CIGWELD 200i Specifications

200iOperating ManualRevision: AC Issue Date: January 10, 2012 Manual No.: 0-5209Operating Features:TRANSMIGMULTI

TRANSMIG 200iGENERAL INFORMATION 1-4 Manual 0-52095. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the spec

TRANSMIG 200iManual 0-5209 1-5 GENERAL INFORMATION1.02 PRINCIPAL SAFETY STANDARDSSafety in Welding and Cutting, ANSI Sta

TRANSMIG 200iGENERAL INFORMATION 1-6 Manual 0-52091.03 DECLARATION OF CONFORMITYManufacturer and Merchandiser of Quality Consumables and Equipment:

TRANSMIG 200iManual 0-5209 2-1 INTRODUCTIONSECTION 2: INTRODUCTION 2.02 Equipment IdentificationThe unit’s identification number (specification or par

TRANSMIG 200iINTRODUCTION 2-2 Manual 0-52092.04 Symbol ChartNote that only some of these symbols will appear on your model.Gas Tungsten Arc Welding

TRANSMIG 200iManual 0-5209 2-3 INTRODUCTION2.05 DescriptionThe Cigweld Transmig 200i is a self contained single phase multi process welding inverter

TRANSMIG 200iINTRODUCTION 2-4 Manual 0-52092.09 Duty CycleThe rated duty cycle of a Welding Power Source, is a statement of the time it may be oper

TRANSMIG 200iManual 0-5209 2-5 INTRODUCTION2.10 SpecificationsDescription Transmig 200i (South Pacific Version) Transmig 200i (Asia Version) Plant

TRANSMIG 200iINTRODUCTION 2-6 Manual 0-52092.11 Optional AccessoriesPart Number DescriptionW4013701 Tweco professional Fusion 250A MIG Torch, 3.0 m

TRANSMIG 200iManual 0-5209 3-1 INSTALLATION, OPERATION AND SETUPSECTION 3: INSTALLATION, OPERATION AND SETUPG. The enclosure design of this power

WE APPRECIATE YOUR BUSINESS!Congratulations on your new CIGWELD product. We are proud to have you as our customer and will strive to provide you with

TRANSMIG 200iINSTALLATION, OPERATION AND SETUP 3-2 Manual 0-52093.05 Electromagnetic Compatibility! WARNINGExtra precautions for Electromagnetic C

TRANSMIG 200iManual 0-5209 3-3 INSTALLATION, OPERATION AND SETUP4. Equipotential Bonding Bonding of all metallic components in the welding instal

TRANSMIG 200iINSTALLATION, OPERATION AND SETUP 3-4 Manual 0-52093.06 Transmig 200i Power Source Controls, Indicators and FeaturesOFFONVoltage Reduc

TRANSMIG 200iManual 0-5209 3-5 INSTALLATION, OPERATION AND SETUP3. Digital Amps Meter (Left Digital Display)MIG ModeThis digital meter is used to

TRANSMIG 200iINSTALLATION, OPERATION AND SETUP 3-6 Manual 0-52096. Positive Welding Output TerminalThe positive welding terminal is used to connect

TRANSMIG 200iManual 0-5209 3-7 INSTALLATION, OPERATION AND SETUP9. Remote Control SocketThe 8 pin Remote Control Socket is used to connect remote

TRANSMIG 200iINSTALLATION, OPERATION AND SETUP 3-8 Manual 0-5209When MMAW (Stick) Mode is SelectedIn this mode the multifunction control knob is use

TRANSMIG 200iManual 0-5209 3-9 INSTALLATION, OPERATION AND SETUP14. Digital Voltage Meter (Right Digital Display)MIG ModeThis digital meter is used

TRANSMIG 200iINSTALLATION, OPERATION AND SETUP 3-10 Manual 0-520917. On / Off SwitchThis Single Phase circuit breaker performs a dual function. It i

TRANSMIG 200iManual 0-5209 3-11 INSTALLATION, OPERATION AND SETUP20. Burnback Control (located in wirefeed compartment) The burnback control is use

! WARNINGSRead and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.While

TRANSMIG 200iINSTALLATION, OPERATION AND SETUP 3-12 Manual 0-52093.08 Installing Spool (300mm diameter) As delivered from the factory, the unit is

TRANSMIG 200iManual 0-5209 3-13 INSTALLATION, OPERATION AND SETUP3.10 Inserting Wire into the Wire Feed MechanismRelease the tension from the pres

TRANSMIG 200iINSTALLATION, OPERATION AND SETUP 3-14 Manual 0-52093.11 Feed Roller Pressure AdjustmentThe pressure (top) roller applies pressure to

TRANSMIG 200iManual 0-5209 3-15 INSTALLATION, OPERATION AND SETUP3.13 Wire Reel BrakeThe wire reel hub incorporates a friction brake which is adju

TRANSMIG 200iINSTALLATION, OPERATION AND SETUP 3-16 Manual 0-52094. DO NOT use the regulator as a control valve. When downstream equipment is not i

TRANSMIG 200iManual 0-5209 3-17 INSTALLATION, OPERATION AND SETUPOperationWith the regulator connected to cylinder or pipeline, and the adjustment

TRANSMIG 200iINSTALLATION, OPERATION AND SETUP 3-18 Manual 0-52093.15 Setup for MIG (GMAW) Welding with Gas Shielded Mig WireA. Select MIG mode wi

TRANSMIG 200iManual 0-5209 3-19 INSTALLATION, OPERATION AND SETUP3.16 Setup for MIG (GMAW) Welding with Gasless Mig WireA. Select MIG mode with t

TRANSMIG 200iINSTALLATION, OPERATION AND SETUP 3-20 Manual 0-52093.17 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded Mig WireA. Select M

TRANSMIG 200iManual 0-5209 3-21 INSTALLATION, OPERATION AND SETUP3.18 Setup for TIG (GTAW) WeldingA. Select Lift TIG mode with the process select

TABLE OF CONTENTSSECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ... 1-11.01 Arc Welding Hazards ...

TRANSMIG 200iINSTALLATION, OPERATION AND SETUP 3-22 Manual 0-52093.19 Setup for STICK (MMAW) Welding A. Connect the Electrode Holder lead to the p

TRANSMIG 200iManual 0-5209 4-1 BASIC WELDING GUIDESECTION 4: BASIC WELDING GUIDE 4.01 MIG (GMAW/FCAW) Basic Welding TechniqueTwo different welding

TRANSMIG 200iBASIC WELDING GUIDE 4-2 Manual 0-5209Position of MIG TorchThe angle of MIG torch to the weld has an effect on the width of the weld.Pus

TRANSMIG 200iManual 0-5209 4-3 BASIC WELDING GUIDEVertical Fillet WeldsArt # A-0899530° to 60° Transverse Angle30° to 60° Transverse AngleDirection

TRANSMIG 200iBASIC WELDING GUIDE 4-4 Manual 0-5209Secondary Adjustable VariablesThese variables cause changes in primary adjustable variables which

TRANSMIG 200iManual 0-5209 4-5 BASIC WELDING GUIDEEstablishing the Arc and Making Weld BeadsBefore attempting to weld on a finished piece of work, it

TRANSMIG 200iBASIC WELDING GUIDE 4-6 Manual 0-5209Cigweld MIG Wire Selection ChartCigweld Welding Wire Selection ChartDescriptionPart Number0.8mmHan

TRANSMIG 200iManual 0-5209 4-7 BASIC WELDING GUIDE4.02 MIG (GMAW/FCAW) Welding TroubleshootingSolving Problems Beyond the Welding TerminalsThe gene

TRANSMIG 200iBASIC WELDING GUIDE 4-8 Manual 0-5209Solving Problems Beyond the Welding Terminals - Inconsistent Wire FeedWire feeding problems can be

TRANSMIG 200iManual 0-5209 4-9 BASIC WELDING GUIDEBasic GMAW (MIG) Welding TroubleshootingFAULT CAUSE REMEDY1 Undercut A Welding arc voltage too hig

TABLE OF CONTENTSSECTION 4: BASIC WELDING GUIDE ... 4-14.01 MIG (GMAW/FCAW)

TRANSMIG 200iBASIC WELDING GUIDE 4-10 Manual 0-52094.03 Stick (MMAW) Basic Welding TechniqueSize of ElectrodeThe electrode size is determined by th

TRANSMIG 200iManual 0-5209 4-11 BASIC WELDING GUIDEArt # A-07687Figure 4-11: Flat Position, Down Hand Butt WeldArt # A-07688Figure 4-12: Flat Positi

TRANSMIG 200iBASIC WELDING GUIDE 4-12 Manual 0-5209Art# A-07693 Figure 4-17: Overhead Position, Butt WeldArt # A-07694Figure 4-18: Overhead Position

TRANSMIG 200iManual 0-5209 4-13 BASIC WELDING GUIDEArc Welding Technique - A Word to BeginnersFor those who have not yet done any welding, the simpl

TRANSMIG 200iBASIC WELDING GUIDE 4-14 Manual 0-5209Rate of TravelAfter the arc is struck, your next concern is to maintain it, and this requires mov

TRANSMIG 200iManual 0-5209 4-15 BASIC WELDING GUIDEB. Fillet WeldsThese are welds of approximately triangular cross-section made by depositing meta

TRANSMIG 200iBASIC WELDING GUIDE 4-16 Manual 0-5209C. Vertical Welds1. Vertical Up Tack weld a three feet length of angle iron to your work bench

TRANSMIG 200iManual 0-5209 4-17 BASIC WELDING GUIDE3. Overhead Welds Apart from the rather awkward position necessary, overhead welding is not muc

TRANSMIG 200iBASIC WELDING GUIDE 4-18 Manual 0-5209DistortionDistortion in some degree is present in all forms of welding. In many cases it is so sm

TRANSMIG 200iManual 0-5209 4-19 BASIC WELDING GUIDEB. Distribution of StressesDistortion may be reduced by selecting a welding sequence which will

TRANSMIG 200iBASIC WELDING GUIDE 4-20 Manual 0-5209Art # A-07710_AB1Block Sequence.The spaces between the welds are filled in when the welds are cool

TRANSMIG 200iManual 0-5209 4-21 BASIC WELDING GUIDEElectrode Selection ChartCIGWELD Electrode Selection ChartDescription Diameter Pack Part No. Appl

TRANSMIG 200iBASIC WELDING GUIDE 4-22 Manual 0-52094.04 Stick (MMAW) Welding TroubleshootingFAULT CAUSE REMEDY1 Welding current varyingARC FORCE co

TRANSMIG 200iManual 0-5209 4-23 BASIC WELDING GUIDE5 Portions of the weld run do not fuse to the surface of the metal or edge of the joint.A Small e

TRANSMIG 200iBASIC WELDING GUIDE 4-24 Manual 0-52094.05 TIG (GTAW) Basic Welding TechniqueGas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Ga

TRANSMIG 200iManual 0-5209 4-25 BASIC WELDING GUIDETungsten Electrode TypesElectrode Type (Ground Finish)Welding Application Features Colour CodeTho

TRANSMIG 200iBASIC WELDING GUIDE 4-26 Manual 0-5209TIG Welding Filler RodsComweld RodAust Std AWS Std Part No. 1.6mmPart No. 2.4mmPart No. 3.2mmType

TRANSMIG 200iManual 0-5209 4-27 BASIC WELDING GUIDE4.06 TIG (GTAW) Welding ProblemsFAULT CAUSE REMEDY1 Excessive bead build up or poor penetration

TRANSMIG 200iBASIC WELDING GUIDE 4-28 Manual 0-52097 Dirty weld pool A Electrode contaminated by contact with work piece or filler rod mate-rial.A Cl

TRANSMIG 200iManual 0-5209 5-1 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTSSECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREME

TRANSMIG 200iManual 0-5209 1-1 GENERAL INFORMATION1.01 ARC WELDING HAZARDS WARNING ELECTRIC SHOCK can kill.Touching liv

TRANSMIG 200iPOWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-2 Manual 0-52098

TRANSMIG 200iManual 0-5209 5-3 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTSB. Insulation ResistanceMinimum insulation resistance for in-

TRANSMIG 200iPOWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-4 Manual 0-5209E.

TRANSMIG 200iManual 0-5209 5-5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS5.03 Cleaning the Welding Power Source WARNINGThere are dang

TRANSMIG 200iPOWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-6 Manual 0-52095.

TRANSMIG 200iManual 0-5209 6-1 KEY SPARE PARTSSECTION 6: KEY SPARE PARTS6.01 Power Source 12368791011 12141315161719204 5 Art # A-10436Item Part N

TRANSMIG 200iKEY SPARE PARTS 6-2 Manual 0-52096.02 Tweco Fusion 250 Mig TorchMIG Torch Part No: W4013701A-0965921 437557678TWECO FUSION MIG TORCH P

TRANSMIG 200iManual 0-5209 7-1 APPENDIXSECTION 7: TRANSMIG 200i CIRCUIT DIAGRAMQ1T14ANEEMCFILTERR39CY1POSITIVENEGATIVE24VDC FANC20Q2T1R100, 102C100

CIGWELD - LIMITED WARRANTY TERMSLIMITED WARRANTY: CIGWELD Pty Ltd, A Thermadyne Company, hereafter, “CIGWELD” warrants to custom-ers of its authorized

TERMS OF WARRANTY – JULY 20101. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply of goods a

TRANSMIG 200iGENERAL INFORMATION 1-2 Manual 0-5209 WARNINGARC RAYS can burn eyes and skin; NOISE can damage hearing.Arc rays from the welding proce

WARRANTY SCHEDULE – JULY 2010These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of sale from the

GLOBAL CUSTOMER SERVICE CONTACT INFORMATIONCigweld, Australia71 Gower StreetPreston, VictoriaAustralia, 3072Telephone: 61-3-9474-7400Fax: 61-3-9474-7

Asia Pacific Regional Headquarters71 Gower StreetPreston, Victoria, Australia, 3072Telephone: +61 3 9474 7400FAX: +61 3 9474 7391Email: enqui

TRANSMIG 200iManual 0-5209 1-3 GENERAL INFORMATION WARNINGFUMES AND GASES can be hazardous to your health.Welding produc