CIGWELD Transtig 220 AC/DC Service Manual
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CIGWELD Transtig 220 AC/DC Service Manual

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220AC/DC
300AC/DC

Service Manual

TRANSTIG

welDING MAChINe

Revision: AB
Operating Features:
Art # A-12276
Issue Date: March 4, 2014
Manual No: 0-5292

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Summary of Contents for CIGWELD Transtig 220 AC/DC

  • Page 1: Welding Machine

    220AC/DC TRANSTIG 300AC/DC welDING MAChINe Art # A-12276 Service Manual Revision: AB Issue Date: March 4, 2014 Manual No: 0-5292 Operating Features:...
  • Page 2 To locate your nearest distributor or Accredited Service Provider call +1300 654 674, or visit us on the web at www.cigweld.com.au This Service Manual has been designed to instruct you on the correct use and operation of your CIGWELD product.
  • Page 3 Manufacturer assumes no liability for its use. Welding Power Supply Service Manual Number 0-5292 for: Cigweld Transtig 220AC/DC Inverter Plant Part Number W1007220 Cigweld Transtig 220AC/DC Power Source (Packed) Part Number W1007221 Cigweld Transtig 300AC/DC Power Source (Packed) Part Number W1007301 Published by:...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ........1-1 1.01 Arc Welding Hazards ..................1-1 1.02 Principal Safety Standards ................1-5 1.03 Servicing Hazards ................... 1-6 1.04 EMF Information ..................... 1-8 SECTION 2: INTRODUCTION ..................2-1 2.01 How To Use This Manual ................
  • Page 5 TABLE OF CONTENTS SECTION 5: ThEORY OF OPERATION ................5-1 5.01 Inverter Design ....................5-1 SECTION 6: TROUBLEShOOTING ................6-1 6.01 Basic Troubleshooting ..................6-1 6.02 Power Source Faults ..................6-2 6.03 Advanced Troubleshooting ................6-3 6.04 Test Equipment and Tools for Troubleshooting and Servicing......6-4 6.05 Visually Inspect ....................

  • Page 7: Arc Welding Safety Instructions And Warnings

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 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.
  • Page 8 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 2. Wear approved safety glasses. Side shields recom- mended. WARNING 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the ARC RAYS can burn eyes and skin; NOISE arc.
  • Page 9 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 3. Remove all flammables within 10M of the welding arc. If this is not possible, tightly cover them with approved covers. WARNING 4. Be alert that welding sparks and hot materials from FUMES AND GASES can be hazardous to welding can easily go through small cracks and your health.
  • Page 10 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 5. Use only correct shielding gas cylinders, a very large volume of scientific findings based on regulators, hoses, and fittings designed for the experiments at the cellular level and from studies specific application; maintain them and associated with animals and people which clearly establish that parts in good condition.

  • Page 11: Principal Safety Standards

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 12: Servicing Hazards

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 1.03 Servicing hazards • Use proper static-proof bags and boxes to store, move, or ship PC boards. WARNING WARNING The symbols shown below are used throughout this manual to call attention to FIRE OR EXPLOSION hazard. and identify possible hazards. When you • Do not place unit on, over, or near combustible see the symbol, watch out, and follow the surfaces.
  • Page 13 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE WARNING FALLING UNIT can cause injury. • Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. • Use equipment of adequate capacity to lift and support unit. • If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. WARNING MOVING PARTS can cause injury, • Keep away from moving parts such as fans.

  • Page 14: Emf Information

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 1.04 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.”...

  • Page 15: Introduction

    Use care to avoid damaging the Additional copies of this manual may be purchased equipment when using bars, hammers, etc., to un- by contacting CIGWELD at the address and phone crate the unit. number for your location listed in the inside back cover of this manual.

  • Page 16: Symbol Chart

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 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- Welding Gun Dangerous Voltage Transformer-Rectifier...

  • Page 17: Description

    • Shielding Gas Hose Assembly pairs be carried out by appropriately qualified persons • Shoulder Strap approved by CIGWELD. Advice in this regard can • Product Bag be obtained by contacting an Accredited CIGWELD • Operating Manual Distributor.
  • Page 18 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Notes INTRODUCTION Manual 0-5292...

  • Page 19: Installation, Operation And Setup

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE SECTION 3: INSTALLATION, OPERATION AND SETUP 3.01 Duty Cycle The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used.

  • Page 20: Specifications

    Due to large variations in performance and specifications of different brands and types of generators, Cigweld cannot guarantee full welding output power or duty cycle on every brand or type of generator. Some small generators incorporate low cost circuit breakers on their outputs. These circuit breakers usually will have a small reset button, and will trip much faster than a switchboard type circuit breaker.

  • Page 21: Environment

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 3.03 Environment These units are designed for use in environments with increased hazard of electric shock as outlined in AS 60974.1 and AS 1674.2. A. Examples of environments with increased hazard of electric shock are: 1.

  • Page 22: Electromagnetic Compatibility

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 3.07 Electromagnetic Compatibility B. Assessment of Area Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following WARNING shall be taken into account Extra precautions for Electromagnetic 1.
  • Page 23 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE C. Methods of Reducing Electromagnetic 5. Earthing of the Workpiece Emissions Where the workpiece is not bonded to earth 1. Mains Supply for electrical safety, nor connected to earth because of it’s size and position, e.g. ship’s Welding equipment should be connected to the hull or building steelwork, a connection mains supply according to the manufacturer’s...
  • Page 24 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Notes INSTALLATION, OPERATION AND SETUP Manual 0-5292...

  • Page 25: Operation

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE SECTION 4: OPERATION 4.01 TRANSTIG 220AC/DC and 300AC/DC Power Source Controls, Indicators and Features A-12033 Figure 4-1: Controls on Front and Rear Panel 1. Electrode Welding Terminal Electrode Welding Terminal. Welding current flows from the Power Source via heavy duty bayonet type terminals.
  • Page 26 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 3. Worklead Welding Terminal Worklead Welding Terminal. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the...
  • Page 27 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE A-12034 Figure 4-3: 14 Pin Remote Control Socket Socket Pin Part Number / Description Trigger Switch Input Trigger Switch Input Remote Control 5k ohm Potentiometers Maximum Remote Control 5k ohm Potentiometers Wiper Remote Control 5k ohm Potentiometers Minimum Remote Control Enable (Short to common to enable remote control) Common Remote 2T (short to common to select remote control active in 2T operation mode only)
  • Page 28 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 10. Welding Mode Button Press the MODE button to select the Welding Process mode. Available modes are GTAW 2T, GTAW 4T, GTAW Spot, GTAW Pulse 2T, GTAW Pulse 4T, and MMAW. 11. MMAW indicator light This light will illuminate when the power source is in MMAW welding mode.
  • Page 29 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 23. FORWARD Welding Parameter Button Press the FORWARD welding parameter button to scroll right through the available welding parameters. 24. Multi Function Control Turn the MULTI FUNCTION CONTROL to adjust the available welding parameters. When not welding, the Multi Function Control is used to adjust all welding parameters, including welding amps.
  • Page 30 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 30. mm indicator light This light will illuminate when “mm” are being shown on the Digital Volt meter Display for electrode diameter size. 31. hOLD indicator light This light will illuminate when the HOLD function is active on the Digital Display at the completion of welding. 32.
  • Page 31 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 41. Initial Current amps (GTAW) and hot Start amps (MMAW) indicator light This light will illuminate when the Initial Current Amps Welding Parameter is selected in GTAW mode, or when Hot Start Amps Welding Parameter is selected in MMAW mode. 42.

  • Page 32: Setup For Tig (Gtaw) Welding

    4.12) then connect the shielding gas hose from the regulator/flowmeter outlet gas INLET on the rear of the Transtig 220 AC/DC or 300 AC/DC Power Source. Connect the gas hose from the TIG torch to the gas OUTLET on the front of the Transtig 220 AC/DC or 300 AC/DC Power Source.
  • Page 33 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE A-12037 Figure 4-6: Setup for TIG Welding Manual 0-5292 OPERATION...
  • Page 34 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE • First, select a Welding Type by pressing the Weld Type (17) button. Welding Type Welding Type Selection DC HF TIG AC Lift TIG DC Lift TIG AC HF TIG • Then, select a Welding Mode by pressing the WELDING MODE (10) button. Welding Welding Mode Selection Mode 2T (Normal Mode) 4T (Latch Mode) Tip Tronic (used to recall saved jobs)

  • Page 35: Transtig 220Ac/Dc And 300Ac/Dc - Tig (Gtaw) Programming Mode

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 4.03 TRANSTIG 220AC/DC and 300AC/DC - TIG (GTAW) Programming Mode A-12039 Figure 4-7: TIG Programming Mode • Press the WELDING MODE (10) button to select the appropriate GTAW mode. Several GTAW operating modes are available. 2T (normal mode). The 2T LED (16) will illuminate. 4T (latch mode). The 4T LED (15) will illuminate. Tiptronic.
  • Page 36 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE • Press the BACK button (22) or FORWARD button (23) until the Base Current A1 Led (44) is illuminated. Use the Multi Function Control (24) to adjust the Welding Current for the Electrode size being used. If the Welding Current does not match the normal operating range of the electrode the Electrode Diameter Out-of-Range indictor Led (50) will illuminate.
  • Page 37 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Up Slope Time This parameter operates in 0 - 99% GTAW modes only and is used to set the time for the weld current to ramp up from Initial current to welding current. Welding Current A1 Transtig 220AC/DC 3 - 220 A Transtig 300AC/DC...
  • Page 38 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE AC balance (AC Output Mode only) This parameter operates in AC 10 – 90% positive GTAW modes and is used to set welding current the penetration to cleaning action ratio for the AC weld current. Generally WAVE BALANCE is set to 50% for AC STICK welding.
  • Page 39 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE AC BALANCE is used for aluminium welding in AC HF GTAW or AC LIFT GTAW operating modes It is used to set the ratio of penetration to cleaning action for the AC GTAW welding arc. Maximum weld penetration is achieved when the AC BALANCE is set to 10%.

  • Page 40: Tig (Gtaw) Welding Secondary Parameters

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 4.04 TIG (GTAW) Welding Secondary Parameters Secondary parameters are available. These are required to be set separately. • Press and hold the WELDING MODE (10) button then press the SAVE (54) button. • Press the BACK button (22) or FORWARD button (23) to select the Parameter. • Use the Multi Function Control (24) to adjust the parameter. • Note that some parameters are only available in certain welding modes. Note that even during welding, these settings can be adjusted and changed. Parameter Range LED Code...

  • Page 41: Gtaw Spot Welding Mode With Dwell Time (Stitch Mode)

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 4.05 GTAW Spot Welding Mode with DWELL Time (Stitch Mode) A-12040 Figure 4-8: GTAW Spot Welding Mode with DWELL Time To enable Spot Welding with Dwell Time (Stitch welding) the parameter “PSP” needs to be set to ON (refer secondary parameters) it is possible to have automated spot welds with this Stitch function.

  • Page 42: Tip Tronic Operation

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 4.06 Tip Tronic Operation In GTAW modes, up to 100 jobs can be saved. These are arranged as 10 jobs numbers, in 10 job sets. These are shown on the meter displays. The first number on the display is the job set, the second is the job number.
  • Page 43 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Load a TipTronic Job • Using the Welding Mode button (10) select TipTronic mode (14). • Use the Multi Function Control (24) to select the job set number and the job number. Set a TipTronic Job as Inactive • Press the SAVE button (54). The display will how the Job Number identification, the job set and job number. • Use the Multi Function Control (24) to select the job set number and the job number. • Press the GAS button (52). •...

  • Page 44: Setup For Stick (Mmaw) Welding

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 4.07 Setup for STICK (MMAW) Welding A. Connect the Electrode Holder lead to the Electrode welding terminal (top). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
  • Page 45 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE A-12042_AB Figure 4-10: Setup for Manual Arc Welding. • First, select Stick Mode by pressing the Welding Mode (10) button. Welding Type Welding Mode Selection Stick Mode • Then, select Welding Type by pressing the welding Type (17) button. Welding Type Welding Type Selection DC Negative Stick Manual 0-5292 4-21 OPERATION...

  • Page 46: Transtig 220Ac/Dc And 300Ac/Dc- Stick (Mmaw)Programming Mode

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Welding Type Welding Type Selection DC Positive Stick 4.08 TRANSTIG 220AC/DC and 300AC/DC- STICK (MMAW)Programming Mode A-12043 Figure 4-11: Stick Programming Mode • Press the WELDING MODE (10) button to select MMAW mode. The MMAW Led (11) will illuminate. • Following MMAW operating modes are available. DC Negative mode. DC Negative Led (19) will illuminate. DC Positive mode.
  • Page 47 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE MMAW Electrode Diameter (mm) Nominal Welding Current (A) 20 - 40 Amps 35 - 60 Amps 45 - 100 Amps 75 - 140 Amps 130 -190 Amps 180 - 260 Amps (not selectable on Transtig 220AC/DC) Table 4-7: Normal Welding Current for MMAW Electrode sizes Parameter Range...
  • Page 48 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE A-12044 Figure 4-12: Stick Programming Mode Press and hold the WELDING MODE (10) button then press the SAVE (54) button. The Arc Dynamic Parameter is selected. In the left hand AMPS display dAr is displayed. In the right hand VOLTS display, the value of the parameter is displayed.

  • Page 49: User Specific Menus And Dead Man Switch Mode

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 4.09 User Specific Menus and Dead Man Switch Mode A-12045 Figure 4-13: User Specific Menus and Dead Man Switch Mode Switch off the power to the unit. Press and hold the BACK Welding Parameter Button (22) . Switch on the power to the unit.

  • Page 50: Mmaw (Stick) Dead Man Switch Mode

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE C08 – Foot Control Minimum Current (GTAW AC mode only) When set to “ON” the increased Foot Control Minimum current is disabled and the minimum current on any electrode is 5A. When set to “OFF” the increased Foot Control Minimum current is enabled.
  • Page 51 Approval from a mine site manager, or work site manager must be obtained in writing before the Dead Man Switch function is altered. Only a suitably qualified electrical tradesperson or Cigweld Service Agent should make any changes to the Power Source.

  • Page 52: Special Function

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 4.11 Special Function Soft Reset • Press and hold the BACK button (22). • Press the SAVE button (54). • All control panel LED’s will light up briefly to confirm the Soft Reset has been completed,. A-12046 Figure 4-15: Soft Reset Master Reset WARNING All saved TipTronic jobs will be erased. All welding and secondary parameters will be restored to the factory setting. •...
  • Page 53 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Control Panel Test • Press and hold the BACK button (22). • Press the FORWARD button (23). • All control panel LED’s and meter displays will light up for approximately 4 seconds. A-12048 Figure 4-17: Control Panel Test Fan Test • Press and hold the BACK button (22). • Press the WELDING TYPE button (17). • The fan will run for approximately 30 seconds. • If the BACK button (22) and WELDING TYPE button (17) are pressed again while the fan is running, the fan test is halted. A-12049 Figure 4-18: Fan Test Manual 0-5292 4-29 OPERATION...
  • Page 54 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Water Pump Test Only for water pump with Net Connection interface • Press and hold the FORWARD button (22). • Press the WELDING TYPE button (17). • The Water Cooler (Net Connection type) will run for approximately 30 seconds. If there is an error, or no pump is connected, the error message will be displayed after approximately 5 seconds. A-12050 Figure 4-19: Water Pump Test OPERATION...

  • Page 55: Information Messages

    Switch machine off, EEProm is faulty then back on. Perform a master reset. If the problem continues have an Accredited CIGWELD Service Provider check the power source. EEProm read / write error Communication with Switch machine off, EEProm is faulty then back on.

  • Page 56: Error Messages

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 4.13 Error Messages If a message has been displayed, have an Accredited CIGWELD Service Provider check the power source. Message Code Error Cause Possible Remedy Thermal Overload of Duty Cycle has been Leave the power source...
  • Page 57 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Temperature Sensor Defective Thermal H a v e a n A c c r e d i t e d Transformer Sensor C I G W E L D S e r v i c e Provider check the power source Temperature Sensor...

  • Page 58: Shielding Gas Regulator Operating Instructions

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 4.14 Shielding Gas Regulator Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Regulator Safety This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.
  • Page 59 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Installation 1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices and damage seats before connecting the regulator. Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition.
  • Page 60 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Adjusting Flow Rate Art: A-05088_AB Figure 4-21: Adjust Flow Rate With the regulator ready for operation, adjust working flow rate as follows: 1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate.

  • Page 61: Foot Control, Part No. W4015800 (Optional Accessory)

    Table 4-13: 8 Pin Socket Description The CIGWELD Foot Control is a foot operated switch and potentiometer which starts and stops the welding process and controls welding current through operation of the foot pedal. Refer to list below for compatible Cigweld power sources.
  • Page 62 50%. Should 100% output be required, the respective front panel control must be set to 100% or maximum, in which case the remote device will then be able to control between 1-100% output. This foot control is compatible with the following Cigweld power sources: WeldSkill 200AC/DC Part No: W1006202...

  • Page 63: Theory Of Operation

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE SECTION 5: ThEORY OF OPERATION 5.01 Inverter Design What does the word inverter mean? The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the incoming AC to DC, and then the transistors create a higher frequency AC. The higher frequency AC then goes on to a much smaller main transformer than in a conventional power supply.
  • Page 64 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Notes THEORY OF OPERATION Manual 0-5292...

  • Page 65: Troubleshooting

    If major complex subassemblies are faulty, then the Welding Power Source must be returned to an ac- credited CIGWELD Service Provider for repair. The basic level of troubleshooting is that which can be performed without special equipment or knowledge.

  • Page 66: Power Source Faults

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 6.02 Power Source Faults The following table is a guide for analysing problems and making repairs to the Power Source. Refer also to the error codes for more information. Fault Possible Cause Remedy There is no weld output The main Power Switch is set to OFF Set main Power Switch to ON and all front panel displays...

  • Page 67: Advanced Troubleshooting

    TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE Error Code E06-00 is The welding output DC voltage is Check the power source internal- displayed too high ly. The control board may need to be replaced W7006305 (Transtig 220ac/dc) W7006330 (Transtig 300ac/dc) Error Code E09-00 is The power source is measuring an Check the shunt &...

  • Page 68: Test Equipment And Tools For Troubleshooting And Servicing

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 6.04 Test Equipment and Tools for Troubleshooting and Servicing Art # A-09849 Figure 6-1: Test Equipment and Tools • Digital Multimeter • DC clip-on ammeter • Screwdriver and spanner • CRO (20 Mhz bandwidth) & isolating transformer 6.05 Visually Inspect Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning or arcing of PCB, transformers, switches, or rectifier when a failure occurs.

  • Page 69: Temperature Monitoring

    TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE 6.06 Temperature Monitoring Three NTC Thermistors are used to monitor internal temperatures. An NTC thermistor has a lower resistance as its temperature increases. The Transformer, Primary Power Module and the EMC Mains Filter board are monitored.

  • Page 70: Control Board Power Supply Monitoring

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 6.07 Control Board Power Supply Monitoring The main control board provides the internal control power supplies for the whole power source. Art # A-12278 Figure 6-3: Control Board Power Supply Monitoring If an internal supply voltage is out of range, the power source will stop and the error code E14 will be displayed. Internal Supply Voltage Lower Limit Upper Limit...

  • Page 71: Main Dc Bus Voltage Monitoring

    TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE 6.08 Main DC Bus Voltage Monitoring The main DC Bus is monitored by the control board. TRANSTIG 220AC/DC TRANSTIG 300AC/DC Art # A-12279 Figure 6-4: Main DC Bus Voltage Monitoring If the DC Bus voltage is out of range, the power source will stop and an error code will be displayed. Mains Voltage DC Bus Voltage Internal Supply Voltage...

  • Page 72: Welding Output Voltage Monitoring

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 6.09 Welding Output Voltage Monitoring The Welding Output Voltage is monitored by the control board. Art # A-12280 Figure 6-5: Welding Output Voltage Monitoring During the start up sequence, if the offset voltage of the shunt resistor is too high, the error code E15-00 is displayed.

  • Page 73: Remote Control Interface

    TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE 6.10 Remote Control Interface The Remote Control Interface is for connecting a hand or foot remote control. It is also possible to use the interface for simple automation. Art # A-12281 Figure 6-6: Remote Control Interface If there is a short circuit between connector pins, the power source will stop and the error code E10 will be displayed.

  • Page 74: Water Cooler Interface

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 6.11 Water Cooler Interface The Water Cooler Interface is for connecting a water cooler. If a water cooler is connected, C02 in the user specific menu needs to be set to OFF. If the flow rate is less than 0.3 l/m or no water cooler is connected, the power source will stop and the error code E05 will be displayed.

  • Page 75: Transtig 220Ac/Dc Pcb Connectors

    TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE 6.13 TRANSTIG 220AC/DC PCB Connectors Main Control PCB (W7006305) This board controls the logic functions of the welding sequence. It also monitors the internal supply voltages, controls the start up sequence, controls the fans, and monitors the mains supply and welding voltages. If any LED should indicate a malfunction has occurred, and resetting the mains power does not clear the fault, the board should be replaced.
  • Page 76 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Positive Meter Lead Negative Meter Signal Measurement connects to Lead connects to DC Bus Voltage X10/1 X10/3 336 VDC +/-10% X10/2 X10/3 336 VDC +/-10% Mains Supply Input X11/2 X11/1 3 – 15 VDC Fan #1 Supply Voltage Fan #2 Supply Voltage X13/2...
  • Page 77 TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE Primary Inverter & PFC PCB (W7006306) This board comprises the PFC input stage, the main DC Bus capacitance, the input current sensor as well as the inverter bridge power module IGBT’s. Art # A-12286 Figure 6-10: Primary Inverter &...
  • Page 78 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Power Module and PFC IGBT internal connections Art # A-12287 Figure 6-11: Power Module and PFC IGBT Internal Connections, TRANSTIG 220AC/DC Positive Meter Lead Negative Meter Signal Measurement connects to Lead connects to IGBT Gate 1 47kΩ...
  • Page 79 TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE Secondary Rectifier PCB (W7006304) This board comprises the secondary rectifier and the IGBT’s for polarity selection and AC/DC output. Art # A-12288 Figure 6-12: Secondary Rectifier PCB, TRANSTIG 220AC/DC Output Diode and Polarity Selection IGBT internal connections Art # A-12291 Figure 6-13: Output Diode and Polarity Selection IGBT Internal Connections, TRANSTIG 220AC/DC Manual 0-5292...
  • Page 80 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Positive Meter Lead Negative Meter Signal Measurement connects to Lead connects to IGBT Gate 1 47kΩ +/-10% 47kΩ +/-10% IGBT Gate 2 IGBT Gate 3 47kΩ +/-10% IGBT Gate 4 47kΩ +/-10% Temperature Sensor Power 68kΩ...

  • Page 81: Transtig 300Ac/Dc Pcb Connectors

    TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE 6.14 TRANSTIG 300AC/DC PCB Connectors Main Control PCB (W7006330) This board controls the logic functions of the welding sequence. It also monitors the internal supply voltages, controls the start up sequence, controls the fans, and monitors the mains supply and welding voltages. Art # A-12290 Figure 6-15: Main Control PCB, TRANSTIG 300AC/DC If any LED should indicate a malfunction has occurred, and resetting the mains power does not clear the fault,...
  • Page 82 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Positive Meter Lead Negative Meter Signal Measurement connects to Lead connects to DC Bus Voltage X10/1 X10/3 325 VDC +/-10% Mains Supply Input X10/2 X10/3 320 VDC +/-10% Fan #1 Supply Voltage X11/2 X11/1 3 –...
  • Page 83 TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE EMC PCB NEFI-1300 (W7006324) This board comprises the mains EMC filter, as well as the soft start circuitry. Art # A-12292 Art # A-12293 Figure 6-16: EMC PCB, TRANSTIG 300AC/DC Manual 0-5292 6-19 Troubleshooting...
  • Page 84 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Primary Inverter PCB (W7006322) This board comprises, the main DC Bus capacitance, the input current sensor as well as the inverter bridge power module IGBT’s. Art # A-12294 Figure 6-17: Primary Inverter PCB, TRANSTIG 300AC/DC Troubleshooting 6-20 Manual 0-5292...
  • Page 85 TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE Power Module IGBT Internal Connections Art # A-12295 Figure 6-18: Power Module IGBT Internal Connections, TRANSTIG 300AC/DC Positive Meter Lead Negative Meter Signal Measurement connects to Lead connects to IGBT Gate 1 47kΩ +/-10% IGBT Gate 2 47kΩ...
  • Page 86 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Secondary Rectifier PCB (W7006323) This board comprises the secondary rectifier and the IGBT’s for polarity selection and AC/DC output. Art # A-12296 Figure 6-19: Secondary Rectifier PCB, TRANSTIG 300AC/DC WARNING In the positions where the cables are attached, the LONGER screws must be used. The rest of the screws are the SHORT ones.
  • Page 87 TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE Positive Meter Lead Negative Meter Signal Measurement connects to Lead connects to IGBT 47kΩ +/-10% IGBT 0.2 – 0.9 VDC > 1kΩ IGBT Diode 0.2 – 0.9 VDC Diode 0.2 – 0.9 VDC Diode >...

  • Page 88: Main Circuit Description

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 6.15 Main Circuit Description Transtig 220AC/DC Art # A-12297 Figure 6-22: Main Circuit Description, Transtig 220AC/DC Transtig 300AC/DC Art # A-12298 Figure 6-23: Main Circuit Description, Transtig 300AC/DC Troubleshooting 6-24 Manual 0-5292...
  • Page 89 TRANSTIG 220AC/DC AND 300 AC/DC POWER SOURCE WARNING Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two minutes for capacitors to discharge after disconnection from mains supply voltage. The mains supply voltage is connected via a switch to the input rectifiers on the main inverter board through an inbuilt soft start and EMC filter on the Input EMC filter board.
  • Page 90 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Notes Troubleshooting 6-26 Manual 0-5292...

  • Page 91: Key Spare Parts

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE SECTION 7: KEY SPARE PARTS 7.01 220AC/DC Power Source A-12051_AB Figure 7-1: Transtig 220AC/DC Spare Parts Manual 0-5292 KEY SPARE PARTS...
  • Page 92 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Transtig 220AC/DC Spare Parts Item Part Number Description W7006300 Cover Control Panel W7006301 Gas Outlet, Front Panel W7006302 Gas inlet, Rear Panel W7006303 Knob, Control W7006304 PCB Secondary Rectifier W7006305 PCB Control W7006306 PCB Primary Inverter W7006307 PCB Display W7006308...

  • Page 93: 300Ac/Dc Power Source

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE 7.02 300AC/DC Power Source A-12052_AB Figure 7-2: Transtig 300AC/DC Spare Parts Manual 0-5292 KEY SPARE PARTS...
  • Page 94 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Transtig 300AC/DC Spare Parts Item Part Number Description W7006300 Cover Control Panel W7006301 Gas Outlet, Front Panel W7006302 Gas inlet, Rear Panel W7006303 Knob, Control W7006323 PCB Secondary Rectifier W7006330 PCB Control W7006322 PCB Primary Inverter W7006307 PCB Display W7006324...

  • Page 95: Appendix A: Circuit Diagram Of 220Ac/Dc

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE APPENDIX A: CIRCUIT DIAGRAM OF 220AC/DC A-12053 X11/1 X12/1 X11/2 X13/1 X12/2 X4/2 X12/3 X13/2 X4/4 X12/4 X15/1 X4/3 X12/5 X4/1 X12/6 X15/2 X12/8 LP10 LP11 PFC1 X2/1 X10/1 X2/2 X10/2 X2/3 X10/3 X2/4 X10/4 X18/1 +VCC...

  • Page 96: Appendix B: Circuit Diagram Of 300Ac/Dc

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE APPENDIX B: CIRCUIT DIAGRAM OF 300AC/DC A-12054 X12/1 X11/1 X12/2 X11/2 X3/1 X12/3 X13/1 X3/2 X12/4 X12/5 X3/4 X12/6 X3/5 X12/7 X13/2 X3/6 X12/8 X15/1 X2/1 X10/1 X2/2 X10/2 X2/3 X10/3 X15/2 LP1A LP2A LP3A X18/1 X18/2...

  • Page 97: Appendix C: Optional Accessories

    TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE APPENDIX C: OPTIONAL ACCESSORIES Part Number Description W4014604 TIG Torch 26F with 4m lead and remote control BGSAK2 TIG Torch accessory kit W4015800 Foot Control with 8m lead 646757 Electrode holder & Work Lead Set 5m 400A 50mm DINSE 646325 Electrode Holder &...
  • Page 98 TRANSTIG 220AC/DC AND 300AC/DC POWER SOURCE Notes APPENDIX Manual 0-5293...
  • Page 99 WELD whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of CIGWELD is authorized to change this warranty in any way or grant any other warranty.
  • Page 100 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 consumption to any one or more of the following (the choice of which shall be at the option of CIGWELD).
  • Page 101 Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the warranty 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 102 To make a claim under the warranty, take the product (with proof of purchase from a Cigweld Accredited Seller) to the store where you purchased the product or contact Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider.

  • Page 103: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Victor Technologies, China CIGWELD, Australia 71 Gower Street No 100 Lao Hongjing Rd Preston, Victoria Minhang District Shanghai, PR, 200235 Australia, 3072 Telephone: 61-3-9474-7400 Telephone: 86-21-64072626 Fax: 86-21-64483032 Fax: 61-3-9474-7391 Email: enquiries@cigweld.com.au Victor Technologies Asia Sdn Bhd...
  • Page 104 Asia Pacific Regional Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX: +61 3 9474 7391 Email: enquiries@cigweld.com.au www.cigweld.com.au...

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