OPERATING INSTRUCTIONS

PULSE TIG WELDING PLANT

Part Number 700641

MANUAL ARC WELDING POWER SOURCE

Part Number 625690

719306

Issue 4

Dec 95

CONTENTS
Page

1. INTRODUCTION ..............................................................................................................4
1.1 Safety .................................................................................................................................................. 4
1.2 Protective Filter Lenses ........................................................................................................................ 5
1.3 Welding Protection............................................................................................................................... 5
1.4 User Responsibility .............................................................................................................................. 5
1.5 Duty Cycle........................................................................................................................................... 5

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

2.1 Specifications....................................................................................................................................... 6
2.2 Features ............................................................................................................................................... 7
2.3 Plant Contents...................................................................................................................................... 8
2.4 Optional Accessories............................................................................................................................ 8

3. INSTALLATION RECOMMENDATIONS .....................................................................8

3.1 Environment......................................................................................................................................... 8
3.2 Location............................................................................................................................................... 9

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

4.1 Introduction ......................................................................................................................................... 9
4.2 Warning............................................................................................................................................... 9
4.3 High Frequency Interference................................................................................................................. 9

5. CONTROLS, INDICATORS, FEATURES & CONNECTIONS ..................................10

5.1 ON/OFF Switch (not illustrated) ........................................................................................................ 10

........................................................................................................................ 10
5.3 WARNING Indicator ................................................................................................................... 10
5.4 WELDING Process Switch .......................................................................................................... 11
5.5 PULSE Selection Switch (Available on the Transtig 16Pi only) ..................................................... 11
5.6 Pulse Frequency Control (Available on the Transtig 16Pi only) ..................................................... 11
5.7 Welding / Pulse Current Control ................................................................................................... 11
5.8 Crater / Spot Selection Switch (Available on the Transtig 16Pi only) ............................................. 12
5.9 UP.DOWN/SPOT(S) Control (Available on the Transtig 16Pi only) ............................................. 12
5.2 POWER Indicator

5.10 Gas Flow Control (Available on the Transtig 16Pi only) ................................................................... 12
5.11 TORCH SWITCH Socket

.......................................................................................................... 12

5.12 Shielding Gas Connection Points (Available on the Transtig 16Pi only)............................................. 12

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

7. SETTING UP A TRANSARC 16i....................................................................................14
8. SEQUENCE OF OPERATION .......................................................................................15
8.1 TIG Welding...................................................................................................................................... 15
8.2 Stick Welding .................................................................................................................................... 15

Page 1

CONTENTS
Page

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

9.1 Spot ON ............................................................................................................................................ 16
9.2 Crater OFF ........................................................................................................................................ 16
9.3 Crater ON.......................................................................................................................................... 17

10. TORCH REPLACEMENT PARTS BREAKDOWN....................................................18

10.1 Torch Consumable Parts .................................................................................................................. 19

11. TIG WELDING GUIDE.................................................................................................19

11.1 Electrode Polarity............................................................................................................................. 19
11.2 Tungsten Electrode Current Ranges.................................................................................................. 19
11.3 CIGWELD Tungsten Electrode Types.............................................................................................. 20
11.4 Guide for Selecting Filler Wire Diameter .......................................................................................... 20
11.5 Shielding Gas Selection .................................................................................................................... 20
11.6 Welding Parameters for Stainless Steel ............................................................................................. 21
11.7 Welding Parameters for Low Carbon & Low Alloy Steel Pipe........................................................... 21

12. STICK WELDING GUIDE............................................................................................21

12.1 Electrode Polarity............................................................................................................................. 21
12.2 Effects of Stick Welding Various Materials ...................................................................................... 22

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

14. BASIC TROUBLESHOOTING.....................................................................................22
14.1 TIG Welding Problems..................................................................................................................... 23
14.2 Stick Welding Problems ................................................................................................................... 24
14.3 Power Source Problems.................................................................................................................... 26

Page 2

TABLES
Page
Table 1 - Filter lens size verses welding current................................................................................... 5
Table 2 - TIG torch (TTR17V12P) replacement parts....................................................................... 18
Table 3 - TIG torch (TTR17V12P) collets........................................................................................ 19
Table 4 - TIG torch (TTR17V12P) collet bodies .............................................................................. 19
Table 5 - TIG torch (TTR17V12P) alumina nozzles.......................................................................... 19
Table 6 - Current ranges for varies tungsten electrode sizes............................................................... 19
Table 7 - CIGWELD tungsten electrode types .................................................................................. 20
Table 8 - Filler wire selection guide................................................................................................... 20
Table 9 - Shielding gas selection ....................................................................................................... 20
Table 10 - TIG welding parameters for stainless steel........................................................................ 21
Table 11 - TIG welding parameters for low carbon & low alloy steel pipe ......................................... 21

FIGURES
Figure 1 - Front view of the Transtig 16Pi & Transarc 16i................................................................. 10
Figure 2 - Connections for the Transtig 16Pi..................................................................................... 13
Figure 3 - Connections for the Transarc 16i ...................................................................................... 14
Figure 4 - TIG torch components...................................................................................................... 18

Page 3

1. INTRODUCTION
The Transtig 16Pi and the Transarc 16i are lightweight, constant current DC Power Sources
incorporating the latest inverter and microprocessor technology to provide numerous process benefits in
easy to operate packages.
The Transtig 16Pi is supplied with standard features normally found only on larger, more expensive TIG
units.
These features include:

Pulse Current with Up-Slope and CRATER Control

Choice of High Frequency or Lift Arc starting

Internal Gas Solenoid

Spot Welding Control

Remote Trigger Switch

When Manual Arc mode is selected the Transtig 16Pi provides excellent arc characteristics with a wide
range of electrodes, including cellulose electrodes.
The Transarc 16i is primarily designed for Manual Arc welding with similar performance in this area to
the Transtig 16Pi. In addition, while it does not incorporate the numerous TIG welding features of the
16Pi, it provides excellent Contact Start (Lift Arc), constant current, DC output for TIG welding.
1.1 Safety
The following basic safety rules should always be followed:
(i)

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

(ii)

Ensure the Power Source is earthed correctly (electrically) in accordance with local regulations.

(iii) Excessive heat in the welding cables may cause fire. Never weld with poor electrical connections, damaged welding cables or exceed the welding cable current
rating as this will produce excessive heat and may cause a fire.
(iv) Always wear the correct protective clothing for protection from sparks, molten
particles and arc rays.
(v)

When welding in confined spaces, always ensure adequate ventilation and constant
observation of the operator.

(vi) Keep combustible materials away from the welding area. Have a suitable fire extinguisher handy.
(vii) Never watch the welding arc with naked eyes. Always use and wear a welding
mask fitted with the correct filter lens.
(viii) Do not stand on damp ground when welding.
(ix) For more complete safety advice please read the safety literature included with the
equipment before starting to weld.

Page 4

1.2 Protective Filter Lenses

Protective filter lenses are provided to reduce the intensity of radiation entering the eye thus
filtering out harmful infra-red, ultra-violet radiation and a percentage of the visible light. Such
filter lenses are incorporated within face shields. To prevent damage to the filter lenses from
molten or hard particles an additional hard clear glass or special plastic external cover lens should
be used. This cover lens should always be kept in place and replaced before the damage impairs
your vision while welding.
1.3 Welding Protection
It is recommended to use a welding helmet, conforming to Australian Standards AS/NZS13371992 when electric arc welding. Use a welding helmet in serviceable condition with the correct
filter lens fitted as per Table 1.
Approximate range of
welding current

Filter lens required for

TIG and STICK

Up to 75
75-100
100-200
200-250
250-350
Over 350

Shade 10
Shade 10
Shade 11
Shade 12
Shade 13
Shade 14

Table 1 - Filter lens size verses welding current

1.4 User Responsibility
This equipment will perform as per the information contained herein when installed, operated,
maintained and repaired in accordance with the instructions provided. This equipment must be
checked periodically. Defective equipment (including welding leads) should not be used. Parts
that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately.
Should such repairs or replacements become necessary, it is recommended that such repairs be
carried out by appropriately qualified persons approved by the Equipment Manufacturer or
CIGWELD. Advice in this regard can be obtained by contacting CIGWELD.
This equipment or any of its parts should not be altered from standard specification without prior
written approval of the Equipment Manufacturer or CIGWELD. The user of this equipment
shall have the sole responsibility for any malfunction which results from improper use or
unauthorised modification from standard specification, faulty maintenance, damage or improper
repair by anyone other than appropriately qualified persons approved by the Equipment
Manufacturer or CIGWELD.
1.5 Duty Cycle
The rated duty cycle of a welding Power Source is the operating time it may be used at its rated
output current without exceeding the temperature limits of the insulation of the component parts.
In Australia a duty cycle period of five minutes is specified in Australian Standard AS 1966 Part
1-1985. To explain the five minute duty cycle period the following example is used. Suppose a
welding Power Source is designed to operate at 40% duty cycle, 160 amperes at 16.4 load volts.
This means that it has been designed and built to provide the rated amperage (160A) at the rated
load voltage (16.4V), for two minutes out of every five minute period (40% of 5 minutes is two
minutes). During the other three minutes of the five minute period the Power Source must idle
and be allowed to cool. The thermal cut-out will operate if the duty cycle is exceeded.

Page 5

2. SPECIFICATIONS, FEATURES, PLANT CONTENTS & ACCESSORIES

2.1 Specifications
Description
Plant assembly
Welding processes

Transtig 16pi

Transarc 16i

700641

625690

Gas Tungsten Arc Welding (TIG)

Manual Metal Arc Welding (STICK)

Plant Mass

8 kg

Power Source Dimensions

130mm x 300mm x 240mm

Manufactured to Standards

AS1966.1, JIS C 9306, IEC974-1

Supply Voltage

220V/240V

Supply Voltage Compensation

10%

Number of Phases

Single

Frequency

50/60 Hz

DC Output Current Range

5A to 160A

DC Open Circuit Voltage

64V

Input Supply Cable

Active, Neutral, Earth 2.5mm2 (50/0.25)

Duty Cycle Time Period

5 minutes

Operating Temperature Range

Ratings

0C to 40C
TIG

STICK

Rated Input Current @ 100% Duty Cycle

12 A

15 A

Maximum Input Current @ 160A

22A

32A

7.5 kVA

9.6 kVA

15A

15A

30A

30A

15A

20A

30A

40A

Rated Output using a 15A Outlet

40% @ 160A (16.4V)

20% @ 160A
(26.4V)

Continuous Output using a 15A Outlet

100% @ 101A (14V)

100% @ 80A (23V)

Rated Output using a 20A Outlet

40% @ 160A (16.4V)

40% @ 160A
(26.4V)

Continuous Output using a 20A Outlet

100% @ 101A (14V)

100% @ 80A
(23V)

Generator Requirement
Rated Outlet at 20% Duty Cycle
Fuse Size at 20% Duty Cycle
Rated Outlet at 40% Duty Cycle
Fuse Size at 40% Duty Cycle

To achieve these ratings, the 15 Amp plug (as supplied) must be replaced with a 20 Amp
plug. This must be carried out by a qualified electrical tradesperson.
Motor start fuses or circuit breakers are recommended for this application. Australian
Standard AS3000 (Clause 2.4.3.4) permits the use of a fuse or circuit breaker rated at two
times the rated input current.

Page 6

2.2 Features
Front Panel Controls
POWER indicator (AC)
WARNING indicator
Current indicator
WELDING process selector
PULSE Selector
Mode Selector (CRATER)
WELDING Current Control
Background Current
(Transtig 16Pi only)
Initial Current
(Transtig 16Pi only)
Pulse Frequency
(Transtig 16Pi only)
UP.DOWN/SPOT(S) Time
(Transtig 16Pi only)
Post Flow Time
(Transtig 16Pi only)
Pre Flow Time
Pulse Width
Output Gas Fitting
Output Terminals
TORCH SWITCH Socket

Green LED
Red LED
Ampere values are marked around the WELD CUR.(A)
control knob.
STICK/HF TIG/LIFT TIG Switch (Transtig 16Pi)
STICK/LIFT TIG Switch
(Transarc 16i)
H/DC(No Pulse)/L Switch (Transtig 16Pi only)
ON/OFF/SPOT Switch
(Transtig 16Pi only)
Front Panel Control Knob
Internally set to 20% of the welding current control
value.
Internally set to 20% of the welding current control
value.
High - 10 to 500Hz
Low - 0.5 to 25Hz
Up Slope & Spot time : 0.5 to 5 seconds
Down Slope time
: 0.5 to 10 seconds
Internally set:
1 to 5 seconds
(increases with the welding current setting)
Fixed at 0.15 seconds
(Transtig 16Pi only)
35%
(Transtig 16Pi only)
5/8 18 UNF
(Transtig 16Pi only)
Twist lock DINSE style socket
Initiates welding power via the torch trigger switch
(TIG only).

Rear Panel
ON/OFF Switch

Circuit breaker mounted on rear panel

Input Gas Fitting

5mm hose nipple

(Transtig 16Pi only)

Torch (Transtig 16Pi only)

Part Number
Type
Cable Length

WP17V122P
WELDCRAFT 150 Amp
3.6 metres

Protection
Thermal overload
Shock detector

DC inverter voltage

WARNING indicator illuminates, welding is interrupted

when Power Module exceeds its temperature rating.
WARNING indicator illuminates, welding is interrupted
momentarily when Power Source receives a heavy
blow.
WARNING indicator illuminates, welding is interrupted
when DC inverter voltage collapses.

Page 7

2.3 Plant Contents

Part Number

Description

700640

Power Source Transtig 16Pi

625690

Power Source Transarc 16i

TTR17V12P

Transtig 16Pi

TIG Torch 150A

BGSAK 2

Torch accessory kit

303660

Flowmeter/regulator

700638

Work lead

703299

Gas hose assembly

7976667

Hose clip

7977160

Plug

700678

Torch trigger lead assembly

Transarc 16i

2.4 Optional Accessories

Part Number
TTR17V12P
BGSAK2

Description
u TIG Torch 150A
u Torch accessory kit

303660

u Flowmeter/regulator

700638

u Work lead

700433

u Torch gas hose kit (includes fitting)

646323

Manual arc (STICK) lead set

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

3. INSTALLATION RECOMMENDATIONS
3.1 Environment
This machine is NOT designed for use in environments with increased hazard of electric shock as
defined in AS3195-1990.
(a) Examples of environments with increased hazard of electric shock are (i)

In locations in which freedom of movement is restricted, so that the operator is

forced to perform the work in a cramped (kneeling, sitting or lying) position with
physical contact with conductive parts;

(ii)

In locations which are fully or partially limited by conductive elements, and in

which there is a high risk of unavoidable or accidental contact by the operator, or

(iii) In wet or damp hot locations where humidity or perspiration considerable reduces
the skin resistance of the human body and the insulation properties of accessories.
(b) Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased
hazard, have been insulated.

Page 8

3.2 Location
Be sure to locate the Power Source according to the following guidelines:
(a)
(b)
(c)
(d)
(e)
(f)

In areas, free from moisture and dust.

Ambient temperature 0C to 40C.
Location free from oil, steam and corrosive gases.
Location not subjected to abnormal vibration or shock.
Location not exposed to direct sunlight or rain.
Place at a distance of 60cm or more from walls or similar that could restrict natural air
flow for cooling.

4. HIGH FREQUENCY CONSIDERATIONS (TRANSTIG 16Pi)

4.1 Introduction
The importance of correct installation of high frequency welding equipment cannot be overemphasised. 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.
4.2 Warning
(a) 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.
(b) Computers
It is also possible that operation close to computer installations may cause computer
malfunction.
4.3 High Frequency Interference
Interference may be transmitted by a high frequency initiated or stabilised arc welding machine in
the following ways:
(a) Direct Radiation
Radiation from the machine can occur if the case is metal and is not properly earthed. 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 earthed.
(b) Transmission via the Supply Lead
Without adequate shielding and filtering, high frequency energy may be fed to the wiring
within the installation (mains) by direct coupling. The energy is then transmitted by both
radiation and conduction. Adequate shielding and filtering is provided in the Power Source.
(c) Radiation from Welding Leads
Radiated interference from welding leads, although pronounced in the vicinity of the leads,
diminishes rapidly with distance. Keeping leads as short as possible will minimise this type of
interference. Looping and suspending of leads should be avoided where possible.
(d) 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 earthing of such objects will prevent re-radiation in
most cases.

Page 9

5. CONTROLS, INDICATORS, FEATURES & CONNECTIONS

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

5.1 ON/OFF Switch (not illustrated)
This product is protected by a 40 Ampere circuit breaker. The circuit breaker is mounted on the
rear panel and doubles as the ON/OFF switch. If the circuit breaker trips the toggle will be in a
centre position indicating an internal malfunction. Do not attempt to restore power without first
consulting an Accredited CIGWELD Service Agent as further damage may occur.
NOTE 1:

The fan will continue to operate for approximately 20 seconds after the circuit
breaker has been switched off.

5.2 POWER Indicator

The POWER indicator (No 8) is green and illuminates when AC power is connected to the Power
Source (with the ON/OFF switch (circuit breaker) switched ON).
5.3 WARNING Indicator
The WARNING indicator (No 7) is red and when illuminated indicates:
(a) An overload fault has occurred and welding is interrupted (normally caused by excessive
duty cycle). When this happens, allow the machine to cool down by leaving the power
switch ON until the warning light extinguishes, or
(b) The Power Source received a heavy blow. Welding is interrupted momentarily when
this occurs, or
(c) The DC voltage to the inverter circuit has collapsed. Welding is interrupted when this
occurs.

Page 10

5.4 WELDING Process Switch

The WELDING process switch (No 4) selects the mode of operation as follows:
(a) STICK Mode
The Power Source is set for manual arc welding and all controls except for the WELD
CUR.(A) control (No 1) are disabled. A built in Arc Force feature is enabled which
provides an increased output current when the arc length is reduced.
(b) HF TIG Mode (Available only on the Transtig 16Pi)
The Power Source is set for TIG welding with high frequency (non contact) arc initiation.
PULSE and CRATER control will function if selected. The arc is initiated by depressing the
torch trigger switch (supplied) which should be attached to the TIG torch handle.
(c) LIFT TIG Mode
The Power Source is set for TIG welding with touch start arc initiation. PULSE and
CRATER control will function if selected. Touching the tungsten onto the work piece with
the trigger switch depressed produces a very low starting current. Moving the tungsten
steadily away from the work piece causes the output to ramp up to the WELD CUR.(A)
control setting.
5.5 PULSE Selection Switch (Available on the Transtig 16Pi only)
The PULSE switch (No 5) is active only when the WELDING process switch (No 4) is set in a
TIG mode. It selects the mode of operation as follows:
(a) H or L Mode
The Power Source will pulse the output current according to the setting on PULSE FREQ.
control (No 2).
(b) DC Mode
The Power Source will provide a constant DC output.
5.6 Pulse Frequency Control (Available on the Transtig 16Pi only)
The PULSE FREQ. control (No 2) adjusts the rate at which the output current is pulsed in both
the high and low ranges. The peak current is set by the WELD CUR.(A) control (No 1) and the
base or background current is automatically adjusted to be 20% of the WELD CUR.(A) control.
This control is only active when the WELDING process switch (No 4) is set in one of the TIG
modes and the PULSE switch (No 5) is set to the H or L position.
5.7 Welding / Pulse Current Control
WELD CUR.(A) control (No 1) adjusts the current output as follows:
(a) Transtig 16Pi with
(i)

PULSE (No 5) in DC position

- constant output current

(ii)

PULSE (No 5) in H or L position

- pulsed output current

(b) Transarc 16i

- constant output current

Page 11

5.8 Crater / Spot Selection Switch (Available on the Transtig 16Pi only)
The CRATER switch (No 6) allows the output current to ramp up and crater or to spot for a set
duration. It is active only when the WELDING process switch (No 4) is set to a TIG mode. The
mode of operation is as follows:
(a) ON Mode
The Power Source will provide reduced start and crater currents which are set to 20% of the
value selected at WELD CUR.(A) control (No 1). The up/down slope time is governed by
the setting on the UP.DOWN/SPOT(S) control (No 3).
(b) OFF Mode
The Power Source will not provide either start or crater currents.
(c) SPOT Mode
The Power Source will provide output current for a time period as set on the
UP.DOWN/SPOT(S) control (No 3). This period is initiated each time the torch switch is
depressed.
5.9 UP.DOWN/SPOT(S) Control (Available on the Transtig 16Pi only)
The UP.DOWN/SPOT(S) control (No 3) adjusts both the up/down slope and spot times. It is
active only when the WELDING process switch (No 4) is set to a TIG mode and the CRATER
switch (No 6) is not in the OFF position.
5.10 Gas Flow Control (Available on the Transtig 16Pi only)
The gas flow times are internally set and are active only when the WELDING process switch (No
4) is set to HF TIG or LIFT TIG modes.
(a) Pre-Flow Gas Time
The pre-flow gas time is the time allowed for the gas to flow prior to arc initiation and is
preset to 0.15 seconds.
(b) Post-Flow Gas Time
The post-flow gas time is the time allowed for gas to flow after arc extinction. It is set
internally to increase with the WELD CUR.(A) control (No 1) value.
5.11 TORCH SWITCH Socket
The TORCH SWITCH Socket (No 9) accepts the external torch trigger switch (CIGWELD Part
No.700678) supplied with the unit. This switch initiates the arc in HF TIG or LIFT TIG modes.
5.12 Shielding Gas Connection Points (Available on the Transtig 16Pi only)
The Transtig 16Pi allows solenoid control of shielding gas via the following connection points:
(a) Front Connection
The TIG torch gas hose is connected to the front of the Power Source.
(b) Rear Connection
The in-coming gas supply connection from the cylinder is made at the rear of the Power
Source. Ensure that it is correctly regulated on the Flowmeter provided.

Page 12

6. SETTING UP A TRANSTIG 16Pi

WARNING 1: Before making any connections to the welding terminals make sure the 240V
mains power to the Power Source is turned off.
WARNING 2: Remove any packaging materials prior to use. Do not block the air vents at
the front or rear of the Power Source.

Figure 2 - Connections for the Transtig 16Pi

Page 13

7. SETTING UP A TRANSARC 16i

WARNING 3: Before making any connections to the welding terminals make sure the 240V
mains power to the Power Source is turned off.
WARNING 4: Remove any packaging materials prior to use. Do not block the air vents at
the front or rear of the Power Source.

Figure 3 - Connections for the Transarc 16i

Page 14

8. SEQUENCE OF OPERATION
8.1 TIG Welding
1. Switch the POWER ON/OFF SWITCH to OFF.
2. Connect the earth clamp, torch cables, torch trigger lead and gas hose as shown in Figure 2.
Ensure that the polarity of the welding leads is correct for the process used.
3. Plug the Power Source in and switch the outlet ON.
4. Set the WELDING process selection switch to HF TIG or LIFT TIG.
5. Select the desired mode of operation with the CRATER selection switch.
If a fixed welding time is required, ie spot, then set the WELDING process selection switch
to HF TIG, the CRATER switch to SPOT and the UP.DOWN/SPOT(S) control to the
desired time.
6. Set the WELD CUR.(A) control to the desired welding current.
7. Switch the POWER ON/OFF SWITCH (located on the rear panel) to the ON position.
8. Depress the torch trigger switch and set the gas flow rate on the regulator/flow meter.
9. Commence welding. If necessary, readjust the WELD CUR.(A) control to obtain the
welding condition required.
10. After completion of welding the Power Source should be left turned ON for 2 to 3 minutes.
This allows the fan to run and cool the internal components.
8.2 Stick Welding
1. Switch the POWER ON/OFF SWITCH to OFF.
2. Connect the earth clamp and electrode holder cables as shown in Figure 3.
Ensure that the polarity of the welding leads is correct for the consumable used.
3. Plug the Power Source in and switch the outlet ON.
4. Set the WELDING process selection switch to STICK.
5. Set the WELD CUR.(A) control to the desired welding current.
6. Switch the POWER ON/OFF SWITCH (located on the rear panel) to the ON position.
This will immediately energise the power supply up to the output terminals and the electrode
holder.
7. Commence welding. If necessary, readjust the WELD CUR.(A) control to obtain the
welding condition required.
8. After completion of welding the Power Source should be left turned ON for 2 to 3 minutes.
This allows the fan to run and cool the internal components.

Page 15

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

9.1 Spot ON
Switch settings:

WELDING = HF TIG
CRATER = SPOT
When the torch trigger switch is depressed and held the Pre Flow gas time is initiated (T1).
After the Pre Flow gas time has expired welding current commences.
The welding current extinguishes after the spot time has expired and the Post Flow gas time is
initiated (T2). The spot time (T5) is determined by the UP.DOWN/SPOT(S) control.
ON
TORCH SWITCH
OFF
T1

T2

T1

T2

ON
GAS FLOW
OFF
ON

WELDING CURRENT
WITH SPOT ON & PULSE OFF

T5

T5

OFF

9.2 Crater OFF

Switch settings:

WELDING = HF TIG or LIFT TIG

CRATER = OFF
When the torch trigger switch is depressed and held the Pre Flow gas time is initiated (T1).
After the Pre Flow gas time has expired welding current commences.
If the PULSE switch = DC then the welding current is constant.
If the PULSE switch = H or L then the welding current is pulsed.
When the torch trigger switch is released then the welding current extinguishes and the Post
Flow gas time is initiated (T2).
ON
TORCH SWITCH
OFF
T1

T2

T1

T2

ON
GAS FLOW
OFF
ON

WELDING CURRENT

WITH CRATER OFF & PULSE OFF

OFF
ON

WELDING CURRENT
WITH CRATER OFF & PULSE ON

OFF

NOTE 2:

Page 16

T1 = gas Pre Flow time, fixed at 0.15 seconds

T2 = gas Post Flow time, variable - set by the position of WELD CUR.(A)
control
T5 = spot welding time, variable
- 0.5 to 5 seconds

9.3 Crater ON
Switch settings:

WELDING = HF TIG or LIFT TIG

CRATER = ON
When the torch trigger switch is depressed and held the Pre Flow gas time is initiated (T1).
After the Pre Flow gas time has expired welding current commences at 20% of the WELD
CUR.(A) control value.
When the torch trigger switch is released then the welding current ramps up to the WELD
CUR.(A) control value. The ramp up time (T3) is determined by the UP.DOWN/SPOT(S)
control.
If the PULSE switch = DC then the welding current is constant.
If the PULSE switch = H or L then the welding current is pulsed.
When the torch trigger switch is depressed and held for a second time the Pre Flow gas time is
initiated (T1) then the welding current ramps down to 20% of the WELD CUR.(A) control
value. The ramp down time (T4) is determined by two times the UP.DOWN/SPOT(S) control.
When the torch trigger switch is released for a second time then the welding current
extinguishes and the Post Flow gas time is initiated (T2).
ON
TORCH SWITCH
OFF

T1

T1

T2

ON
GAS FLOW
OFF

T3

T4

ON
WELDING CURRENT
WITH CRATER ON & PULSE OFF
OFF
WELDING CURRENT
WITH CRATER ON & PULSE ON

NOTE 3:

ON
OFF

T1 = gas Pre Flow time, fixed at 0.15 seconds

T2 = gas Post Flow time, variable - set by the position of WELD CUR.(A)
control
T3 = Up slope time, variable
- 0.5 to 5 seconds
T4 = Down slope time, variable
- 1 to 10 seconds

Page 17

10. TORCH REPLACEMENT PARTS BREAKDOWN

(Where TTR17V12P TIG Torch is supplied as standard)

Figure 4 - TIG torch components

ITEM NO.

PART NO.

DESCRIPTION

BG57Y02

Back Cap Long

BG57Y04

Back Cap Short

BG18CG

Cup Gasket

BG57Y012
BG57Y032

Power Cable 3.8m (two piece)

Power Cable 7.6m (two piece)

BGR17HV

Torch Body

BGR17VS

Valve Stem

BG15H

Handle

Collet

Collet Body Refer to Table 4 on page 19

10

Nozzle

Refer to Table 3 on page 19

Refer to Table 5 on page 19

Table 2 - TIG torch (TTR17V12P) replacement parts

Page 18

10.1 Torch Consumable Parts

(a) Collets
Size (mm)

Part Number

1.0

BG10N22

1.6

BG10N23

2.4

BG10N24

3.2

BG10N25

Table 3 - TIG torch (TTR17V12P) collets

(b) Collet Bodies
Size (mm)

Part Number

1.0

BG10N30

1.6

BG10N31

2.4

BG10N32

3.2

BG10N28

Table 4 - TIG torch (TTR17V12P) collet bodies

(c) Alumina Nozzles
Size (mm)

Part Number

6.0

BG10N50

8.0

BG10N49

10.0

BG10N48

11.0

BG10N47

12.5

BG10N46

16.0

BG10N45

19.0

BG10N44

Table 5 - TIG torch (TTR17V12P) alumina nozzles

11. TIG WELDING GUIDE

11.1 Electrode Polarity
Connect the TIG torch to the terminal and the work lead to the + terminal for direct current
straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG
welding. It allows limited wear of the electrode since 70% of the heat is concentrated at the
work piece.
11.2 Tungsten Electrode Current Ranges
Electrode Diameter (mm)

Constant Current (A)

1.0
1.6
2.4
3.2

2 - 30
8 - 70
12 - 150
20 - 250

Table 6 - Current ranges for varies tungsten electrode sizes

Page 19

11.3 CIGWELD Tungsten Electrode Types

Electrode Type
(Ground Finish)
Thoriated 2%

l Ceriated 2%

l Zirconated 1%

NOTE 4

Welding Application
DC welding of mild steel,
stainless steel and copper.
AC & DC welding of mild
steel, stainless steel, copper,
aluminium, magnesium and
their alloys
High quality AC welding of
aluminium, magnesium and
their alloys.

Features
Excellent arc starting, Long
life, High current carrying
capacity.
Longer life, More stable
arc, Easier starting, Wider
current range, Narrower
more concentrated arc.
Self cleaning, Long life,
Maintains balled end, High
current carrying capacity.

Colour
Code
Red

Grey

White

Table 7 - CIGWELD tungsten electrode types

The Transtig 16Pi and Transarc 16i are DC welders and can not be used for
AC welding application.

11.4 Guide for Selecting Filler Wire Diameter

NOTE 5:

Welding Current (A)

Filler Wire Diameter (mm). Refer to NOTE 5.

10-20
20-50
50 - 100
100 - 200

1.2
1.2 - 1.6
1.6 - 2.4
1.6 - 3.2

Table 8 - Filler wire selection guide

The filler wire diameter specified in Table 8 is a guide only, other diameter wires
may be used according to the welding application.

11.5 Shielding Gas Selection

Alloy
Carbon Steel
Stainless Steel
Nickel Alloy
Copper
Titanium

Shielding Gas
Welding Argon
Welding Argon, Argoshield 71T, 80T, 81T
Welding Argon, Argoshield 71T
Welding Argon, Argoshield 81T
Welding Argon, Argoshield 80T, 81T

Table 9 - Shielding gas selection

Argoshield is a registered trade mark of BOC Gases Limited.

Page 20

11.6 Welding Parameters for Stainless Steel

Base
Metal
Thickness

Current
Range DC
Amperes

Travel Speed
mm/min.

Argon Gas
Flow Rate
Litres/min.

Joint Type

Butt
1.0 mm

30 - 50

150 - 400

Lap
Fillet
Butt

1.5 mm

50 - 90

150 - 350

Lap
Fillet
Butt

3.0 mm

100 - 150

100 - 250

Lap
Fillet

Table 10 - TIG welding parameters for stainless steel

11.7 Welding Parameters for Low Carbon & Low Alloy Steel Pipe
Electrode Type &
Diameter

Current Range DC
Amperes

Filler Rod for

Root Pass

Thoriated 2%
2.4 mm

120 - 170

Yes

Thoriated 2%
2.4 mm

100 - 160

Yes

Thoriated 2%
2.4 mm

90 - 130

No

Joint Preparation

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

12. STICK WELDING GUIDE

12.1 Electrode Polarity
Stick electrodes are generally connected to the + terminal and the work lead to the terminal
but if in doubt consult the electrode manufacturers literature.

Page 21

12.2 Effects of Stick Welding Various Materials

(a) High tensile and alloy steels
The two most prominent effects of welding these steels are the formation of a hardened zone
in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of
under-bead cracks. Hardened zone and under-bead cracks in the weld area may be reduced
by using the correct electrodes, preheating, using higher current settings, using larger
electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.
(b) Manganese steels
The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For
this reason it is absolutely essential to keep manganese steel cool during welding by
quenching after each weld or skip welding to distribute the heat.
(c) Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme
brittleness, generally cracks when attempts are made to weld it. Trouble may also be
experienced when welding white-heart malleable, due to the porosity caused by gas held in
this type of iron.
(d) Copper and alloys
The most important factor is the high rate of heat conductivity of copper, making preheating
of heavy sections necessary to give proper fusion of weld and base metal.

13. ROUTINE MAINTENANCE & INSPECTION

The only routine maintenance required for the Power Source is thorough cleaning and inspection, with
the frequency depending on the usage and the operating environment.
WARNING 5: Disconnect the Power Source from the 240V mains power before disassembling the Power Source.
Do not operate the Power Source with panels removed. Special maintenance is not necessary for the
control unit parts in the Power Source. If these parts are damaged for any reason, replacement is
recommended.
CAUTION 1:

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

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

14. BASIC TROUBLESHOOTING

Troubleshooting and repairing the Transtig 16Pi and Transarc 16i should be undertaken only by those
familiar with high voltage, high power electronic equipment.
WARNING 6: There are extremely dangerous voltage and power levels present inside these
products. Do not attempt to diagnose or repair unless you have had training
in power electronics measurement and troubleshooting techniques.
The basic level of troubleshooting is that which can be performed without special equipment or knowledge, and without removing the Power Source from the plastic enclosure.
If major complex subassemblies are faulty, then the Power Source must be returned to an Accredited
CIGWELD Service Agent for repair.

Page 22

14.1 TIG Welding Problems

FAULT
1 Electrode melts &
oxidises when an
arc is struck.

POSSIBLE CAUSE

REMEDY

A No gas flowing to welding

region.

A Check the gas lines for kinks

or breaks and gas cylinder
contents.

B Torch is clogged with dust.

C Gas hose is cut.
D Gas passage contains
impurities.

B Clean torch
C Replace gas hose.
D Disconnect gas hose from the
rear of Power Source then
raise gas pressure and blow
out impurities.

E Gas regulator turned off.

E Turn on.
F Torch valve is turned off.
F Turn on.
G The electrode is too small for G Increase electrode diameter or
the welding current.
reduce the welding current.
2 Shielding gas
continues to flow
for more than 5
seconds after the
welding arc has
extinguished.

Gas valve is faulty or jammed

open.

Have an Accredited
CIGWELD Service Agent
repair or replace gas valve.

3 Electrode melts
when arc is struck.

Electrode is connected to the

+ terminal.

Connect the electrode to the

terminal.

4 Dirty weld pool.

A Electrode contaminated
through contact with work
piece or filler rod material.
B Gas contaminated with air.

A Clean the electrode by

grinding off the contaminates.

5 Poor weld finish.

Inadequate shielding gas.

Increase gas flow or check

gas line for gas flow
problems.

6 Arc flutters during

TIG welding.

Tungsten electrode is too

large for the welding current.

Select the right size electrode.

Refer to Table 6.

7 Arc start is not

smooth.

B Check gas lines for cuts and

loose fitting or change gas
cylinder.

A Tungsten electrode is too

A Select the right size electrode.
large for the welding current.
Refer to Table 6.
B The wrong electrode is being B Select the right electrode
used for the welding job
type. Refer to Table 7.
C Gas flow rate is too high.
C Select the correct rate for the
welding job.
Refer to Table 10.
D Incorrect shielding gas is
D Select the right shielding gas.
being used.
Refer to Table 9.
E Poor work clamp connection E Improve connection to work
to work piece.
piece.
Page 23

TIG Welding Problems (continued)

FAULT
8 Welding arc can
not be established
due to the lack of
HF.

POSSIBLE CAUSE
A Torch trigger switch is
disconnected or is damaged.
B Welding process selection
switch is set to STICK.

REMEDY
A Connect the torch trigger
switch or have it repaired.
B Set to HF TIG.

A Work clamp is not connected A Connect the work clamp to

9 Welding arc can
the work piece or connect the
to the work piece or the
not be established
work/torch leads to the right
work/torch leads are not
but the HF is being
welding terminals.
connected to the right
produced.
welding terminals.
B Torch lead is disconnected.
C The distance between the
electrode and the work piece
to too large.
D Gas flow incorrectly set,
cylinder empty or the torch
valve is turned off.

B Connect it to the terminal.

C Reduce the distance.

D Select the right rate for the

welding job, change cylinders
or turn torch valve on. Refer
to Table 10.

14.2 Stick Welding Problems

FAULT

CAUSE

1 Non-metallic
A May be trapped in undercut
particles are
from previous run.
trapped in the weld
metal.
B Joint preparation too
restricted.
C
D

E
F

Page 24

REMEDY

A If a bad undercut is present,

clean slag out and cover with
a run from a smaller gauge
electrode.
B Allow for adequate penetration and room for cleaning
out the slag.
Irregular deposits allow slag C If very bad, chip or grind out
to be trapped.
irregularities.
Lack of penetration with slag D Use smaller electrode with
trapped beneath weld bead.
sufficient current to give
adequate penetration. Use
suitable tools to remove all
slag from corners.
Rust or mill scale is prevent- E Clean joint before welding.
ing full fusion.
Wrong electrode for position F Use electrodes designed for
in which welding is done.
position in which welding is
done, otherwise proper
control of slag is difficult.

Stick Welding Problems (continued)

FAULT

POSSIBLE CAUSE

2 A groove has been A Welding current is too high.

formed in the base B Welding arc is too long.
metal adjacent to
the toe of a weld
C Angle of the electrode is
and has not been
incorrect.
filled by the weld
metal (Undercut).
D Joint preparation does not
allow correct electrode angle.
E Electrode too large for joint.
F Insufficient deposit time at
edge of weave.
3

A gap is left by
failure of the weld
metal to fill the root
of the weld.
Portions of the
weld run does not
fuse to the surface
of the metal or
edge of the joint.

A
B
C
A

B
C

REMEDY
A Reduce welding current
B Reduce the length of the
welding arc.
C Electrode should not be
inclined less than 45 to the
vertical face

D Allow more room in joint for

manipulation of the electrode.
E Use smaller gauge electrode.
F Pause for a moment at edge
of weave to allow weld metal
build-up.
Welding current is too low.
A Increase welding current
Electrode too large for joint. B Use smaller diameter
electrode.
Insufficient gap.
C Allow wider gap.
Small electrodes used on
A Use larger electrodes and preheavy cold plate.
heat the plate.
Welding current is too low.
Increase welding current.
Wrong electrode angle.
B Adjust angle so the welding
C arc is directed more into the
base metal.
Travel speed of electrode is
Reduce travel speed of
too high.
D electrode
Scale or dirt on joint surface.
Clean surface before welding.

E
Gas pockets or
A High levels of sulphur in
voids in weld metal
steel.
(Porosity).
B Electrodes are damp.
C Welding current is too high.
D Surface impurities such as oil,
grease, paint, etc.
Crack occurring in A Rigidity of joint.
weld metal soon
after solidification
commences
B Insufficient throat thickness.

C Welding current is too high.

E
A Use an electrode that is
designed for high sulphur
steels.
B Dry electrodes before use.
C Reduce welding current.
D Clean joint before welding.
A Redesign to relieve weld joint
of severe stresses or use
crack resistance electrodes.
B Travel slightly slower to
allow greater build up in
throat.
C Decrease welding current.

Page 25

14.3 Power Source Problems

FAULT
1

POSSIBLE CAUSE

POWER lamp is lit A Torch trigger switch lead is

disconnected.
but welding arc
cant be
B One of the TIG modes are
selected when trying to
established.
STICK weld.
ON/OFF Switch is OFF.
Mains supply
voltage is ON but
POWER lamp is
not lit.
A Mains primary fuse is blown.
POWER lamp is
not lit, fan does not B ON/OFF Switch is OFF or
defective.
operate and
welding arc cant
be established.
C Mains supply voltage is OFF.
POWER lamp is
Defective POWER lamp.
not lit, fan operates
and welding arc
can be established.
Welding current
Duty cycle rating has been
cant be established
exceeded.
or adjusted and
WARNING lamp
is lit.
No gas flow when A Gas hose is cut.
the torch trigger
B Gas passage contains
switch is
impurities.
depressed.

Gas flow wont

shut off

C Gas regulator turned off.

D Torch trigger switch lead is
disconnected or switch/cable
is faulty.
A Gas valve is faulty.

B Gas valve jammed open.

Page 26

REMEDY
A Reconnect.
B Select STICK welding mode
for Manual Metal Arc
Welding.
Switch ON.

A Replace primary fuse.

B If Switch is ON then have an
Accredited CIGWELD
Service Agent replace
ON/OFF Switch.
C Switch ON.
Have an Accredited
CIGWELD Service Agent
replace POWER lamp.
Leave the Power Source
switched ON to let it cool
down then operate within
rated duty cycle.
A Replace gas hose.
B Disconnect gas hose from the
rear of Power Source then
raise gas pressure and blow
out impurities.
C Turn gas regulator on.
D Reconnect lead or repair
faulty switch/cable.
A Have an Accredited
CIGWELD Service Agent
replace gas valve.
B Have an Accredited
CIGWELD Service Agent
repair or replace gas valve.