Tweco 250i User Manual
250
240
PFC
250i
TRANSMIG
MULTI PROCESS WELDING
INVERTER
2RT
WIRE FEEDER (OPTIONAL)
Operating Manual
Revision: AB Issue Date: September 1, 2011 Manual No.: 0-5187
Operating Features:
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received, then check for a newer version of the manual on our website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 Pacifi c) Part Number W1003250
Cigweld Transmig 250i Inverter Power Source (South Pacifi c) 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: September 1, 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 ...................................................................................... 1-4
1.03 Declaration of Conformity ....................................................................................... 1-6
SECTION 2: INTRODUCTION ................................................................................. 2-1
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 ..................................................... 3-1
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 3-15
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 ................................................. 3-19
3.13 Attaching the Tweco Professional MIG Torch (Euro)............................................. 3-21
3.14 Installing a Handispool (200mm diameter)........................................................... 3-22
3.15 Installing a Standard Spool (300mm diameter) .................................................... 3-23
3.16 Inserting Wire into the Feed Mechanism ............................................................. 3-24
3.17 Feed Roller Pressure Adjustment.......................................................................... 3-25
3.18 Feed Roller Alignment........................................................................................... 3-25
3.19 Changing the Feed Roll ......................................................................................... 3-26
3.20 Input And Output Wire Guide Installation ............................................................. 3-27
3.21 Wire Reel Brake .................................................................................................... 3-28
3.22 Shielding Gas Regulator Operating Instructions ................................................... 3-28
3.23 Set-up MIG (GMAW) Welding with Gas Shielded MIG Wire ................................. 3-32
3.24 Set-up for MIG (FCAW) Welding with Gasless MIG Wire ...................................... 3-33
3.25 Set-up for LIFT TIG (GTAW) Welding .................................................................... 3-35
3.26 Set-up for Metal Manual Metal Arc Welding (MMAW) .......................................... 3-36
TABLE OF CONTENTS
SECTION 4: BASIC WELDING GUIDE ....................................................................... 4-1
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
SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS ............... 5-1
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 ............................................................... A-1
APPENDIX 2: TRANSMIG 250i CIRCUIT DIAGRAM ........................................................ A-2
CIGWELD LIMITED WARRANTY ............................................................................ RC-2
TERMS OF WARRANTY – APRIL 2010 .................................................................... RC-3
WARRANTY SCHEDULE – APRIL 2010 .................................................................... RC-4
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .............................. Inside Rear Cover
This page intentionally blank
TRANSMIG 250i
!
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
Receptacle RatingAuxiliary Power
Voltage Input
V
Figure 2-1 Symbol chart
INTRODUCTION 2-2 Manual 0-5187
Art # A-10344
INTRODUCTION TRANSMIG 250i
!
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
NOTE
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
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
Figure 3-1: Transmig Control Panel
INSTALLATION/SETUP 3-4 Manual 0-5187
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
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
A-09594
2
1
2
5
8
3
4
6
7
3
4
5
6
7
8
Remote Wirespeed in GMAW mode
Remote Amps in GTAW mode
Trigger Switch
W
V
Remote Volts in
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.
CAUTION
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
TRANSMIG 250i INSTALLATION/SETUP
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 flows 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.
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 flash the first 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.
Arc Control
Push For Inductance
Then press and release the Advanced
Features button (Control No 6) to enter or
Left Knob
Right Knob
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
General Operation
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.
LIFT TIG
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
Select the weld process (Control No 4) you wish to view
selected weld process mode of the machine.
Advanced Features for.
INSTALLATION/SETUP 3-10 Manual 0-5187
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.
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
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
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
Right Knob Selection
Art # A-10321
Figure 3-5 MIG Advanced Menu
Manual 0-5187 3-11 INSTALLATION/SETUP
TRANSMIG 250i INSTALLATION/SETUP
Right Display
Function Left Display
MIG Operator
Controls
Pre Flow (MIG
Setting)
Run In RUN/IN 70% 30 – 150 %
Post Flow (MIG
Setting)
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/
enabled if
Spot=ON)
Stitch STCH OFF OFF – ON
Stitch Time
(Only shown/
enabled if
Stitch=ON)
Dwell Time
(Only shown/
enabled if
Stitch=ON)
Arc Type ARC-/TYPE AUTO AUTO – CV-M
Wire Feed Speed
Units
MIG/CNTL LOCL LOCL - REMT
PRE-/FLOW 0.1 S 0.0 – 5 S
POST/FLOW 0.5 S 0.0 – 30 S
SPOT/TIME 2.0 S 0.1 – 20.0 S
STCH/TIME 2.0 S 0.2 – 4.0 S
DWEL/TIME 0.5 S 0.1 – 1.0 S
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
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