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TRANSMIG
MULTI PROCESS WELDING
INVERTER
Service Manual
Revision: AA Issue Date: September 14, 2012 Manual No.: 0-5188
Operating Features:
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. They will help you to avoid potential hazards that may exist when
working with this product.
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received, then check for a newer version of the manual on our website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.
Published by:
Victor Technologies.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.cigweld.com
Copyright 2012 by
Victor Technologies.
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.
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....................................................................................................... 2-4
2.09 Duty Cycle............................................................................................................... 2-5
2.10 Specifications.......................................................................................................... 2-6
SECTION 3: INSTALLATION OPERATION AND SETUP...................................................... 3-1
3.01 Environment............................................................................................................ 3-1
3.02 Location................................................................................................................... 3-1
3.03 Ventilation................................................................................................................ 3-1
3.04 Mains Supply Voltage Requirements....................................................................... 3-1
3.05 Electromagnetic Compatibility................................................................................. 3-3
3.06 Power Source Controls, Indicators and Features..................................................... 3-4
3.07 Advanced Features Details..................................................................................... 3-10
3.08 Optional Wire Feeder Controls, Indicators and Features........................................ 3-15
3.09 Optional Wire Feeder Set Up MIG (GMAW) Welding with Gas Shielded MIG Wire.3-16
3.10 Optional Wire Feeder Set-up for MIG (FCAW) Welding with Gasless MIG Wire..... 3-17
3.11 Fitting of Optional Roll Cage.................................................................................. 3-18
3.12 Assembly and Fitting of Optional Welding Trolley.................................................. 3-19
3.13 Attaching the Tweco Professional MIG Torch (Euro)............................................. 3-21
3.14 Installing a Handispool (200mm diameter)........................................................... 3-22
3.15 Installing a Standard Spool (300mm diameter)..................................................... 3-23
3.16 Inserting Wire into the Feed Mechanism .............................................................. 3-24
3.17 Feed Roller Pressure Adjustment.......................................................................... 3-25
3.18 Feed Roller Alignment........................................................................................... 3-25
3.19 Changing the Feed Roll.......................................................................................... 3-26
3.20 Input And Output Wire Guide Installation.............................................................. 3-27
3.21 Wire Reel Brake..................................................................................................... 3-28
3.22 Shielding Gas Regulator Operating Instructions.................................................... 3-28
3.23 Set-up MIG (GMAW) Welding with Gas Shielded MIG Wire.................................. 3-32
3.24 Set-up for MIG (FCAW) Welding with Gasless MIG Wire....................................... 3-33
3.25 Set-up for LIFT TIG (GTAW) Welding..................................................................... 3-35
3.26 Set-up for Metal Manual Metal Arc Welding (MMAW)........................................... 3-36
SECTION 4:
BASIC WELDING GUIDE ................................................................................. 4-1
4.01 MIG (GMAW/FCAW) Basic Welding Technique........................................................ 4-1
4.02 MIG (GMAW/FCAW) Welding Troubleshooting........................................................ 4-4
4.03 Stick (MMAW) Basic Welding Technique................................................................. 4-7
4.04 Stick (MMAW) Welding Troubleshooting............................................................... 4-16
4.05 TIG (GTAW) Basic Welding Technique................................................................... 4-18
4.06 TIG (GTAW) Welding Problems............................................................................. 4-21
SECTION 5: theory of operation............................................................................... 5-1
5.01 Theory of Operation Flow Chart............................................................................... 5-1
SECTION 6: Trouble shooting................................................................................. 6-1
6.01 Power Source Problems.......................................................................................... 6-1
6.02 Tools Needed for Troubleshooting and Servicing..................................................... 6-3
6.03 Checking Unit Before Applying Power..................................................................... 6-3
6.04 Routine Service and Calibration Requirements........................................................ 6-4
6.05 Dip Switch Settings for Calibration.......................................................................... 6-7
6.06 Output Current / Amperage Calibration.................................................................... 6-8
6.07 Output Voltage Calibration..................................................................................... 6-10
6.08 Wire Speed Calibration.......................................................................................... 6-11
6.09 Case Removal........................................................................................................ 6-14
6.10 Visually Inspect..................................................................................................... 6-14
6.11 Preliminary check of the main inverter board........................................................ 6-15
6.12 PCB Pin Out Connections...................................................................................... 6-18
6:13 Waveforms............................................................................................................ 6-20
6.14 Circuit Diagram...................................................................................................... 6-24
6.15 Cleaning the Welding Power Source...................................................................... 6-25
6.16 Cleaning the Feed Rolls......................................................................................... 6-26
SECTION 7:
DISASSEMBLY PROCEDURE............................................................................ 7-1
7.01 Safety Precautions for Disassembly........................................................................ 7-1
7.02 Front Panel (Operator Interface) Circuit Board PCB Removal.................................. 7-1
7.03 Input Power Cord and Power Switch / Circuit Breaker Removal.............................. 7-3
7.04 EMI PCB Removal................................................................................................... 7-4
7.05 MOV PCB Removal.................................................................................................. 7-4
7.06 High Speed (HS) Fan Shroud Removal ................................................................... 7-5
7.07 HS and LS Fan Removal.......................................................................................... 7-6
7.08 Drive Motor Removal............................................................................................... 7-7
7.09 Main PCB Removal.................................................................................................. 7-8
SECTION 8: Replacement PARTS............................................................................. 8-1
8.01 Tweco Fusion 250 Mig Torch................................................................................... 8-1
8.02 Transmig 250i Power Source................................................................................... 8-2
! 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 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
WARNING of service.
ELECTRIC SHOCK can kill. 7. Use fully insulated electrode holders. Never dip holder
in water to cool it or lay it down on the ground or the
Touching live electrical parts can cause fatal work surface. DO NOT touch holders connected to
shocks or severe burns. The electrode and two welding machines at the same time or touch other
work circuit is electrically live whenever the people with the holder or electrode.
output is on. The input power circuit and ma-
chine internal circuits are also live when power 8. DO NOT use worn, damaged, undersized, or poorly
is ON. In semiautomatic or automatic wire spliced cables.
welding, the wire, wire reel, drive roll housing, 9. DO NOT wrap cables around your body.
and all metal parts touching the welding wire
10. Ground the workpiece to a good electrical (earth)
are electrically live. Incorrectly installed or
ground.
improperly grounded equipment is a hazard.
11. DO NOT touch electrode while in contact with the work
1. DO NOT touch live electrical parts.
(ground) circuit.
2. Wear dry, hole-free insulating gloves and body protec-
12. Use only well-maintained equipment. Repair or replace
tion.
damaged parts at once.
3. Insulate yourself from work and ground using dry
13. In confined spaces or damp locations, DO NOT use
insulating mats or covers.
a welder with AC output unless it is equipped with a
4. Disconnect input power or stop engine before install- voltage reducer. Use equipment with DC output.
ing or servicing this equipment. Lock input power
14. Wear a safety harness to prevent falling if working
disconnect switch open, or remove line fuses so power
above floor level.
cannot be turned on accidentally.
15. Keep all panels and covers securely in place.
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.
6. DO NOT weld in locations near degreasing, cleaning, or FLYING SPARKS AND HOT METAL can cause
spraying operations. The heat and rays of the arc can injury.
react with vapours to form highly toxic and irritating Chipping and grinding cause flying metal. As
gases. welds cool, they can throw off slag.
7. Do NOT weld on coated metals, such as galvanized, 1. Wear approved face shield or safety goggles. Side
lead, or cadmium plated steel, unless the coating is shields recommended.
removed from the weld area, the area is well ventilated,
and if necessary, while wearing an air-supplied respi- 2. Wear proper body protection to protect skin.
rator. The coatings and any metals containing these
elements can give off toxic fumes if welded.
WARNING
CYLINDERS can explode if damaged.
WARNING Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
WELDING can cause fire or explosion.
explode. Since gas cylinders are normally
Sparks and spatter fly off from the welding arc. part of the welding process, be sure to treat
The flying sparks and hot metal, weld spatter, them carefully.
hot workpiece, and hot equipment can cause
1. Protect compressed gas cylinders from excessive
fires and burns. Accidental contact of electrode
heat, mechanical shocks, and arcs.
or welding wire to metal objects can cause
sparks, overheating, or fire. 2. Install and secure cylinders in an upright position by
chaining them to a stationary support or equipment
1. Protect yourself and others from flying sparks and hot
cylinder rack to prevent falling or tipping.
metal.
3. Keep cylinders away from any welding or other electri-
2. Do NOT weld where flying sparks can strike flammable
cal circuits.
material.
! WARNING
This product, when used for welding or cut-
ting, produces fumes or gases which contain
chemicals know to the State of California to
cause birth defects and, in some cases, cancer.
(California Health & Safety code Sec. 25249.5
et seq.)
NOTE
Considerations About Welding And The Effects
of Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Con-
clusions Section of the U.S. Congress, Office of
Technology Assessment, Biological Effects of Power
Description of equipment: Welding Equipment (GMAW, FCAW, GTAW, MMAW) including, but not limited to CIGWELD
Transmig 250i Multi Process Welding Inverter, CIGWELD Transmig 2RT wire feeder and associated accessories.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.
The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive 73/23/EU,
as recently changed in Directive 93/68/EU and to the National legislation for the enforcement of the Directive.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among them are:
• IEC 60974-10 applicable to Industrial Equipment - generic emissions and regulations.
• AS 1674 Safety in welding and allied processes.
• AS 60974.1 / IEC 60974-1 applicable to welding equipment and associated accessories.
Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is incorporated into
the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance, ultra
safe operation and world class quality for more than 30 years and will continue to achieve excellence.
! WARNING
2.03 Receipt of Equipment
When you receive the equipment, check it against the
Gives information regarding possible personal invoice to make sure it is complete and inspect the equip-
injury. Warnings will be enclosed in a box ment for possible damage due to shipping. If there is any
such as this. 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
CAUTION inside back cover of this manual.
Refers to possible equipment damage. Cau- Include all equipment identification numbers as described
tions will be shown in bold type. above along with a full description of the parts in error.
NOTE Move the equipment to the installation site before un-
Offers helpful information concerning certain crating the unit. Use care to avoid damaging the equip-
operating procedures. Notes will be shown ment when using bars, hammers, etc., to un-crate the unit.
in italics
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.
X
Continuous Weld
Circuit Breaker Duty Cycle
Mode
Manual Metal
Amperage t1 Preflow Time
Arc Welding (MMAW)
The Transmig 250i and 2RT Wirefeeder are fully compliant Lift unit with integrated hand holds at the front and rear
to Australian Standard AS 60974.1 and IEC 60974.1. The of the unit.
Transmig 250i MIG provides excellent welding perfor- Use handcart or similar device of adequate capacity.
mance across a broad range of applications when used
with the correct welding consumables and procedures. If using a fork lift vehicle, place and secure unit on a proper
The following instructions detail how to correctly and skid before transporting.
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.
90
80
70
TIG (GTAW)
Duty Cycle (percentage)
60
Safe
50
40
Operating
Region
30
20
Stick (MMAW)
MIG (GMAW)
10
0
0 25 50 75 100 125 150 175 200 225 250
Figure 2-2: Transmig 250i Duty Cycle with Factory Fitted Supply Lead and Plug
90
80
TIG (GTAW)
70
MIG (GMAW)
Duty Cycle (percentage)
60
Safe
50
40
Operating
Region
30 Stick (MMAW)
20
10
0
0 25 50 75 100 125 150 175 200 225 250
Figure 2-3: Transmig 250i Duty Cycle with Upgraded Supply Lead and Plug
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.
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
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT
TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging
procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting
OFF and red-tagging circuit breaker or other disconnecting device.
Electrical Input Requirements
Operate the welding power source from a single-phase 50/60 Hz, AC power source. The Welding Power Source must be:
• Correctly installed, if necessary, by a qualified electrician.
• Correctly earthed (electrically) in accordance with local regulations.
• Connected to the correct size power point, fuze and primary supply lead based on Table 3-1.
• Connected with a customer-supplied grounding cable to the grounding stud on the top-rear of the power source as
required by applicable Local and National Codes or local authority having jurisdiction. Grounding stud is identified
with this symbol:
WARNING
Any electrical work must be carried out by a qualified Electrical Tradesperson.
4
Power Fault
Process
ON OFF MIG
LIFT TIG
STICK 5
Trigger
2T Normal
Advanced
Left Knob Right Knob Features
Art # A-10123_AB
7 9 10 8
11
The green power indicator will be illuminated when the
13
welder is turned ON and indicates the presence of power.
3. Fault Indicator
+ -
14 15
16 Art # A-10319 The yellow fault indicator will be illuminated when any
of the faults are detected. ALL Faults will illuminate the
Figure 3-2: Transmig Front Connections indicator
4. Weld Process Selection Button
1. VRD Indicator Press and release this button to change the selected weld
process mode from MIG to LIFT TIG to STICK. The weld
process will change to the next process in the sequence
ON OFF each time the button is pressed and released. The red
indicators next to the button will illuminate to identify MIG
A VRD (voltage reduction device) is designed to reduce or LIFT TIG or STICK process mode.
electric shock hazards present on the output of welding
power source when operating in STICK mode. Note that
the presence of VRD should not be used as a substitute
for the use of appropriate safety practices as indicated in . WARNING
section one of this manual. When the Power light is lit, the machine is
Both the green and red indicator lights only operate in connected to the Mains supply voltage and
STICK mode. the internal electrical components are at Mains
voltage potential.
The green VRD ON light illuminates (red light is OFF)
when the VRD is active. Under this condition the open
5. 2T - 4T Trigger Latch Button
circuit voltage of the unit is limited to below 35V DC, thus
reducing the potential of serious electric shock (such as
when changing electrodes).
The red VRD OFF light illuminates (green light is OFF) Press and release the button to change the selected op-
when the VRD is inactive. Under this condition the output erating mode of the trigger. The selected mode can be
voltage of the unit will be at welding potential which in either “2T” (unlatched) or “4T” (latched) operation. The
some cases may exceed 35V DC. red indicator next to the button will illuminate to identify
which mode is selected (2T or 4T). In the 4T mode once
the weld has been started you can release the trigger and
continue welding until the trigger is activated again or the
WARNING
welding arc is broken to stop the welding arc.
When the red VRD indicator is on and welding
is being performed, the presence of dangerous
voltage may be present at the electrode.
MIG Mode
This digital meter is used to display the pre-set (preview) Wirefeed Speed in Metres Per Minute (MPM) in MIG mode
and actual welding amperage of the power source when welding. At times of non-welding, the digital meter will dis-
play a pre-set (preview) value of Wirefeed Speed. This value can be adjusted by varying the Left Knob (Control No 7).
STICK and LIFT TIG Modes
The digital meter is used to display the pre-set (preview) amperage in STICK / LIFT TIG modes and actual welding
amperage of the power source when welding. At times of non-welding, the amperage meter will display a pre-set
(preview) value in both STICK and LIFT TIG modes. This value can be adjusted by varying the Left Knob (Control No 7).
When welding, this digital meter will display actual welding amperage in all modes.
At the completion of welding, the digital meter will hold the last recorded amperage value for a period of approximately
10 seconds in all modes. The amperage meter will hold the value until; (1) any of the front panel controls are adjusted
in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amper-
age will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the
unit will return to preview mode.
The display is also used for providing error messages to the user and showing other information, which will be ex-
plained in Section 5.
10. Right Digital Display
MIG Mode
This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding voltage of the power
source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Voltage. This
value can be adjusted by varying the Right Knob (Control No 8).
STICK and LIFT TIG Modes
This digital meter is used to display the Welding Output Terminal Voltage in STICK / LIFT TIG modes during non-welding
or welding. This value can not be adjusted by varying the Right Knob (Control No 8).
When welding, this digital meter will display actual welding voltage in all modes.
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.
Solenoid
D Trigger
Valve
- 3
F E
G
G
J D
C
E 1
H
I
1
B
2 2
A
F
H 3 3
Wirespeed Voltage
Potentiometer Potentiometer
A
+
C M Motor
24V
Art # A-10320
B -
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the
bayonet terminal.
CAUTION
Loose welding terminal connections can cause
overheating and result in the male plug being
fused in the bayonet terminal. The Advanced Features menu items are viewed by turning
16. MIG Torch Polarity Lead the left knob (Control No 7) to move forward or backward
through the list. The function names in the menu will be
The polarity lead is used to connect the MIG Torch to displayed in abbreviated form in the left alpha-numeric
the appropriate positive or negative output terminal display. In the case of two part names or abbreviations,
(allowing polarity reversal for different welding ap- the left display will alternately flash the first part of the
plications). In general, the polarity lead should be function name and then the second part, followed by a
connected in to the positive welding terminal (+) when brief “blank” interval. For each function, the right alpha-
using steel, stainless steel or aluminium electrode numeric display will show its present value.
wire. When using gasless wire, the polarity lead is
generally connected to the negative welding termi-
nal (-). If in doubt, consult the manufacturer of the
electrode wire for the correct polarity. It is essential, Right Knob
If the welder is in Advanced Features mode and the Weld Process Selection button (Control No 4) is pressed, the
welder will exit Advanced Features mode, saving any change made, and change to the next weld process function in
the sequence: MIG, TIG, stick. If you wish to view the Advanced Features for the next process you will need to enter
the Advanced Features function again.
Right Knob
Arc Control
Push For Inductance
If the welder is in Advanced Features mode and the right knob (Control No 8) is pressed for one (1) second (to enter
Arc Control Function) the welder will exit Advanced Features mode, saving any change made, and enter the Arc Control
Function for the currently selected weld process.
MIG (GMAW/FCAW)Mode Advanced Features Menu Map
Left Display Right Display
* SPOT TIME and STCH TIME are only active when SPOT or STCH are “ON”.
Note “SPOT” and “STCH” are MUTUALLY EXCLUSIVE functions. If the user enables either function and the system
detects that the OTHER function is already ON, the system will automatically turn the OTHER conflicting function OFF.
Left Display: Where (2) items shown, e.g. RUN- / IN, the display will alternate (flash) between the (2) items
Left Display: Where (2) items shown, e.g. RUN- / IN, the display will alternate (flash) between the (2) items
"Right Display
Function Left Display (Factory De- Limits Comments
fault Values)"
LOCL = Local control of the Amps with the
TIG Operator machines controls
TIG/CNTL LOCL LOCL - REMT
Controls REMT = Remote control of the Amps with an
accessory device
Pre Flow (TIG Shielding gas flows for the time specified before
PRE-/FLOW 0.1 S 0.0 – 5 S
Setting) an arc is initiated
Post Flow (TIG Shielding gas flows for the time specified after
POST/FLOW 10.0 S 0.0 – 30 S
Setting) an arc has extinguished
Left Display: Where (2) items shown, e.g. HOT- / STRT, the display will alternate (flash) between the (2) items
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
Wirespeed Volts
Art # A-10324
Gas Hose
Control Cable
Art # 10335
+ -
Work Lead
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 Welding Power Cable may need to be switched. Follow
the wire manufacturers recommendation.
NOTE
Spool hub and feed plate set up and operation are the same as the 250i which can be reviewed later in this
section starting at 3.14.
Control Cable
Art # 10350_AB
+ -
Work Lead
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 Welding Power Cable may need to be switched. Follow
the wire manufacturers recommendation.
NOTE
Spool hub and feed plate set up and operation are the same as the 250i which can be reviewed later in this
section starting at 3.14.
Rear
Rear
2nd
1st
3 Nuts
Front
5. First, use the 3 nuts (included) and secure the power source to the roll cage. Second, attach the front roll bar
and secure all hardware now. When you are done it should look like the first part of Figure 3-13.
6. Attach the Cross Bar to the front and rear roll bars with hardware shown and the bracket with the screw from
the top of the welder cover removed earlier. See Figure 3-13.
Art # A-10325
Chain
3 screws
provided
3 screws provided
to secure 250i
Art # A-10326
2. Mount the 250i power source to the bottom tray aligning the 3 holes in the bottom of the power source with
the 3 holes in the base. Secure with the 3 screws provided.
! WARNING
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
Art # A-10407
Art # A-10338
2. If equipped, align the keyways of the MIG Torch Switch connector pigtail with the 8 pin receptacle to the right
of the MIG Torch cable and plug them together. Secure by turning the locking ring to the right (clockwise ).
Refer to Figure 3-17.
NOTE
When disconnecting the MIG Torch trigger switch leads from the machine, DO NOT pull on the wires.
Loosen the locking ring and gently pull the plug out of the socket.
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.
Fibre Washer
Retaining Clip
200mm Use inner holes on Pin
Wire Spool Spool Hub
Flat Washer
Wire Spool Large Hole
Hub Nut
Spool Hub
Flat Washer Keyed Washer
Small Hole Spring A-10340
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.
Spool Hub
Retaining Clip
Fibre Washer
Use outer holes
300mm Pin
Wire Spool
Flat Washer
Wire Spool Large Hole
Hub Nut
WARNING
ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power source before
proceeding. DO NOT reattach the input power until told to do so in these instructions.
1. Loosen the Spring Pressure Adjusting Knob if needed and swing it down (First part of Figure. 3-20)
2. Move the Pressure (top) Roller Arm by swinging it to the right. (Second part of Figure. 3-20)
3. Make sure the end of the wire is free of any burrs and is straight. Pass the end of wire through the Inlet Wire
Guide and over the Feedroll. Make certain the proper groove is being used. (Second part of Figure. 3-20)
4. Pass the MIG wire over the drive roll groove, through the outlet guide and out past the MIG Torch Adaptor.
Then fit the MIG Torch as per Section 3.13 ensuring the MIG wire passes into the MIG Torch liner of the MIG
Torch.)
5. Close the Pressure Roller Arm. (Figure. 3-21)
6. Swing the Spring Pressure Adjusting Knob back into place. (Figure. 3-21)
7. Use the Spring Pressure Adjusting Knob to create a “snug” condition. (Clockwise to tighten and Counter
Clockwise to loosen). (Figure. 3-21)
8. Figure 3-23 shows the result with wire installed. Continue to the next section for proper setting of tension.
1 2
3 4
Art # A-10030
5 7
Art # A-10031
2
Art # A-10415
Figure 3-22: 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.
.045 .045
1.2 1.2
NOTE
All grooved feed rolls have their wire size or range stamped on the side of the roll. On rolls with different
size grooves, the outer (visible when installed) stamped wire size indicates the groove in use.
Refer to feed roll kit in the Appendix for the proper selection and ordering of feed roll kits. Kit includes drive rolls, an
input wire guide and an output wire guide for a specific wire type and size.
Feed rolls are removed by twisting the feed roll retainer cap and aligning the retaining knob splines/tabs with the drive
gear splines. Feedrolls are installed by putting the feedroll onto the drive gear splines and twisting the feedroll retainer
cap so that the splines/tabs rest against the face of the feedroll where they will click into place.
NOTE
Installation of all styles of feed rolls for the Transmig 250i are identical.
WARNING
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.
MIG Torch
Adapter Lock
Bolt
Art # A-10346_AB
Pressure Adjustment
Knob
Art # A-10032
CAUTION
Excessive tension on the brake will cause rapid wear of mechanical wire feed parts, over heating of electrical
componentry and possibly an increased incidence of wire Burnback into the contact tip.
NOTE
Correct adjustment will result in the wire reel circumference continuing no further than 20mm after release
of the MIG Torch trigger switch. The wire should be slack without becoming dislodged from the reel.
! WARNING
This equipment is designed for use with welding grade (Inert) shielding gases only.
NOTE
Shielding Gas Regulator not included in the Transmig 250i (Asia Version) Plant Part No W1003250M.
NOTE
Shielding Gas is not required if the unit is used with self shielded FCAW (flux cored arc welding) wires
This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in accordance
with the instructions provided. Equipment must be checked periodically and repaired, replaced, or reset as necessary
for continued safe and reliable performance. Defective equipment should not be used. Parts that are broken, missing,
obviously worn, distorted, or contaminated should be replaced immediately.
The user of this equipment will generally have the sole responsibility for any malfunction, which results from improper
use, faulty maintenance, or by repair by anyone other than an accredited repairer.
CAUTION
Match regulator to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to a
cylinder containing any other gas.
LOW PRESSURE
GAUGE (DELIVERY) HIGH PRESSURE
GAUGE (SUPPLY)
OUTLET
PRESSURE
CONNECTION
ADJUSTING
SCREW
INLET
CONNECTION
Art # A-10108
1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices and
damage seats before connecting the regulator.
Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition.
Wipe with a clean lint free cloth.
2. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking agree and
that the regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed for a particular gas
or gases to a cylinder containing any other gas.
3. Connect the regulator inlet connection to cylinder or pipeline and tighten it firmly but not excessively, with a
suitable spanner.
4. Attach supplied gas line between the regulator output and the desired input at the rear of the power source.
MIG Spool Torch and TIG in the bottom fitting and regular MIG Torch in the top fitting.
Art # A-10239
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 recom-
mended that testing for leaks at the regulator connection points be carried out using a suitable leak detection
solution or soapy water.
Art: A-05088_AB
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 down-
stream valve. Bleed welding grade shielding gas into a well ventilated area and away from any ignition source.
Turn adjusting screw counterclockwise, until the required flow rate is indicated on the gauge. Close downstream
valve.
3. Adjust regulator pressure adjusting screw to the required flow rate, indicated on gauge dial. (Refer to Figure
3-28)
The gas flow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas flow rates may
cause turbulence and weld porosity.
Argon or argon based gas flow rates:
- Workshop welding: 10-15 LPM
- Outdoor welding: 15-20 LPM
Shutdown
Close cylinder valve whenever the regulator is not in use. To shut down for extended periods (more than 30 minutes).
1. Close cylinder or upstream valve tightly.
2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from any
ignition source.
3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.
4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove regulators.
+ - Negative Output
Terminal
(Dinse® type 50mm)
Art # A-10282
1. Turn the Main ON/OFF switch OFF (located on the rear panel).
2. Check that the MIG wire size, contact tip, MIG Torch liner and drive roll groove are all the same size before
fitting the MIG wire into the Power Source.
3. Connect the MIG Torch Polarity Lead to the positive welding terminal (+). If in doubt, consult the MIG electrode
wire manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is
essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
4. Fit the MIG wire spool and MIG Torch to the Power Source. (Refer to section 3.14 to 3.21 ).
5. Connect the work lead to the negative welding terminal (-). If in doubt, consult the MIG electrode wire manu-
facturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential,
however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
6. Fit the welding grade shielding gas regulator/flow gauge to the shielding gas cylinder (refer to Section 3.22)
then connect the shielding gas hose from the rear of the power source to the regulator/flow gauge outlet.
7. Turn the Main ON/OFF switch ON (located on the rear panel).
8. Select MIG mode with the process selection control. (Refer to Section 3.06.4 for further information)
9. Remove the MIG Torch nozzle and contact tip.
10. Depress MIG Torch trigger to feed the MIG wire out through the MIG Torch gas diffuser then fit the contact
tip on the MIG wire and securely fasten it to the MIG Torch then Fit the nozzle in place.
WARNING
Before connecting the work clamp to the work make sure the mains power supply is switched OFF.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary
support to prevent falling or tipping.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the
terminal.
Remove any packaging material prior to use. DO NOT block the air vents at the front or rear of the Welding
Power Source.
NOTE
Depending on the type of wire you will be using the MIG Torch polarity may need to be switched. Follow
the wire manufacturers recommendation.
3.24 Set-up for MIG (FCAW) Welding with Gasless MIG Wire
The Transmig 250i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Torch. The Fusion MIG Torch is designed
with an ergonomic handle and fewer parts to cause performance problems. The Fusion MIG Torch uses standard
readily available Tweco consumable parts.
When using a gasless flux cored wire, you do not need to have an external gas source attached to the unit. If one is,
then make sure it is turned OFF.
For most Self Shielded Flux Cored Wire, connect the Work Lead to the positive + terminal and connect the MIG Torch
polarity lead to the negative - terminal.
+ - Positive Output
Terminal
(Dinse® type 50mm)
Art # A-10283
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.
! WARNING
Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
NOTE
The following steps will assume that you have already set up the proper shielding gas as outlined in Sub
Section 3.22.
NOTE
The following set up is known as Straight Polarity or DC Electrode Negative. This is commonly used for
DC TIG welding on most materials such as steel and stainless steel.
1. Switch the ON/OFF Switch (located on the rear panel) to OFF.
2. Connect the work lead cable to the positive output terminal, and the TIG Torch cable to the negative output
terminal. Refer to Figure 3-32.
3. Connect the gas line/hose to the proper shielding gas source. Refer to Figure 3-32.
4. Be sure the gas valve on the TIG Torch is closed, and slowly open the Argon Cylinder Valve to the fully open
position.
5. Connect the work lead clamp to your work piece.
6. The tungsten must be ground to a blunt point (similar to a pencil) in order to achieve optimum welding results.
See illustration. It is critical to grind the tungsten electrode in the direction the grinding wheel is turning. Grind
at a 30 degree angle and never to a sharp point.
2 to 2-1/2 Times
Electrode Diameter
Electrode
Art # A-00503_AB
Art # A-10284
! WARNING
Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
NOTE
The following set up is known as DC Electrode Positive or reverse polarity. Please consult with the stick
electrode manufacturer for specific polarity recommendations.
Art # A-10285
+ -
Negative Output
Terminal
(Dinse® type 50mm)
the very basic concepts in using the Mig mode of weld- Figure 4-2
ing, where a MIG Torch is hand held, and the electrode
(welding wire) is fed into a weld puddle, and the arc is Position of MIG Torch
shielded by an inert welding grade shielding gas or inert
welding grade shielding gas mixture. The angle of MIG Torch to the weld has an effect on the
width of the weld.
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.
Push Vertical Drag/Pull
Shielding is obtained from an externally supplied welding
grade shielding gas or welding grade shielding gas mix-
Art # A-07185_AB
ture. The process is normally applied semi automatically;
however the process may be operated automatically and Figure 4-3
can be machine operated. The process can be used to
weld thin and fairly thick steels, and some non-ferrous The MIG Torch should be held at an angle to the weld joint.
metals in all positions. (See Secondary Adjustment Variables below)
Shielding Gas Hold the MIG Torch so that the welding seam is viewed
Nozzle
Molten Weld Metal Electrode
at all times. Always wear the welding helmet with proper
Arc filter lenses and use the proper safety equipment.
Solidified
Weld Metal Base Metal
CAUTION
GMAW Process Art # A-8991_AB
Art # A-08998_AB
If the Wirespeed is too high for the welding voltage,
Transverse and Longitudinal “stubbing” will occur as the wire dips into the molten
Nozzle Axes
pool and does not melt. Welding in these conditions
Figure 4-9 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 cor-
Direction of Gun Travel rect 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.
Leading or “Pushing”
90° Trailing or “Pulling”
Angle Angle
(Forward Pointing) (Backward Pointing)
Figure 4-10
FAULT CAUSE
1 Shielding gas cylinder contents Ensure that the shielding gas cylinder is not empty and the
and flow meter. flow meter is correctly adjusted to 15 liters per minute.
2 Gas leaks. Check for gas leaks between the regulator/cylinder connec-
tion and in the gas hose to the Power Source.
3 Internal gas hose in the Power Ensure the hose from the solenoid valve to the MIG Torch
Source. adaptor has not fractured and that it is connected to the MIG
Torch adaptor.
4 Welding in a windy environment. Shield the weld area from the wind or increase the gas flow.
5 Welding dirty, oily, painted, Clean contaminates off the work piece.
oxidized or greasy plate.
6 Distance between the MIG Torch Keep the distance between the MIG Torch nozzle and the work
nozzle and the work piece. piece to a minimum.
7 Maintain the MIG Torch in good A Ensure that the gas holes are not blocked and gas is exiting
working order. 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
! 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.
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.
B Replace feed roller if worn.
4 Wire rubbed against the misaligned Misalignment of inlet/outlet guides
guides and reduced wire feed ability.
5 Liner blocked with swarf A Increased amounts of swarf are produced by the wire
passing through the feed roller when excessive pres-
sure 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.
6 Incorrect or worn contact tip A The contact tip transfers the weld current to the elec-
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
B. Austenitic manganese steels Figure 4-12: Flat Position, Gravity Fillet Weld
The effect on manganese steel of slow cooling from
high temperatures is to embrittle it. For this reason it
is absolutely essential to keep manganese steel cool
during welding by quenching after each weld or skip
welding to distribute the heat. Suitable Electrode types
are Cobalarc Austex or Cobalarc Mangcraft. Art # A-07689
Art A-07691
Art # A-07692
Art# A-07693
Art # A-07694
1.6mm
Not less than
Single Vee Butt Joint 45° Double Vee Butt Joint Not less than
70°
1.6mm max
Tee Joints
Fillet Joint (Fillet both sides of the
joint)
Art # A-10347
Contraction
with tension
Art # A-07707
B. Distribution of Stresses
Distortion may be reduced by selecting a welding
sequence which will distribute the stresses suitably
so that they tend to cancel each other out. See Fig-
ures 4-30 through 4-33 for various weld sequences.
Choice of a suitable weld sequence is probably the
most effective method of overcoming distortion,
although an unsuitable sequence may exaggerate it.
Simultaneous welding of both sides of a joint by two
welders is often successful in eliminating distortion.
Figure 4-33: Examples of Distortion
Art # A-07710_AB
Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
Figure 4-34: Welding Sequence
1
2
3
4
Art # A-07711_AB
Art # A-07428_AB
Art # A-07713_AB
2.0mm 1 kg WEG1020
2.0mm 2.5 kg WEG2520
2.5mm 1 kg WEG1025
2.5mm 2.5 kg WEG2525
User-friendly GP electrode for welding thin section mild and galvanised
WeldSkill GP 2.5mm 5 kg WEG5025
steels. Excellent for vertical down fillet welding applications.
3.2mm 1 kg WEG1032
3.2mm 2.5 kg WEG2532
3.2mm 5 kg WEG5032
4.0mm 5 kg WEG5040
2.5mm 2.5 kg 612752
2.5mm 5 kg 611752
Ferrocraft 16 Hydrogen Controlled type offering exceptional AC/DC performance in
3.2mm 2.5 kg 612753
Twincoat all welding positions.
3.2mm 5 kg 611753
4.0mm 5 kg 611754
2.5mm 2.5 kg 611602
Satincrome Stainless Steel type for 19Cr/10Ni stainless grades including 201,
3.2mm 2.5 kg 611603
308L-17 202, 301, 302, 303, 304, 304L, 305, 308, etc
4.0mm 2.5 kg 611604
2.5mm 2.5 kg 611692
Satincrome Stainless Steel type for 309 and 309L grades. It is also suitable for
3.2mm 2.5 kg 611693
309Mo-17 welding of dissimilar welding of other 300 series stainless steels.
4.0mm 2.5 kg 611694
2.0mm 2,5 kg 611661
2.5mm 2.5 kg 611662
Satincrome Stainless Steel type for welding of matching Mo bearing grades, 316
3.2mm 2.5 kg 611663
316L-17 and 316L.
2.5/3.2mm Blisterpack 322215
4.0mm 2.5 kg 611664
3.2mm 2.5 kg 611723 For repair and maintenance welding of S.G. cast iron, meehanite and
Castcraft 55
4.0mm 2.5 kg 611724 other cast irons. It produces high strength weld than Castcraft 100.
Incorrect sequence
Insufficient
gap
Art # A-04273
Table 4-5a:
A-09658_AB
Gas Cup
Either Ceramic,
Work Piece High-lmpact or
Can Be Any Commercial Water Cooled
Metal Metal
Tungsten Electrode
Non-Consumable
Welds Made With or Without
Inert Gas
Addition of Filler Metal
Shields Electrode
and Weld Puddle
Table 4-8
NOTE
The Transmig 250i Inverter is not suited for AC Tig welding.
TIG Welding Filler Rods
Comweld Aust Std AWS Std Part No. Part No. Part No. Type/Application
Rod 1.6mm 2.4mm 3.2mm
LW1 R4 ER70S-4 321411 — — For mild-medium strength steels.
LW1-6 R6 ER70S-6 321417 — — Pipes, tubing, roll cages, etc.
Supersteel R2 ER70S-2 321370 — —
CrMo1 RB2 ER80S-B2 — 321379 — For welding of high strength Cr-Mo
CrMo2 RB3 ER90S-B3 — 321383 — steels used at elevated tempera-
tures.
308L R308L ER308L 321406 321407 — For stainless steels. Stainless pipes,
309L R309L ER309L 321403 321404 — tubing, architectural uses, etc.
316L R316L ER316L 321400 321401 —
Table 4-9
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.
4 Weld bead too wide or Travel speed too slow Increase travel speed.
excessive bead build up or
excessive penetration in
butt joint.
5 Uneven leg length in fillet Wrong placement of Re-position filler rod.
joint filler rod
6 Electrode melts or oxidizes A TIG Torch lead connect- A Connect TIG Torch lead to negative weld-
when an arc is struck. ed to positive welding ing terminal.
terminal.
B No gas flowing to weld- B Check the gas lines for kinks or breaks
ing region. and gas cylinder contents.
10 Arc flutters during TIG Tungsten electrode is Select the right size electrode. Refer to
welding. too large for the weld- Table 4-7 Cigweld Electrode Selection
ing current. Chart.
Traveler
PFC Heat
Inv Ribbon PWM
sinks
Cable Spool Gun
Interface
M Drive
Bias (PWM) CPU Push/Pull Gun
5.01 Theory of Operation Flow Chart
D
C
5-1
Feed Low Cost Mig
Acces. 10 Pin Connector
Fans plate Motor
Pendant
Mechanical Tig Gun
Welding Output Cooling
SECTION 5: THEORY OF OPERATION
Art # A-09849
Turn SW1 to OFF position, and disconnect unit from primary line voltage before working on unit.
Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are off
before removing case.
Before troubleshooting or applying power to unit, complete the following checks to avoid causing further
damage.
Pre-Power Check List
The following are resistance measurements on the Transmig 250i power board while it is in an unpowered state.
The first location is the placement of the positive terminal of a Digital Multimeter (DMM); the second location is
for the negative terminal of the DMM and follows the word “to” in each line.
• DC+ to GND PRI = Ramps slowly from 23.3 to 42K
• DC+ to lower (left) leg of R20 = 33 ohm
• DC+ to Large Upper heat sink = 22.42K
• DC+ to Transformer Primary Connections = 423K
• GND PRI to Transformer Primary Connections = 225K
• Transformer Primary Connections to Large Upper heat sink = 225K
• Transformer Sec-Sec = < 5 Ohm
• Transformer Sec to IND Out = 168K
• P14-1 to P14-5: This is the primary referenced Bias supply and should read 15VDC +/- 0.5V shortly after
power is applied.
• P10-1 to P10-5: The first secondary referenced Bias supply should read 24VDC +/- 1.0V
• P10-4 to P10-5: Bias supply, -15VDC +/- 0.5V
• P10-6 to P10-5: Bias supply, 15VDC +/-0.25VDC
! WARNING
There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do
not attempt to open or repair unless you are an accredited CIGWELD Service Provider. Disconnect the
Welding Power Source from the Mains Supply Voltage before disassembling.
Routine Inspection, Testing & Maintenance
The inspection and testing of the power source and associated accessories shall be carried out in accordance with
Section 5 of AS 1674.2 - 2007: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insula-
tion resistance test and an earthing test to ensure the integrity of the unit is compliant with Cigweld's original
specifications.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in
AS 1674.2 - 2007, then the above tests should be carried out prior to entering this location.
A. Testing Schedule
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, includ-
ing the date of the most recent inspection.
A transportable power source is deemed to be any equipment that is not permanently connected and fixed in
the position in which it is operated.
C. Earthing/Grounding
The resistance shall not exceed 1Ω between any metal of a power source where such metal is required to be
earthed, and -
1. The earth terminal of a fixed power source; or
2. The earth terminal of the associated plug of a transportable power source
Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring
supplying Cigweld welding power sources should be inspected by a licensed electrical worker in accordance
with the requirements below -
1. For outlets/wiring and associated accessories supplying transportable equipment - at least once every
3 months; and
2. For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12 months.
D. Voltage Reduction Device (VRD)
Units fitted with VRD's, shall have the periodic tests outlined in Table 6-3 below conducted by an accredited
CIGWELD service provider. Testing shall be conducted at intervals as outlined below -
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
Description Required Parameters
VRD Open Circuit Voltage Less than 35V; at nominal input voltage
VRD Turn ON Resistance Less than 200 ohms
VRD Turn OFF Time Less than 0.3 seconds
Table 6-3: VRD Periodic Tests
WARNING
Only qualified personnel should attempt to conduct calibration procedures.
DO NOT TOUCH the electrode wire while it is being fed through the system. The electrode wire can be
at welding voltage potential.
1. Disconnect the input power to the welding power supply.
3. Remove (4) front panel screws. 4. Apply power to the 250i Note that ERR 30 is
displayed at power up.
5. Enter Advanced Features Mode by pressing &
releasing Advanced Features Button.
Art # A-10406
Figure 6-4: Screw Location
4. Locate the SERVICE Dip switch on the back of 6. Using the left knob, scroll through the menu list
the control board and set the number "1" dip to find and select “AMP CAL PROC”.
switch to the "ON" position.
ON Left Knob
.
7. Press and release the left knob to enter the
1 2
amperage calibration procedure.
12. Turn the left knob clockwise until the left display
shows “AMP CAL” and the right display shows
the word “SAVE”.
Art # A-10406
Left Knob
12. Turn the left knob clockwise until the left display
shows “VOLT CAL” and the right display shows
the word “SAVE”.
6. Using the left knob, scroll through the menu list
to find and select “VOLT CAL PROC”.
Left Knob
Left Knob
Left Knob
Left Knob
Left Knob
Art # A-10406
WARNING NOTE
DO NOT TOUCH the electrode wire while it is The power supply requires two values to
being fed through the system. The electrode properly calibrate wire feed speed. A low
wire will be at welding voltage potential. feed speed value and a high feed speed
value. Default speeds span the most typical
Required Equipment/Tools:
jobs. You may choose alternates that better
• Appropriate personal protective gear: gloves, represent your work. The closer an upper or
safety glasses, etc. lower speed is to an actual procedure, the
better the accuracy.
• Tape measure
• Spool of desired filler metal
• MIG Gun
• T15 (Torx) driver
Manual 0-5188 6-11 TROUBLE SHOOTING
Left Knob
5. Turn the left knob clockwise until the left display
shows “PULL / TRIG” and the right display
shows “LOWR”.
10. Using the right knob, adjust the wire feed speed
Left Knob
value in the right display to the desired upper
wire feed calibration speed (in units per minute)
Right Knob
Arc Control
WARNING Push For Inductance
WARNING
Right Knob
Ensure that both Dinse polarity connections
have been removed from the front of the unit
Arc Control
Push For Inductance
or live filler metal wire will be present during
this part of the procedure.
Right Knob
Arc Control
Push For Inductance
15. Turn the left knob clockwise until the left display Art # A-10406
shows “WFS / CAL”. The right display will show Figure 6-8: Screw Location
the word “SAVE”.
20. Locate the SERVICE Dip switch on the back of
the control board and set the number "1" dip
switch to the "OFF" position.
Left Knob
21. Reinstall the control panel with all (4) screws.
22. Re-connect the input power to the welding
power supply. Calibration is complete.
16. Press and release the left knob to save the new
calibration settings. If the calibration data passes
the internal data checks, the calibration data will
be saved.
Left Knob
! WARNING
Any electrical work must be carried out by a qualified Electrical Tradesperson.
Case Removal
Art # A-10568
1 Remove the seven top screws including the front & rear mouldings.
2 Remove the three bottom screws securing the cover panel.
3 Slightly spread the front & rear mouldings while lifting the cover.
! WARNING
Any electrical work must be carried out by a qualified Electrical Tradesperson.
Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning or
arcing of PCB, transformers, switches, or rectifier when a failure occurs. Carefully inspect all components within
these units.
Look in particular for the following:
a) With the unit truned on check the 4 LED lights near the top center of the Main PCB. They should all be
illuminated.
b) Loose or broken wires or connectors.
c) Burned or scorched parts or wires or evidence of arcing.
d) Any accumulation of metal dust or filings that may have caused shorting or arcing.
If any parts are damaged, they must be replaced. Refer to the Spare Parts section for a complete list of components
used in the Power Source.
Locate the faulty component(s) then replace where necessary.
Warning
Dangerous voltages are present during testing. Only qualified personnel should attempt to test or
troubleshoot this system.
1. First with power applied, check the 4 LED lights in the upper center of the Main PCB. If the board is OK,
they will all be illuminated. See red dots if viewing on line.
Figure 6-10:
Manual 0-5188 6-15 TROUBLE SHOOTING
Pin Signal
1 3.3 V
2 TxD
3 RxD
4 Ground
5 Program
Figure 6-12
Current and voltage for typical GMAW start in short-circuit transfer mode
Figure 6-13
Figure 6-14
Current and voltage waveforms for PWM controlled GMAW wire feed motor
Figure 6-15
Figure 6-16
Figure 6-17
Figure 6-18
Figure 6-19
Art # A11457
Art # A11457
Figure 6-20
Warning!
Disconnect input power before maintaining.
Maintain more often if used under severe conditions
Each Use
Weekly
3 Months
6 Months
Art # A-10240
Figure 6-21
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.
! Read and follow safety information in Section 6.03 before proceeding. Follow anti static precautions
when handling any PCB (Printed Circuit Board).
Unplug unit before beginning disassembly procedure.
Read and follow safety information in Section 6.03 before proceeding with dis-
assembly. Follow anti static precautions when handling any PCB (Printed Circuit Board).
Unplug the unit before beginning disassembly procedure.
1. Remove four (4) Control Panel screws (#1).
#1
Art # A-1
Art # A-10???
3. Flip the panel assembly over and remove the two knobs. Remove the nuts on the knob shafts. Flip the panel
over again and gently spread the three (3) tabs shown below to lift the PCB from the panel surface.
Art # A-10???
Figure 7-3:
Read and follow safety information in Section 6.03 before proceeding with disassembly
Unplug the unit before beginning disassembly procedure.
1. Disconnect the Input Power Cord ground wire from the Center Chassis (#1).
2. Remove the two (2) screws from the bracket holding the Power Switch/Circuit Breaker in place located on the
rear panel (#2).
#2
#1
Figure 7-4: Power Cord Ground Wire and Switch Bracket Screw Removal
3. Loosen and remove the four wires form the Switch/Circuit Breaker noting color and location.
4. Remove the two (2) screws and the strain relief holding the Input Power Cord to the rear panel (#4).
#4
Read and follow safety information in Section 6.03 before proceeding with disas-
sembly. Follow anti static precautions when handling any PCB (Printed Circuit Board).
Unplug the unit before beginning disassembly procedure.
1. Label then remove the four (4) wires that are connected to the EMI board (#1).
2. Remove the four (4) scews holding the EMI board in place (#2).
#2
#1
Read and follow safety information in Section 6.03 before proceeding with disas-
sembly. Follow anti static precautions when handling any PCB (Printed Circuit Board).
Unplug the unit before beginning disassembly procedure.
1. Remove the two (2) mounting screws shown below (#1).
#1
Read and follow safety information in Section 6.03 before proceeding with disas-
sembly.
Unplug the unit before beginning disassembly procedure.
Disconnect and bleed off any pressure from the Shielding Gas line.
1. Disconnect the Shielding Gas solenoid valve from the HS Fan shroud (#1). You will need to cut the clamp to
the right of the valve. Remove the hose and then the nut holding the valve in place. You will also need a new
clamp when reassembling.
2. Remove two the two (2) screws holding the MOV board in place. Be careful not to touch or allow anything to
touch, smear or scratch the thinly spread compound on the components on the back of the PCB (#2).
3. Remove the four (4) screws that mount the Fan Shroud to the Main PCB (#3) and remove the fan shroud.
#1 #2
#3
Read and follow safety information in Section 6.03 before proceeding with disassembly
Unplug the unit before beginning disassembly procedure.
1. Remove the four (4) screws on the rear panel that hold the two fans in place (#1).
2. Remove the two (2)bottom screws holding the Rear Panel to the Power Supply (#2).
#1
#2
3. Note the location of the fan wires and disconnect them from the PCB.
4. Push the Rear Panel out enough to remove the fans.
Read and follow safety information in Section 6.03 before proceeding with disassembly
Unplug the unit before beginning Disassembly procedure.
1. Use caution and cut the wire tie holding the red and black motor wires to other harnesses (#1).
2. Disconnect the Red and Black motor wires from the blue wires where shown (#2).
#1
#2
#5
#4
Read and follow safety information in Section 6.03 before proceeding with dis-
assembly. Follow anti static precautions when handling any PCB (Printed Circuit Board).
Unplug the unit before beginning disassembly procedure.
Disconnect and blead off any Shielding Gas pressure from the system before starting this procedure.
1. Disconnect the Shielding Gas solenoid valve from the HS Fan shroud (#1). You will need to cut the clamp to
the right of the valve, remove the hose and then the nut holding the valve in place. You will also need a new
clamp when reassembling.
2. Remove Input Power Switch/Circuit Breaker. See subsection "7.03 Input Power Cord and Power Switch / Circuit
Breaker Removal" for instructions on this. This is to get access to mounting screw in upper right corner of
the Main PCB.
3. Remove the two (2) bottom screws holding the rear panel to the power supply. Pull the rear panel back enough
to gain better access to the Main PCB.
4. Label and note all wires attached to the Main PCB and remove them. This will include wires from the MOV PCB
that go to the EMI PCB and one to the Ground stud with the input power cable ground wire.
5. Remove the seven (7) screws that mount the Main PCB to the center chassis(#5) . Four (4) of the screws hold
the HS Fan shroud to the Main PCB.
#5
1 2 3 4 5 A-10341
7
6
Figure 8-1
7
3 6
4
Art # 10332
Figure 8-2
19
18
4 3 17
16 15
8 9
14
7
12
10 11
13
Figure 8-3: Right Side and Front Replacement Parts
TRANSMIG 250i POWER SOURCE SPARE PARTS (RIGHT SIDE AND FRONT)
ITEM PART NUMBER DESCRIPTION
1 W7005330 PCB, 250i Main Power
2 W7005347 PCB, EMI, 250A
3 W7003036 Socket 8 pin (Note: 8 pin Control Plug Part# is UOA706900)
? W7005336 PCB, Control Assy, 250i
6 W7005335 Control Knob
7 W7005308 Polarity Cable
8 W7005304 Dinse, Socket Panel, 50mm
9 W7005357 Socket 10 pin (Note: 10 pin Control Plug Part# is W7005358)
10 W7005354 Motor, Wire Drive, RH, 20VDC
11 W7005322 Shroud
12 W7005351 Inductor
13 W7005315 Solenoid,24V,0-0.8MPa
14 W7005302 Transformer, Main, 250i
15 W7005331 PCB, Mov/Bridge, 250A
16 W7005317 Fan, 92x25 LS 24V
17 W7005316 Fan, 92x38 HS 24V
18 W7005355 Inlet, Gas, QC, Male
19 W7005318 Power switch/breaker
Table 8-3
Manual 0-5188 8-3 REPLACEMENT PARTS
FLUX FLUX
HARD CORED SOFT
CORED
(0.6 to 1.0) (0.8,0.9,1.0) (1.2, 1.6) (0.9, 1.0, 1.2)
Top
Drive
Roll
Bottom
Drive
Art # A-10349
Roll
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
Art # A11458
Art # A11458
Notes
This Warranty Statement should be read in conjunction with the Warranty Schedule contained in the operating instructions of the
product. This schedule contains the warranty period applicable to the product
This warranty is provided in addition to other rights and remedies you have under law: Our goods come with guarantees which
cannot be excluded under the Australian Consumer Law. You are entitled to replacement or refund for a major failure and to
compensation for other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if
the goods fail to be of acceptable quality and the failure does not amount to a major failure.
Any claim under this warranty must be made within the warranty period which commences on the date of purchase of the product.
To make a claim under the warranty, take the product (with proof of purchase from a Cigweld Accredited Seller) to the store where
you purchased the product, or contact Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider.
All costs associated with lodging the warranty claim including the return of goods to Cigweld or our Nominated Accredited Distributor/
Accredited Service Provider is the responsibility of the consumer.
Consumers are reminded to install, operate, and maintain the product only in accordance with the Operating Instructions supplied
with the product. Additional copies of Operating Instructions are available from Cigweld Customer Care 1300 654 674 or the
Website. This warranty does not cover failures due to use in an abnormal manner, use of parts which are not manufactured and
distributed by the manufacturer and which may affect product safety and performance, and repair or replacement by other than
authorised Cigweld Service Providers.
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