Operating Manual Transtig 200 Pi Transtig 200 Pi Transtig 250 Pi Transtig 300 Pi 719438 Issue 3 0502 (Power Source) (Plant) (Power Source) (Power Source) Part No.
Transtig 200Pi, 250Pi, 300Pi Manufacturer and Merchandiser of Quality Consumables and Equipment: CIGWELD Address: 71 Gower St, Preston Victoria 3072 Australia Description of equipment: Welding Equipment (GTAW & MMAW). CIGWELD Transtig 200Pi, 250Pi, 300Pi 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.
Transtig 200Pi, 250Pi, 300Pi CONTENTS Page 1. Introduction ......................................................................................................................5 2. Electromagnetic Compatibility ........................................................................................7 3. General Information.........................................................................................................9 4. Safe Practices For The Use Of Welding Equipment ............................
Transtig 200Pi, 250Pi, 300Pi FIGURES Figure 1 – Transtig 200 Pi Power Source............................................................................................23 Figure 2 – Transtig 250 Pi Power Source............................................................................................23 Figure 3 – Transtig 300 Pi Power Source............................................................................................24 Figure 4 – Transtig 200Pi, 250Pi, 300Pi Set-up..........................
Transtig 200Pi, 250Pi, 300Pi 1. Introduction 1.1 Notes, Cautions and Warnings Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorised as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system. CAUTION A procedure which, if not properly followed, may cause damage to the equipment.
Transtig 200Pi, 250Pi, 300Pi ♦ Refer to the Victorian Occupational Health and safety (Confined Spaces) Regulations 1996 and Code of Practice or its equivalent for other states and / or countries. ELECTRIC SHOCK Electric Shock can injure or kill. The welding arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace. ♦ Never touch any parts that are electrically “live” or “hot.” ♦ Wear dry gloves and clothing.
Transtig 200Pi, 250Pi, 300Pi 2. Electromagnetic Compatibility WARNING 2 Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation. 2.1 Installation and use - Users Responsibility The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions.
Transtig 200Pi, 250Pi, 300Pi 2.3 Methods of Reducing Electromagnetic Emissions a) Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent.
Transtig 200Pi, 250Pi, 300Pi 3. General Information The Transtig 200Pi, 250Pi, 300Pi are light weight, constant current power sources incorporating the latest digital inverter technology to provide exceptional DC arc characteristics. TIG welding features include torch trigger latch operation (Slope), pre/post gas flow control, pulse control, spot weld control, TIG DC HF start, TIG DC lift arc start, hot start control and Up/Down Slope (crater fill) control.
Transtig 200Pi, 250Pi, 300Pi 3.3 Terms Of Warranty - April 2002 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 warranties as to merchantability and fitness for purpose) associated with the supply of goods and services.
Transtig 200Pi, 250Pi, 300Pi 3.4 Warranty Schedule - March 2001 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.
Transtig 200Pi, 250Pi, 300Pi ♦ During pauses between welding runs, electrode holders should be so placed that they cannot make electrical contact with persons or conductive objects. ♦ The welding leads, both the electrode lead and the work lead, must be protected from damage. Damaged leads must not be used. ♦ Keep combustible materials away from the welding area. Have a suitable fire extinguisher handy. ♦ Do not stand on damp ground when welding. 4.
Transtig 200Pi, 250Pi, 300Pi 5.1 Resuscitation Efficient resuscitation requires training which is available from the St John’s Ambulance Association, Red Cross and other sources. 1 Don’t become a victim. Switch off power if possible. If not, remove victim from contact, using some insulating material. 2 If unconscious, place victim on their side and clear vomit and other foreign matter from mouth. Check for breathing by look, listen and feel. If not breathing, commence expired air resuscitation (E.A.R.).
Transtig 200Pi, 250Pi, 300Pi 6.
Transtig 200Pi, 250Pi, 300Pi NOTE 2 Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service. 6.
Transtig 200Pi, 250Pi, 300Pi Parameter DOWN SLOPE CRATER CUR. POST-FLOW Description This parameter operates in TIG modes only and is used to set the time for the weld current to ramp down, after the torch trigger switch has been pressed, to CRATER CUR. This control is used to eliminate the crater that can form at the completion of a weld. This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to set the finish current for TIG.
Transtig 200Pi, 250Pi, 300Pi Weld Mode Weld Parameter BASE (WELD) TIG or STICK Parameter Range Factory Setting Incremental Unit 5 to 250A 80A 1A SPOT TIME 0.5 to 5.0 sec 2 sec 0.1 sec PULSE WIDTH 15 to 80% 50% 1% PULSE FREQ. 0.5 to 500Hz 100.0Hz See Table 7 DOWN SLOPE 0 to 25 sec 3 sec 0.1 sec CRATER CUR. 5 to 250A 30A 1A POST-FLOW 0.0 to 60 sec 10 sec 0.
Transtig 200Pi, 250Pi, 300Pi Feature Front Control Cover Description • Protects front panel controls Digital Meter • Displays selected weld parameter value • Displays average weld current when welding • Displays average weld current for 8 seconds after weld has been completed • A selected weld parameter value can be adjusted at any time even whilst welding Save/Load (recall) (Transtig 300Pi only) • Five welding programs can be saved or loaded (recalled) by using the Save/Load buttons • The programs rem
Transtig 200Pi, 250Pi, 300Pi 6.
Transtig 200Pi, 250Pi, 300Pi 7. Voltage Reduction Device (VRD) WARNING WELDING IN HAZARDOUS ENVIRONMENTS Before welding in hazardous environments the VOLTAGE REDUCTION DEVICE (VRD) MUST BE TURNED ON. For example confined spaces, wet areas and hot humid conditions are classed as hazardous environments. WARNING VRD TURN ON PROCEDURE CIGWELD recommends that an Accredited CIGWELD Service Agent TURNS ON the VOLTAGE REDUCTION DEVICE (VRD) as they have the knowledge and equipment to preform this operation.
Transtig 200Pi, 250Pi, 300Pi In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests should also be conducted by an accredited CIGWELD service agent. Description AS3195 & IEC 60974-1 Requirements VRD Open Circuit Voltage Less than 20V; at Vin=240V or 415V VRD Turn ON Resistance Less than 200 ohms VRD Turn OFF Time Less than 0.
Transtig 200Pi, 250Pi, 300Pi 8.5 240V Mains Current Circuit Requirements for the Transtig 200 Pi The Welding Power Source must be: ♦ Correctly installed, if necessary, by a qualified electrician. ♦ Correctly earthed (electrically) in accordance with local regulations. ♦ Connected to the correct size 240V Mains Current Circuit as per the Specifications WARNING 4 CIGWELD advises that this equipment be electrically connected by a qualified electrical trades-person.
Transtig 200Pi, 250Pi, 300Pi b) Transmission via the Supply Lead Without adequate shielding and filtering, high frequency energy may be fed to the wiring within the installation (mains) by direct coupling. The energy is then transmitted by both radiation and conduction. Adequate shielding and filtering is provided in the Power Source. c) Radiation from Welding Leads Radiated interference from welding leads, although pronounced in the vicinity of the leads, diminishes rapidly with distance.
Transtig 200Pi, 250Pi, 300Pi 1 7 6 2 5 3 8 4 Figure 3 – Transtig 300 Pi Power Source 10.1 Control Knob • This control sets the selected weld parameter, rotating it clockwise increase the parameter whilst anti-clockwise rotation decreases the parameter. Pushing the knob in sets the adjusted parameter and the intelligent controls proceeds to the next weld parameter for the selected weld mode. 10.
Transtig 200Pi, 250Pi, 300Pi E b) Transtig 300 Pi The 14 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. Socket Pin A A A B C D E F G H I J K LMN B C L D I N M E 5k ohms J K H G F Front view of 14 Socket Receptacle Function Torch Switch Input (24V) to energise weld current.
Transtig 200Pi, 250Pi, 300Pi WARNING 5 When the welder is connected to the Mains supply voltage, the internal electrical components maybe at 240V potential with respect to earth. 10.7 Input Cable ‡ The input cable connects the Mains supply voltage to the equipment. 10.8 Gas Inlet ˆ The Gas Inlet connects the welding gas to the in-built solenoid valve. A 5/8 18UNF male nut & nipple is supplied with the Transtig 200Pi, 250Pi, 300Pi to connect a 5mm ID gas hose to the Gas Inlet fitting. 11.
Transtig 200Pi, 250Pi, 300Pi 12.1 Stick Welding VRD ON PULSE OFF Refer to Manual for correct use HOT START STD PULSE ON PEAK PULSE CUR. WIDTH PULSE BASE FREQ. (WELD) UP SLOPE INITIAL CUR. SLOPE DOWN SLOPE CRATER CUR. (m)sec SPOT •Connect work lead to negative terminal •Connect electrode lead to positive terminal •Set HOT START current, press control knob POST-FLOW % •Refer to section 7 on page 20 for recommendations on VRD.
Transtig 200Pi, 250Pi, 300Pi PULSE VRD ON OFF Refer to Manual for correct use UP SLOPE HOT START •Refer to NOTE 4 on page 26 •Refer to CAUTION 3 on page 26 •Connect work lead to positive terminal •Connect TIG torch to negative terminal •Switch machine on, press control knob •Set PRE-FLOW time, press control knob •Set HOT START current, press control knob •Set INTIAL CUR current, press control knob •Set UP SLOPE time, press control knob •Set BASE (WELD) current, press control knob •Set DOWN SLOPE time,
Transtig 200Pi, 250Pi, 300Pi PULSE VRD ON OFF Refer to Manual for correct use UP SLOPE HOT START STD PULSE ON PEAK PULSE CUR. WIDTH PULSE BASE FREQ. (WELD) SLOPE DOWN SLOPE CRATER CUR. REPEAT SPOT SPOT TIME INITIAL CUR. POST-FLOW PRE-FLOW STICK HF TIG Hz (m)sec % A LIFT TIG Figure 11 – HF TIG REPEAT Mode – PULSE ON PULSE VRD ON OFF Refer to Manual for correct use UP SLOPE HOT START STD PULSE ON PEAK PULSE CUR. WIDTH PULSE BASE FREQ. (WELD) INITIAL CUR.
Transtig 200Pi, 250Pi, 300Pi 12.3 LIFT TIG Welding PULSE VRD ON OFF Refer to Manual for correct use UP SLOPE HOT START •Refer to NOTE 4 on page 26 STD PULSE ON PEAK PULSE CUR. WIDTH PULSE BASE FREQ.
Transtig 200Pi, 250Pi, 300Pi PULSE VRD ON OFF Refer to Manual for correct use HOT START UP SLOPE STD PULSE ON PEAK PULSE CUR. WIDTH PULSE BASE FREQ. (WELD) INITIAL CUR. SLOPE REPEAT DOWN SLOPE SPOT CRATER CUR. SPOT TIME POST-FLOW PRE-FLOW STICK HF TIG Hz (m)sec % A LIFT TIG Figure 17 – LIFT TIG SLOPE Mode – PULSE ON PULSE VRD ON OFF Refer to Manual for correct use HOT START UP SLOPE STD PULSE ON PEAK PULSE CUR. WIDTH PULSE FREQ. BASE (WELD) SLOPE REPEAT DOWN SLOPE SPOT CRATER CUR.
Transtig 200Pi, 250Pi, 300Pi 12.
Transtig 200Pi, 250Pi, 300Pi 13.4 Welding Parameters for Stainless Steel Base Metal Thickness 1.0mm 1.2mm DC Current DC Current Filler Rod Dia. Argon Gas (if required) Flow Rate Range for Range for Litres/min. Mild Steel Stainless Steel 35-45 20-30 1.6mm 5-7 40-50 25-35 45-55 30-45 1.6mm 7 50-60 35-50 60-70 40-60 1.6mm 7 70-90 50-70 80-100 65-85 2.4mm 7 90-115 90-110 115-135 100-125 3.2mm 10 140-165 125-150 160-175 135-160 4.0mm 10 170-200 160-180 7 1.6mm 3.2mm 4.8mm 6.
Transtig 200Pi, 250Pi, 300Pi 13.7 Welding Parameters for Low Carbon & Low Alloy Steel Pipe Electrode Type & Diameter Current Range DC Amperes Filler Rod for Root Pass Thoriated 2% 2.4 mm 120 - 170 Yes Thoriated 2% 2.4 mm 100 - 160 Yes Thoriated 2% 2.4 mm 90 - 130 No Joint Preparation Table 14 - TIG welding parameters for low carbon & low alloy steel pipe 14. Basic Arc Welding Guide 14.
Transtig 200Pi, 250Pi, 300Pi Metals being joined Electrode Size & Part No. CIGWELD Electrode Comments Mild steel 2.5mm 611182 3.2mm 611183 4.0mm 611184 Satincraft 13 (AS/NZS E4113-0) Ideal electrodes for all general purpose work. Features include out standing operator appeal, easy arc starting and low spatter. Mild steel 2.5mm 611242 3.2mm 611243 4.
Transtig 200Pi, 250Pi, 300Pi In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests should also be conducted by an accredited CIGWELD service agent. Description AS3195 & IEC 60974-1 Requirements VRD Open Circuit Voltage Less than 20V; at Vin=240V VRD Turn ON Resistance Less than 200 ohms VRD Turn OFF Time Less than 0.
Transtig 200Pi, 250Pi, 300Pi Description 3 Electrode melts or oxidises when an arc is struck. Possible Cause Remedy A No gas flowing to welding region. A Check the gas lines for kinks or breaks and gas cylinder contents. B Torch is clogged with dust. B Clean torch C Gas hose is cut. C Replace gas hose. D Gas passage contains impurities. D Disconnect gas hose from torch then raise gas pressure and blow out impurities. E Gas regulator turned off. E Turn on. F Torch valve is turned off.
Transtig 200Pi, 250Pi, 300Pi Description Possible Cause 3 A gap is left by failure A Welding current is too low. of the weld metal to fill B Electrode too large for joint. the root of the weld. C Insufficient gap. D Incorrect sequence. Remedy A Increase welding current B Use smaller diameter electrode. C Allow wider gap. D Use correct build-up sequence. Figure 21 – Example of insufficient gap or incorrect sequence 4 Portions of the weld run do not fuse to the surface of the metal or edge of the joint.
Transtig 200Pi, 250Pi, 300Pi 16.3 Power Source Problems Description 1 The welding arc cannot be established Possible Cause Remedy A The Mains supply voltage has not been switched ON. A Switch ON the Mains supply voltage. B The Welding Power Source switch is switched OFF. B Switch ON the Welding Power Source. C Loose connections internally. C Have an Accredited CIGWELD Service Agent repair the connection. 2 Maximum output welding current can not be achieved with nominal Mains supply voltage.
Transtig 200Pi, 250Pi, 300Pi 16.4 Power Source Error Codes Description 1 E01 error code displayed Temperature sensor TH1 (protects IGBTs) is greater than 80ºC for about 1 second 2 E02 error code displayed Temperature sensor TH2 (protects secondary diodes) is greater than 80ºC for about 1 second Possible Cause Remedy A The Welding Power Source’s duty cycle A Let Power Source cool down t within its duty cycle. has been exceeded. B Fan ceases to operate.
Transtig 200Pi, 250Pi, 300Pi Description Possible Cause Remedy 6 E12 error code displayed Under mains supply (input) voltage primary capacitors is reduced for one second A Mains supply voltage warning; it is down to 304V ac for 3 phase machine. A Have an Accredited CIGWEL Agent or a qualified electrici the Mains voltage B One phase has dropped out for 3 phase machine B Have an Accredited CIGWEL Agent or a qualified electrici the primary cable & fuses.
Transtig 200Pi, 250Pi, 300Pi Description 13 E99 error code displayed Mains supply (input) voltage has been turned off but control circuit has power from the primary capacitors Possible Cause Remedy A Main on/off switch on machine has been turned off A Turn on/off switch on.
