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CIGWELD 250i Transmig Operating Manua

Multi process welding inverter/ 2rt wire feeder;
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See also: Service Manual
250i
2RT
Operating Manual
TRANSMIG
MULTI PROCESS WELDING
INVERTER
WIRE FEEDER (OPTIONAL)
Revision: AD
Issue Date: October 12, 2011
Operating Features:
Manual No.: 0-5187
250
240 PFC

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Summary of Contents for CIGWELD 250i Transmig

  • Page 1 250i TRANSMIG MULTI PROCESS WELDING INVERTER WIRE FEEDER (OPTIONAL) Operating Manual Revision: AD Issue Date: October 12, 2011 Manual No.: 0-5187 Operating Features: 240 PFC...
  • Page 2 +1300 654 674, or visit us on the web at www.thermadyne.com This Operating Manual has been designed to instruct you on the correct use and operation of your CIGWELD product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precau- tions.
  • Page 3 Operating Manual Number 0-5187 for: Cigweld Transmig 250i Inverter Plant (South Pacific) Part Number W1003250 Cigweld Transmig 250i Inverter Power Source (South Pacific) Part Number W1003251 Cigweld Transmig 250i Inverter Plant (Asia) Part Number W1003250M Cigweld Transmig 2RT Wirefeeder (Optional - All Regions)

  • Page 4: Table Of Contents

    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 ..................
  • Page 5 Power Source .................. 6-2 APPENDIX 1: OPTIONS AND ACCESSORIES ............... A-1 APPENDIX 2: TRANSMIG 250i CIRCUIT DIAGRAM ............A-2 CIGWELD LIMITED WARRANTY ................RC-2 TERMS OF WARRANTY – APRIL 2010 ..............RC-3 WARRANTY SCHEDULE – APRIL 2010 ..............RC-4 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ..........RC-5...
  • Page 6 This page intentionally blank...

  • Page 7: Arc Welding Safety Instructions And Warnings

    TRANSMIG 250i SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. Do NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT. Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.
  • Page 8 TRANSMIG 250i 2. Wear approved safety glasses. Side shields recom- mended. 3. Use protective screens or barriers to protect others WARNING from flash and glare; warn others not to watch the arc. ARC RAYS can burn eyes and skin; NOISE can 4.
  • Page 9 TRANSMIG 250i 3. Remove all flammables within 10M of the welding arc. If this is not possible, tightly cover them with approved covers. WARNING 4. Be alert that welding sparks and hot materials from FUMES AND GASES can be hazardous to your welding can easily go through small cracks and open- health.
  • Page 10 TRANSMIG 250i 4. Never allow a welding electrode to touch any cylinder. Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing 5. Use only correct shielding gas cylinders, regulators, Office, May 1989): “...there is now a very large volume hoses, and fittings designed for the specific application;...

  • Page 11: Principal Safety Standards

    TRANSMIG 250i 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 12: Declaration Of Conformity

    Victoria 3072 Australia Description of equipment: Welding Equipment (GMAW, FCAW, GTAW, MMAW) including, but not limited to CIGWELD Transmig 250i Multi Process Welding Inverter, CIGWELD Transmig 2RT wire feeder and associated accessories. Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

  • Page 13: Section 2: Introduction

    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 equip- ment identification numbers.

  • Page 14: Symbol Chart

    TRANSMIG 250i INTRODUCTION 2.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Torch Dangerous Voltage Transformer-Rectifier Purging Of Gas...

  • Page 15: Description

    INTRODUCTION TRANSMIG 250i 2.07 Transportation Methods 2.05 Description The Cigweld Transmig 250i is a self contained single phase multi process welding inverter that is capable of perform- WARNING ing GMAW/FCAW (MIG), MMAW (Stick) and GTAW (Lift TIG) welding processes. The Transmig 250i is equipped ELECTRIC SHOCK can kill.

  • Page 16: Packaged Items

    TRANSMIG 250i INTRODUCTION 2.08 Packaged Items Transmig 250i MIG Plant - Asia (Part number W1003250M) Transmig 250i Plant - • Transmig 250i Inverter Power Source South Pacific (Part No. W1003250) • MIG Torch,Tweco Fusion 250A, 3.6M, Euro, STD • Transmig 250i Inverter Power Source • Leadset, 250A, 4M, 50D • MIG Torch,Tweco Fusion 250A, 3.6M, Euro, STD • Gas Hose, 3M, Female 3/8 BSP • Regulator / Flow Meter - COMET 250 ARG 55LPM 2GA • Operating Manual • Leadset, 250A, 4M, 50D • Drive Roll 'V' Knurled 1.2mm • Gas Hose, 3M • Drive Roll 'U' Groove 1.2mm • Operating Manual • Drive Roll 'V' Groove 0.6-0.9mm • Drive Roll 'V' Knurled 1.2mm • Drive Roll 'V' Groove 0.9-1.2mm, Fitted • Drive Roll 'U' Groove 1.2mm • Pressure Roll 0.6-1.2mm Solid Wire, Fitted • Drive Roll 'V' Groove 0.6-0.9mm...

  • Page 17: Duty Cycle

    INTRODUCTION TRANSMIG 250i 2.09 Duty Cycle The rated duty cycle of a Welding Power Source is a statement of the time it may be operated at its rated welding cur- rent output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used.

  • Page 18: Specifications

    TRANSMIG 250i INTRODUCTION 2.10 Specifications Description TRANSMIG 250i MULTI PROCESS WELDING INVERTER Power Source Dimensions H 440mm x W 260mm x D 600mm Power Source Mass 29.5kg Cooling Fan Cooled Welder Type Multi Process Inverter Power Source Australian Standard AS 60974.1-2006 / IEC60974.1 Number of Phases Single Phase Nominal Supply Voltage...

  • Page 19: Section 3: Installation Operation And Setup

    INSTALLATION/SETUP TRANSMIG 250i SECTION 3: INSTALLATION OPERATION AND SETUP G. The enclosure design of this power source meets the 3.01 Environment requirements of IP23S as outlined in AS60529. This These units are designed for use in environments with provides adequate protection against solid objects increased hazard of electric shock as outlined in AS (greater than 12mm), and direct protection from verti- cal drops.
  • Page 20 TRANSMIG 250i INSTALLATION/SETUP WARNING The Transmig 250i must be electrically connected by a qualified electrical trades-person. Damage to the PCA (Power Control Assembly) could occur if 276 VAC or higher is applied to the Primary Power Cable 50/60 Hz Primary Supply Minimum Minimum Current &...

  • Page 21: Electromagnetic Compatibility

    INSTALLATION/SETUP TRANSMIG 250i 5. The health of people around, e.g. the use of pace- 3.05 Electromagnetic Compatibility makers and hearing aids. 6. Equipment used for calibration and measurement. WARNING 7. The time of day that welding or other activities are to be carried out.

  • Page 22: Power Source Controls, Indicators And Features

    TRANSMIG 250i INSTALLATION/SETUP 4. Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time.
  • Page 23 INSTALLATION/SETUP TRANSMIG 250i 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 Art # A-10319 of the faults are detected.
  • Page 24 TRANSMIG 250i INSTALLATION/SETUP 6. Advanced Features Button revert back to showing the weld current measurements when the knob is not being turned. 8. Right Knob: Multifunction Control - MIG Voltage / Arc Control (Inductance) & STICK Arc Force Press and release the Advanced Features button to enter or exit from the advanced programming mode.
  • Page 25 INSTALLATION/SETUP TRANSMIG 250i To access the Arc Control function, push inward on the right knob and hold it for approximately 2 seconds. This feature can be accessed and adjusted during welding. The left display will change to show the Arc Control parameter name that is in effect for the current MIG or STICK Modes and the right display will show its present value.
  • Page 26 TRANSMIG 250i INSTALLATION/SETUP which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode.
  • Page 27 INSTALLATION/SETUP TRANSMIG 250i 13. 10 Pin Accessories Socket The 10 pin Accessories Socket is used to connect remote devices such as 2RT wirefeeder to the welding power source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. Peripheral Resistor Trigger...

  • Page 28: Advanced Features Details

    TRANSMIG 250i INSTALLATION/SETUP 15. Negative Welding Output Terminal General Operation The negative welding terminal is used to connect the LIFT TIG welding output of the power source to the appropriate welding accessory such as the MIG Torch (via the MIG Select the weld process (Control No 4) Torch polarity lead), TIG torch or work lead.
  • Page 29 INSTALLATION/SETUP TRANSMIG 250i LIFT TIG If the welder is in Advanced Features mode and the Weld Process Selection button (Control No 4) is pressed, the welder will exit Advanced Features mode, saving any change made, and change to the next weld process function in the sequence: MIG, TIG, stick.
  • Page 30 TRANSMIG 250i INSTALLATION/SETUP Right Display Function Left Display (Factory De- Limits Comments fault Values) LOCL = Local control of the Wirespeed MIG Operator and Voltage with the machines controls. MIG/CNTL LOCL LOCL - REMT Controls REMT = Remote control of the Wirespeed and Voltage with an accessory device.
  • Page 31 INSTALLATION/SETUP TRANSMIG 250i Right Display Function Left Display (Factory De- Limits Comments fault Values) Provides Arc On Hours that the power source has Arc Hour Accu- welded. The number displayed is in hours and mulated Run- 0.0 – 9999.9 read only. It will rollover to 0 once 10,000 hours time have been reached.
  • Page 32 TRANSMIG 250i INSTALLATION/SETUP "Right Display Function Left Display (Factory De- Limits Comments fault Values)" In “2T” (unlatched), the unit will enter down slope mode as soon as the trigger switch is released (ie if Down Slope is set to 5.0 S, the unit will ramp down from the present welding current to zero over 5 seconds).

  • Page 33: Optional Wire Feeder Controls, Indicators And Features

    INSTALLATION/SETUP TRANSMIG 250i Right Display Function Left Display (Factory De- Limits Comments fault Values) LOCL = Local control of the Amps with the Stick Operator machines controls STCK/CNTL LOCL LOCL - REMT Controls REMT = Remote control of the Amps with an accessory device Hot Start is used to improve the start charac- Hot Start...

  • Page 34: Optional Wire Feeder Set Up Mig (Gmaw) Welding With Gas Shielded Mig Wire

    TRANSMIG 250i INSTALLATION/SETUP Wirespeed Volts WFS Control Volts Control Left Knob Right Knob 8 Pin Remote Euro Connector Connector Art # A-10324 Figure 3-8: 2RT Front Panel Controls The Tweco professional MIG Torch will connect to the 2RT just as it does to the 250i power source. The electrode Polarity setting is done at the power source.

  • Page 35: Optional Wire Feeder Set-Up For Mig (Fcaw) Welding With Gasless Mig Wire

    INSTALLATION/SETUP TRANSMIG 250i CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal. Remove any packaging material prior to use. DO NOT block the air vents at the front or rear of the Welding Power Source.

  • Page 36: Fitting Of Optional Roll Cage

    TRANSMIG 250i INSTALLATION/SETUP 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.
  • Page 37 INSTALLATION/SETUP TRANSMIG 250i 3 Nuts Front 3 Studs Art # A-10337 These holes are not used Figure 3-12: Mounting Welder to Roll Cage. 5. First, use the 3 nuts (included) and secure the power source to the roll cage. Second, attach the front roll bar and secure all hardware now.

  • Page 38: Assembly And Fitting Of Optional Welding Trolley

    TRANSMIG 250i INSTALLATION/SETUP 3.12 Assembly and Fitting of Optional Welding Trolley Assemble the Welding Trolley according to Figure 3-14. Read all steps before beginning and ensure all hardware is tightened properly. 1. Attach the front base section to the upright rear section with the 3 screws provided. NOTE If attached, the optional roll cage must be removed before mounting to the Welding Trolley as the same mounting holes are used for both.
  • Page 39 INSTALLATION/SETUP TRANSMIG 250i Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping. Art # A-10327 Figure 3-15: Welding Trolley and Welding Equipment Rear Hand Grip Front Hand Grip Art # A-10407 Figure 3-16: Location of Hand Grips...

  • Page 40: Attaching The Tweco Professional Mig Torch (Euro)

    TRANSMIG 250i INSTALLATION/SETUP 3.13 Attaching the Tweco Professional MIG Torch (Euro) 1. Align the pins on the MIG Torch Cable with the pin holes of the MIG Torch receptacle on the front of the system above the positive(+) dinse type receptacle. Press the MIG Torch in and secure by turning the locking ring to the right (clockwise).Refer to Figure 3-17.

  • Page 41: Installing A Handispool (200Mm Diameter)

    INSTALLATION/SETUP TRANSMIG 250i 3.14 Installing a Handispool (200mm diameter) In order to fit a Handispool (200mm diameter) assemble parts in the sequence shown in Figure 3-18. Installation of wire spool. 1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull. 2.

  • Page 42: Installing A Standard Spool (300Mm Diameter)

    TRANSMIG 250i INSTALLATION/SETUP 3.15 Installing a Standard Spool (300mm diameter) As delivered from the factory, the unit is set for a 15 kg or 300mm spool. Installation of wire spool. Refer to Figure 3-19. 1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull. 2.

  • Page 43: Inserting Wire Into The Feed Mechanism

    INSTALLATION/SETUP TRANSMIG 250i 3.16 Inserting Wire into the Feed Mechanism WARNING ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power source before proceeding. DO NOT reattach the input power until told to do so in these instructions. 1.

  • Page 44: Feed Roller Pressure Adjustment

    TRANSMIG 250i INSTALLATION/SETUP 3.17 Feed Roller Pressure Adjustment NOTE Before attempting to set the drive roller pressure you must select GMAW mode on the front panel. See earlier in section 3 for information on how to select this feature. Once selected it will allow the activation of the drive roll when the trigger on the MIG Torch is activated.

  • Page 45: Changing The Feed Roll

    INSTALLATION/SETUP TRANSMIG 250i 3.19 Changing the Feed Roll NOTE Feedrolls often come with a rust prohibitive coating that needs to be cleaned off before installation. A Feedroll consists of two different sized grooves. As delivered from the factory the drive roll is installed for 0.9mm / 1.2mm.

  • Page 46: Input And Output Wire Guide Installation

    TRANSMIG 250i INSTALLATION/SETUP 3.20 Input And Output Wire Guide Installation NOTE 0.9mm / 1.2mm feed rolls and guides are installed from the factory. Other sizes need to be purchased separately. Input Wire Guide - Install (the shorter one) by loosening the input guide lockscrew and inserting the guide into the hole in the feedhead assembly.

  • Page 47: Wire Reel Brake

    INSTALLATION/SETUP TRANSMIG 250i 3.21 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking. If it is considered necessary, adjustment can be made by turning the tri-lobe nut inside the open end of the wire reel hub. Clockwise rotation will tighten the brake.
  • Page 48 TRANSMIG 250i INSTALLATION/SETUP Shielding Gas Regulator Safety This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it. If the equipment is improperly used, hazardous conditions are created that may cause accidents. It is the users responsibility to prevent such conditions.
  • Page 49 INSTALLATION/SETUP TRANSMIG 250i NOTE The regulator/flow meters used with argon based and carbon dioxide shielding gases are different. The regulator/flow meter supplied is for argon based shielding gases. If carbon dioxide is to be used a suitable carbon dioxide regulator/flow meter will need to be fitted. NOTE All valves downstream of the regulator must be opened to obtain a true flow rate reading on the outlet gauge.
  • Page 50 TRANSMIG 250i INSTALLATION/SETUP 3. Purge air or other unwanted welding grade shielding gas from equipment connected to the regulator by indi- vidually opening then closing the equipment control valves. Complete purging may take up to ten seconds or more, depending upon the length and size of the hose being purged. Adjusting Flow Rate Art: A-05088_AB Figure 3-28: Adjust Flow Rate...

  • Page 51: Set-Up Mig (Gmaw) Welding With Gas Shielded Mig Wire

    INSTALLATION/SETUP TRANSMIG 250i 3.23 Set-up MIG (GMAW) Welding with Gas Shielded MIG Wire The Transmig 250i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Torch. The Fusion MIG Torch is designed with an ergonomic handle and fewer parts to cause performance problems. The Fusion MIG Torch uses standard readily available Tweco consumable parts.

  • Page 52: Set-Up For Mig (Fcaw) Welding With Gasless Mig Wire

    TRANSMIG 250i INSTALLATION/SETUP 11. Refer to the Weld Guide located on the inside of the wire feed compartment door for further information on Voltage/Wirespeed settings. WARNING Before connecting the work clamp to the work make sure the mains power supply is switched OFF. Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping.

  • Page 53: Set-Up For Lift Tig (Gtaw) Welding

    INSTALLATION/SETUP TRANSMIG 250i 1. Turn the Main ON/OFF switch OFF (located on the rear panel). CAUTION 2. Check that the MIG wire size, contact tip, MIG Torch liner and drive roll groove are all the same size Loose welding terminal connections can cause before fitting the MIG wire into the Power Source.

  • Page 54: Set-Up For Metal Manual Metal Arc Welding (Mmaw)

    TRANSMIG 250i INSTALLATION/SETUP 6. The tungsten must be ground to a blunt point (similar to a pencil) in order to achieve optimum welding results. See illustration. It is critical to grind the tungsten electrode in the direction the grinding wheel is turning. Grind at a 30 degree angle and never to a sharp point.
  • Page 55 INSTALLATION/SETUP TRANSMIG 250i Art # A-10285 Negative Output Terminal (Dinse ® type 50mm) Figure 3-33: Setup for STICK Welding reverse polarity shown. 3. Set the welding process to STICK. 4. Set the Weld Current Control Knob to the desired amperage. 5.
  • Page 56 TRANSMIG 250i INSTALLATION/SETUP Notes INSTALLATION/SETUP 3-38 Manual 0-5187...

  • Page 57: Basic Welding Guide

    BASIC WELDING TRANSMIG 250I SECTION 4: Shielding Gas Nozzle (Optional) (Optional) BASIC WELDING GUIDE Molten Metal Flux Cored Molten Electrode Slag Slag 4.01 MIG (GMAW/FCAW) Basic Welding Solidified Technique Base Metal Weld Metal Two different welding processes are covered in this sec- FCAW Process Art # A-08992_AB tion (GMAW and FCAW), with the intention of providing...
  • Page 58 TRANSMIG 250I BASIC WELDING Travel Speed The speed at which the molten pool travels influences the width of the weld and penetration of the welding run. MIG Welding (GMAW) Variables Most of the welding done by all processes is on carbon steel.
  • Page 59 BASIC WELDING TRANSMIG 250I Establishing the Arc and Making Weld Beads Gas Nozzle Before attempting to weld on a finished piece of work, it Contact Tip (Tube) Tip to is recommended that practice welds be made on a sample Electrode Wire Work Distance Actual Stick-out metal of the same material as that of the finished piece.

  • Page 60: Mig (Gmaw/Fcaw) Welding Troubleshooting

    TRANSMIG 250I 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 profile 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.
  • Page 61 BASIC WELDING TRANSMIG 250I Problem 2 - Inconsistent Wire Feed WARNING Disengage the feed roll when testing for gas flow by ear. Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1 Feed roller driven by motor in the Wire spool brake is too tight.
  • Page 62 B Low primary voltage B Contact supply authority. C Fault in power source C Have an Accredited CIGWELD Service Provider test then replace the faulty component. 8 Arc does not have The MIG Torch has been Connect the MIG torch to the positive (+) welding...

  • Page 63: Stick (Mmaw) Basic Welding Technique

    If in doubt consult the The electrodes dealt with in this publication can be used electrode data sheet or your nearest Accredited CIGWELD in most positions, i.e. they are suitable for welding in Distributor.
  • Page 64 TRANSMIG 250I BASIC WELDING Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined Art # A-07690 to ensure proper penetration of the weld metal and to produce sound joints.
  • Page 65 BASIC WELDING TRANSMIG 250I Open Square Butt Single Vee Butt Joint Not less than 70° Joint 1.6mm max Gap varies from 1.6mm to 4.8mm depending on plate thickness 1.6mm Not less than Single Vee Butt Joint Double Vee Butt Joint Not less than 45°...
  • Page 66 TRANSMIG 250I BASIC WELDING Striking the Arc If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. Practice this on a piece of scrap plate before going on to If the travel is too slow, the weld metal piles up and the more exacting work.
  • Page 67 BASIC WELDING TRANSMIG 250I Heavy plate will require several runs to complete the Art # A-07700_AB joint. After completing the first run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run.

  • Page 68: Distortion

    TRANSMIG 250I BASIC WELDING Art # A-07702 Art # A-07704 Figure 4-28: Overhead Fillet Weld Figure 4-26: Multi Run Vertical Fillet Weld Distortion Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur.

  • Page 69: Overcoming Distortion Effects

    BASIC WELDING TRANSMIG 250I weld is at a high temperature and hence rather soft, C. Restraint of Parts and, by expanding, pushes against the cooler, harder Forcible restraint of the components being welded is metal further away, and tends to bulge (or is "upset". often used to prevent distortion.
  • Page 70 TRANSMIG 250I BASIC WELDING Art # A-07710 Figure 4-34: Welding Sequence Art # A-07711 Figure 4-35: Step back Sequence Art # A-07428_AB Figure 4-36: Chain Intermittent Welding Art # A-07713_AB Figure 4-37: Staggered Intermittent Welding BASIC WELDING 4-14 Manual 0-5187...
  • Page 71 It has better “wetting” action than 2.5/3.2mm Blisterpack 322217 Castcraft 55. 4.0mm 2.5 kg 611734 Table 4-4: Cigweld Electrode Selection Chart Further information on CIGWELD electrodes can be found at the website www.thermadyne.com. Manual 0-5187 4-15 BASIC WELDING...

  • Page 72: Stick (Mmaw) Welding Troubleshooting

    TRANSMIG 250I BASIC WELDING 4.04 Stick (MMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE is set at a val- Reduce the ARC FORCE until welding current is varying ue that causes the welding reasonably constant while prohibiting the elec- current to vary excessively trode from sticking to the work piece when you with the arc length.
  • Page 73 BASIC WELDING TRANSMIG 250I 4 A groove has been A Welding current is too A Reduce welding current. formed in the base high. metal adjacent to B Welding arc is too long. B Reduce the length of the welding arc. the toe of a weld and has not been C Angle of the electrode is...

  • Page 74: Tig (Gtaw) Basic Welding Technique

    TRANSMIG 250I BASIC WELDING 4.05 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable) electrode and the work piece.
  • Page 75 BASIC WELDING TRANSMIG 250I Tungsten Electrode Types Electrode Type Welding Application Features Colour Code (Ground Finish) DC welding of mild Excellent arc starting, Thoriated 2% steel, stainless steel Long life, High current and copper carrying capacity High quality AC weld- Self cleaning, Long ing of aluminium, life, Maintains balled...
  • Page 76 TIG Welding is generally regarded as a specialised process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www.thermadyne.com or contact Cigweld. BASIC WELDING 4-20...

  • Page 77: Tig (Gtaw) Welding Problems

    BASIC WELDING TRANSMIG 250I 4.06 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive beard build up Welding current is too Increase weld current and/or faulty joint or poor penetration or poor preparation. fusion at edges of weld. 2 Weld bead too wide and Welding current is too Decrease weld current.
  • Page 78 9 Arc start is not smooth. A Tungsten electrode is A Select the right size electrode. Refer to too large for the weld- Table 4-7 Cigweld Electrode Selection ing current. Chart. B The wrong electrode B Select the right electrode type. Refer to...

  • Page 79: Section 5: Power Source Problems And Routine Service Requirements

    Power board indicates Over B. Ensure that air vents are not blocked/ temperature fault condition of obstructed power components C. Consult an Accredited CIGWELD Service Provider. Input Power Fault Supply OK signal from Power A. Check input power connections and cables...
  • Page 80 A. Inspect MIG wire spool and feedplate for open circuit during MIG weld improper tension or 'bird's nest'. B. Inspect MIG Torch and cable for damage or obstruction C. Consult an Accredited CIGWELD Service Provider. Weld Fault Welder detected a fault during Consult an Accredited CIGWELD Service the weld process Provider if symptom recurs frequently.

  • Page 81: Routine Service And Calibration Requirements

    There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do NOT attempt to open or repair unless you are an accredited CIGWELD Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.
  • Page 82 2. The earth terminal of the associated plug of a transportable power source Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring sup- plying CIGWELD welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below - 1.
  • Page 83 Output current (A) to be checked to ensure it falls within applicable CIGWELD power source specifications Output Voltage (V) to be checked to ensure it falls within applicable CIGWELD power source specifications Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required CIGWELD power source / wire feeder specifications...

  • Page 84: Cleaning The Welding Power Source

    Replace all exterior broken parts of power supply 6 Months Bring the unit to an authorized CIGWELD Service Provider to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions.

  • Page 85: Cleaning The Feed Rolls

    PROBLEMS/SERVICE TRANSMIG 250i 5.04 Cleaning the Feed Rolls Clean the grooves in the drive rolls frequently. This can be done by using a small wire brush. Also wipe off, or clean the grooves on the upper feed roll. After cleaning, tighten the feed roll retaining knobs.
  • Page 86 TRANSMIG 250i PROBLEMS/SERVICE Notes PROBLEMS AND ROUTINE SERVICE Manual 0-5187...

  • Page 87: Section 6: Key Spare Parts

    REPLACEMENT PARTS TRANSMIG 250i SECTION 6: KEY SPARE PARTS 6.01 TWECO FUSION 250 MIG TORCH A-10341 Figure 6-1 TWECO FUSION MIG TORCH PARTS ITEM PART NO. DESCRIPTION OTW22/50 Nozzle 13mm OTW22/62 Nozzle 16mm OTW14/23 Contact Tip 0.6mm OTW14/30 Contact Tip 0.8mm OTW14/35 Contact Tip 0.9mm OTW14/40...

  • Page 88: Transmig 250 I Power Source

    TRANSMIG 250i REPLACEMENT PARTS 6.02 TRANSMIG 250 POWER SOURCE Art # 10332 Figure 6-2 TRANSMIG 250i POWER SOURCE SPARE PARTS (LEFT SIDE) ITEM PART NUMBER DESCRIPTION W7005311 Spool Hub Assembly W7005353 Wire Drive Assembly, 250i. (Does not include motor) 375838-002 Guide, Inlet 0.6-1.6mm See Appendix 1 Roll, Pressure No Groove...

  • Page 89: Replacement Parts

    REPLACEMENT PARTS TRANSMIG 250i Art # A-10333 Figure 6-3 Right side and Front Replacement Parts TRANSMIG 250i POWER SOURCE SPARE PARTS (RIGHT SIDE AND FRONT) ITEM PART NUMBER DESCRIPTION W7005330 PCB, 250i Main Power W7005347 PCB, EMI, 250A W7003036 Socket 8 pin (Note: 8 pin Control Plug Part# is UOA706900) W7005336 PCB, Control Assy, 250i W7005304...
  • Page 90 TRANSMIG 250i REPLACEMENT PARTS Notes REPLACEMENT PARTS Manual 0-5187...

  • Page 91: Appendix 1: Options And Accessories

    APPENDIX TRANSMIG 250i APPENDIX 1: OPTIONS AND ACCESSORIES Description Part Number Tweco Professional Fusion 250 MIG Torch, 3.6 metre Euro OTWF212X3035 Tweco 4, 400A MIG torch, 3.6 metre Euro OTWX412/3545 Tig Torch 26, Flex neck, 4m lead, 3m gas hose, 8 pin connector, accessory kit (Requires Gas Control Kit, W4014600 W4014200, to use this TIG Torch)

  • Page 92: Appendix 2: Transmig 250I Circuit Diagram

    TRANSMIG 250i APPENDIX APPENDIX 2: TRANSMIG 250i CIRCUIT DIAGRAM NOTE 1 LINE BREAKER FERRITE EMI BOARD LOAD FRONT PANEL VIDENT SOL+ POT_RETURN TRIG_SOL_RTN WFSPOT2 VBIAS TRIG2 MOTOR+ MOTOR- VPOT2 AUX TRIG VPOT1 WFSPOT1 POT_RETURN VBIAS TRIG_RETURN TRIG1 FRONT PANEL CONTROL BOARD CURRENT SENSOR WELD OUTPUT + INDUCTOR...
  • Page 93 APPENDIX TRANSMIG 250i CHASSIS GND NOTE 1 BRIDGE + BRIDGE - COMMON MODE CHOKE BRIDGE / MOV BOARD GND PRI HI-POT TEMP SW HI-POT TRANSFORMER Art # A-10334 Revision Date Thermadyne World Headquarters PROTOTYPE 07/12/2011 16052 Swingley Ridge Road, Suite 300 St Louis, Missouri 63017 USA Date Printed Date Revised...
  • Page 94 TRANSMIG 250i APPENDIX Notes APPENDIX Manual 0-5187...
  • Page 95 This page intentionally blank...

  • Page 96: Cigweld Limited Warranty

    CIGWELD’s sole option, of any components or parts of the product determined by CIGWELD to be defective.

  • Page 97: Terms Of Warranty - April 2010

    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).

  • Page 98: Warranty Schedule - April 2010

    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.

  • Page 99: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Cigweld, Australia Thermadyne, China 71 Gower Street RM 102A Preston, Victoria 685 Ding Xi Rd Australia, 3072 Chang Ning District Telephone: 61-3-9474-7400 Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 61-3-9474-7391 Fax: 86-21-69171139 Email: cigweldsales@cigweld.com.au Thermadyne Asia Sdn Bhd...
  • Page 100 Asia Pacific Regional Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX: +61 3 9474 7391 Email: enquiries@thermadyne.com.au www.thermadyne.com...

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