CIGWELD TRANSTIG 300 AC/DC Service Manual
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CIGWELD TRANSTIG 300 AC/DC Service Manual

Inverter arc
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See also: Operating Manual
300 AC/DC
Service Manual
TRANSTIG
INVERTER ARC WELDER
Revision: AA
Operating Features:
®
Issue Date: June 30, 2008
INVERTER
50
Hz
60
Manual No.: 0-5002
415
3
V

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  • Page 1 300 AC/DC ® TRANSTIG INVERTER ARC WELDER Service Manual Revision: AA Issue Date: June 30, 2008 Manual No.: 0-5002 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.
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Transtig 300 AC/DC Inverter Arc Welder Service Manual Number 0-5002 for: Part Number 700723 Published by: Thermadyne Industries Inc.

  • Page 4: Table Of Contents

    OPERATOR CONTROLS ................4-1 4.01 Transtig 300 AC/DC Controls ................4-1 4.02 Weld Process Selection for Transtig 300 AC/DC ..........4-3 4.03 Weld Parameter Descriptions for Transtig 300 AC/DC ........4-4 4.04 Weld Parameters for Transtig 300 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 13.2.9 E83 "Abnormalities in Mains Supply Voltage Detection" ....13-5 13.2.10 E85 "Pre-charge abnormality" ............13-6 13.2.11 E94 "Thermistor malfunction" ............13-6 13.2.12 E99 "Initial Power Receiving" ............13-6 13.03 Verification and Remedy to Failures without Indication Codes ....13-6 13.3.1 "Cooling Fan (FAN1) Failure"...
  • Page 7 APPENDIX 2: CONNECTION WIRING GUIDE ............A-6 APPENDIX 3: TRANSTIG 300 AC/DC INTERCONNECT DIAGRAM ........A-8 APPENDIX 4: DIODE TESTING BASICS ..............A-10 APPENDIX 5: TRANSTIG 300 AC/DC OPTIONS AND ACCESSORIES ....... A-11 CIGWELD LIMITED WARRANTY Terms of Warranty – January 2008 Warranty Schedule –...

  • Page 9: Arc Welding Safety Instructions And Warnings

    SERVICE MANUAL TRANSTIG 300 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 300 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 300 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 300 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 300 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

    Acrobat PDF format by when using this Service Manual. going to the Cigweld web site listed below and clicking on the Literature Library link: http://www.cigweld.au.com June 30, 2008...

  • Page 16: Symbol Chart

    TRANSTIG 300 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 300 AC/DC 2.05 Description The Cigweld Transtig 300 AC/DC is a self contained three-phase AC/DC arc welding power source with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, gas control valve, built in Sloper and Pulser, lift arc...

  • Page 18: Functional Block Diagrams

    TRANSTIG 300 AC/DC SERVICE MANUAL 2.06 Functional Block Diagrams Figure 2-2 illustrates the functional block diagram of the Transtig 300 AC/DC power source. DC Power Secondary To each control circuit Voltage Sensor +/-12VDC +15VDC Hall Current Input Main Input IGBT...

  • Page 19: Specifications

    Protection Class IP23S Cigweld continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
  • Page 20 TRANSTIG 300 AC/DC SERVICE MANUAL THIS PAGE LEFT INTENTIONALLY BLANK June 30, 2008...

  • Page 21: Installation

    TRANSTIG 300 AC/DC SECTION 3: INSTALLATION 3.03 Electrical Input Connections 3.01 Environment The Transtig 300 AC/DC is designed for use in hazardous environments. Examples of environments WARNING with increased hazardous environments 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 415V Mains Current Circuit as per the Specifications WARNING CIGWELD advises that this equipment be electrically connected by a qualified electrical trades- person. The following 415V Mains Current Circuit recommendations are required to obtain the maximum welding...

  • Page 23: High Frequency Introduction

    SERVICE MANUAL TRANSTIG 300 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 300 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 300 AC/DC SECTION 4: OPERATOR CONTROLS 4.01 Transtig 300 AC/DC Controls Art # A-07444_AC Figure 4-1: Transtig 300 AC/DC Power Source 1. Control Knob: This control sets the selected weld Socket Function parameter, rotating it clockwise increases the parameter that is indicated on the digital meter.
  • Page 26 TRANSTIG 300 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 300 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 300 AC/DC June 30, 2008...

  • Page 28: Weld Parameter Descriptions For Transtig 300 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 300 AC/DC Front Panel Parameter Description June 30, 2008...
  • Page 29 SERVICE MANUAL TRANSTIG 300 AC/DC PEAK CUR. PULSE This parameter sets the PEAK weld current when in mode WELD SLOPE REPEAT This parameter sets the TIG WELD current in SPOT PULSE modes when is OFF. This parameter also sets the STICK weld current.

  • Page 30: Weld Parameters For Transtig 300 Ac/Dc

    3 sec 0.1 sec CRATER CUR. 5 to 300A POST-FLOW 0.0 to 60 sec 10 sec 0.1 sec Table 4-4: Weld Parameters for Transtig 300 AC/DC PULSE FREQ. Range Incremental Unit 0.5 to 20Hz 0.1Hz 20 to 100Hz 100 to 500Hz Table 4-5: PULSE FREQ.

  • Page 31: Power Source Features

    SERVICE MANUAL TRANSTIG 300 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 300 AC/DC SERVICE MANUAL Feature Description • Save/Load Function A total number of 5 programs can be saved into the 300 AC/DC memory. SAVE the Current Weld Parameters into Memory • Press and HOLD the SAVE button. 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 use. Do not block the air vents at the front Figure 5-1: Transtig 300 AC/DC Set-up or rear or sides of the Welding Power Source. CAUTION DO NOT change the Weld Mode or Weld Process Mode until after POST-FLOW time has finished.
  • Page 34 TRANSTIG 300 AC/DC SERVICE MANUAL NOTES June 30, 2008...

  • Page 35: Sequence Of Operation

    SERVICE MANUAL TRANSTIG 300 AC/DC SECTION 6: SEQUENCE OF OPERATION Scroll Buttons are used to select the parameters to be set. The LED’s show which function is being adjusted on the weld sequence graph. Refer to the Symbols Table located in the front of the manual for Symbol descriptions.

  • Page 36: Stick Welding

    TRANSTIG 300 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 300 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

    6.06 Save-Load Operation A total number of 5 programs can be saved into the Transtig 300 AC/DC memory. SAVE the Current Weld Parameters into Memory • Press and HOLD the SAVE button. Beep will sound and digital display will show a number 1.

  • Page 39: Basic Tig Welding Guide

    SERVICE MANUAL TRANSTIG 300 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 300 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 300 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 300 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 300 AC/DC SECTION 8: BASIC ARC WELDING GUIDE 8.01 Electrode Polarity Stick electrodes are generally connected to the ‘+’ terminal and the work lead to the ‘-’ terminal but if in doubt consult the electrode manufacturers literature.
  • Page 44 TRANSTIG 300 AC/DC SERVICE MANUAL Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications. There are a great number of electrodes used for specialized industrial purposes, which are not of particular interest for everyday general work.

  • 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 300 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 Agent for repair.
  • Page 48 TRANSTIG 300 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 300 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 300 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 300 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 300 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 Cigweld 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 Provider repair 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: 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 56 TRANSTIG 300 AC/DC SERVICE MANUAL NOTES June 30, 2008 11-2...

  • Page 57: Power Source Error Codes

    SERVICE MANUAL TRANSTIG 300 AC/DC SECTION 12: POWER SOURCE ERROR CODES Description Possible Cause Remedy Remarks A The Welding Power A Let Power Source 1 E01 error code Weld current Source’s duty cycle cool down then displayed ceases. Buzzer has been exceeded.
  • Page 58 TRANSTIG 300 AC/DC SERVICE MANUAL E11 error code Primary supply Have an accredited Weld current ceases. displayed voltage is greater Cigweld Service Buzzer sounds Over Primary supply than the nominal Provider or a contstantly. voltage plus 10%. qualified electrician Error code E11...
  • Page 59 SERVICE MANUAL TRANSTIG 300 AC/DC E82 error code The Primary supply Have an accredited No weld current is displayed (input) voltage Cigweld Service available. Buzzer Rated voltage fluctuates and is Provider or a sounds constantly. selection circuit not stable. qualified electrician Switch machine OFF abnormality.
  • Page 60 TRANSTIG 300 AC/DC SERVICE MANUAL E94 error code The Welding Power Have an accredited Weld current ceases. displayed Source’s Cigweld Service Buzzer sounds Temperature sensor temperature Provider check or constantly. Switch TH1 for IGBTs or replace the machine OFF. sensors have sensor TH2 for malfunctioned.

  • Page 61: Advanced Troubleshooting

    SERVICE MANUAL TRANSTIG 300 AC/DC ADVANCED TROUBLESHOOTING 13.1 System-Level Fault Isola- ADVANCED TROUBLESHOOTING If you are here, all of the troubleshooting sugges- tions in Section 8-Basic Troubleshooting have tion either failed to resolve the faulty operation or have indicated that one or more of the subsystems If none of the suggestions provided in Section 8 within the power supply are defective.
  • Page 62 TRANSTIG 300 AC/DC SERVICE MANUAL ADVANCED TROUBLESHOOTING 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 dis- engaged from the front and rear panels.

  • Page 63: Verification And Remedy To The Indicated Error Codes

    SERVICE MANUAL TRANSTIG 300 AC/DC ADVANCED TROUBLESHOOTING 13.2.1 E01 "Over-Temperature at 6) Remove protection cover sheet by removing the plastic tabs. the primary 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 64: E02 "Over-Temperature At The Secondary Side

    TRANSTIG 300 AC/DC SERVICE MANUAL ADVANCED TROUBLESHOOTING 13.2.2 E02 "Over-Temperature at 13.2.3 E03 "Transformer Over-Cur- the secondary side" rent Failure" Cause Cause Occurs when an over-temperature condition of the Occurs when excessive current is detected flow- secondary IGBT and diode are detected.

  • Page 65: E04 "Torch Cable Failure

    SERVICE MANUAL TRANSTIG 300 AC/DC ADVANCED TROUBLESHOOTING 13.2.4 E04 "Torch Cable Failure" 13.2.6 E12 "Main Supply Under Volt- age" Cause Cause The combined length of the torch cable and the work cable is too long. Main supply voltage occurs at about 150V or less.

  • Page 66: E82 "Rated Voltage Selection Circuit Abnormality

    TRANSTIG 300 AC/DC SERVICE MANUAL ADVANCED TROUBLESHOOTING 13.2.8 E82 "Rated Voltage Selection c) Verify PCB4 (WK-4819) and replace it if neces- sary. Circuit abnormality" Check whether there are any abnormalities on the appearance of PCB4. Cause Replace PCB4. Refer to section 14.3.4.

  • Page 67: E94 "Thermistor Malfunction

    SERVICE MANUAL TRANSTIG 300 AC/DC ADVANCED TROUBLESHOOTING 13.3 13.2.11 E94 "Thermistor malfunction" Verification and Remedy to Failures without Indication Cause Codes Thermistors for detecting temperature of internal components have malfunctioned. Refer to Note on Section 13.02. Verification/Remedy 13.3.1 "Cooling Fan (FAN1) Failure"...

  • Page 68: Gas Valve Failure" (No Gas Flow Through Unit)

    TRANSTIG 300 AC/DC SERVICE MANUAL ADVANCED TROUBLESHOOTING 13.3.2 "Gas Valve Failure" (No Gas 13.3.3 "No Weld Output" flow through unit) When in High Frequency TIG (HF TIG) mode, if the High Frequency is not generated (present), refer to Cause "High Frequency Output Failure". Refer to section 13.3.5.

  • Page 69: Operating Panel Failure

    SERVICE MANUAL TRANSTIG 300 AC/DC ADVANCED TROUBLESHOOTING c) Verify the no-load voltage (OCV). Contact the manufacturer if you find any bro- (Applies to STICK, High Frequency TIG (HF ken connectors or a damaged wiring har- TIG) mode.) nesses. Refer to the section "Verification of No-load b) Verify the connection between PCB5 voltage (OCV)"...

  • Page 70: Fault Isolation Tests

    TRANSTIG 300 AC/DC SERVICE MANUAL ADVANCED TROUBLESHOOTING 13.4 b) Verify the connection between High Frequency Fault Isolation Tests (HF UNIT1) and the current limiting resistor (R2). 13.4.1 Preparation Verify the connection between HF UNIT1 and The following initial conditions must be met...

  • Page 71: Verification Of The Power Input Circuitry

    SERVICE MANUAL TRANSTIG 300 AC/DC ADVANCED TROUBLESHOOTING 13.5 Verification of the Power 3) Verify input voltage after the input switch (S1) using an AC voltmeter. (The capability of the Input Circuitry voltmeter should be more than 600VAC.) • Using an AC voltmeter, measure between CAUTION the points U2 and V2 on the input switch, S1.

  • Page 72: Supply Voltage

    TRANSTIG 300 AC/DC SERVICE MANUAL ADVANCED TROUBLESHOOTING 6) Verify bus voltage (the voltage of the electro- 2) On the PCB3 (WK-5548) and PCB6 (WK- lytic capacitor after rectification) using a DC 5549), measure the voltages according to the voltmeter. The capability of the DVM following table.

  • Page 73: Verification Of The Cooling Fan, Fan1, Drive Circuitry

    SERVICE MANUAL TRANSTIG 300 AC/DC ADVANCED TROUBLESHOOTING 3) If any of these voltages are not present or 2) Using the measurement taken above, follow are below a 10% tolerance, replace the the chart below for possible failure modes. PCB3 (WK-5548). Refer to section 14.3.3.

  • Page 74: Verification Of The Gas Valve, Sol1, Drive Circuitry

    TRANSTIG 300 AC/DC SERVICE MANUAL ADVANCED TROUBLESHOOTING 13.5.4 Verification of the Gas Valve, 13.5.5 Verification of the primary SOL1, Drive Circuitry Diode (D1) CAUTION CAUTION Before performing any portion of the procedure Before performing any portion of the procedure below, make certain the unit is placed in the initial below, make certain the unit is placed in the initial set up condition as described in section 13.4.1...

  • Page 75: Verification Of The Secondary Diode (D2-D7)

    SERVICE MANUAL TRANSTIG 300 AC/DC ADVANCED TROUBLESHOOTING 13.5.6 Verification of the secondary 1) Check whether there are any abnormalities on the appearance of PCB8-PCB11. Diode (D2-D7) 2) Verify the characteristic of the primary IGBT CAUTION (Q1-Q24), using a diode tester.

  • Page 76: Verification Of The Secondary Igbt (Q25-Q26)

    TRANSTIG 300 AC/DC SERVICE MANUAL ADVANCED TROUBLESHOOTING 13.5.8 Verification of the secondary 13.5.9 Verification of No-load Volt- IGBT (Q25-Q26) age (OCV) CAUTION CAUTION Before performing any portion of the procedure Before performing any portion of the procedure below, make certain the unit is placed in the initial below, make certain the unit is placed in the initial set up condition as described in section 13.4.1.
  • Page 77 SERVICE MANUAL TRANSTIG 300 AC/DC ADVANCED TROUBLESHOOTING b. Verify the no-load voltage (OCV) in High Fre- quency TIG mode. WARNING This welding mode produces high frequency and high voltage. Extra care shall be taken to prevent electric shock. 1) When in HF TIG mode, the unit will gener- ate high voltage.
  • Page 78 TRANSTIG 300 AC/DC SERVICE MANUAL THIS PAGE LEFT INTENTIONALLY BLANK 13-18 June 30, 2008...

  • Page 79: Maintenance

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 14.1 Maintenance List MAINTENANCE DWG No. Parts name Reference page Part No. 12- 7 W7001313 PCB2 Print Circuit Board (WK-5597) 12- 9 W7001314 PCB3 Print Circuit Board (WK-5548) 12- 10 10-6635 PCB4 Print Circuit Board (WK-4819)
  • Page 80 SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE DWG No. Parts name Reference page Part No. Print Circuit Board (WK-5493) PCB1 12- 6 W7001312 Print Circuit Board (WK-5549) PCB6 12- 11 W7001738 Print Circuit Board PCB8 (Q1-Q6) 12- 12 W7001318 (WK-5479) (Primary IGBT)
  • Page 81 TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE DWG No. Parts name Reference page Part No. CON1 Remote Socket 12- 28 W7001666 Primary Diode 12- 30 10-6769 Secondary Diode 12- 30 10-6629 Secondary Diode 12- 30 10-6629 Secondary Diode 12- 30 10-6629...
  • Page 82 SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE DWG No. Parts name Reference page Part No. Coupling Coil 12- 22 W7001382 Current Trans 12- 32 W7001304 Current Trans 12- 32 FAN1 Cooling Fan 12- 24 W7001307 FCH1 Reactor 12- 22 W7001681 HCT1...

  • Page 83: Service Tools

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 14.2 Service Tools 14.2.1 Tools and parts The tools and parts to be used for maintenance are shown by icons. Long Nose Philips Head Silicon Spanner C-Ring Pliers Snap Band Pliers Compound Screwdriver 14.2.2 Notes of disassembly and assembly...

  • Page 84: Replacement Procedure

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 14.3 Replacement Procedure 14.3.1 PCB1 (WK-5493) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB2 (WK-5597). [Reference page : 12-7] 3) Remove the diode (D1). [Reference page : 12-30] 4) Remove the current trans (CT2/CT3). [Reference page : 12-33] 5) Remove the gas tube.

  • Page 85: Pcb2 (Wk-5597)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 8) Remove the 18 screws and remove the PCB1 (WK-5493). 14.3.2 PCB2 (WK-5597) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the screw and then disconnect the four ground terminals. Disconnect the 19 connectors.

  • Page 86: Pcb3 (Wk-5548), Pcb7 (Wk-5550)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 4) Remove the six screws, three terminals and three connectors from the PCB2 (WK-5597). 5) Remove the two PCB supporters and then the PCB2 (WK-5597) and insulation sheet. 14.3.3 PCB3 (WK-5548), PCB7 (WK-5550) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB4 (WK-4819).
  • Page 87 TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 6) Remove the screw and then the four ground terminals. Remove the four screws and then remove the PCB3 and PCB7 unit. Disconnect the three connectors from the PCB7 (WK-5550). CN14 CN15 CN13 7) Disconnect the one connector and remove the two screws, and then remove the PCB7 (WK-5550) from the PCB3 (WK-5548).

  • Page 88: Pcb4 (Wk-4819)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 14.3.4 PCB4 (WK-4819) 1) Remove the Side Panel. [Reference page : 11-1] 2) Disconnect the two connectors. Remove the two screws and three connectors and remove the PCB4 (WK-4819). 14.3.5 PCB5 (WK-5551) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB6 (WK-5549).

  • Page 89: Pcb6 (Wk-5449)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 14.3.6 PCB6 (WK-5549) 1) Remove the Side Panel. [Reference page :11-1] 2) Disconnect the six connectors. CN21 CN17 CN20 3) Remove the three screws and five connectors. Remove the PCB6 (WK-5549). CN27 CN18 CN32...

  • Page 90: Pcb10, Pcb11 (Wk-5479) And Q13-Q24 "Primary Igbt

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 14.3.8 PCB10, PCB11 (WK-5479) and Q13-Q24 “Primary IGBT” 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the eight screws and four device clips. Remove the four connectors and six screws. Remove the PCB10 (WK-5479) and PCB11 (WK-5479).

  • Page 91: Pcb13 (Wk-5528)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 14.3.10 PCB13 (WK-5528) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the operation cover. 3) Remove the jog dial cap. Holding the jog dial down, loosen the screw and remove the jog dial.

  • Page 92: Pcb14 (Wk-5594) (T1-T2 "Main Trans Former")

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 5) Remove the one connector and two screws. Remove the PCB13 (WK-5528). 14.3.11 PCB14 (WK-5594) (T1-T2 “Main Trans former”) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the coupling coil (CC1). [Reference page : 12-23] 3) Remove the PCB16 (WK-5569).

  • Page 93: Pcb15 (Wk-5606)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 8) Remove the four screws from the PCB1 (WK-5477). Remove the seven terminals. The cables is drawn out. 9) Remove the four screws and two terminals from the bottom. Remove the two screws from the rear side and pull out the PCB14 (WK-5594).

  • Page 94: Pcb16 (Wk-5569)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 14.3.13 PCB16 (WK-5569) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the gas tube and two terminals. Remove the six connectors, two screws and two terminals. 3) Remove the four screws and then the PCB16 (WK-5569).

  • Page 95: Pcb20 (Wk-5499)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 4) Remove the three print circuit board supporters from the PCB17 (WK-5570). 14.3.15 PCB20 (WK-5499) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the gas tube from the front side. 3) Disconnect the two connectors.

  • Page 96: Pcb21 (Wk-4917)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 14.3.16 PCB21 (WK-4917) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the six screws from the switch (S1) and remove the six terminals. 3) Remove the four screws and then open the rear plate.

  • Page 97: Pcb22 (Wk-5022)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 5) Remove the three screws and the bus bar from the PCB21 (WK-4917). 14.3.17 PCB22 (WK-5022) 1) Remove the Side Panel. [Reference page : 11-1] 2) Disconnect one connector. Remove four screws and one terminal. Remove the PCB19 (WK-5022).

  • Page 98: Current Limiting Resistor (R6)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 14.3.18 Current Limiting Resistor (R6) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the high freguency unit (HF.UNIT1). [Reference page : 12-28] 3) Remove the screws and then remove the current limiting resistor (R6).

  • Page 99: Resistor (R7, R8)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 14.3.20 Resistor (R7, R8) 1) Remove the Side Panel. [Referance page : 11-1] 2) Remove four screws and three terminals. 3) Cut off one snap band and disconnect one connector. Remove the one screw.
  • Page 100 SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 5) Remove four screws and open the rear panel. 6) Remove four screws and six terminals. Remove the resistors (R7 and R8). 14-22 June 30, 2008...

  • Page 101: Coupling Coil (Cc1)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 14.3.21 Coupling Coil (CC1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the gas tube. Remove the two bolts, and one terminal. Remove the four screws and open the front cabinet.

  • Page 102: Primary Thermistor (Th1)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 7) Remove the one screw and one terminal. Remove the four screws and inductor (FCH1). 14.3.23 Primary Thermistor (TH1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Disconnect the one connector. Remove the one screw and then detach the primary thermistor (TH1).

  • Page 103: Secondary Thermistor (Th2)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 14.3.24 Secondary Thermistor (TH2) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB16 (WK-5569). [Reference page : 12-16] 3) Cut the three snap bands and disconnect the one connector. Remove the one screw and secondary thermister (TH2).

  • Page 104: Solenoid Valve (Sol1)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 3) Cut the one snap band and disconnect the one connector. CN11 4) Remove the two screws and detach the cooling fan (FAN1). Do not have the wrong direction of the fan when reinstalling.

  • Page 105: Main On/Off Switch (S1)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 3) Remove the C ring and detach the solenoid valve (SOL1). When reinstalling, make sure that the C ring seats in the solenoid valve groove. 14.3.27 Main ON/OFF Switch (S1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the six screws and six terminals.

  • Page 106: Remote Socket (Con1)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 14.3.28 Remote Socket (CON1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the reactor (L105). [Reference page : 12-36] 3) Disconnect the three connectors. Remove the one screw and four ground terminals.

  • Page 107: Hall Current Sensor (Hct1)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 3) Remove the two screws and detach the high freguency unit (HF. UNIT1). 14.3.30 Hall Current Sensor (HCT1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB16 (WK-5569). [Reference page : 12-16] 3) Remove the PCB20 (WK-5499).

  • Page 108: Primary Diode (D1)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 7) Remove the connector, three screws and one terminal. Remove the bus bar. Remove the hall current sensor (HCT1). 14.3.31 Primary Diode (D1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB3 (WK-5548). [Reference page : 12-8] 3) Remove four screws and three terminals.

  • Page 109: Secondary Diode (D2-D7)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 5) Remove two screws and remove the PCB22 unit. 6) Remove the six screws and 14 terminals. Remove the two screws and then detach the primary diode (D1). Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base.

  • Page 110: Secondary Igbt (Q25-Q26) And Pcb18-Pcb19

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 5) Remove the 12 screws and then detach the secondary diodes (D2, D3, D4, D5, D6, D7). Do not have the wrong direction of the diodes when reinstalling. Before installing a new diodes, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base.

  • Page 111: Current Trans (Ct2, Ct3)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 14.3.34 Current Trans (CT2, CT3) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove four screws and three terminals. 3) Cut off one snap band and disconnect one connector. Remove the one screw.

  • Page 112: Ring Core (L1)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 5) Remove the gas tube and two terminals. Remove the four screws and open the rear cabinet. 6) Cut the three snap bands and remove the connector from the PCB3 (WK-5548). Remove two screws and three terminals from the PCB1 (WK-5493).
  • Page 113 TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 3) Cut off one snap band and disconnect one connector. Remove the one screw. 4) Remove two screws and remove the PCB22 unit. 5) Remove the gas tube and two terminals. Remove the four screws and open the rear cabinet.

  • Page 114: Ring Core (L105)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 6) Remove the two screws and three terminals. Cut the snap band and remove the ring core (L1). 14.3.36 Ring Core (L105) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the operation cover.

  • Page 115: Reactor (L101)

    TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 4) Remove the ring core (L105). 14.3.37 Reactor (L101) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove four screws and remove the three ground cables. 3) Disconnect the connector CN1 on the PCB22. Remove the screw..

  • Page 116: Reactor (L102)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 4) Remove the PCB22 unit. 5) Cut the snap band. Remove the reactor (L101) from the Input cable. 14.3.38 Reactor (L102) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove four screws and three terminals.
  • Page 117 TRANSTIG 300 AC/DC SERVICE MANUAL MAINTENANCE 3) Cut off one snap band and disconnect one connector. Remove the one screw. 4) Remove two screws and remove the PCB22 unit. 5) Remove six screws, nine terminals and remove the reactor (L102).

  • Page 118: Reactor (L103)

    SERVICE MANUAL TRANSTIG 300 AC/DC MAINTENANCE 14.3.39 Reactor (L103) 1) Remove the Side Panel. [Reference page: 11-1] 2) Remove one screw and two terminals. 3) Remove four screws and open the rear panel. Remove one nut, one washer and one terminal.

  • Page 119: Appendix 1 Parts List

    TRANSTIG 300 AC/DC SERVICE MANUAL APPENDIX 1 PARTS LIST Equipment Identification How To Use This Parts List All identification numbers as described in the The Parts List is a combination of an illustra- Introduction chapter must be furnished when tion and a corresponding list of parts which ordering parts or making inquiries.
  • Page 120 SERVICE MANUAL TRANSTIG 300 AC/DC PAR TS LIST DWG No. Part No. Description Additional Information QTY. PCB13 W7001320 PCB, gen 3.1, IPS WK-5528 U01 ENCODER PCB PCB14 W7001435 PCB, gen 3.1, IPS WK-5594 01 TRANS PCB PCB15 W7001321 PCB, gen 3.1, IPS...
  • Page 121 TRANSTIG 300 AC/DC SERVICE MANUAL PARTS LIST DWG No. Part No. Description Additional Information QTY. p i l , s i , s i 10-6669 Post, 1 (M4-M5), gen 3.1, IPS EBA424900 (M4-M5) W7001358 Post, 11 (M5-M5), gen 3.1, IPS...
  • Page 122 SERVICE MANUAL TRANSTIG 300 AC/DC PARTS LIST June 30, 2008...
  • Page 123 TRANSTIG 300 AC/DC SERVICE MANUAL PARTS LIST 4 96 June 30, 2008...

  • Page 124: Appendix 2 Connection Wiring Guide

    SERVICE MANUAL TRANSTIG 300 AC/DC APPENDIX 2 CONNECTION WIRING GUIDE APPENDIX 2 Connection Wiring Guide Destination Destination PCB2 PCB4 PCB3 CN33 PCB6 CN20 PCB2 PCB3 PCB4 PCB2 PCB6 HCT1 PCB2 PCB6 PCB2 PCB21 PCB6 PCB16 PCB3 PCB6 CN17 PCB20 FAN1...
  • Page 125 TRANSTIG 300 AC/DC SERVICE MANUAL THIS PAGE LEFT INTENTIONALLY BLANK June 30, 2008...

  • Page 126: Appendix 3 Interconnect Diagram

    SERVICE MANUAL TRANSTIG 300 AC/DC APPENDIX 3 INTERCONNECT DIAGRAM INTERCONNECT DIAGRAM APPENDIX 3 INTERCONNECT DIAGRAM TB13 TB10 TB11 TB14 TB15 TB12 PCB8 PCB10 PCB1 K(7) Main IGBT IGBT G(6) Circuit Gate Gate L102 Board Circuit Circuit [WK-5493] Board Board R(3)
  • Page 127 TRANSTIG 300 AC/DC SERVICE MANUAL INTERCONNECT DIAGRAM PCB15 DIODE Snubber PCB17 Circuit Board IGBT Snubber [WK-5606] Circuit Board 1 2 3 PCB14 [WK-5570] +Output TRANS FCH1 Board Terminal [WK-5594] TB35 HCT1 PCB18 PCB19 TB33 IGBT Gate IGBT Gate Circuit Board...

  • Page 128: Appendix 4 Diode Testing Basics

    SERVICE MANUAL TRANSTIG 300 AC/DC APPENDIX 4 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. 1. Locate the diode module to be tested.
  • Page 129 200Pi, 200AC/DC hand pendant only Hand pendant OTD 10/2005 300Pi, 300AC/DC, 400i hand pendant only OTD 10/4016 200Pi, 200AC/DC Foot controller OTD 10/2007 300Pi, 300AC/DC, 400i CIGWELD COMET argon regulator 301527 Regulator only CIGWELD COMET argon flowmeter 0-15 lpm 301710 Flowmeter only CIGWELD COMET argon flowmeter...

  • Page 130: Cigweld Limited Warranty

    “Purchaser” that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the CIGWELD products as stated below, CIGWELD shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with CIGWELD’s specifications, instructions,...
  • Page 131 CIGWELD. 4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supply of goods which are not of a kind ordinarily acquired for personal, domestic or household use or consump- tion to any one or more of the following (the choice of which shall be at the option of CIGWELD).
  • Page 132 Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the war- ranty period extend more than the time stated plus one year from the date CIGWELD delivered the product to the Accredited Distributor. Unless otherwise stated the warranty period includes parts and labour. CIGWELD reserves the right to request documented evidence of date of purchase.

  • Page 133: Global Customer Service Contact Information

    48000 Rawang Selangor Darul Ehsan 800-426-1888 West Malaysia Fax: 800-535-0557 Telephone: 603+ 6092 2988 Email: sales@thermalarc.com Fax : 603+ 6092 1085 Thermadyne Canada Cigweld, Australia 2070 Wyecroft Road 71 Gower Street Oakville, Ontario Preston, Victoria Canada, L6L5V6 Australia, 3072 Telephone: (905)-827-1111...
  • Page 134 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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