CIGWELD Transmig 210 User manual

MIGTRN0001 Issue 2 14/09/98
Operating Manual
TRANSMIG 210 Compact Power Source 704832
Remote Power Source 704808
TRANSMIG 250 Compact Power Source 704833
Remote Power Source 704809
2R TRANSMIG 210/250 Wirefeeder 704975
TRANSMIG 310 Compact Power Source 704836
TRANSMIG 330 Remote Power Source 705085
2R TRANSMIG 330 Wirefeeder 704841

OperatingManual Transmig 210, 250, 310, 330
CONTENTS Page
DOC No: MIGTRN0001 Page 1of 31
Issue No: 2 Date: 14/09/98
1. INTRODUCTION..................................................................................................................7
1.1 Duty Cycle................................................................................................................................................7
2. SPECIFICATIONS................................................................................................................8
2.1 Transmig 210 and Transmig 250 Specifications.........................................................................................8
2.2 Transmig 310 and Transmig 330 Specifications.........................................................................................9
2.3 MIG Torch Specifications.........................................................................................................................9
2.4 Wirefeeder Specifications........................................................................................................................10
2.5 Plant Contents.........................................................................................................................................10
2.6 Optional Accessories...............................................................................................................................11
3. INSTALLATION RECOMMENDATIONS.......................................................................12
3.1 Environment............................................................................................................................................12
3.2 Location..................................................................................................................................................12
3.3 Ventilation..............................................................................................................................................12
3.4 Mains Supply Voltage Requirements.......................................................................................................12
3.5 Alternative Mains Supply Voltage Requirements.....................................................................................13
4. SET UP FOR COMPACT TRANSMIGS...........................................................................14
5. SET UP FOR REMOTE TRANSMIG WITH WIREFEEDER.........................................15
5.1 Power Source Connections......................................................................................................................15
5.2 Wirefeeder Connections...........................................................................................................................15
6. Power Source / 2R Wirefeeder Controls, Indicators and Features.....................................16
6.1 Indicator Light........................................................................................................................................16
6.2 Standby/Coarse Voltage Control Switch and Fine Voltage Control Switch...............................................16
6.3 Digital Ammeter and Voltmeter (Standard for Transmig 330 Only)..........................................................17
6.4 Torch Polarity Lead (Compact Models Only)...........................................................................................17
6.5 Positive and Negative Welding Terminals................................................................................................17
6.6 Wirefeeder Control Socket (Remote Wirefeeder Models Only).................................................................17
6.7 Thermal Overload...................................................................................................................................17
6.8 Choice of Inductance Setting (Transmig 210 & 250 Only).......................................................................18
6.9 Wirespeed Control (Compact Models & 2R Wirefeeder Only)..................................................................18
6.10 Spot Timer (Compact Models & 2R Wirefeeder Only)...........................................................................18
6.11 Dwell Timer (Compact Models & 2R Wirefeeder Only).........................................................................18
6.12 Mode Selector Switch (Compact Models & 2R Wirefeeder Only)...........................................................18
6.13 Burnback Control (Compact Models & 2R Wirefeeder Only).................................................................18
6.14 Wirefeeder Driver Roller Pressure Adjustment (Compact Models & 2R Wirefeeder Only)......................19
6.15 Wire Reel Brake (Compact Models & 2R Wirefeeder Only)...................................................................19
7. TWECO MIG TORCH (P/N 717578 where supplied)........................................................19
7.1 Introduction............................................................................................................................................19
7.2 Torch Consumable Parts.........................................................................................................................19

Transmig 210, 250, 310, 33
CONTENTS Page
Page 2of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
7.3 MIG Torch Components.........................................................................................................................21
7.4 Installing A New Conduit Liner...............................................................................................................22
7.5 MIG Torch Maintenance.........................................................................................................................22
8. BASIC WELDING TECHNIQUE.......................................................................................23
8.1 Setting of the Power Source & Wirefeeder...............................................................................................23
8.2 Position of MIG Torch............................................................................................................................23
8.3 Distance from the MIG Torch Nozzle to the Work Piece..........................................................................23
8.4 Travel Speed...........................................................................................................................................23
8.5 Stitch Welding Operation........................................................................................................................23
8.6 Spot Welding Operation..........................................................................................................................24
9. ROUTINE MAINTENANCE & INSPECTION..................................................................24
9.1 Improved Current Accuracy Calibration Procedure for the Digital Meter..................................................25
10. BASIC TROUBLESHOOTING.........................................................................................26
10.1 Solving Problems Beyond the Welding Terminals..................................................................................26
10.2 Welding Problems.................................................................................................................................28
10.3 Power Source Problems.........................................................................................................................29
10.4 Key Spare Parts....................................................................................................................................31

Transmig 210, 250, 310, 330
CONTENTS Page
DOC No: MIGTRN0001 Page 5of 31
Issue No: 2 Date: 14/09/98
TABLES
Table 1 - Factory fitted Mains supply leads fitted to the Transmig Power Sources..................................13
Table 2 - Mains supply lead sizes for alternative Mains supply voltages..................................................13
Table 3 - MIG torch gas diffusers..........................................................................................................19
Table 4 - MIG torch contact tips............................................................................................................20
Table 5 - MIG torch nozzles..................................................................................................................20
Table 6 - MIG torch conduit liners.........................................................................................................20
Table 7 - MIG Torch components..........................................................................................................21

Transmig 210, 250, 310, 330
FIGURES
Page
Page 6of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
Figure 1 - Transmig duty cycle curves.....................................................................................................7
Figure 2 - Voltage settings for Transmig 210/250..................................................................................13
Figure 3 - Voltage settings for Transmig 310/330..................................................................................13
Figure 4 - Compact Transmig Setup......................................................................................................14
Figure 5 - Remote Transmig Setup........................................................................................................15
Figure 6 - Compact Transmig controls...................................................................................................16
Figure 7 - Remote Transmig controls.....................................................................................................16
Figure 8 - Wirefeeder controls...............................................................................................................16
Figure 9 - Examples of the digital read outs...........................................................................................17
Figure 10 - Exploded view of MIG torch...............................................................................................21
Figure 11 - Conduit liner trim length......................................................................................................22
Figure 12 - MIG Torch angle.................................................................................................................23

Transmig 210, 250, 310, 330
DOC No: MIGTRN0001 Page 7of 31
Issue No: 2 Date: 14/09/98
1. INTRODUCTION
The Transmig 210, 250, 310 and 330 are semi-automatic Gas Metal Arc Welder (GMAW-commonly
MIG) with either integrated or separate wire feed unit. These products are designed to meet the broad
operating needs of the metal fabrication industry where production efficiency is vital. They are designed
and manufactured in Australia to Australian Standard AS1966.1-1985.
The Transmig range gives excellent performance on mild steel, stainless steel, aluminium, silicon bronze
and some hard facing wires with the Argon based of shielding gases. The Transmig range also gives
excellent results on mild steel using CO2(carbon dioxide) shielding gas.
The Transmig Plants are supplied as a complete welding package (apart from gas cylinder and electrode
wire). The following instructions detail how to correctly set up your new Transmig and give guidelines on
gaining the best production efficiency. Please read these instructions thoroughly before using your
Transmig.
1.1 Duty Cycle
The rated duty cycle
of a welding Power
Source is the
operating time it may
be used at its rated
output current with-
out exceeding the
temperature limits of
the insulation of the
component parts. In
Australia a duty cycle
period of 5 minutes is
specified in Australian
Standard AS 1966
Part 1-1985. To
explain the 5 minute
duty cycle period the following example is used. Suppose a welding Power Source is designed to
operate at 30% duty cycle, 250 amperes at 26 volts. This means that it has been designed and built
to provide the rated amperage (250A) at the rated voltage (26V), for 1.5 minutes out of every 5
minute period (30% of 5 minutes is 1.5 minutes). During the other 3.5 minutes of the 5 minute
period the Power Source must idle and be allowed to cool. The thermal cut-out will operate if the
duty cycle is exceeded.
CAUTION 1:The above times are not accumulative.
0
10
20
30
40
50
60
70
80
90
100
0
20 40 60 80
100 120 140 160 180 200 220 240 260 280 300 320
Welding Current (amp)
Duty Cycle (percentage)
330
Transmig 210
Transmig 250
Safe
Operating
Region
210
250
Transmig 310
Transmig 330
Figure 1- Transmig duty cycle curves

Transmig 210, 250, 310, 330
Page 8of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
2. SPECIFICATIONS
2.1 Transmig 210 and Transmig 250 Specifications
Transmig 210 Transmig 250
Compact Remote Compact Remote
Plant Assembly part number 704830 704831 704833 704834
Plant Mass 77Kg 107Kg 78Kg 108Kg
Plant Dimensions 860mm x 490mm x 845mm 860mm x 490mm x 845mm
Power Source part number 704832 704808 704835 704809
Power Source Mass 60Kg 58.5Kg 61Kg 59.5Kg
Power Source Dimensions 640 x 310 x 732 640 x 310 x 732
Number of Phases Single Phase Single Phase
Frequency 50 / 60 Hz 50 / 60 Hz
Open Circuit Voltage Range 18.9 to 34.2V 19 to 43V
Output Current Range 25 to 210A 30 to 250A
Rated Output for 15A Outlet at 240V 210A @ 25%
148A @ 50%
105A @ 100%
184A @ 25%
130A @ 50%
92A @ 100%
µRated Output for 20A Outlet at 240V 210A @ 36%
164A @ 60%
127A @ 100%
¾
ÙRated Output for 25A Outlet at 240V ¾
250A @ 25%
180A @ 50%
127A @ 100%
Duty Cycle Period 5 minutes or 10 minutes 5 minutes or 10 minutes
Number of Output Voltage Values 16 16
Wire Size Range 0.6 - 0.9 Hard / 0.9 - 1.2 Soft 0.6 - 0.9 Hard / 0.9 - 1.2 Soft
Operating Temperature Range 0°C to 40°C 0°C to 40°C
Primary input voltage 200V 220V 240V 200V 220V 240V
ÑRated Input Current (output of 127A) 25A 23A 21A 30A 27A 25A
Rated kVA (output of 127A) 5kVA 5kVA 5kVA 6kVA 6kVA 6kVA
Maximum Input Current 42A 38A 35A 52A 47A 43A
Generator Requirements 8.5kVA 8.5kVA 8.5kVA 10kVA 10kVA 10kVA
Rated Outlet @ Max Duty Cycle 25A 23A 20A 30A 27A 25A
ªFuse Size @ Max Duty Cycle 50A 50A 40A 60A 60A 50A
ÑThe Rated Input Current should be used for the determination of cable size & supply
requirements.
ªMotor start fuses or motor start thermal circuit breakers are recommended for this application.
Australian Standard AS3000 (Clause 2.4.3.4) permits the use of a fuse or circuit breaker rated at
two times the rated input current.
µTo achieve this rating, the 15 Amp plug and primary supply lead (as supplied) must be replaced
with a 20 Amp plug & lead. This must be carried out by a qualified electrical tradesperson.

Transmig 210, 250, 310, 330
DOC No: MIGTRN0001 Page 9of 31
Issue No: 2 Date: 14/09/98
ÙTo achieve this rating, the 15 Amp plug and primary supply lead (as supplied) must be replaced
with a 25 Amp plug & lead. This must be carried out by a qualified electrical tradesperson.
2.2 Transmig 310 and Transmig 330 Specifications
Transmig 310 Transmig 330
Plant Assembly part number 704836 704839
Plant Mass 87Kg 117Kg
Plant Dimensions 860mm x 490mm x 845mm 860mm x 490mm x 845mm
Power Source part number 704838 705085
Power Source Mass 71Kg 70Kg
Power Source Dimensions 640 x 310 x 732 640 x 310 x 732
Number of Phases Three Phase Three Phase
Frequency 50 / 60 Hz 50 / 60 Hz
Open Circuit Voltage Range 17.5 to 41.2V 17.5 to 41.2V
Output Current Range 25 to 310A 25 to 330A
Rated Output Duty Cycle 310A @ 30%
220A @ 60%
170A @ 100%
330A @ 30%
228A @ 60%
177A @ 100%
Duty Cycle Period 5 minutes or 10 minutes 5 minutes or 10 minutes
Number of Output Voltage Values 24 24
Wire Size Range 0.6 - 1.2 Hard / 0.9 - 1.2 Soft 0.6 - 1.2 Hard / 0.9 - 1.2 Soft
Operating Temperature Range 0°C to 40°C 0°C to 40°C
Primary input voltage 220V 380V 415V 220V 380V 415V
ÑRated Input Current for output current
at 100% duty cycle. 21A 12A 11A 21A 12A 11A
Rated kVA for output current at
100% duty cycle. 8kVA 8kVA 8kVA 8kVA 8kVA 8kVA
Maximum Input Current 36A 21A 19A 38A 22A 20A
Generator Requirements 13.7kVA13.7kVA13.7kVA14.4kVA14.4kVA14.4kVA
Rated Outlet @ Max Duty Cycle 25A 15A 15A 25A 15A 15A
ªFuse Size @ Max Duty Cycle 50A 30A 20A 50A 30A 20A
ÑThe Rated Input Current should be used for the determination of cable size & supply
requirements.
ªMotor start fuses or motor start thermal circuit breakers are recommended for this application.
Australian Standard AS3000 (Clause 2.4.3.4) permits the use of a fuse or circuit breaker rated at
two times the rated input current.
2.3 MIG Torch Specifications
Torch Part Number 717578
Torch Type TWECO 250A (Eliminator Consumables)
Torch Cable Length 3.6 metre

Transmig 210, 250, 310, 330
Page 10 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
2.4 Wirefeeder Specifications
Wirefeeder 704975
(Transmig 210 & 250 Remote) 704841 (Transmig 330)
Mass 21Kg 23Kg
Dimensions 600 x 245 x 475
Motor Supply Voltage 36V AC
Motor Supply VA 180VA
Control Supply Voltage 24V AC
Control Supply VA 30VA
Minimum Wire Speed One metre per minute
Maximum Wire Speed 17 metres per minute
Wire Diameter: Mild Steel 0.6, 0.8, 0.9
Stainless Steel 0.8, 0.9
Aluminium 0.9, 1.0, 1.2
Flux Cored 0.8, 0.9, 1.2
Operating Temperature Range 0°C to 40°C
Wire Spool Size 15Kg Maximum
Spot Time Range 0 to 2.5 Seconds
Stitch ‘ON‘ Time 0 to 2.5 Seconds
Stitch ‘OFF‘ Time 0 to 2.5 Seconds
Burnback Time Range 0 to 0.15 Seconds
2.5 Plant Contents
Transmig 210 Transmig 250 Transmig 310 Transmig 330
CompactRemoteCompactRemote Compact Remote
Wheeling Kit 444444
Roll on Cylinder Carrier 444444
Power Source 444444
Operating Instructions 444444
3 Metre Work Lead 4¾4¾4¾
8 Metre Work Lead ¾4¾4¾4
2R Wirefeeder (8 metre) ¾4¾4¾4
Regulator / Flowmeter 444444
TWECO MIG torch 250A 444444
Feed Roller 0.6/0.8 Hard 444444
Feed Roller 0.9/1.2 Hard 444444

Transmig 210, 250, 310, 330
DOC No: MIGTRN0001 Page 11 of 31
Issue No: 2 Date: 14/09/98
2.6 Optional Accessories
Part Description Transmig 210 Transmig 250 Transmig 310Transmig 330
Number CompactRemoteCompactRemote Compact Remote
705103 Digital Meter Kit 44444Standard
704914 Wirefeeder Swivel Base ¾4¾4¾4
704913 Wirefeeder Trolley ¾4¾4¾4
704917 110Volt Aux Supply Kit 444444
ELC2123035250A Eliminator torch (3.6M)
(fits Transmig adaptor)
444444
ELC4123545450A Eliminator torch (3.6M)
(fits Transmig adaptor)
444444
704343 Torch trigger lead to suit
Eliminator torch
444444
704099 Work lead (3m) 4444¾¾
705163 Work lead (3m) ¾¾¾¾44
704829 Work lead (8m) 4444¾¾
704828 Work lead (8m) ¾¾¾¾44
704912 8 M Interconnection Extension ¾4¾4¾¾
704465 8 M Interconnection Extension ¾¾¾¾¾4
717162 TWECO No.2 torch (3.6M)
(adaptor 704915 required)
444444
717201 TWECO No.4 torch (3.6M)
(adaptor 704915 required)
444444
704915 TWECO No.2 & 4 Adaptor 444444
7977036 Feed roll, 0.6/0.8 Hard Wire 444444
7977660 Feed roll, 0.9/1.2 Hard Wire 444444
7977037 Feed roll, 1.0/1.2 Hard Wire 444444
7977731 Feed roll, 0.8/0.9 Soft Wire 444444
7977264 Feed roll, 1.0/1.2 Soft Wire 444444
7977732 Feed roll, 0.8/0.9 Flux cored 444444
704277 Feed roll, 1.0/1.2 Flux cored 444444
ELC94L Eliminator Torch trigger lock 444444
705000 MIG pliers (size No 1) 444444
705001 MIG pliers (size No 2) 444444
646265 Weld measurement gauge 444444
705277 Auxiliary transformer kit
240/36/24V 44¾¾¾¾
705278 Auxiliary transformer kit 240-
220-200/36/24V ¾¾44¾¾
705126 Auxiliary transformer kit 415-
380-220/36/24V ¾¾¾¾44

Transmig 210, 250, 310, 330
Page 12 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
3. INSTALLATION RECOMMENDATIONS
3.1 Environment
The Transmigs are NOT designed for use in environments with increased hazard of electric shock as
defined in AS3195-1990.
a) Examples of environments with increased hazard of electric shock are -
i) In locations in which freedom of movement is restricted, so that the operator is
forced to perform the work in a cramped (kneeling, sitting or lying) position with
physical contact with conductive parts;
ii) In locations which are fully or partially limited by conductive elements, and in which
there is a high risk of unavoidable or accidental contact by the operator, or
iii) In wet or damp hot locations where humidity or perspiration considerable reduces the
skin resistance of the human body and the insulation properties of accessories.
b) Environments with increased hazard of electric shock do not include places where
electrically conductive parts in the near vicinity of the operator, which can cause increased
hazard, have been insulated.
3.2 Location
Be sure to locate the Power Source according to the following guidelines:
a) In areas, free from moisture and dust.
b) Ambient temperature 0°C to 40°C.
c) In areas, free from oil, steam and corrosive gases.
d) In areas, not subjected to abnormal vibration or shock.
e) In areas, not exposed to direct sunlight or rain.
f) Place at a distance of 30cm or more from walls or similar that could restrict natural air flow
for cooling.
g) The minimum ground clearance for these products is 140mm.
3.3 Ventilation
Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively
ventilated.
3.4 Mains Supply Voltage Requirements
The Mains supply voltage should be within ± 10% of the rated Mains supply voltage. Too low a
voltage may cause poor welding performance or the wirefeeder malfunction. Too high a supply
voltage will cause components to overheat and possibly fail.
The Transmig is supplied with an input lead to which an appropriate plug should be fitted.
Install a power outlet for each Power Source and fit fuses as per Transmig 210 and Transmig 250
Specifications or Transmig 310 and Transmig 330 Specifications.
WARNING 1:CIGWELD advises that your Transmig be electrically connected by a qualified
electrical tradesperson.
Refer to Table 1 for the ratings of the Mains supply leads that are supplied with the various Transmig
Power Sources.

Transmig 210, 250, 310, 330
DOC No: MIGTRN0001 Page 13 of 31
Issue No: 2 Date: 14/09/98
Transmig Mains Supply Lead
Size
Lead
Current
Rating
Lead
Length Machine Voltage
Setting Duty Cycle
210 1.5mm216 Amps 3 metre 240 Volt 210A @ 25%
250 1.5mm216 Amps 3 metre 240 Volt 184A @ 25%
310 1mm212 Amps 3.7 metre 415/440 Volt 310A @ 30%
330 1mm212 Amps 3.7 metre 415/440 Volt 330A @ 30%
Table 1- Factory fitted Mains supply leads fitted to the Transmig Power Sources
CAUTION 2:The Transmig Mains supply leads should be replaced with leads as specified in Table
2when the Transmigs Mains supply voltage is changed or when it is plugged into a
higher rated Mains outlet.
3.5 Alternative Mains Supply Voltage Requirements
The Power Sources are suitable for the following Mains supply voltages:
Mains Supply
Voltage Setting Mains Supply Lead Size Mains Outlet Size Fuse Size Machines Duty Cycle
Export Model
Only 200 Volt 4mm225 Amp ª50 Amp
Export Model
Only 220 Volt 4mm225 Amp ª50 Amp210A @ 36%
Transmig 210 240 Volt 2.5mm220 Amp ª40 Amp
200 Volt 6mm230 Amp ª60 Amp
Transmig 250 220 Volt 6mm230 Amp ª60 Amp250A @ 25%
See Figure 2 240 Volt 4mm225 Amp ª50 Amp
220 Volt 2.5mm220 Amp ª40 Amp
Transmig 310 380 Volt 1.5mm215 Amp ª20 Amp310A @ 30%
See Figure 3 415/440 Volt 1mm215 Amp ª20 Amp
220 Volt 2.5mm220 Amp ª40 Amp
Transmig 330 380 Volt 1.5mm215 Amp ª20 Amp330A @ 30%
See Figure 3 415/440 Volt 1mm215 Amp ª20 Amp
Table 2- Mains supply lead sizes for alternative Mains supply voltages
Figure 2- Voltage settings for Transmig 210/250 Figure 3- Voltage settings for Transmig 310/330

Transmig 210, 250, 310, 330
Page 14 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
4. SET UP FOR COMPACT TRANSMIGS
Refer to Figure 4 for the plant setup of a compact Transmig.
a) Remove all packaging materials.
b) Fit the fixed and swivel wheels to the Power Source.
WARNING 2:To obtain adequate air flow and cooling for the Power Source components, the
four wheels must be fitted. Alternatively, the Power Source may be raised
140mm from the floor using supports that do not restrict airflow.
c) Connect the work lead to the negative welding terminal (-) [positive welding terminal (+)
for flux cored wire].
d) Connect the TORCH lead to the positive welding terminal (+) [negative welding terminal
(-) for flux cored wire].
e) Position a gas cylinder on the rear tray and lock securely to the Power Source cylinder
bracket with the chain provided. If this arrangement is not used then ensure that the gas
cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an
upright position.
f) Fit the gas Regulator/Flowmeter to the gas
cylinder.
g) Connect the gas hose from the rear of the Power
Source to the Flowmeter outlet.
h) Two dual groove feed rollers are supplied as
standard with the plant. These can accommodate
0.6, 0.8, 0.9 and 1.2 diameter hard wires. Select
the roller required with the chosen wire size
marking facing outwards.
i) Fit the electrode wire spool to the wire reel hub
located behind the wire compartment door.
Ensure that the drive dog-pin engages the mating
hole in the wire spool. Push the 'R' clip into place
to retain the wire spool securely. The wire should
feed from the bottom of the spool.
j) Fit the TWECO MIG torch to the wire feed unit
by releasing the torch locking screw in the brass
torch adaptor and pushing in the torch fitting until
the plastic torch casing meets the brass adaptor.
Tighten the torch locking screw securely. Also
ensure that the adjacent black knurled screw in the
wire feeder casting is securely tightened. Remove the contact tip from the torch.
k) Connect the two black torch trigger leads to the torch trigger terminals.
l) Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide,
between the rollers, through the outlet guide and into the torch.
m) Lower the pressure lever and with the torch lead reasonably straight, feed the wire through
the torch. Fit the appropriate contact tip.
CAUTION 3:The electrode wire will be at welding voltage potential whilst it is being fed
through the system.
Figure 4- Compact Transmig Setup

Transmig 210, 250, 310, 330
DOC No: MIGTRN0001 Page 15 of 31
Issue No: 2 Date: 14/09/98
5. SET UP FOR REMOTE TRANSMIG WITH WIREFEEDER
Refer to Figure 5 for the plant setup of a remote Transmig with wirefeeder.
5.1 Power Source Connections
a) Remove all packaging materials.
b) Fit the fixed and swivel wheels to the Power Source. Refer to WARNING 2.
c) Connect the work lead to the negative welding terminal (-) [positive welding terminal (+)
for flux cored wire].
d) Position a gas cylinder on the rear tray and lock securely to the Power Source cylinder
bracket with the chain provided. If this arrangement is not used then ensure that the gas
cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an
upright position.
e) Fit the gas regulator and Flowmeter to the gas cylinder.
5.2 Wirefeeder Connections
a) Connect the welding power cable to the
positive welding terminal (+) [negative
welding terminal (-) for flux cored wire].
b) Connect the control cable to the front of the
Power Source of the Transmig 210 remote or
Transmig 250 remote or Transmig 330.
c) Connect the gas hose from the rear of the
wire feeder unit to the Flowmeter outlet.
d) Two dual groove feed rollers are supplied as
standard with the plant. These can
accommodate 0.6, 0.8, 0.9, 1.0 and 1.2
diameter hard wires. Select the roller
required with the chosen wire size marking
facing outwards.
e) Fit the electrode wire spool to the wire reel
hub located behind the wire compartment
door. Ensure that the drive dog-pin engages
the mating hole in the wire spool. Push the
'R' clip into place to retain the wire spool
securely. The wire should feed from the
bottom of the spool.
f) Fit the torch to the wire feed unit by releasing the torch locking screw in the brass torch
adaptor and pushing in the torch fitting until the plastic torch casing meets the brass
adaptor. Tighten the torch locking screw securely. Also ensure that the adjacent black
knurled screw in the wire feeder casting is securely tightened. Remove the contact tip from
the torch.
g) Connect the torch trigger lead to the torch trigger terminals.
h) Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide,
between the rollers, through the outlet guide and into the torch.
i) Lower the pressure lever and with the torch lead reasonably straight, feed the wire through
the torch. Fit the appropriate contact tip. Refer to CAUTION 3.
Figure 5- Remote Transmig Setup

Transmig 210, 250, 310, 330
Page 16 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
6. Power Source / 2R Wirefeeder Controls, Indicators and Features
WirespeedControl
SpotTimerControl
DwellTimerControl
ModeSelector
Switch
BrassTorchAdaptor
IndicatorLight
On/Off&Coarse
VoltageControlSwitch
FineVoltage
ControlSwitch
NegativeWelding
CurrentTerminal
PositiveWelding
CurrentTerminal
OptionalMeter
(standardontheTransmig330)
TorchPolarityLead
IndicatorLight
On/Off&Coarse
VoltageControlSwitch
FineVoltage
ControlSwitch
NegativeWelding
CurrentTerminal
WirefeederControl
Socket
PositiveWelding
CurrentTerminal
OptionalMeter
(standardontheTransmig330)
Ammeter/Voltmeter
Switch
Figure 6- Compact Transmig controls Figure 7- Remote Transmig controls
6.1 Indicator Light
The indicator light is provided to indicate when the Transmig is connected to the Mains supply
voltage.
WARNING 3:When the light is lit, the machine is connected to the Mains supply voltage and
the internal electrical components are at Mains voltage potential.
6.2 Standby/Coarse Voltage Control Switch and Fine Voltage Control Switch
The Coarse Voltage Control switch turns off the fan and auxiliary power in the STANDBY position.
It sets the voltage level to the welding terminals in the remaining positions, increasing the voltage as
it is rotated in the clockwise direction. The Fine Voltage Control switch increases the voltage (in
smaller increments than the Coarse switch) as it is rotated in the clockwise direction.
WARNING 4:The Coarse & Fine Voltage Control switches MUST NOT BE SWITCHED
during the welding process.
Wirespeed
Control
SpotTimer
Control
PowerCable
ControlCable
GasHose
DwellTimer
Control
ModeSelector
Switch
BrassTorch
Adaptor
Figure 8- Wirefeeder controls

Transmig 210, 250, 310, 330
DOC No: MIGTRN0001 Page 17 of 31
Issue No: 2 Date: 14/09/98
6.3 Digital Ammeter and Voltmeter (Standard for Transmig 330 Only)
Where fitted an average reading ammeter and voltmeter is provided to allow accurate monitoring
(5% tolerance) of welding current and voltage. Refer to section 9.1 on page 25 for the Improved
Current Accuracy Calibration Procedure for the Digital Meter.
The Digital Meter will display both welding current and voltage. To toggle between the current and
voltage readings depress the push button switch mounted below the meters display. See Figure 9 for
an example of current and voltage displays.
Value displayed for 157 Amp Value displayed for 23.4 Volts
Figure 9- Examples of the digital read outs
6.4 Torch Polarity Lead (Compact Models Only)
This lead selects the welding voltage polarity of the electrode wire. Plug it into the positive welding
terminal ( + ) when using steel, stainless steel or aluminium electrode wire. Plug the Torch Polarity
Lead into the negative welding terminal ( - ) when using gasless electrode wire. If in doubt, consult
the manufacturer of the electrode wire for the correct polarity.
6.5 Positive and Negative Welding Terminals
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.
WARNING 5:Loose welding terminal connections can cause overheating and result in the
male plug being fused in the bayonet terminal.
6.6 Wirefeeder Control Socket (Remote Wirefeeder Models Only)
This socket accepts the male plug on the control cable from the Wirefeeder. The male plug should
be fully inserted into the control socket then locked into position by turning the retaining ring on the
male plug in a clockwise direction.
6.7 Thermal Overload
The critical component for thermal protection is the rectifier stack, which is fitted with a thermal
overload cutout device. If the overload operates then the machine should be left to cool for
approximately 15 minutes before resuming welding. There will be no danger of transformer damage
if the Power Source is operated within its duty cycle, refer to section 1.1 for an explain of duty cycle
and section 2for the Power Source specifications.

Transmig 210, 250, 310, 330
Page 18 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
6.8 Choice of Inductance Setting (Transmig 210 & 250 Only)
The Transmig 210 & 250 have two inductance taps. These inductance terminals are the positive
welding terminals. Inductance selection can effect the spatter level and penetration characteristics of
the weld. The correct choice depends upon the shielding gas, transfer mode and the material type.
Used for:
1. CO2shielded welding.
2. Dip transfer with Æ1.2mm wires (CO2or mixed gas).
3. Gives a hotter weld in DIP transfer.
Used for:
1. Spray transfer
2. Aluminium and Flux Cored wires.
3. Gives a cooler weld in DIP transfer.
CAUTION 4:If in doubt, use the high inductance setting.
6.9 Wirespeed Control (Compact Models & 2R Wirefeeder Only)
The Wirespeed Control knob controls the welding current via the electrode wire feed rate. ie the
speed of the wire feed motor.
6.10 Spot Timer (Compact Models & 2R Wirefeeder Only)
With the MODE SELECTOR switch is switched to the SPOT position, the SPOT TIME knob
controls the duration of a single spot weld.
With the MODE SELECTOR switch is switched to the STITCH position, the SPOT TIME knob
controls the welding or 'ON' time whilst stitch welding.
6.11 Dwell Timer (Compact Models & 2R Wirefeeder Only)
The DWELL TIME knob controls the interval or 'OFF' time whilst stitch welding.
6.12 Mode Selector Switch (Compact Models & 2R Wirefeeder Only)
The Mode Selector switch selects the method of welding mode.
a) SPOT This mode of welding is used to weld two plates together at a desired
location by melting the top & bottom plates together to form a nugget
between them. The spot time period is set by the SPOT TIME control
knob. Refer to CAUTION 5.
CAUTION 5:A spot nozzle (P/N EL22I62FAS) should be used on the MIG torch to obtain
consistent spot welds.
b) CONTINUOUS This mode of welding is used to weld two or more components together
with a continuous weld.
c) STITCH This mode of welding is used to weld two or more components together
with a stitch weld. The SPOT TIME knob controls the welding or 'ON'
time whilst the DWELL TIME knob controls the interval or 'OFF' time
for stitch welding.
6.13 Burnback Control (Compact Models & 2R Wirefeeder Only)
The amount of electrode wire that is burnt back out of the weld pool, when the torch trigger switch
is released, can be adjusted by the potentiometer shaft that is located inside the wire spool cavity
compartment above the wire feed motor.
High Inductance Symbol
Low Inductance Symbol

Transmig 210, 250, 310, 330
DOC No: MIGTRN0001 Page 19 of 31
Issue No: 2 Date: 14/09/98
6.14 Wirefeeder Driver Roller Pressure Adjustment (Compact Models & 2R
Wirefeeder Only)
The moveable roller applies pressure to the grooved roller via screw adjustable spring pressure. The
adjustable spring screw should be adjusted to a minimum pressure that will provide satisfactory wire
feed without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear,
distortion or burn-back jam, the correct feed roll groove size is used, the feed roll groove is not
worn, the conduit liner should be checked for kinks and clogging by metal flakes and swarf. If this is
not the cause of slipping, the feedroll pressure can be increased by rotating the adjustable spring
screw clockwise. Excessive pressure may cause rapid wear of the feed roller, motor shaft and motor
bearings. Refer to CAUTION 7.
6.15 Wire Reel Brake (Compact Models & 2R Wirefeeder Only)
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 large nut inside the
open end of the wire reel hub. Clockwise rotation will tighten the brake. Correct adjustment will
result in the reel circumference continuing no further than 20mm after release of the Torch trigger
switch. The electrode wire should be slack without becoming dislodged from the reel.
CAUTION 6:Excessive tension on the brake will cause rapid wear of mechanical wire feed
parts, overheating of electrical componentry and possibly an increased incidence
of wire Burnback into the contact tip.
7. TWECO MIG TORCH (P/N 717578 where supplied)
7.1 Introduction
The TWECO 250A gun fitted to the Transmig offers robust construction, unparalleled reliability and
easy replacement of consumable parts. The TWECO 250A has an operating capacity in excess of
the capacity of the Transmigs and can be expected to give trouble free service.
TWECO MIG Torches may be fitted to many different types of MIG welding plants so that your
whole shop can be converted to TWECO. Not only will this give greater reliability (and hence
greater productivity), but it will reduce stockholdings of consumable parts. See your CIGWELD
distributor for details.
CAUTION 7:Genuine TWECO contact tips and lines should be used. Many non-genuine liners
use inferior materials which can cause wire feed problems.
7.2 Torch Consumable Parts
NOTE 1:* denotes parts that are supplied as standard with MIG torch 717578.
a) Gas Diffusers
Part No. Part No.
* EL52 (slide on nozzles) EL52CT (screw on nozzles)
Table 3- MIG torch gas diffusers

Transmig 210, 250, 310, 330
Page 20 of 31 DOC No: MIGTRN0001
Date: 14/09/98 Issue No: 2
b) Contact Tips STANDARD TAPERED
Wire Size
(mm) Part No. Wire Size (mm) Part No.
0.6 not available 0.6 EL16T23
0.8 EL1630 0.8 EL16T30
0.9 * EL1635 0.9 EL16T35
1.0 EL1640 1.0 EL16T40
1.2 EL1645 1.2 EL16T45
1.2 Alum EL16A364 1.2 Alum EL16AT364
Table 4- MIG torch contact tips
c) Nozzles
Bore Size
(mm) Part No. Bore Size (mm) Part No.
9.5 EL22A37 9.5 EL22CT37
9.5 EL22A37F 9.5 EL22CT37F
12.7 EL22A50 12.7 EL22CT50
12.7 EL22A50F 12.7 EL22CT50F
12.7 EL22I50P 12.7 EL22CT50P
15.9 EL22A62 15.9 EL22CT62
15.9 EL22A62F 15.9 EL22CT62F
15.9 * EL22I62P 15.9 EL22CT62P
19.1 EL22A75 19.1 EL22CT75
19.1 EL22A75F 19.1 EL22CT75F
15.9 EL22I62FAS (Spot Nozzle) CT = Coarse Thread
F = Flush Tip P=Protruding Tip
Table 5- MIG torch nozzles
d) Conduit liners
HARD ELECTRODE WIRE SOFT ELECTRODE WIRE
Wire Size Part No. Wire Size (mm) Part No.
0.6 OTW42/23 0.6 Alum not available
0.8 OTW42/3035 0.8 Alum not available
0.9 * OTW42/3035 0.9 Alum OTW42N/3545
1.0 OTW42/4045 or OTW44/3545 1.0 Alum or
1.2 OTW42/4045 or OTW44/3545 1.2 Alum OTW44N/3545
Table 6- MIG torch conduit liners

Transmig 210, 250, 310, 330
DOC No: MIGTRN0001 Page 21 of 31
Issue No: 2 Date: 14/09/98
7.3 MIG Torch Components
Refer to Figure 10 for a pictorial representation of the components listed in Table 7.
1
2
3
4
5
6
7
22 23
8
14
9
13
12
10
11
18 17 1516
Figure 10 - Exploded view of MIG torch
Item Part No. Description Qty
1¾Nozzle (refer to Table 5)1
2¾Contact tip (refer to Table 4)1
3¾Gas diffuser (refer to Table 3)1
4WM6345 Conductor tube 1
5OTW45B O-Ring, Gun Handle 1
6OTW90721H Handle kit (includes items 7, 22 & 23) 1
7Insert & screw (refer to item 6) 2
8n/a Handle cap 1
9n/a Support 1
10 ELC94 Trigger Lever 1
11 ELC94B Trigger blades 1
12 ¾Butt Splice (insulated crimp link 1.5mm2 )2
13 ELC1042 Cap screw 1
14 OTW9072110 Cable assembly 1
15 OTW224 O-Ring, Connector Plug 2
16 OTW44C Set screw 8/32 UNC 1
17 OTW350174 Connector plug 1
18 ¾Conduit liner (refer to Table 6)1
22 ¾Gun hanger (refer to item 6) 1
23 ¾Hanger screw (refer to item 6) 1
24 ELC94L Locking Trigger (not shown) (option) 
Table 7- MIG Torch components