead fillet welds. Use a 3.2mm Ferrocraft 12XP
electrode at 100 amps, and deposit the first run
by simply drawing the electrode along at a steady
rate. You will notice that the weld deposit is rather
convex, due to the effect of gravity before the
metal freezes.
Distortion
Distortion in some degree is present in all forms of
welding. In many cases it is so small that it is barely
perceptible, but in other cases allowance has to be made
before welding commences for the distortion that will
subsequently occur. The study of distortion is so complex
that only a brief outline can be attempted hear.
The Cause of Distortion
Distortion is caused by:
A. Contraction of Weld Metal:
Molten steel shrinks approximately 11 per cent in
volume on cooling to room temperature. This means
that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions.
In a welded joint, the metal becomes attached to the
side of the joint and cannot contract freely. Therefore,
cooling causes the weld metal to flow plastically, that
is, the weld itself has to stretch if it is to overcome
the effect of shrinking volume and still be attached
to the edge of the joint. If the restraint is very great,
as, for example, in a heavy section of plate, the weld
metal may crack. Even in cases where the weld
metal does not crack, there will still remain stresses
"Locked-up" in the structure. If the joint material is
relatively weak, for example, a butt joint in 2.0mm
sheet, the contracting weld metal may cause the sheet
to become distorted.
B. Expansion and Contraction of Parent Metal in
the Fusion Zone:
While welding is proceeding, a relatively small
volume of the adjacent plate material is heated to a
very high temperature and attempts to expand in all
directions. It is able to do this freely at right angles
to the surface of the plate (i.e., "through the weld",
but when it attempts to expand "across the weld" or
"along the weld", it meets considerable resistance, and
to fulfil the desire for continued expansion, it has to
deform plastically, that is, the metal adjacent to the
BASIC WELDING 4-12 Manual 0-5187
BASIC WELDING TRANSMIG 250I
Upsetting
weld is at a high temperature and hence rather soft,
and, by expanding, pushes against the cooler, harder
metal further away, and tends to bulge (or is "upset".
When the weld area begins to cool, the "upset" metal
attempts to contract as much as it expanded, but,
because it has been "upset" it does not resume its
former shape, and the contraction of the new shape
exerts a strong pull on adjacent metal. Several things
can then happen.
The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the
powerful contraction stresses (distortion), or the weld
may crack, in any case, there will remain "locked-up"
stresses in the job. Figures 4-29 and 4- 30 illustrate
how distortion is created.
Hot
Weld
Hot
Expansion with
compression
Cool
Art # A-07705_AB
Figure 4-29: Parent Metal Expansion
Art # A-07706_AB
Weld
Permanent Upset
C. Restraint of Parts
Forcible restraint of the components being welded is
often used to prevent distortion. Jigs, positions, and
tack welds are methods employed with this in view.
D. Presetting
It is possible in some cases to tell from past experience or to find by trial and error (or less frequently,
to calculate) how much distortion will take place in a
given welded structure. By correct pre-setting of the
components to be welded, constructional stresses
can be made to pull the parts into correct alignment.
A simple example is shown in Figure 4-31.
E. Preheating
Suitable preheating of parts of the structure other
than the area to be welded can be sometimes used
to reduce distortion. Figure 4-32 shows a simple
application. By removing the heating source from b
and c as soon as welding is completed, the sections
b and c will contract at a similar rate, thus reducing
distortion.
Contraction
with tension
Figure 4-30: Parent Metal Contraction
Overcoming Distortion Effects
There are several methods of minimizing distortion effects.
A. Peening
This is done by hammering the weld while it is still
hot. The weld metal is flattened slightly and because of
this the tensile stresses are reduced a little. The effect
of peening is relatively shallow, and is not advisable
on the last layer.
B. Distribution of Stresses
Distortion may be reduced by selecting a welding
sequence which will distribute the stresses suitably
so that they tend to cancel each other out. See Figures 4-30 through 4-33 for various weld sequences.
Choice of a suitable weld sequence is probably the
most effective method of overcoming distortion,
although an unsuitable sequence may exaggerate it.
Simultaneous welding of both sides of a joint by two
welders is often successful in eliminating distortion.
Art # A-07707
Figure 4-31: Principle of Presetting
Art # A-07708
B
Dotted lines show effect if no preheat is used
Weld
C
PreheatPreheat
Figure 4-32: Reduction of Distortion by Preheating
Art # A-07709
Figure 4-33: Examples of Distortion
Manual 0-5187 4-13 BASIC WELDING
TRANSMIG 250I BASIC WELDING
Art # A-07710
Figure 4-34: Welding Sequence
Art # A-07711
Figure 4-35: Step back Sequence
Art # A-07428_AB
Figure 4-36: Chain Intermittent Welding
Art # A-07713_AB
Figure 4-37: Staggered Intermittent Welding
BASIC WELDING 4-14 Manual 0-5187
BASIC WELDING TRANSMIG 250I
Electrode Selection Chart
CIGWELD Electrode Selection Chart
Description Diameter Pack Part No. Application
Satincraft 13
2.5mm
2.5mm
3.2mm
3.2mm
4.0mm
1kg
2.5kg
1kg
2.5kg
5kg
322135
612182
322136
612183
611184
General purpose electrode suitable for all positional welding and
galvanised steel.
Ferrocraft 12XP
WeldSkill GP
Ferrocraft 16
Twincoat
Satincrome
308L-17
Satincrome
309Mo-17
Satincrome
316L-17
Weldall
2.0mm
2.0mm
2.5mm
2.5mm
3.2mm
3.2mm
4.0mm
2.0mm
2.0mm
2.5mm
2.5mm
2.5mm
3.2mm
3.2mm
3.2mm
4.0mm
2.5mm
2.5mm
3.2mm
3.2mm
4.0mm
2.5mm
3.2mm
4.0mm
2.5mm
3.2mm
4.0mm
2.0mm
2.5mm
3.2mm
2.5/3.2mm
4.0mm
2.5mm
3.2mm
2.5/3.2mm
4.0mm
1kg
2.5kg
1kg
2.5kg
1kg
2.5kg
5kg
1 kg
2.5 kg
1 kg
2.5 kg
5 kg
1 kg
2.5 kg
5 kg
5 kg
2.5 kg
5 kg
2.5 kg
5 kg
5 kg
2.5 kg
2.5 kg
2.5 kg
2.5 kg
2.5 kg
2.5 kg
2,5 kg
2.5 kg
2.5 kg
Blisterpack
2.5 kg
2.5 kg
2.5 kg
Blisterpack
2.5 kg
322128
612231
322129
612232
322138
612233
611234
WEG1020
WEG2520
WEG1025
WEG2525
WEG5025
WEG1032
WEG2532
WEG5032
WEG5040
612752
611752
612753
611753
611754
611602
611603
611604
611692
611693
611694
611661
611662
611663
322215
611664
611702
611703
322216
611704
General purpose, Xtra performance electrode recommended for all
positional (inc. Vertical down) welding of mild and galvanised steel.
User-friendly GP electrode for welding thin section mild and galvanised
steels. Excellent for vertical down fillet welding applications.
Hydrogen Controlled type offering exceptional AC/DC performance in
all welding positions.
Stainless Steel type for 19Cr/10Ni stainless grades including 201,
202, 301, 302, 303, 304, 304L, 305, 308, etc
Stainless Steel type for 309 and 309L grades. It is also suitable for
welding of dissimilar welding of other 300 series stainless steels.
Stainless Steel type for welding of matching Mo bearing grades, 316
and 316L.
High alloy stainless steel type for welding of unknown steels, repair of
die or tool steels and for joining dissimilar steels. (Not recommended
for cast iron).
Castcraft 55
Castcraft 100
3.2mm
4.0mm
2.5mm
3.2mm
2.5/3.2mm
4.0mm
Further information on CIGWELD electrodes can be found at the website www.thermadyne.com.
Manual 0-5187 4-15 BASIC WELDING
2.5 kg
2.5 kg
2.5 kg
2.5 kg
Blisterpack
2.5 kg
611723
611724
611732
611733
322217
611734
For repair and maintenance welding of S.G. cast iron, meehanite and
other cast irons. It produces high strength weld than Castcraft 100.
Soft, Ductile Nickel type electrode for repair and maintenance welding
of a wide range of cast irons. It has better “wetting” action than
Castcraft 55.
Table 4-4: Cigweld Electrode Selection Chart
TRANSMIG 250I BASIC WELDING
4.04 Stick (MMAW) Welding Troubleshooting
FAULT CAUSE REMEDY
1 Welding current
varying
2 A gap is left by
failure of the weld
metal to fill the
root of the weld.
3 Non-metallic par-
ticles are trapped
in the weld metal.
ARC FORCE is set at a value that causes the welding
current to vary excessively
with the arc length.
Reduce the ARC FORCE until welding current is
reasonably constant while prohibiting the electrode from sticking to the work piece when you
“dig” the electrode into the workpiece.
A Welding current too low A Increase welding current.
B Electrode too large for
B Use smaller diameter electrode.
joint.
C Insufficient gap. C Allow wider gap.
A Non-metallic particles may
be trapped in undercut
A If a bad undercut is present clean slag out and
cover with a run from a smaller gauge electrode.
from previous run.
B Joint preparation too
restricted.
C Irregular deposits allow
B Allow for adequate penetration and room for
cleaning out the slag.
C If very bad, chip or grind out irregularities.
slag to be trapped.
D Lack of penetration with
slag trapped beneath weld
bead.
D Use smaller electrode with sufficient current to
give adequate penetration. Use suitable tools to
remove all slag from comers.
E Rust or mill scale is pre-
E Clean joint before welding.
venting full fusion.
F Wrong electrode for posi-
tion in which welding is
done.
Art # A-04273
F Use electrodes designed for position in which
welding is done, otherwise proper control of slag
is difficult.
Incorrect sequence
Insufficient
gap
Figure 4-38: Example of insufficient gap or incorrect sequence
Table 4-5a:
BASIC WELDING 4-16 Manual 0-5187
BASIC WELDING TRANSMIG 250I
4 A groove has been
formed in the base
metal adjacent to
the toe of a weld
and has not been
filled by the weld
metal (undercut).
5 Portions of the
weld run do not
fuse to the surface
of the metal or
edge of the joint.
A Welding current is too
A Reduce welding current.
high.
B Welding arc is too long. B Reduce the length of the welding arc.
C Angle of the electrode is
incorrect.
D Joint preparation does not
allow correct electrode
C Electrode should not be inclined less than 45° to
the vertical face.
D Allow more room in joint for manipulation of the
electrode.
angle.
E Electrode too large for
E Use smaller gauge electrode.
joint.
F Insufficient deposit time at
edge of weave.
G Power source is set for
F Pause for a moment at edge of weave to allow
weld metal buildup.
G Set power source to STICK (MMAW) mode.
MIG (GMAW) welding.
A Small electrodes used on
A Use larger electrodes and preheat the plate.
heavy cold plate.
B Welding current is too low. B Increase welding current.
C Wrong electrode angle. C Adjust angle so the welding arc is directed more
into the base metal.
D Travel speed of electrode
D Reduce travel speed of electrode.
is too high.
E Scale or dirt on joint
E Clean surface before welding.
surface.
Lack of fusion caused by dirt,
electrode angle incorrect,
rate of travel too high
Lack o fside fusion, scale
dirt, small electrode,
amperage too low
Lack of inter-run fusion
Art # A-04274
Lack of Root Fusion
Figure 4-39: Example of Lack of Fusion
Table 4-5b: Stick MMAW metal welding trouble shooting
Manual 0-5187 4-17 BASIC WELDING
TRANSMIG 250I BASIC WELDING
4.05 TIG (GTAW) Basic Welding Technique
Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in
which fusion is produced by an electric arc that is established between a single tungsten (non-consumable) electrode
and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture
which is generally Argon based. A filler metal may also be added manually in some circumstances depending on the
welding application.
A-09658_AB
Gas Cup
Either Ceramic,
Work Piece
Can Be Any Commercial
Metal
Welds Made With or Without
Addition of Filler Metal
High-lmpact or
Water Cooled
Metal
Tungsten Electrode
Non-Consumable
Inert Gas
Shields Electrode
and Weld Puddle
Figure 4-40: TIG Welding Application Shot
Tungsten Electrode Current Ranges
Electrode Diameter DC Current (Amps)
Table 4-6: Current Ranges for Various Tungsten Electrode Sizes
Guide for Selecting Filler Wire Diameter
Filler Wire Diameter DC Current Range (Amps)
Table 4-7: Filler Wire Selection Guide
1.0mm 30-60
1.6mm 60-115
2.4mm 100-165
3.2mm 135-200
4.0mm 190-280
4.8mm 250-340
1.6mm 20-90
2.4mm 65-115
3.2mm 100-165
4.8mm 200-350
BASIC WELDING 4-18 Manual 0-5187
BASIC WELDING TRANSMIG 250I
Tungsten Electrode Types
Electrode Type
(Ground Finish)
Thoriated 2%
Zirconated 1%
Ceriated 2%
Welding Application Features Colour Code
DC welding of mild
steel, stainless steel
and copper
High quality AC welding of aluminium,
magnesium and their
alloys.
AC & DC welding of
mild steel, stainless
steel, copper, aluminium, magnesium and
their alloys
Excellent arc starting,
Long life, High current
carrying capacity
Self cleaning, Long
life, Maintains balled
end, High current carrying capacity.
Longer life, More
stable arc, Easier
starting, Wider current
range, Narrower more
concentrated arc.
Table 4-8
NOTE
The Transmig 250i Inverter is not suited for AC Tig welding.
Red
White
Grey
TIG Welding Filler Rods
Comweld
Aust Std AWS Std Part No.
Rod
LW1
LW1-6
Supersteel
CrMo1
CrMo2
308L
309L
316L
R4
R6
R2
RB2
RB3
R308L
R309L
R316L
ER70S-4
ER70S-6
ER70S-2
ER80S-B2
ER90S-B3
ER308L
ER309L
ER316L
1.6mm
321411
321417
321370
—
—
321406
321403
321400
Part No.
2.4mm
—
—
—
321379
321383
321407
321404
321401
Table 4-9
Part No.
3.2mm
—
—
—
—
—
—
—
—
Type/Application
For mild-medium strength steels.
Pipes, tubing, roll cages, etc.
For welding of high strength Cr-Mo
steels used at elevated temperatures.
For stainless steels. Stainless pipes,
tubing, architectural uses, etc.
Manual 0-5187 4-19 BASIC WELDING
TRANSMIG 250I BASIC WELDING
Base Metal
Thickness
1.0mm 35-45
1.2mm 45-55
1.6mm 60-70
3.2mm 80-100
4.8mm 115-135
6.4mm 160-175
DC Current
for Mild
Steel
40-50
50-60
70-90
90-115
140-165
170-200
DC Current
for Stainless
Steel
20-30
25-35
30-45
35-50
40-60
50-70
65-85
90-110
100-125
125-150
135-160
160-180
Tungsten
Electrode
Diameter
Filler Rod
Diameter (if
required)
Argon Gas
Flow Rate
Litres/min
Joint Type
1.0mm 1.6mm 5-7 Butt/Corner
Lap/Fillet
1.0mm 1.6mm 5-7 Butt/Corner
Lap/Fillet
1.6mm 1.6mm 7 Butt/Corner
Lap/Fillet
1.6mm 2.4mm 7 Butt/Corner
Lap/Fillet
2.4mm 3.2mm 10 Butt/Corner
Lap/Fillet
3.2mm 4.0mm 10 Butt/Corner
Lap/Fillet
Table 4-10
TIG Welding is generally regarded as a specialised process that requires operator competency. While many of the
principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding
process is outside the scope of this Operating Manual. For further information please refer to www.thermadyne.com
or contact Cigweld.
BASIC WELDING 4-20 Manual 0-5187
BASIC WELDING TRANSMIG 250I
4.06 TIG (GTAW) Welding Problems
FAULT CAUSE REMEDY
1 Excessive beard build up
or poor penetration or poor
fusion at edges of weld.
2 Weld bead too wide and
flat or undercut at edges
of weld or excessive burn
through.
3 Weld bead too small or
insufficient penetration or
ripples in bead are widely
spaced apart.
4 Weld bead too wide or
excessive bead build up or
excessive penetration in
butt joint.
5 Uneven leg length in fillet
joint
6 Electrode melts or oxidizes
when an arc is struck.
Welding current is too
low
Welding current is too
high
Travel speed too fast Reduce travel speed.
Travel speed too slow Increase travel speed.
Wrong placement of
filler rod
A TIG Torch lead connect-
ed to positive welding
terminal.
Increase weld current and/or faulty joint
preparation.
Decrease weld current.
Re-position filler rod.
A Connect TIG Torch lead to negative weld-
ing terminal.
B No gas flowing to weld-
ing region.
C TIG Torch is clogged
with dust or dirt.
D Gas hose is cut. D Replace gas hose.
E Gas passage contains
impurities.
F Gas regulator turned
OFF.
G TIG Torch valve is
turned OFF.
H The electrode is too
small for the welding
current.
I Power source is set for
MIG welding.
B Check the gas lines for kinks or breaks
and gas cylinder contents.
C Clean TIG Torch.
E Disconnect gas hose from the rear of
Power Source then raise gas pressure
and blow out impurities.
F Turn ON.
G Turn ON.
H Increase electrode diameter or reduce the
welding current.
I Set Power Source to LIFT TIG mode.
Manual 0-5187 4-21 BASIC WELDING
TRANSMIG 250I BASIC WELDING
7 Dirty weld pool A Electrode contaminated
by contact with work
piece or filler rod material.
B Work piece surface has
foreign material on it.
C Gas contaminated with
air.
8 Poor weld finish Inadequate shielding
gas.
9 Arc start is not smooth. A Tungsten electrode is
too large for the welding current.
B The wrong electrode
is being used for the
welding job.
C Gas flow rate is too
high.
A Clean the electrode by grinding off the
contaminates.
B Clean surface.
C Check gas lines for cuts and loose fitting
or change gas cylinder.
Increase gas flow or check gas line for
gas flow problems.
A Select the right size electrode. Refer to
Table 4-7 Cigweld Electrode Selection
Chart.
B Select the right electrode type. Refer to
Table 4-9 Cigweld Electrode Selection
Chart.
C Select the right rate for the welding job.
Refer to Table 4-11.
10 Arc flutters during TIG
welding.
D Incorrect shielding gas
D Select the right shielding gas.
is being used.
E Poor work clamp con-
E Improve connection to work piece.
nection to work piece.
Tungsten electrode is
too large for the welding current.
Select the right size electrode. Refer to
Table 4-7 Cigweld Electrode Selection
Chart.
Table 4-11: TIG (GTAW) Welding Problems
BASIC WELDING 4-22 Manual 0-5187
PROBLEMS/SERVICE TRANSMIG 250i
SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE
REQUIREMENTS
5.01 Power Source Problems
Error Code CAUSE REMEDY
1 Over Temperature
Fault
2 Input Power Fault Supply OK signal from Power
3 VBIAS Voltage Low
Fault
4 Ground Fault Excessive current detected
8 Input Sensor Fault Unexpected reading of voltage
9 Fan Fault Cooling Fan Failure detected
10 Inverter Output Fault Substandard output voltage
11 VRD Fault Insufficient Voltage for
14 Trigger Fault Fault occurred detecting
OverTemp signal from
Power board indicates Over
temperature fault condition of
power components
board indicates input power
voltage is out of range (too
high or too low)
Controller board circuit
monitor indicates VBIAS
voltage too low
(< 13.7 VDC)
on Ground wire of power
connection
or current sensor during
power-up sef test
on Inverter board
condition detected by
controller before weld started
electrode contact detection by
controller
trigger state/condition
A. Decrease duty cycle of welding activity
B. Ensure that air vents are not blocked/
obstructed
C. Consult an Accredited CIGWELD Service
Provider.
A. Check input power connections and cables
for damage or improper insertion
B. Verify input voltage levels meet product
requirements
Consult an Accredited CIGWELD Service
Provider.
A. Isolate welder chassis from work piece.
Check workpiece ground connection.
B. Check for MIG wire feed problem in spool/
feedplate. Verify wire is not contacting
chassis.
A. Inspect ribbon cable between power supply
and display board.
B. Consult an accredited CIGWELD service
provider.
A. Examine fan vents for potential obstruction.
B. Consult an Accredited CIGWELD Service
Provider.
Consult an Accredited CIGWELD Service
Provider.
A. Check all welding cable connections, cable
and MIG Torch/electrode holder integrity.
Remove any potential short circuits before
restoring power.
B. Consult an Accredited CIGWELD Service
Provider.
A. Trigger may be already activated when MIG
process mode is selected - verify that trigger
is not accidentally activated
B. Trigger may be faulty and/or dirty, test and
replace MIG Torch/trigger device
Manual 0-5187 5-1 PROBLEMS AND ROUTINE SERVICE
TRANSMIG 250i PROBLEMS/SERVICE
15 Wirefeed Fault Welder detects prolonged
open circuit during MIG weld
A. Inspect MIG wire spool and feedplate for
impropertensionor'bird'snest'.
B. Inspect MIG Torch and cable for damage or
obstruction
C. Consult an Accredited CIGWELD Service
Provider.
23 Weld Fault Welder detected a fault during
the weld process
24 Code Memory Fault Welder detected a fault in
program flash memory
25 Nonvolatile Memory
Fault
Welder detected a fault in
parameter NVROM.
Consult an Accredited CIGWELD Service
Provider if symptom recurs frequently.
Firmware image is corrupted. Consult an
Accredited CIGWELD Service Provider.
A. Welding may still be possible, but no weld
setting changes can be saved.
B. Consult an Accredited CIGWELD Service
Provider.
26 Unknown PCB Fault Welder control board cannot
identify an attached inverter
Consult an Accredited CIGWELD Service
Provider.
board and/or determine its
own identity
30 Service Mode Switch
Fault
SERVICE DIP switch is
enabled
Welding is disabled while SERVICE Mode DIP
switch is enabled. Disable SERVICE Mode
switch to resume welding.
31 Controller Fault Welder control board has
detected a hardware fault on
Consult an Accredited CIGWELD Service
Provider if symptom recurs frequently.
itself
33 Calibration Fault An output (current, voltage,
or motor) fault was detected
while attempting a calibration
process
34 User Calibration
Abort
User-initiated abort/
interruption of an active
A. Check integrity of welder cables, MIG Torch
or electrode holder and retry calibration.
B. Check MIG wire spool, feedplate area for
wire feed issues, correct and retry calibration
Restart/reselect calibration process and retry
calibration when ready.
calibration process occurred
(usually, release of trigger too
early)
35 Parameter Fault Welder control board has
detected a parameter out of
range
System Parameter re-initialization has been
automatically performed or is required
(Factory Default Reset)
Note 1: If the left display is alternate flashing "Err" and "Code" this is indicating that the fault was detected
but has either stopped occurring or is in the process of clearing itself. If this is the case, the flashing error
message will return to normal display functionality within 10 seconds unless another fault occurs. If the
left display shows a steady "Err" this is indicating that the fault is persistent and is still being detected.
Note 2: Flashing Amperage and Voltage displays (when welding) indicates that the machines maximum
output power rating (300A x 26.7V = 8kVA) is being exceeded and the system is automatically reducing
the output. If welding is ceased while the displays are flashing, the last values will be displayed for 10
seconds or until controls are adjusted..
Table 5-1: Power Source Problems
PROBLEMS AND ROUTINE SERVICE 5-2 Manual 0-5187
PROBLEMS/SERVICE TRANSMIG 250i
!
5.02 Routine Service and Calibration Requirements
WARNING
There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do
NOT attempt to open or repair unless you are an accredited CIGWELD Service Provider. Disconnect the
Welding Power Source from the Mains Supply Voltage before disassembling.
Routine Inspection, Testing & Maintenance
The inspection and testing of the power source and associated accessories shall be carried out in accordance with
Section 5 of AS 1674.2 - 2007: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insula-
tionresistancetestandanearthingtesttoensuretheintegrityoftheunitiscompliantwithCigweld'soriginal
specifications.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in
AS 1674.2 - 2007, then the above tests should be carried out prior to entering this location.
A. Testing Schedule
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, including the date of the most recent inspection.
A transportable power source is deemed to be any equipment that is not permanently connected and fixed in
the position in which it is operated.
B. Insulation Resistance
Minimum insulation resistance for in-service CIGWELD Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 5-2 below. Power sources that do not meet the insulation
resistance requirements set out below shall be withdrawn from service and not returned until repairs have
been performed such that the requirements outlined below are met.
Components to be Tested
Input circuit (including any connected control circuits) to welding circuit
(including any connected control circuits)
All circuits to exposed conductive parts
Welding circuit (including any connected control circuits) to any auxiliary
circuit which operates at a voltage exceeding extra low voltage
Welding circuit (including any connected control circuits) to any auxiliary
circuit which operates at a voltage not exceeding extra low voltage
Minimum Insulation
Resistance (MΩ)
5
2.5
10
1
Separate welding circuit to separate welding circuit
Table 5-2: Minimum Insulation Resistance Requirements: CIGWELD Inverter Power Sources
Manual 0-5187 5-3 PROBLEMS AND ROUTINE SERVICE
1
TRANSMIG 250i PROBLEMS/SERVICE
C. Earthing/Grounding
The resistance shall not exceed 1Ω between any metal of a power source where such metal is required to be
earthed, and -
1. The earth terminal of a fixed power source; or
2. The earth terminal of the associated plug of a transportable power source
Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying CIGWELD welding power sources should be inspected by a licensed electrical worker in accordance
with the requirements below -
1. For outlets/wiring and associated accessories supplying transportable equipment - at least once every
3 months; and
2. For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12 months.
D. Voltage Reduction Device (VRD)
UnitsttedwithVRD's,shallhavetheperiodictestsoutlinedinTable5-3belowconductedbyanaccredited
CIGWELD service provider. Testing shall be conducted at intervals as outlined below -
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
Description Required Parameters
VRD Open Circuit Voltage Less than 35V; at nominal input voltage
VRD Turn ON Resistance Less than 200 ohms
VRD Turn OFF Time Less than 0.3 seconds
Table 5-3: VRD Periodic Tests
E. General Maintenance Checks
Welding equipment should be regularly checked by an accredited CIGWELD Service Provider to ensure that:
1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly
connected and in good condition.
2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short
circuit.
3. The Welding System is clean internally, especially from metal filing, slag, and loose material.
F. Accessories
Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be
inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable
condition. All unsafe accessories shall not be used.
G. Repairs
If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited
CIGWELD Service Provider.
PROBLEMS AND ROUTINE SERVICE 5-4 Manual 0-5187
PROBLEMS/SERVICE TRANSMIG 250i
Power Source Calibration
A. Schedule
Output testing of all CIGWELD Inverter Power Sources and applicable accessories shall be conducted at regular
intervals to ensure they fall within specified levels. Calibration intervals shall be as outlined below -
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined
in AS 1674.2 - 2007, then the above tests should be carried out prior to entering this location.
B. Calibration Requirements
Where applicable, the tests outlined in Table 5-4 below shall be conducted by an accredited CIGWELD service
agent.
Testing Requirements
Output current (A) to be checked to ensure it falls within applicable CIGWELD power source specifications
Output Voltage (V) to be checked to ensure it falls within applicable CIGWELD power source specifications
Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required CIGWELD power
source / wire feeder specifications
Accuracy of digital meters to be checked to ensure it falls within applicable CIGWELD power source specifications
Table 5-4: Calibration Parameters
Periodic calibration of other parameters such as timing functions are not required unless a specific fault has
been identified.
C. Calibration Equipment
All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question. Only test equipment with valid calibration certificates (NATA certified
laboratories) shall be utilized.
Manual 0-5187 5-5 PROBLEMS AND ROUTINE SERVICE
TRANSMIG 250i PROBLEMS/SERVICE
5.03 Cleaning the Welding Power Source
Warning!
Disconnect input power before maintaining.
Maintain more often if used under severe conditions
Each Use
Visual check of
regulator and pressure
Visually inspect the torch
body and consumables
Replace all
broken parts
Visual check of torch
Consumable parts
Weekly
Visually inspect the
cables and leads.
Replace as needed
3 Months
Clean
exterior
of power supply
6 Months
Bring the unit to an authorized
CIGWELD Service Provider
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.
Art # A-10240
Figure 5-1 Routine Cleaning
PROBLEMS AND ROUTINE SERVICE 5-6 Manual 0-5187
PROBLEMS/SERVICE TRANSMIG 250i
5.04 Cleaning the Feed Rolls
Clean the grooves in the drive rolls frequently. This can
be done by using a small wire brush. Also wipe off, or
clean the grooves on the upper feed roll. After cleaning,
tighten the feed roll retaining knobs.
CAUTION
Do NOT use compressed air to clean the
Welding Power Source. Compressed air
can force metal particles to lodge between
live electrical parts and earthed metal parts
within the Welding Power Source. This may
result in arcing between these parts and their
eventual failure.
Manual 0-5187 5-7 PROBLEMS AND ROUTINE SERVICE
TRANSMIG 250i PROBLEMS/SERVICE
Notes
PROBLEMS AND ROUTINE SERVICE 5-8 Manual 0-5187
REPLACEMENT PARTS TRANSMIG 250i
SECTION 6: KEY SPARE PARTS
6.01 TWECO FUSION 250 MIG TORCH
21 43
55
767
8
Figure 6-1
TWECO FUSION MIG TORCH PARTS
ITEM PART NO. DESCRIPTION
A-10341
7
1
OTW22/50 Nozzle 13mm
OTW22/62 Nozzle 16mm
OTW14/23 Contact Tip 0.6mm
OTW14/30 Contact Tip 0.8mm
2
OTW14/35 Contact Tip 0.9mm
OTW14/40 Contact Tip 1.0mm
OTW14/45 Contact Tip 1.2mm
3 OTW32 Insulator
4 OTW52 Gas Diffuser
5 62J-45S Conductor Tube, 45 Degree
6 W7005001 Trigger Assembly
7 W7005000 Handle Mouldings
OTW42/3035 Liner 0.8-0.9mm Hard Wire
8
OTW42N/3545 Liner 0.9-1.2mm Soft Wire
OTW42/4045 Liner 1.0-1.2mm Hard Wire
Table 6-1
Manual 0-5187 6-1 REPLACEMENT PARTS
TRANSMIG 250i REPLACEMENT PARTS
1
2
4
5
7
3
6
Art # 10332
6.02 TRANSMIG 250i POWER SOURCE
Figure 6-2
TRANSMIG 250i POWER SOURCE SPARE PARTS (LEFT SIDE)
ITEM PART NUMBER DESCRIPTION
1 W7005311 Spool Hub Assembly
2 W7005353 Wire Drive Assembly, 250i. (Does not include motor)
3 375838-002 Guide, Inlet 0.6-1.6mm
4 See Appendix 1 Roll, Pressure No Groove
5 See Appendix 1 Roll, Feed Dual V
6 W6000801 Guide, Outlet 0.9-1.2mm
7 W7005354 Motor, Wire Drive, RH, 20VDC.
Table 6-2
REPLACEMENT PARTS 6-2 Manual 0-5187
REPLACEMENT PARTS TRANSMIG 250i
1
Art # A-10333
2
13
12
3
4
11
7
5
6
8
9
10
Figure 6-3 Right side and Front Replacement Parts
TRANSMIG 250i POWER SOURCE SPARE PARTS (RIGHT SIDE AND FRONT)
ITEM PART NUMBER DESCRIPTION
1 W7005330 PCB, 250i Main Power
2 W7005347 PCB, EMI, 250A
3 W7003036 Socket 8 pin (Note: 8 pin Control Plug Part# is UOA706900)
4 W7005336 PCB, Control Assy, 250i
5 W7005304 Dinse, Socket Panel, 50mm
6 W7005357 Socket 10 pin (Note: 10 pin Control Plug Part# is W7005358)
7 W7005315 Solenoid,24V,0-0.8MPa
8 W7005351 Inductor
9 W7005302 Transformer, Main, 250i
10 W7005331 PCB, Mov/Bridge, 250A
11 W7005317 Fan, 92x25 LS 24V
12 W7005316 Fan, 92x38 HS 24V
13 W7005355 Inlet, Gas, QC, Male
Table 6-3
Manual 0-5187 6-3 REPLACEMENT PARTS
TRANSMIG 250i REPLACEMENT PARTS
Notes
REPLACEMENT PARTS 6-4 Manual 0-5187
APPENDIX TRANSMIG 250i
APPENDIX 1: OPTIONS AND ACCESSORIES
Description Part Number
Tweco Professional Fusion 250 MIG Torch, 3.6 metre Euro OTWF212X3035
Tweco 4, 400A MIG torch, 3.6 metre Euro OTWX412/3545
Tig Torch 26, Flex neck, 4m lead, 3m gas hose, 8 pin
connector, accessory kit (Requires Gas Control Kit,
W4014200, to use this TIG Torch)
Tig Torch 26V, Flex neck, 4m lead, gas valve, 3m gas hose, 8
pin connector, accessory kit
Gas Hose Assembly W7004913
Roll Cage, 250i W4015100
Trolley, 4 Wheel, 200i 250i W4015000
2RT Wirefeeder w/ 8 M Interconnection cable assy W3000500
Tig Torch Gas Control Kit (used with Tig Torch W4014600) W4014200
Table A-1: Options and Accessories
W4014600
W4014601
FLUX
CORED
(1.2, 1.6)
SOFT
(0.9, 1.0, 1.2)
Art # A-10349
Top
Drive
Roll
Bottom
Drive
Roll
HARD
(0.6 to 1.0)
FLUX
CORED
(0.8,0.9,1.0)
Figure A-1: Drive Roll Chart
Wire Size Wire Type Top Drive Roll Bottom Drive Roll Inlet Guide Outlet Guide
0.6mm HARD W6001100 W6001102 W6000900 W6000800
0.8mm HARD W6001100 W6001102 W6000900 W6000801
0.9mm HARD W6001100 W6001102 W6000900 W6000801
1.0mm HARD W6001100 W6001103 W6000900 W6000801
1.2mm HARD W6001100 W6001103 W6000900 W6000801
0.8mm FLUX CORED W6001101 W6001102 W6000900 W6000801
0.9mm FLUX CORED W6001101 W6001102 W6000900 W6000801
1.0mm FLUX CORED W6001101 W6001103 W6000900 W6000801
1.2mm FLUX CORED W6001100 W6001104 W6000900 W6000801
1.6mm FLUX CORED W6001100 W6001105 W6000900 W6000802
0.9mm SOFT W6001106 W6001106 W6001000 W6000801
1.0mm SOFT W6001107 W6001107 W6001000 W6000801
1.2mm SOFT W6001108 W6001108 W6001000 W6000801
Table A-2: Wire, Drive Roll and Guide Recommended Combinations
Manual 0-5187 A-1 APPENDIX
TRANSMIG 250i APPENDIX
APPENDIX 2: TRANSMIG 250i CIRCUIT DIAGRAM
1
L1
L2
GND
GND
A
FRONT PANEL
J
VIDENT
SOL+
WFSPOT2
VBIAS
TRIG2
MOTOR+
MOTOR-
VPOT2
VPOT1
WFSPOT1
VBIAS
N/C
TRIG1
N/C
I
E
G
F
H
D
C
B
A
8
7
6
5
4
3
2
1
1
2
3
4
5
POT_RETURN
TRIG_SOL_RTN
POT_RETURN
B
TRIG_RETURN
LINE
BREAKER
LOAD
CONTROL BOARD
NOTE 1
FERRITE
AUX TRIG
FRONT PANEL
2
EMI BOARD
1
P2
50
3
C
D
WELD OUTPUT +
WELD OUTPUT -
1
1
FRONT PANEL
NOTES:
1. EMI ASSEMBLY, COMMON MODE CHOKE AND FERRITE (IF USED)
Art # A-10334
1
CURRENT SENSOR
1
2
3
4
INDUCTOR
Rev
2
Revision
3
Date
By
APPENDIX A-2 Manual 0-5187
APPENDIX TRANSMIG 250i
4
123456789
1
CHASSIS GND
BRIDGE + BRIDGE -
BRIDGE / MOV BOARD
P1 P2 P3
NI CANI CA
123
4
10
5
123456789
NOTE 1
COMMON MODE CHOKE
MOTOR
12341324121
101112
P8
6
A
GAS SOL
TIG SOL
BREAKER
FAN
FAN
2
P4
P6P5
DC+
1
2
P7
B
Rev
00 PROTOTYPE
Revision
4
P12
50
2
1
1
2
3
4
5
6
By
GAC 07/12/2011
P9
P10
HI-POT
TEMP SW
P11
P13
HI-POT
1
2
SECSEC CT
TRANSFORMER
PRI PRI
Date
The information contained here in is proprietary to Thermadyne.
Not for release, reproduction or distribution without written consent.
Title
SCHEMATIC
SCH, SYS, NEXT GEN WELDER
5
GND PRI
P14
C
Art # A-10334
Thermadyne World Headquarte rs
16052 Swingley Ridge Road, Suite 300
St Louis, Missouri 63017 USA
Date Printed
Drawn
Size
Drawing Number
7/12/2011
GAC
B
Date Revised
Date
Sheet
02/14/2011
1 1
D
7/12/2011
of
42X500100
6
Manual 0-5187 A-3 APPENDIX
TRANSMIG 250i APPENDIX
Notes
APPENDIX A-4 Manual 0-5187
This page intentionally blank
CIGWELD 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 BUSINESS
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.
TERMS OF WARRANTY – APRIL 2010
1. 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 services. 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 pursuant 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 CIG-
WELD 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 ar-
rangement with CIGWELD.
Replacement parts or accessories which may affect product safety or performance and which are not manu-
factured, 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 consumption 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.
WARRANTY SCHEDULE – APRIL 2010
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 warranty period
extend more than the time stated plus one year from the date CIGWELD delivered the product to the Accredited
Distributor. Unless otherwise stated the warranty period includes parts and labour. CIGWELD reserves the right
to request documented evidence of date of purchase.
TRANSMIG 250i MULTI PROCESS WELDING POWER SOURCE
TRANSMIG 2RT REMOTE WIREFEEDER
Original Main Power Magnetics
Original Main Power Rectifiers, Printed Circuit Boards and Power Switch
Semiconductors 2 Year 2 Year
All other circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semiconductors 1 Year 1 Year
ACCESSORIES WARRANTY PERIOD
Mig Torch, electrode holder lead and work lead
Mig Torch Consumable Items NIL
Gas regulator/flowmeter (excluding seat assembly, pressure gauges,
elastomer seals and O-Rings). 1 Year
Regulator seat assemblies and pressure gauges.
Elastomer seals and O-Rings used in the equipment.
Please note that the information detailed in this statement supersedes any prior published data produced by
CIGWELD.
WARRANTY
PERIOD LABOUR
3 Year 2 Year
3 Months
6 Months
3 Months
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7391
Email: cigweldsales@cigweld.com.au
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: sales@thermalarc.com
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
PT. Thermadyne Utama Indonesia
Jl. Angsana II Blok AE No. 28
Delta Silicon I, Cikarang - Sukaresmi
Bekasi, 17550
Indonesia
Tel: +62 21 8990 6095
Fax: +62 21 8990 6096 / 1867
http://www.thermadyne.com
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
Asia Pacific Regional Headquarters
71 Gower Street
Preston, Victoria, Australia, 3072
Telephone: +61 3 9474 7400
FAX: +61 3 9474 7391
Email: enquiries@thermadyne.com.au
www.thermadyne.com
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