CIGWELD 300Pi Operating Manual
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CIGWELD 300Pi Operating Manual

Transtig welding inverter
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300Pi
Operating Manual
TRANSTIG
weldING INveRTeR
Revision: AD
Issue Date: December 10, 2013
Operating Features:
A-12096
A-12096
Manual No.: 0-5309

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  • Page 1 300Pi TRANSTIG weldING INveRTeR A-12096 A-12096 Operating Manual Revision: AD Issue Date: December 10, 2013 Manual No.: 0-5309 Operating Features:...
  • Page 2 To locate your nearest distributor or 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 While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. Operating Manual Number 0-5309 for: Cigweld Transtig 300Pi Power Source (packed) Part Number W1008300 Published by: CIGWELD Pty Ltd...

  • Page 4: Table Of Contents

    3.04 Mains Supply Voltage Requirements .............. 3-1 3.05 Electromagnetic Compatibility ................ 3-1 3.06 Transtig 300Pi Power Source Controls, Indicators and Features ....3-3 3.07 Setup for TIG (GTAW) Welding ..............3-10 3.08 Setup for Manual Arc (MMAW) Welding ............. 3-14 3.09...
  • Page 5 KEY SPARE PARTS ................... 6-1 6.01 Power Source ....................6-1 6.02 TIG Torch W4014604 ..................6-3 APPENDIX: TRANSTIG 300Pi CIRCUIT DIAGRAM 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 300Pi 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. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
  • Page 8 TRANSTIG 300Pi 2. Wear approved safety glasses. Side shields recom- mended. 3. Use protective screens or barriers to protect others WARNING from flash and glare; warn others not to watch the arc. ARC RAYS can burn eyes and skin; NOISE can damage hearing.
  • Page 9 TRANSTIG 300Pi 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 300Pi 5. Use only correct shielding gas cylinders, a very large volume of scientific findings based on regulators, hoses, and fittings designed for the experiments at the cellular level and from studies specific application; maintain them and associated with animals and people which clearly establish that parts in good condition.

  • Page 11: Principal Safety Standards

    TRANSTIG 300Pi 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. 20402.

  • Page 12: Declaration Of Conformity

    71 Gower St, Preston Victoria 3072 Australia Description of equipment: Welding Equipment (GTAW, MMAW) including, but not limited to CIGWELD Transtig 300Pi Welding Inverter 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.

  • Page 13: Introduction

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

  • Page 14: Symbol Chart

    TRANSTIG 300Pi 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...

  • Page 15: Description

    TRANSTIG 300Pi 2.05 Description 2.07 Transporting Methods The Cigweld Transtig 300Pi is a self contained three This unit is equipped with a handle for carrying phase multi process welding inverter that is capable purposes. of performing MMAW (Stick) and GTAW (HF and Lift TIG) welding processes.

  • Page 16: Duty Cycle

    (300A) for 3.5 minutes, i.e. arc welding time, out of every 10 minute period (35% of 10 minutes is 3.5 minutes). During the other 6.5 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool. A-12097 Figure 2-1: Transtig 300Pi Duty Cycle INTRODUCTION Manual 0-5309...

  • Page 17: Specifications

    250A @ 60%, 20.0V 200A @ 100%, 18.0V Protection Class IP23S Table 2-1: Transtig 300Pi Specifications NOTE 1 Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.

  • Page 18: Options And Accessories

    Minimum Generator Recommendation 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 19: Installation, Operation And Setup

    TRANSTIG 300Pi SECTION 3: INSTALLATION, OPERATION AND SETUP conditions. For further information please refer 3.01 Environment to AS 60529. These units are designed for use in environments with H. Precautions must be taken against the power increased hazard of electric shock as outlined in AS source toppling over.
  • Page 20 TRANSTIG 300Pi action may be as simple as earthing the welding C. Methods of Reducing Electromagnetic circuit, see NOTE below. In other cases it could Emissions involve constructing an electromagnetic screen 1. Mains Supply enclosing the Welding Power Source and the work, complete with associated input filters.

  • Page 21: Transtig 300Pi Power Source Controls, Indicators And Features

    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. 3.06 Transtig 300Pi Power Source Controls, Indicators and Features (Pulse) Art # A-12099_AB...
  • Page 22 TRANSTIG 300Pi Fail to safe operation This welding power source is also protected by a special protection feature called “Fail to Safe Operation” which is available in this model. The output of the power source will be disabled and the fault indicator will illuminate if the “Fail to Safe”...
  • Page 23 TRANSTIG 300Pi (Pulse) A-12100 Figure 3-3: Parameter Led's 6. Positive Welding Output Terminal The positive welding terminal is used to connect the welding output of the power source to the electrode holder lead or work lead. Positive welding current flows from the power source via this heavy duty bayonet type terminal.
  • Page 24 TRANSTIG 300Pi 8. Remote Control Socket The 8 pin Remote Control Socket is used to connect remote control devices to the welding power source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. A-11662 Figure 3-4: Remote Control Socket...
  • Page 25 TRANSTIG 300Pi A-11663 4T Latch Mode This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator can press and release the torch trigger and the output will remain active. To deactivate the power source, the trigger switch must again be depressed and released, thus eliminating the need for the operator to hold the torch trigger.
  • Page 26 TRANSTIG 300Pi Note that when the unit is powered on the mode selection control will automatically default to LIFT TIG/HF TIG mode. This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work piece during power up.
  • Page 27 18. Fan on Demand The Transtig 300Pi is fitted with a fan on demand feature. Fan on demand automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimize the amount of contaminants such as dust that are drawn into the power source.

  • Page 28: Setup For Tig (Gtaw) Welding

    TRANSTIG 300Pi 3.07 Setup for TIG (GTAW) Welding A. Select HF TIG or Lift TIG mode with the process selection control (refer to Section 3.06.11 for further information). B. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the power source via heavy duty bayonet type terminals.
  • Page 29 TRANSTIG 300Pi LIFT TIG and HF TIG Programming Mode Programming Parameter Control Panel Display Pre Flow This parameter operates in 2T and 4T HF TIG mode only and is used to provide gas to the weld zone prior to (Pulse) striking the arc, once the torch trigger switch has been pressed.
  • Page 30 TRANSTIG 300Pi DC Pulse Mode / DC mode This parameter selects DC PULSE operating mode or DC operating mode. (Pulse) Adjust the multi function control knob to change between DC Pulse and DC modes. Range is DC or DC Pulse Mode.
  • Page 31 TRANSTIG 300Pi Pulse Width This parameter sets the percentage “on” time of the PULSE FREQUENCY for BASE weld current when in DC (Pulse) PULSE operating mode. Range is 15 to 80%. Factory default is 50%. A-12109 Pulse Frequency This parameter sets the PULSE FREQUENCY when in DC PULSE operating mode.

  • Page 32: Setup For Manual Arc (Mmaw) Welding

    TRANSTIG 300Pi Crater Current This parameter operates in TIG modes only. In 2T mode this is the current at the (Pulse) end of the down slope current ramp. When the welding current reaches the Crater Current value, the welding current will cease and the unit will enter Post Flow mode.
  • Page 33 TRANSTIG 300Pi A-12114 Figure 3-7: Setup for Manual Arc Welding STICK Programming Mode Programming Parameter Control Panel Display Hot Start This parameter operates in STICK mode to improve the start characteristics for stick electrodes (Pulse) HOT START current is on top of the BASE current.

  • Page 34: Factory Reset

    TRANSTIG 300Pi Programming Parameter Control Panel Display Base Current This parameter sets the STICK weld current. Range is 5 to 300A. Factory default (Pulse) is 120A. A-12116 Arc Force Arc Force is effective when in STICK mode only. Arc Force control provides...

  • Page 35: Shielding Gas Regulator Operating Instructions

    TRANSTIG 300Pi 3.10 Shielding Gas Regulator Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Regulator Safety This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.
  • Page 36 TRANSTIG 300Pi 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 37: Foot Control Part No. W4015800 (Optional Accessory)

    Table 3-3 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 38 TRANSTIG 300Pi Installation Attach the 8-pin connector on the end of the cable to the 8-pin receptacle on the front of the welding machine. To complete the connection, align the keyway, insert the plug, and rotate the threaded collar fully clockwise.

  • Page 39: 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 40 TRANSTIG 300Pi 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 41 TRANSTIG 300Pi 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 42 TRANSTIG 300Pi 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 43 TRANSTIG 300Pi 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.
  • Page 44 TRANSTIG 300Pi from the vertical. Some electrodes require to be sloped about 20º away from the perpendicular position 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 45 TRANSTIG 300Pi 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 46 TRANSTIG 300Pi 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 47 TRANSTIG 300Pi 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 48 TRANSTIG 300Pi 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-07712 Figure 4-26: Chain Intermittent Welding...
  • Page 49 It Blisterpack 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 0-5309 4-11 BASIC WELDING GUIDE...

  • Page 50: Stick (Mmaw) Welding Troubleshooting

    TRANSTIG 300Pi 4.02 Stick (MMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE is set at a val- Reduce the ARC FORCE until welding current is varying ue that causes the welding reasonably constant while prohibiting the elec-...
  • Page 51 TRANSTIG 300Pi 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.

  • Page 52: Tig (Gtaw) Basic Welding Technique

    TRANSTIG 300Pi 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 53 TRANSTIG 300Pi 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...

  • Page 54: Tig (Gtaw) Welding Problems

    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. 4.04 TIG (GTAW) Welding Problems...
  • Page 55 Electrode Selection Chart. B The wrong electrode B Select the right size tungsten electrode is being used for the type. Refer to Table 4-5 Cigweld Tungsten welding job. Electrode Selection Chart. C Gas flow rate is too C Select the right shielding gas flow rate for high.
  • Page 56 TRANSTIG 300Pi BASIC WELDING GUIDE 4-18 Manual 0-5309...

  • Page 57: Power Source Problems And Routine Service Requirements

    D Empty gas cylinder. D Replace gas cylinder. 5 Gas flow continues after A Gas valve has jammed open A Have an accredited CIGWELD the torch trigger switch has due to impurities in the gas service provider repair or replace been released (TIG mode).

  • Page 58: 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's original specifications.
  • Page 59 TRANSTIG 300Pi B. Insulation Resistance Minimum insulation resistance for in-service Cigweld Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 6-1below. Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.
  • Page 60 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 61: Cleaning The Welding Power Source

    TRANSTIG 300Pi 5.03 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.
  • Page 62 TRANSTIG 300Pi POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-6 Manual 0-5309...

  • Page 63: Key Spare Parts

    TRANSTIG 300Pi SECTION 6: KEY SPARE PARTS 6.01 Power Source Art # A-12119_AB Art # A-12120_AB Manual 0-5309 KEY SPARE PARTS...
  • Page 64 TRANSTIG 300Pi A-12121 Figure 6-1 TRANSTIG 300Pi POWER SOURCE SPARE PARTS ITEM PART NUMBER DESCRIPTION W7006400 PCB Assembly, Power Inverter W7006401 PCB EMC Filter W7006402 PCB Filter Control W7006403 PCB Aux Power Supply W7006404 PCB Control W7006405 PCB Assembly, Input Rectifier / DC Bus...

  • Page 65: Tig Torch W

    TRANSTIG 300Pi 6.02 TIG Torch W4014604 TIG Torch W4014604 spare parts diagram A-11669 Figure 6-2 TIG TORCH SPARE PARTS ITEM PART NO. DESCRIPTION W7005900 Trigger assembly for 26F torch W7005901 Handle assembly for 26F torch W7005902 Dinse 50mm for 26F torch...

  • Page 66: Appendix: Transtig 300Pi Circuit Diagram

    TRANSTIG 300Pi APPENDIX: TRANSTIG 300Pi CIRCUIT DIAGRAM Manual 0-5309 APPENDIX...

  • Page 67: Cigweld - Limited Warranty Terms

    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 68: Terms Of Warranty – January

    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 69: Warranty Schedule – January

    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 70 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 71: Global Customer Service Contact Information

    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 72 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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