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130i Service Manual TRANSARc

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2. 8 6 5 7 11733 Figure 4 1 Front Panel Figure 4 2 Rear Panel 1 VRD ON OFF Indicator Lights A VRD voltage reduction device is a hazard reducing device designed to reduce electric shock hazards present on the output of welding power source when operating in MMAW stick mode Note that the presence of VRD should not be used as a substitute for the use of appropriate safety practices as indicated in section one of this manual Both the green and red indicator lights only operate in MMAW stick mode The green VRD ON light illuminates red light is off when the VRD is active Under this condition the open circuit voltage of the unit is limited to below 10V DC thus reducing the potential of serious electric shock such as when changing electrodes The red VRD OFF light illuminates green light is off when the VRD is inactive Under this condition the output voltage of the unit will be at welding potential which in some cases may exceed 25V DC Manual 0 5282 4 1 INSTALLATION OPERATION AND SETUP TRANSARC 1301 2 3 4 Fail to safe operation This welding
3. DISASSEMBLY PROCEDURE 1 6 Manual 0 5282 TRANSARC 130i SECTION 8 ASSEMBLY PROCEDURES 8 01 Installing Base Panel 1 Install input rectifier if it is removed 2 Install base panel screws to assemble the base panel A 11862 Manual 0 5282 8 1 ASSEMBLY PROCEDURE TRANSARC 130i 8 02 Installing Rear Panel 1 Reinstall on off switch Reinstall power cord Reinstall fan install 4 screws Reinstall ground wire Reinstall gas hose to gas inlet Reinstall input wire gt l SY O Reinstall rear panel 2 screws to install rear panel 7128 11863 ASSEMBLY PROCEDURE 8 2 Manual 5282 TRANSARC 1301 8 03 Installing Front Panel assembly 1 Reinstall Positive Output Terminals Bolt 2 Reinstall Negative Output Terminals 3 Reinstall gas hose to gas outlet 4 Reinstall 8 pin wire 5 Reinstall 2 screws to install front panel Manual 0 5282 8 3 ASSEMBLY PROCEDURE TRANSARC 130i 8 04 Installing Display PCB 1 Plug the ribbon cable into the socket make sure it is correctly installed with the levers in the locked posi tion 2 Reinstall three screws to install display PCB 3 Reinstall set screw to install knob 4 nstall the 4 screws Hot Start 11865 ASSEMBLY PROCEDURE 8 4 Manual 5282 TRANSARC 130i 8 05 Installing Soleno
4. __ 0 0 00 Trigger Switch Input 1 2 3 Trigger Switch Input 4 4 Not connected 5k ohm maximum connection to 5k ohm remote control potentiometer Zero ohm minimum connection to 5k ohm remote control potentiometer Wiper arm connection to 5k ohm remote control Amps GTAW TIG mode potentiometer Not connected Table 4 1 8 Shielding Gas Outlet The Shielding Gas Outlet located on the front panel is a 5 8 18 UNF female gas fitting and is utilised for the connection of a suitable TIG Torch 9 Trigger Mode Control The trigger mode control is used to switch the functionality of the of the torch trigger between 2T normal and 4T latch mode Note that pressing the Trigger Mode Button while turning the mains power on will perform a factory reset 2T Normal Mode In this mode the torch trigger must remain depressed for the welding output to be active Press and hold the torch trigger to activate the power source weld Release the torch trigger switch to cease welding 2T LIFT TIG Weld m Current Initial Current Lift TIG Current Crater Current Tungsten Lifted Off the Work Piece Postflow TRIGGER TRIGGER PRESSED RELEASED 721 41 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
5. 9 3 3 05 High Frequency detta AA 9 4 3 06 High Frequency Interference a 9 4 3 07 X Electromagnetic Compatibility u s 9 4 SECTION 4 INSTALLATION OPERATION AND SETUP 4 1 4 01 130i Power Source Controls Indicators and Features 4 1 4 02 Shielding Gas Regulator Operating Instructions where supplied 4 11 4 03 Setup for TIG GTAW Welding tionen Rotten rss 4 13 4 04 Foot Control Part No W4015800 Optional 4 14 4 05 Setup for Manual Arc MMAW Welding 4 16 SECTION 5 THEORY OF OPERATION Bec 5 1 5 01 RTT ETT 5 1 SECTION 6 TROUBLESHOOTING aa NIKA TABANG 6 1 6 01 Basic Troubleshooting Power Source 6 1 6 02 Factory Reset 6 2 6 03 Advanced Troubleshooting sse 6 3 6 04 Test Equipment and Tools 6 3 6 05 Visually InSpeGL o Lu ool stark 6 3 6 06 Preliminary DC Bus measurement of the main inverter board 6 4 6 07 Preliminary check of the main inverter board
6. Description Not Used Trigger Switch Trigger Switch Not Used Potentiometer Maximum Potentiometer Minimum Potentiometer Wiper Not Used Table 4 2 4 c 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 shieldin
7. 7 puE S e 9 5 D 7 E at 4 11748 Figure 9 1 Manual 0 5282 6 1 KEY SPARE PARTS TRANSARC 1301 W7003019 Dinse Socket 25mm W7005811 W7005812 Shielding Gas Outlet 5 8 18 W7005814 CT Output 9 W7004908 Shielding Gas Solenoid Valve Assembl 10 W7005605 Shielding Gas Inlet Quick Connect 13 W7003004 Fan Assembly 14 W7003010 Input Rectifier Shown mounted to PCB Power item 1 15 705152 Dinse Plug Male 25mm not shown Table 9 1 Control Socket 8 pin Note that 8 pin control plug is part number UOA706900 9 02 TIG Torch W4013804 where supplied TIG Torch W4013804 spare parts diagram Figure 9 2 TIG TORCH SPARE PARTS PART NO DESCRIPTION W7005900 Trigger assembly for 26F torch 17F torch W7006100 Handle assembly for 17F torch Back Cap Long Table 9 2 KEY SPARE PARTS 6 2 Manual 0 5282 TRANSARC 1301 9 03 Stick Electrode Holder with Trigger Switch 646762 where supplied Stick Electrode Holder with Trigger Switch 646762 spare parts diagram A 11710 Figure 9 3 W7006003 Dinse 25mm for electrode holder 646162 400A electrode holder handle assembly UOA706900 Cable Plug 8 pin Table 9 3 Note The Welding cable with integrated control wires is not available as a separate spare part Manua
8. c21 19 E HALL EFFECT COUT2 T2 11854 i 3 0 NEGATIVE The mains supply voltage is connected via a double pole switch to the input rectifiers on the main inverter board through an EMC filter Overvoltage protection is provided by varistor CY1 The rectifier output charges the main capacitor bank C5 C6 C7 C8 C9 and C10 to high voltage Inrush current limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds The primary igbt transistors T3 T4 T5 and T6 switch the transformer primary at high frequency and varying duty cycle The transformer return wire is taken from the terminal ZBQY1 the voltage at this point is approximately half the DC bus voltage Secondary output voltage from the transformer is rectified by the output diodes D1 and D2 to DC This DC is controlled by the PWM of the primary side igbt transistors and is filtered by an inductor before connecting to the welding output terminals IGBT1 to IGBT8 control whether AC or DC output is sent to the welding terminals A thermal overload device thermal switch is fixed to the rectifier heatsink When an over temperature occurs the control circuit inhibits the trigger gas solenoid and the welding output The thermal overload indicator LED on the front panel is illuminated The current transformer CT1 provides a signal to the control circuit to indicate both transformer prima
9. INTRODUCTION 2 2 Manual 0 9282 TRANSARC 1301 3 SAFETY AND INSTALLATION 3 01 Duty Cycle The rated duty cycle of a Welding Power Source is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts To explain the 10 minute duty cycle period the following example is used Suppose a Welding Power Source is designed to operate at a 25 duty cycle 130 amperes at 25 2 volts This means that it has been designed and built to provide the rated amperage 130A for 2 5 minutes i e arc welding time out of every 10 minute period 25 of 10 minutes is 2 5 minutes During the other 7 5 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool 100 90 80 70 60 50 40 SAFE OPERATING REGION TIG amp STICK 30 20 Duty Cycle PERCENTAGE 10 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 Welding Current AMPS A 1782 Figure 3 1 Transarc 130i Duty Cycle Manual 0 5282 34 AFETY AND INSTALLATION TRANSARC 1301 3 02 Specifications Plant Part No W1007130 Plant Part No Mine Spec W1007131 Power Source Part No Mine Spec W1007129 Power Source Dimensions Power Source Mass ooling Welder Type Australian Standard Number of Phases Nomi
10. R32C83 d e m E cas Raaksomicag 20 192 T LE p gs us E a 206859 0201 moo a 7 m 53 N 1111 2556 ots S mA 4 1 usos _ M eru SL 209 R29 8 R60C28 3 JA CAL Remot Imax CE T gin PIS IT TA 9 8 Sa a 207 S DT US Jj mm a jG HE dee ak O Jk 4L eS B EX a cu Br m Ta 1882 L7 cs 7 us Eu mu ms mum 11853 R22 R12 souncE ms Imin While the power source is turned off set SW1 position 2 to OFF to allow calibration of output volts amp amps 2 Output Current Calibration Select STICK mode on the front panel Connect a load to the output terminals The load should be of a resistance to give between 20V 25V at 130A Set front panel AMPS control to minimum Adjust Imin trimpot until output amps is 0 5A Set front panel AMPS control to maximum Adjust Imax trimpot until output amps is 130A Recheck settings Set front panel AMPS control to maximum Adjust A potentiometer so Amps display reads within 0
11. signal 15 VDC DY2 Header Pin Pin function signal DYiHeaderPin signal 424 V solenoid positive 24 VDC No connection No connection No connection FJ QF Header Pin signal Table 6 12 FJ QF Header pin function used RXHeaderPin signal Inrush Resistor Olnrush Resistor Table 6 13 Header pin function connects to Inrush Resistor Manual 0 5282 6 9 TROUBLESHOOTIN TRANSARC 130i 2 Display PCB TROUBLESHOOTIN initial amps Serial display D OUT DeadMan Switch 5V in Dead Man mode Encoder Output pulse output Encoder Output 0 button Encoder direction A 11849 gt 5 i lt 847 31 stickl percent 5 mm 2 INET Ka e 1000 lift tigl 012 arc force e e 4 Ul4 9900 A oT 110000000000 ads na a URDOFF o e ge 5 115 current AT JEN up slope crater 5 VDC digital 5 VDC digital 5 VDC digital 5 VDC digital 5 VDC digital 5 VDC digital 5 VDC digital 5 VDC digital 5 VDC 5 VDC 0 VDC 5 VDC Table 6 14 J12 Header pin function connects to MB header on control PCB 6 10 J12 Manual 0 5282 TRANSARC 1301 3
12. 1 DIP Switch SW1 control PCB 23 C70 RSSRSSC6SCO4 R5 R87 9 29 IA 11 39 s 9202 Hd nn R38 R4 HI 1 R82 Bio c15 DIS R45 881207 16 C47 2R63R31 R40R51R57 IT EET ET T C99 R53R50RI1C98 206884 201 LULU maa C182 R124 R101 C36 R96 R95 R94 R138 C21 20 cs C86 131 183 R32C83 R137 d a N C100 2 zi C102 2111 R99 m 26207 5 SH oo U801 U803 a Rss 1 L 1 R212 8 R211 U4 c59 SW1 position Function 4 11852 C103 150 R97 C187 R58 C35 82508249 TRANSARC 1301 R7 C6 R8 U m 9303 C31R62R61 a eiii e Ho e HI 2 R67 C153 R154U13 gt tat pil RISICI50 C5 208 mi R152 U15 e mj R65 020 R153 R7oL_ Table 6 27 SW1 Dip Switch functions Manual 0 5282 6 13 A 11851 TROUBLESHOOTIN TRANSARC 1301 6 12
13. 274VAC 3 There is no weld output and Unit has overheated Allow unit to cool with fan running the yellow over temperature until over temperature light light is on extinguishes Airflow inlet or outlet ducts Remove blockages from airflow are blocked ducts Fan does not operate Replace fan Check fan wiring header is plugged securely into Control board Check fan wiring is not damaged 4 Mode switch does not A Faulty Display board A Replace Display board change welding mode 5 The weld output does Internal wiring fault A Check continuity of internal wiring operate when the torch from8 pin control socket through to trigger switch is depressed boards B Over temperature light is Allow unit to cool C Trigger wires shorted to weld C Repair trigger wires in torch voltage inside TIG torch D Trigger wires or torch switch Check amp Repair faulty Faulty Power Inverter board Replace Power Inverter board Faulty Control board Replace Control board Faulty Display board Replace Display board Manual 0 5282 6 1 TROUBLESHOOTIN TRANSARC 130i Weld Output operates when the torch trigger switch is depressed but the gas valve does not operate Internal wiring fault Faulty Solenoid Impurity in gas system causing solenoid to stay open or closed Faulty Power Inverter board Faulty Control board Table 6 1 Power Source Faults 6 02 Factory Reset Information Check solenoid wiring header is plugged secur
14. 5A of the measured value Press the front panel AMPS control for 2 seconds so that the meter displays weld volts Disconnect the load from the output terminals Measure output welding voltage and adjust WVF potentiometer so Volts display reads within 0 1V of the measured value Press the front panel AMPS control for 2 seconds so that the meter display weld amps Turn off the mains power off to the machine Set SW1 2 back to the ON position TROUBLESHOOTIN 6 14 Manual 0 5282 TRANSARC 130i 3 Remote Calibration Select LIFT TIG mode on the front panel Remove the load from the output terminals Set front panel AMPS control to maximum Connect a remote control device and set the remote control potentiometer to maximum Adjust the CAL REMOTE trimpot until the display starts to fall below 130A Slowly adjust the CAL REMOTE trimpot until the display is just reading 130A 0A Manual 0 5282 6 15 TROUBLESHOOTIN TRANSARC 130i 6 13 Main Circuit Description WARNING gm E up o Lo E o Lo x Lun E coro Turn off power and disconnect mains supply plug from receptacle before working on the unit Allow two minutes for capacitors to discharge after disconnection from mains supply voltage bl 2 0 R39 C20 C17 d d d COUT1 V8 e 5 y R63
15. 6 5 6 08 Check main input rectifier usitata tdt idees 6 6 6 09 DC Bus voltage measurement 6 7 0 10 COMING CHORE A 6 8 TABLE OF CONTENTS 6 11 DIP switch settings Control 6 13 6 14 6 13 Main Circuit Description 6 16 As 6 17 7 DISASSEMBLY PROCEDURE 7 1 7 01 Safety Precautions for 58858110 cnn 7 1 7 1 7 09 Control 2 4 7 2 7 04 Solenoid Valve and Current Transformer Output 7 3 7 05 Display Removal 7 4 7 06 X Front Panel assembly Removal 7 5 7 07 Rear Panel Removal anas AALALA 7 6 7 08 Base Panel Removal pgka 7 1 8 ASSEMBLY PROCEDURES 8 1 8 01 installing Base au 8 1 8 02 installing Rear Paan etx nca A RS SO 8 2 8 03 installing Front Panel Assembly 8 3 8 04 Installing Display 8 4 8
16. Calibration 23r 7 HBBHBECESCU4 C3 85 n zm ja US R7 RB 2 ERR HO 58 ml 1m 11 E mi 0202 hae Ka 2 R39 R38 882 R5Bcas U303 caneonet Mad ces EID RIZ7 m e Bl 4 c2 cR nym FA mol Es mall trs C100 R132 0203 C32 a E 86 RIBICIB3
17. Circuit Breaker AC Auxiliary Power Ex Hz mom HEH Direct Current DC Ground D pole Auxiliary Power 1 Receptacle Rating Auxiliary Power Three Phase Three Phase Static LAORE Frequency Converter Transformer Rectifier Remote Percentage o Panel Local Shielded Metal Arc Welding SMAW Gas Metal Arc Welding GMAW Gas Tungsten Arc Welding GTAW Fa Air Carbon Arc Cutting CAC A Constant Current Constant Voltage Or Constant Potential High Temperature Ri Touch Start GTAW pod Variable Inductance Ko TRANSARC 130i Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Welding Gun Purging Of Gas Continuous Weld Mode EI 2 Step Trigger _ Operation Press to initiate wirefeed and welding release to stop d 4 Step Trigger Operation Press and hold for preflow release to start arc Press to stop arc and hold for preflow Burnback Time Inches Per Minute Meters Per Minute See Note Note For environments with increased hazard of electrical shock Power Supplier bearing the mark conform to EN501 when used in conjunction with hand torches with exposed tips if equipped with properly installed standoff guides Cannot be disposed with household garbage Manual 0 5282 1 7 GENERAL INFORMATION83 5 1301 1 05 Servicing Hazards AN WARNING The symbols shown below are used throughout this manual to ca
18. a mainline supplier to major welding industry sectors in the Asia Pacific and emerging global markets including Manufacturing Construction Mining Automotive Engineering Rural and DIY We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery Superior customer service and technical support together with excellence in sales and marketing expertise Above all we are committed to develop technologically advanced products to achieve a safer working environment for industry operators WARNINGS E ve Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Operating Manual Number 0 5283 for Cigweld Transarc 130i Inverter Plant Part Number W1007130 Cigweld Transarc 130i Mine Spec Inverter Plant Part Number W1007131 Cigweld Transarc 130i Mine Spec Power Source packed Part Number W1007129 Published by CIGWELD Pty Ltd 71 Gower Street Preston Victoria Australia 3072 4613 9474 7400 61 3 9474 7391 www cigweld com au Copyright 2013 by CIGWELD Pty Ltd rights reserved Reproduction of this work in whole or in part without writ
19. 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 3 Radiation from Welding Leads Radiated 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 of interference Looping and suspending of leads should be avoided wherever possible 4 Re Radiation from Unearthed Metallic Objects A major factor contributing to interference is re radiation from unearthed metallic objects close to the welding leads Effective grounding of such objects will prevent re radiation in most cases AFETY AND INSTALLATION 3 4 3 07 Electromagnetic Compatibility o SN WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation A Installation and Use Users Responsibility The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the weld
20. responsible for having a qualified electrician promptly correct any interference problem resulting from the installation If notified by the about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference A WARNING READ INSTRUCTIONS Use Testing Booklet Part No 150 853 when servicing this unit Consult the Owner s Manual for welding safety precautions Use only genuine replacement parts from the manufacturer GENERAL INFORMATION83 TRANSARC 1301 1 06 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electromagnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromag
21. to 7 02 before removing the control board Remove 2 screws from control PCB Disconnect WV harness from WV connector Disconnect GUN harness from GUN connector Disconnect DY harness from DY connector Disconnect FAN harness from FAN connector Disconnect QF harness from QF connector Disconnect MB harness from MB connector Disconnect OT2 harness from OT2 connector o o Disconnect OT1 harness from connector 10 Disconnect IFB harness from IFB connector 11 Disconnect DRIVE harness from DRIVE connector 12 Disconnect SOURCE harness from SOURCE connector Ensure to unplug all harness from the control PCB pin 11856 DISASSEMBLY PROCEDURE 1 2 Manual 0 5282 TRANSARC 130i 7 04 Solenoid Valve and Current Transformer Output Removal A Read and follow safety information in Section 6 03 before proceeding with disassembly 1 2 3 4 9 6 Unplug control wire Dismantle two clips over the hose Unscrew the nut Then the solenoid valve is disassembled Disconnect the weld cable from the welding output terminal Unplug the Current Transformer Output control wire Then the Current Transformer Output is disassembled Manual 0 5282 1 3 DISASSEMBLY PROCEDURE TRANSARC 130i 7 05 Display PCB Removal A Read and follow safety information in Section 6 03 before proceeding with disassembly pe NGO PO Remove Display PCB Screws Unscrew the set sc
22. to section 4 01 02 Remote Control Socket for further information E Fitthe welding grade shielding gas regulator flowmeter to the shielding gas cylinder refer to Section 4 02 then connect the shielding gas hose from the Power Source to the regulator flowmeter outlet WARNING Before connecting the work clamp to the work and inserting the 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 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 Manual 0 5282 4 13 INSTALLATION OPERATION AND SETUP TRANSARC 1301 D o LI Negative Welding Terminal Tig Torch Positive Welding Terminal Work Lead Figure 4 7 Setup for TIG Welding 4 04 Foot Control Part No W4015800 Optional Accessory Art A 11339 Art A 11340 Figure 4 9 8 Pin Control Plug INSTALLATION OPERATION AND SETUP 4 14 Manual 0 5282 TRANSARC 1301
23. 05 Installing Solenoid Valve and Current Transformer Output 8 5 806 Installing Control 8 6 8 07 Installing Case assente cane tI mun pue as pasas 8 7 SECTION 9 9 1 9 01 lit RETE 9 1 9 02 TIG Torch W4013804 where supplied 9 2 9 03 Stick Electrode Holder with Trigger Switch 646762 where supplied 9 3 CIGWELD LIMITED WARRANTY TERMS TERMS WARRANTY January 2013 WARRANTY SCHEDULE January 2013 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION TRANSARC 1301 SECTION 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 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 en
24. 88 HF GUN d UU m n mero e 4 sa vo 4 cm uso ge 2 225 208 ms ET Y C87 D 15 C58 0201 LIE J fimm 2 Il 8 162 mee lus zu 11111 LI Imin eus MM us E WV m Leo source 11850 DRIVE SOURCE WVHeaderPin Pinfuncion 4 Positive welding terminal 1 2 Negative welding terminal Table 6 15 WVIN Header pin function GUN Header Pin function Trigger 8 pin socket pin3 Trigger 8 pin socket pin 3 pi pi Remote Amps Pot 8 pin socket pin 6 Trigger 8 pin socket pin 3 0 VDC Table 6 16 Header pin function connects to remote 8 pin socket on front of power source DYHeaderPin Pinfuncion signal 0 VDC 24 VDC 24 VDC Table 6 17 DY Header pin function connects to DY1 header on inverter PCB FAN Header Pin signal Fan control signal 0V Fan ON p 24 VDC 24 VDC Table 6 18 FAN Header pin function connects to Fan QFHeaderPin Pin function signal Solenoid control signal OV Solenoid ON 24 VDC 24 VDC Table 6 19 Header pin function connects to Solenoid
25. CIGWELD Professional 01 TRANSARG WELDING INVERTER Revision AA Issue Date February 18 2013 Manual No 0 5282 Operating Features CIGWELD 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 This Service Manual has been designed to instruct you on the correct use and operation of your CIGWELD product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide CIGWELD is the Market Leading Brand of Arc Welding Products for Victor Technologies International We are
26. ESS 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 forthe 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 The Trade Practices Act 1974 Commonwealth and similar State Territory legislation relating to the supply of goods and services protects c
27. ICK with Dead Man Switch Weld Voltage 8 Volts VRD Voltage Zero 0 Volts at Zero 0 Volts at Welding Terminals Welding Terminals 1 TRIGGER TRIGGER TRIGGER TRIGGER PRESSED RELEASED PRESSED RELEASED Electrode Touches A 11745 Work Piece within 3 seconds There will be OV on the Power Source welding terminals and both VRD lights will be off In both 2T and 4T modes if the stick electrode is not touched to the work piece within three seconds the welding output will be inhibited Release the trigger to reset and press the trigger again to reactivate the VRD Note that if the Dead Man Switch function is disabled 2T and 4T are not available in STICK mode Information on how to disable the Dead Man Switch function is available from Cigweld Technical Customer Care on 461 3 9474 7400 Approval from a mine site manager or Work site manager must be obtained 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 If 4T operation is selected when using the Dead Man Switch mode the use of an observer is recommended Manual 0 5282 4 9 INSTALLATION OPERATION AND SETUP TRANSARC 1301 10 Process Sele
28. LIFT TIG the tungsten electrode Range is 0 0 to 30 0 seconds Factory default is 5 0 seconds 5 Positive Welding Output Terminal The positive welding terminal is used to connect the welding output of the power source to the electrode holder lead or work lead Positive welding current flows from 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 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 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 Figure 4 4 Remote Control Socket INSTALLATION OPERATION AND SETUP 4 6 Manual 0 5282 TRANSARC 1301 21
29. Manual 0 5282 6 1 TROUBLESHOOTIN TRANSARC 1301 MB HeaderPin Pintunction Serial display data 10 0 Serial display data LOAD Serial display data amp eprom D IN 5 VDC digital 5 VDC digital al di ial di 5 VDC digital 5 VDC digital 5 VDC digital 6 Encoder Output A pulse output 5VDC digital 5 VDC digital 8 Encoder direction 5 digital 9 2T ATpushbuton 0vwhenbutonpushed 5VDC 5 VDC 0 VDC 5 VDC Table 6 20 MB Header pin function connects to J12 header on display PCB PFC Header Pin _____2 PFCOK signal O PFCOK Table 6 21 Header pin function not used OTiHeaderPin infmdion Table 6 22 OT1 Header pin function connects to thermostats OT2HeaderPin Link to OV ___2 Table 6 23 2 Header pin function link 2 HFHeaderPin 1 2 Hreotolin OV HFOF J Table 6 24 HF Header pin function not used DRIVE Header Pin 00 1 15 VDC 15 VDC pk 15 VDC pk 15 VDC pk 15 VDC pk 15 VDC pk 7 0 VDC Table 6 25 DRIVE Header pin function connects to IN header on inverter PCB SOURCE Header Pin 1 2 0 VDC 0 VDC 3 24 VDC 24 VDC Table 6 26 SOURCE Header pin function connects to DY2 header on inverter PCB TROUBLESHOOTIN 6 12 Manual 0 5282 6 11 DIP switch settings Control PCB
30. Offers helpful information concerning certain operating procedures Notes will be shown in italics You will also notice icons from the safety section ap pearing throughout the manual These are to advise you of specific types of hazards or cautions related to the portion of information that follows Some may have multiple hazards that apply and would look something like this r PA 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the machine Equipment which does not have a nameplate attached to the machine is identified only by the specification or part number printed on the shipping container Record these numbers for future reference MANUAL 0 5282 2 1 2 03 Receipt of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment w
31. STALLATION OPERATION AND SETUP TRANSARC 1301 Programming Parameter Control Panel Display Arc Force Arc Force is effective when in STICK mode only Arc Force control Process provides an adjustable amount of Te nm Arc Force or dig control This O feature can be particularly beneficial Trigger FT NG in providing the operator the ability 7 to compensate for variability in joint fit up in certain situations with particular electrodes In general increasing the Arc Force control toward 100 maximum Arc Force allows greater penetration control to be achieved Range is 0 to 100 Factory default is 3096 LIFT TIG Programming Mode Programming Parameter Control Panel Display Initial Current This parameter operates in TIG 4 mode only and is used to set the Process start current for TIG In 4T mode the Initial Current remains on until e the torch trigger switch is released fi LIFT TIG after it has been depressed In 2T 7 mode this is the Initial Current for the Up Slope current ramp Range is 5 to 130A Factory default is 30A STICK Up Slope This parameter operates in TIG mode only and is used to set the Procgss time for the weld current to ramp stick Trigger up from INITIAL current to BASE current LIFT TIG Range is 0 0 to 15 0 seconds Factory default is 1 0 second INSTALLATION OPERATION AND SETUP 4 4 Manu
32. age 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 Adjusting Flow Rate Art A 05088 AB Figure 4 6 Adjust Flow Rate 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 INSTALLATION OPERATION AND SETUP 4 12 Manual 0 5282 TRANSARC 130i Shutdown Close cylinder valve whenever the regul
33. aining these elements can give off toxic fumes if welded WELDING can cause fire or explosion WARNING Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot workpiece and hot equipment can cause fires and burns Accidental con tract of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flam mable material Manual 0 5282 9 TRANSARC 1301 Remove all flammables within 35 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding cur rent from travelling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes 10 Remove stick electrode from holder or cut off 1 2 3 4 welding wire at contact tip when not in use 4h gt 27 WARNING FLYING SPARKS AND HOT METAL can cause inju
34. al 0 5282 TRANSARC 1301 Base Current This parameter sets the TIG welding current Range is 5 to 130A Factory default is 120A Down Slope This parameter operates in TIG 5 Hot Start mode only and is used to set P a the time for the weld current to ia ramp down to the crater current 5 This control is used to eliminate LIFT TIG the crater that can form at the 7 S completion of weld Range is 0 0 to 25 0 seconds Factory default is 3 0 seconds Crater Current This parameter operates in TIG Os ig Fautob mode only P Process Arc Force Q In 2T mode this is the current at piu the end of the down slope current la LIFT TIG ramp When the welding current 7 IUD seo pru reaches the Crater Current value the welding current will cease and the unit will enter Post Flow mode In 4T mode this is the current at the end of the down slope current ramp The welding current will remain at the Crater Current value until the torch trigger is released at which time the welding current will cease and the unit will enter Post Flow mode Range is 5 to 130A Factory default is 30A Manual 0 5282 4 5 INSTALLATION OPERATION AND SETUP TRANSARC 1301 Post Flow This parameter operates in TIG 2 mode only and is used to adjust the post gas flow time once the arc has an extinguished This control is used 5 to dramatically reduce oxidation of j
35. ator 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 4 03 Setup for TIG GTAW Welding A Select Lift TIG mode with the process selection control refer to Section 4 01 10 for further information B Connect the TIG Torch to the negative welding terminal Welding current flows from the power source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection C Connect the work lead to the positive welding terminal Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection D Connect the TIG torch trigger switch the 8 pin socket located on the front of the power source as shown below The TIG torch will require a trigger switch to operate in Lift TIG Mode NOTE If the torch has a remote TIG torch current control fitted then it will require to be connected 10 the 8 pin socket Refer
36. bject ofthe 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 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 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 l
37. cal systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coher ent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cable around the body 4 Keep welding power source and cables as far away from body as practical OUT PACEMAKERS The above procedures are among those also normally recommended for pace maker wearers Consult your doctor for complete information 1 4 Manual 0 5282 TRANSARC 130i 1 02 Principal Safety Standards Safety in Welding and Cutting ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Nationa
38. covered electrodes MMAW Gas Tungsten Arc Welding GTAW TIG Plasma Arc Welding Resistance Welding Refer to standard AS NZS 1338 1 1992 for comprehensive information regarding the above table GENERAL INFORMATION 1 2 Manual 0 5282 E WARNING FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners Work in a confined space only if it is well venti lated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe Donot weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapours to form highly toxic and irritating gases Donot weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals cont
39. ction Control The process selection control is used to select the desired welding mode Two modes are available GTAW Lift TIG and MMAW Stick modes Refer to section 4 03 for GTAW TIG set up details or section 4 04 for MMAW stick set up details Note that when the unit is powered on the mode selection control will automatically default to LIFT 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 Fault 6 paan Os ag voL 12 Shielding Gas Inlet The Shield Gas Inlet connection is used to supply the appropriate shieldinng gas to the unit Refer to sect
40. d securely to achieve a sound electrical connection AN 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 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 Negative Welding Terminal RW Positive Welding Terminal Work Lead Electrode Holder Figure 3 10 Setup for Manual Arc Welding INSTALLATION OPERATION AND SETUP 4 16 Manual 0 5282 TRANSARC 130i SECTION 5 THEORY OF OPERATION 5 01 Inverter Design What does the word inverter mean The term inverter refers to the ability to change DC power into AC Inverter power supplies immediately rectify the incoming AC to DC and then the transistors create a higher frequency AC The higher frequency AC then goes on to a much smaller main transformer than in a conventional power supply The AC is then rectified to extremely smooth DC The diagram to the below shows the basic electrical wiring of a DC output inverter power supply Inverter Technology Summary Rectifier Filter IGBT Transformer Rectifier Inductor AC 50 60Hz DC Rippled DC Smo
41. ely into Control board Check solenoid wiring is not damaged Replace Solenoid Clean out gas system Disassemble solenoid amp clean out impurities Replace Power Inverter board Replace Control board To perform a Factory Reset press the Trigger Mode Button while turning on the mains power Note NOTE in some cases a fault may be caused by mis adjustment of parameters Performing a factory reset may correct this Press Parameter TROUBLESHOOTIN Process STICK Trigger LIFT TIG Figure 6 2 6 2 A 11746 Manual 0 5282 TRANSARC 1301 6 03 Advanced Troubleshooting If the problem cannot be solved by the basic external troubleshooting guide the Power Source cover will have to be removed to allow the technician to analyze failures with a few common tools WARNING c aE R Turn off power and disconnect mains supply plug from receptacle before working on the unit Allow two minutes for capacitors to discharge after disconnection from mains supply voltage Checking Unit Before Applying Power AAAS A Turn SW1 to OFF position and disconnect unit from primary line voltage before working on unit Significant DC voltage can remain on capacitors after unit is Off Wait until all front panel LED s are off before removing case A Check DC bus voltage according to Section 6 09 afte
42. en in use WARNING Thermal Arc advises that this equipment be electrically connected by a qualified electrician Manual 0 5282 3 3 AFETY AND INSTALLATION TRANSARC 130i 3 05 High Frequency Introduction The importance of correct installation of high frequency welding equipment cannot be overemphasized Interference due to high frequency initiated or stabilised arc is almost invariably traced to improper installation The following information is intended as a guide for personnel installing high frequency welding machines A WARNING EXPLOSIVES The high frequency section of this machine has an output similar to a radio transmitter The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing WARNING COMPUTER u It is also possible that operation close to computer installations may cause computer malfunction 3 06 High Frequency Interference Interference may be transmitted by a high frequency initiated or stabilised arc welding machine in the following ways 1 Direct Radiation Radiation from the machine can occur if the case is metal and is not properly grounded It can occur through apertures such as open access panels The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properly grounded 2 Transmission via the Supply Lead Without adequate shielding and filtering high
43. f 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 given Cigweld Pty Ltd A B N 56007226815 71 Gower Street Preston Victoria Australia 3072 Phone 1300 654 674 Email enquiries cigweld com au Website www cigweld com au This warranty is provided in addition to other rights and remedies you have under law 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
44. g gas timer where fitted Note that some power sources may require the remote local switch set to remote the maximum setting of the power source will be determined by the respective front panel control irrespective of the remote control device setting As an example if the output current on the power source front panel is set to 50 of the available current and the remote control device is set to 10090 output or maximum the maximum achievable output from the unit will be 50 Should 10096 output be required the respective front panel control must be set to 10096 or maximum in which case the remote device will then be able to control between 1 100 output Note The foot control will only work correctly when power source trigger mode 2T Normal is selected Manual 0 5282 4 15 INSTALLATION OPERATION AND SETUP TRANSARC 1301 4 05 Setup for Manual Arc MMAW Welding A Connect the Electrode Holder lead to the positive welding terminal 4 If in doubt consult the electrode manufacturer Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection B Connect work lead to the negative welding terminal If in doubt consult the electrode manufacturer Welding current flows from the power source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turne
45. gine 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 m WARNING ELECTRIC SHOCK can kill 7 Use fully insulated electrode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode 5 Properly install and ground this equipment accord ing to its Owner s Manual and national state and local codes Turn off all equipment when not in use Disconnect power to equipment if it will be left unattended or out of service Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live when ever the output is on The input power 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 a
46. hen using bars hammers etc to un crate the unit 2 04 Description The Cigweld Transarc 130i is a self contained single phase multi process welding inverter that is capable of performing MMAW Stick and GTAW Lift TIG weld ing processes The unit is equipped with an integrated voltage reduction device VRD applicable in stick mode only digital amperage voltage meter and a host of other features in order to fully satisfy the broad oper ating needs of the modern welding professional The unit is also fully compliant to Australian Standard AS 60974 1 and IEC 60974 1 The Transarc 130i provides excellent welding perfor mance across a broad range of applications when used with the correct welding consumables and procedures The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efficiency and quality from the Power Source Please read these instructions thoroughly before using the unit 2 05 Transportation Methods AFN 7 Disconnect input power conductors from de energized supply line before moving the welding power source Lift unit with handle on top of case Use handcart or similar device of adequate capacity If using a fork lift vehicle secure the unit on a proper skid before transporting INTRODUCTION TRANSARC 1301 Notes
47. hina No 100 Lao Hongjing Rd Minhang District Shanghai PR 200235 Telephone 86 21 64072626 Fax 86 21 64483032 Victor Technologies Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Victor Technologies Italy S r L Via Benaco 3 20098 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Victor Technologies International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 Asia Pacific Regional Headquarters 71 Gower Street Preston Victoria Australia 3072 Av AN Telephone 61 3 9474 7400 61 3 9474 7391 Email enquiries cigweld com au www cigweld com au
48. id Valve and Current Transformer Output Reinstall Current Transformer Output Connect the control wire to Current Transformer Output Connect the weld cable to the welding output terminal Install the two clips over the gas hose Install the screw to install the solenoid value GY c Plug the wire for solenoid valve Manual 0 5282 8 5 ASSEMBLY PROCEDURE TRANSARC 130i 8 06 Installing Control PCB o o gt Install 2 screws control PCB Plug WV harness to WV connector Plug GUN harness to GUN connector Plug DY harness to DY connector Plug FAN harness to FAN connector Plug QF harness to QF connector Plug MB harness to MB connector Plug OT2 harness to OT2 connector 9 Plug OT1 harness to OT1 connector 10 Plug IFB harness to IFB connector 11 Plug DRIVE harness to DRIVE connector 12 Plug SOURCE harness to SOURCE connector Ensure to plug all harness to the control PCB EMBLY PROCEDURE 8 6 Manual 5282 TRANSARC 130i 8 07 Installing Case 1 Install 12 screws to install the case Manual 0 5282 8 7 ASSEMBLY PROCEDURE TRANSARC 1301 Notes ASSEMBLY PROCEDURE 8 8 Manual 5282 TRANSARC 130i SECTION 6 KEY SPARE PARTS 9 01 Power Source 8 9 10 11 12 notsupplied 13 14
49. ielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening the entire welding installation may be considered for special applications Manual 0 5282 3 5 AFETY AND INSTALLATION TRANSARC 1301 Notes AFETY AND INSTALLATION 3 6 Manual 0 5282 TRANSARC 1301 4 INSTALLATION OPERATION AND SETUP 4 01 Transarc 130i Power Source Controls Indicators and Features 13 A 11743 AS BLG 12
50. illuminate to indicate which weld sequence step is currently active When not welding the parameter LED will illuminate to show which parameter is currently being adjusted In MMAW Stick mode the adjustable parameters are weld current hot start current amp arc force In GTAW Lift Tig mode the adjustable parameters are initial current up slope time weld current down slope time crater current post flow INSTALLATION OPERATION AND SETUP 4 2 Manual 0 5282 TRANSARC 1301 Multi Function Control Initial Current A 11734 STICK Programming Mode Programming Parameter Hot Start This parameter operates in STICK mode to improve the start characteristics for stick electrodes HOT START current is on top of the BASE current e g HOT START current 130 amps when BASE WELD 100 amps amp HOT START 30 amps Range is 0 to 70A Factory default is 20A Note that maximum weld current is 170A Base Current This parameter sets the STICK weld current Range is 5 to 130A Factory default is 80 Manual 0 5282 STICK e LIFT TIG Down Slope 4T Post Flow Crater Current Base Current Figure 4 3 Programming Mode Control Panel Display Fauto Os Hot Start Process eo STICK Tigger TTS OS Hot Start Process Arc Force STICK Q Trigger LIFT TIG IN
51. ing circuit see NOTE below In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer Trouble some NOTE The welding circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorised by a person who is competent to assess Whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Further guidance is given 974 13 Arc Welding Equipment Installation and use under preparation B Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account 1 Other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment Radio and television transmitters and receivers Computer and other control equipment Safety critical equipment e g guarding of industrial equipment The health of people around e g the use of pace makers and hearing aids Manual 0 5282 TRANSARC 1301 Equipment used for calibration measurement The time of day that welding or other activities are to be car
52. ing gear gas cylinders or any other accessories Use equipment of adequate capacity to lift and support unit If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit WARNING MOVING PARTS can cause injury Keep away from moving parts such as fans Keep away from pinch points such as drive rolls Have only qualified persons remove doors panels covers or guards for maintenance as necessary Keep hands hair loose clothing and tools away from moving parts Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power NG WARNING MAGNETIC FIELDS can affect Implanted Medical Devices Wearers of Pacemakers and other Implanted Medical Devices should keep away from servic ing areas until consulting their doctor and the device manufacturer WARNING OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit na A WARNING RADIATION can cause interference Manual 0 5282 TRANSARC 130i High frequency H F can interfere with radio navigation safety services computers and communications equipment Have only qualified persons familiar with elec tronic equipment install test and service producing units The user is
53. int 7 Table 6 4 IGBT s Multimeter set to measure ohms 0 nrushResistor Multimeter Lead Placement Ohms Negative meter lead to testpoint 10 Table 6 5 Inrush Multimeter set to measure ohms 0 DIODE Testing Multimeter Lead Placement Negative meter lead to testpoint 12 Negative meter lead to testpoint 14 DIODE T16 T17 Positive meter lead to testpoint 15 0 2 0 8 VDC Negative meter lead to testpoint 16 Table 6 6 Diodes Multimeter set to measure Diode Voltage 6 08 Check main input rectifier E 2 11846 TROUBLESHOOTIN 6 6 Manual 0 5282 TRANSARC 1301 Input Rectifier Testing Multimeter Lead Placement Diode Voltage AC1 to DC Positive meter lead to testpoint 17 0 2 0 8 VDC Negative meter lead to testpoint 18 2 to DC Positive meter lead to testpoint 19 0 2 0 8 VDC Negative meter lead to testpoint 18 AC1 to DC Positive meter lead to testpoint 17 0 2 0 8 VDC Negative meter lead to testpoint 20 2 to DC Positive meter lead to testpoint 19 0 2 0 8 VDC Negative meter lead to testpoint 20 Table 6 7 Input Rectifier Multimeter set to measure Diode Voltage 6 09 DC Bus voltage measurement Apply voltage to the Power Source There are extremely dangerous voltage and power levels present inside these Power Source
54. ion 3 08 for GTAW TIG set up details WARNING Only Inert Shielding Gases specifically designed for welding applications should be used 13 0n Off Switch This switch is used to turn the unit on off 14 Fan on Demand The Transarc 130i is fitted with a fan on demand feature Fan on demand automatically switches the cooling fan off when it is not required This has two main advantages 1 to minimize power consumption and 2 to minimize the amount of contaminants such as dust that are drawn into the power source Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required INSTALLATION OPERATION AND SETUP 4 10 Manual 0 5282 TRANSARC 1301 4 02 Shielding Gas Regulator Operating Instructions where supplied 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 SPECIFIC PROCEDURES for the use of regulators are listed below 1 NEVER subject the regulator to inlet p
55. l 0 5282 6 3 KEY SPARE PARTS TRANSARC 1301 5 KEY SPARE PARTS 6 4 Manual 0 5282 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 BUSIN
56. l Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safety in welding and allied processes Part 1 Fire Precautions AS 1674 1 1997 from SAI Global Limited www saiglobal com Safety in welding and allied processes Part 2 Electrical AS 1674 2 2007 from SAI Global Limited www saiglobal com Filters for eye protectors Filters for protection against radiation generated in welding and allied operations AS NZS 1338 1 1992 from SAI Global Limited www saiglobal com Manual 0 5282 1 5 GENERAL INFORMATION83 TRANSARC 130i 1 03 Declaration of Conformity Manufacturer CIGWELD Address 71 Gower St Preston Victoria 3072 Australia Description of equipment Welding Equipment GTAW MMAW including but not limited to CIGWELD Transarc 130i Welding In
57. letion of welding the meter will hold the last recorded value for a period of approximately 10 seconds During the hold time the display will flash to indicate the hold function is active The meter will hold the value until 1 the Multi Function Control is adjusted in which case the unit will revert to preview mode 2 welding is recommenced in which case actual welding amperage or voltage will be displayed or 3 a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode The value displayed in preview mode and welding mode is steady not flashing Multi Function Control When not welding the Multi Function Control is used to adjust all welding parameters including welding amps A short press on the Multi Function Control will save the parameter value then increment to the next available parameter The parameter LED will illuminate and the Multi Function Control will then adjust the parameter The parameter value is shown on the meter figure 3 1 Item 2 and the LED s next to the meter indicate if the parameter is Amps Seconds or Another press on the Multi Function Control will save the parameter value then increment to the next available parameter During welding adjustment of the Multi Function Control will adjust the actual welding amps no other parameters are adjustable during welding Parameter LED s Weld Activity LED s When welding the weld activity graph LED s will
58. limits of normal Operation A special STICK electrode holder is required for use with a Power Source fitted with a Trigger Switch This electrode holder has a trigger switch attached to it and a control cable that connects to the remote control socket of the Power Source The 130i Mine Spec plant comes standard with one of these special electrode holders fitted with an integrated trigger switch The Dead Man Switch function is active in both 2T and 4T STICK mode Welding with the Dead Man Switch is as follows 2T MODE 1 Press the trigger on the electrode holder 2 The Power Source will now output the VRD volts and the VRD ON led will be lit 3 Touch the Stick Electrode to the work and commence welding as usual 4 Release the trigger to cease welding There will be OV on the Power Source welding terminals and both VRD lights will be off 4T MODE 1 Press the trigger on the electrode holder The Power Source will now output the VRD volts and the VRD ON led will be lit 2 3 Touch the Stick Electrode to the work and commence welding as usual 4 Release the trigger and continue welding 5 Press and release the trigger to cease welding INSTALLATION OPERATION AND SETUP 4 8 Manual 0 5282 TRANSARC 1301 Weld Voltage 8 Volts VRD Voltage Zero 0 Volts at Welding Terminals Zero 0 Volts at Welding Terminals Electrode Touches TRIGGER Work Piece within PRESSED a socande TRIGGER RELEASED 4T ST
59. ll attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard Only qualified persons should test main lain and repair this unit Only qualified persons should test main lain and repair this unit gt WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Turn Off welding power source and wire feeder and disconnect and lockout input power using line disconnect switch circuit breakers or by removing plug from receptacle or stop engine before servicing unless the procedure specifi cally requires an energized unit Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground Do not leave live unit unattended If this procedure requires and energized unit have only personnel familiar with and following standard safety practices do the job When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free Disconnect input power conductors from de energized supply line BEFORE moving a welding power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters Turn Off inverters disconnect input power and discharge input capacitors according to instruc tions in Troubleshooting Section before touching any parts S WARNING STATIC ESD can damage PC boards Put on grounded wrist stra
60. nal Supply Voltage Nominal Supply Frequency Welding Current Range Nominal DC Open Circuit Voltage VRD ON Nominal DC Open Circuit Voltage OFF Factory Fitted Supply Plug Rating Effective Input Current refer Note 2 Maximum Input Current Minimum Single Phase Generator 4 8k W 6 2k VA at 0 8 PF Recommendation refer Note 4 STICK MMAW Welding Output 40 10 130A 25 25 2V min 80A 60 23 2V 60A 100 22 4V TIG GTAW Welding Output 40 C 10 min 130A 25 15 2V 80A 60 13 2V 60A Q 10095 12 4V Protection Class Table 3 1 Transarc 130i Specifications NOTE 1 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 NOTE2 The Effective Input Current should be used for the determination of cable size amp supply requirements NOTE 3 Motor start fuses or thermal circuit breakers are recommended for this application Check local requirements for your situation in this regard NOTE 4 Minimum Generator Recommendation at the Maximum Output Duty Cycle AFETY AND INSTALLATION 3 2 Manual 0 5282 TRANSARC 1301 Due to large variations in performance and specifications of different brands and types of generators Cigweld ca
61. nd all metal parts 9 Do not wrap cables around your body touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment 65 a hazard 10 Ground the workpiece to a good electrical earth ground 1 Do not touch live electrical parts 2 Wear dry hole free insulating gloves and body protection 3 Insulate yourself from work and ground using dry insulating mats or covers 4 Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch open or remove line fuses so power cannot be turned on acciden tally Manual 0 5282 11 Do not touch electrode while in contact with the work ground circuit 12 Use only well maintained equipment Repair or replace damaged parts at once 13 In confined spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output 14 Wear a safety harness to prevent falling if working above floor level 15 Keep all panels and covers securely in place GENERAL INFORMATION83 TRANSARC 130i 2 Wear approved safety glasses Side shields recom 4h mended 22 3 Use protective screens or barriers to protect others el from flash glare warn others to watch the ARC RAYS can burn eyes and skin NOISE arc can damage hearing 4 Wear protective clothing made from durable Arc ra
62. netic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recommended GENERAL INFORMATION 1 10 0 5282 TRANSARC 1301 2 INTRODUCTION 2 01 How to Use This Manual To ensure safe operation read the entire manual includ ing the chapter on safety instructions and warnings Throughout this manual the word WARNING CAU TION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows WARNING Gives information regarding possible per sonal injury Warnings will be enclosed in a box such as this CAUTION Refers to possible equipment damage Cau tions will be shown in bold type NOTE
63. nnot guarantee full welding output power or duty cycle on every brand or type of generator Some small generators incorporate low cost circuit breakers on their outputs These circuit breakers usually will have a small reset button and will trip much faster than a switchboard type circuit breaker This may result in not being able to achieve full output or duty cycle from the power source generator combination For this reason we recommend a generator that incorporates switchboard type circuit breakers Cigweld recommends that when selecting a generator that the particular power source generator combination be adequately trialled to ensure the combination performs to the users expectations NOTE 5 CIGWELD reserves the right to change product performance and specifications without notice 3 03 Environment These units are designed for use in environments with increased hazard of electric shock as outlined in AS 60974 1 and AS 1674 2 Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock Please refer to relevant local standards for further information prior to using in such areas A In locations in which freedom of movement is restricted so that the operator is forced to perform the work in a cramped kneeling sitting or lying position with physical contact with conductive parts In locations which are fully or partially limited by conductive elements and in which the
64. ns In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendation Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Work Piece Where the work piece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the work piece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the work piece to earth should be made by direct connection to the work piece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and sh
65. onsumers 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 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 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 su
66. oss 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 TRANSARC 130i POWER SOURCE AGHAM PARTS LABOUR Original main power magnetics Original main power rectifiers printed circuit boards and power switch semiconductors All other circuits and components including but not limited to relays switches 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 0 rings used in the equipment 3 Months Please note that the information detailed in this statement supersedes any prior published data produced by CIGWELD VICTOR CIGWELD TECHNOLOGIES TY INNOVATION TO SHAPE THE WORLD Australia Terms o
67. oth AC 23KHz AC 23KHz DC Rippled DC Smooth High Voltage High Voltage High voltage High Voltage Low Voltage Low Voltage Low Voltage Low Amperage Low Amperage Low Amperage Low Amperage High Amperage High Amperage High Amperage Art A 09846 Manual 0 5282 5 1 THEORY OF OPERATION TRANSARC 1301 Notes THEORY OF OPERATION 5 2 Manual 0 5282 TRANSARC 130i SECTION 6 TROUBLESHOOTING 6 01 Basic Troubleshooting Power Source Faults The following table is a guide for analyzing problems and making repairs to the Power Source Possible Cause There is no weld output and The main Power Switch is A Set main Power Switch to ON all front panel displays are set to OFF off B Line fuse is blown B Replace Line fuse C The Power Switch is C Replace main Power Switch faulty D Faulty Power Inverter board D Replace Power Inverter board E Faulty Control board E Replace Control board F Faulty Display board F Replace Display board There is weld output and The internal protection circuit Check to see if mains supply voltage all front panel displays are to shut the unit down if the is lt 274VAC A generator with poor off or flickering on amp off mains supply voltage is too voltage regulation may cause a high has operated supply voltage in excess of 274VAC Connect Power Source to a supply voltage
68. 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 CIGWELD WERWALDYNAWICS STODDY CIGWELD GLOBAL CUSTOMER SERVICE CONTACT INFORMATION CIGWELD Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7391 Email enquiries cigweld com au Victor Technologies USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Victor Technologies Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Victor Technologies Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 PT Victor Technologies Utama Indonesia Jl Angsana Il Blok AE 28 Delta Silicon Cikarang Sukaresmi Bekasi 17550 Indonesia Tel 62 21 8990 6095 Fax 62 21 8990 6096 1867 http www Victortechnologies com Victor Technologies C
69. p BEFORE handling boards or parts GENERAL INFORMATION Use proper static proof bags and boxes to store move or ship PC boards a WARNING FIRE OR EXPLOSION hazard J Do not place unit on over or near combustible surfaces Do not service unit near flammables PEN c WARNING FLYING METAL or DIRT can injure eyes Wear safety glasses with side shields or face shield during servicing Be careful not to short metal tools parts or wires together during testing and servicing z HOT PARTS can cause sever burns WARNING Do not touch hot parts bare handed Allow cooling period before working on equip ment To handle not parts use proper tools and or wear heavy insulated welding gloves and cloth WARNING EXPLODING PARTS can cause injury Failed parts can explode or cause other parts to explode when power is applied to inverters Always wear a face shield and long sleeves when servicing inverters 2 3 WARNING SHOCK HAZARD from testing Turn Off welding power source and wire feeder or stop engine before making or changing meter lead connections Use at least one meter lead that has a self retaining spring clip such as an alligator clip Read instructions for test equipment Manual 0 5282 WARNING FALLING UNIT can cause injury Use lifting eye to lift unit only NOT runn
70. 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 Manual 0 5282 4 7 INSTALLATION OPERATION AND SETUP TRANSARC 1301 4 LIFT TIG Weld Initial Current Current Lift TIG Current Tungsten Lifted Off the Work Piece Postflow TRIGGER TRIGGER TRIGGER TRIGGER PRESSED RELEASED PRESSED RELEASED A 11725 Crater Current STICK Dead Man Switch Mode A special trigger mode called Dead Man Switch mode is available on the 130i when welding with STICK electrodes In this mode there will be no output voltage at all from the Power Source until the trigger is pressed This provides the greatest level of safety for the operator and is mandatory on some work sites While the Dead Man Switch function greatly increases operator safety standard welding safety procedures should still be followed When the trigger is pressed the VRD voltage is activated and the user can start welding as normal For extra Safety if welding has not commenced within 3 seconds after the trigger is pressed the Power Source will turn off the VRD and the trigger must be released amp pressed again to start welding If the trigger is released during welding all welding power is shut off within the time
71. power source is also protected by a special protection feature called Fail to Safe Operation which is available in all welding modes The output of the power source will be disabled and the fault indicator will illuminate if the Fail to Safe protection has operated The Fail to Safe protection will not automatically reset The mains power switch must be turned off to reset the power source The display will also show error code E 1 if the Fail to Safe protection has operated Fault 6 5 9 A ee O 9 Vo L OH A 11690 Digital Meter Amps and Volts The digital meter is used to display the pre set parameter values when not welding and actual output current or voltage when welding of the power source A long press 2s on the Multi Function Control toggles between the display of amps and volts If you are in amps display mode when not welding long press of more than 2 seconds on the Multi Function Control will set the 130i to volts display mode the meter will show actual output volts for 5 seconds then revert to display amp adjustment of parameters During welding the meter will show actual welding volts If you are in volts display mode when not welding long press of more than 2 seconds on the Multi Function Control will set the 130i to amps display mode the meter will revert to display amp adjustment of parameters During welding the meter will show actual welding amps At the comp
72. pply voltage OFF Upper capacitor bank Positive meter lead to testpoint 1 Negative meter lead to testpoint 2 Lower capacitor bank Positive meter lead to testpoint 2 0 VDC Negative meter lead to testpoint 3 Table 6 2 DC BUS Multimeter set to measure DC volts TROUBLESHOOTIN 6 4 Manual 0 5282 TRANSARC 1301 6 07 Preliminary check of the main inverter board A Read and follow safety information in Section 6 03 before proceeding 9193913 m 8 a 2223 e i 290 080 160 lo O OL CA H L 1181070 e e i Taki 5 J hi AG a m NL T UM 2213 LILILILILI IGBT Testing Multimeter Lead Placement Diode Voltage Positive meter lead to testpoint 3 IRL ye Negative meter lead to testpoint 4 Positive meter lead to testpoint 5 IBBETI Negative meter lead to testpoint 6 Positive meter lead to testpoint 7 Negative meter lead to testpoint 8 Table 6 3 IGBT s set to measure Diode Voltage Manual 0 5282 6 5 TROUBLESHOOTIN TRANSARC 130i IGBT Testing MulltimeterLead Placement IGBT V8 amp V8 1 Positive meter lead to testpoint 4 5150 O Negative meter lead to testpoint 3 Negative meter lead to testpoint 5 Negative meter lead to testpo
73. r removing case A Before troubleshooting or applying power to unit complete the following checks to avoid causing further damage 6 04 Test Equipment and Tools Digital Multimeter DCclip on ammeter e Screwdriver and spanner CRO 20 Mhz bandwidth amp isolating transformer 6 05 Visually Inspect Visually inspect the inside of the Power Source The levels of current present in these units can cause burning or arcing of PCB transformers switches or rectifier when a failure occurs Carefully inspect all components within these units Look in particular for the following Loose or broken wires or connectors b Burned or scorched parts or wires or evidence of arcing c Any accumulation of metal dust or filings that may have caused shorting or arcing If any parts are damaged they must be replaced Refer to the Spare Parts section for a complete list of components used in the Power Source Locate the faulty component s then replace where necessary Manual 0 5282 6 3 TROUBLESHOOTIN TRANSARC 130i 6 06 Preliminary DC Bus measurement of the main inverter board A WARNING Check DC bus voltage has discharged to less than 5VDC before servicing Ensure the mains supply plug is disconnected from receptacle Bp paa FE a Prem 39841940842 a HU A 11844 DC Bus Testing Multimeter Lead Placement Voltage with Su
74. re is a high risk of unavoidable or accidental contact by the operator In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator which can cause increased hazard have been insulated 3 04 Location Be sure to locate the welder according to the following guidelines In areas free from moisture and dust Ambient temperature between 10 to 40 14 F to 104 In areas free from oil steam and corrosive gases In areas not subjected to abnormal vibration or shock In areas not exposed to direct sunlight or rain Place at a distance of 300mm 12 or more from walls or similar that could restrict natural air flow for cooling The enclosure design of this power source meets the requirements of 235 as outlined in AS60529 This provides adequate protection against solid objects greater than 12mm and direct protection from vertical drops Under no circumstances should the unit be operated or connected in a micro environment that will exceed the stated conditions For further information please refer to AS 60529 Precautions must be taken against the power source toppling over The power source must be located on a suitable horizontal surface in the upright position wh
75. ressure greater than its rated inlet pressure 2 NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition NEVER loosen a connection or attempt to remove any part of a regulator until the gas pressure has been relieved Under pressure gas can dangerously propel a loose part 3 DO NOT remove the regulator from a cylinder without first closing the cylinder valve and releasing gas in the regulator high and low pressure chambers 4 DO NOT use the regulator as a control valve When downstream equipment is not in use for extended periods of time shut off the gas at the cylinder valve and release the gas from the equipment 5 OPEN the cylinder valve SLOWLY Close after use User Responsibilities 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 CONNECT a regulator designed for a partic
76. rew to remove the knob Unplug the harness Unscrew three screws to disassemble the display PCB Mot Start rere A 11858 DISASSEMBLY PROCEDURE 1 4 K v3 ON OFFoM M Manual 0 5282 TRANSARC 130i 7 06 Front Panel assembly Removal A Read and follow safety information in Section 6 03 before proceeding with disassembly Remove front panel screws Remove Positive Output Terminal Bolt 1 2 3 Remove Negative Output Terminal Bolt 4 Disconnect hose from outlet 5 Remove 8 pin remote control harness from the control pcb A 11859 Manual 0 5282 1 5 DISASSEMBLY PROCEDURE TRANSARC 130i 1 07 Rear Panel Removal A Read and follow safety information in Section 6 03 before proceeding with disassembly Remove 2 screws on rear panel Remove On Off Switch wire Remove gas hose from gas inlet Remove ground screw Remove fan screws to disassemble the fan Remove power Cord by push the clip spes OO Remove On Off switch by push the clip A 11860 DISASSEMBLY PROCEDURE 1 6 Manual 0 5282 TRANSARC 130i 7 08 Base Panel Removal Read and follow safety information in Section 6 03 before proceeding with disassembly 1 Remove 4 screws to disassemble the base panel 2 Remove input rectifier only if it is faulty and needs to be replaced 11861 Manual 0 5282 14 DISASSEMBLY PROCEDURE TRANSARC 1301 Notes
77. ried out The immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may require additional protection measures The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises C 1 Methods Reducing Electromagnetic Emissions 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 Shielding should be electrically continuous throughout its length The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure Maintenance of Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructio
78. ry Chipping and grinding cause flying metal As welds cool they can throw off slag Wear approved face shield or safety goggles Side shields recommended Wear proper body protection to protect skin J WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equip ment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder GENERAL INFORMATION83 TRANSARC 1301 5 Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition 6 Turn face away from valve outlet when opening cylinder valve 7 Keep protective cap in place over valve except when cylinder is in use or connected for use 8 Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and ca
79. ry current and also detect transformer saturation The Hall effect current sensor CT2 is powered from regulated amp supplies and provides a voltage signal proportional to the output welding current to allow the control circuit to regulate welding current TROUBLESHOOTIN 6 16 Manual 0 5282 TRANSARC 130i 1 R2 4R 50W NEGATIVE WELD POSITIVE R100 102 C100 R101 103 C101 NEGATIVE TROUBLESHOOTIN 6 17 Manual 0 5282 TRANSARC 1301 Notes TROUBLESHOOTIN 6 18 Manual 0 5282 TRANSARC 1301 7 DISASSEMBLY PROCEDURE 1 01 Safety Precautions for Disassembly 23 Read and follow safety information in Section 6 02 before proceeding Unplug unit before beginning Disassembly procedure 7 02 Case Removal A Read and follow safety information in Section 6 03 before proceeding with disassembly 1 Unscrew 12 Screws to disassemble two parts of case Remove the case 1 Input 240VAC SOH serow 1 Manual 0 5282 14 DISASSEMBLY PROCEDURE TRANSARC 130i 7 03 Control PCB Removal AN Read and follow safety information in Section 6 03 before proceeding with disassembly Remove case refer
80. s Do not attempt to d agnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Once power is applied to the Power Source there are extremely hazardous voltage and power levels present Do not touch any live parts Manual 0 5282 6 7 TROUBLESHOOTIN TRANSARC 130i DC Bus Testing Multimeter Lead Placement Voltage with Supply voltage OFF Upper capacitor bank Positive meter lead to testpoint 1 150 200 VDC Negative meter lead to testpoint 2 Negative meter lead to testpoint 3 Negative meter lead to testpoint 3 Table 6 8 DC BUS Multimeter set to measure DC volts Note These DC voltages are at nominal mains supply voltage of 240VAC 6 10 PCB Connectors 1 Inverter PCB NIJA va 16 10 Mi NIDA 2545044043 Were ETE m NG IH 1 y x o 21 NEN A 11848 TROUBLESHOOTIN 6 8 Manual 0 5282 TRANSARC 130i IGBT 1 pwm drive signal 15V p p square wave 15 VDC pk 4 IGBT pwm drive signal 15V p p square wave 15VDOpk 5 IGBT1pwm drive signal 15V p p square wave 15VDOpk 6 Rectified secondary of currenttranstormerTR8 15VDCpk Table 6 9 IN Header pin function connects to DRIVE header on control PCB Pinfuntion
81. tch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from bat tery 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 amp 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 amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Govern ment Printing Office May 1989 there is now GENERAL INFORMATION a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with and produce changes in biologi
82. ten permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date February 18 2013 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial TABLE OF 5 SECTION 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 1 1 1 01 Arc Welding Hazards esses esee enne nennen tenentes 1 1 1 02 Principal Safety Standards 1 5 1 03 Declaration of Conformity daanan haaa NAG 1 6 D Ree 1 7 1 05 Servicing 220815 AP 1 8 1 06 SUN 1 10 SECTION 2 INTRODUCTION rr AA AE 2 1 2 01 How To Dee TS Marais asa KANA 2 1 2 02 Equipment Identification 2 1 203 20 2 1 2 04 Description RERO 2 1 2 05 Transportation 5 2 1 SECTION 3 SAFETY AND INSTALLATION eese mmm 3 1 3 01 E Ir MEET D YA 3 1 202 0 3 2 3039 aues tod KA AA AA fai in 3 3
83. ular gas or gases to a cylinder containing any other gas EN FS KED a ai Fone Figure 4 5 Fit Regulator to Cylinder Manual 0 5282 4 11 INSTALLATION OPERATION AND SETUP TRANSARC 1301 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 dam
84. verter 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 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 e 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 GENERAL INFORMATION 1 6 Manual 0 5282 1 04 Symbol Chart Note that only some of these symbols will appear on your model rac Dangerous Voltage
85. ys from the welding process produce flame resistant material wool and leather and intense heat and strong ultraviolet rays foot protection that can burn eyes and skin Noise from 5 Use approved ear plugs or ear muffs if noise level some processes can damage hearing is high 1 Usea Welding Helmet or Welding Faceshield fitted 6 with a proper shade of filter see ANSI Z49 1 and AS 1674 listed in Safety Standards to protect your face and eyes when welding or watching Never wear contact lenses while welding Recommended Protective Filters for Electric Welding Approximate Range of Minimum Shade Number of o Process Welding Current in Amps Filter s Less than or equal to 100 100 to 200 200 to 300 300 to 400 Greater than 400 Less than or equal to 150 Gas Metal Arc Welding GWAW 150 to 250 MIG other than Aluminium and 250 to 300 Stainless Steel 300 to 400 Greater than 400 Gas Metal Arc Welding GMAW Less than or equal to 250 MIG Aluminium and Stainless Steel 250 to 350 Less than or equal to 100 100 to 200 200 to 250 250 to 350 Greater than 350 Less than or equal to 300 Flux cored Arc Welding FCAW with 300 to 400 or without shielding gas 400 to 500 Greater than 500 Air Arc Gouging Less than or equal to 400 50 to 100 Plasma Arc Cutting 100 to 400 400 to 800 Plasma Arc Spraying Less than or equal to 20 20 to 100 100 to 400 400 to 800 14 Safety Spectacles or eye shield Manual Metal Arc Welding

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