Tweco 2RT User Manual

300

2RT

TRANSMIG

WIRE FEEDER

Operating Manual

Revision: AA Issue Date: October 25, 2011 Manual No.: 0-5196

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
[phone], 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received, then check for a newer version of the manual on our website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 0-5196 for:

Cigweld Transmig 2RT Wirefeeder Part Number W3000500

Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

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: October 25, 2011
Revision Date:

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 ............................................................................. 2-1

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 .............................................................................................. 2-3

2.09 Specifications ................................................................................................. 2-4

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 ........................................................................ 3-1

3.06 2RT Wire Feeder Controls, Indicators and Features ........................................ 3-3

3.07 Transmig 250i Power Source Controls, Indicators and Features ..................... 3-5

3.08 Advanced Features Details .............................................................................. 3-7

3.09 Wire Feeder Set Up MIG (GMAW) Welding with Gas Shielded MIG Wire ........ 3-8

3.10 Wire Feeder Set-up for MIG (FCAW) Welding with Gasless MIG Wire ............ 3-9

3.11 Attaching the Tweco Professional MIG Torch (Euro) ..................................... 3-10

3.12 Installing a Handi Spool (200mm diameter) ................................................. 3-11

3.13 Installing a Standard Spool (300mm diameter) ............................................ 3-12

3.14 Inserting Wire into the Feed Mechanism ...................................................... 3-13

3.15 Feed Roller Pressure Adjustment .................................................................. 3-14

3.16 Feed Roller Alignment ................................................................................... 3-14

3.17 Changing the Feed Roll ................................................................................. 3-15

3.18 Input And Output Wire Guide Installation ..................................................... 3-15

3.19 Wire Reel Brake ............................................................................................ 3-16

3.20 Shielding Gas Regulator Operating Instructions ........................................... 3-17

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

SECTION 5: ROUTINE SERVICE REQUIREMENTS ...................................................... 5-1

5.01 Cleaning the Welding Power Source ............................................................... 5-1

5.02 Cleaning the Feed Rolls ................................................................................... 5-2

TABLE OF CONTENTS

SECTION 6: KEY SPARE PARTS .......................................................................... 6-1

6.01 2RT Wire Feeder replacement parts ................................................................ 6-1

APPENDIX 1: OPTIONS AND ACCESSORIES ............................................................ A-1

APPENDIX 2: 2RT WIRING SCHEMATIC ................................................................. 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 ........................................... RC-5

TRANSMIG 2RT

!

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 0-5196 1-1 GENERAL INFORMATION

TRANSMIG 2RT

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 0-5196

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.

TRANSMIG 2RT

2. Do not weld where flying sparks can strike flammable
material.

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.

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

2. If inside, ventilate the area and/or use exhaust at the
arc 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.

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.

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.

1. Wear approved face shield or safety goggles. Side
shields recommended.

2. Wear proper body protection to protect skin.

WARNING

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.

Manual 0-5196 1-3 GENERAL INFORMATION

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.

TRANSMIG 2RT

!

3. Keep cylinders away from any welding or other electri­cal circuits.

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.

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

1. Keep all doors, panels, covers, and guards closed and
securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or 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.)

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

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

ABOUT PACEMAKERS:

The above procedures are among those
also normally recommended for pacemaker
wearers. Consult your doctor for complete
information.

NOTE

Considerations About Welding And The Effects
of Low Frequency Electric and Magnetic Fields

GENERAL INFORMATION 1-4 Manual 0-5196

TRANSMIG 2RT

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 0-5196 1-5 GENERAL INFORMATION

TRANSMIG 2RT

1.03 Declaration of Conformity

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

Australia

Description of equipment: Welding Equipment (GMAW, FCAW, ) including, but not limited to 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:

• IEC60974-10applicabletoIndustrialEquipment-genericemissionsandregulations.

• AS1674Safetyinweldingandalliedprocesses.

• IEC60974-5Arcweldingequipment,Wirefeeders.

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 0-5196

INTRODUCTION TRANSMIG 2RT

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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 0-5196 2-1 INTRODUCTION

TRANSMIG 2RT 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 0-5196

Art # A-10344

INTRODUCTION TRANSMIG 2RT

!

2.05 Description

The Transmig 2RT Wirefeeder is fully compliant to Stand­ard IEC 60974.5.The Transmig 2RT Wirefeeder when used
in conjunction with the Transmig 250i Multi Process Weld­er provides excellent MIG welding performance across a
broad range of applications when used with the correct
welding consumables and procedures. The instructions
in the next section 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.

2.06 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.

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 handle at the top 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.

2.08 Packaged Items

Transmig 2RT Wirefeeder

(Part No. W3000500)

•Transmig2RTWirefeeder

•8MInterconnectionLead,Fitted

•OperatingManual

•DriveRoll0.9-1.2mm,Fitted

•PressureRoll0.6-1.2mmSolidWire,Fitted

•OutletGuide0.9-1.2mm,Fitted

Manual 0-5196 2-3 INTRODUCTION

TRANSMIG 2RT INTRODUCTION

2.09 Specifications

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

MIG (GMAW) Welding Output,
40°C, 10 min

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

Table 2-1: Transmig 2RT Specification

30% @ 350A
60% @ 250A

100% @ 205A

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 2-4 Manual 0-5196

INSTALLATION/SETUP TRANSMIG 2RT

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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 IEC

60974.5.

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.

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.

WARNING

This equipment should be electrically
connected by a qualified electrician.

3.03 Ventilation

WARNING

Since the inhalation of welding fumes can
be harmful, ensure that the welding area is
effectively ventilated.

3.04 Mains Supply Voltage Requirements

See Operating Manual for Transmig 250i.

3.05 Electromagnetic Compatibility

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. The enclosure design of this Wire Feeder 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.

G. Precautions must be taken against the Wire Feeder

toppling over. The Wire Feeder must be located on
a suitable horizontal surface in the upright position
when in use.

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.

Manual 0-5196 3-1 INSTALLATION/SETUP

TRANSMIG 2RT INSTALLATION/SETUP

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.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial
equipment.

5. The health of people around, e.g. the use of pace­makers and hearing aids.

6. Equipment used for calibration and measurement.

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.

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.

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

5. Earthing/grounding of the Work Piece

Where the work piece is not bonded to earth for electri-

cal 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.

INSTALLATION/SETUP 3-2 Manual 0-5196

INSTALLATION/SETUP TRANSMIG 2RT

3.06 2RT Wire Feeder Controls, Indicators and Features

The 2RT Wirefeeder is designed to be used with the
Transmig 250i. Select MIG Process and REMT in the
Advanced Features menu on the Transmig 250i to enable
the controls on the 2RT wirefeeder. See the 250i Operat­ing manual for details.

Wirespeed

1

3

Left Knob

Figure 3-1: 2RT Front Panel Controls

Right Knob

Art # A-10404

Volts

2

4

5

1. Left Knob: WFS (Wire Feed Speed) Control
Amperage Control

Wirespeed

Left Knob

The Left Knob controls the Wirespeed in the wirefeeder.
It adjusts the preview wire speed display in the power
source. The amperage control knob adjusts the amount
of welding current delivered by the power source. 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 of the Transmig
250i 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 on the 2RT is turned, and will
automatically revert back to showing the set weld current
measurements when the knob is not being turned.

REMOTE

LOCAL

Art # A-10470_AB

Figure 3-2: 2RT Local/Remote Switch

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 sub
sections 3.09 and 3.10.

2. Right Knob: MIG Voltage Control

Right Knob

MIG Voltage Control

In this mode the control knob is used to adjust the output
voltage of the power source. It adjusts the preview volt­age display in the power source. The welding voltage is
increased by turning the knob on the 2RT 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 of the power supply 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 on the power supply will briefly switch to
show the adjusted value as the knob on the 2RT is turned,
and will automatically revert back to showing the set weld
current measurements when the knob is not being turned.

Manual 0-5196 3-3 INSTALLATION/SETUP

TRANSMIG 2RT INSTALLATION/SETUP

8

3. 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.

4. Remote Control Socket

The 8 pin Remote Control Socket is used to connect remote control devices to the 2RT Wirefeeder. To make con­nections, align keyway, insert plug, and rotate threaded collar fully clockwise.

1
2

1

2

5

8

3

4

6

7

3

4

5

6

7

Trigger Switch

W

V

Remote Volts in
GMAW Mode

A-10477

Remote Wirespeed 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 Volts MIG mode potentiometer.

Table 3-1

5. Local/Remote Switch (Located in wire feed compartment)

The remote / local switch(inside the 2RT) is used to switch between using the controls on the wire feeder and
using controls on a remote device attached to the wirefeeder (such as a MIG Gun with remote voltage and wire
feed speed control). To use the controls on the wirefeeder the switch must be in the Local position. When the lo­cal/remote switch is in the local position, the 2 RT wirefeeder controls will take over and all voltage and wire feed
speed will be made from there. To use a remote control device (such as a MIG Gun with remote voltage and wire
feed speed control) the switch must be in the Remote position. Note that the MIG Gun trigger will operate at all
times regardless of the position of the local remote switch (i.e. in both local and remote modes).

INSTALLATION/SETUP 3-4 Manual 0-5196

INSTALLATION/SETUP TRANSMIG 2RT

3.07 Transmig 250i Power Source Controls, Indicators and Features

NOTE:

See Transmig 250i Operator Manual for more information.

1

2

3

ON OFF

Amps

Left Knob Right Knob

Wirespeed

7

Power

Arc Control

Push For Inductance

9 10

Fault

Volts

8

Figure 3-4: Transmig Control Panel

12

Process

Trigger

MIG

LIFT TIG

STICK

2T Normal

4T Latch

Advanced
Features

4

5

6

Art # A-10123_AB

11

14

+

16

-

Art # A-10319

13

15

Figure 3-5: 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.

Manual 0-5196 3-5 INSTALLATION/SETUP

TRANSMIG 2RT INSTALLATION/SETUP

CONTINUATION OF 250I POWER SOURCE CONTROLS

1. VRD Indicator

5. 2T - 4T Trigger Latch Button

ON OFF

WARNING

When the red VRD indicator is on and welding
is being performed, the presence of dangerous
voltage may be present at the electrode.

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

6. Advanced Features Button

Gas Purge.

7. Left Knob: Amperage Control (Wirespeed)

Left Knob

8. Right Knob: Multifunction Control - MIG Voltage /

MIG Voltage Control

LIFT TIG

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.

Right Knob

Arc Control

Push For Inductance

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

INSTALLATION/SETUP 3-6 Manual 0-5196

INSTALLATION/SETUP TRANSMIG 2RT

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).

10. Right Digital Display

Loose welding terminal connections can cause
overheating and result in the male plug being
fused in the bayonet terminal.

15. Negative Welding Output Terminal

CAUTION

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).

11. MIG Torch Adaptor (Euro Style)

The MIG Torch adaptor is the connection point for the
MIG welding Torch if not using the 2RT.

12. Remote Control Socket

The 8 pin Remote Control Socket is used to connect
remote Control devices to the welding power source.

See Transmig 250i Operator Manual for more infor­mation.

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.

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 2RT
polarity lead), 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) when the 2RT remote wirefeeder is not in use.

See Transmig 250i Operator Manual for more infor­mation.

13. 10 Pin Accessories Socket

The 10 pin Accessories Socket is used to connect
remote devices such as the 2RT wirefeeder to the
welding power source. See Transmig 250i Operator
Manual for more information.

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 2RT polarity 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.

Manual 0-5196 3-7 INSTALLATION/SETUP

3.08 Advanced Features Details

See Operating Manual for Transmig 250i for details.

TRANSMIG 2RT INSTALLATION/SETUP

3.09 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 that can be used with the 2RT Wire
Feeder. 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 Fusion 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 Transmig 250i and
connect the Welding Power Cable from the back of the 2RT to the positive + terminal on the front of the Transmig
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 Transmig 250i welding power source.

Connect the MIG Torch to the front of the 2RT as you would to the front of the Transmig 250i. See Figure 3-6 below
and Section 3.11.

Front View 2RT

Work Lead

Rear View 2RT

Gas Hose

Control Cable

Welding Power Cable
from Wire Feeder

Front View 250i

+

-

Art # 10335

Figure 3-6: Setup for 2RT Wirefeeder with Gas Shielded MIG Wire

WARNING

Before connecting the work clamp to the work make sure the mains power supply is switched off.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the
terminal.

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.

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 3.12.

INSTALLATION/SETUP 3-8 Manual 0-5196

INSTALLATION/SETUP TRANSMIG 2RT

3.10 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 that can be used with the 2RT Wire
Feeder. 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 Fusion consumable parts.

When using a gasless flux cored wire, you do not need to have an external gas source attached to the 2RT Wire Feeder.
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 on the front of the 250i
and connect the Welding Power Cable 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. See Figure 3-7 below.

Front View 2RT

Rear View 2RT

Control Cable

Front View 250i

+

-

Art # 10350_AB

Work Lead

Welding Power Cable
from Wire Feeder

Figure 3-7: Setup for 2RT Wirefeeder with Gasless MIG Wire

WARNING

Before connecting the work clamp to the work make sure the mains power supply is switched off.

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.

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 3.12.

Manual 0-5196 3-9 INSTALLATION/SETUP

TRANSMIG 2RT INSTALLATION/SETUP

3.11 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.
Press the MIG Torch in and secure by turning the locking ring to the right (clockwise). Refer to Figure 3-8.

Attach MIG Torch. Turn
locking ring to the right

Art # A-10398

Figure 3-8: 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 3-8.

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 3-10 Manual 0-5196

INSTALLATION/SETUP TRANSMIG 2RT

3.12 Installing a Handi Spool (200mm diameter)

In order to fit a Handi Spool (200mm diameter) assemble parts in the sequence shown in Figure 3-9.

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 Wire Wheel Brake has been pre-adjusted at the factory. However if adjustment is required, refer to
Section 3.20

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

200mm
Wire Spool

Flat Washer
Large Hole

Spring

Fibre Washer

Retaining Clip
Use inner holes on
Spool Hub

Keyed Washer

Spool Hub

Pin

Figure 3-9: 200mm Handi Spool Installation

Art # A-10402

Manual 0-5196 3-11 INSTALLATION/SETUP

TRANSMIG 2RT INSTALLATION/SETUP

3.13 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 3-10.

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 3.20

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

300mm
Wire Spool

Spring

Fibre Washer

Retaining Clip
Use outer holes on
Spool Hub

Keyed Washer

Spool Hub

Pin

Figure 3-10: Standard 300mm Spool Installation

Art # A-10403

INSTALLATION/SETUP 3-12 Manual 0-5196

INSTALLATION/SETUP TRANSMIG 2RT

3.14 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. 3-11)

2. Move the Pressure (top) Roller Arm by swinging it to the right. (Second part of Figure. 3-11)

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. 3-11)

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 3.11 ensuring the MIG wire passes into the MIG Torch liner of the MIG
Torch.

5. Close the Pressure Roller Arm. (Figure. 3-12)

6. Swing the Spring Pressure Adjusting Knob back into place. (Figure. 3-12)

7. Use the Spring Pressure Adjusting Knob to create a “snug” condition. (Clockwise to tighten and Counter
Clockwise to loosen). (Figure. 3-12)

8. Continue to the next section for proper setting of tension.

1

3

Art # A-10030

Figure 3-11: Opening Pressure Arm and Inserting Wire

5

2

4

7

6

Art # A-10031

Figure 3-12: Closing Pressure Arm and Adjusting Tension

Manual 0-5196 3-13 INSTALLATION/SETUP

TRANSMIG 2RT INSTALLATION/SETUP

3.15 Feed Roller Pressure Adjustment

NOTE

Before attempting to set the drive roller pressure you must select GMAW mode on the front panel. See
Transmig 250i manual 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.

3.16 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 3-13, 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 3-13: Top View of Feed Plate with Pressure Arm Open

NOTE

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 3-14 Manual 0-5196

INSTALLATION/SETUP TRANSMIG 2RT

3.17 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.

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.

3.18 Input And Output Wire Guide Installation

NOTE

WARNING

NOTE

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 3-14: 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.

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 lock bolt. This will aid with alignment. Install
the output wire guide 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.

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.

Manual 0-5196 3-15 INSTALLATION/SETUP

TRANSMIG 2RT INSTALLATION/SETUP

Art # A-10471_AB

Input Guide Lockscrew

Output Guide Lockscrew

MIG Torch
Adapter Lock
Bolt

Art # A-10346_AB

Input Wire Guide

Output Wire Guide

Figure 3-15: Wire Guide Installation

3.19 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 3-16).

Wheel Brake adjusting tri-lobe nut

Pressure Adjustment
Knob

REMOTE

LOCAL

Figure 3-16: 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.

INSTALLATION/SETUP 3-16 Manual 0-5196

INSTALLATION/SETUP TRANSMIG 2RT

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.

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

3.20 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 2RT.

NOTE

Shielding Gas is not required if the unit is
used with self shielded FCAW (flux cored arc
welding) wires.

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.

This equipment will perform safely and reliable only when
installed, operated, 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

SPECIFIC PROCEDURES for the use of regulators are
listed below.

Art # A-10108

INLET

CONNECTION

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 releas-

Figure 3-17: Adjusting Flow Rate

NOTE

The regulator/flow meters used with argon
based and carbon dioxide shielding gases are
different. The regulator/flow meter supplied
with certain Transmig 250i welders 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.

ing gas in the regulator high and low pressure
chambers.

Manual 0-5196 3-17 INSTALLATION/SETUP

TRANSMIG 2RT INSTALLATION/SETUP

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 the gas line from the back of the 2RT to the regulator output.

Ensure that the gas
cylinder is secured to
a building pillar, wall
bracket or otherwise
securely fixed in an
upright position.

Art # A-10401

Figure 3-18: 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.

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.

INSTALLATION/SETUP 3-18 Manual 0-5196

INSTALLATION/SETUP TRANSMIG 2RT

Adjusting Flow Rate

Art: A-05088_AB

Figure 3-19: 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 back to
Figure 3-19)

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.

Manual 0-5196 3-19 INSTALLATION/SETUP

TRANSMIG 2RT INSTALLATION/SETUP

Notes

INSTALLATION/SETUP 3-20 Manual 0-5196

BASIC WELDING TRANSMIG 2RT

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, CO2 welding, Micro Wire Welding,
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

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.

CAUTION

GMAW Process

Art # A-8991_AB

Do not pull the MIG Torch back when the arc

Figure 4-1

is established. This will create excessive wire
extension (stick-out) and make a very poor

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

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.

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 0-5196 4-1 BASIC WELDING

TRANSMIG 2RT 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

Vertical Fillet Welds

Figure 4-5

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

2. Wire Feed Speed. Increase in wire feed speed
increases weld current, Decrease in wire feed
speed decreases weld current.

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 0-5196

BASIC WELDING TRANSMIG 2RT

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

Axis of Weld

Transverse and Longitudinal
Nozzle Axes

Art # A-08998_AB

Figure 4-9

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 and the welding Voltage Control. 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
and Voltage settings are not adjusted to suit the electrode
wire diameter and the dimensions of the work piece.

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 0-5196 4-3 BASIC WELDING

TRANSMIG 2RT BASIC WELDING

Electrode Wire Size Selection

The choice of Electrode wire size and shielding gas used depends on the following

• Thicknessofthemetaltobewelded

• Typeofjoint

• CapacityofthewirefeedunitandPowerSource

• Theamountofpenetrationrequired

• Thedepositionraterequired

• Thebeadproledesired

• Thepositionofwelding

• Costofthewire

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 molten weld pool which is in the process of escaping during solidification of the molten 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 litres 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.

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.

Table 4-1: MIG (GMAW / FCAW) Welding Troubleshooting

BASIC WELDING 4-4 Manual 0-5196

BASIC WELDING TRANSMIG 2RT

!

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 0-5196 4-5 BASIC WELDING

TRANSMIG 2RT BASIC WELDING

Basic MIG (GMAW/FCAW) Welding Troubleshooting

FAULT CAUSE REMEDY

1 Undercut A Welding arc voltage too

high.

B Incorrect MIG Torch angle B Adjust angle.

C Excessive heat input C Increase the MIG Torch travel speed and/or decrease

2 Lack of penetration A Welding current too low A Increase welding current by increasing wire feed

B Joint preparation too nar-

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,
voltage too low. Concave,
voltage too high.

A Decrease voltage or increase the wire feed speed.

welding current by decreasing the voltage or
decreasing the wire feed speed.

speed and increasing voltage.

B Increase joint angle or gap.

A Adjust voltage and current by adjusting the voltage

control and the wirespeed control.

B Wire is wandering. B Replace contact tip.

C Incorrect shielding gas C Check shielding gas.

D Insufficient or excessive

heat input

6 Weld cracking A Weld beads too small A Decrease travel speed

B Weld penetration narrow

and deep

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

7 Cold weld puddle A Loose welding cable con-

nection.

B Low primary voltage B Contact supply authority.

C Fault in power source C Have an Accredited CIGWELD Service Provider test

8 Arc does not have

a crisp sound that
short arc exhibits
when the wirefeed
speed and voltage are
adjusted correctly.

The Wirefeeder has been
connected to the wrong
voltage polarity on the
front panel of the power
source.

D Adjust the wirespeed control or the voltage control.

B Reduce current and voltage and increase MIG Torch

travel speed or select a lower penetration shielding
gas.

or cool slowly.

A Check all welding cable connections.

then replace the faulty component.

Connect the Wirefeeder to the positive (+) welding
terminal for solid wires and gas shielded flux cored
wires. Refer to the electrode wire manufacturer for
the correct polarity.

Table4-3: GMAW (MIG) Welding Problems

BASIC WELDING 4-6 Manual 0-5196

PROBLEMS/SERVICE TRANSMIG 2RT

SECTION 5: ROUTINE SERVICE REQUIREMENTS

5.01 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 wirefeeder

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-10472

Figure 5-1 Routine Cleaning

Manual 0-5196 5-1 PROBLEMS AND ROUTINE SERVICE

TRANSMIG 2RT PROBLEMS/SERVICE

5.02 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.

PROBLEMS AND ROUTINE SERVICE 5-2 Manual 0-5196

REPLACEMENT PARTS TRANSMIG 2RT

SECTION 6: KEY SPARE PARTS

6.01 2RT WIRE FEEDER REPLACEMENT PARTS

Figure 6-1

TRANSMIG 2RT SPARE PARTS (LEFT SIDE)

ITEM PART NUMBER DESCRIPTION

1 W7005311 Spool Hub Assembly

2 W7005353 Wire Drive Assembly, (Does not include motor or feed rolls)

3 W6000900 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 6-1

Manual 0-5196 6-1 REPLACEMENT PARTS

TRANSMIG 2RT REPLACEMENT PARTS

Notes

REPLACEMENT PARTS 6-2 Manual 0-5196

APPENDIX TRANSMIG 2RT

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

Table A-1: Options and Accessories

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 0-5196 A-1 APPENDIX

TRANSMIG 2RT APPENDIX

APPENDIX 2: 2RT WIRING SCHEMATIC

Figure A-2: 2RT Wiring Schematic

APPENDIX A-2 Manual 0-5196

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.

WARRANTY

TRANSMIG 2RT WIREFEEDER

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

Please note that the information detailed in this statement supersedes any prior published data produced by
CIGWELD.

PERIOD LABOUR

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Cigweld, Australia

71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

Thermadyne USA

2800 Airport Road
Denton, Tx 76207 USA
Telephone: [phone]
800-426-1888
Fax: [phone]
Email: [e-mail]

Thermadyne Canada

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Thermadyne, China

RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: [phone]
Fax: [phone]

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: [phone]
Fax: [phone]

Thermadyne Europe

Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: [phone]
Fax: [phone]

PT. Thermadyne Utama Indonesia

Jl. Angsana II Blok AE No. 28
Delta Silicon I, Cikarang - Sukaresmi
Bekasi, 17550
Indonesia
Tel: [phone]
Fax: [phone] / 1867
http://www.thermadyne.com

Thermadyne International

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Asia Pacific Regional Headquarters

71 Gower Street
Preston, Victoria, Australia, 3072
Telephone: [phone]
FAX:

[phone]

Email: [e-mail]

www.thermadyne.com

Printed in: U.S.A.