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CIGWELD TRANSTIG 300 AC/DC User Manual

CIGWELD TRANSTIG 300 AC/DC
134 pages
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415
V
3
50
60
Hz
INVERTER
Service Manual
TRANSTIG
®
Revision: AA Issue Date: June 30, 2008 Manual No.: 0-5002
Operating Features:
INVERTER ARC WELDER
300 AC/DC

Table of Contents

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CIGWELD TRANSTIG 300 AC/DC Specifications

General IconGeneral
Duty Cycle60% at 300A
Protection ClassIP23
Welding ProcessTIG / Stick
Output Current Range5-300 Amps
Dimensions500mm x 250mm x 420mm

Summary

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Arc Welding Hazards

Details electrical hazards and necessary precautions during arc welding operations.

Principal Safety Standards

Lists essential safety standards and codes for welding and cutting processes.

Declaration of Conformity

States equipment compliance with applicable regulations and standards.

INTRODUCTION

How To Use This Manual

Provides guidance on effectively reading and understanding the service manual's content.

Equipment Identification

Explains how to locate and record the unit's identification and serial numbers.

Receipt Of Equipment

Instructs on checking equipment upon receipt for completeness and shipping damage.

Symbol Chart

Illustrates and defines symbols used on the welding equipment for clarity.

Description

Provides a general overview of the welding power source features and capabilities.

Functional Block Diagrams

Presents a visual representation of the power source's internal functional components.

Transporting Methods

Details safe procedures for moving and transporting the welding power source.

Specifications

Lists the technical specifications, ratings, and performance data of the welding equipment.

INSTALLATION

Environment

Describes suitable and hazardous environmental conditions for welder operation.

Location

Provides guidelines for selecting an appropriate and safe installation location.

Electrical Input Connections

Outlines procedures and warnings for connecting the welder to the electrical power supply.

Mains Supply Voltage Requirements

Specifies the required mains supply voltage and current circuit recommendations.

High Frequency Introduction

Explains the importance of correct high-frequency installation to prevent interference.

High Frequency Interference

Details ways high frequency interference can be transmitted and how to mitigate it.

Duty Cycle

Defines duty cycle and explains its impact on welder operation and warranty.

OPERATOR CONTROLS

Transtig 300 AC/DC Controls

Identifies and describes the various controls and connectors on the power source front panel.

Weld Process Selection

Explains how to select different welding modes (STICK, HF TIG, LIFT TIG) and operation modes.

Weld Parameter Descriptions

Details the function and purpose of each weld parameter adjustable on the front panel.

Weld Parameters Table

Provides a comprehensive table of weld parameters and their ranges for different modes.

Power Source Features

Lists and describes the key features and functionalities of the welding power source.

SET-UP FOR SMAW (STICK) AND GTAW (TIG)

SEQUENCE OF OPERATION

Stick Welding

Outlines the step-by-step procedure for performing stick welding operations.

AC or DC HF TIG Welding

Details the sequence for setting up and performing AC or DC HF TIG welding.

Slope Mode Sequence

Explains the operational sequence for the slope mode in TIG welding.

Slope Mode with Repeat Sequence

Describes the operation of the slope mode when combined with the repeat function.

Pulse Controls

Explains the function and benefits of using pulse controls in welding.

Save-Load Operation

Guides on saving and retrieving welding parameter programs for future use.

BASIC TIG WELDING GUIDE

Fluttery Arc Explanation

Discusses the phenomenon of arc flutter in AC TIG welding on aluminum.

Electrode Polarity

Explains the connection of the TIG torch and work lead for direct current straight polarity.

Tungsten Electrode Current Ranges

Provides recommended current ranges for various tungsten electrode sizes.

Tungsten Electrode Types

Lists different tungsten electrode types, their applications, and color codes.

Filler Wire Diameter Guide

Offers guidance on selecting the appropriate filler wire diameter for welding.

Shielding Gas Selection

Recommends shielding gases for different metal alloys used in welding.

TIG Welding Parameters (Steel Pipe)

Details TIG welding parameters for low carbon and low alloy steel pipe.

Welding Parameters for Aluminum

Provides recommended parameters for welding aluminum using TIG.

Welding Parameters for Steel

Provides recommended parameters for welding steel using TIG.

BASIC ARC WELDING GUIDE

Electrode Polarity

Specifies electrode polarity connections for stick welding.

Effects of Stick Welding Materials

Discusses the effects of stick welding on various metals like steel, cast iron, and copper.

ROUTINE MAINTENANCE

BASIC TROUBLESHOOTING

TIG Welding Problems

Lists common TIG welding issues, their possible causes, and remedies.

Stick Welding Problems

Identifies potential problems in stick welding and provides solutions.

Power Source Problems

Details issues related to the welding power source and their corresponding fixes.

VOLTAGE REDUCTION DEVICE (VRD)

VRD Specification

Outlines the technical specifications for the Voltage Reduction Device (VRD).

VRD Maintenance

Provides instructions for routine inspection and testing of the VRD.

POWER SOURCE ERROR CODES

Troubleshooting Specific Error Codes

Lists common error codes, their causes, remedies, and remarks for power source issues.

ADVANCED TROUBLESHOOTING

System-Level Fault Isolation

Describes how to isolate faults within the power supply's internal subsystems.

Verification and Remedy to Indicated Error Codes

Provides detailed steps for verifying and resolving issues indicated by specific error codes.

Verification and Remedy to Failures without Indication Codes

Offers troubleshooting steps for failures not associated with specific error codes.

Fault Isolation Tests

Outlines preparation and execution of fault isolation tests for diagnosing issues.

Verification of the Power Input Circuitry

Details procedures for testing the power input circuitry using voltage measurements.

MAINTENANCE

Maintenance List

Presents a list of components and their corresponding part numbers for maintenance.

Service Tools

Identifies the necessary tools and parts required for performing maintenance tasks.

Component Replacement Procedures

Provides step-by-step instructions for replacing various internal components of the unit.

APPENDIX 1: PARTS LIST

Equipment Identification

Explains the importance of identification numbers for ordering parts.

How To Use This Parts List

Guides the user on how to interpret and use the provided parts list.

APPENDIX 2: CONNECTION WIRING GUIDE

APPENDIX 3: INTERCONNECT DIAGRAM

APPENDIX 4: DIODE TESTING BASICS

APPENDIX 5: OPTIONS AND ACCESSORIES

CIGWELD LIMITED WARRANTY

Terms of Warranty

Details the conditions, exclusions, and limitations of the product warranty.

Warranty Schedule

Outlines the warranty periods for different components of the welding equipment.

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

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