CIGWELD TRANSMIG 220 User manual

OPERATING MANUAL
MIG POWER SOURCE
Model Description Plant Power Source
TRANSMIG 220 710024 710025
(Single Phase)
TRANSMIG 250 710018 710019
(Single Phase)
TRANSMIG 253 710009 710013
(Three Phase)
PART NO. ISSUE DATE
719454 02 403

Manufacturer and Merchandiser of Quality Consumables and Equipment: CIGWELD
Head Office Address: 71 Gower St, Preston
Victoria 3072
Australia
Description of equipment: Welding Equipment (Mig/Mag). CIGWELD Transmig 220, 250, 253 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.
National Standard and Technical Specifications
The product(s) are guided in design to a number of standards and technical requirements as listed below:
* AS1966-1 relevant clauses applicable to welding equipment and associated accessories.
* AS/NZS 3195:1995 relevant clauses applicable to portable machines for electric arc welding and allied processes.
* AS/NZS 3652-(EMC Directive EN50199) applicable to arc welding equipment –generic emissions and
regulations.
* AS1939-1990 relevant clauses applicable to degree of protection provided by enclosures for electrical equipment
IP21
* 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 extensive equipment range with superior performance, ultra
safe operation and world class quality for more than 30 years and will continue to achieve excellence.

Transmigs 220, 250 & 253
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Table Of Contents
Page
1Unpacking Your Transmig.........................................................................................................1
2Rear Wheel Assembly...............................................................................................................1
3Front Swivel Castors And Cylinder Tray Assembly..............................................................1
4Rear Cylinder Bracket Assembly.............................................................................................2
5Introduction..................................................................................................................................2
6Electromagnetic Compatibility..................................................................................................6
7Electromagnetic Compatibility - Methods Of Reducing Emissions.....................................7
8General Information ...................................................................................................................8
9Safe Practices For The Use Of Welding Equipment...........................................................10
10 Resuscitation For Electric Shock Victims.............................................................................11
11 Specifications............................................................................................................................13
12 Installation Recommendations...............................................................................................16
13 Set Up For Compact Transmig...............................................................................................18
14 Power Source Controls, Indicators and Features ...............................................................19
15 MIG Torch..................................................................................................................................22
16 Basic Welding Technique........................................................................................................24
17 Routine Maintenance & Inspection ...........................................................................................24
18 Basic Troubleshooting.............................................................................................................25
19 Spare Parts................................................................................................................................29
20 Transmig 220 & 250 Compact Power Source Circuit Diagram.........................................30
21 Transmig 253 Compact Power Source Circuit Diagram....................................................31

Transmigs 220, 250 & 253
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Tables
Page
Table 1 – List of Accessory Items......................................................................................................1
Table 2 - Filter lens size verses welding current ..............................................................................11
Table 3 – Input Supply Circuit Requirements (Maximum Output)..................................................17
Table 4 – Torch TD-15 Components................................................................................................22
Table 5 – Torch TD-15 Contact Tips................................................................................................22
Table 6 –Torch Liners (Conduits) ....................................................................................................22
Table 7 – Basic Spare Parts ..............................................................................................................29
Figures
Page
Figure 1 - Castor and Tray Assembly.................................................................................................1
Figure 2 - Cylinder Bracket Assembly...............................................................................................2
Figure 3 – Example of the TRANSMIG 250 duty cycle curve..........................................................8
Figure 4 – Input Supply Voltage Set ................................................................................................18
Figure 5 - Compact TRANSMIG controls .......................................................................................19
Figure 6 - Examples of the digital read outs.....................................................................................20
Figure 7 - Standard 300mm spool set-up..........................................................................................21
Figure 8 - Conduit trim length..........................................................................................................23
Figure 9 - MIG Torch angle ..........................................................................................................24
Figure 10 - MIG Power Source Schematic for Transmig 220 & 250...............................................30

Transmigs 220, 250 & 253
1 Unpacking Your Transmig
Carefully unpack the Transmig and check that all items listed in table 1 are present.
Description Quantity
Cylinder Tray 1
Chain Bracket 1
Castor Swivel 2
Wheel 2
Axle 1
Washer ½ inch 2
Fastener (End Cap) 2
Screw M8 12
Screw M5 2
Chain 1
Table 1 – List of Accessory Items
2 Rear Wheel Assembly
a) Insert the axle through the cylinder tray.
b) Install the washers, wheels, and Fastener in the position as shown Figure 1.
3 Front Swivel Castors And Cylinder Tray Assembly
a) Install the two swivel castors in the position as shown in Figure 1 using M8 fasteners.
b) Remove M5 screws, as shown by (A) in Figure 1, from either side of power source.
c) Install assembled cylinder tray in position shown in Figure 1 using the M8 fasteners.
(A)
To be removed
before cylinder
tray assembled
Figure 1 - Castor and Tray Assembly
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Transmigs 220, 250 & 253
4 Rear Cylinder Bracket Assembly
a) Install the cylinder bracket in the position as shown in Figure 2 using M5 fasteners
b) Install the chain to cylinder bracket.
Figure 2 - Cylinder Bracket Assembly
5 Introduction
5.1 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to highlight important
information. These highlights are categorised as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in
efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may cause injury to the operator or others in the operating
area.
5.2 Important Safety Precautions
WARNING
OPERATION AND MAINTENANCE OF WELDING ARC EQUIPMENT CAN BE DANGEROUS
AND HAZARDOUS TO YOUR HEALTH.
To prevent possible injury, read, understand and follow all warnings, safety precautions
and instructions before using the equipment. Call your local distributor if you have any
questions.
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Transmigs 220, 250 & 253
GASES AND FUMES
Gases and fumes produced during the welding process can be dangerous and hazardous to
your health.
• Keep all fumes and gases from the breathing area. Keep your head out of the welding
fume plume.
• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and
gases.
• The kinds of fumes and gases from the welding arc depend on the kind of metal being
used, coatings on the metal, and the different processes. You must be very careful when
cutting or welding any metals which may contain one or more of the following:
Antimony Beryllium Cobalt Manganese Selenium
Arsenic Cadmium Copper Mercury Silver
Barium Chromium Lead Nickel Vanadium
• Always read the Material Safety Data Sheets (MSD’s) that should be supplied with the
material you are using. These MSDS’s will give you the information regarding the kind and
amount of fumes and gases that may be dangerous to your health.
• For information on how to test for fumes and gases in your workplace, refer to item 1 in
Subsection 5.3, Publications in this manual.
• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.
• Do not use the welding torch in an area where combustible or explosive gases or materials are
located.
• Phosgene, a toxic gas, is generated from the vapours of chlorinated solvents and cleansers.
Remove all sources of these vapours.
• Refer to the Victorian Occupational Health and safety (Confined Spaces) Regulations 1996
and Code of Practice or its equivalent for other states and / or countries.
ELECTRIC SHOCK
Electric Shock can injure or kill. The welding arc process uses and produces high voltage
electrical energy. This electric energy can cause severe or fatal shock to the operator or others in
the workplace.
• Never touch any parts that are electrically “live” or “hot.”
• Wear dry gloves and clothing. Insulate yourself from the work-piece or other parts of the
welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or damp.
• Install and maintain equipment according to NEC code, refer to item 4 in Subsection 5.3,
Publications.
• Disconnect power supply before performing any service or repairs.
Read and follow all the instructions in the Operating Manual.
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Transmigs 220, 250 & 253
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the welding arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that
cannot be removed must be protected.
• Ventilate all flammable or explosive vapours from the workplace.
• Do not cut or weld on containers that may have held combustibles.
• Provide a fire watch when working in an area where fire hazards may exist.
• Hydrogen gas may be formed and trapped under aluminium work-pieces when they are cut
underwater or while using a water table. DO NOT cut aluminium alloys underwater or on a
water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas
that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to
exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of
hearing.
• To protect your hearing from loud noise, wear protective earplugs and/or earmuffs. Protect
others in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1 in Subsection 5.3, Publications, in this
manual.
ARC RAYS
Arc Rays can injure your eyes and burn your skin. The welding arc process produces very
bright ultra violet and infra red light. These arc rays will damage your eyes and burn your
skin if you are not properly protected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety
glasses with side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or
dirty.
• Protect others in the work area from the arc rays. Use protective booths, screens or shields.
• Use the shade of lens as recommended in the Operating Manual.
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Transmigs 220, 250 & 253
5.3 Publications
Refer to the following standards or their latest revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the
Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND
CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE
AND FACE PROTECTION, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable
from the American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING
PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New
York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND
ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269
10.NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269
11.CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS,
obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
12.CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from
the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3
13.NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding
Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14.American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR
THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING
THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15.ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from
American National Standards Institute, 1430 Broadway, New York, NY 10018
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Transmigs 220, 250 & 253
6 Electromagnetic Compatibility
WARNING
Extra precautions for Electromagnetic Compatibility may be required when this welding power source is
used in a domestic situation.
6.1 Installation and use – User’s Responsibility
The user is responsible for installing and using the welding equipment according to the
manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the
responsibility of the user of the welding equipment to resolve the situation with the technical
assistance of the manufacturer. In some cases this remedial action may be as simple as earthing
the welding circuit. In other cases it could involve constructing an electromagnetic screen
enclosing the welding power source and the work, complete with associated input filters. In all
cases, electromagnetic disturbances shall be reduced to the point where they are no longer
troublesome.
NOTE 1
The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements
should only be authorised by a person who is competent to assess whether the changes will increase the risk
of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of
other equipment. Further guidance is given in IEC 974-13 Arc Welding Equipment - Installation and use
(under preparation).
6.2 Assessment of Area
Before installing welding equipment, the user shall make an assessment of potential
electromagnetic problems in the surrounding area. The following shall be taken into account
i) Other supply cables, control cables, signalling and telephone cables; above, below
and adjacent to the welding equipment.
ii) Radio, television transmitters and receivers.
iii) Computer and other control equipment.
iv) Safety critical equipment, e.g. guarding of industrial equipment.
v) The health of people around, e.g. the use of pacemakers and hearing aids.
vi) Equipment used for calibration and measurement.
vii) The immunity of other equipment in the environment, the user shall ensure that other
equipment being used in the environment is compatible. This may require additional
protection measures.
viii) The time of day that welding or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the structure of the building and
other activities that are taking place. The surrounding area may extend beyond the boundaries of
the premises.
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Transmigs 220, 250 & 253
7 Electromagnetic Compatibility - Methods Of Reducing Emissions
7.1 Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s
recommendations. If interference occurs, it may be necessary to take additional precautions such
as filtering of the mains supply. Consideration should be given to shielding the supply cable of
permanently installed welding equipment in metallic conduit or equivalent. Shielding should be
electrically continuous throughout its length. The shielding should be connected to the welding
power source so that good electrical contact is maintained between the conduit and the welding
power source enclosure.
7.2 Maintenance of Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s
recommendations. All access and service doors and covers should be closed and properly
fastened when the welding equipment is in operation. The welding equipment should not be
modified in any way except for those changes and adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of arc striking and stabilising devices should be
adjusted and maintained according to the manufacturer’s recommendations.
7.3 Welding Cables
The welding cables should be kept as short as possible and should be positioned close together,
running at or close to the floor level.
7.4 Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be
considered. However, Metallic components bonded to the work piece will increase the risk that
the operator could receive a shock by touching the metallic components and the electrode at the
same time. The operator should be insulated from all such bonded metallic components.
7.5 Earthing of the Work-piece
Where the work-piece is not bonded to earth for electrical safety, nor connected to earth because
of it’s size and position, e.g. ship’s hull or building steelwork, a connection bonding the work-
piece to earth may reduce emissions in some, but not all instances. Care should be taken to
prevent the earthing of the work-piece increasing the risk of injury to users, or damage to other
electrical equipment. Where necessary, the connection of the work-piece to earth should be
made by direct connection to the work-piece, but in some countries where direct connection is
not permitted, the bonding should be achieved by suitable capacitance, selected according to
national regulations.
7.6 Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may
alleviate problems of interference. Screening the entire welding installation may be considered
for special applications.
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Transmigs 220, 250 & 253
8 General Information
These TRANSMIG’s are semi-automatic Gas Metal Arc Welders (GMAW-commonly MIG).
They are designed is to meet the broad operating needs of the metal fabrication industry where
production efficiency is vital. Australian Standard AS1966.1 was used to guide the design.
The TRANSMIG range gives excellent performance on mild steel, stainless steel, aluminium,
silicon bronze and some hard facing wires with Argon based shielding gases. The Power Sources
also give excellent results on mild steel using Carbon Dioxide shielding gas.
The TRANSMIG range is supplied as a complete package ready to weld (apart from shielding
gas, electrode wire and Hiderok TM welding helmet). The following instructions detail how to
correctly set up the machine and give guidelines on gaining the best production efficiency from
the Power Source. Please read these instructions thoroughly before using your TRANSMIG
welder.
8.1 User Responsibility
This equipment will perform as per the information contained herein when installed, operated,
maintained and repaired in accordance with the instructions provided. This equipment must be
checked periodically. Defective equipment (including welding leads) should not be used. Parts
that are broken, missing, plainly worn, distorted or contaminated, should be replaced
immediately. Should such repairs or replacements become necessary, it is recommended that
such repairs be carried out by appropriately qualified persons approved by CIGWELD. Advice
in this regard can be obtained by contacting CIGWELD.
This equipment or any of its parts should not be altered from standard specification without
prior written approval of CIGWELD. The user of this equipment shall have the sole
responsibility for any malfunction which results from improper use or unauthorised
modification from standard specification, faulty maintenance, damage or improper repair by
anyone other than appropriately qualified persons approved by CIGWELD.
8.2 Duty Cycle
Duty Cycle is the amount of arc-on
time (actual welding or cutting
time) during any 10 minute period
that a machine can operate at its
rated output without damaging
internal components. For example,
the Transmig 250 is designed for
30% duty cycle at 250 amps. This
means that it has been designed and
built to provide the rated amperage,
250 amps, for 3 minute out of every
10 minute period. During the other
7 minutes of the 10 minute periods
the Transmig must idle and be allowed to cool. The thermal cut-out will operate if the duty cycle
is exceeded. Note that all duty cycles are calculated for a maximum ambient temperature of
40°C. Duty cycles must be reduced, i.e. reduce the arc-on time, when the ambient temperature
exceeds 40°C.
Duty Cycle
0
20
40
60
80
100
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280
Welding Current (Amps)
Duty Cycle (%)
Safe Operating
ZONE
Figure 3 – Example of the TRANSMIG 250 duty cycle curve
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Transmigs 220, 250 & 253
8.3 Terms Of Warranty - May 2001
1. The Trade Practices Act 1974 (Australian Commonwealth) and similar State Territory legislation relating to
the supply of goods and services, protects consumers' interests by ensuring that consumers are entitled in
certain situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including
warranties as to merchantability and fitness for purpose) associated with the supply of goods and services. A
consumer should seek legal advice as to the nature and extent of these protected interests. In some
circumstances, the supplier of goods and services may legally stipulate that the said conditions, warranties,
guarantees, rights and remedies are limited or entirely excluded. The warranties set out in Clause 2 shall be
additional to any non-excludable warranties to which the Customer may be entitled pursuant to any statute.
2. Subject to Clause 3. CIGWELD gives the following warranties to the Customer:
Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantable
quality and reasonably fit for the purpose for which they are supplied by CIGWELD.
CIGWELD will repair or, at its option, replace those of the goods which, upon examination, are found by
CIGWELD to be defective in workmanship and/or materials.
CIGWELD reserves the right to request documented evidence of date of purchase.
3. The Warranty in Clause 2;
Is conditional upon:
The Customer notifying CIGWELD or our Accredited Distributor in writing of its claim within seven (7)
days of becoming aware of the basis thereof, and at its own expense returning the goods which are the
subject of the claim to CIGWELD or nominated Accredited Distributor/Accredited Service Agent.
The goods being used in accordance with the Manufacturer's Operating Manuals, and under competent
supervision.
Does not apply to:
Obsolete goods sold at auction, second-hand goods and prototype goods.
Breakdown or malfunction caused by accident, misuse or normal wear and tear.
Repairs or replacement made other than by CIGWELD or Accredited Service Agents, unless by prior
arrangement with CIGWELD.
Replacement parts or accessories which may affect product safety or performance and which are not
manufactured, distributed or approved by CIGWELD.
4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supply
of goods which are not of a kind ordinarily acquired for personal, domestic or household use or consumption
to any one or more of the following (the choice of which shall be at the option of CIGWELD).
The replacement of the goods or the supply of equivalent goods.
The repair of goods.
The payment of cost of replacing the goods or acquiring equivalent goods.
The payment of the cost of having goods repaired.
5. Except as provided in Clauses 2 to 4 above, to the extent permitted by statute, CIGWELD hereby excludes
all liability for any loss, damage, death or injury of any kind whatsoever occasioned to the Customer in
respect of the supply of goods including direct, indirect, consequential or incidental loss, damage or injury of
any kind.
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Transmigs 220, 250 & 253
8.4 Transmig Warranty Schedule - May 2001
These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of sale from
the Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the warranty period
extend more than the time stated plus one year from the date CIGWELD delivered the product to the Accredited
Distributor. Unless otherwise stated the warranty period includes parts and labour.
CIGWELD reserves the right to request documented evidence of date of purchase.
WARRANTY PERIODGMAW EQUIPMENT
Transmig
Main Welding Transformer and Inductor (Power Magnetics)..........................
.
.
..................... .3 years
Original Main Power Rectifiers, Control P.C. Boards......................................
.
.
.......................1 year
All other circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors..............
.
.
.......................1 year
MIG Torch........................................................................................................
.
.
..................….3 months
Please note that the information detailed in this statement supersedes any prior published data produced by
CIGWELD.
9 Safe Practices For The Use Of Welding Equipment
In many situations the “striking” voltage can be hazardous. Any person touching simultaneously
the electrode lead/terminal and the work lead/terminal may receive a serious electrical shock.
Additional precautions must be exercised where two Welding Power Sources are being used close
to each other because, under certain conditions, the voltages between the welding terminals of the
two Welding Power Sources could be two times the specified open circuit voltage.
It is essential that the Welding Power Source be correctly installed, if necessary, by a qualified
electrician and maintained in sound mechanical and electrical condition. It is also important that
the Welding Power Source be switched off when not in use.
9.1 Precautions to be taken by Operators
♦ Whenever practicable, all parts of the welding circuit should be isolated from earth and other
conducting material and under no circumstances should any earthing conductor of the
electrical installation be used in place of the work lead.
♦ The Mains supply voltage should be switched off before connecting or disconnecting
welding leads. Welding lead connections must have clean contact surfaces and must be
securely tightened. Poor connections will result in overheating and loss of welding current.
All parts of the welding circuit, including the return paths, are to be considered electrically
alive, so the operator must ensure that no part of the body is placed in such a position that it
will provide a path for an electric current.
♦ Welding operators should avoid direct contact with the work to be welded or against any
metal in contact with the work. When this cannot be avoided the operator must not touch
any exposed portion of the MIG Torch with any part of the body. Should this occur, the
operator will risk completing the electrical circuit through the body.
♦ When welding in confined spaces where reasonable movement is restricted ensure that the
area is well ventilated and the operator is under constant observation by a person who can
immediately switch off power and give assistance in an emergency.
♦ During pauses between welding runs, MIG Torch should be so placed that they cannot make
electrical contact with persons or conductive objects.
♦ The welding leads, both the MIG Torch lead and the work lead must be protected from
damage. Damaged leads must not be used.
♦ Keep combustible materials from welding area. Have a suitable fire extinguisher handy.
♦ Do not stand on damp ground when welding.
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Transmigs 220, 250 & 253
9.2 Personal Protection
The radiation from an electric arc during the welding process can seriously harm eyes and skin.
It is essential that the following precautions be taken:
♦ Gloves should be flameproof gauntlet type to protect hands and wrists from heat burns and
harmful radiations. They should be kept dry and in good repair.
♦ Protective clothing must protect the operator from burns, spatter and harmful radiation.
Woollen clothing is preferable to cotton because of its greater flame resistance. Clothing
should be free from oil or grease. Wear leggings and spats to protect the lower portion of
the legs and to prevent slag and molten metal from falling into boots or shoes.
♦ Face Shield, it is recommended to use a welding face shield, conforming to the relevant
standards, when electric arc welding. Use a welding face shield in serviceable condition
and fitted with an eye filter lens to safely reduce harmful radiation from the arc as
described in Table 2.
Description of
Process Approximate Range of Welding Current Amperes Filters Recommended Shade Number
GMAW / FCAW Up to 149 10
GMAW / FCAW 150 – 249 11
GMAW / FCAW 250-300 12
Table 2 - Filter lens size verses welding current
Protective filter lenses are provided to reduce the intensity of radiation entering the eye
thus filtering out harmful infra-red, ultra-violet radiation and a percentage of the visible
light. Such filter lenses are incorporated within face shields. To prevent damage to the
filter lenses from molten or hard particles an additional hard clear glass or special clear
external cover lens is provided. This cover lens should always be kept in place and
replaced before the damage impairs your vision while welding.
10 Resuscitation For Electric Shock Victims
Electric shock may kill immediately. Early resuscitation is required if a life is to be saved. Every
Second Counts! Electrical currents may:
♦ Stop the heart;
♦ Cause contraction of the muscles of the body;
♦ Paralyse breathing due to paralysis of the centre of respiration in the brain;
♦ Cause burns.
The victims often cannot free themselves from the current and may not be able to breathe due to
fixation of the chest.
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Transmigs 220, 250 & 253
10.1 Resuscitation
Efficient resuscitation requires training which is available from the St John’s Ambulance
Association, Red Cross and other sources. 2 If unconscious, place victim on their side and
clear vomit and other foreign matter from mouth.
Check for breathing by look, listen and feel. If
not breathing, commence expired air
resuscitation (E.A.R.). This should take no
longer than 3 or 4 seconds.
1 Don’t become a victim. Switch off power if
possible. If not, remove victim from contact,
using some insulating material.
4 Begin artificial breathing - 5 full breaths in 10
seconds, sealing nostrils with cheek or holding
nose closed.
3 Place victim flat on their back on a hard surface,
open airway - using head tilt and jaw support as
shown.
6 If pulse is absent and you have been trained,
begin cardio pulmonary resuscitation (C.P.R).
Cardiac Compression - depress lower end of
breast bone (sternum) 4cm to 5cm, less for small
children.
5 Check carotid pulse in neck. If pulse is present,
continue E.A.R.
15 breaths per minute for adults.
20 breaths per minute for children.
One rescuer - 2 breaths, 15 compressions in 15
seconds, i.e. 4 cycles per minute.
Two rescuers - 1 breath, 5 compressions in 5
seconds, i.e. 12 cycles per minute.
7 Check for return of pulse and breathing after 1
minute and at least every 2 minutes. Continue
uninterrupted until trained assistance is available.
When breathing and pulse return, turn on side
and continue observation.
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Transmigs 220, 250 & 253
11 Specifications
11.1 MIG Torch Specifications
Torch Part No. T161510302
TD-15
Torch Model No.
Torch Cable Length 3.0m
11.2 Wire Drive Specifications
Motor Supply Voltage 12VAC
Minimum Wire Speed 1m per minute
Maximum Wire Speed 20m per minute
Wire Diameter Mild Steel: 0.6mm (.024”), 0.8mm (.030”), 0.9mm (.035”)
Stainless Steel: 0.6mm (.024”), 0.8mm (.030”), 0.9mm (.035”)
Aluminium: 0.9mm (.035”), 1.0mm (.040”), 1.2mm (.045”)
Flux Cored: 0.8mm (.030”), 0.9mm (.035”), 1.2mm (.045”)
Welding connection 25mm2Dinse Plug
Wire Spool Size 15kg Maximum
Burn-back Time Range 0 to 0.5 Seconds
11.3 Plant Contents for Transmig 220, 250 or 253
Part Number Description
T161510302 Torch
310335 Regulator CO2
704099 Work Lead 3m
719454 Operating Manual
7977036 Feed Roll 0.6/0.8 Hard(fitted)
11.4 Power Source Only Contents for Transmig 220, 250 or 253
Part Number Description
704099 Work Lead 3m
719454 Operating Manual
7977036 Feed Roll 0.6/0.8 Hard(fitted)
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Transmigs 220, 250 & 253
11.5 Machine Specifications
a) For the Single Phase Models Transmig 220 and 250
Description (Refer NOTE 2) TRANSMIG 220 TRANSMIG 250
Plant Assembly 710024 (710025*) 710018 (710019*)
Plant Mass
(*Deduct 2kg for Power Source Only model) 87kg 91kg
Plant Dimensions
(including wheels and cylinder carrier) H 1000mm x W 430mm x D 880mm
Power Source Mass 83kg 86kg
Power Source Dimensions
(fitted wheels and cylinder carrier) H 760mm x W 355mm x L 850mm
Supply Voltage 220V 240V 220V 240V
Supply Phasing 1∅
Frequency 50 Hz / 60 Hz
Input Current @ 100% Duty Cycle 22.4A 20.5A 28.0A 27.0A
Power Input @ 100% Duty Cycle 3.6kVA 3.6kVA 7.3kVA 10
Maximum Input Current ∇44.5A ∇41.0A ∇51.0A ∇49.0A
Generator Requirement ♣10kVA ♣10kVA ♣12kVA ♣12kVA
Supply Power @ no load 970VA 1120VA 970VA 1120VA
Supply VA @ max. output 9.8kVA 9.8kVA 12.2kVA 12.2kVA
Efficiency @ max. output 60% 60% 55% 55%
Power Factor @ max. output 0.85 0.86 0.85 0.86
Open Circuit Voltage Range 18 to 40V 18 to 40V 18 to 42V 18 to 42V
Output Current Range 30 to 220A 30 to 220A 30 to 250A 30 to 250A
Rated Output Duty Cycle 220A @ 25% 250A @ 30%
100% Duty Cycle Output Rating 110A @ 20V 135A @ 21V
Duty Cycle Period 10 minutes
Number of Output Voltage Values 16
Wire Size Range 0.6mm - 1.2mm Hard
0.8mm - 1.2mm Soft
0.8mm - 1.2mm F.C.
∇The Rated Input Current should be used for the determination of cable size & supply requirements.
♣ Generator Requirements at the Maximum Output Duty Cycle.
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