CIGWELD TRANSTIG 200 AC/DC Service Manual
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CIGWELD TRANSTIG 200 AC/DC Service Manual

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200 AC/DC
Service Manual
TRANSTIG
INVERTER ARC WELDER
Revision No: AA
Operating Features:
200
Amp
®
Issue Date: January 17, 2008
50
1
60
Manual No.: 0-5001
240
INVERTER
Hz
V

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Summary of Contents for CIGWELD TRANSTIG 200 AC/DC

  • Page 1 200 AC/DC ® TRANSTIG INVERTER ARC WELDER Service Manual Revision No: AA Issue Date: January 17, 2008 Manual No.: 0-5001 Operating Features: INVERTER...
  • Page 2 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 please call +61-3-9474-7400, or visit us on the web at www.cigweld.com.au.
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Transtig 200 AC/DC Inverter Arc Welder Operating Manual Number 0-5001 for: Part Number 700719 Published by: Thermadyne Industries Inc.

  • Page 4: Table Of Contents

    OPERATOR CONTROLS ................4-1 4.01 Transtig 200 AC/DC Controls ................4-1 4.02 Weld Process Selection for Transtig 200 AC/DC ..........4-3 4.03 Weld Parameter Descriptions for Transtig 200 AC/DC ........4-4 4.04 Weld Parameters for Transtig 200 AC/DC ............4-6 4.05 Power Source Features...................
  • Page 5 TABLE OF CONTENTS TABLE OF CONTENTS (continued) SECTION 7: BASIC TIG WELDING GUIDE ............... 7-1 7.01 Explanation of “Fluttery Arc” when AC TIG Welding on Aluminum ....7-1 7.02 Electrode Polarity ................... 7-2 7.03 Tungsten Electrode Current Ranges ............... 7-2 7.04 Tungsten Electrode Types ................
  • Page 6 TABLE OF CONTENTS 12.2.9 E83 "Abnormalities in Mains Supply Voltage Detection" ...... 6-5 12.2.10 E85 "Pre-charge abnormality" ............6-6 12.2.11 E94 "Thermistor malfunction" ............6-6 12.2.12 E99 "Initial Power Receiving" ............. 6-6 12.03 Verification and Remedy to Failures without Indication Codes ..... 6-6 12.3.1 "Cooling Fan (FAN1) Failure"...
  • Page 7 APPENDIX 2: CONNECTION WIRING GUIDE ............A-5 APPENDIX 3: DIODE TESTING BASICS ..............A-7 APPENDIX 4: TRANSTIG 200 AC/DC ACCESSORIES ..........A-8 APPENDIX 5: TRANSTIG 200 AC/DC INTERCONNECTION DIAGRAM ....... A-9 CIGWELD LIMITED WARRANTY Terms of Warranty – January 2008 Warranty Schedule –...
  • Page 8 THIS PAGE LEFT INTENTIONALLY BLANK...

  • Page 9: Arc Welding Safety Instructions And Warnings

    SERVICE MANUAL TRANSTIG 200 AC/DC 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.
  • Page 10 TRANSTIG 200 AC/DC SERVICE MANUAL WARNING WARNING FUMES AND GASES can be hazardous to ARC RAYS can burn eyes and skin; NOISE your health. can damage hearing. Welding produces fumes and gases. Arc rays from the welding process Breathing these fumes and gases can be produce intense heat and strong ultraviolet hazardous to your health.
  • Page 11 SERVICE MANUAL TRANSTIG 200 AC/DC WARNING WARNING FLYING SPARKS AND HOT METAL can WELDING can cause fire or explosion. cause injury. Sparks and spatter fly off from the welding Chipping and grinding cause flying metal. arc. The flying sparks and hot metal, weld As welds cool, they can throw off slag.
  • Page 12 TRANSTIG 200 AC/DC SERVICE MANUAL WARNING WARNING MOVING PARTS can cause injury. Engines can be dangerous. Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing. WARNING 1. Keep all doors, panels, covers, and guards closed and securely in place.

  • Page 13: Principal Safety Standards

    SERVICE MANUAL TRANSTIG 200 AC/DC 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the WARNING operator. 3. Do not coil or drape cable around the body. STEAM AND PRESSURIZED HOT 4.

  • Page 14: Declaration Of Conformity

    Australia Description of equipment: Welding Equipment (GMAW, MMAW, GTAW). Including, but not limited to CIGWELD Transtig 200 Pi, Transtig 200 AC/DC, Transarc 300 Si, Transtig 300 Pi, Transtig 300 AC/DC, Transmig 400 i 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.

  • Page 15: Introduction

    Manual are manufactured in various number for your location listed in the inside back cover configurations for differing global of this manual. Include the Transtig 200 AC/DC requirements. Some specifications and Service Manual number and equipment identification and electrical data quoted within this numbers.

  • Page 16: Symbol Chart

    TRANSTIG 200 AC/DC SERVICE MANUAL 2.04 Symbol Chart Note that only some of these symbols will appear on your model Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter-...

  • Page 17: Description

    SERVICE MANUAL TRANSTIG 200 AC/DC 2.05 Description The Transtig 200 AC/DC is a self contained single- phase AC/DC arc welding power source with Constant Current (CC) output characteristics. This unit is Art # A-07443 equipped with a Digital Volt/Amperage Meter, gas...

  • Page 18: Functional Block Diagrams

    Mode select Switches Panel Circuit Board Art # A-07267 Figure 2-2: Transtig 200 AC/DC Functional Block Diagram 2.07 Transporting Methods • Lift unit with handle on top of case. • Use handcart or similar device of adequate This unit is equipped with a handle for carrying capacity.

  • Page 19: Parameter Specifications

    SERVICE MANUAL TRANSTIG 200 AC/DC 2.08 Parameter Specifications Parameter Transtig 200 AC/DC Power Source Part Number 700719 Cooling Fan Cooled Welder Type Inverter Power Source Welding Power Source Mass 19kg Dimensions H 360mm x W 180mm x L 420mm Manufactured to Australian Standard AS 60974.1-2006...
  • Page 20 TRANSTIG 200 AC/DC SERVICE MANUAL NOTES January 17, 2008...

  • Page 21: Installation

    TRANSTIG 200 AC/DC SECTION 3: INSTALLATION 3.03 Electrical Input Connections 3.01 Environment The Transtig 200 AC/DC is designed for use in hazardous environments. Examples of environments WARNING with increased hazardous conditions are: a. In locations in which freedom of movement is ELECTRIC SHOCK can kill;...

  • Page 22: Mains Supply Voltage Requirements

    • Connected to the correct size 240V Mains Current Circuit as per the Specifications WARNING CIGWELD advises that this equipment be electrically connected by a qualified electrical trades- person. The following 240V Mains Current Circuit recommendations are required to obtain the maximum welding...

  • Page 23: High Frequency Introduction

    SERVICE MANUAL TRANSTIG 200 AC/DC 3.05 High Frequency Introduction 3.06 High Frequency Interference The importance of correct installation of high Interference may be transmitted by a high frequency frequency welding equipment cannot be initiated or stabilized arc welding machine in the overemphasized.

  • Page 24: Duty Cycle

    TRANSTIG 200 AC/DC SERVICE MANUAL 3.07 Duty Cycle CAUTION The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be Continually exceeding the duty cycle operated at a given output without causing ratings can cause damage to the welding overheating and damage to the unit.

  • Page 25: Operator Controls

    TRANSTIG 200 AC/DC SECTION 4: OPERATOR CONTROLS 4.01 Transtig 200 AC/DC Controls Art # A-08341_AC Figure 4-1: Transtig 200 AC/DC Power Source 1. Control Knob: This control sets the selected weld Socket Pin Function parameter, rotating it clockwise increases the Earth (Ground) parameter that is indicated on the digital meter.
  • Page 26 TRANSTIG 200 AC/DC SERVICE MANUAL 3. Positive Terminal: Welding current flows from the Power Source via heavy duty Dinse type WARNING terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a When the welder is connected to the sound electrical connection.

  • Page 27: Weld Process Selection For Transtig 200 Ac/Dc

    SPOT Pulse operation in TIG Modes PULSE ON/OFF Selects AC or DC weld current Selects mode of operation: Panel or Remote Operation PANEL/REMOTE Table 4-2: Weld Process selection versus Weld Mode for Transtig 200 AC/DC January 17, 2008...

  • Page 28: Weld Parameter Descriptions For Transtig 200 Ac/Dc

    This parameter operates in TIG modes only and is used to set the time for the weld current to ramp up, after the torch trigger switch has been pressed then released, from INITIAL CUR to PEAK or BASE current Table 4-3: Transtig 200 AC/DC Front Panel Parameter Description January 17, 2008...
  • Page 29 The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs into the 200AC/DC memory. Note: Press button for three seconds to store settings. Table 4-3: Transtig 200 AC/DC Front Panel Parameter Description (cont.) January 17, 2008...

  • Page 30: Weld Parameters For Transtig 200 Ac/Dc

    0.1 sec CRATER CUR. 5 to 185A POST-FLOW 0.0 to 60 sec 10 sec 0.1 sec Table 4-4: Weld Parameters for Transtig 200 AC/DC PULSE FREQ. Range Incremental Unit 0.5 to 20Hz 0.1Hz 20 to 100Hz 100 to 500Hz Table 4-5: PULSE FREQ. Range and Incremental Units...

  • Page 31: Power Source Features

    SERVICE MANUAL TRANSTIG 200 AC/DC 4.05 Power Source Features Feature Description • New Digital Control Almost all welding parameters are adjustable • Touch Panel Switches Touch switches eliminate mechanical damage • Front Control Cover Protects front panel controls • Digital Meter Displays selected weld parameter value •...
  • Page 32 TRANSTIG 200 AC/DC SERVICE MANUAL Feature Description • A total number of 5 programs can be saved into the 200 Save/Load Function AC/DC memory. SAVE the Current Weld Parameters into Memory • SAVE Press and HOLD the button for three seconds. Beep will sound and the Digital Meter will show a number 1.

  • Page 33: Set-Up For Smaw (Stick) And Gtaw (Tig)

    Art # A-07843 CAUTION Remove any packaging material prior to Figure 5-1: Transtig 200 AC/DC Set-up use. Do not block the air vents at the front or rear or sides of the Welding Power Source.
  • Page 34 TRANSTIG 200 AC/DC SERVICE MANUAL NOTES January 17, 2008...

  • Page 35: Sequence Of Operation

    Symbol descriptions. PRESS AND HOLD Art # A-07272_AC Figure 6-1: Transtig 200 AC/DC Front Panel 1. Pulse Function: Pressing this button enables the TIG current pulse functions. 2. Remote Current Function: Pressing this buttons enables remote current functions.

  • Page 36: Stick Welding

    TRANSTIG 200 AC/DC SERVICE MANUAL 6.01 Stick Welding 6.02 AC or DC HF TIG Welding · Connect work lead to negative terminal · Connect work lead to positive terminal · Connect electrode lead to positive terminal · Connect TIG torch to gas terminal ·...

  • Page 37: Slope Mode Sequence

    SERVICE MANUAL TRANSTIG 200 AC/DC 6.03 Slope Mode Sequence Art # A-04989 Switch Switch Switch Switch Closed Closed Open Open Weld Current Down Slope Slope Initial Final Current Current Preflow Postflow Figure 6-2: Slope Mode Sequence NOTE Slope function operates with a Remote ON/OFF device only 1.

  • Page 38: Pulse Controls

    TRANSTIG 200 AC/DC SERVICE MANUAL 6.05 Pulse Controls (Pulse Width) (Pulse Frequency) Art # A-04990 (Peak Current) (Base) Background Current Figure 6-3: Pulse Controls The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows: 1) Control puddle –...

  • Page 39: Basic Tig Welding Guide

    SERVICE MANUAL TRANSTIG 200 AC/DC SECTION 7: BASIC TIG WELDING GUIDE 7.01 Explanation of “Fluttery Arc” This idea is supported by the observation that once when AC TIG Welding on fluttering starts it can be made to stop by working...

  • Page 40: Electrode Polarity

    TRANSTIG 200 AC/DC SERVICE MANUAL 7.02 Electrode Polarity Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK 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.

  • Page 41: Guide For Selecting Filler Wire Diameter

    SERVICE MANUAL TRANSTIG 200 AC/DC 7.05 Guide for Selecting Filler Wire Diameter NOTE The filler wire diameter specified in Table 7-4 is a guide only, other diameter wires may be used according to the welding application AC Current Range DC Current Range...

  • Page 42: Welding Parameters For Aluminum

    TRANSTIG 200 AC/DC SERVICE MANUAL 7.08 Welding Parameters for Aluminum Filler Rod Base Metal AC Current for Tungsten Argon Gas Joint Type Diameter Thickness Aluminum Electrode Flow Rate Diameter (if required) Liters/min 0.040” 30-45 0.040” 1/16” Butt/Corner 1.0mm 35-50 1.0mm 1.6mm...

  • Page 43: Basic Arc Welding Guide

    SERVICE MANUAL TRANSTIG 200 AC/DC SECTION 8: BASIC ARC WELDING GUIDE 8.01 Electrode Polarity Types of Electrodes Stick electrodes are generally connected to the ‘+’ Arc Welding electrodes are classified into a number terminal and the work lead to the ‘-’ terminal but if in of groups depending on their applications.
  • Page 44 TRANSTIG 200 AC/DC SERVICE MANUAL Metals being Electrode Comments joined Mild Steel 6013 Ideal electrodes for all general purpose work. Features include outstanding operator appeal, easy arc starting and low spatter. Mild Steel 7014 All positional electrode for use on...

  • Page 45: Routine Maintenance

    Turn Power Switch to OFF before proceeding. Internal cleaning of the unit should be done every 6 months by an authorized CIGWELD Service Center to remove any accumulated dirt and dust. This may need to be done more frequently under exceptionally dirty conditions.
  • Page 46 TRANSTIG 200 AC/DC SERVICE MANUAL Warning! Disconnect input power before maintaining. Maintain more often if used under severe conditions Each Use Visual check of torch Visual check of Consumable parts regulator and pressure Weekly Visually inspect the torch Visually inspect the body and consumables cables and leads.

  • Page 47: Basic Troubleshooting

    WARNING There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an accredited CIGWELD Service Provider and you have had training in power measurements and troubleshooting techniques. If major complex subassemblies are faulty, then the Welding Power Source must be returned to an accredited CIGWELD Service Provider for repair.
  • Page 48 TRANSTIG 200 AC/DC SERVICE MANUAL Description Possible Cause Remedy Electrode melts when Electrode is connected to the A Connect the electrode to the arc is struck. ‘+’ terminal. ‘−’ terminal. WAVE BALANCE WAVE BALANCE is greater Reduced than 50%. to below 50% or increase the electrode size.
  • Page 49 SERVICE MANUAL TRANSTIG 200 AC/DC Description Possible Cause Remedy 11 Welding arc cannot A Work clamp is not connected to A Connect the work clamp to the be established. the work piece or the work/torch work piece or connect the...

  • Page 50: Stick Welding Problems

    TRANSTIG 200 AC/DC SERVICE MANUAL 10.02 Stick Welding Problems Description Possible Cause Remedy 1 Gas pockets or Electrodes are damp. Dry electrodes before use. voids in weld metal Welding current is too high. Reduce welding current. (Porosity). Surface impurities such as oil, Clean joint before welding.
  • Page 51 SERVICE MANUAL TRANSTIG 200 AC/DC Description Possible Cause Remedy 4 Portions of the weld Small electrodes used on heavy Use larger electrodes and run do not fuse to the cold plate. pre-heat the plate. surface of the metal Welding current is too low.
  • Page 52 TRANSTIG 200 AC/DC SERVICE MANUAL Description Possible Cause Remedy 5 Non-metallic particles A Non-metallic particles may be A If bad undercut is present, clean are trapped in the trapped in undercut from slag out and cover with a run weld metal (slag previous run.

  • Page 53: Power Source Problems

    The Welding Power Source Switch ON the Welding switch is switched OFF. Power Source. C Loose connections internally. C Have an accredited CIGWELD Service Provider repair the connection. 2 Maximum output Defective control circuit. Have an accredited welding current can...
  • Page 54 Switch machine OFF then ON to reset solenoid valve sequence. B Gas valve is faulty. B Have an accredited CIGWELD Service Agent Provider or replace the gas valve. C Gas valve jammed open. C Have an accredited CIGWELD Service Provider repair or replace the gas valve.

  • Page 55: Power Source Error Codes

    SERVICE MANUAL TRANSTIG 200 AC/DC 10.04 Power Source Error Codes Description Possible Cause Remedy Remarks E01 error code A The Welding Power A Let Power Source cool Weld current displayed. Source's duty cycle has down then keep within its ceases. Buzzer Temperature been exceeded.

  • Page 56: Power Source Error Codes (Con't)

    TRANSTIG 200 AC/DC SERVICE MANUAL 10.04 Power Source Error Codes (con't) Description Possible Cause Remedy Remarks 6 E14 error code Mains supply voltage is Have an Accredited Weld current displayed. less than the nominal Cigweld Service Provider available. Buzzer Under mains...

  • Page 57: Voltage Reduction Device (Vrd)

    In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests should also be conducted by an accredited Cigweld service Provider. Description Required Parameters VRD Open Circuit Voltage Less than 20V;...
  • Page 58 TRANSTIG 200 AC/DC SERVICE MANUAL NOTES January 17, 2008 11-2...

  • Page 59: Advanced Trouble Shooting

    Service Manual, the subassembly should be replaced with a new one. The faulty subassembly Figure 12-1: Switch OFF should then be returned to Cigweld through estab- lished procedures. CAUTION WARNING...
  • Page 60 TRANSTIG 200 AC/DC SERVICE MANUAL 2) Remove all screws and nuts on the Side Panel. 4) Pull the front panel slightly forward and pull the rear panel slightly backward. The interlocking hooks of the side case covers can now be disengaged from the front and rear panels.

  • Page 61: Verification And Remedy To The Indicated Error Codes

    SERVICE MANUAL TRANSTIG 200 AC/DC 6) Remove protection cover sheet by removing 12.2.1 E01 "Over-Temperature at the primary the plastic tabs. side" Cause Occurs when an over-temperature condition of the primary IGBT is detected. Verification/Remedy a. Unit may be in thermal shutdown mode.

  • Page 62: E02 "Over-Temperature At The Secondary Side

    TRANSTIG 200 AC/DC SERVICE MANUAL 12.2.2 E02 "Over-Temperature at the 12.2.3 E03 "Primary Over-Current Failure" secondary side" Cause Cause Occurs when excessive current is detected flowing into the primary side of the main trans- Occurs when an over-temperature condition former.

  • Page 63: E11 "Main Supply Over Voltage

    SERVICE MANUAL TRANSTIG 200 AC/DC Refer to 2.9 for the recommended duty cycle. • Re-install the harness with a secure connection. • Contact the manufacturer if you find any bro- b. Replace PCB6 (WK-5549) and PCB13 (WK- ken connectors or a damaged wiring harness.

  • Page 64: E85 "Pre-Charge Abnormality

    TRANSTIG 200 AC/DC SERVICE MANUAL 12.2.10 E85 "Pre-charge abnormality" 12.2.12 E99 "Initial Power Receiving" Cause Cause Due to malfunction inside the Welding Power Occurs when the initial AC power received sig- Source, primary capacitors are not charging nal has not reached the CPU. This error oc- correctly.

  • Page 65: Gas Valve Failure" (No Gas Flow Through Unit)

    SERVICE MANUAL TRANSTIG 200 AC/DC • Replace the fan if there are any broken, cracked e. Replace the PCB6 (WK-5549). or missing fan blades. • Refer to section 13.3.5. • Refer to section 13.3.24. 12.3.3 "No Weld Output" b. Verify the wiring harness between the cooling fan (FAN1) and CN11 on PCB3 (WK-5548).

  • Page 66: Operating Panel Failure

    TRANSTIG 200 AC/DC SERVICE MANUAL • If performing the "No-Load Voltage Failure" pro- 12.3.5 "High Frequency Output Failure" (Unit cedure does not rectify the failure, perform the does not generate High Frequency.) following tests in the sequence below. Replace Cause any defective components found.

  • Page 67: Fault Isolation Tests

    SERVICE MANUAL TRANSTIG 200 AC/DC • Verify the connection between AC1-AC2, con- firm that the quick-disconnect terminals are in- WARNING serted onto the terminals of HF UNIT1 correctly and completely. Dangerous voltage and power levels are • Confirm there are no short circuits, burnt or present inside this unit.

  • Page 68: Verification Of Power Supply Voltage

    TRANSTIG 200 AC/DC SERVICE MANUAL 2. If the input voltage is out of the operating range 6. Verify bus voltage (the voltage of the electrolytic of the unit, which is 10% (187 ~ 253 /414 ~ 506 capacitor after rectification) using a DC voltme- VAC) of the rated voltage (208, 230/ 460V), verify ter.

  • Page 69: Verification Of The Cooling Fan, Fan1, Drive Circuitry

    SERVICE MANUAL TRANSTIG 200 AC/DC 12.5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry CAUTION Before performing any portion of the pro- cedure below, make certain the unit is placed in the initial set up condition as described in section 12. 4.1 "Preparation".

  • Page 70: Verification Of The Gas Valve, Sol1, Drive Circuitry

    TRANSTIG 200 AC/DC SERVICE MANUAL • During low output and standby, fan rotation becomes slower. Therefore, exact voltage mea- surement becomes impossible. Voltage • When verifying the voltage, confirm that the AC measurement. Remedy (1PIN-2PIN of input voltage remains within the operating range...

  • Page 71: Verification Of The Secondary Diode (D2, D4, D5)

    SERVICE MANUAL TRANSTIG 200 AC/DC 12.5.6 Verification of the secondary Diode (D2, D4, D5) CAUTION Before performing any portion of the pro- cedure below, make certain the unit is placed in the initial set up condition as described in section 12. 4.1 "Preparation".

  • Page 72: Verification Of The Primary Igbt (Q1-Q12)

    TRANSTIG 200 AC/DC SERVICE MANUAL 12.5.7 Verification of the primary IGBT (Q1- 12.5.8 Verification of the secondary IGBT Q12) (Q13) CAUTION CAUTION Before performing any portion of the pro- Before performing any portion of the pro- cedure below, make certain the unit is...

  • Page 73: Verification Of No-Load Voltage (Ocv)

    SERVICE MANUAL TRANSTIG 200 AC/DC 12.5.9 Verification of No-load Voltage (OCV) 3. When in HF TIG mode, the unit will generate high voltage. To prevent personal harm and test equip- ment damage, mark and then remove the indi- CAUTION cated wire from the HF UNIT1 shown in Figure 6- 18.
  • Page 74 TRANSTIG 200 AC/DC SERVICE MANUAL THIS PAGE LEFT INTENTIONALLY BLANK 12-16 January 17, 2008...

  • Page 75: Maintenance

    SERVICE MANUAL TRANSTIG 200 AC/DC 13 MAINTENANCE Maintenance List MAINTENANCE DWG No. Parts name Reference page Part No. 13-9 PCB3 Print Circuit Board (WK-5548) W7001314 13-13 PCB10 Print Circuit Board (WK-5527) W7001812 13-13 W7001320 PCB11 Print Circuit Board (WK-5528) 13-15...
  • Page 76 TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE DWG No. Parts name Reference page Part No. 13-6 W7001402 PCB1 Print Circuit Board (WK-5477) 13-7 W7001601 PCB2 Print Circuit Board (WK-5596) 13-10 10-6635 PCB4 Print Circuit Board (WK-4819) 13-10 W7001417 PCB5 Print Circuit Board (WK-5551)
  • Page 77 SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE DWG No. Parts name Reference page Part No. 13-24 W7001384 Coupling Coil 13-15 W7001304 Current Trans 13-32 10-6628 Primary Diode 13-33 10-6629 Secondary Diode 13-33 10-6629 Secondary Diode 13-33 10-6629 Secondary Diode 13-31 W7001502...
  • Page 78 TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE DWG No. Parts name Reference page Part No. 13-29 W7001595 CON1 Remote Connector 13-27 W7001307 FAN1 Cooling Fan 13-34 10-6643 Q13 (PCB15) Secondary IGBT (WK-3367) 13-22 10-5137 Discharge Resistor 13-23 W7001452 Current Limiting Resistor...

  • Page 79: Service Tools

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE Service Tools 2.1 Tools and parts The tools and parts to be used for maintenance are shown by icons. Philips Head Long Nose Silicon Spanner C-Ring Pliers Snap Band Pliers Screwdriver Compound (5.5, 8, 10, 17mm) 2.2 Notes of disassembly and assembly...

  • Page 80: Replacement Procedure

    TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE Replacement Procedure 3.1 PCB1 (WK-5477) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the PCB18 (WK-5861). [Reference page: 12-21] 3) Remove PCB2 (WK-5596). [Reference page: 12-7] 4) Remove the PCB8 (WK-5479). [Reference page: 12-11] 5) Remove the PCB9 (WK-5479).

  • Page 81: Pcb2 (Wk-5596)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 3.2 PCB2 (WK-5596) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the PCB18 (WK-5861). [Reference page: 12-11] 3) Disconnect the 13 connectors. CN17 CN19 CN21 CN11 4) Remove the four screws and two ground terminals.
  • Page 82 TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE Remove the Insulated Sheet. CN15 CN14 6) Remove the three screws and seven terminals. Remove the PCB2 (WK-5596). 7) Disconnect the three connectors and two terminal from the PCB2 (WK-5596). 13-8 January 17, 2008...

  • Page 83: Pcb3 (Wk-5548), Pcb5 (Wk-5551)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 3.3 PCB3 (WK-5548), PCB5 (WK-5551) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove PCB4 (WK-4819). [Reference page: 12-10] 3) Remove PCB6 (WK-5549). [Reference page: 12-10] 4) Remove PCB7 (WK-5550). [Reference page: 12-11] 5) Disconnect the 11 connectors.

  • Page 84: Pcb4 (Wk-4819)

    TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 8) Disconnect the two connectors from the PCB3 (WK-5548). CN18 CN33 3.4 PCB4 (WK-4819) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the two screws and three connectors and remove the PCB4 (WK-4819).

  • Page 85: Pcb7 (Wk-5550)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 3) Remove the three screws and five connectors. Remove the PCB6 (WK-5549). CN27 CN18 CN32 CN30 CN31 3.6 PCB7 (WK-5550) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the PCB6 (WK-5549). [Reference page: 12-10] 3) Remove the two screws and three connectors.

  • Page 86: Pcb9 (Wk-5479) (Igbt (Q7~Q12))

    TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 3) Remove the two connectors and three screws. Remove the PCB8 (WK-5479). Remember to install silicone rubber sheets when reinstalling the PCB8 (WK-5479). 3.8 PCB9 (WK-5479) (IGBT (Q7~Q12)) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the four screws and two IGBT Chassis.

  • Page 87: Pcb10 (Wk-5527)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 3.9 PCB10 (WK-5527) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the PCB11 (WK-5528). [Reference page: 12-13] 3) Remove the three latches of Front Control Cover and then the PCB10 (WK-5527). When reinstalling the PCB10 (WK-5527), engage two latches of Front Control Cover first.
  • Page 88 TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 3) Remove the Knob Cap. Holding the Knob down, loosen the screw and remove the Knob. 4) Disconnect the one connector from the PCB10 (WK-5527). Remove the four screws. Pull out the Opera- tion Panel and bring it down.

  • Page 89: Pcb12 (Wk-5615), Transformer (T1), Current Trans (Ct2)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 3.11 PCB12 (WK-5615), Transformer (T1), Current Trans (CT2) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove PCB13 (WK-5569). [Reference page: 12-18] 3) Disconnect the one connector and cut the one snap band.
  • Page 90 TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 6) Remove the 16 screws. 7) Remove the PCB12 and T1 unit. 8) Cut the one snap band and remove the Current Trans (CT2). 13-16 January 17, 2008...
  • Page 91 SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 9) Remove the Dust Cover Sheet. Extend the electrode and remove the T-D Bus Bar1, T-D Bus Bar2 and T Center Bus Bar. 10) Remove the two PCB supporters and cushion. Remove the four screws and remove the Main Trans (T1).

  • Page 92: Pcb13 (Wk-5569)

    TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 3.12 PCB13 (WK-5569) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the Nylon Hose. Remove the four screws. Remove the two terminals and open the Rear Panel. 3) Disconnect the six connectors and remove the two screws and two terminals.

  • Page 93: Pcb16 (Wk-5499)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 3.13 PCB16 (WK-5499) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the Nylon Hose. 3) Disconnect the two connectors. Remove the three PCB supporters and remove the PCB16 (WK-5499). 3.14 PCB14 (WK-5570) 1) Remove the Side Panel.

  • Page 94: Pcb17 (Wk-4917)

    TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 4) Remove the three PCB supporters from the PCB14 (WK-5570). 3.15 PCB17 (WK-4917) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the four screws and four terminals. 3) Remove the four screws and then open the Rear Board.

  • Page 95: Pcb18 (Wk-5861)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 4) Disconnect the one connector. Remove the two screws and one ground terminal and remove the PCB17 unit. 5) Remove the two screws and remove the S1 Bus Bar from the PCB17 (WK-4917). 3.16 PCB18 (WK-5861) 1) Remove the Side Panel.

  • Page 96: Discharge Resistor (R3)

    TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 3.17 Discharge Resistor (R3) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the Nylon Hose. Remove the two bolts, two toothed washers, one washer, and one terminal. 3) Remove the four screws and open the Front Panel.

  • Page 97: Current Limiting Resistor (R4, R5)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 5) Remove the one screw and one nut and remove the one terminal. 6) Remove the two screws and remove the Discharge Resistor (R3). 3.18 Current Limiting Resistor (R4, R5) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the PCB18 (WK-5861).

  • Page 98: Resistor On High Frequency Unit (R6)

    TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 3.19 Resistor on High Frequency Unit (R6) 1) Remove the Side Panel. [Reference page: 11-1] 2) Cut the one snap band and remove the two terminals. Remove the one screw and remove the Resistor on High Frequency Unit (R6).

  • Page 99: Reactor (Fch1)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 4) Remove the two terminals. Remove the one screw and two terminals. 5) Remove the one screw and one nut. Remove the one screw and Coupling Coil (CC1). 3.21 Reactor (FCH1) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the PCB16 (WK-5499).

  • Page 100: Primary Thermistor (Th1)

    TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 6) Remove the four screws and remove the Reactor (FCH1). Remove the Insulating Sheet. 3.22 Primary Thermistor (TH1) 1) Remove the Side Panel. [Reference page: 11-1] 2) Cut the three snap bands. Disconnect the one connector.

  • Page 101: Cooling Fan (Fan1)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 5) Cut the four snap bands. Disconnect the one connector. Remove the one screw and then detach the Secondary Thermistor (TH2). Before installing a new therminstor, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base.

  • Page 102: Solenoid Valve (Sol1)

    TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 4) Remove the two screws and detach the Cooling Fan (FAN1). Do not have the wrong direction of the fan when reinstalling. 3.25 Solenoid Valve (SOL1) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the Nylon Hose.

  • Page 103: Main On/Off Switch (S1)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 3.26 Main ON/OFF Switch (S1) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the four screws and four terminals. 3) Remove the two screws and detach the Main ON/OFF Switch (S1). Remove the two posts.
  • Page 104 TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 3) Remove the four screws. Pull out the Front Control Cover and bring it down. 4) Disconnect the two connectors. Remove the one screw and two ground terminals. CN15 CN14 5) Remove the two screws and Remote Socket (CON1).

  • Page 105: High Freguency Unit (Hf.unit1)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 3.28 High Freguency Unit (HF.UNIT1) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the High Freguency Gap. Remove the six terminals. 3) Remove the two screws, two washers and detach the High Freguency Unit (HF. UNIT1).

  • Page 106: Primary Diode (D1)

    TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 3) Remove the one screw and one nut. Disconnect the one connector. 4) Remove the one screw. Remove the Hall C. T. (HCT1) while slighty pressing down the bus bar. 3.30 Primary Diode (D1) 1) Remove the Side Panel.

  • Page 107: Secondary Diode (D2, D4, D5)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 3.31 Secondary Diode (D2, D4, D5) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the PCB13 (WK-5569). [Reference page: 12-18] 3) Remove the PCB12 (WK-5615). [Reference page: 12-15] 4) Remove the two screws and two nuts and remove the bus bar.

  • Page 108: Secondary Igbt (Q13) (Pcb15 (Wk-3367))

    TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 3.32 Secondary IGBT (Q13) (PCB15 (WK-3367)) 1) Remove the side cover. [Reference page: 11-1] 2) Remove the PCB16 (WK-5499). [Reference page: 12-19] 3) Remove the PCB14 (WK-5570). [Reference page: 12-19] 4) Remove the one bolt and remove the one toothed washer, one washer and one terminal.

  • Page 109: Reactor (L101)

    SERVICE MANUAL TRANSTIG 200 AC/DC MAINTENANCE 3.33 Reactor (L101) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove the Earth Inductance (L103). [Reference page: 12-35] 3) Remove the two screws and two cables. 4) Cut the snap band. Open the Reactor (L101) and Remove the Reactor (L101).
  • Page 110 TRANSTIG 200 AC/DC SERVICE MANUAL MAINTENANCE 3) Remove the two screws and the nut. Remove the Earth Inductance (L103). 13-36 January 17, 2008...
  • Page 111 SERVICE MANUAL TRANSTIG 200 AC/DC THIS PAGE LEFT INTENTIONALLY BLANK January 17, 2008 13-37...

  • Page 112: Appendix 1 Parts List

    To determine the part number, description, quantity, or application of an item, simply locate the item in question from the illustration and refer to that item number in the correspond- ing Parts List. TRANSTIG 200 AC/DC 700719 DWG No. Part No.

  • Page 113: Parts List

    SERVICE MANUAL TRANSTIG 200 AC/DC PARTS LIST & R4-5 W7001452 Resistor, gen 3.1, IPS MHS20A221KI 20W 220Ω W7001451 Resistor, gen 3.1, IPS MHS20A101KI 20W 100Ω W7001453 Switch, gen 3.1, IPS DCP-52SR50C-480V 2P-480V (185ACDC) 5505NBR1.5 DC24V 11VA/10W (with Gas SOL1 W7001604 Solenoid Valve, gen 3.1, IPS...
  • Page 114 TRANSTIG 200 AC/DC SERVICE MANUAL PARTS LIST DWG No. Part No. Description Type & Rating QTY. W7001616 Sheet, dust cover F, gen 3.1, IPS E1B935200 W7001609 Sheet, dust cover R, gen 3.1, IPS E1B935600 W7001374 Clip, gen 3.1, IPS #74 NATURAL 4 W7001618 Hose, Nylon, gen 3.1, IPS...
  • Page 115 SERVICE MANUAL TRANSTIG 200 AC/DC PARTS LIST January 17, 2008...

  • Page 116: Appendix 2 Connection Wiring Guide

    TRANSTIG 200 AC/DC SERVICE MANUAL APPENDIX 2 CONNECTION WIRING GUIDE CONNECTION WIRING GUIDE APPENDIX 2 Connection Wiring Guide Destination PCB2 PCB3 PCB2 PCB3 PCB3 PCB17 PCB3 FAN1 PCB3 CN11 SOL1 PCB3 CN20 PCB8 PCB3 CN21 PCB8 PCB3 CN22 PCB9 PCB3...
  • Page 117 SERVICE MANUAL TRANSTIG 200 AC/DC CONNECTION WIRING GUIDE CN21 PCB17 CN17 PCB6 CN20 FAN1 CN33 PCB4 SOL1 PCB10 PCB11 CN18 PCB7 CN11 CN15 CN20 CN22 CN14 CN20 CN23 CON1 CN21 PCB9 PCB3 PCB8 PCB16 PCB15 PCB2 HCT1 PCB13 January 17, 2008...

  • Page 118: Appendix 3 Diode Testing Basics

    TRANSTIG 200 AC/DC SERVICE MANUAL APPENDIX 3 DIODE TESTING BASICS DIODE TESTING BASIC APPENDIX 4 DIODE TESTING BASIC Testing of diode modules requires a digital Volt/ Ohmmeter that has a diode test scale.Locate the diode module to be tested.Remove cables from mounting studs on diodes to isolate them within the module.Set the digital volt/ohm meter to the diode...

  • Page 119: Appendix 4: Transtig 200 Ac/Dc Accessories

    SERVICE MANUAL TRANSTIG 200 AC/DC APPENDIX 4: TRANSTIG 200 AC/DC ACCESSORIES Description Part No. Details 17 Series air cooled TIG torch 518710402 TIG torch with 4 metre cable & remote (suitable for TransTig 200Pi) current control 26 Series air cooled TIG torch 538720401 TIG torch with 4 metre cable &...

  • Page 120: Appendix 5: Transtig 200 Ac/Dc Interconnection Diagram

    TRANSTIG 200 AC/DC SERVICE MANUAL APPENDIX 5: TRANSTIG 200 AC/DC INTERCONNECTION DIAGRAM PCB1 K(7) Main PCB8 G(6) Circuit Board IGBT Gate [WK-5493] Circuit Board R(3) PCB18 [WK-5479] L101 CE Filter Circuit Board [WK-5861] S(4) T(5) Ground Ground L103 PCB17 PCB2...
  • Page 121 SERVICE MANUAL TRANSTIG 200 AC/DC PCB12 PCB14 DIODE Snubber IGBT Snubber Circuit Board Circuit Board [WK-5615] [WK-5570] FCH1 TB20 PCB15 TB22 IGBT Gate Circuit Board +Output TB12 [WK-3367] Terminal TB21 1 2 3 4 5 1 2 3 4 5...
  • Page 122 TRANSTIG 200 AC/DC SERVICE MANUAL NOTES A-11 January 17, 2008...

  • Page 123: Cigweld Limited Warranty

    CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedes of the Purchaser set forth heren are exclusve and the lablty of CIGWELD wth respect to any contract, or anythng done n connecton therewth such as the performance or breach thereof, or from the manufacture, sale, delvery, resale, or use...
  • Page 124 CIGWELD. 4. CIGWELD declares that, to the extent permtted by law, t hereby lmts ts lablty n respect of the supply of goods whch are not of a knd ordnarly acqured for personal, domestc or household use or consumpton to any one or more of the followng (the choce of whch shall be at the opton of CIGWELD).
  • Page 125 Accredted Dstrbutor of the equpment. Notwthstandng the foregong, n no event shall the warranty perod extend more than the tme stated plus one year from the date CIGWELD delvered the product to the Accredted Dstrbutor. Unless otherwse stated the warranty perod ncludes parts and labour. CIGWELD reserves the rght to request documented evdence of date of purchase.

  • Page 127: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne, China Cigweld, Australia RM 102A 71 Gower Street 685 Ding Xi Rd Preston, Victoria Chang Ning District Australia, 3072 Telephone: 61-3-9474-7400 Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 61-3-9474-7510 Fax: 86-21-69171139 Email: cigweldsales@cigweld.com.au Thermadyne Asia Sdn Bhd...
  • Page 128 Corporate Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX: +61 3 9474 7488 Email: cigweldsales@cigweld.com.au www.cigweld.com.au...

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