CIGWELD A-12030 Operating Manual Download

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TRANSTIG 220 AC/DC AND 300AC/DC POWER SOURCE

Manual 0-5293

4-15

BASIC WELDING GUIDE

Tungsten Electrode Types

Electrode Type

(Ground Finish)

Welding Application

Features

Colour Code

Thoriated 2%

DC welding of mild

steel, stainless steel

and copper

Excellent arc starting,

Long life, High current

carrying capacity

Red

Zirconated 1%

High quality AC weld-

ing of aluminium,

magnesium and their

alloys.

Self cleaning, Long

life, Maintains balled

end, High current car-

rying capacity.

White

Ceriated 2%

AC & DC welding of

mild steel, stainless

steel, copper, alumin-

ium, magnesium and

their alloys

Longer life, More

stable arc, Easier

starting, Wider current

range, Narrower more

concentrated arc.

Grey

Table 4-5: Tungsten Electrode Types

TIG Welding Filler Rods

Comweld

Rod

Aust Std AWS Std

Part No.

1.6mm

Part No.

2.4mm

Part No.

3.2mm

Type/Application

LW1

LW1-6

Supersteel

ER70S-4

ER70S-6

ER70S-2

321412

321418

321373

321412

321418

321373

—

For mild-medium strength steels.

Pipes, tubing, roll cages, etc.

CrMo1

CrMo2

RB2

RB3

ER80S-B2

ER90S-B3

—

321379

321383

—

For welding of high strength Cr-Mo

steels used at elevated tempera-

tures.

308L

309L

316L

R308L

R309L

R316L

ER308L

ER309L

ER316L

321406

321403

321400

321407

321404

321401

—

For stainless steels. Stainless pipes,

tubing, architectural uses, etc.

AL4043

R4043

321610

321611

321612 For cast and wrought aluminium

alloys.

AL5356

R5356

321640

321641

321642

Table 4-6: TIG Welding Filler Rods

Summary of Contents for A-12030

Page 1: ...A 12030 220AC DC 300AC DC Operating Manual Revision AB Issue Date February 28 2014 Manual No 0 5293 Operating Features TRANSTIG welding machine ...

Page 2: ...hey will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide CIGWELD is the Market Leading Brand of Arc Welding Products for Victor Technologies Inc We are a mainline supplier to major welding industry sectors in the Asia Pacific and emerging global markets including Manufacturing Co...

Page 3: ...hed by CIGWELD Pty Ltd 71 Gower Street Preston Victoria Australia 3072 www cigweld com au Copyright 2013 2014 by CIGWELD All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether...

Page 4: ... 1 3 05 High Frequency Introduction 3 1 3 06 High Frequency Interference 3 2 3 07 Electromagnetic Compatibility 3 2 3 08 TRANSTIG 220AC DC and 300AC DC Power Source Controls Indicators and Features 3 4 3 09 Setup for TIG GTAW Welding 3 11 3 10 TRANSTIG 220AC DC and 300AC DC TIG GTAW Programming Mode 3 14 3 11 TIG GTAW Welding Secondary Parameters 3 18 3 12 GTAW Spot Welding Mode with DWELL Time St...

Page 5: ...IREMENTS 5 1 5 01 Basic Troubleshooting 5 1 5 02 Power Source Problems 5 1 5 03 Routine Service and Calibration Requirements 5 2 5 04 Cleaning the Welding Power Source 5 4 SECTION 6 KEY SPARE PARTS 6 1 6 01 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 2...

Page 6: ......

Page 7: ...workpiece to a good electrical earth ground 11 Do not touch electrode while in contact with the work ground circuit 12 Use only well maintained equipment Repair or replace damaged parts at once 13 In confined spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output 14 Wear a safety harness to prevent falling if working ab...

Page 8: ... Process Approximate Range of Welding Current in Amps Minimum Shade Number of Filter s Manual Metal Arc Welding covered electrodes MMAW Less than or equal to 100 8 100 to 200 10 200 to 300 11 300 to 400 12 Greater than 400 13 Gas Metal Arc Welding GWAW MIG other than Aluminium and Stainless Steel Less than or equal to 150 10 150 to 250 11 250 to 300 12 300 to 400 13 Greater than 400 14 Gas Metal A...

Page 9: ... fire 1 Protect yourself and others from flying sparks and hot metal 2 Do not weld where flying sparks can strike flam mable material 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 4 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas 5 Watch for...

Page 10: ...me cases cancer California Health Safety code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Con clusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Govern men...

Page 11: ...phlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard Z87 1 from American National Standards Institute 14...

Page 12: ...Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements among them are AS 60974 10 IEC 60974 10 EMC Directive applicable to arc welding equipment generic emissions and regulations AS 60974 1 2006 IEC 60974 1 applicable to welding equipment and associated accessories AS1674 Safety in welding and allied processes Extensive pr...

Page 13: ...ur area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 01 How To Use This Manual To ensure safe operation read the entire...

Page 14: ...W Increase Decrease Circuit Breaker AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04937 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Preflow Time Postflow ...

Page 15: ...mmediately Should such repairs or replacements become necessary it is recommended that such re pairs be carried out by appropriately qualified persons approved by CIGWELD Advice in this regard can be obtained by contacting an Accredited CIGWELD Distributor This equipment or any of its parts should not be al tered from standard specification without prior written approval of CIGWELD The user of thi...

Page 16: ...the component parts To explain the 10 minute duty cycle period the following example is used Suppose a Welding Power Source is designed to operate at a 40 duty cycle 170 amperes at 26 8 volts This means that it has been designed and built to provide the rated amperage 170A for 4 minutes i e arc welding time out of every 10 minute period 40 of 10 minutes is 4 minutes During the other 6 minutes of t...

Page 17: ...Voltage VRD active 23V DC 25V DC Protection Class IP23S IP23S Table 2 1 Power Source Specification NOTE Note 1 Due to variations that can occur in manufactured products claimed performance volt ages 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 main...

Page 18: ...Part Number Description W4014604 TIG Torch 26F with 4m lead and remote control BGSAK2 TIG Torch accessory kit W4015800 Foot Control with 8m lead 646757 Electrode holder Work Lead Set 5m 400A 50mm DINSE 646325 Electrode Holder Work Lead Set 8m 400A 50mm DINSE 646763 Electrode Holder w Deadman Switch Work Lead Set 8m 400A 50mm DINSE 301526 Comet Edge Argon regulator Flowmeter 704461 50mm Male DINSE ...

Page 19: ...icinity of blasting operations due to the danger of premature firing 3 01 Environment These units are designed for use in environments with increased hazard of electric shock as outlined in AS60974 1 and AS1674 2 A Examples of environments with increased hazard of electric shock are 1 In locations in which freedom of movement is restricted so that the operator is forced to perform the work in a cr...

Page 20: ...agnetic 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 see NOTE below In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work ...

Page 21: ...ations 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 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...

Page 22: ... pin receptacle is used to connect a trigger switch or remote control to the welding Power Source circuitry To make connections align keyway insert plug and rotate threaded collar fully clockwise The socket information is included in the event the supplied cable is not suitable and it is necessary to wire a plug or cable to interface with the 8 pin receptacle Socket Pin Part Number Description 1 N...

Page 23: ...ternal electrical components are at Mains voltage potential 6 Mains Supply Lead The Transtig 220AC DC is fitted with a heavy duty 15 Amp mains supply lead and plug The Transtig 300AC DC is fitted with a heavy duty three phase mains supply lead 7 Gas Inlet The Shielding Gas Inlet connection is used to supply the appropriate shielding gas to the unit The gas inlet is located on the rear of the Power...

Page 24: ...trol 5k ohm Potentiometers Wiper 5 Remote Control 5k ohm Potentiometers Minimum 6 Remote Control Enable Short to common to enable remote control 7 Common 8 Remote 2T short to common to select remote control active in 2T operation mode only 9 Volt free relay contact Weld Amps 0A 10 Volt free relay contact Weld Amps 0A 11 Not used 12 Not used 13 Not used 14 Not used Table 3 2 14 Pin Interconnection ...

Page 25: ...t when operating in GTAW TIG mode the power source will remain activated until the selected downslope time has elapsed 16 2T normal indicator light This light will illuminate when the power source is in GTAW 2T welding mode In this mode the torch trigger must remain depressed for the welding output to be active Press and hold the torch trigger to activate the power source weld Release the torch tr...

Page 26: ...it will revert to preview mode 2 welding is recommenced in which case actual welding amperage will be displayed or 3 a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode 26 Seconds indicator light This light will illuminate when Seconds are being shown on the Digital Ammeter Display 27 Amps indicator light This light will illuminate ...

Page 27: ...eing shown on the Digital Volt meter Display 35 Hz frequency indicator light This light will illuminate when Hz frequency is being shown on the Digital Volt meter Display 36 percentage indicator light This light will illuminate when percentage is being shown on the Digital Volt meter Display 37 Job Number indicator light This light will illuminate when Job Number is being shown on the Digital Volt...

Page 28: ...ing Parameter is selected 47 AC Balance indicator light This light will illuminate when the AC Balance Welding Parameter is selected 48 Crater Current indicator light This light will illuminate when the Crater Current Welding Parameter is selected 49 Crater Current time indicator light This light will illuminate when the Crater Current Time Welding Parameter is selected 50 Electrode Diameter Out o...

Page 29: ...lug being fused in the bayonet terminal D Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below The TIG torch will require a trigger switch to operate in Lift TIG or HF TIG Mode NOTE If the TIG torch has a remote TIG torch current control fitted then it will require to be connected to the 8 pin socket Refer to section 3 08 Remote Control ...

Page 30: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE INSTALLATION OPERATION AND SETUP 3 12 Manual 0 5293 A 12037 10 17 Figure 3 6 Setup for TIG Welding ...

Page 31: ...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 Mode Welding Mode Selection 2T Normal Mode 4T Latch Mode Tip Tronic used to recall saved jobs Spot Mode 2T Pulse Welding Normal Mode 4T Pulse Welding Latch Mode ...

Page 32: ...button to select the welding output type Several GTAW operating modes are available AC welding output mode The AC Led 21 will illuminate DC Negative welding output mode The DC Negative Led 19 will illuminate HF AC welding output mode The HF Led 18 and the AC Led 21 will illuminate HF DC Negative welding output mode The HF Led 18 and the DC Negative Led 19 will illuminate WARNING In HF operating mo...

Page 33: ...g Current for GTAW Electrode size Note that Normal recommended Welding Current AC Amps are dependent on the type of electrode and on the AC Balance Parameter setting Parameter Range LED Code Left Display Parameter Value Right Display Factory Setting Shielding Gas Pre Flow time This parameter operates in GTAW modes only and is used to provide gas to the weld zone prior to striking the arc once the ...

Page 34: ...ion of a weld 0 99 20 Crater Current AE This parameter operates in GTAW modes only This is the current at the end of the down slope current ramp The welding current will remain at the Crater Current value until the Crater Current Time has elapsed at which time the welding current will cease and the unit will enter Post Flow mode This control is used to eliminate the crater that can form at the com...

Page 35: ...ctrode size being used 1 0 3 2 1 0 4 0 2 4 AC frequency This parameter operates in AC mode only and is used to set the frequency for the AC weld current 30 200Hz 60 Spot Welding Time This parameter sets the spot welding time 0 01 10 0 seconds 1 0 Spot Welding Dwell Time only available with Spot Welding Dwell Time enabled refer to secondary parameters This parameter sets the dwell off time between ...

Page 36: ... FORWARD button 23 to select the Parameter Use the Multi Function Control 24 to adjust the parameter Note that some parameters are only available in certain welding modes Note that even during welding these settings can be adjusted and changed Parameter Range LED Code Left Display Parameter Value Right Display Factory Setting Ignition Peak Correction The ignition peak current is set after ignition...

Page 37: ...SP needs to be set to ON refer secondary parameters it is possible to have automated spot welds with this Stitch function In 2T mode the stitch welds are repeated for as long as the trigger is held in In 4T mode press and release the trigger to start the stitch welds press and release the trigger to end the stitch welds The parameters tSP and tSO determine the spot time length and the dwell off ti...

Page 38: ...ows tSO Use the Multi Function Control 24 to set the required SPOT DWELL or OFF time required If the Electrode Diameter Out of Range indictor Led 50 is illuminated it is still possible to weld 3 13 Tip Tronic Operation In GTAW modes up to 100 jobs can be saved These are arranged as 10 jobs numbers in 10 job sets These are shown on the meter displays The first number on the display is the job set t...

Page 39: ... mode 14 Use the Multi Function Control 24 to select the job set number and the job number Set a TipTronic Job as Inactive Press the SAVE button 54 The display will how the Job Number identification the job set and job number Use the Multi Function Control 24 to select the job set number and the job number Press the GAS button 52 The TipTronic job is now inactive Note that the JOB LED 53 will exti...

Page 40: ...nd turned securely to achieve a sound electrical connection B Connect the work lead to the Worklead welding terminal bottom If in doubt consult the electrode manufacturer 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 C Select STICK and electrode po...

Page 41: ...DC POWER SOURCE Manual 0 5293 3 23 INSTALLATION OPERATION AND SETUP 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 ...

Page 42: ...ate Following MMAW operating modes are available DC Negative mode DC Negative Led 19 will illuminate DC Positive mode DC Positive Led 20 will illuminate Press the BACK button 22 or FORWARD button 23 so the Electrode Diameter Led 42 and mm LED 30 are illuminated Use the Multi Function Control 24 to adjust the Electrode size being used Press the BACK button 22 or FORWARD button 23 so the Hot Start A...

Page 43: ...mal Welding Current for MMAW Electrode sizes Parameter Range LED Code Left Display Parameter Value Right Display Factory Setting Welding Current A1 Transtig 220AC DC Transtig 300AC DC 10 170A 10 200A 100 Electrode Diameter Transtig 220AC DC Transtig 300AC DC Set this parameters to the electrode size being used 1 5 4 0 1 5 5 0 2 5 Hot Start AS This parameter operates in MMAW mode and is used to imp...

Page 44: ...Note that even during welding these settings can be adjusted and changed Parameter Range LED Code Left Display Parameter Value Right Display Factory Setting Arc Dynamic Arc Force Arc Force is effective in MMAW Mode only Arc Force control provides an adjustable amount of Arc Force or dig This feature can be particularly beneficial in providing the operator the ability to compensate for variability ...

Page 45: ...been set switch the power off to the unit to save the settings Menu item Range LED Code Left Display Parameter Value Right Display Factory Setting C02 Water Pump Error Message Display Set this to ON if a water cooler without a suitable interface lead is being used Set this to OFF if a water cooler with a suitable interface lead is being used ON OFF ON C06 Downslope Mode When set to ON in 4T mode t...

Page 46: ...voltage at all from the Power Source until the trigger is pressed This provides the greatest level of safety for the operator and is mandatory on some work sites While the Dead Man Switch function greatly increases operator safety standard welding safety procedures should still be followed When the trigger is pressed the VRD voltage is activated and the user can start welding as normal For extra s...

Page 47: ...Power Source will now output the VRD volts and the VRD led will be lit 3 Touch the MMAW Stick Electrode to the work and commence welding as usual 4 Release the trigger and continue welding 5 Press and release the trigger to cease welding There will be 0V on the Power Source welding terminals and the VRD light will be off In both 2T and 4T modes if the MMAW Stick electrode is not touched to the wor...

Page 48: ...d 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 Press and hold the BACK button 22 Press the hold the SAVE button 54 All control panel LED s will light up briefly to confirm the Soft Reset has been completed After 5 seconds all the control panel LED s will light again briefly t...

Page 49: ...ontrol 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 ...

Page 50: ...d after approximately 5 seconds A 12050 Figure 3 19 Water Pump Test 3 19 Information Messages If a message has been displayed the power source may only function to a limited capacity The cause of the condition must be remedied as soon as possible Message Code Note Cause Possible Remedy Mains Supply Under Voltage Mains Supply Voltage is too low Check Mains Supply Voltage Fans Fan Fault Have an Accr...

Page 51: ... switched ON and allow it to cool Thermal Overload of Transformer Duty Cycle has been exceeded Leave the power source switched ON and allow it to cool Thermal Overload of PFC Module Duty Cycle has been exceeded Leave the power source switched ON and allow it to cool Mains Supply Over Voltage Mains Supply Voltage is too high Check Mains Supply Voltage Water Pump in water cooled operation Torch Moni...

Page 52: ...age Fault Have an Accredited C I G W E L D S e r v i c e Provider check the power source Current Detection Current Detection Fault Have an Accredited C I G W E L D S e r v i c e Provider check the power source Shutdown due to over current Mains Supply Current is too high Have an Accredited C I G W E L D S e r v i c e Provider check the power source HF Ignition Faulty HF Ignition Faulty Have an Acc...

Page 53: ...ion or attempt to remove any part of a regulator until the gas pressure has been relieved Under pressure gas can dangerously propel a loose part 3 DO NOT remove the regulator from a cylinder without first closing the cylinder valve and releasing gas in the regulator high and low pressure chambers 4 DO NOT use the regulator as a control valve When downstream equipment is not in use for extended per...

Page 54: ...suitable spanner 4 Connect and tighten the outlet hose firmly and attach down stream equipment 5 To protect sensitive down stream equipment a separate safety device may be necessary if the regulator is not fitted with a pressure relief device Operation With the regulator connected to cylinder or pipeline and the adjustment screw knob fully disengaged pressurize as follows 1 Stand to one side of re...

Page 55: ...ng gas to discharge from regulator by opening the downstream valve Bleed welding grade shielding gas into a well ventilated area and away from any ignition source Turn adjusting screw counter clockwise until the required flow rate is indicated on the gauge Close downstream valve Shutdown Close cylinder valve whenever the regulator is not in use To shut down for extended periods more than 30 minute...

Page 56: ...in 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 Foot Control Operation Press the foot pedal to start the machine output functions The foot control potentiometer controls the welding current up to the level set on the welding power source Note t...

Page 57: ...e output from the unit will be 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 Transmig 175i Part No W1005176 Transmig 200i Part No W1005202 Transmig 250i Part...

Page 58: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE INSTALLATION OPERATION AND SETUP 3 40 Manual 0 5293 ...

Page 59: ...rea may be reduced by using the correct electrodes preheating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tempering in a furnace Hydrogen controlled Electrodes must be used for this application Use Ferrocraft 61 or 16TXP for normal strength 500 MPa steels and Alloycraft range for higher strength steels B Austenitic manganese steels The ef...

Page 60: ...lications call for welds to be made in positions intermediate between these Some of the common types of welds are shown in Figures 4 5 through 4 12 Art A 07687 Figure 4 1 Flat Position Down Hand Butt Weld Art A 07688 Figure 4 2 Flat Position Gravity Fillet Weld Art A 07689 Figure 4 3 Horizontal Position Butt Weld Art A 07690 Figure 4 4 Horizontal Vertical HV Position Art A 07691 Figure 4 5 Vertica...

Page 61: ... of the weld metal and to produce sound joints In general surfaces being welded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 4 9 Gap varies from 1 6mm 1 16 to 4 8mm 3 16 depending on plate thickness Joint Open Square Butt 1 6mm 1 16 max 1 6mm 1 16 Single Vee Butt Joint Not less than 70 Double Vee Butt ...

Page 62: ...ng work You may at first experience difficulty due to the tip of the electrode sticking to the work piece This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough A low amperage will accentuate it This freezing on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck As soon as the ...

Page 63: ...and deposit a similar weld Art A 07697_AB Tack Weld 20 30 Electrode Tack Weld Figure 4 11 Butt Weld Art A 07698 Figure 4 12 Weld Build up Sequence Heavy plate will require several runs to complete the joint After completing the first run chip the slag out and clean the weld with a wire brush It is important to do this to prevent slag being trapped by the second run Subsequent runs are then deposit...

Page 64: ...ocraft 21 electrode and set the current at 100 amps Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet The electrode needs to be about 10º from the horizontal to enable a good bead to be deposited Refer Figure 4 15 Use a short arc and do not attempt to weave on the first run When the first run has been completed de slag the weld deposit and begin...

Page 65: ...e difficult that downhand welding Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch The electrode is held at 45º to the horizontal and tilted 10º in the line of tra...

Page 66: ...ume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions It is able to do this freely at right angles to the surface of the plate i e through the weld but when it attempts to expand across the weld or along the weld it meets considerable resistance and to fulfil the desire for continued expansion it has to deform plastically that is the metal...

Page 67: ...s in view D Presetting It is possible in some cases to tell from past experience or to find by trial and error or less frequently to calculate how much distortion will take place in a given welded structure By correct pre setting of the components to be welded constructional stresses can be made to pull the parts into correct alignment A simple example is shown in Figure 4 21 E Preheating Suitable...

Page 68: ...07710_AB 1 Block Sequence The spaces between the welds are filled in when the welds are cool 2 3 Figure 4 24 Welding Sequence Art A 07711_AB 4 3 2 1 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 ...

Page 69: ...mm 3 2mm 4 0mm 2 5 kg 2 5 kg 2 5 kg 611602 611603 611604 Stainless Steel type for 19Cr 10Ni stainless grades including 201 202 301 302 303 304 304L 305 308 etc Satincrome 309Mo 17 2 5mm 3 2mm 4 0mm 2 5 kg 2 5 kg 2 5 kg 611692 611693 611694 Stainless Steel type for 309 and 309L grades It is also suitable for welding of dissimilar welding of other 300 series stainless steels Satincrome 316L 17 2 0mm...

Page 70: ...ular deposits allow slag to be trapped C If very bad chip or grind out irregularities D Lack of penetration with slag trapped beneath weld bead D Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to remove all slag from comers E Rust or mill scale is pre venting full fusion E Clean joint before welding F Wrong electrode for posi tion in which welding is ...

Page 71: ...phur in steel A Use an electrode that is designed for high sul phur steels B Electrodes are damp B Dry electrodes before use C Welding current is too high C Reduce welding current D Surface impurities such as oil grease paint etc D Clean joint before welding E Welding in a windy envi ronment E Shield the weld area from the wind F Electrode damaged ie flux coating incomplete F Discard damaged elect...

Page 72: ...s depending on the welding application Welds Made With or Without Addition of Filler Metal Work Piece Can Be Any Commercial Metal Gas Cup Either Ceramic High lmpact or Water Cooled Metal Inert Gas Shields Electrode and Weld Puddle Tungsten Electrode Non Consumable Art A 09658_AC Figure 4 28 TIG Welding Application Shot Tungsten Electrode Current Ranges Electrode Diameter DC Current Amps 0 040 1 0m...

Page 73: ... starting Wider current range Narrower more concentrated arc Grey Table 4 5 Tungsten Electrode Types TIG Welding Filler Rods Comweld Rod Aust Std AWS Std Part No 1 6mm Part No 2 4mm Part No 3 2mm Type Application LW1 LW1 6 Supersteel R4 R6 R2 ER70S 4 ER70S 6 ER70S 2 321412 321418 321373 321412 321418 321373 For mild medium strength steels Pipes tubing roll cages etc CrMo1 CrMo2 RB2 RB3 ER80S B2 ER...

Page 74: ...ectrode Diameter Filler Rod Diameter if required Argon Gas Flow Rate Litres min Joint Type 1 0mm 35 45 40 50 20 30 25 35 1 0mm 1 6mm 5 7 Butt Corner Lap Fillet 1 2mm 45 55 50 60 30 45 35 50 1 0mm 1 6mm 5 7 Butt Corner Lap Fillet 1 6mm 60 70 70 90 40 60 50 70 1 6mm 1 6mm 7 Butt Corner Lap Fillet 3 2mm 80 100 90 115 65 85 90 110 1 6mm 2 4mm 7 Butt Corner Lap Fillet 4 8mm 115 135 140 165 100 125 125 ...

Page 75: ...r oxidises when an arc is struck A Torch lead connected to positive welding terminal A Connect torch lead to negative welding terminal B No gas flowing to weld ing region B Check the gas lines for kinks or breaks and gas cylinder contents C Torch is clogged with dust or dirt C Clean torch D Gas hose is cut D Replace gas hose E Gas passage contains impurities E Disconnect gas hose from the rear of ...

Page 76: ... electrode is being used for the welding job B Select the right tungsten electrode type Refer to Table 4 5 CIGWELD Tungsten Electrode Selection Chart C Gas flow rate is too high C Select the right rate for the welding job Refer to Table 4 7 D Incorrect shielding gas is being used D Select the right shielding gas E Poor work clamp con nection to work piece E Improve connection to work piece 10 Arc ...

Page 77: ...ight is not lit and welding arc cannot be established A B Primary control fuse is blown Broken connection in primary circuit A B Replace primary control fuse Have an Accredited CIGWELD Service Provider check primary circuit 3 Error Code E01 is displayed and unit will not commence welding when the torch trigger switch is depressed Duty cycle of power source has been exceeded Leave the power source ...

Page 78: ...The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging including the date of the most recent inspection A transportable power source is deemed to be any equipment that is not permanently connected and fixed in the position in which it is operated B Insulation Resistance Minimum insulation resistance for in service CIGWELD Inverter Power Sources shall...

Page 79: ...mpetent person to ensure that the equipment is in a safe and serviceable condition All unsafe accessories shall not be used F Repairs If any parts are damaged for any reason it is recommended that replacement be performed by an ac credited CIGWELD Service Provider Power Source Calibration A Schedule Output testing of all CIGWELD Inverter Power Sources and applicable accessories shall be conducted ...

Page 80: ...l be utilized 5 04 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 To clean the Welding Power Source open the enclosure and use a vacuum cleaner to remove any acc...

Page 81: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE Manual 0 5293 6 1 KEY SPARE PARTS SECTION 6 KEY SPARE PARTS 6 01 220AC DC Power Source A 12051_AB Figure 6 1 Transtig 220AC DC Spare Parts ...

Page 82: ...6 PCB Primary Inverter 8 W7006307 PCB Display 9 W7006308 PCB NEFI NTC 10 W7006309 Transformer Inverter 11 W7006310 Switch On Off 12 W7006311 Rectifier Bridge Mains Supply 13 W7006314 Cable Assy 8 pin remote 14 W7006313 Cable Assy 4 pin CAN 15 W7006312 Cable Assy 14 pin remote 16 W7006315 Solenoid 24VDC 17 W7006316 Fan 12VDC 18 W7006317 Inductor HF 19 W7006318 PFC Module 500V 50A 20 W7006319 IGBT 2...

Page 83: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE Manual 0 5293 6 3 KEY SPARE PARTS 6 02 300AC DC Power Source A 12052_AB Figure 6 2 Transtig 300AC DC Spare Parts ...

Page 84: ...r 8 W7006307 PCB Display 9 W7006324 PCB NEFI 1300 10 W7006325 Transformer Control 11 W7006326 Transformer Inverter 12 W7006327 Switch On Off 3 pole 13 W7006328 Rectifier Bridge B6 36A Mains Supply 14 W7006314 Cable Assy 8 pin remote 15 W7006313 Cable Assy 4 pin CAN 16 W7006312 Cable Assy 14 pin remote 17 W7006315 Solenoid 24VDC 18 W7006316 Fan 12VDC 19 W7006317 Inductor HF 20 W7006319 IGBT 21 W700...

Page 85: ...X10 4 TR2 TR1 LP1 X1 X5 X8 1 X8 2 F1 C1 X7 2 X7 1 R1 X11 1 X11 2 M1 M X13 1 X13 2 M2 M X15 1 X15 2 M3 M X4 X3 X17 1 1 X17 2 2 X17 3 3 X17 4 4 X17 5 5 X17 6 6 X17 7 7 X17 8 8 X17 9 9 X17 10 10 X18 3 3 X18 4 4 X5 A5 X3 X1 E2 A8 T1 X9 I1 2 stroke I 0 extern Y1 X12 2 X12 1 L1 X6 1 X6 2 3 5 7 6 X18 2 2 X18 1 1 X4 X7 X8 A14 A15 A12 A6 X2 X3 C2 A7 A10 A3 A13 X2 1 X2 3 A9 A11 1 1a Q1 2 2a X4 3 X4 1 X12 5 ...

Page 86: ...7 9 9 X17 10 10 X18 3 3 X18 4 4 X5 X3 I1 2 stroke I 0 extern Y1 X12 2 X12 1 L1 X18 2 2 X18 1 1 X4 X1 L1 2 L2 6 L3 10 Q1 L2 L3 LP2 LP3 A4 AC AC AC 3 LP2A LP3A A1 X1 X2 3 A5 X10 3 X12 3 X3 1 X3 2 X12 4 X12 5 X3 4 X12 6 X3 5 X12 7 X3 6 X12 8 A2 LP5 LP4 LP1 LP2 LP3 X4 X5 X6 brown white black gray T1 A3 F2 X3 1 X3 2 A1 A7 LP1 X4 1 X1 1 X1 2 X1 3 400V 230V 0V T2 TR4 TR2 TR1 TR3 LP6 F3 X2 1 X2 2 C2 X2 3 ...

Page 87: ...OR CONSEQUENTIAL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSINESS INTERRUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELD with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by CIG WELD whethe...

Page 88: ...r 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 Provider The goods being used in accordance with the Manufacturer s Operating Manuals and under competent supervision Does not apply to Obsolete...

Page 89: ...C POWER SOURCE WARRANTY PERIOD PARTS LABOUR Original main power magnetics 3 Year 2 Year Original main power rectifiers printed circuit boards and power switch semiconductors 2 Year 2 Year All other circuits and components including but not limited to relays switches contactors solenoids fans and electric motors 1 Year 1 Year ACCESSORIES WARRANTY PERIOD TIG torch electrode holder lead and work lead...

Page 90: ...urn of goods to Cigweld or our Nominated Accredited Distributor Accredited Service Provider are the responsibility of the consumer This warranty is given Cigweld Pty Ltd A B N 56007226815 71 Gower Street Preston Victoria Australia 3072 Phone 1300 654 674 Email enquiries cigweld com au Website www cigweld com au This warranty is provided in addition to other rights and remedies you have under law O...

Page 91: ... 1257 224800 PT Victor Technologies Utama Indonesia Jl Angsana II Blok AE No 28 Delta Silicon I Cikarang Sukaresmi Bekasi 17550 Indonesia Tel 62 21 8990 6095 Fax 62 21 8990 6096 1867 http www Victortechnologies com Victor Technologies China No 100 Lao Hongjing Rd Minhang District Shanghai PR 200235 Telephone 86 21 64072626 Fax 86 21 64483032 Victor Technologies Asia Sdn Bhd Lot 151 Jalan Industri ...

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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