CIGWELD transarc 300 Si User manual

50
60Hz
3
PHASE
GTAW
SMAW CC 300
AMP
415
V
INVERTER
DC
300 Si
TRANSARC®
INVERTER ARC WELDER
Service Manual
Revision: AA Issue Date: January 15, 2008 Manual No: 0-5000
Operating Features:

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 agency call 800-752-7621, or visit us
on the web at www.cigweld.au.com.
This Operating 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 a Global Brand of Arc Welding Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through market-
leading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.

i
!
WARNING
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 judgment, the Manufacturer
assumes no liability for its use.
Service Manual Number 0-5000 for:
Transarc 300 Si Inverter Welding Power Supply Part No. 625781
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermadyne.com
Copyright © 2008 by
Thermadyne Industires, Inc.
® 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 neg-
ligence, accident, or any other cause.
Publication Date: January 15, 2008
Record the following information for Warranty purposes:
Where Purchased: _______________________________
Purchase Date: _______________________________
Equipment Serial #: _______________________________

Table of Contents
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards....................................................................................... 1-1
1.02 Principal Safety Standards.............................................................................. 1-4
1.03 Precautions De Securite En Soudage A L’arc .................................................. 1-5
1.04 Dangers relatifs au soudage à l’arc ................................................................. 1-5
1.05 Principales Normes De Securite ..................................................................... 1-8
1.06 Declaration Of Conformity .............................................................................. 1-9
SECTION 2:
INTRODUCTION AND DESCRIPTION .............................................................. 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 Symbol Chart .................................................................................................. 2-2
2.05 Description...................................................................................................... 2-3
2.06 Functional Block Diagrams.............................................................................. 2-3
2.07 Transporting Methods..................................................................................... 2-4
SECTION 3:
INSTALLATION RECOMMENDATIONS............................................................. 3-1
3.01 Environment.................................................................................................... 3-1
3.02 Location .......................................................................................................... 3-1
3.03 Electrical Input Connections............................................................................ 3-1
3.04 Mains Supply Voltage Requirements .............................................................. 3-2
3.05 Specifications.................................................................................................. 3-3
3.05 Duty Cycle....................................................................................................... 3-4
SECTION 4:
OPERATOR CONTROLS ............................................................................. 4-1
4.01 Transarc 300 Si Controls................................................................................. 4-1
4.02 Weld Parameter Description ........................................................................... 4-2
4.03 Weld Parameters for Transarc 300 Si.............................................................. 4-3
4.04 Power Source Features ................................................................................... 4-4
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG) .................................................. 5-1
SECTION 6:
SEQUENCE OF OPERATION......................................................................... 6-1
6.01 Stick Welding.................................................................................................. 6-1
6.02 DC LIFT TIG Welding....................................................................................... 6-1

Table of Contents
SECTION 7:
BASIC TIG WELDING GUIDE........................................................................ 7-1
7.01 Electrode Polarity............................................................................................ 7-1
7.02 Tungsten Electrode Current Ranges ................................................................ 7-1
7.03 Tungsten Electrode Types ............................................................................... 7-1
7.04 Guide for Selecting Filler Wire Diameter ......................................................... 7-1
7.05 Shielding Gas Selection .................................................................................. 7-2
7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe................... 7-2
SECTION 8:
BASIC ARC WELDING GUIDE....................................................................... 8-1
8.01 Electrode Polarity............................................................................................ 8-1
8.02 Effects of Stick Welding Various Materials...................................................... 8-1
SECTION 9:
ROUTINE MAINTENANCE .......................................................................... 9-1
9.01 VRD Specification ........................................................................................... 9-3
9.01 VRD Maintenance ........................................................................................... 9-3
SECTION 10:
BASIC TROUBLESHOOTING .......................................................................10-1
10.01 TIG Welding Problems................................................................................ 10-1
10.02 Stick Welding Problems.............................................................................. 10-3
10.03 Power Source Problems ............................................................................. 10-4
10.04 Power Source Error Codes.......................................................................... 10-5
SECTION 11:
ADVANCED TROUBLESHOOTING .................................................................11-1
11.01 System-Level Fault Isolation ....................................................................... 11-1
11.1.1 Opening the Enclosure....................................................................... 11-1
11.02 Verification and Remedy to the Indicated Error Codes................................ 11-3
11.2.1 E01 “Over-Temperature at the primary side”..................................... 11-3
11.2.2 E02 “Over-Temperature at the secondary side”................................. 11-4
11.2.3 E03 “Transformer Over-Current Failure” ........................................... 11-4
11.2.4 E04 “Torch Cable Failure” ................................................................. 11-5
11.2.5 E11 “Main Supply Over Volt-age” ...................................................... 11-5
11.2.6 E12 “Main Supply Under Volt-age”.................................................... 11-5
11.2.7 E81 “Wrong Main Supply Voltage” .................................................... 11-5
11.2.8 E82 “Rated Voltage Selection Circuit abnormality” ............................ 11-6
11.2.9 E83 “Abnormalities in Mains Supply Voltage Detection”.................... 11-6
11.2.10 E85 “Pre-charge abnormality” ......................................................... 11-6
11.2.11 E94 “Thermistor malfunction” ......................................................... 11-7
11.2.12 E99 “Initial Power Receiving” .......................................................... 11-7
11.03 Verification and Remedy to Failures without Indication Codes.................... 11-7
11.3.1 “Cooling Fan (FAN1) Failure” (Fan is not rotating.) ............................ 11-7
11.3.2 ”No Weld Output” .............................................................................. 11-8
11.3.3 ”Operating Panel Failure”................................................................... 11-9
11.04 Fault Isolation Tests .................................................................................. 11-10
11.4.1 Preparation ...................................................................................... 11-10

Table of Contents
11.05 Verification of the Power Input Circuitry ................................................... 11-11
11.5.1 Verification of the AC Input Voltage using an AC voltmeter.............. 11-11
11.5.2 Verification of the Power Supply Voltage ......................................... 11-12
11.5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry ...................... 11-13
11.5.4 Verification of the Gas Valve, SOL1, Drive Circuitry ......................... 11-14
11.5.5 Verification of the Primary Diode (D1)............................................. 11-14
11.5.6 Verification of the Secondary Diode (D2-D7)................................... 11-15
11.5.7 Verification of the Primary IGBT (Q1-Q24) ...................................... 11-15
11.5.8 Verification of the Secondary IGBT (Q25-Q26) ................................ 11-16
11.5.9 Verification of No-load Volt-age (OCV)............................................. 11-16
SECTION 12:
MAINTENANCE ......................................................................................12-1
12.01 Maintenance List......................................................................................... 12-1
12.02 Service Tools............................................................................................... 12-5
12.2.1 Tools and parts .................................................................................. 12-5
12.2.2 Notes of disassembly and assembly.................................................. 12-5
12.03Replacement Procedure............................................................................... 12-6
12.3.1 PCB1(WK-5493) ................................................................................ 12-6
12.3.2 PCB2 (WK-5597) ............................................................................... 12-7
12.3.3 PCB3 (WK-5548), PCB7 (WK-5550).................................................. 12-8
12.3.4 PCB4 (WK-4819) ............................................................................. 12-10
12.3.5 PCB5 (WK-5551) ............................................................................. 12-10
12.3.6 PCB6 (WK-5549) ............................................................................. 12-10
12.3.7 PCB8, PCB9 (WK-5479) and Q1-Q12 “Primary IGBT” ..................... 12-11
12.3.8 PCB10, PCB11 (WK-5479) and Q13-Q24 “Primary IGBT” ............... 12-12
12.3.9 PCB12 (WK-5527) ........................................................................... 12-12
12.3.10 PCB13 (WK-5528) ......................................................................... 12-13
12.3.11 PCB14 (WK-5594) <T1 “Main Transformer”> ................................ 12-14
12.3.12 PCB15 (WK-5606) ......................................................................... 12-15
12.3.13 PCB20 (WK-5499) ......................................................................... 12-16
12.3.14 PCB21 (WK-4917) ......................................................................... 12-16
12.3.15 PCB22 (WK-5022) ......................................................................... 12-18
12.3.16 Current Limiting Resistor (R6) ...................................................... 12-18
12.3.17 Resistor (R7, R8)........................................................................... 12-19
12.3.18 Reactor (FCH1) ...............................................................................12.21
12.3.19 Primary Thermistor (TH1) ............................................................. 12-22
12.3.20 Secondary Thermistor (TH2) ......................................................... 12-23
12.3.21 Cooling Fan (FAN1)........................................................................ 12-23
12.3.22 Main ON/OFF Switch (S1) .............................................................. 12-25
12.3.23 Input Voltage Switch (S2).............................................................. 12-26
12.3.24 Remote Socket (CON1).................................................................. 12-27
12.3.25 Hall Current Sensor (HCT1) ........................................................... 12-28
12.3.26 Primary Diode (D1)........................................................................ 12-29
12.3.27 Secondary Diode (D2, D4, D5 and D7) .......................................... 12-30
12.3.28 Current Trans (CT2, CT3)............................................................... 12-31

Table of Contents
12.3.29 Ring Core (L1) ............................................................................... 12-32
12.3.30 Ring Core (L105) ........................................................................... 12-34
12.3.31 Reactor (L101) .............................................................................. 12-35
12.3.32 Reactor (L102) .............................................................................. 12-36
12.3.33 Reactor (L103) .............................................................................. 12-37
APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1
APPENDIX 2: INTERCONNECT DIAGRAM .............................................................. A-2
APPENDIX 3: PARTS LIST................................................................................. A-3
APPENDIX 4: CONNECTION WIRING GUIDE............................................................ A-8
APPENDIX 5: DIODE TESTING BASICS .................................................................A-10
CIQWELD LIMITED WARRANTY
Terms of Warranty – January 2008
Warranty Schedule – January 2008
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION........................... Inside Rear Cover

TRANSARC 300 Si SERVICE MANUAL
January 15, 2008
vi
THIS PAGE LEFT INTENTIONALLY BLANK.

SERVICE MANUAL TRANSARC 300 Si
January 15, 2008 1-1
SECTION 1:
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 American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. 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.
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. Wear a welding helmet fitted with a proper shade of filter (see ANSI
Z49.1 listed in Safety Standards) to protect your face and eyes when
welding or watching.
2. Wear approved safety glasses. Side shields recommended.
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.

TRANSARC 300 Si SERVICE MANUAL
January 15, 2008
1-2
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 vapors to form
highly toxic and irritating gases.
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 air-supplied
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 contact 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.
2. Do not weld where flying sparks can strike flammable material.
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 traveling 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.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
Welding or cutting
Electrode S ize
Filter
Welding or cutting
Electrode S ize
Filter
Torch soldering 2
Gas metal-arc
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting Ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc
Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in.,
12 Plasma arc cutting
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.