CIGWELD A-12030 Operating Manual
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CIGWELD A-12030 Operating Manual

220ac/dc 300ac/dc transtig welding machine
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220AC/DC
300AC/DC
Operating Manual
TRANSTIG
welDING MAChINe
Revision: AB
Operating Features:
Issue Date: February 28, 2014
A-12030
Manual No: 0-5293

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  • Page 1 220AC/DC TRANSTIG 300AC/DC welDING MAChINe A-12030 Operating Manual Revision: AB Issue Date: February 28, 2014 Manual No: 0-5293 Operating Features:...
  • Page 2 To locate your nearest distributor or Accredited Service Provider call +1300 654 674, or visit us on the web at www.cigweld.com.au This Operating Manual has been designed to instruct you on the correct use and operation of your CIGWELD product.
  • Page 3 Manufacturer assumes no liability for its use. Welding Power Supply Operating Manual Number 0-5293 for: Cigweld Transtig 220AC/DC Inverter Plant Part Number W1007220 Cigweld Transtig 220AC/DC Power Source (Packed) Part Number W1007221 Cigweld Transtig 300AC/DC Power Source (Packed) Part Number W1007301 Published by:...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ........1-1 1.01 Arc Welding Hazards ..................1-1 1.02 Principal Safety Standards ................1-5 1.03 Declaration of Conformity ................1-6 SECTION 2: INTRODUCTION ..................2-1 2.01 How To Use This Manual ................2-1 2.02 Equipment Identification .................
  • Page 5 220AC/DC Power Source ................6-1 6.02 300AC/DC Power Source ................6-3 APPENDIX A: CIRCUIT DIAGRAM OF 220AC/DC APPENDIX B: CIRCUIT DIAGRAM OF 300AC/DC CIGWELD - LIMITED WARRANTY TERMS TERMS OF WARRANTY – January 2013 WARRANTY SCHEDULE – January 2013 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION...

  • Page 7: Arc Welding Safety Instructions And Warnings

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS.
  • Page 8 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 2. Wear approved safety glasses. Side shields recom- mended. WARNING 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the ARC RAYS can burn eyes and skin; NOISE arc.
  • Page 9 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. WARNING 4. Be alert that welding sparks and hot materials from FUMES AND GASES can be hazardous to welding can easily go through small cracks and your health.
  • Page 10 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 5. Use only correct shielding gas cylinders, The following is a quotation from the General Con- regulators, hoses, and fittings designed for the clusions Section of the U.S. Congress, Office of specific application; maintain them and associated Technology Assessment, Biological Effects of Power parts in good condition.

  • Page 11: Principal Safety Standards

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 12: Declaration Of Conformity

    71 Gower St, Preston Victoria 3072 Australia Description of equipment: CIGWELD Transtig 220AC/DC and 300AC/DC INVERTER Power Source and associ- ated accessories. * Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

  • Page 13: Introduction

    Use care to avoid damaging the Additional copies of this manual may be purchased equipment when using bars, hammers, etc., to un- by contacting CIGWELD at the address and phone crate the unit. number for your location listed in the inside back cover of this manual.

  • Page 14: Symbol Chart

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 2.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier...

  • Page 15: Description

    • Electrode Holder with 5m lead become necessary, it is recommended that such re- • Work Clamp with 5m lead pairs be carried out by appropriately qualified persons approved by CIGWELD. Advice in this regard can • Shielding Gas Hose Assembly be obtained by contacting an Accredited CIGWELD • Shoulder Strap Distributor.

  • Page 16: Duty Cycle

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Transtig 300AC/DC Inverter Power Source (Part No. W1007301) • Transtig 300 AC/DC Inverter Power Source • Shoulder Strap • Operating Manual • Shielding Gas Hose Assembly 2.09 Duty Cycle The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts.

  • Page 17: Specifications

    Note 4: Generator Requirements at the Maximum Output Duty Cycle. Due to large variations in performance and specifications of different brands and types of genera- tors, Cigweld cannot guarantee full welding output power or duty cycle on every brand or type of generator.

  • Page 18: Optional Accessories

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Cigweld recommends that when selecting a generator, that the particular power source / generator combination be adequately trialled to ensure the combination performs to the users expectations. Note 5: CIGWELD reserves the right to change product performance and specifications without notice.

  • Page 19: Installation, Operation And Setup

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE SECTION 3: INSTALLATION, OPERATION AND SETUP 3.01 Environment conditions. For further information please refer to AS 60529. These units are designed for use in environments H. Precautions must be taken against the power with increased hazard of electric shock as outlined in source toppling over.

  • Page 20: High Frequency Interference

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see NOTE below. In other cases WARNING COMPUTER it could involve constructing an electromagnetic It is also possible that operation close screen enclosing the Welding Power Source and to computer installations may cause the work, complete with associated input filters.
  • Page 21 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE C. Methods of Reducing Electromagnetic Emissions 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.

  • Page 22: Transtig 220Ac/Dc And 300Ac/Dc Power Source Controls, Indicators And Features

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 3.08 TRANSTIG 220AC/DC and 300AC/DC Power Source Controls, Indicators and Features A-12033 Figure 3-1: Controls on Front and Rear Panel 1. Electrode Welding Terminal Electrode Welding Terminal. Welding current flows from the Power Source via heavy duty bayonet type terminals.
  • Page 23 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 3. Worklead Welding Terminal Worklead Welding Terminal. 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 CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the...
  • Page 24 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE A-12034 Figure 3-3: 14 Pin Remote Control Socket Socket Pin Part Number / Description Trigger Switch Input Trigger Switch Input Remote Control 5k ohm Potentiometers Maximum Remote Control 5k ohm Potentiometers Wiper Remote Control 5k ohm Potentiometers Minimum Remote Control Enable (Short to common to enable remote control) Common Remote 2T (short to common to select remote control active in 2T operation mode only)
  • Page 25 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 10. Welding Mode Button Press the MODE button to select the Welding Process mode. Available modes are GTAW 2T, GTAW 4T, GTAW Spot, GTAW Pulse 2T, GTAW Pulse 4T, and MMAW. 11. MMAW indicator light This light will illuminate when the power source is in MMAW welding mode.
  • Page 26 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 23. FORWARD Welding Parameter Button Press the FORWARD welding parameter button to scroll right through the available welding parameters. 24. Multi Function Control Turn the MULTI FUNCTION CONTROL to adjust the available welding parameters. When not welding, the Multi Function Control is used to adjust all welding parameters, including welding amps.
  • Page 27 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 30. mm indicator light This light will illuminate when “mm” are being shown on the Digital Volt meter Display for electrode diameter size. 31. HOLD indicator light This light will illuminate when the HOLD function is active on the Digital Display at the completion of welding. 32.
  • Page 28 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 41. Initial Current amps (GTAW) and Hot Start amps (MMAW) indicator light This light will illuminate when the Initial Current Amps Welding Parameter is selected in GTAW mode, or when Hot Start Amps Welding Parameter is selected in MMAW mode. 42.

  • Page 29: Setup For Tig (Gtaw) Welding

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 3.09 Setup for TIG (GTAW) Welding A. Select a GTAW operation mode with the welding mode & welding type buttons (refer to Section 3.10 for further information). B. Connect the TIG Torch to the Electrode welding terminal (top). Welding current flows from the power source via heavy duty bayonet type terminals.
  • Page 30 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE A-12037 Figure 3-6: Setup for TIG Welding INSTALLATION, OPERATION AND SETUP 3-12 Manual 0-5293...
  • Page 31 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE • First, select a Welding Type by pressing the Weld Type (17) button. Welding Type Welding Type Selection DC HF TIG AC Lift TIG DC Lift TIG AC HF TIG • Then, select a Welding Mode by pressing the WELDING MODE (10) button. Welding Welding Mode Selection Mode 2T (Normal Mode) 4T (Latch Mode) Tip Tronic (used to recall saved jobs)

  • Page 32: Transtig 220Ac/Dc And 300Ac/Dc - Tig (Gtaw) Programming Mode

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 3.10 TRANSTIG 220AC/DC and 300AC/DC - TIG (GTAW) Programming Mode A-12039 Figure 3-7: TIG Programming Mode • Press the WELDING MODE (10) button to select the appropriate GTAW mode. Several GTAW operating modes are available. 2T (normal mode). The 2T LED (16) will illuminate. 4T (latch mode). The 4T LED (15) will illuminate. Tiptronic.
  • Page 33 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Use the Multi Function Control (24) to adjust the Electrode size being used. • Press the BACK button (22) or FORWARD button (23) until the Base Current A1 Led (44) is illuminated. Use the Multi Function Control (24) to adjust the Welding Current for the Electrode size being used. If the Welding Current does not match the normal operating range of the electrode the Electrode Diameter Out-of-Range indictor Led (50) will illuminate.
  • Page 34 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Up Slope Time This parameter operates in 0 - 99% GTAW modes only and is used to set the time for the weld current to ramp up from Initial current to welding current. Welding Current A1 Transtig 220AC/DC 3 - 220 A Transtig 300AC/DC...
  • Page 35 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE AC balance (AC Output Mode only) This parameter operates in AC 10 – 90% positive GTAW modes and is used to set welding current the penetration to cleaning action ratio for the AC weld current. Generally WAVE BALANCE is set to 50% for AC STICK welding.

  • Page 36: Tig (Gtaw) Welding Secondary Parameters

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Maximum weld penetration is achieved when the AC BALANCE is set to 10%. Maximum cleaning of heavily oxidised aluminium or magnesium alloys is achieved when the WAVE BALANCE is set to 90%. AC Balance = 50% AC Balance = 10% AC Balance = 65% Balanced with 50% penetration...

  • Page 37: Gtaw Spot Welding Mode With Dwell Time (Stitch Mode)

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Software Version Information 3.02 Slope On / Off The up slope and down slope can be disabled. When this feature is set to OFF, current increase, current decrease, initial current and crater current are not available in the main parameters.

  • Page 38: Tip Tronic Operation

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE • Press the BACK button (22) or FORWARD button (23) to select the “PSP” Parameter. • Use the Multi Function Control (24) to set “PSP” to ON (to enable stitch welding • Press the BACK button (22) or FORWARD button (23) until the Base Current A1 Led (44) is illuminated. Use the Multi Function Control (24) to adjust the Welding Current for the Electrode size being used. If the Welding Current does not match the normal operating range of the electrode the Electrode Diameter Out-of- Range indictor Led (50) will illuminate.
  • Page 39 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE • Set all the required GTAW welding parameters. Using the Welding Mode button (10) and the Welding Type button (17). Do NOT select TipTronic mode (14) at this stage. As an example, we may select HF, AC, 4T Pulse GTAW (LED’s 18, 21, 16 and 12 will be illuminated. •...

  • Page 40: Setup For Stick (Mmaw) Welding

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE In our example we are copying from Job Number 2-9. • Press the SAVE button (54). • Use the Multi Function Control (24) to select the “destination” job set number and the job number. In our example we are copying to Job Number 6-7. • Press and hold the SAVE button (54) until all LED’s illuminate briefly to indicate a Save has been completed 3.14 Setup for STICK (MMAW) Welding A.
  • Page 41 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE A-12042_AB Figure 3-10: Setup for Manual Arc Welding. • First, select Stick Mode by pressing the Welding Mode (10) button. Welding Type Welding Mode Selection Stick Mode Manual 0-5293 3-23 INSTALLATION, OPERATION AND SETUP...

  • Page 42: Transtig 220Ac/Dc And 300Ac/Dc- Stick (Mmaw)Programming Mode

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE • Then, select Welding Type by pressing the welding Type (17) button. Welding Type Welding Type Selection DC Negative Stick DC Positive Stick 3.15 TRANSTIG 220AC/DC and 300AC/DC- STICK (MMAW)Programming Mode A-12043 Figure 3-11: Stick Programming Mode • Press the WELDING MODE (10) button to select MMAW mode. The MMAW Led (11) will illuminate. • Following MMAW operating modes are available. DC Negative mode. DC Negative Led (19) will illuminate. DC Positive mode.
  • Page 43 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Use the Multi Function Control (24) to adjust the Hot Start Amps Time. • Press the BACK button (22) or FORWARD button (23) until the Base Current A1 Led (44) is illuminated. Use the Multi Function Control (24) to adjust the Welding Current for the Electrode size being used. If the Welding Current does not match the normal operating range of the electrode the Electrode Diameter Out-of-Range indictor Led (50) will illuminate.
  • Page 44 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE A-12044 Figure 3-12: Stick Programming Mode Press and hold the WELDING MODE (10) button then press the SAVE (54) button. The Arc Dynamic Parameter is selected. In the left hand AMPS display dAr is displayed. In the right hand VOLTS display, the value of the parameter is displayed.

  • Page 45: User Specific Menus And Dead Man Switch Mode

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 3.16 User Specific Menus and Dead Man Switch Mode A-12045 Figure 3-13: User Specific Menus and Dead Man Switch Mode • Switch off the power to the unit. Press and hold the BACK Welding Parameter Button (22) . Switch on the power to the unit. The User Specific Menus are activated.

  • Page 46: Mmaw (Stick) Dead Man Switch Mode

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE C08 – Foot Control Minimum Current (GTAW AC mode only) When set to “ON” the increased Foot Control Minimum current is disabled and the minimum current on any electrode is 5A. When set to “OFF” the increased Foot Control Minimum current is enabled.
  • Page 47 Approval from a mine site manager, or work site manager must be obtained in writing before the Dead Man Switch function is altered. Only a suitably qualified electrical tradesperson or Cigweld Service Agent should make any changes to the Power Source.

  • Page 48: Special Function

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 3.18 Special Function Soft Reset • Press and hold the BACK button (22). • Press the SAVE button (54). • All control panel LED’s will light up briefly to confirm the Soft Reset has been completed,. A-12046 Figure 3-15: Soft Reset Master Reset WARNING All saved TipTronic jobs will be erased. All welding and secondary parameters will be restored to the factory setting. •...
  • Page 49 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Control Panel Test • Press and hold the BACK button (22). • Press the FORWARD button (23). • All control panel LED’s and meter displays will light up for approximately 4 seconds. A-12048 Figure 3-17: Control Panel Test Fan Test • Press and hold the BACK button (22). • Press the WELDING TYPE button (17). • The fan will run for approximately 30 seconds. • If the BACK button (22) and WELDING TYPE button (17) are pressed again while the fan is running, the fan test is halted. A-12049 Figure 3-18: Fan Test Manual 0-5293 3-31 INSTALLATION, OPERATION AND SETUP...

  • Page 50: Information Messages

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Water Pump Test Only for water pump with Net Connection interface • Press and hold the FORWARD button (22). • Press the WELDING TYPE button (17). • The Water Cooler (Net Connection type) will run for approximately 30 seconds. If there is an error, or no pump is connected, the error message will be displayed after approximately 5 seconds. A-12050 Figure 3-19: Water Pump Test 3.19 Information Messages...

  • Page 51: Error Messages

    Accredited CIGWELD Service Provider check the power source. Table 3-11: Information Messages 3.20 Error Messages If a message has been displayed, have an Accredited CIGWELD Service Provider check the power source. Message Code Error Cause Possible Remedy Thermal Overload of...
  • Page 52 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Message Code Error Cause Possible Remedy Power Section Fault Power Section start H a v e a n A c c r e d i t e d up Fault C I G W E L D S e r v i c e Provider check the power source Temperature Sensor...

  • Page 53: Shielding Gas Regulator Operating Instructions

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Power Module Power Module not H a v e a n A c c r e d i t e d symmetrical C I G W E L D S e r v i c e Provider check the power source Table 3-12: Error Message...
  • Page 54 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Art: A-05087 Figure 3-20: Fit Regulator to Cylinder Installation 1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices and damage seats before connecting the regulator. Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition.
  • Page 55 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Adjusting Flow Rate Art: A-05088_AB Figure 3-21: Adjust Flow Rate With the regulator ready for operation, adjust working flow rate as follows: 1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate.

  • Page 56: Foot Control, Part No. W4015800 (Optional Accessory)

    Table 3-13: 8 Pin Socket Description The CIGWELD Foot Control is a foot operated switch and potentiometer which starts and stops the welding process and controls welding current through operation of the foot pedal. Refer to list below for compatible Cigweld power sources.
  • Page 57 50%. Should 100% output be required, the respective front panel control must be set to 100% or maximum, in which case the remote device will then be able to control between 1-100% output. This foot control is compatible with the following Cigweld power sources: WeldSkill 200AC/DC Part No: W1006202...
  • Page 58 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE INSTALLATION, OPERATION AND SETUP 3-40 Manual 0-5293...

  • Page 59: Basic Welding Guide

    Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited CIGWELD Distributor. Effects of Arc Welding Various Materials A.
  • Page 60 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Welding Position The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these.
  • Page 61 TRANSTIG 220 AC/DC AND 300AC/DC POWER SOURCE Art# A-07693 Figure 4-7: Overhead Position, Butt Weld Art # A-07694 Figure 4-8: Overhead Position, Fillet Weld Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.
  • Page 62 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Arc Welding Technique - A Word to Beginners For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position.
  • Page 63 TRANSTIG 220 AC/DC AND 300AC/DC POWER SOURCE If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. If the travel is too slow, the weld metal piles up and the bead will be too large. Making Welded Joints Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.
  • Page 64 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE to prevent slag from running ahead of the weld. Refer to Figure 4-13. Do not attempt to build up much larger than 6.4mm width with a 3.2mm electrode, otherwise the weld metal tends to sag towards the base, and undercut forms on the vertical leg.
  • Page 65 TRANSTIG 220 AC/DC AND 300AC/DC POWER SOURCE Art # A-07702 Figure 4-16: Multi Run Vertical Fillet Weld Art # A-07703 Figure 4-17: Examples of Vertical Fillet Welds 2. Vertical Down The Ferrocraft 21 electrode makes welding in this position particularly easy. Use a 3.2mm electrode at 100 amps.
  • Page 66 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Distortion Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur.
  • Page 67 TRANSTIG 220 AC/DC AND 300AC/DC POWER SOURCE B. Distribution of Stresses Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 4-20 through 4-23 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it.
  • Page 68 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool. Figure 4-24: Welding Sequence Art # A-07711_AB Figure 4-25: Step back Sequence Art # A-07428_AB Figure 4-26: Chain Intermittent Welding Art # A-07713_AB Figure 4-27: Staggered Intermittent Welding BASIC WELDING GUIDE...
  • Page 69 It 2.5/3.2mm Blisterpack 322217 has better “wetting” action than Castcraft 55. 4.0mm 2.5 kg 611734 Table 4-1: CIGWELD Electrode Selection Chart Further information on CIGWELD electrodes can be found at the website www.cigweld.com.au Manual 0-5293 4-11 BASIC WELDING GUIDE...

  • Page 70: Stick (Mmaw) Welding Troubleshooting

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 4.02 Stick (MMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE parameter is Reduce the ARC FORCE parameter until welding varying set at a value that causes current is reasonably constant while prohibit- the welding current to vary ing the electrode from sticking to the work piece excessively with the arc...
  • Page 71 TRANSTIG 220 AC/DC AND 300AC/DC POWER SOURCE 5 Portions of the A Small electrodes used on A Use larger electrodes and preheat the plate. weld run do not heavy cold plate. fuse to the surface B Welding current is too low. B Increase welding current. of the metal or C Wrong electrode angle.

  • Page 72: Tig (Gtaw) Basic Welding Technique

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 4.03 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non- consumable) electrode and the work piece.
  • Page 73 TRANSTIG 220 AC/DC AND 300AC/DC POWER SOURCE Tungsten Electrode Types Electrode Type Welding Application Features Colour Code (Ground Finish) DC welding of mild Excellent arc starting, Thoriated 2% steel, stainless steel Long life, High current and copper carrying capacity High quality AC weld- Self cleaning, Long ing of aluminium, life, Maintains balled...
  • Page 74 Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www. cigweld.com.au or contact CIGWELD. BASIC WELDING GUIDE...

  • Page 75: Tig (Gtaw) Welding Problems

    TRANSTIG 220 AC/DC AND 300AC/DC POWER SOURCE 4.04 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive bead build up or Welding current is too Increase weld current and/or faulty joint poor penetration or poor preparation. fusion at edges of weld. 2 Weld bead too wide and Welding current is too Decrease weld current.
  • Page 76 9 Arc start is not smooth. A Tungsten electrode is A Select the right size tungsten electrode. too large for the weld- Refer to Table 4-3 CIGWELD Tungsten ing current. Electrode Selection Chart. B The wrong electrode B Select the right tungsten electrode type.

  • Page 77: Power Source Problems And Routine Service Requirements

    If major complex subassemblies are faulty, then the Welding Power Source must be returned to an ac- credited CIGWELD Service Provider for repair. The basic level of troubleshooting is that which can be performed without special equipment or knowledge. Refer also to section 4 for solving welding problems.

  • Page 78: Routine Service And Calibration Requirements

    The inspection and testing of the power source and associated accessories shall be carried out in accordance with Section 5 of AS 1674.2 - 2007: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with CIGWELD original specifications.
  • Page 79 Output current (A) to be checked to ensure it falls within applicable CIGWELD power source specifications Output Voltage (V) to be checked to ensure it falls within applicable CIGWELD power source specifications Accuracy of digital meters to be checked to ensure it falls within applicable CIGWELD power source specifi- cations...

  • Page 80: Cleaning The Welding Power Source

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE C. Calibration Equipment All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question. Only test equipment with valid calibration certificates (NATA certified laboratories) shall be utilized. 5.04 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product.

  • Page 81: Key Spare Parts

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE SECTION 6: KEY SPARE PARTS 6.01 220AC/DC Power Source A-12051_AB Figure 6-1: Transtig 220AC/DC Spare Parts Manual 0-5293 KEY SPARE PARTS...
  • Page 82 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Transtig 220AC/DC Spare Parts Item Part Number Description W7006300 Cover Control Panel W7006301 Gas Outlet, Front Panel W7006302 Gas inlet, Rear Panel W7006303 Knob, Control W7006304 PCB Secondary Rectifier W7006305 PCB Control W7006306 PCB Primary Inverter W7006307 PCB Display W7006308...

  • Page 83: 300Ac/Dc Power Source

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 6.02 300AC/DC Power Source A-12052_AB Figure 6-2: Transtig 300AC/DC Spare Parts Manual 0-5293 KEY SPARE PARTS...
  • Page 84 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Transtig 300AC/DC Spare Parts Item Part Number Description W7006300 Cover Control Panel W7006301 Gas Outlet, Front Panel W7006302 Gas inlet, Rear Panel W7006303 Knob, Control W7006323 PCB Secondary Rectifier W7006330 PCB Control W7006322 PCB Primary Inverter W7006307 PCB Display W7006324...
  • Page 85 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE APPENDIX A: CIRCUIT DIAGRAM OF 220AC/ A-12053 X11/1 X12/1 X11/2 X13/1 X12/2 X4/2 X12/3 X13/2 X4/4 X12/4 X15/1 X4/3 X12/5 X4/1 X12/6 X15/2 X12/8 LP10 LP11 PFC1 X2/1 X10/1 X2/2 X10/2 X2/3 X10/3 X2/4 X10/4 X18/1 +VCC...
  • Page 86 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE APPENDIX B: CIRCUIT DIAGRAM OF 300AC/ A-12054 X12/1 X11/1 X12/2 X11/2 X3/1 X12/3 X13/1 X3/2 X12/4 X12/5 X3/4 X12/6 X3/5 X12/7 X13/2 X3/6 X12/8 X15/1 X2/1 X10/1 X2/2 X10/2 X2/3 X10/3 X15/2 LP1A LP2A LP3A X18/1 X18/2...
  • Page 87 WELD whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of CIGWELD is authorized to change this warranty in any way or grant any other warranty.
  • Page 88 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).
  • Page 89 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.
  • Page 90 To make a claim under the warranty, take the product (with proof of purchase from a Cigweld Accredited Seller) to the store where you purchased the product or contact Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider.
  • Page 91 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Victor Technologies, China CIGWELD, Australia 71 Gower Street No 100 Lao Hongjing Rd Preston, Victoria Minhang District Shanghai, PR, 200235 Australia, 3072 Telephone: 61-3-9474-7400 Telephone: 86-21-64072626 Fax: 86-21-64483032 Fax: 61-3-9474-7391 Email: enquiries@cigweld.com.au Victor Technologies Asia Sdn Bhd...
  • Page 92 Asia Pacific Regional Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX: +61 3 9474 7391 Email: enquiries@cigweld.com.au www.cigweld.com.au...

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