transtig 16pi transarc 16i

719306 Issue 4 Dec 95

OPERATING INSTRUCTIONS

PULSE TIG WELDING PLANTPart Number 700641

MANUAL ARC WELDING POWER SOURCE

Part Number 625690

CONTENTSPage

Page 1

1. INTRODUCTION ..............................................................................................................41.1 Safety..................................................................................................................................................4

1.2 Protective Filter Lenses........................................................................................................................5

1.3 Welding Protection...............................................................................................................................5

1.4 User Responsibility..............................................................................................................................5

1.5 Duty Cycle...........................................................................................................................................5

2. SPECIFICATIONS, FEATURES, PLANT CONTENTS & ACCESSORIES................62.1 Specifications.......................................................................................................................................6

2.2 Features...............................................................................................................................................7

2.3 Plant Contents......................................................................................................................................8

2.4 Optional Accessories............................................................................................................................8

3. INSTALLATION RECOMMENDATION S.....................................................................83.1 Environment.........................................................................................................................................8

3.2 Location...............................................................................................................................................9

4. HIGH FREQUENCY CONSIDERATIONS (TRANSTIG 16Pi).....................................94.1 Introduction.........................................................................................................................................9

4.2 Warning...............................................................................................................................................9

4.3 High Frequency Interference.................................................................................................................9

5. CONTROLS, INDICATORS, FEATURES & CONNECTIONS..................................105.1 ON/OFF Switch (not illustrated) ........................................................................................................ 10

5.2 POWER Indicator ........................................................................................................................ 105.3 WARNING Indicator ................................................................................................................... 105.4 WELDING Process Switch .......................................................................................................... 115.5 PULSE Selection Switch (Available on the Transtig 16Pi only) ..................................................... 115.6 Pulse Frequency Control (Available on the Transtig 16Pi only) ..................................................... 115.7 Welding / Pulse Current Control ................................................................................................... 115.8 Crater / Spot Selection Switch (Available on the Transtig 16Pi only) ............................................. 125.9 UP.DOWN/SPOT(S) Control (Available on the Transtig 16Pi only) ............................................. 125.10 Gas Flow Control (Available on the Transtig 16Pi only) ................................................................... 12

5.11 TORCH SWITCH Socket .......................................................................................................... 125.12 Shielding Gas Connection Points (Available on the Transtig 16Pi only)............................................. 12

6. SETTING UP A TRANSTIG 16Pi...................................................................................13

7. SETTING UP A TRANSARC 16i....................................................................................14

8. SEQUENCE OF OPERATION.......................................................................................158.1 TIG Welding...................................................................................................................................... 15

8.2 Stick Welding.................................................................................................................................... 15

CONTENTSPage

Page 2

9. TIG WELDING SEQUENCE CONTROLS (TRANSTIG 16Pi Only)...........................169.1 Spot ON ............................................................................................................................................ 16

9.2 Crater OFF........................................................................................................................................ 16

9.3 Crater ON.......................................................................................................................................... 17

10. TORCH REPLACEMENT PARTS BREAKDOWN....................................................1810.1 Torch Consumable Parts.................................................................................................................. 19

11. TIG WELDING GUIDE.................................................................................................1911.1 Electrode Polarity............................................................................................................................. 19

11.2 Tungsten Electrode Current Ranges.................................................................................................. 19

11.3 CIGWELD Tungsten Electrode Types.............................................................................................. 20

11.4 Guide for Selecting Filler Wire Diameter.......................................................................................... 20

11.5 Shielding Gas Selection.................................................................................................................... 20

11.6 Welding Parameters for Stainless Steel ............................................................................................. 21

11.7 Welding Parameters for Low Carbon & Low Alloy Steel Pipe........................................................... 21

12. STICK WELDING GUIDE............................................................................................2112.1 Electrode Polarity............................................................................................................................. 21

12.2 Effects of Stick Welding Various Materials...................................................................................... 22

13. ROUTINE MAINTENANCE & INSPECTION............................................................22

14. BASIC TROUBLESHOOTING.....................................................................................2214.1 TIG Welding Problems..................................................................................................................... 23

14.2 Stick Welding Problems................................................................................................................... 24

14.3 Power Source Problems.................................................................................................................... 26

TABLESPage

Table 1 - Filter lens size verses welding current...................................................................................5

Table 2 - TIG torch (TTR17V12P) replacement parts.......................................................................18

Table 3 - TIG torch (TTR17V12P) collets........................................................................................19

Table 4 - TIG torch (TTR17V12P) collet bodies..............................................................................19

Table 5 - TIG torch (TTR17V12P) alumina nozzles..........................................................................19

Table 6 - Current ranges for varies tungsten electrode sizes...............................................................19

Table 7 - CIGWELD tungsten electrode types..................................................................................20

Table 8 - Filler wire selection guide...................................................................................................20

Table 9 - Shielding gas selection.......................................................................................................20

Table 10 - TIG welding parameters for stainless steel........................................................................21

Table 11 - TIG welding parameters for low carbon & low alloy steel pipe.........................................21

FIGURESFigure 1 - Front view of the Transtig 16Pi & Transarc 16i.................................................................10

Figure 2 - Connections for the Transtig 16Pi.....................................................................................13

Figure 3 - Connections for the Transarc 16i ......................................................................................14

Figure 4 - TIG torch components......................................................................................................18

1. INTRODUCTIONThe Transtig 16Pi and the Transarc 16i are lightweight, constant current DC Power Sourcesincorporating the latest inverter and microprocessor technology to provide numerous process benefits ineasy to operate packages.The Transtig 16Pi is supplied with standard features normally found only on larger, more expensive TIGunits.These features include:

Pulse Current with Up-Slope and CRATER Control

Choice of High Frequency or Lift Arc starting

Internal Gas Solenoid

Spot Welding Control

Remote Trigger SwitchWhen Manual Arc mode is selected the Transtig 16Pi provides excellent arc characteristics with a widerange of electrodes, including cellulose electrodes.The Transarc 16i is primarily designed for Manual Arc welding with similar performance in this area tothe Transtig 16Pi. In addition, while it does not incorporate the numerous TIG welding features of the16Pi, it provides excellent Contact Start (Lift Arc), constant current, DC output for TIG welding.

1.1 SafetyThe following basic safety rules should always be followed:

(i) Ensure the machine is correctly installed, if necessary, by a qualified electrician.

(ii) Ensure the Power Source is earthed correctly (electrically) in accordance with lo-cal regulations.

(iii) Excessive heat in the welding cables may cause fire. Never weld with poor elec-trical connections, damaged welding cables or exceed the welding cable currentrating as this will produce excessive heat and may cause a fire.

(iv) Always wear the correct protective clothing for protection from sparks, moltenparticles and arc rays.

(v) When welding in confined spaces, always ensure adequate ventilation and constantobservation of the operator.

(vi) Keep combustible materials away from the welding area. Have a suitable fire ex-tinguisher handy.

(vii) Never watch the welding arc with naked eyes. Always use and wear a weldingmask fitted with the correct filter lens.

(viii) Do not stand on damp ground when welding.

(ix) For more complete safety advice please read the safety literature included with theequipment before starting to weld.

1.2 Protective Filter LensesProtective filter lenses are provided to reduce the intensity of radiation entering the eye thusfiltering out harmful infra-red, ultra-violet radiation and a percentage of the visible light. Suchfilter lenses are incorporated within face shields. To prevent damage to the filter lenses frommolten or hard particles an additional hard clear glass or special plastic external cover lens shouldbe used. This cover lens should always be kept in place and replaced before the damage impairsyour vision while welding.

1.3 Welding ProtectionIt is recommended to use a welding helmet, conforming to Australian Standards AS/NZS1337-1992 when electric arc welding. Use a welding helmet in serviceable condition with the correctfilter lens fitted as per Table 1.

Approximate range ofwelding current

Filter lens required forTIG and STICK

Up to 75 Shade 1075-100 Shade 10100-200 Shade 11200-250 Shade 12250-350 Shade 13Over 350 Shade 14

Table 1 - Filter lens size verses welding current

1.4 User ResponsibilityThis equipment will perform as per the information contained herein when installed, operated,maintained and repaired in accordance with the instructions provided. This equipment must bechecked periodically. Defective equipment (including welding leads) should not be used. Partsthat are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs becarried out by appropriately qualified persons approved by the Equipment Manufacturer orCIGWELD. Advice in this regard can be obtained by contacting CIGWELD.This equipment or any of its parts should not be altered from standard specification without priorwritten approval of the Equipment Manufacturer or CIGWELD. The user of this equipmentshall have the sole responsibility for any malfunction which results from improper use orunauthorised modification from standard specification, faulty maintenance, damage or improperrepair by anyone other than appropriately qualified persons approved by the EquipmentManufacturer or CIGWELD.

1.5 Duty CycleThe rated duty cycle of a welding Power Source is the operating time it may be used at its ratedoutput current without exceeding the temperature limits of the insulation of the component parts. In Australia a duty cycle period of five minutes is specified in Australian Standard AS 1966 Part1-1985. To explain the five minute duty cycle period the following example is used. Suppose awelding Power Source is designed to operate at 40% duty cycle, 160 amperes at 16.4 load volts. This means that it has been designed and built to provide the rated amperage (160A) at the ratedload voltage (16.4V), for two minutes out of every five minute period (40% of 5 minutes is twominutes). During the other three minutes of the five minute period the Power Source must idleand be allowed to cool. The thermal cut-out will operate if the duty cycle is exceeded.

2. SPECIFICATIONS, FEATURES, PLANT CONTENTS & ACCESSORIES

2.1 Specifications

Description Transtig 16pi Transarc 16i

Plant assembly 700641 625690

Welding processes Gas Tungsten Arc Welding (TIG)Manual Metal Arc Welding (STICK)

Plant Mass 8 kg

Power Source Dimensions 130mm x 300mm x 240mm

Manufactured to Standards AS1966.1, JIS C 9306, IEC974-1

Supply Voltage 220V/240V

Supply Voltage Compensation 10%

Number of Phases Single

Frequency 50/60 Hz

DC Output Current Range 5A to 160A

DC Open Circuit Voltage 64V

Input Supply Cable Active, Neutral, Earth 2.5mm2 (50/0.25)

Duty Cycle Time Period 5 minutes

Operating Temperature Range 0C to 40C

Ratings TIG STICK

Rated Input Current @ 100% Duty Cycle 12 A 15 A

Maximum Input Current @ 160A 22A 32A

Generator Requirement 7.5 kVA 9.6 kVA

Rated Outlet at 20% Duty Cycle 15A 15A

Fuse Size at 20% Duty Cycle 30A 30A

Rated Outlet at 40% Duty Cycle 15A 20A

Fuse Size at 40% Duty Cycle 30A 40A

Rated Output using a 15A Outlet 40% @ 160A (16.4V) 20% @ 160A(26.4V)

Continuous Output using a 15A Outlet100% @ 101A (14V)100% @ 80A (23V)

Rated Output using a 20A Outlet 40% @ 160A (16.4V) 40% @ 160A(26.4V)

Continuous Output using a 20A Outlet100% @ 101A (14V) 100% @ 80A(23V)

To achieve these ratings, the 15 Amp plug (as supplied) must be replaced with a 20 Ampplug. This must be carried out by a qualified electrical tradesperson.

Motor start fuses or circuit breakers are recommended for this application. AustralianStandard AS3000 (Clause 2.4.3.4) permits the use of a fuse or circuit breaker rated at twotimes the rated input current.

2.2 Features

Front Panel Controls

POWER indicator (AC) Green LEDWARNING indicator Red LEDCurrent indicator Ampere values are marked around the WELD CUR.(A)

control knob.WELDING process selectorSTICK/HF TIG/LIFT TIG Switch (Transtig 16Pi)

STICK/LIFT TIG Switch (Transarc 16i)PULSE Selector H/DC(No Pulse)/L Switch(Transtig 16Pi only)Mode Selector (CRATER) ON/OFF/SPOT Switch (Transtig 16Pi only)WELDING Current ControlFront Panel Control KnobBackground Current(Transtig 16Pi only)

Internally set to 20% of the welding current controlvalue.

Initial Current(Transtig 16Pi only)

Internally set to 20% of the welding current controlvalue.

Pulse Frequency(Transtig 16Pi only)

High - 10 to 500HzLow - 0.5 to 25Hz

UP.DOWN/SPOT(S) Time(Transtig 16Pi only)

Up Slope & Spot time: 0.5 to 5 secondsDown Slope time : 0.5 to 10 seconds

Post Flow Time(Transtig 16Pi only)

Internally set: 1 to 5 seconds(increases with the welding current setting)

Pre Flow Time Fixed at 0.15 seconds(Transtig 16Pi only)Pulse Width 35% (Transtig 16Pi only)Output Gas Fitting 5/8 18 UNF (Transtig 16Pi only)Output Terminals Twist lock DINSE style socketTORCH SWITCH Socket Initiates welding power via the torch trigger switch

(TIG only).

Rear Panel

ON/OFF Switch Circuit breaker mounted on rear panel

Input Gas Fitting 5mm hose nipple (Transtig 16Pi only)

Torch (Transtig 16Pi only)

Part Number WP17V122PType WELDCRAFT 150 AmpCable Length 3.6 metres

Protection

Thermal overload WARNING indicator illuminates, welding is interruptedwhen Power Module exceeds its temperature rating.

Shock detector WARNING indicator illuminates, welding is interruptedmomentarily when Power Source receives a heavyblow.

DC inverter voltage WARNING indicator illuminates, welding is interruptedwhen DC inverter voltage collapses.

2.3 Plant Contents

Part Number Description Transtig 16Pi Transarc 16i

700640 Power Source Transtig 16Pi 625690 Power Source Transarc 16i

TTR17V12P TIG Torch 150A BGSAK 2 Torch accessory kit 303660 Flowmeter/regulator 700638 Work lead 703299 Gas hose assembly 7976667 Hose clip 7977160 Plug 700678 Torch trigger lead assembly

2.4 Optional Accessories

Part Number Description

TTR17V12P u TIG Torch 150A

BGSAK2 u Torch accessory kit

303660 u Flowmeter/regulator

700638 u Work lead

700433 u Torch gas hose kit (includes fitting)

646323 Manual arc (STICK) lead set

u Required to set up the Transarc 16i for TIG welding.

3. INSTALLATION RECOMMENDATIONS

3.1 EnvironmentThis machine is NOT designed for use in environments with increased hazard of electric shock asdefined in AS3195-1990.

(a) Examples of environments with increased hazard of electric shock are -

(i) In locations in which freedom of movement is restricted, so that the operator isforced to perform the work in a cramped (kneeling, sitting or lying) position withphysical contact with conductive parts;

(ii) In locations which are fully or partially limited by conductive elements, and inwhich there is a high risk of unavoidable or accidental contact by the operator, or

(iii) In wet or damp hot locations where humidity or perspiration considerable reducesthe skin resistance of the human body and the insulation properties of accessories.

(b) Environments with increased hazard of electric shock do not include places where elec-trically conductive parts in the near vicinity of the operator, which can cause increasedhazard, have been insulated.

3.2 LocationBe sure to locate the Power Source according to the following guidelines:

(a) In areas, free from moisture and dust.

(b) Ambient temperature 0C to 40C.(c) Location free from oil, steam and corrosive gases.

(d) Location not subjected to abnormal vibration or shock.

(e) Location not exposed to direct sunlight or rain.

(f) Place at a distance of 60cm or more from walls or similar that could restrict natural airflow for cooling.

4. HIGH FREQUENCY CONSIDERATIONS (TRANSTIG 16Pi)

4.1 IntroductionThe importance of correct installation of high frequency welding equipment cannot be over-emphasised. Interference due to high frequency initiated or stabilised arc is almost invariablytraced to improper installation. The following information is intended as a guide for personnelinstalling high frequency welding machines.

4.2 Warning

(a) ExplosivesThe high frequency section of this machine has an output similar to a radio transmitter. Themachine should NOT be used in the vicinity of blasting operations due to the danger ofpremature firing.

(b) ComputersIt is also possible that operation close to computer installations may cause computermalfunction.

4.3 High Frequency InterferenceInterference may be transmitted by a high frequency initiated or stabilised arc welding machine inthe following ways:

(a) Direct RadiationRadiation from the machine can occur if the case is metal and is not properly earthed. It canoccur through apertures such as open access panels. The shielding of the high frequency unitin the Power Source will prevent direct radiation if the equipment is properly earthed.

(b) Transmission via the Supply LeadWithout adequate shielding and filtering, high frequency energy may be fed to the wiringwithin the installation (mains) by direct coupling. The energy is then transmitted by bothradiation and conduction. Adequate shielding and filtering is provided in the Power Source.

(c) Radiation from Welding LeadsRadiated interference from welding leads, although pronounced in the vicinity of the leads,diminishes rapidly with distance. Keeping leads as short as possible will minimise this type ofinterference. Looping and suspending of leads should be avoided where possible.

(d) Re-radiation from Unearthed Metallic ObjectsA major factor contributing to interference is re-radiation from unearthed metallic objectsclose to the welding leads. Effective earthing of such objects will prevent re-radiation inmost cases.

5. CONTROLS, INDICATORS, FEATURES & CONNECTIONS

Figure 1 - Front view of the Transtig 16Pi & Transarc 16i

5.1 ON/OFF Switch (not illustrated)This product is protected by a 40 Ampere circuit breaker. The circuit breaker is mounted on therear panel and doubles as the ON/OFF switch. If the circuit breaker trips the toggle will be in acentre position indicating an internal malfunction. Do not attempt to restore power without firstconsulting an Accredited CIGWELD Service Agent as further damage may occur.

NOTE 1: The fan will continue to operate for approximately 20 seconds after the circuitbreaker has been switched off.

5.2 POWER Indicator The POWER indicator (No 8) is green and illuminates when AC power is connected to the PowerSource (with the ON/OFF switch (circuit breaker) switched ON).

5.3 WARNING Indicator The WARNING indicator (No 7) is red and when illuminated indicates:

(a) An overload fault has occurred and welding is interrupted (normally caused by excessiveduty cycle). When this happens, allow the machine to cool down by leaving the powerswitch ON until the warning light extinguishes, or

(b) The Power Source received a heavy blow. Welding is interrupted momentarily whenthis occurs, or

(c) The DC voltage to the inverter circuit has collapsed. Welding is interrupted when thisoccurs.

5.4 WELDING Process Switch The WELDING process switch (No 4) selects the mode of operation as follows:

(a) STICK ModeThe Power Source is set for manual arc welding and all controls except for the WELDCUR.(A) control (No 1) are disabled. A built in Arc Force feature is enabled whichprovides an increased output current when the arc length is reduced.

(b) HF TIG Mode (Available only on the Transtig 16Pi)The Power Source is set for TIG welding with high frequency (non contact) arc initiation. PULSE and CRATER control will function if selected. The arc is initiated by depressing thetorch trigger switch (supplied) which should be attached to the TIG torch handle.

(c) LIFT TIG ModeThe Power Source is set for TIG welding with touch start arc initiation. PULSE andCRATER control will function if selected. Touching the tungsten onto the work piece withthe trigger switch depressed produces a very low starting current. Moving the tungstensteadily away from the work piece causes the output to ramp up to the WELD CUR.(A)control setting.

5.5 PULSE Selection Switch (Available on the Transtig 16Pi only) The PULSE switch (No 5) is active only when the WELDING process switch (No 4) is set in aTIG mode. It selects the mode of operation as follows:

(a) H or L ModeThe Power Source will pulse the output current according to the setting on PULSE FREQ.control (No 2).

(b) DC ModeThe Power Source will provide a constant DC output.

5.6 Pulse Frequency Control (Available on the Transtig 16Pi only) The PULSE FREQ. control (No 2) adjusts the rate at which the output current is pulsed in boththe high and low ranges. The peak current is set by the WELD CUR.(A) control (No 1) and thebase or background current is automatically adjusted to be 20% of the WELD CUR.(A) control. This control is only active when the WELDING process switch (No 4) is set in one of the TIGmodes and the PULSE switch (No 5) is set to the H or L position.

5.7 Welding / Pulse Current Control WELD CUR.(A) control (No 1) adjusts the current output as follows:

(a) Transtig 16Pi with

(i) PULSE (No 5) in DC position - constant output current

(ii) PULSE (No 5) in H or L position - pulsed output current

(b) Transarc 16i - constant output current

5.8 Crater / Spot Selection Switch (Available on the Transtig 16Pi only) The CRATER switch (No 6) allows the output current to ramp up and crater or to spot for a setduration. It is active only when the WELDING process switch (No 4) is set to a TIG mode. Themode of operation is as follows:

(a) ON ModeThe Power Source will provide reduced start and crater currents which are set to 20% of thevalue selected at WELD CUR.(A) control (No 1). The up/down slope time is governed bythe setting on the UP.DOWN/SPOT(S) control (No 3).

(b) OFF ModeThe Power Source will not provide either start or crater currents.

(c) SPOT ModeThe Power Source will provide output current for a time period as set on theUP.DOWN/SPOT(S) control (No 3). This period is initiated each time the torch switch isdepressed.

5.9 UP.DOWN/SPOT(S) Control (Available on the Transtig 16Pi only) The UP.DOWN/SPOT(S) control (No 3) adjusts both the up/down slope and spot times. It isactive only when the WELDING process switch (No 4) is set to a TIG mode and the CRATERswitch (No 6) is not in the OFF position.

5.10 Gas Flow Control (Available on the Transtig 16Pi only)The gas flow times are internally set and are active only when the WELDING process switch (No4) is set to HF TIG or LIFT TIG modes.

(a) Pre-Flow Gas TimeThe pre-flow gas time is the time allowed for the gas to flow prior to arc initiation and ispreset to 0.15 seconds.

(b) Post-Flow Gas TimeThe post-flow gas time is the time allowed for gas to flow after arc extinction. It is setinternally to increase with the WELD CUR.(A) control (No 1) value.

5.11 TORCH SWITCH Socket The TORCH SWITCH Socket (No 9) accepts the external torch trigger switch (CIGWELD PartNo.700678) supplied with the unit. This switch initiates the arc in HF TIG or LIFT TIG modes.

5.12 Shielding Gas Connection Points (Available on the Transtig 16Pi only)The Transtig 16Pi allows solenoid control of shielding gas via the following connection points:

(a) Front ConnectionThe TIG torch gas hose is connected to the front of the Power Source.

(b) Rear ConnectionThe in-coming gas supply connection from the cylinder is made at the rear of the PowerSource. Ensure that it is correctly regulated on the Flowmeter provided.

6. SETTING UP A TRANSTIG 16Pi

WARNING 1: Before making any connections to the welding terminals make sure the 240Vmains power to the Power Source is turned off.

WARNING 2: Remove any packaging materials prior to use. Do not block the air vents atthe front or rear of the Power Source.

Figure 2 - Connections for the Transtig 16Pi

7. SETTING UP A TRANSARC 16i

WARNING 3: Before making any connections to the welding terminals make sure the 240Vmains power to the Power Source is turned off.

WARNING 4: Remove any packaging materials prior to use. Do not block the air vents atthe front or rear of the Power Source.

Figure 3 - Connections for the Transarc 16i

8. SEQUENCE OF OPERATION

8.1 TIG Welding

1. Switch the POWER ON/OFF SWITCH to OFF.

2. Connect the earth clamp, torch cables, torch trigger lead and gas hose as shown in Figure 2.Ensure that the polarity of the welding leads is correct for the process used.

3. Plug the Power Source in and switch the outlet ON.

4. Set the WELDING process selection switch to HF TIG or LIFT TIG .

5. Select the desired mode of operation with the CRATER selection switch.If a fixed welding time is required, ie spot, then set the WELDING process selection switchto HF TIG, the CRATER switch to SPOT and the UP.DOWN/SPOT(S) control to thedesired time.

6. Set the WELD CUR.(A) control to the desired welding current.

7. Switch the POWER ON/OFF SWITCH (located on the rear panel) to the ON position.

8. Depress the torch trigger switch and set the gas flow rate on the regulator/flow meter.

9. Commence welding. If necessary, readjust the WELD CUR.(A) control to obtain thewelding condition required.

10. After completion of welding the Power Source should be left turned ON for 2 to 3 minutes.This allows the fan to run and cool the internal components.

8.2 Stick Welding

1. Switch the POWER ON/OFF SWITCH to OFF.

2. Connect the earth clamp and electrode holder cables as shown in Figure 3.Ensure that the polarity of the welding leads is correct for the consumable used.

3. Plug the Power Source in and switch the outlet ON.

4. Set the WELDING process selection switch to STICK.

5. Set the WELD CUR.(A) control to the desired welding current.

6. Switch the POWER ON/OFF SWITCH (located on the rear panel) to the ON position. This will immediately energise the power supply up to the output terminals and the electrodeholder.

7. Commence welding. If necessary, readjust the WELD CUR.(A) control to obtain thewelding condition required.

8. After completion of welding the Power Source should be left turned ON for 2 to 3 minutes.This allows the fan to run and cool the internal components.

9. TIG WELDING SEQUENCE CONTROLS (TRANSTIG 16Pi Only)

9.1 Spot ONSwitch settings: WELDING= HF TIG

CRATER = SPOT

When the torch trigger switch is depressed and held the Pre Flow gas time is initiated (T1). After the Pre Flow gas time has expired welding current commences. The welding current extinguishes after the spot time has expired and the Post Flow gas time is

initiated (T2). The spot time (T5) is determined by the UP.DOWN/SPOT(S) control.ON

TORCH SWITCHOFF

T1 T2 T1 T2

WITH SPOT ON & PULSE OFF

GAS FLOWON

OFF

WELDING CURRENTON

OFFT5 T5

9.2 Crater OFFSwitch settings: WELDING= HF TIG or LIFT TIG

CRATER = OFF

When the torch trigger switch is depressed and held the Pre Flow gas time is initiated (T1). After the Pre Flow gas time has expired welding current commences.

If the PULSE switch = DC then the welding current is constant.If the PULSE switch = H or L then the welding current is pulsed.

When the torch trigger switch is released then the welding current extinguishes and the PostFlow gas time is initiated (T2).

WITH CRATER OFF & PULSE ONWELDING CURRENT

ON

OFF

ONTORCH SWITCH

OFFT1 T2 T1 T2

WITH CRATER OFF & PULSE OFF

GAS FLOWON

OFF

WELDING CURRENTON

OFF

NOTE 2: T1 = gas Pre Flow time, fixed at 0.15 secondsT2 = gas Post Flow time, variable- set by the position of WELD CUR.(A)

controlT5 = spot welding time, variable- 0.5 to 5 seconds

9.3 Crater ONSwitch settings: WELDING= HF TIG or LIFT TIG

CRATER = ON

When the torch trigger switch is depressed and held the Pre Flow gas time is initiated (T1). After the Pre Flow gas time has expired welding current commences at 20% of the WELD

CUR.(A) control value.

When the torch trigger switch is released then the welding current ramps up to the WELDCUR.(A) control value. The ramp up time (T3) is determined by the UP.DOWN/SPOT(S)control.If the PULSE switch = DC then the welding current is constant.If the PULSE switch = H or L then the welding current is pulsed.

When the torch trigger switch is depressed and held for a second time the Pre Flow gas time isinitiated (T1) then the welding current ramps down to 20% of the WELD CUR.(A) controlvalue. The ramp down time (T4) is determined by two times the UP.DOWN/SPOT(S) control.

When the torch trigger switch is released for a second time then the welding currentextinguishes and the Post Flow gas time is initiated (T2).

TORCH SWITCHON

OFF

WITH CRATER ON & PULSE OFF

GAS FLOWON

OFF

WELDING CURRENTON

OFF

WITH CRATER ON & PULSE ONWELDING CURRENT

ON

OFF

T1 T2

T3 T4

T1

NOTE 3: T1 = gas Pre Flow time, fixed at 0.15 secondsT2 = gas Post Flow time, variable- set by the position of WELD CUR.(A)

controlT3 = Up slope time, variable - 0.5 to 5 secondsT4 = Down slope time, variable- 1 to 10 seconds

10. TORCH REPLACEMENT PARTS BREAKDOWN(Where TTR17V12P TIG Torch is supplied as standard)

ITEM NO. PART NO. DESCRIPTION

1 BG57Y02 Back Cap Long

2 BG57Y04 Back Cap Short

3 BG18CG Cup Gasket

4 BG57Y012BG57Y032

Power Cable 3.8m (two piece)Power Cable 7.6m (two piece)

5 BGR17HV Torch Body

6 BGR17VS Valve Stem

7 BG15H Handle

8 Collet Refer to Table 3 on page 19

9 Collet Body Refer to Table 4 on page 19

10 Nozzle Refer to Table 5 on page 19

Table 2 - TIG torch (TTR17V12P) replacement parts

Figure 4 - TIG torch components

10.1 Torch Consumable Parts

(a) Collets

Size (mm) Part Number

1.0 BG10N22

1.6 BG10N23

2.4 BG10N24

3.2 BG10N25

Table 3 - TIG torch (TTR17V12P) collets(b) Collet Bodies


1.0 BG10N30

1.6 BG10N31

2.4 BG10N32

3.2 BG10N28

Table 4 - TIG torch (TTR17V12P) collet bodies(c) Alumina Nozzles


6.0 BG10N50

8.0 BG10N49

10.0 BG10N48

11.0 BG10N47

12.5 BG10N46

16.0 BG10N45

19.0 BG10N44

Table 5 - TIG torch (TTR17V12P) alumina nozzles

11. TIG WELDING GUIDE

11.1 Electrode Polarity

Connect the TIG torch to the - terminal and the work lead to the + terminal for direct currentstraight polarity. Direct current straight polarity is the most widely used polarity for DC TIGwelding. It allows limited wear of the electrode since 70% of the heat is concentrated at thework piece.

11.2 Tungsten Electrode Current Ranges

Electrode Diameter (mm) Constant Current (A)

1.0 2 - 301.6 8 - 702.4 12 - 1503.2 20 - 250

Table 6 - Current ranges for varies tungsten electrode sizes

11.3 CIGWELD Tungsten Electrode Types

Electrode Type(Ground Finish)

Welding Application Features ColourCode

Thoriated 2%DC welding of mild steel,stainless steel and copper.

Excellent arc starting, Longlife, High current carryingcapacity.

Red

l Ceriated 2%AC & DC welding of mildsteel, stainless steel, copper,aluminium, magnesium andtheir alloys

Longer life, More stablearc, Easier starting, Widercurrent range, Narrowermore concentrated arc.

Grey

l Zirconated 1%High quality AC welding ofaluminium, magnesium andtheir alloys.

Self cleaning, Long life,Maintains balled end, Highcurrent carrying capacity.

White

Table 7 - CIGWELD tungsten electrode types

NOTE 4 The Transtig 16Pi and Transarc 16i are DC welders and can not be used forAC welding application.

11.4 Guide for Selecting Filler Wire Diameter

Welding Current (A) Filler Wire Diameter (mm). Refer to NOTE 5.

10-20 1.220-50 1.2 - 1.6

50 - 100 1.6 - 2.4100 - 200 1.6 - 3.2

Table 8 - Filler wire selection guide

NOTE 5: The filler wire diameter specified in Table 8 is a guide only, other diameter wiresmay be used according to the welding application.

11.5 Shielding Gas Selection

Alloy Shielding Gas

Carbon Steel Welding ArgonStainless Steel Welding Argon, Argoshield 71T, 80T, 81TNickel Alloy Welding Argon, Argoshield 71TCopper Welding Argon, Argoshield 81TTitanium Welding Argon, Argoshield 80T, 81T

Table 9 - Shielding gas selectionArgoshield is a registered trade mark of BOC Gases Limited.

11.6 Welding Parameters for Stainless Steel

BaseMetal

Thickness

CurrentRange DCAmperes

Travel Speedmm/min.

Argon GasFlow RateLitres/min.

Joint Type

Butt

1.0 mm 30 - 50 150 - 400 5 Lap

Fillet

Butt

1.5 mm 50 - 90 150 - 350 6 Lap

Fillet

Butt

3.0 mm 100 - 150 100 - 250 7 Lap

Fillet

Table 10 - TIG welding parameters for stainless steel

11.7 Welding Parameters for Low Carbon & Low Alloy Steel Pipe

Electrode Type &Diameter

Current Range DCAmperes

Filler Rod forRoot Pass

Joint Preparation

Thoriated 2%2.4 mm 120 - 170 Yes

Thoriated 2%2.4 mm 100 - 160 Yes

Thoriated 2%2.4 mm 90 - 130 No

Table 11 - TIG welding parameters for low carbon & low alloy steel pipe

12. STICK WELDING GUIDE

12.1 Electrode Polarity

Stick electrodes are generally connected to the + terminal and the work lead to the - terminalbut if in doubt consult the electrode manufacturers literature.

12.2 Effects of Stick Welding Various Materials

(a) High tensile and alloy steelsThe two most prominent effects of welding these steels are the formation of a hardened zonein the weld area, and, if suitable precautions are not taken, the occurrence in this zone ofunder-bead cracks. Hardened zone and under-bead cracks in the weld area may be reducedby using the correct electrodes, preheating, using higher current settings, using largerelectrodes sizes, short runs for larger electrode deposits or tempering in a furnace.

(b) Manganese steelsThe effect on manganese steel of slow cooling from high temperatures is to embrittle it. Forthis reason it is absolutely essential to keep manganese steel cool during welding byquenching after each weld or skip welding to distribute the heat.

(c) Cast IronMost types of cast iron, except white iron, are weldable. White iron, because of its extremebrittleness, generally cracks when attempts are made to weld it. Trouble may also beexperienced when welding white-heart malleable, due to the porosity caused by gas held inthis type of iron.

(d) Copper and alloysThe most important factor is the high rate of heat conductivity of copper, making preheatingof heavy sections necessary to give proper fusion of weld and base metal.

13. ROUTINE MAINTENANCE & INSPECTIONThe only routine maintenance required for the Power Source is thorough cleaning and inspection, withthe frequency depending on the usage and the operating environment.

WARNING 5: Disconnect the Power Source from the 240V mains power before disassem-bling the Power Source.

Do not operate the Power Source with panels removed. Special maintenance is not necessary for thecontrol unit parts in the Power Source. If these parts are damaged for any reason, replacement isrecommended.

CAUTION 1: Do not blow air into the Power Source during cleaning. Blowing air into thePower Source can cause metal particles to interfere with sensitive electrical /electronic components and cause damage to the Power Source.

To clean the Power Source, open the enclosure and use a vacuum cleaner to remove any accumulateddirt and dust. The Power Source should also be wiped clean. If necessary, solvents that are recom-mended for cleaning electrical apparatus may be used.

14. BASIC TROUBLESHOOTING

Troubleshooting and repairing the Transtig 16Pi and Transarc 16i should be undertaken only by thosefamiliar with high voltage, high power electronic equipment.WARNING 6: There are extremely dangerous voltage and power levels present inside these

products. Do not attempt to diagnose or repair unless you have had trainingin power electronics measurement and troubleshooting techniques.

The basic level of troubleshooting is that which can be performed without special equipment or knowl-edge, and without removing the Power Source from the plastic enclosure.

If major complex subassemblies are faulty, then the Power Source must be returned to an AccreditedCIGWELD Service Agent for repair.

14.1 TIG Welding Problems

FAULT POSSIBLE CAUSE REMEDY

1 Electrode melts &oxidises when anarc is struck.

A No gas flowing to weldingregion.

A Check the gas lines for kinksor breaks and gas cylindercontents.

B Torch is clogged with dust.B Clean torch

C Gas hose is cut. C Replace gas hose.

D Gas passage containsimpurities.

D Disconnect gas hose from therear of Power Source thenraise gas pressure and blowout impurities.

E Gas regulator turned off.E Turn on.

F Torch valve is turned off. F Turn on.

G The electrode is too small forthe welding current.

G Increase electrode diameter orreduce the welding current.

2 Shielding gascontinues to flowfor more than 5seconds after thewelding arc hasextinguished.

Gas valve is faulty or jammedopen.

Have an AccreditedCIGWELD Service Agentrepair or replace gas valve.

3 Electrode meltswhen arc is struck.

Electrode is connected to the+ terminal.

Connect the electrode to the- terminal.

4 Dirty weld pool. A Electrode contaminatedthrough contact with workpiece or filler rod material.

A Clean the electrode bygrinding off the contaminates.

B Gas contaminated with air.B Check gas lines for cuts andloose fitting or change gascylinder.

5 Poor weld finish. Inadequate shielding gas. Increase gas flow or checkgas line for gas flowproblems.

6 Arc flutters duringTIG welding.

Tungsten electrode is toolarge for the welding current.

Select the right size electrode. Refer to Table 6.

7 Arc start is notsmooth.

A Tungsten electrode is toolarge for the welding current.

A Select the right size electrode. Refer to Table 6.

B The wrong electrode is beingused for the welding job

B Select the right electrodetype. Refer to Table 7.

C Gas flow rate is too high.C Select the correct rate for thewelding job.Refer to Table 10.

D Incorrect shielding gas isbeing used.

D Select the right shielding gas. Refer to Table 9.

E Poor work clamp connectionto work piece.

E Improve connection to workpiece.

TIG Welding Problems (continued)


8 Welding arc cannot be establisheddue to the lack ofHF.

A

B

Torch trigger switch isdisconnected or is damaged.

Welding process selectionswitch is set to STICK.

A

B

Connect the torch triggerswitch or have it repaired.

Set to HF TIG.

9 Welding arc cannot be establishedbut the HF is beingproduced.

A Work clamp is not connectedto the work piece or thework/torch leads are notconnected to the rightwelding terminals.

A Connect the work clamp tothe work piece or connect thework/torch leads to the rightwelding terminals.

B Torch lead is disconnected. B Connect it to the - terminal.C The distance between the

electrode and the work pieceto too large.

C Reduce the distance.

D Gas flow incorrectly set,cylinder empty or the torchvalve is turned off.

D Select the right rate for thewelding job, change cylindersor turn torch valve on. Referto Table 10.

14.2 Stick Welding Problems

FAULT CAUSE REMEDY

1 Non-metallicparticles aretrapped in the weldmetal.

A May be trapped in undercutfrom previous run.

A If a bad undercut is present,clean slag out and cover witha run from a smaller gaugeelectrode.

B Joint preparation toorestricted.

B Allow for adequate penetra-tion and room for cleaningout the slag.

C Irregular deposits allow slagto be trapped.

C If very bad, chip or grind outirregularities.

D Lack of penetration with slagtrapped beneath weld bead.

D Use smaller electrode withsufficient current to giveadequate penetration. Usesuitable tools to remove allslag from corners.

E Rust or mill scale is prevent-ing full fusion.

E Clean joint before welding.

F Wrong electrode for positionin which welding is done.

F Use electrodes designed forposition in which welding isdone, otherwise propercontrol of slag is difficult.

Stick Welding Problems (continued)


2 A groove has beenformed in the basemetal adjacent tothe toe of a weldand has not beenfilled by the weldmetal (Undercut).

A

B

C

Welding current is too high.

Welding arc is too long.

Angle of the electrode isincorrect.

A

B

C

Reduce welding current

Reduce the length of thewelding arc.

Electrode should not beinclined less than 45 to thevertical face

D Joint preparation does notallow correct electrode angle.

D Allow more room in joint formanipulation of the electrode.

E Electrode too large for joint.E Use smaller gauge electrode.F Insufficient deposit time at

edge of weave.F Pause for a moment at edge

of weave to allow weld metalbuild-up.

3 A gap is left byfailure of the weldmetal to fill the rootof the weld.

AB

C

Welding current is too low.Electrode too large for joint.

Insufficient gap.

AB

C

Increase welding currentUse smaller diameterelectrode.Allow wider gap.

4 Portions of theweld run does notfuse to the surfaceof the metal oredge of the joint.

A

BC

D

E

Small electrodes used onheavy cold plate.Welding current is too low.Wrong electrode angle.

Travel speed of electrode istoo high.Scale or dirt on joint surface.

A

BC

D

E

Use larger electrodes and pre-heat the plate.Increase welding current.Adjust angle so the weldingarc is directed more into thebase metal.Reduce travel speed ofelectrodeClean surface before welding.

5 Gas pockets orvoids in weld metal(Porosity).

A High levels of sulphur insteel.

A Use an electrode that isdesigned for high sulphursteels.

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.

6 Crack occurring inweld metal soonafter solidificationcommences

A Rigidity of joint. A Redesign to relieve weld jointof severe stresses or usecrack resistance electrodes.

B Insufficient throat thickness.B Travel slightly slower toallow greater build up inthroat.

C Welding current is too high.C Decrease welding current.

14.3 Power Source Problems


1 POWER lamp is litbut welding arccant beestablished.

A

B

Torch trigger switch lead isdisconnected.One of the TIG modes areselected when trying toSTICK weld.

A

B

Reconnect.

Select STICK welding modefor Manual Metal ArcWelding.

2 Mains supplyvoltage is ON butPOWER lamp isnot lit.

ON/OFF Switch is OFF. Switch ON.

3 POWER lamp isnot lit, fan does notoperate andwelding arc cantbe established.

AB

C

Mains primary fuse is blown.ON/OFF Switch is OFF ordefective.

Mains supply voltage is OFF.

AB

C

Replace primary fuse.If Switch is ON then have anAccredited CIGWELDService Agent replaceON/OFF Switch.Switch ON.

4 POWER lamp isnot lit, fan operatesand welding arccan be established.

Defective POWER lamp. Have an AccreditedCIGWELD Service Agentreplace POWER lamp.

5 Welding currentcant be establishedor adjusted andWARNING lampis lit.

Duty cycle rating has beenexceeded.

Leave the Power Sourceswitched ON to let it cooldown then operate withinrated duty cycle.

6 No gas flow whenthe torch triggerswitch isdepressed.

AB

Gas hose is cut.Gas passage containsimpurities.

AB

Replace gas hose.Disconnect gas hose from therear of Power Source thenraise gas pressure and blowout impurities.

C Gas regulator turned off.C Turn gas regulator on.D Torch trigger switch lead is

disconnected or switch/cableis faulty.

D Reconnect lead or repairfaulty switch/cable.

7 Gas flow wontshut off

A Gas valve is faulty. A Have an AccreditedCIGWELD Service Agentreplace gas valve.

B Gas valve jammed open. B Have an AccreditedCIGWELD Service Agentrepair or replace gas valve.

TRANSARC16i TRANSTIG 16Pi Table of ContentsIntroductionSpecificationsInstallationHigh FrequencyControlsSet Up Transtig 16PiSet Up Transarc 16iSequence of OperationTIG Welding Controls 16PiTorch PartsTIG Welding GuideStick Welding GuideRoutine MaintenanceBasic Troubleshooting

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