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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