Cigweld 170ti TRANSTIG UsMan (EN)
Cigweld 170ti TRANSTIG UsMan (EN)
Cigweld 170ti TRANSTIG UsMan (EN)
TRANSTIG
WELDING INVERTER
A-11692
Operating Manual
Revision: AA Issue Date: January 10, 2013 Manual No.: 0-5279
Operating Features:
PFC
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Cigweld product. We are proud
to have you as our customer and will strive to provide you with
the best service and reliability in the industry. This product
is backed by our extensive warranty and world-wide service
network. To locate your nearest distributor or service provider call
+1300 654 674, or visit us on the web at www.cigweld.com.au
Published by:
CIGWELD Pty Ltd
71 Gower Street
Preston, Victoria, Australia, 3072
+61 3 9474 7400 +61 3 9474 7391
www.cigweld.com.au
Copyright 2013 by
CIGWELD Pty Ltd.
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 such error
results from negligence, accident, or any other cause.
SECTION 1:
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ..................................... 1-1
1.01 Arc Welding Hazards....................................................................................... 1-1
1.02 Principal Safety Standards .............................................................................. 1-5
1.03 Declaration of Conformity ............................................................................... 1-6
SECTION 2:
INTRODUCTION ..................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Symbol Chart .................................................................................................. 2-2
2.05 Description ..................................................................................................... 2-3
2.06 User Responsibility ......................................................................................... 2-3
2.07 Transporting Methods ..................................................................................... 2-3
2.08 Packaged Items .............................................................................................. 2-3
2.09 Duty Cycle....................................................................................................... 2-4
2.10 Specifications ................................................................................................. 2-5
2.11 Options and Accessories ................................................................................ 2-6
SECTION 3:
INSTALLATION, OPERATION AND SETUP ........................................................ 3-1
3.01 Environment ................................................................................................... 3-1
3.02 Location .......................................................................................................... 3-1
3.03 Ventilation ....................................................................................................... 3-1
3.04 Mains Supply Voltage Requirements .............................................................. 3-1
3.05 Electromagnetic Compatibility ........................................................................ 3-1
3.06 Transtig 170Ti Power Source Controls, Indicators and Features ..................... 3-3
3.07 Shielding Gas Regulator Operating Instructions ........................................... 3-13
3.08 Setup for TIG (GTAW) Welding ..................................................................... 3-16
3.09 Foot Control Part No. W4015800 (Optional Accessory)................................ 3-18
3.10 Setup for Manual Arc (MMAW) Welding ..................................................... 3-19
SECTION 4:
BASIC WELDING GUIDE ............................................................................ 4-1
4.01 Stick (MMAW) Basic Welding Technique ........................................................ 4-1
4.02 Stick (MMAW) Welding Troubleshooting ...................................................... 4-12
4.03 TIG (GTAW) Basic Welding Technique .......................................................... 4-14
4.04 TIG (GTAW) Welding Problems..................................................................... 4-16
SECTION 5:
POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS .................... 5-1
5.01 Power Source Problems ................................................................................. 5-1
5.02 Routine Service and Calibration Requirements ............................................... 5-2
5.03 Cleaning the Welding Power Source ............................................................... 5-4
5.04 Factory Reset Procedure................................................................................. 5-5
TABLE OF CONTENTS
SECTION 6:
KEY SPARE PARTS................................................................................... 6-1
6.01 Power Source ................................................................................................. 6-1
6.02 TIG Torch W4014604 ...................................................................................... 6-2
6.03 Stick Electrode holder with Trigger Switch 646761 (where supplied) ............. 6-3
APPENDIX: TRANSTIG 170Ti CIRCUIT DIAGRAM ...................................................... A-1
! 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.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be
learned through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the Australian Standard AS1674.2-2007 entitled: Safety in welding and allied
processes Part 2: Electrical. This publication and other guides to what you should learn before operating
this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION,
MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards 5. Properly install and ground this equipment accord-
ing to its Owner’s Manual and national, state, and
local codes.
6. Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or
WARNING out of service.
ELECTRIC SHOCK can kill. 7. Use fully insulated electrode holders. Never dip
holder in water to cool it or lay it down on the
Touching live electrical parts can cause ground or the work surface. Do not touch holders
fatal shocks or severe burns. The electrode connected to two welding machines at the same
and work circuit is electrically live when- time or touch other people with the holder or
ever the output is on. The input power cir- electrode.
cuit and machine internal circuits are also
live when power is on. In semiautomatic 8. Do not use worn, damaged, undersized, or poorly
or automatic wire welding, the wire, wire spliced cables.
reel, drive roll housing, and all metal parts 9. Do not wrap cables around your body.
touching the welding wire are electrically
live. Incorrectly installed or improperly 10. Ground the workpiece to a good electrical (earth)
grounded equipment is a hazard. ground.
1. Do not touch live electrical parts. 11. Do not touch electrode while in contact with the
work (ground) circuit.
2. Wear dry, hole-free insulating gloves and body
protection. 12. Use only well-maintained equipment. Repair or
replace damaged parts at once.
3. Insulate yourself from work and ground using dry
insulating mats or covers. 13. In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
4. Disconnect input power or stop engine before voltage reducer. Use equipment with DC output.
installing or servicing this equipment. Lock input
power disconnect switch open, or remove line 14. Wear a safety harness to prevent falling if working
fuses so power cannot be turned on acciden- above floor level.
tally. 15. Keep all panels and covers securely in place.
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.
6. Do not weld in locations near degreasing, cleaning, FLYING SPARKS AND HOT METAL can
or spraying operations. The heat and rays of the cause injury.
arc can react with vapours to form highly toxic Chipping and grinding cause flying metal.
and irritating gases. As welds cool, they can throw off slag.
7. Do not weld on coated metals, such as galvanized, 1. Wear approved face shield or safety goggles. Side
lead, or cadmium plated steel, unless the coating shields recommended.
is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an air- 2. Wear proper body protection to protect skin.
supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded. WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
WARNING high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
WELDING can cause fire or explosion.
part of the welding process, be sure to
Sparks and spatter fly off from the welding treat them carefully.
arc. The flying sparks and hot metal, weld
1. Protect compressed gas cylinders from excessive
spatter, hot workpiece, and hot equipment
heat, mechanical shocks, and arcs.
can cause fires and burns. Accidental con-
tact of electrode or welding wire to metal 2. Install and secure cylinders in an upright position
objects can cause sparks, overheating, by chaining them to a stationary support or equip-
or fire. ment cylinder rack to prevent falling or tipping.
1. Protect yourself and others from flying sparks and 3. Keep cylinders away from any welding or other
hot metal. electrical circuits.
2. Do not weld where flying sparks can strike flam- 4. Never allow a welding electrode to touch any
mable material. cylinder.
4. To prevent accidental starting during servicing, The above procedures are among those
disconnect negative (-) battery cable from bat- also normally recommended for pace-
tery. maker wearers. Consult your doctor for
complete information.
5. Keep hands, hair, loose clothing, and tools away
from moving parts.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
! WARNING
This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals know to the State of
California to cause birth defects and, in
some 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-
ment Printing Office, May 1989): “...there is now
Description of equipment: Welding Equipment (GTAW, MMAW) including, but not limited to CIGWELD Transtig
170Ti 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.
The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (2006/95 EC)
and to the National legislation for the enforcement of the Directive.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among them
are:
• IEC 60974-10 applicable to Industrial Equipment - generic emissions and regulations.
• AS 1674 Safety in welding and allied processes.
• AS 60974.1 / IEC 60974-1 applicable to welding equipment and associated accessories.
Extensive product design verification is conducted at the manufacturing facility as part of the routine design
and manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is in-
corporated into the manufacturing process to ensure the manufactured product meets or exceeds all design
specifications.
CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance,
ultra safe operation and world class quality for more than 30 years and will continue to achieve excellence.
! WARNING
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
A WARNING gives information regarding
invoice to make sure it is complete and inspect the
possible personal injury.
equipment for possible damage due to shipping. If
there is any damage, notify the carrier immediately to
file a claim. Furnish complete information concerning
CAUTION damage claims or shipping errors to the location in
A CAUTION refers to possible equipment your area listed in the inside back cover of this manual.
damage. Include all equipment identification numbers as
NOTE described above along with a full description of the
parts in error.
A NOTE offers helpful information con-
cerning certain operating procedures. Move the equipment to the installation site before
un-crating the unit. 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. Include the Owner’s Manual number and
equipment identification numbers.
Continuous Weld
Circuit Breaker
X Duty Cycle
Mode
Shielded Metal
Amperage t1 Preflow Time
Arc Welding (SMAW)
A-11693
A. In areas, free from moisture and dust. Any electrical work must be carried out by
a qualified Electrical Tradesperson.
B. Ambient temperature between 0° C to 40° C.
C. In areas, free from oil, steam and corrosive 3.05 Electromagnetic Compatibility
gases.
D. In areas, not subjected to abnormal vibration or
shock.
! WARNING
A-11646
A-11694
A-11690
Base Current
This parameter sets the STICK weld
current.
Range is 5 to 170A. Factory default
is 120A.
Initial Current
This parameter operates in TIG
modes only and is used to set the
start current for TIG. In 4T mode
the Initial Current remains on until
the torch trigger switch is released
after it has been depressed. In 2T
mode this is the Initial Current for
the Up Slope current ramp.
Range is 5 to 170A. Factory default
is 30A.
Base Current
This parameter sets the TIG welding
current.
Range is 5 to 170A. Factory default
is 120A.
Down Slope
This parameter operates in TIG
modes only and is used to set
the time for the weld current to
ramp down to the crater current.
This control is used to eliminate
the crater that can form at the
completion of a weld.
Range is 0.0 to 25.0 seconds.
Factory default is 3.0 seconds.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused
in the bayonet terminal.
6. Negative Welding Output Terminal
The negative welding terminal is used to connect the welding output of the power source to the TIG
torch or work lead. Negative welding current flows to the power source via this heavy duty bayonet type
terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound
electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused
in the bayonet terminal.
7. 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
7 Wiper arm connection to 5k ohm remote control Amps GTAW (TIG) mode potentiometer.
8 Not connected.
Table 3-1
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.
Note that when operating in GTAW (TIG mode), the power source will remain activated until the selected
downslope time has elapsed.
A-11707
A-11708
There will be 0V on the Power Source welding terminals and both VRD lights will be off.
! WARNING
Approval from a mine site manager, or work site manager must be obtained in writing before the
Dead Man Switch function is disabled. Only a suitably qualified electrical tradesperson or Cigweld
Service Provider should make any changes to the Power Source.
! WARNING
The Power Source must be turned off and unplugged from the mains supply before the Dead Man
Switch function is changed
! WARNING
If 4T operation is selected when using the Dead Man Switch mode, the use of an observer is
recommended.
10. Process Selection Control
The process selection control is used to select the desired welding mode. Three modes are available, GTAW
(HF TIG), GTAW (Lift TIG) and (MMAW (Stick) modes. Refer to section 3.08 for GTAW (TIG) set-up details
or section 3.10 for MMAW (stick) set-up details.
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.
11. Thermal Overload Indicator
This welding power source is protected by a self resetting thermostat. The indicator will illuminate if the
duty cycle of the power source has been exceeded. Should the thermal overload indicator illuminate the
output of the power source will be disabled. Once the power source cools down this light will go OFF and
the over temperature condition will automatically reset. Note that the mains power switch should remain
in the on position such that the fan continues to operate thus allowing the unit to cool sufficiently. Do not
switch the unit off should a thermal overload condition be present.
The display will also show error code E-- in the event of an over current or over temperature.
A-11665
! WARNING
Only Inert Shielding Gases specifically designed for welding applications should be used.
13. On / Off Switch
This switch is used to turn the unit on/off.
! 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.
If the equipment is improperly used, hazardous conditions are created that may cause accidents. It is the
users responsibility to prevent such conditions. Before handing or using the equipment, understand and
comply at all times with the safe practices prescribed in this instruction.
This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in
accordance with the instructions provided. Equipment must be checked periodically and repaired, replaced,
or reset as necessary for continued safe and reliable performance. Defective equipment should not be used.
Parts that are broken, missing, obviously worn, distorted, or contaminated should be replaced immediately.
The user of this equipment will generally have the sole responsibility for any malfunction, which results from
improper use, faulty maintenance, or by repair by anyone other than an accredited repairer.
CAUTION
Match regulator to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to
a cylinder containing any other gas.
Art: A-05087
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. Wipe with a clean lint free cloth.
2. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking
agree and that the regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed
for a particular gas or gases to a cylinder containing any other gas.
3. Connect the regulator inlet connection to cylinder or pipeline and tighten it firmly but not excessively,
with a 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 regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure
surge may damage internal regulator parts.
2. With valves on downstream equipment closed, adjust regulator to approximate working pressure. It is
recommended that testing for leaks at the regulator connection points be carried out using a suitable
leak detection solution or soapy water.
3. Purge air or other unwanted welding grade shielding gas from equipment connected to the regulator
by individually opening then closing the equipment control valves. Complete purging may take up to
ten seconds or more, depending upon the length and size of the hose being purged.
Art: A-05088_AB
With the regulator ready for operation, adjust working flow rate as follows:
1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required
flow rate.
NOTE
It may be necessary to re-check the shielding gas regulator flow rate following the first weld sequence
due to back pressure present within shielding gas hose assembly.
2. To reduce flow rate, allow the welding grade shielding 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 counterclockwise, 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
minutes).
1. Close cylinder or upstream valve tightly.
2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away
from any ignition source.
3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.
4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove
regulators.
! WARNING
Before connecting the work clamp to the work and inserting the tungsten electrode in the TIG Torch
make sure the mains power supply is switched off.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a stationary
support to prevent falling or tipping.
CAUTION
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.
Loose welding terminal connections can cause overheating and result in the male plug being fused
in the terminal.
A-11666
Art # A-11338
1 2
3 4 5
6 7 8
Art # A-11339
Art # A-11340
Pin Description
1 Not Used
2 Trigger Switch
3 Trigger Switch
4 Not Used
5 Potentiometer Maximum
6 Potentiometer Minimum
7 Potentiometer Wiper
8 Not Used
Table 3-2
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.
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.
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 that the maximum current must be set on the
power source by the operator prior to the foot control being connected, although this can be adjusted while
you are welding.
With the foot control connected, the power source will only display minimum preview Amps until the foot
control is depressed then it displays actual welding current when welding. Pressing the pedal to increases
the welding current; letting up on the pedal decreases the welding current. Releasing the pedal completely
extinguishes the arc and initiates the post-flow shielding gas timer (where fitted).
! WARNING
Before connecting the work clamp to the work and inserting the electrode in the electrode holder
make sure the mains power supply is switched off.
CAUTION
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.
Loose welding terminal connections can cause overheating and result in the male plug being
fused.
Art # A-07687
Art # A-07688
Art # A-07689
Art # A-07690
Art A-07691
Art # A-07692
Art# A-07693
Art # A-07694
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.
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.
Open Square Butt Single Vee Butt Joint Not less than
70°
Joint 1.6mm (1/16” ) max
Gap varies from
1.6mm (1/16”) to 4.8mm (3/16”)
depending on plate thickness
1.6mm (1/16”)
Not less than Not less than
Single Vee Butt Joint 45° Double Vee Butt Joint
70°
1.6mm (1/16”) max
Tee Joints
Fillet Joint (Fillet both sides of the
joint)
Art # A-07695_AE
1.6 mm (1/16”)
Arc Length
The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will
find that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the
weld metal comes across in large, irregular blobs. The weld bead is flattened and spatter increases. A short
arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being
blanketed by slag and the electrode tip being solidified in. If this should happen, give the electrode a quick
twist back over the weld to detach it. Contact or "touch-weld" electrodes such as Ferrocraft 21 do not stick in
this way, and make welding much easier.
Rate of Travel
After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards
the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the
plate to form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel
has to be adjusted so that a well-formed bead is produced.
Tack Weld
Art # A-07697_AB
Art # A-07698
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 deposited using either a weave technique or single beads laid down
in the sequence shown in Figure 4-12. The width of weave should not be more than three times the core
wire diameter of the electrode. When the joint is completely filled, the back is either machined, ground or
gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing
the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar
purpose to the backing run in securing proper fusion at the root of the weld.
B. Fillet Welds
These are welds of approximately triangular cross-section made by depositing metal in the corner of two
faces meeting at right angles. Refer to Figure 4-4.
A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be
tacked together at right angles. Using a 3.2mm Ferrocraft 21 electrode at 100 amps, position angle iron
with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) fillet. Strike the
arc and immediately bring the electrode to a position perpendicular to the line of the fillet and about 45º
Art # A-07699_AB
Art # A-07700_AB
6
3 5
1 2 4
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm
Ferrocraft 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
the second run at the bottom. This time a slight weaving motion is necessary to cover the first run and
obtain good fusion at the edges. At the completion of each side motion, pause for a moment to allow
weld metal to build up at the edges, otherwise undercut will form and too much metal will accumulate
in the centre of the weld. Figure 4-16 illustrates multi-run technique and Figure 4-17 shows the effects
of pausing at the edge of weave and of weaving too rapidly.
Art # A-07701
Art # A-07703
2. Vertical Down
The Ferrocraft 21 electrode makes welding in this position particularly easy. Use a 3.2mm electrode at
100 amps. The tip of the electrode is held in light contact with the work and the speed of downward
travel is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should
point upwards at an angle of about 45º.
3. Overhead Welds
Apart from the rather awkward position necessary, overhead welding is not much more 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 travel (Figure 4-18). The tip of
the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique
is not advisable for overhead fillet welds. Use a 3.2mm Ferrocraft 12XP electrode at 100 amps, and
deposit the first run by simply drawing the electrode along at a steady rate. You will notice that the
weld deposit is rather convex, due to the effect of gravity before the metal freezes.
Art # A-07704
Expansion with
compression
Art # A-07706_AB
Weld Permanent Upset
Contraction
with tension
Art # A-07707
Art # A-07708
B C
Preheat Preheat
Weld
Art # A-07709
Art # A-07710_AB
Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
1
2
3
4
Art # A-07711_AB
Art # A-07712
Art # A-07713_AB
Art # A-05866_AC
Incorrect Sequence
6 Gas pockets or A High levels of sulphur in A Use an electrode that is designed for high sul-
voids in weld steel. phur steels.
metal (porosity) B Electrodes are damp. B Dry electrodes before use.
C Welding current is too C Reduce welding current.
high.
D Surface impurities such as D Clean joint before welding.
oil, grease, paint, etc.
E Welding in a windy envi- E Shield the weld area from the wind.
ronment.
F Electrode damaged ie flux F Discard damaged electrodes and only use elec-
coating incomplete. trodes with a complete flux coating.
7 Crack occurring in A Rigidity of joint. A Redesign to relieve weld joint of severe stresses
weld metal soon or use crack resistance electrodes.
after solidification B Insufficient throat thick- B Travel slightly slower to allow greater build up in
commences ness. throat.
C Weld current is too high. C Decrease welding current.
Slag
trapped in
undercut
Not cleaned,
or incorrect
electrode
Slag trapped in root
Art # A-05868_AC Figure 3: Example of Slag Inclusion
Table 4-2: Welding Problems MMAW (Stick)
A-09658_AB
Gas Cup
Either Ceramic,
Work Piece High-lmpact or
Can Be Any Commercial Water Cooled
Metal Metal
Tungsten Electrode
Non-Consumable
Welds Made With or Without
Inert Gas
Addition of Filler Metal
Shields Electrode
and Weld Puddle
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 Red
and copper carrying capacity
High quality AC weld- Self cleaning, Long
ing of aluminium, life, Maintains balled
Zirconated 1% White
magnesium and their end, High current car-
alloys. rying capacity.
Table 4-5
Base Metal DC Current DC Current Tungsten Filler Rod Argon Gas Joint Type
Thickness for Mild for Stainless Electrode Diameter (if Flow Rate
Steel Steel Diameter required) Litres/min
0.040” 35-45 20-30 0.040” 1/16” 5-7 Butt/Corner
1.0mm 40-50 25-35 1.0mm 1.6mm Lap/Fillet
0.045” 45-55 30-45 0.040” 1/16” 5-7 Butt/Corner
1.2mm 50-60 35-50 1.0mm 1.6mm Lap/Fillet
1/16” 60-70 40-60 1/16” 1/16” 7 Butt/Corner
1.6mm 70-90 50-70 1.6mm 1.6mm Lap/Fillet
1/8” 80-100 65-85 1/16” 3/32” 7 Butt/Corner
3.2mm 90-115 90-110 1.6mm 2.4mm Lap/Fillet
3/16” 115-135 100-125 3/32” 1/8” 10 Butt/Corner
4.8mm 140-165 125-150 2.4mm 3.2mm Lap/Fillet
1/4” 160-175 135-160 1/8” 5/32” 10 Butt/Corner
6.4mm 170-200 160-180 3.2mm 4.0mm Lap/Fillet
Table 4-7
4 Weld bead too wide or Travel speed too slow Increase travel speed.
excessive bead build up or
excessive penetration in
butt joint.
5 Uneven leg length in fillet Wrong placement of Re-position filler rod.
joint filler rod
6 Electrode melts or oxidises A Torch lead connected A Connect torch lead to negative welding
when an arc is struck. to positive welding terminal.
terminal.
B No gas flowing to weld- B Check the gas lines for kinks or breaks
ing region. and gas cylinder contents.
10 Arc flutters during TIG Tungsten electrode is Select the right size tungsten electrode.
welding. too large for the weld- Refer to Table 4-3 Cigweld Tungsten
ing current. Electrode Selection Chart.
Table 4-8: GTAW (TIG) Welding Problems
Manual 0-5279 5-1 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS
TRANSTIG 170Ti
10 Fault light is on, and E-1 is A Fail to Safe protection has A Reset mains power, if fault does not
shown on the Amps display. operated in STICK mode- clear then have an accredited CIG-
VRD fault. WELD service provider repair unit.
B Fail to safe protection has B Reset mains power, if fault does not
operated in TIG mode- In- clear then have an accredited CIG-
verter fault. WELD service provider repair unit.
C External voltage has been C Reset mains power and remove the
applied to the welding source of the external voltage
circuit
Table 5-1
! WARNING
There are extremely dangerous voltage and power levels present inside this Inverter Power Source.
Do not attempt to open or repair unless you are an accredited CIGWELD Service Provider. Discon-
nect the Welding Power Source from the Mains Supply Voltage before disassembling.
Routine Inspection, Testing & Maintenance
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.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined
in AS 1674.2 - 2007, then the above tests should be carried out prior to entering this location.
A. Testing Schedule
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
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 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.
POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-2 Manual 0-5279
TRANSTIG 170Ti
Minimum Insulation
Components to be Tested
Resistance (MΩ)
Input circuit (including any connected control circuits) to welding circuit
5
(including any connected control circuits)
All circuits to exposed conductive parts 2.5
Welding circuit (including any connected control circuits) to any auxiliary
10
circuit which operates at a voltage exceeding extra low voltage
Welding circuit (including any connected control circuits) to any auxiliary
1
circuit which operates at a voltage not exceeding extra low voltage
Separate welding circuit to separate welding circuit 1
Table 5-2: Minimum Insulation Resistance Requirements: Cigweld Inverter Power Sources
C. Earthing
The resistance shall not exceed 1Ω between any metal of a power source where such metal is required
to be earthed, and -
1. The earth terminal of a fixed power source; or
2. The earth terminal of the associated plug of a transportable power source
Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring
supplying Cigweld welding power sources should be inspected by a licensed electrical worker in accordance
with the requirements below -
1. For outlets/wiring and associated accessories supplying transportable equipment - at least once
every 3 months; and
2. For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12
months.
D. Voltage Reduction Device (VRD)
Units fitted with VRD's, shall have the periodic tests outlined in Table 6-2 below conducted by an accredited
CIGWELD service provider. Testing shall be conducted at intervals as outlined below -
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
Description Required Parameters
VRD Open Circuit Voltage Less than 35V; at nominal input voltage
VRD Turn OFF Resistance Less than 200 ohms
VRD Turn ON Time Less than 0.3 seconds
Table 5-3: VRD Periodic Tests
Manual 0-5279 5-3 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS
TRANSTIG 170Ti
F. Accessories
Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be
inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable
condition. All unsafe accessories shall not be used.
G. 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 at
regular intervals to ensure they fall within specified levels. Calibration intervals shall be as outlined below -
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as
outlined in AS 1674.2 - 2007, then the above tests should be carried out prior to entering this location.
B. Calibration Requirements
Where applicable, the tests outlined in Table 6-3 below shall be conducted by an accredited CIGWELD
service agent.
Testing Requirements
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
Table 5-4: Calibration Parameters
Periodic calibration of other parameters such as timing functions are not required unless a specific fault
has been identified.
C. Calibration Equipment
All equipment used for Power Source calibration shall be in proper working condition and be suitable for
conducting the measurement in question. Only test equipment with valid calibration certificates (NATA
certified laboratories) shall be utilized.
! 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 accumulated
dirt, metal filings, slag and loose material.
POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-4 Manual 0-5279
TRANSTIG 170Ti
5.04 Factory Reset Procedure
To perform a Factory Reset, press the Trigger Mode Button while turning on the mains power.
A-11709
Figure 5-1
Manual 0-5279 5-5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS
TRANSTIG 170Ti
POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-6 Manual 0-5279
TRANSTIG 170Ti
SECTION 6:
KEY SPARE PARTS
6.01 Power Source
A-11668
Figure 6-1
A-11669
Figure 6-2
A-11710
Figure 6-3
NOTE
The Welding cable with integrated control wires is not available as a separate spare part.
R39 C20
SW1 T14
A R2 T1 L1 POSITIVE
EMC INPUT
FILTER 4R 50W RECTIFIER
CY1
COUT1
N
CT1 T18
V8 Q2
R56 C21
E C19 C22 C24
C101
NEGATIVE R101, 103
NEGATIVE HALL
WELDING TERMINALS
NEUTRAL
EFFECT
COUT2
FILTER NEUTRAL CT2
ACTIVE
NEGATIVE
IN DY2 DY1 JC GUN OUT GUN IN HF 220V T2
A-1
HF COIL
FJ
HF
SOU HF
110/220V
QF
SOLENOID
TH1
OT1
MB
J12
OT2
WELD NEGATIVE
APPENDIX: TRANSTIG 170Ti CIRCUIT DIAGRAM
WELD POSITIVE
WV
A-11670
TRANSTIG 170Ti
APPENDIX
CIGWELD - LIMITED WARRANTY TERMS
LIMITED WARRANTY: CIGWELD Pty Ltd, A Victor Technologies Company, hereafter, “CIGWELD” warrants to
customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in work-
manship or material. Should any failure to conform to this warranty appear within the time period applicable to
the CIGWELD products as stated below, CIGWELD shall, upon notification thereof and substantiation that the
product has been stored, installed, operated, and maintained in accordance with CIGWELD’s specifications,
instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair,
neglect, alteration, or accident, correct such defects by suitable repair or replacement, at CIGWELD’s sole
option, of any components or parts of the product determined by CIGWELD to be defective.
CIGWELD MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND
IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: CIGWELD SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL,
INDIRECT 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 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.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES
ARE USED WHICH IN CIGWELD’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY
CIGWELD PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD
TO PURCHASER BY NON-AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers
the products to the Purchaser. 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 authorized
distributor.
TERMS OF WARRANTY – JANUARY 2013
1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply
of goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain
situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including war-
ranties as to merchantability and fitness for purpose) associated with the supply of goods and services.
A consumer should seek legal advice as to the nature and extent of these protected interests. In some
circumstances, the supplier of goods and services may legally stipulate that the said conditions, warran-
ties, guarantees, rights and remedies are limited or entirely excluded. The warranties set out in Clause 2
shall be additional to any nonexcludable warranties to which the Customer may be entitled pursuant to any
statute.
2. Subject to Clause 3. CIGWELD gives the following warranties to the Customer:
Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantable
quality and reasonably fit for the purpose for which they are supplied by CIGWELD.
CIGWELD will repair or, at its option, replace those of the goods which, upon examination, are found by
CIGWELD to be defective in workmanship and/or materials.
CIGWELD reserves the right to request documented evidence of date of purchase.
3. The Warranty in Clause 2;
Is conditional upon:
The Customer notifying CIGWELD or 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 goods sold at auction, second-hand goods and prototype goods.
Breakdown or malfunction caused by accident, misuse or normal wear and tear.
Repairs or replacement made other than by CIGWELD or Accredited Service Providers, unless by prior
arrangement with CIGWELD.
Replacement parts or accessories which may affect product safety or performance and which are not
manufactured, distributed or approved by 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).
The replacement of the goods or the supply of equivalent goods.
The repair of goods.
The payment of cost of replacing the goods or acquiring equivalent goods.
The payment of the cost of having goods repaired.
5. Except as provided in Clauses 2 to 4 above, to the extent permitted by statute, CIGWELD hereby excludes
all liability for any loss, damage, death or injury of any kind whatsoever occasioned to the Customer in
respect of the supply of goods including direct, indirect, consequential or incidental loss, damage or injury
of any kind.
WARRANTY SCHEDULE – JANUARY 2013
These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of
sale from the 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.
WARRANTY PERIOD
TRANSTIG170Ti POWER SOURCE
PARTS LABOUR
Original main power magnetics. 3 Year 2 Year
Original main power rectifiers, printed circuit boards and power switch 2 Year 2 Year
semiconductors.
All other circuits and components including, but not limited to, relays, switches, 1 Year 1 Year
contactors, solenoids, fans and electric motors.
ACCESSORIES WARRANTY PERIOD
TIG torch, electrode holder lead and work lead. 3 Months
TIG torch consumable items. NIL
Gas regulator/flowmeter (excluding seat assembly, pressure gauges, elastomer 1 Year
seals and “O” rings).
Regulator seat assemblies and pressure gauges. 6 Months
Elastomer seals and “O” rings used in the equipment. 3 Months
Please note that the information detailed in this statement supersedes any prior published data produced by
CIGWELD.
Australia Terms of Warranty – 2013
Effective 1st January 2012, all warranties against defects (also known as a manufacturer’s war-
ranty) supplied with goods or services must comply with the new Australian consumer law regula-
tions (2010).
This Warranty Statement should be read in conjunction with the Warranty Schedule contained in
the operating instructions of the product. This schedule contains the warranty period applicable to
the product
Any claim under this warranty must be made within the warranty period which commences on the
date of purchase of the product. 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.
All costs associated with lodging the warranty claim including the return of goods to Cigweld or
our Nominated Accredited Distributor/Accredited Service Provider are the responsibility of the
consumer.
This warranty is provided in addition to other rights and remedies you have under law: Our goods
come with guarantees which cannot be excluded under the Australian Consumer Law. You are
entitled to replacement or refund for a major failure and to compensation for other reasonably
foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the
goods fail to be of acceptable quality and the failure does not amount to a major failure.
Failures due to incorrect use are not covered by this warranty and consumers are reminded to
only use the product in accordance with the Operating Instruction supplied with the product. Ad-
ditional copies of Operating Instructions are available from Cigweld Customer Care 1300 654 674
or the Website.
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION