Tweco 130i User Manual

130i

TRANSARC

WELDING INVERTER

Service Manual

Revision: AA Issue Date: February 18, 2013 Manual No.: 0-5282
Operating Features:

A-11843

PFC

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Cigweld product. We are proud
to have you as our customer and will strive to provide you with
the best service and reliability in the industry. This product
is backed by our extensive warranty and world-wide service
network. To locate your nearest distributor or service provider call
[phone], 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 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 market­leading, 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

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
[phone] [phone]

www.cigweld.com.au

Copyright 2013 by
CIGWELD Pty Ltd.

All rights reserved.

Reproduction of this work, in whole or in part, without written 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 CONTENTS

SECTION 1:

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ..................................... 1-1

1.01 Arc Welding Hazards ....................................................................................... 1-1

1.02 Principal Safety Standards .............................................................................. 1-5

1.03 Declaration of Conformity ............................................................................... 1-6

1.04 Symbol Chart .................................................................................................. 1-7

1.05 Servicing Hazards ........................................................................................... 1-8

1.06 EMF Information ........................................................................................... 1-10

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

2.01 How to Use This Manual ................................................................................. 2-1

2.02 Equipment Identification ................................................................................. 2-1

2.03 Receipt of Equipment ...................................................................................... 2-1

2.04 Description ..................................................................................................... 2-1

2.05 Transportation Methods .................................................................................. 2-1

SECTION 3:

SAFETY AND INSTALLATION ....................................................................... 3-1

3.01 Duty Cycle ....................................................................................................... 3-1

3.02 Specifications ................................................................................................. 3-2

3.03 Environment ................................................................................................... 3-3

3.04 Location .......................................................................................................... 3-3

3.05 High Frequency Introduction .......................................................................... 3-4

3.06 High Frequency Interference ........................................................................... 3-4

3.07 Electromagnetic Compatibility ........................................................................ 3-4

SECTION 4:

INSTALLATION, OPERATION AND SETUP ........................................................ 4-1

4.01 Transarc 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 ..................................................................... 4-13

4.04 Foot Control Part No. W4015800 (Optional Accessory) ................................ 4-14

4.05 Setup for Manual Arc (MMAW) Welding ..................................................... 4-16

SECTION 5:

THEORY OF OPERATION ............................................................................ 5-1

5.01 Inverter Design ............................................................................................... 5-1

SECTION 6:

TROUBLESHOOTING ................................................................................ 6-1

6.01 Basic Troubleshooting-Power Source Faults ................................................... 6-1

6.02 Factory Reset Information .............................................................................. 6-2

6.03 Advanced Troubleshooting .............................................................................. 6-3

6.04 Test Equipment and Tools .............................................................................. 6-3

6.05 Visually Inspect ............................................................................................... 6-3

6.06 Preliminary DC Bus measurement of the main inverter board ........................ 6-4

6.07 Preliminary check of the main inverter board ................................................. 6-5

6.08 Check main input rectifier ............................................................................... 6-6

6.09 DC Bus voltage measurement ......................................................................... 6-7

6.10 PCB Connectors .............................................................................................. 6-8

TABLE OF CONTENTS

6.11 DIP switch settings, Control PCB .................................................................. 6-13

6.12 Calibration .................................................................................................... 6-14

6.13 Main Circuit Description ............................................................................... 6-16

6.14 Circuit Diagram ............................................................................................. 6-17

SECTION 7:

DISASSEMBLY PROCEDURE ....................................................................... 7-1

7.01 Safety Precautions for Disassembly ............................................................... 7-1

7.02 Case Removal ................................................................................................. 7-1

7.03 Control PCB Removal ..................................................................................... 7-2

7.04 Solenoid Valve and Current Transformer Output Removal .............................. 7-3

7.05 Display PCB Removal ..................................................................................... 7-4

7.06 Front Panel assembly Removal ...................................................................... 7-5

7.07 Rear Panel Removal ........................................................................................ 7-6

7.08 Base Panel Removal ....................................................................................... 7-7

SECTION 8:

ASSEMBLY PROCEDURES .......................................................................... 8-1

8.01 Installing Base Panel ...................................................................................... 8-1

8.02 Installing Rear Panel ....................................................................................... 8-2

8.03 Installing Front Panel assembly ...................................................................... 8-3

8.04 Installing Display PCB ..................................................................................... 8-4

8.05 Installing Solenoid Valve and Current Transformer Output ............................. 8-5

8.06 Installing Control PCB ..................................................................................... 8-6

8.07 Installing Case ................................................................................................ 8-7

SECTION 9:

KEY SPARE PARTS ................................................................................... 9-1

9.01 Power Source ................................................................................................. 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 OF WARRANTY – January 2013

WARRANTY SCHEDULE – January 2013

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

TRANSARC 130i

!

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 engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the Australian Standard AS1674.2-2007 entitled: Safety in welding and allied
processes Part 2: Electrical. This publication and other guides to what you should learn before operating
this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION,

MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause
fatal shocks or severe burns. The electrode
and work circuit is electrically live when­ever the output is on. The input power cir­cuit and machine internal circuits are also
live when power is on. In semiautomatic
or automatic wire welding, the wire, wire
reel, drive roll housing, and all metal parts
touching the welding wire are electrically
live. Incorrectly installed or improperly
grounded equipment is a hazard.

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 acciden­tally.

5. Properly install and ground this equipment accord­ing to its Owner’s Manual and national, state, and
local codes.

6. Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or
out of service.

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.

8. Do not use worn, damaged, undersized, or poorly
spliced cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth)
ground.

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.

Manual 0-5282 1-1 GENERAL INFORMATION83

TRANSARC 130i

2. Wear approved safety glasses. Side shields recom­mended.

WARNING

ARC RAYS can burn eyes and skin; NOISE
can damage hearing.

Arc rays from the welding process produce
intense heat and strong ultraviolet rays
that can burn eyes and skin. Noise from
some processes can damage hearing.

1. Use a Welding Helmet or Welding Faceshield fitted
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.

Recommended Protective Filters for Electric Welding

Description of Process

Manual Metal Arc Welding - covered
electrodes (MMAW)

Gas Metal Arc Welding (GWAW)
(MIG) other than Aluminium and
Stainless Steel

Gas Metal Arc Welding (GMAW)
(MIG) Aluminium and Stainless Steel

Gas Tungsten Arc Welding (GTAW)
(TIG)

Flux-cored Arc Welding (FCAW) -with
or without shielding gas.

Air - Arc Gouging Less than or equal to 400 12

Plasma - Arc Cutting

Plasma - Arc Spraying

Plasma - Arc Welding

Submerged - Arc Welding

Resistance Welding

Approximate Range of

Welding Current in Amps

Less than or equal to 100 8

Greater than 400 13

Less than or equal to 150 10

Greater than 400 14

Less than or equal to 250 12

Less than or equal to 100 10

Greater than 350 14

Less than or equal to 300 11

Greater than 500 14

Less than or equal to 20 8

3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the
arc.

4. Wear protective clothing made from durable,
flame-resistant material (wool and leather) and
foot protection.

5. Use approved ear plugs or ear muffs if noise level
is high.

6. Never wear contact lenses while welding.

Minimum Shade Number of

Filter(s)

100 to 200 10
200 to 300 11
300 to 400 12

150 to 250 11
250 to 300 12
300 to 400 13

250 to 350 13

100 to 200 11
200 to 250 12
250 to 350 13

300 to 400 12
400 to 500 13

50 to 100 10
100 to 400 12
400 to 800 14

—

20 to 100 10
100 to 400 12
400 to 800 14

—

—

Safety Spectacles or eye

15

2(5)

shield

Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.

GENERAL INFORMATION 1-2 Manual 0-5282

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.

1. Keep your head out of the fumes. Do not breath
the fumes.

2. If inside, ventilate the area and/or use exhaust at
the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied
respirator.

4. Read the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals,
consumables, coatings, and cleaners.

5. Work in a confined space only if it is well venti­lated, 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.

6. Do not 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.

TRANSARC 130i

3. Remove all flammables within 35 ft (10.7 m) of the
welding arc. If this is not possible, tightly cover
them with approved covers.

4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher
nearby.

6. Be aware that welding on a ceiling, floor, bulkhead,
or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks
or drums.

8. Connect work cable to the work as close to the
welding area as practical to prevent welding cur­rent from travelling long, possibly unknown paths
and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL can
cause injury.

Chipping and grinding cause flying metal.
As welds cool, they can throw off slag.

7. Do not 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 air­supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded.

WARNING

WELDING can cause fire or explosion.

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

­tact of electrode or welding wire to metal
objects can cause sparks, overheating,
or fire.

1. Protect yourself and others from flying sparks and
hot metal.

1. Wear approved face shield or safety goggles. Side
shields recommended.

2. Wear proper body protection to protect skin.

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.

1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position
by chaining them to a stationary support or equip­ment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other
electrical circuits.

2. Do not weld where flying sparks can strike flam­mable material.

Manual 0-5282 1-3 GENERAL INFORMATION83

4. Never allow a welding electrode to touch any
cylinder.

TRANSARC 130i

!

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 catch loose clothing.

1. Keep all doors, panels, covers, and guards closed
and securely in place.

2. Stop engine before installing or connecting unit.

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, biological 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 coher­ent 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.

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 bat­tery.

5. Keep hands, hair, loose clothing, and tools away
from moving parts.

6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.

WARNING

This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals know to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety code Sec. 25249.5 et seq.)

NOTE

ABOUT PACEMAKERS:

The above procedures are among those
also normally recommended for pace­maker wearers. Consult your doctor for
complete information.

Considerations About Welding And The
Effects of Low Frequency Electric and
Magnetic Fields

The following is a quotation from the General Con­clusions Section of the U.S. Congress, Office of
Technology Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background
Paper, OTA-BP-E-63 (Washington, DC: U.S. Govern­ment Printing Office, May 1989): “...there is now

GENERAL INFORMATION 1-4 Manual 0-5282

TRANSARC 130i

1.02 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, 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.

National 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, Stan­dards 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 Inverter and associated accessories.

Serial numbers are unique with each individual piece of equipment and details description, parts used to
manufacture a unit and date of manufacture.

The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (2006/95 EC)
and to the National legislation for the enforcement of the Directive.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements among them
are:

• IEC60974-10applicabletoIndustrialEquipment-genericemissionsandregulations.

• AS1674Safetyinweldingandalliedprocesses.

• AS60974.1/IEC60974-1applicabletoweldingequipmentandassociatedaccessories.

Extensive product design verification is conducted at the manufacturing facility as part of the routine design
and manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is in­corporated 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: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192

Note that only some of these symbols will appear on your model.

TRANSARC 130i

On

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

X

%

Single Phase

Three Phase

Three Phase Static
Frequency Converter­Transformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal
Arc Welding (SMAW)

Gas Metal Arc
Welding (GMAW)

Wire Feed Function

Wire Feed Towards
Workpiece With
Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld
Mode

Spot Weld Mode

Spot Time

t

t2

Preflow Time

Postflow Time

t1

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth
(Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc
Welding (GTAW)

Air Carbon Arc
Cutting (CAC-A)

Constant Current

Constant Voltage
Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

2 Step Trigger
Operation

Press to initiate wirefeed and
welding, release to stop.

4 Step Trigger
Operation

Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.

Burnback Time

t

IPM

MPM

S

Inches Per Minute

Meters Per Minute

See Note

See Note

115V 15A

Receptacle Rating­Auxiliary Power

V

Voltage Input

S

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

Art # A-04130_AB

TRANSARC 130i

1.05 Servicing Hazards

!

WARNING

The symbols shown below are used
throughout this manual to call 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
tain, and repair this unit.

Only qualified persons should test, main
tain, and repair this unit.

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 specifi­cally 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.

• Useproperstatic-proofbagsandboxestostore,

move, or ship PC boards.

WARNING

FIRE OR EXPLOSION hazard.

• Donotplaceuniton,over,ornearcombustible

surfaces.

• Donotserviceunitnearammables.

-

-

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.

WARNING

HOT PARTS can cause sever burns.

• 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 cloth­ing to prevent burns.

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.

SIGNIFICANT DC VOLTAGE exists after removal

of input power on inverters.

• TurnOffinverters,disconnectinputpower,and

discharge input capacitors according to instruc­tions in Troubleshooting Section before touching
any parts.

WARNING

STATIC (ESD) can damage PC boards.

• PutongroundedwriststrapBEFOREhandling

boards or parts.

GENERAL INFORMATION 1-8 Manual 0-5282

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.

WARNING

WARNING

FALLING UNIT can cause injury.

• Useliftingeyetoliftunitonly,NOTrunning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.

TRANSARC 130i

• High-frequency(H.F.)can interfere with radio

navigation, safety services, computers, and
communications equipment.

• Haveonlyqualiedpersonsfamiliarwithelec­tronic equipment install, test, and service H.F.
producing units.

• Theuserisresponsiblefor havingaqualied

electrician promptly correct any interference
problem resulting from the installation.

• IfnotiedbytheFCCaboutinterference,stop

using the equipment at once.

• Havethe installation regularly checked and

maintained.

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.

WARNING

MAGNETIC FIELDS can affect Implanted
Medical Devices.

• Wearersof Pacemakers andother Implanted

Medical Devices should keep away from servic­ing areas until consulting their doctor and the
device manufacturer.

• 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.

!

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.

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lterairowtounit.

WARNING

H.F. RADIATION can cause interference.

Manual 0-5282 1-9 GENERAL INFORMATION83

TRANSARC 130i

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 electromagnetic 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 Manual 0-5282

SECTION 2:

!

INTRODUCTION

TRANSARC 130i

2.01 How to Use This Manual

To ensure safe operation, read the entire manual, includ­ing the chapter on safety instructions and warnings.

Throughout this manual, the word WARNING, CAU­TION and NOTE may appear. Pay particular attention to
the information provided under these headings. These
special annotations are easily recognized as follows:

!

Gives information regarding possible per­sonal injury. Warnings will be enclosed in a
box such as this.

Refers to possible equipment damage. Cau
tions will be shown in bold type.

NOTE
Offers helpful information concerning certain

operating procedures. Notes will be shown
in italics

You will also notice icons from the safety section ap­pearing 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:

WARNING

CAUTION

-

2.02 Equipment Identification

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 when 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) weld­ing 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 oper­ating 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.

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 INTRODUCTION

2.05 Transportation Methods

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.

TRANSARC 130i

Notes

INTRODUCTION

2- 2 Manual 0-5282

TRANSARC 130i

SECTION 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.

Figure 3-1: Transarc 130i Duty Cycle

A-11732

Manual 0-5282 3-1

AFETY AND INSTALLATION

TRANSARC 130i

3.02 Specifications

Plant Part No

Description Transarc 130i

W1007130
Plant Part No (Mine Spec)
Power Source Part No (Mine Spec)

W1007131

W1007129
Power Source Dimensions H306mmxW121mmxD376mm
Power Source Mass 7 KG
Cooling Fan Cooled
Welder Type Multi Process Inverter Power Source
Australian Standard AS 60974.1-2006 / IEC 60974.1
Number of Phases Single Phase
Nominal Supply Voltage 240V ± 15%

Nominal Supply Frequency 50/60Hz
Welding Current Range 5-130A
Nominal DC Open Circuit Voltage (VRD ON) 8V
Nominal DC Open Circuit Voltage (VRD OFF) 66V
Factory Fitted Supply Plug Rating 10 Amps
Effective Input Current (I
Maximum Input Current (I
Minimum Single Phase Generator

1eff ) refer Note 2 9 Amps

1max) 17 Amps

4.8k W (6.2k VA at 0.8 PF)

Recommendation (refer Note 4)
STICK (MMAW) Welding Output, 40ºC, 10

min.

130A @ 25%, 25.2V

80A @ 60%, 23.2V

60A @ 100%, 22.4V

TIG (GTAW) Welding Output, 40ºC, 10 min. 130A @ 25%, 15.2V

80A @ 60%, 13.2V

60A @ 100%, 12.4V

Protection Class IP23S

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.

NOTE 2

The Effective Input Current should be used for the determination of cable size & 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.

SAFETY AND INSTALLATION

3-2 Manual 0-5282

TRANSARC 130i

Due to large variations in performance and specifications of different brands and types of generators,
Cigweld cannot 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.

B. 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.

C. 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°Cto40°C(14°Fto104°F).

• 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 owfor

cooling

• TheenclosuredesignofthispowersourcemeetstherequirementsofIP23S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 when 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.

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

It is also possible that operation close to
computer installations may cause computer
malfunction.

3.07 Electromagnetic Compatibility

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 welding 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.

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 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.

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 in IEC 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.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial
equipment.

5. The health of people around, e.g. the use of pace­makers and hearing aids.

SAFETY AND INSTALLATION

3-4 Manual 0-5282

TRANSARC 130i

6. Equipment used for calibration and measurement.

7. The time of day that welding or other activities are to be carried out.

8. 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. Methods of Reducing Electromagnetic Emissions

1. 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.

2. Maintenance of Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All

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 instructions. In particular, the spark gaps of arc striking and stabilizing devices
should be adjusted and maintained according to the manufacturer’s recommendation

3. 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.

4. 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.

5. 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.

6. Screening and Shielding

Selective screening and shielding 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

Notes

TRANSARC 130i

SAFETY AND INSTALLATION

3-6 Manual 0-5282

TRANSARC 130i

SECTION 4:

INSTALLATION, OPERATION AND SETUP

4.01 Transarc 130i Power Source Controls, Indicators and Features

A-11743

A-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 130i

Fail to safe operation

This welding 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.

A-11690

2. 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 & 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 & adjustment
of parameters. During welding, the meter will show actual welding amps.

At the completion 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).

3. 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.

4. Parameter LED's (Weld Activity LED's)

When welding, the weld activity graph LED's will 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 & 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