CIGWELD 200 Pi Transtig Service Manual

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INVERTER ARC WELDER

240

50 60

INVERTER

200 Pi

Service Manual

TRANSTIG

Revision No: AA Issue Date: March 31, 2008 Manual No.: 0-4967 Operating Features:

WE APPRECIA TE YOUR BUSINESS!

Congratulations on your new Cigweld product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1300-654-674, or visit us on the web at www.cigweld.com.au.

This Operating Manual has been designed to instruct you on the correct use and operation of your CIGWELD product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

CIGWELD is the Market Leading Brand of Arc Welding Products for Thermadyne Industries Inc. We are a mainline supplier to major welding industry sectors in the Asia Pacific and emerging global markets including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through marketleading, dependable brands that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced products to achieve a safer working environment for industry operators.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Transtig 200Pi Inverter Arc Welder Instruction Manual Number 0-4967 for: Catalog Number 700720

Published by: Thermadyne Industries, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermadyne.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: March 31, 2008 December 21, 2007

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

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

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

1.02 PRINCIPAL SAFETY STANDARDS .................................................................. 1-5

1.03 DECLARATION OF CONFORMITY ................................................................... 1-6

SECTION 2:

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

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

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

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 Symbol Chart ................................................................................................. 2-2

2.05 Description ..................................................................................................... 2-3

2.06 Functional Block Diagrams ............................................................................. 2-4

2.07 Transporting Methods .................................................................................... 2-4

2.08 Specifications ................................................................................................. 2-5

SECTION 3:

INSTALLATION ...................................................................................... 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location ......................................................................................................... 3-1

3.03 Electrical Input Connections ........................................................................... 3-1

3.04 Mains Supply Voltage Requirements .............................................................. 3-2

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

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

3.07 Duty Cycle ...................................................................................................... 3-4

SECTION 4:

OPERATION........................................................................................... 4-1

4.01 Transtig 200 Pi Controls ................................................................................. 4-1

4.02 Weld Process Selection for Transtig 200 Pi.................................................... 4-2

4.03 Weld Parameter Descriptions for Transtig 200 Pi........................................... 4-3

4.04 Weld Parameters for Transtig 200 Pi.............................................................. 4-4

4.05 Power Source Features ................................................................................... 4-5

4.06 Set-Up for SMAW (STICK) and GTAW (TIG)................................................... 4-7

4.07 Sequence of Operation ................................................................................... 4-8

4.08 Stick Welding ................................................................................................. 4-9

4.09 HF TIG & Lift TIG Welding .............................................................................. 4-9

4.10 Slope Mode Sequence .................................................................................. 4-10

4.11 Slope Mode with Repeat Sequence .............................................................. 4-10

4.12 Pulse Controls .............................................................................................. 4-11

4.13 Basic TIG Welding Guide .............................................................................. 4-12

4.14 Basic Arc Welding Guide .............................................................................. 4-14

TABLE OF CONTENTS (continued)

TABLE OF CONTENTS

SECTION 5:

SERVICE .............................................................................................. 5-1

5.01 Routine Maintenance ...................................................................................... 5-1

5.02 Maintenance Diagram ..................................................................................... 5-2

5.03 Basic Troubleshooting .................................................................................... 5-3

5.04 TIG Welding Problems ................................................................................... 5-4

5.05 Stick Welding Problems ................................................................................. 5-6

5.06 Power Source Problems ................................................................................. 5-9

5.07 Power Source Error Codes ........................................................................... 5-11

5.08 Voltage Reduction Device (VRD) .................................................................. 5-13

SECTION 6:

ADVANCED TROUBLE SHOOTING ................................................................. 6-1

6.01 System-Level Fault Isolation .......................................................................... 6-1

6.1.1 Opening the Enclosure .......................................................................... 6-1

6.02 Verification and Remedy to the Indicated Error Codes ................................... 6-3

6.2.1 E01 "Over-Temperature at the primary side" .......................................... 6-3

6.2.2 E02 "Over-Temperature at the secondary side" ...................................... 6-3

6.2.3 E03 "Primary Over-Current Failure"........................................................ 6-4

6.2.4 E94 “Thermistor malfunction” ............................................................... 6-4

6.2.5 E99 “Initial Power Receiving” ................................................................ 6-4

6.2.6 E04 "Torch Cable Failure" ....................................................................... 6-5

6.2.7 E93 "Memory Chip (EEPROM) error." .................................................... 6-5

6.03 Verification and Remedy to Failures without Indication Codes ....................... 6-6

6.3.1 "Cooling Fan (FAN1) Failure" (Fan is not rotating.)................................. 6-6

6.3.2 "Gas Valve Failure" (No Gas flow through unit) ...................................... 6-7

6.3.3 "No Weld Output" ................................................................................... 6-7

6.3.4 "Operating Panel Failure"........................................................................ 6-7

6.3.5 "High Frequency Output Failure" ............................................................ 6-8

6.04 Fault Isolation Tests........................................................................................ 6-9

6.4.1 Preparation ............................................................................................ 6-9

6.05 Verification of the Power Input Circuitry ......................................................... 6-9

6.5.1 Verification of the AC Input Voltage using an AC Voltmeter................... 6-9

6.5.2 Verification of Power Supply Voltage................................................... 6-10

6.5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry .......................... 6-11

6.5.4 Verification of the Gas Valve, SOL1, Drive Circuitry............................. 6-12

6.5.5 Verification of the primary Diode (D1) ................................................. 6-12

6.5.6 Verification of the secondary Diode (D2, D3) ...................................... 6-13

6.5.7 Verification of the primary IGBT (Q1A-Q4C) ........................................ 6-13

6.5.8 Verification of No-load Voltage (OCV) ................................................. 6-14

TABLE OF CONTENTS

SECTION 7:

MAINTENANCE ....................................................................................... 7-1

7.01 Subsystem Test and Replacement Procedures............................................... 7-1

7.1.1 Preparation ............................................................................................ 7-1

7.1.2 Test and Replacement Parts List ........................................................... 7-1

7.02 Service Tools ................................................................................................. 7-4

7.2.1 Tools and parts ...................................................................................... 7-4

7.2.2 Notes of disassembly and assembly ..................................................... 7-4

7.03 Replacement Procedure ................................................................................. 7-5

7.3.1 PCB1 (WK-5713) and Primary Diode D1 ............................................... 7-6

7.3.2 PCB2 (WK-5417), Capacitor C1 and Resistor R1 .................................. 7-8

7.3.3 PCB3 (WK-5609) and T1 “Transformer” ............................................. 7-10

7.3.4 PCB4 (WK-5449) ................................................................................. 7-11

7.3.5 PCB5 (WK-5548) ................................................................................. 7-12

7.3.6 PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT” ................................. 7-13

7.3.7PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT” .................................. 7-14

7.3.8 D2 and D3 “Secondary Diode” ............................................................ 7-15

7.3.9 C.C. “Coupling Coil” and FCH1 “Reactor” ............................................7-15

7.3.10 CT1 “Hole Current Trans” .................................................................. 7-17

7.3.11 FAN1 “Cooling Fan” ........................................................................... 7-18

7.3.12 HF UNIT1 “High Frequency Unit”....................................................... 7-19

7.3.13 SOL1 “Solenoid GAS Valve” .............................................................. 7-20

7.3.14 C101-C102 “Capacitor”, L101 “Ring Core” and S1 “Switch”............. 7-21

7.3.15 CON1 “Remote Receptacle” .............................................................. 7-22

7.3.16 TH1 “Primary Thermistor” ................................................................ 7-23

7.3.17 TH2 “Secondary Thermistor” ............................................................ 7-22

7.3.18 C103 “Capacitor” and L102 “Reactor”............................................... 7-24

7.3.19 L103 “Reactor”.................................................................................. 7-24

7.3.20 C2 “Capacitor” and R2 “Resistor” ..................................................... 7-25

APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1

APPENDIX 2: PARTS LIST ................................................................................ A-2

APPENDIX 3: CONNECTION WIRING GUIDE ........................................................... A-6

APPENDIX 4: INTERCONNECT DIAGRAM ............................................................... A-8

APPENDIX 5: DIODE TESTING BASICS ................................................................. A-10

CIGWELD LIMITED WARRANTY

Terms of Warranty – December 2007

Warranty Schedule – December 2007

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

SERVICE MANUAL TRANSTIG 200 Pi

March 31, 2008

1-1

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

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

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

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

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

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

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

9. Do not wrap cables around your body.

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

11.Do not touch electrode while in contact with the work (ground) circuit.

12.Use only well-maintained equipment. Repair or replace damaged parts at once.

13.In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

14.Wear a safety harness to prevent falling if working above floor level.

15.Keep all panels and covers securely in place.

SECTION 1:

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

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

MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

TRANSTIG 200 Pi SERVICE MANUAL

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March 31, 2008

WARNING

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

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

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

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

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

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

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

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

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

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

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

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

Welding or Cutting

operation

Electrode size Metal Thickness

or Welding Current

Filter

shade

no.

Weldin g or Cutting operation Electrode size Metal

Thickness or Welding

Current

Filter

shade

no.

Torch soldering All 2

Torch brazing All 2 or 3 Non Ferrous b ase metal All 11

Ferrous base metal

All 1 2

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding (TIG)

All 1 2

Medium 1 – 6 in., 25 – 150 mm 4 or 5 Atomic Hydrogen welding

All 1 2

Heavy Over 6 in., 150 mm 5 or 6 Carbon Arc welding

All 1 2

Plasma arc Welding

All 1 2

Light Under 1/8 in., 3 mm 4 or 5 Carbon Arc Gouging

Medium 1/8 – 1/2 in., 3 – 12 mm 5 or 6 Light 12

Heavy Over 1/2 in., 12 mm 6 or 8 Heavy 14

Under 5/32 in., 4 mm 10 Light Under 300 Amp 9 Under 5/32 to ¼ in., 4 to 6.4mm

Medium 300 to 400 Amp 12

Over ¼ in., 6.4 mm

Heavy Over 40 0 Amp 14

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73

Plasma arc cutting

Oxygen cutting

Gas metal arc welding

Gas welding

Shielded metal-arc welding (stick) electrodes

SERVICE MANUAL TRANSTIG 200 Pi

March 31, 2008

1-3

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

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

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

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

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

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

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

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

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

9. Do not use welder to thaw frozen pipes.

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

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

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

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

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

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

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

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

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

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

TRANSTIG 200 Pi SERVICE MANUAL

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March 31, 2008

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open flames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

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

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

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

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

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

SERVICE MANUAL TRANSTIG 200 Pi

March 31, 2008

1-5

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hot and under pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

WARNING

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

NOTE

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

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear sciencebased advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from body as practical.

ABOUT PACEMAKERS:

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

1.02 PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safety in welding and allied processes Part 2: Electrical, AS1674.2-2007 from SAI Global Limited, www.saiglobal.com

TRANSTIG 200 Pi SERVICE MANUAL

1-6

March 31, 2008

1.03 DECLARATION OF CONFORMITY

Manufacturer: CIGWELD Address: 71 Gower St, Preston

Victoria 3072

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.

The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive 73/23/EU, as recently changed in Directive 93/68/EU and to the National legislation for the enforcement of the Directive.

National Standard and Technical Specifications

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

• AS/NZS 3652-(EMC Directive EN50199) applicable to arc welding equipment - generic emissions and

regulations.

• EN60974-1 applicable to welding equipment and associated accessories.

• AS60974.1 applicable to welding equipment and associated accessories.

Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance, ultra safe operation and world class quality for more than 30 years and will continue to achieve excellence.

2-1

March 31, 2008

SERVICE MANUAL TRANSTIG 200 Pi

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part numbers listed on page i.

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

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

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

Additional copies of this manual may be purchased by contacting Cigweld at the address and phone number for your location listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Cigweld web site listed below and clicking on the Literature Library link:

http://www.cigweld.com.au

2.02 Equipment Identification

The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel. Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers on the bottom of page i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.

Include all equipment identification numbers as described above along with a full description of the parts in error.

Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to uncrate the unit.

CAUTION

The products applicable to this Service Manual are manufactured in various configurations for differing global requirements. Some specifications and and electrical data quoted within this Service Manual may not be applicable to all products and regions. For this reason due caution and care must be exercised when using this Service Manual.

2-2

March 31, 2008

TRANSTIG 200 Pi SERVICE MANUAL

2.04 Symbol Chart

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

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Dangerous Voltage

Off

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Receptacle RatingAuxiliary Power

Art # A-04937

115V 15A

IPM

MPM

Fuse

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld Mode

Press to initiate wirefeed and welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Disturbance In Ground System

Welding Gun

Burnback Time

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

4 Step Trigger Operation

2 Step Trigger Operation

2-3

March 31, 2008

SERVICE MANUAL TRANSTIG 200 Pi

2.05 Description

The Cigweld Transtig 200 Pi is a self contained singlephase 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 starter, and high-frequency arc starter for use with Gas Tungsten Arc Welding (GTAW), Gas Tungsten Arc Welding-Pulsed (GTAW-P) Gas Tungsten Arc WeldingSloped (GTAW-S), and Shielded Metal Arc Welding (SMAW) processes. The power source is totally enclosed in an impact resistant, flame resistant and non-conductive plastic case.

NOTE

Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source. Curves of other settings will fall between the curves shown.

Art # A-06027

160A1A (A)

(V)

OCV

STICK Process

200A25A (A)

(V)

OCV

10V

200A (A)

(V)

OCV

HF TIG Process

LIFT TIG Process

Figure 2-1: Transtig 200 Pi Volt-Ampere Curves

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TRANSTIG 200 Pi SERVICE MANUAL

2.06 Functional Block Diagrams

Figure 2-2 illustrates the functional block diagram of the Transtig 200 Pi power source.

Art # A-06029

To each control circuit

Main Circuit Switch

Filter

Input Diode

Capacitor

DC Power Primary Voltage

Sensor

IGBT

Inverter

Thermal

Detector

Main

Transformers

(T1)

Output

Inductor

Output Diodes

Transformer

(HCT1)

Hall Current

Lift Tig Mode Output Short

Sensing

Circuit

Stick Mode

VRD

Sensing

Circuit

Thermal

Sensor

Circuit

Drive

Circuit

+/-12VDC +18VDC +24VDC +5VDC

Trouble

Sensing

Circuit

Torch Control

Connection

(CON1)

Current

Adjustment

Circuit

Reference

Adjustment &

Mode select Switch

Panel Circuit Board

Sequence

Control

Fan Control

Circuit

Fan

Input

Power

Primary

Circuit Sensor

Gas Control

Circuit

Solenoid

Coupling

Coil

High

Frequency

Unit

HF Unit Control

Circuit

Figure 2-2: Transtig 200 Pi Functional Block Diagram

2.07 Transporting Methods

These units are equipped with a handle for carrying purposes.

WARNING

ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source.

WARNING

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Lift unit with handle on top of case.

Use handcart or similar device of adequate capacity.

If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

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SERVICE MANUAL TRANSTIG 200 Pi

2.08 Specifications

Parameter Transtig 200Pi

Power Source Part Number 700720 Cooling Fan Cooled Welder Type Inverter Power Source Welding Power Source Mass 8kg Dimensions H 260mm x W 130mm x L 320mm Manufactured to Australian Standard AS 60974.1-2006 Number of Phases 1 Nominal Supply Voltage 240V ±15% Nominal Supply Frequency 50Hz Protection Class IP23S

Standard Specifications (Applicable with factory fitted Supply Plug) Parameter Transtig 200Pi

Welding Current Range 5 - 200 Amps Open Circuit Voltage 65V Factory Fitted Supply Plug Rating 15 Amps Effective Input Current (I1eff) 15 Amps Maximum Input Current (I1 max) 36.7 Amps Single Phase Generator Requirement 8.8 KVA

Welding Output 40

C, 10 min

(Quoted figures refer to MMAW output)

160A @ 15%, 26.4V

80A @ 60%, 23.2V

62A @ 100%, 22.5V

Welding Output 40

C, 10 min

(Quoted figures refer to GTAW output)

200A @ 20%, 18.0V 130A @ 60%, 15.2V

100A @ 100%, 14.0V

Upgraded Specifications (Applicable with upgraded Supply Plug) Parameter Transtig 200Pi

Welding Current Range 5 - 200 Amps Open Circuit Voltage 65V Upgraded Supply Plug Rating Required 25 Amps Effective Input Current (I1eff) 21.7 Amps Maximum Input Current (I1 max) 36.7 Amps Single Phase Generator Requirement 8.8 KVA

Welding Output 40

C, 10 min

(Quoted figures refer to MMAW output)

160A @ 35%, 26.4V 130A @ 60%, 25.2V

100A @ 100%, 24.0V

Welding Output 40

C, 10 min

(Quoted figures refer to GTAW output)

200A @ 20%, 18.0V 130A @ 60%, 15.2V

100A @ 100%, 14.0V

Table 2-1: Specifications

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.

The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above

specifications due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components, installation location and conditions and local power grid supply conditions.

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TRANSTIG 200 Pi SERVICE MANUAL

THIS PAGE LEFT INTENTIONALLY BLANK.

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3-1

SECTION 3:

INSTALLATION

3.03 Electrical Input Connections

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.

DO NOT TOUCH live electrical parts.

SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

3.01 Environment

The Transtig 200 Pi is designed for use in hazardous environments. Examples of environments with increased hazardous environments are:

a. In locations in which freedom of movement is

restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts;

b. In locations which are fully or partially limited by

conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator, or

c. In wet or damp hot locations where humidity or

perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories.

Environments with hazardous environments do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.

3.02 Location

Be sure to locate the welder according to the following guidelines:

· In areas, free from moisture and dust.

· Ambient temperature between 0 degrees C to 40 degrees C.

· In areas, free from oil, steam and corrosive gases.

· In areas, not subjected to abnormal vibration or shock.

· In areas, not exposed to direct sunlight or rain.

· Place at a distance of 12” (304.79mm) or more from walls or similar that could restrict natural airflow for cooling.

WARNING

Cigweld advises that this equipment be electrically connected by a qualified electrician.

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3.04 Mains Supply Voltage Requirements

The Mains supply voltage should be within ± 15% of the rated Mains supply voltage. Too low a voltage may cause the fuse or circuit breaker to rupture due to the increased primary current. Too high a supply voltage will cause the Power Source to fail.

240V Mains Current Circuit Requirements for the Transtig 200 Pi

The Welding Power Source must be:

• Correctly installed, if necessary, by a qualified electrician.

• Correctly earthed (electrically) in accordance with local regulations.

• 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 tradesperson.

The following 240V Mains Current Circuit recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment:

NOTE

This product has been fitted with a 15 amp input supply plug as standard. In order to achieve maximum welding output and duty cycle, it is recommended to increase the rating of the supply plug as indicated below.

Model Mains Supply Lead Minimum 240V Mains Input Supply

Size (Factory Current Circuit Size Plug Current Fitted) Rating

Transtig 200 Pi 2.5 mm2 36.7 Amps 25A

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3-3

3.05 High Frequency Introduction

The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation. The following information is intended as a guide for personnel installing high frequency welding machines.

WARNING: EXPLOSIVES

The high frequency section of this machine has an output similar to a radio transmitter. The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing.

WARNING: COMPUTERS

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

3.06 High Frequency Interference

Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following ways:

1. Direct Radiation: Radiation from the machine can

occur if the case is metal and is not properly grounded. It can occur through apertures such as open access panels. The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properly grounded.

2. Transmission via the Supply Lead: Without

adequate shielding and filtering, high frequency energy may be fed to the wiring within the installation (mains) by direct coupling. The energy is then transmitted by both radiation and conduction. Adequate shielding and filtering is provided in the Power Source.

3. Radiation from Welding Leads: Radiated

interference from welding leads, although pronounced in the vicinity of the leads, diminishes rapidly with distance. Keeping leads as short as possible will minimize this type of interference. Looping and suspending of leads should be avoided where possible.

4. Re-radiation from Unearthed Metallic Objects:

A major factor contributing to interference is reradiation from unearthed metallic objects close to the welding leads. Effective grounding of such objects will prevent re-radiation in most cases.

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March 31, 2008

3.07 Duty Cycle

The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases. If the welding amperes are increased beyond the rated output, the duty cycle will decrease.

WARNING

Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature.

CAUTION

Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty.

NOTE

Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.

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4-1

Art # A-08343

180

410

360

Figure 4-1: Transtig 200 Pi Power Source

SECTION 4:

OPERATION

4.01 Transtig 200 Pi Controls

1. Control Knob: This control sets the selected weld

parameter, rotating it clockwise increases the parameter and is indicated on the digital meter. Pushing the knob inward displays the actual welding voltage.

2. Remote Control Socket:

The 8 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Front View of 8-Socket Receptacle

123

45678

Gnd.

5k Ohms

Art # A-08344

Figure 4-2: Front view of 8-Socket Receptacle

3. Positive Terminal:

Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

4. Negative Terminal: Welding current flows from

the Power Source via heavy duty Dinse type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

Socket

Function

1 Earth (Ground) 2 Torch Switch Input (24V) to

energize weld current. (connect pins 2 & 3 to turn on welding current)

3 Torch Switch Input (0V) to

energize weld current (connect pins 2 & 3 to turn on welding current)

4 Connect pin 4 to pin 8 to instruct

machine that a remote current control device is connected (12V DC supply)

5 5k ohm (maximum) connection

to 5k ohm remote control potentiometer

6 Zero ohm (minimum)

connection to 5k ohm remote control potentiometer

7 Wiper arm connection to 5k ohm

remote control potentiometer

8 Connect pin 4 to pin 8 to instruct

machine that a remote current control device is connected (0V)

Table 4-1: Socket Pin Functions

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March 31, 2008

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.

5. Gas Outlet: The Gas Outlet is a 5/8-18 UNF female

gas fitting.

6. ON/OFF Switch:

This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the Power Supply.

WARNING

When the welder is connected to the Primary supply voltage, the internal electrical components maybe at 240V potential with respect to earth.

7. Input Cable: The input cable connects the Primary

supply voltage to the equipment.

8. Gas Inlet:

The Gas Inlet is a 5/8-18 UNF female

gas fitting.

4.02 Weld Process Selection for Transtig 200 Pi

STICK HF TIG LIFT TIG

STD

SLOPE

REPEAT

SPOT

PULSE

ON/OFF

Weld Mode

Weld Process Selection Description

Yes Yes Yes

2T operation in TIG Modes using remote devices to control contactor & current

4T operation in TIG Modes with crater fill using a remote contactor device to control sequence.

No Yes Yes

4T operation in TIG Modes with repeat operation and crater fill using a remote co ntactor device.

No Yes Yes

2T operation spot welding in HF TIG using a remote contactor device.

No Yes Yes Pulse operation in TIG Modes

No Yes No

Table 4-2: Weld Process Selection Versus Weld Mode for Transtig 200 Pi

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4-3

Parameter Description

PRE-FLOW

This parameter operates in TIG modes only and is used to get gas to the weld zone prior to striking the arc, once the torch trigger switch has been pressed. This control is used to dramatically reduce weld porosity at the start of a weld.

HOT START

This parameter operates in all weld modes except Lift TIG mode and is used to heat up the weld zone in TIG modes or improve the start characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the

BASE (WELD)

current. e.g.

HOT START

current = 130 amps when

BASE (WELD)

100 amps &

HOT START

= 30 amps

INITIAL CUR.

This parameter operates in

SLOPE

REPEAT

(4T) TIG modes only and is used to set the start current for TIG. The Start Current remains on until the torch trigger switch is released after it has been depressed.

UP SLOPE

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

PEAK CUR.

This parameter sets the PEAK weld current when in

PULSE

mode

WELD

This parameter sets the TIG WELD current in

STD, SLOPE, REPEAT

and

SPOT

modes when

PULSE

is off. This parameter also sets the STICK weld current.

BASE

(Background

Current)

This parameter sets the Background current when in Pulse TIG mode.

SPOT TIME

This parameter sets the duration of the

SPOT TIME

HF TIG

mode only

PULSE

WIDTH

This parameter sets the percentage on time of the

PULSE FREQUENCY

for PEAK

weld current when the

PULSE

is on.

PULSE FREQ.

This parameter sets the

PULSE FREQUENCY

when the

PULSE

is on.

Art # A-06032_AB

Figure 4-3: Transtig 200 Pi Front Panel

4.03 Weld Parameter Descriptions for Transtig 200 Pi

200 Pi Table 4-3: Parameter Descriptions

TRANSTIG 200 Pi SERVICE MANUAL

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March 31, 2008

Parameter Description

DOWN SLOPE

This parameter operates in TIG modes only and is used to set the time for the weld current to ramp down, after the torch trigger switch has been pressed, to

CRATER

CUR.

This control is used to eliminate the crater that can form at the completion of a

weld.

CRATER CUR.

This parameter operates in

SLOP

REPEA

(4T) TIG modes only and is used to set the finish curren t for TIG. The CRAT ER Current remains on until the torch trigger switch is released after it has been depressed.

POST-FLOW

This parameter operates in TIG modes only and is used to adjust the post gas flow time once the arc has extinguished. This control is used to dramatically reduce oxidation of the tungsten electrode. The SAVE/LOAD buttons are used to save and retrieve a total number of 5 program s into the 200 Pi memory. NOTE: SAVE/LOAD button must remain depressed for 3 seconds in order to save or load the settings.

Table 4-3 (continued): Parameter Descriptions

4.04 Weld Parameters for Transtig 200 Pi

Weld

Parameter

Range

Factory

Setting

Incremental

Unit

STICK

TIG

LIFT

TIG

PRE-FLOW

0.0 to 1.0 sec 0.1 sec 0.1 sec No Yes Yes

HOT START

0 to 70A 20A 1A Yes Yes No

INITIAL CUR.

1 to 200A 30A 1A No Yes Yes

UP SLOPE

0 to 15 sec 1 sec 0.1 sec No Yes Yes

PEAK CUR.

1 to 200A 120A 1A No Yes Yes

WELD CUR

1 to 200A 230V 80A 1A No Yes Yes

(TIG)

1 to 85A 115V 80A 1A No Yes Yes

WELD CUR

1 to 160A 230V 80A 1A Yes No No

(STICK)

1 to 85A 115V 80A 1A Yes No No

SPOT TIME

0.5 to 5.0 sec 2 sec 0.1 sec No Yes Yes

PULSE WIDTH

15 to 80% 50% 1% No Yes Yes

PULSE FREQ.

0.5 to 500Hz 100.0Hz See Table 4-5 No Yes Yes

DOWN SLOPE

0 to 25 sec 3 sec 0.1 sec No Yes Yes

CRATER CUR.

1 to 200A 30A 1A No Yes Yes

POST-FLOW

0.0 to 60 sec 10 sec 0.1 sec No Yes Yes

Weld Mode

Table 4-4: Weld Parameters for Transtig 200 Pi

PULSE FREQ. Range Incremental Unit

0.5 to 20Hz 0.1Hz

20 to 100Hz 1Hz

100 to 500Hz 5Hz

Table 4-5: PULSE FREQ. Range and Incremental Units

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4-5

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 Displays selected weld parameter value Displays weld current when welding Displays weld current for 20 seconds after weld has been completed A selected weld parameter value can be adjusted at any time even while welding

ON/OFF switch

Primary voltage Supply ON/OFF switch located on rear panel A total number of 5 programs can be saved into the 200 Pi memory

SAVE

the Current Weld Parameters into Memory

Press and hold the

SAVE

button for 3 seconds Select a memory location by rotating the control knob, 1 to 5 is displayed on the meter After selecting the desired memory location (ie 1 to 5), press the right scroll button and the machine will give a been to confirm the weld parameters from the control panel are saved.

LOAD

(retrieve) a Program to Control Panel

Press and hold the

LOAD

Digital Meter

Save/Load Function

Table 4-6: Power Source Features

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March 31, 2008

Feature Description

Reduces the OCV when the power supply is not in use. Eliminates the need for add on voltage reducers and has no effect on arc starting. VRD fully complies to AS 60974.1 When Stick mode is selected the green VRD light is ON when not welding and red when welding. When in TIG modes VRD is off. For the selected weld parameter, rotating the knob clockwise increases the parameter Rotating the knob counterclockwise decreases the parameter A selected weld parameter value can be adjusted at any time even while welding Pushing the knob in displays actual arc voltage.

Self Diagnosis Using Error Codes

An error code is displayed on the

Digital Meter

when a problem occurs with Primary supply voltage or internal component problems. Refer to troubleshooting guide.

Voltage Reduction Device (VRD)

Control Knob

Table 4-6 (continued): Power Source Features

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4-7

4.06 Set-Up for SMAW (STICK) and GTAW (TIG)

Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short-term overload without adverse effects. The welding current range values should be used as a guide only. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between different classes of electrodes, welding current at any one setting would vary according to the type of electrode in use. The operator should use the welding current range values as a guide, then finally adjust the current setting to suit the application.

WARNING

Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front 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.

Art # A-07843

Figure 4-4: Transtig 200 Pi Set-Up

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March 31, 2008

4.07 Sequence of Operation

NOTE

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 Symbols Table located in the front of the manual for Symbol descriptions.

Figure 4-5: Transtig 200 Pi Front Panel

Art # A-06034_AB

1. Pulse Function: Pressing this button enables the

TIG current pulse functions.

2. Scroll Buttons: used to select the parameter to

be set. The LED’s show which function is being adjusted on the weld sequence graph.

3. Digital LED Display: Welding amperage and

parameter values are displayed in this window. Internal warnings such as over temperature, low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen.

4. Control Knob: allows the operator to adjust the

output amperage within the entire range of the power source, also used to set each parameter value. Pushing the knob inward displays the actual welding voltage.

5. Process Button: This button selects between

STICK, Lift or HF TIG mode.

6. 8 Pin Remote Control Receptacle: for connecting

remote device.

7. TIG Mode Functions: Pressing this button scrolls

through the output TIG function modes (Standard, Slope, Slope w/repeat, Spot).

8. Save/Load Button: by using the Save & Load

buttons the operator can easily save up to 5 welding parameter program. NOTE: SAVE/LOAD button must remain depressed for 3 seconds in order to save or load the settings.

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4-9

4.08 Stick Welding

· Connect work lead to negative terminal

· Connect electrode lead to positive terminal

· Switch machine on

· Set weld current

· Connect remote control device if required

Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

· Set

HOT START

· Set

WELD

current

Commence welding

4.09 HF TIG & Lift TIG Welding

· Connect work lead to positive terminal

· Connect TIG torch to negative terminal

· Switch machine on

· Set

WELD

current.

· Connect remote control device. A remote control device is required for use during LIFT TIG and HF TIG operation. See section 3.01, section 2 “

Remote Control Socket

”, for complete details

of the remote device.

Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

· Set

PRE-FLOW

time

· Set

HOT START

current

· Set

POST-FLOW

time

· Set

WELD

current

· Set

POST-FLOW

time

Slope Mode Parameters if required

· Set

INTIAL CUR

current

· Set

UP SLOPE

time

· Set (WELD)

PEAK CUR

current

· Set

BASE

current

· Set

DOWN SLOPE

time

· Set

CRATER CUR

current

Pulse Mode parameters if required

· Set

PULSE WIDTH

% for

PEAK CURRENT

Set PEAK CURRENT

· Set

PULSE FREQ

Commence welding

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March 31, 2008

4.10 Slope Mode Sequence

Switch Closed

Switch Open

Switch Closed

Switch Open

Preﬂow

Initial Current

Up Slope

Weld Current

Down Slope

Final Current

Postﬂow

Art # A-05069_AB

Figure 4-6: Slope Mode Sequence

1) To start Slope sequence Close remote switch contacts. Once the welding arc is established the Power Source will maintain initial current setting as long as the remote switch contacts are closed.

a) In the HF TIG mode, after Preflow time High

Frequency is present at the torch. When the torch is positioned close to the work the welding current will transfer to the work and establish the arc at the initial current setting.

b) In the Lift TIG mode, after Preflow time Lift

Start current is present at the torch. When the electrode is touched to the work and lifted off, the welding arc is established at the initial current setting.

2) Open Remote Switch: current increases to weld current. Once welding arc has reached weld current the power source will maintain weld current as long as the remote switch contacts are open.

3) Close Remote Switch: Welding current decreases to final current setting. Once final welding current is reached the power source will maintain final current setting as long as the remote switch contacts are closed.

4) Open Remote Switch: Welding arc stops and post flow begins.

4.11 Slope Mode with Repeat Sequence

The repeat function is operated during the down slope cycle of the Slope Sequence and is active through the down slope period only. During the down slope period by opening the Remote Switch contacts the current will increase back to weld current. Within the Down Slope period the repeat function can operated as many times as desired. To continue slope cycle and end slope sequence close remote switch contacts and allow weld current to reach final current setting. Once final current setting is reached opening the Remote Switch again will turn off the welding arc and post flow begins.

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4-11

4.12 Pulse Controls

(Pulse Width)

(Pulse Frequency)

(Peak Current)

(Base) Background Current

Art # A-05070

Figure 4-7: Pulse Controls

The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows:

1) Control puddle: size and fluidity (especially out of position).

2) Increase penetration

3) Travel speed control

4) Better consistent quality

5) Distortion on lighter or thinner materials.

Pulse-current provides a system in which the welding current continuously changes between two levels. During the periods of Peak current heating and fusion takes place and during the background (base) current periods, cooling and solidification take place. Pulse Width is the time in one cycle the current stays at the peak current setting. Pulse Frequency measured in Hertz is the number of cycles per second the current travels between peak and background current settings. It is as if the foot rheostat were moved up and down to increase and decrease the welding current on a regular basis. The faster you moved the foot rheostat up and down the faster the frequency.

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March 31, 2008

4.13 Basic TIG Welding Guide

1. 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.

2. Tungsten Electrode Current Ranges:

Electrode Diameter DC Current (Amps)

0.040” (1.0mm) 30 – 60 1/16” (1.6mm) 60 – 115 3/32” (2.4mm) 100 – 165

1/8” (3.2mm) 135 – 200 5/32” (4.0mm) 190 – 280 3/16” (4.8mm) 250 – 340

Table 4-7: Current Ranges for Various Tungsten Electrode Sizes

3. Tungsten Electrode Types:

Electrode Type (Ground Finish)

Welding Application Features

Color

Code

Thoriated 2%

DC welding of mild steel, stainless steel and copper.

Excellent arc starting, Long life, High current carrying capacity.

Red

Ceriated 2%

DC welding of mild steel, stainless steel, copper, aluminium, magnesium and their alloys

Longer life, More stable arc, Easier starting, Wider current range, Narrower more concentrated arc.

Grey

Table 4-8: Tungsten Electrode Types

4. Guide for Selecting Filler Wire Diameter:

Filler Wire Diameter DC Current Range (Amps)

1/16” (1.6 mm) 20 - 90 3/32” (2.4 mm) 65 - 115

1/8” (3.2 mm) 100 - 165

3/16” (4.8 mm) 200-350

Table 4-9: Filler Wire Selection Guide

NOTE

The filler wire diameter specified in Table 4-9 is a guide only, other diameter wires may be used according to the welding application.

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4-13

5. Shielding Gas Selection:

Alloy Shielding Gas

Aluminium & alloys Argon

Carbon Steel Argon

Stainless Steel Argon

Copper Argon

Table 4-10: Shielding Gas Selection

6. TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe:

Electrode Type

& Diameter

Current Range

DC Amperes

Fillet Rod for

Root Pass

Joint

Preparation

Thoriated 2%

3/32'' (2.4mm)

120-170 Yes

Thoriated 2%

3/32'' (2.4mm)

100-160 Yes

Thoriated 2%

3/32'' (2.4mm)

90-130 No

Table 4-11: TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe

Base Metal

Thickness

DC Current

for Mild

Steel

DC Current

for

Stainless

Steel

Tungsten

Electrode

Diameter

Filler Rod

Diameter (if

required)

Argon Gas

Flow Rate Liters/min

Joint Type

0.040”

1.0mm

35-45 40-

20-30 25-

0.040”

1.0mm

1/16”

1.6mm

5-7

Butt/Corner

Lap/ Fillet

0.045”

1.2mm

45-55 50-

30-45 35-

0.040”

1.0mm

1/16”

1.6mm

5-7

Butt/Corner

Lap/ Fillet

1/16”

1.6mm

60-70 70-

40-60 50-

1/16”

1.6mm

1/16”

1.6mm

Butt/Corner

Lap/ Fillet

1/8”

3.2mm

80-100 90-

115

65-85 90-

110

1/16”

1.6mm

3/32”

2.4mm

Butt/Corner

Lap/ Fillet

3/16”

4.8mm

115-135

140-165

100-125

125-150

3/32”

2.4mm

1/8”

3.2mm

Butt/Corner

Lap/ Fillet

¼” 6.4mm

160-175

170-200

135-160

160-180

1/8”

3.2mm

5/32”

4.0mm

Butt/Corner

Lap/ Fillet

Table 4-12: DC TIG Welding Parameters

NOTE

The information outlined above is for general guidance only. Specific parameters should be used according to the welding application

TRANSTIG 200 Pi SERVICE MANUAL

4-14

March 31, 2008

4.14 Basic Arc Welding Guide

1. 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.

2. Effects of Stick Welding Various Materials:

A. High tensile and alloy steels

The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.

B. Manganese steels

The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.

C. Cast Iron

Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the porosity caused by gas held in this type of iron.

D. Copper and alloys

The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections necessary to give proper fusion of weld and base metal.

E. 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. These include some low hydrogen types for high tensile steel, cellulose types for welding large diameter pipes, etc. The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be encountered; are all easy to use and all will work on even the most basic of welding machines.

Metals being joined Electrode Comments

Mild steel 6013

Ideal electrodes for all general purpose work. Features include out standing operator appeal, easy arc starting and low spatter.

Mild steel 7014

All positional electrode for use on mild and galvanized steel furniture, plates, fences, gates, pipes and tanks etc. Especially suitable for vertical-down welding.

Cast iron 99% Nickel Suitable for joining all cast irons except white cast iron.

Stainless steel 318L-16

High corrosion resistance. Ideal for dairy work, etc. On stainless steels.

Copper, Bronze,

Brass, etc.

Bronze 5.7

ERCUSI-A

Easy to use electrode for marine fittings, water taps and valves, water trough float arms, etc. Also for joining copper to

steel and for bronze overlays on steel shafts. High Alloy Steels, Dissimilar Metals,

Crack Resistance. All

Hard-To-Weld Jobs.

312-16

It will weld most problematical jobs such as springs, shafts,

broken joins mild steel to stainless and alloy steels. Not

suitable for Aluminum.

Table 4-13: Types of Electrodes

SERVICE MANUAL TRANSTIG 200 Pi

5-1

March 31, 2008

SECTION 5:

SERVICE

5.01 Routine Maintenance

The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

WARNING

Disconnect primary power at the source before opening the enclosure. Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge.

To clean the unit, open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should also be wiped clean, if necessary; with solvents that are recommended for cleaning electrical apparatus.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

TRANSTIG 200 Pi SERVICE MANUAL

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March 31, 2008

5.02 Maintenance Diagram

Warning! Disconnect input power before maintaining.

Each Use

Visual check of regulator and pressure

Visual check of torch Consumable parts

Weekly

Visually inspect the torch body and consumables

Visually inspect the cables and leads. Replace as needed

3 Months

Clean exterior of power supply

6 Months

Replace all broken parts

Bring the unit to an authorized CIGWELD Service Provider to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions.

Maintain mo

re often if used under severe conditions

Art # A-07681_AC

SERVICE MANUAL TRANSTIG 200 Pi

5-3

March 31, 2008

5.03 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.

The basic level of troubleshooting is that which can be performed without special equipment or knowledge.

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March 31, 2008

5.04 TIG Welding Problems

Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique.

1 Excessive bead build-up or poor

penetration or poor fusion at edges of weld

Welding current is too low Increase weld current

and/or faulty joint preparation

2 Weld bead too wide and flat or

undercut at edges of weld or excessive burn through

Welding current is too high Decrease weld current

3 Weld bead too small or insufficient

penetration or ripples in bead are widely spaced apart

Travel speed too fast Reduce travel speed

4 Weld bead too wide or excessive

bead build-up or excessive penetration in butt joint

Travel speed too slow Increase travel speed

5 Uneven leg length in fillet joint Wrong placement of filler

rod

Re-position filler rod

6 Electrode melts when arc is struck Electrode is connected to

the '+' terminal

Connect the electrode to the '-' terminal

7 Dirty weld pool A Electrode contaminated

through contact with work piece or filler rod material

A Clean the electrode by

grinding off the contaminates

B Gas contaminated with air B Check gas lines for cuts

and loose fitting or change gas cylinder

8 Electrode melts or oxidizes when

an arc is struck

A No gas flowing to welding

region

A Check the gas lines for

kinks or breaks and gas

cylinder contents B Torch is clogged with dust B Clean torch C Gas hose is cut C Replace gas hose D Gas passage contains

impurities

D Disconnect gas hose from

torch then raise gas

pressure and blow out

impurities E Gas regulator turned off E Turn on F Torch valve is turned off F Turn on G The electrode is too small

for the welding current

G Increase electrode

diameter or reduce the

welding current

9 Poor weld finish Inadequate shielding gas Increase gas flow or

check gas line for gas

flow problems

Description Possible Cause Remedy

Table 5-1: TIG Welding Problems

SERVICE MANUAL TRANSTIG 200 Pi

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March 31, 2008

10 Arc flutters during TIG welding A Tungsten electrode is too

large for the welding current

A Select the right size

electrode. Refer to Basic TIG Welding Guide

B Absence of oxides in the

weld pool

B Refer to Basic TIG

Welding Guide for ways to reduce arc flutter

11 Welding arc cannot be established A Work clamp is not

connected to the work piece or the work/torch leads are not connected to the right terminals

A Connect the work clamp

to the work piece or connect the work/torch leads to the right welding terminals

B Torch lead is disconnected B Connect it to the '-'

terminal

C Gas flow incorrectly set,

cylinder empty or the torch valve is off

C Select the right flow rate,

change cylinders or turn torch valve on

12 Arc start is not smooth A Tungsten electrode is too

large for the welding current

A Select the right size

electrode. Refer to Basic TIG Welding Guide

B The wrong electrode is

being used for the welding job

B Select the right size

electrode. Refer to Basic TIG Welding Guide

C Gas flow rate is too high C Select the correct rate for

the welding job. Refer to Basic TIG Welding Guide

D Incorrect shielding gas is

being used

D Select the right shielding

gas. Refer to Basic TIG Welding Guide

E Poor work clamp

connection to work piece

E Improve connection to

work piece

Possible CauseDescription Remedy

Table 5-1 (continued): TIG Welding Problems

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March 31, 2008

5.05 Stick Welding Problems

1 Gas pockets or voids in weld metal

(Porosity)

A Electrodes are damp A Dry electrodes before use

B Welding current is too high B Reduce welding current C Surface impurities such as

oil, grease, paint, etc

C Clean joint before welding

2 Crack occurring in weld metal soon

after solidification commences

A Rigidity of joint A Redesign to relieve weld

joint of severe stresses or use crack resistance electrodes

B Insufficient throat thickness B Travel slightly slower to

alloy greater build-up in throat

C Cooling rate is too high C Preheat plate and cool

slowly

3 A gap is left by failure of the weld

metal to fill the root of the weld

A Welding current is too low A Increase welding current

B Electrode too large for joint B Use smaller diameter

electrode C Insufficient gap C Allow wider gap D Incorrect sequence D Use correct build-up

sequence

Possible CauseDescription Remedy

Table 5-2: STICK Welding Problems

Insufﬁcient Gap

Incorrect Sequence

Art # A-05866_AB

Figure 5-1: Example of Insufficient Gap or Incorrect Sequence

SERVICE MANUAL TRANSTIG 200 Pi

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March 31, 2008

4 Portions of the weld run do not

fuse to the surface of the metal or edge of the joint

A Small electrodes used on

heavy cold plate

A Use larger electrodes and

preheat the plate

B Welding current is too low B Increase welding current C Wrong electrode angle C Adjust angle so the

welding arc is directed more into the base metal

D Travel speed of electrode is

too high

D Reduce travel speed of

electrode

E Scale or dirt on joint surface E Clean surface before

welding

Possible CauseDescription Remedy

Table 5-2 (continued): STICK Welding Problems

Art # A-05867_AB

Lack of inter-run fusion

Lack of side fusion, scale dirt, small electrode, amperage too low

Lack of root fusion

Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high

Figure 5-2: Example of Lack of Fusion

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March 31, 2008

5 Non-metallic particles are trapped

in the weld metal (slag inclusion)

A Non-metallic particles may

be trapped in undercut from previous run

A If bad undercut is

present, clean slag out

and cover with a run from

a smaller diameter

electrode B Joint preparation too

restricted

B Allow for adequate

penetration and room for

cleaning out the slag C Irregular deposits allow slag

to be trapped

C If very bad, chip or grind

out irregularities D Lack of penetration with

slag trapped beneath weld bead

D Use smaller electrode with

sufficient current to give

adequate penetration. Use

suitable tools to remove

all slag from corners E Rust or mill scale is

preventing full fusion

E Clean joint before welding

F Wrong electrode for position

in which welding is done

F Use electrodes designed

for position in which

welding is done,

otherwise proper control

of slag is difficult

Possible CauseDescription Remedy

Table 5-2 (continued): STICK Welding Problems

Not cleaned, or incorrect electrode

Slag trapped in undercut

Slag trapped in root

Art # A-05868

Figure 5-3: Examples of Slag Inclusion

SERVICE MANUAL TRANSTIG 200 Pi

5-9

March 31, 2008

5.06 Power Source Problems

1 The welding arc cannot be

established

A The Primary supply voltage

has not been switched ON

A Switch ON the Primary

supply voltage

B The Welding Power Source

switch is switched OFF

B Switch ON the Welding

Power Source

C Loose connections

internally

C Have an Accredited

Cigweld Service Provider repair the connection

2 Maximum output welding current

cannot be achieved with nominal Mains supply voltage

Defective control circuit Have an Accredited

Cigweld Service Provider inspect then repair the welder

3 Welding current reduces when

welding

Poor work lead connection to the work piece

Ensure that the work lead has a positive electrical connection to the work piece

4 No gas flow when the torch trigger

switch is depressed

A Gas hose is cut A Replace gas hose

B Gas passage contains

impurities

B Disconnect gas hose from

the rear of Power Source then raise gas pressure and blow out impurities

C Gas regulator turned off C Turn gas regulator on

Possible CauseDescription Remedy

Table 5-3: Power Source Problems

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5-10

March 31, 2008

5 Gas flow won't shut off A Weld Mode (

STD, SLOPE,

REPEAT or SPOT

) was

changed before

POST-

FLOW

gas time had finished

A Strike an arc to complete

the weld cycle OR switch

machine off then on to

reset solenoid valve

sequence B Gas valve is faulty B Have an Accredited

Cigweld Service Provider

replace gas valve C Gas valve jammed open C Have an Accredited

Cigweld Service Provider

repair or replace gas valve

POST-FLOW

control is set

to 60 sec.

D Reduce

POST-FLOW

time

6 The TIG electrode has been

contaminated due to the gas flow shutting off before the programmed

POST-FLOW

time has

elapsed

The Weld Process Mode (

STICK, HF TIG or LIFT TIG

) was changed before POSTFLOW gas time had finished

Do not change Weld Process Mode before the

POST-FLOW

gas time had

finished

Possible CauseDescription Remedy

Table 5-3 (continued): Power Source Problems

SERVICE MANUAL TRANSTIG 200 Pi

5-11

March 31, 2008

5.07 Power Source Error Codes

Remarks

A The Welding Power

Source's duty cycle has been exceeded

A Let Power Source cool

down then keep within its duty cycle

B Fan ceases to operate B Have an Accredited

Cigweld Service Provider investigate

C Air flow is restricted by

vents being blocked

C Unblock vents then let

Power Source cool down

A The Welding Power

Source's duty cycle has been exceeded

A Let Power Source cool

down then keep within its duty cycle

B Fan ceases to operate B Have an Accredited

Cigweld Service Provider investigate

C Air flow is restricted by

vents being blocked

C Unblock vents then let

Power Source cool down

A Primary current too high

because welding arc is too long

A Reduce length of welding

arc

B Mains supply voltage is

more than 10% below nominal voltage

B Have an Accredited

Cigweld Service Provider or a qualified electrician check for low Mains voltage

4 E04 error code

displayed Output voltage exceeds the secondary voltage specification.

TIG torch cable and/or work lead are too long or leads are coiled.

Reduce the length of the TIG torch cable and/or work lead or un-coiled leads.

Weld current ceases. Buzzer sounds constantly. Switch machine OFF then ON to reset E04 error.

5 E93 error code

displayed. Memory chip (EEPROM) on control PCB cannot read/write weld parameters

Memory chip (EEPROM) error

Have an Accredited Cigweld Service Provider check the control PCB

Weld current ceases. Buzzer sounds constantly. Switch machine off

Possible CauseDescription Remedy

E01 error code displayed. Temperature sensor TH1 (protects IGBTs) is greater than 80°C for about 1 second

Weld current ceases. Buzzer sounds constantly. E01 resets when TH1 decreases to 70°C for about 30 seconds

E02 error code displayed. Temperature sensor TH2 (protects IGBTs) is greater than 90°C for about 1 second

Weld current ceases. Buzzer sounds constantly. E02 resets when TH2 decreases to 70°C for about 30 seconds

E03 error code displayed. Primary (input) current too high

Weld current ceases. Buzzer sounds constantly. Switch machine off then on to reset E03 error

Table 5-4: Power Source Error Codes

TRANSTIG 200 Pi SERVICE MANUAL

5-12

March 31, 2008

Remarks

6 E94 error code

displayed. Temperature sensor TH1 for IGBTs is an open circuit

The Welding Power Source's temperature sensors have malfunctioned

Have an Accredited Cigweld Service Provider check or replace the temperature sensors

Weld current ceases. Buzzer sounds constantly. Switch machine off.

A Main on/off switch on

machine has been turned off

A Turn on/off switch on

B Mains supply (input)

voltage has been turned off

B Have an Accredited

Cigweld Service Provider or a qualified electrician check the Main voltage and fuses

7 E99 error code

displayed. Mains supply (input) voltage has been turned off, but control circuit has power from the primary

Weld current ceases. Buzzer sounds constantly. Must switch machine off then on to reset E99 error

Possible CauseDescription Remedy

Table 5-4 (continued): Power Source Error Codes

SERVICE MANUAL TRANSTIG 200 Pi

5-13

March 31, 2008

5.08 Voltage Reduction Device (VRD)

1. VRD Specification:

Description Transtig 200 Pi Notes

VRD Open Circuit Voltage 15.3 to 19.8V Open circuit voltage between welding

terminals

VRD Resistance 148 to 193 ohms The required resistance between welding

terminals to turn ON the welding power

VRD Turn OFF Time 0.2 to 0.3 seconds The time taken to turn OFF the welding

power once the welding current has stopped

Table 5-5: VRD Specification

2. VRD Maintenance:

Routine inspection and testing (power source):

An inspection of the power source, an insulation resistance test and an earth resistance test shall be carried out.

a) For transportable equipment, at least once every 3 months; and

b) For fixed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record of the periodic tests.

NOTE

A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated.

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; at Vin=240V

VRD Turn ON

Resistance

Less than 200 ohms

VRD Turn OFF

Time

Less than 0.3 seconds

Table 5-6: Periodic Tests

If this equipment is used in a hazardous location or environments with a high risk of electrocution then the above tests should be carried out prior to entering this location.

TRANSTIG 200 Pi SERVICE MANUAL

5-14

March 31, 2008

THIS PAGE LEFT INTENTIONALLY BLANK.

6 ADVANCED TROUBLESHOOTING

6 – 1

ADVANCED TROUBLESHOOTING

If you are here, all of the troubleshooting suggestions in Section 5 - Basic Troubleshooting have either failed to resolve the faulty operation or have indicated that one or more of the subsystems within the power supply are defective. This section provides the information needed to take live measurements on the various subsystems within the power supply, and replace those subsystems that prove faulty.

CAUTION

Troubleshooting and repairing this unit is a process, which should be undertaken only by those familiar with high voltage/high power electronic equipment.

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have training in power electronics, measurement and troubleshooting techniques.

Under no circumstances are field repairs to be attempted on printed circuit boards or other subassemblies of this unit. Evidence of unauthorized repairs will void the factory warranty. If a subassembly is found to be defective by executing any of the procedures in this Service Manual, the subassembly should be replaced with a new one. The faulty subassembly should then be returned to Thermal Arc through established procedures.

WARNING

Disconnect primary power at the source before disassembling the power supply. Frequently review the "Important Safety Precautions" in section 1.02. Be sure the operator is equipped with proper gloves, clothing and eye and ear protection. Make sure no part of the operator's body comes into contact with the work piece or any internal components while the unit is activated.

6.1

System-Level Fault Isolation

If none of the suggestions provided in Section 8 have solved the problem or corrected the faulty operation, the next step is to isolate one or more of the internal subassemblies that may be defective.

CAUTION

Perform all steps in each procedure, in sequence. Skipping portions of procedures, or performing steps out of sequence can result in damage to the unit, and possible injury, or worse, to the operator.

6.1.1 Opening the Enclosure

1) Verify that the switch of power supply and the switch on switchboard (distribution panel) are all OFF.

Figure 6 -1: Switch OFF

CAUTION

2) Remove all screws and nuts on the side panels.

Figure 6- 2: Remove screws

SERVICE MANUAL

TRANSTIG 200 Pi

6 – 2

3) Loosen the screws on the front panel and the rear panel by turning them approximately two turns CCW.

NOTE

DO NOT remove the screws completely.

Figure 6-3: Loosen screws

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.

Figure 6- 4: Loosen front and rear panels

5) Remove the side panels.

Figure 6- 5: Remove Side Panel

6) Remove protection cover sheet by removing the plastic tabs.

Figure 6- 6: Remove PCB cover

NOTE

When you re-assemble the parts, conduct the above process backwards.

TRANSTIG 200 Pi

ADVANCED TROUBLESHOOTING

SERVICE MANUAL

6 – 3

6.2

Verification and Remedy

to the Indicated Error Codes

NOTE

The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete and then remove the cases to continue your inspection and repair (or maintenance) inside the power supply. As for the removal and installation of the case, Refer to section 6.1-1.

NOTE

During the "Verification/Remedy" procedures below, follow the alphabetical sequence (a, b, c...) and proceed with your verification and confirmation.

NOTE

After you Verify and replace all spare parts and components, verify that there are no damaged harnesses or connectors, uninstalled or loose screws.

6.2.1 E01 “Over-Temperature at 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.

 Review the rated duty cycle of the unit per

section 3.8. Exceeding the duty cycle can damage the unit and void the warranty. Refer also to section 1.6 for additional information.

b) Verify the ventilating condition.

 Maintain a clear and unobstructed distance

of more than 30cm in the front and more that 50cm in the rear of the unit for ventilation purposes.

 Verify and maintain clean, dust free, front and

rear airflow paths. Cleaning and removing dust from the front and rear panels once every six months in a normal working environment is recommended. Extremely dusty environments will require more frequent cleanings.

c) Verify the operation of the cooling fan, FAN1,

and replace it if necessary.

 Verify the condition of FAN1. Verify that there

are no broken or cracked fan blades and that FAN1 is not producing any abnormal sounds.

 If broken or cracked FAN1 blades, or abnor-

mal sounds are emanating from FAN1, replace FAN1.

 Refer to section7.3-11 for additional FAN1

tests.

 Refer to section

6.5-3 for the replacement of

FAN1 .

d) Replace PCB4 (WK-5449) and PCB5 (WK-

5448).

 Refer to section

7.3-4, 3-5 for the replace-

ment of PCB4 and PCB5.

6.2.2 E02 “Over-Temperature at the secondary side”

Cause

Occurs when an over-temperature condition of the secondary IGBT and diode are detected.

Verification/Remedy

a) Unit may be in thermal shutdown mode.

 Review the rated duty cycle of the unit per

section Chapter 3.8. Exceeding the duty cycle can damage the unit and void the warranty.

b) Verify the ventilating condition.

 Maintain a clear and unobstructed distance

of more than 30cm in the front and more that 50cm in the rear of the unit for ventilation purposes.

 Verify and maintain clean, dust free, front and

SERVICE MANUAL

ADVANCED TROUBLESHOOTING

TRANSTIG 200 Pi

6 – 4

c) Verify the operation of the cooling fan, FAN1,

and replace it if necessary.

 Verify the condition of FAN1. Verify that there

are no broken or cracked fan blades and that FAN1 is not producing any abnormal sounds.

 If broken or cracked FAN1 blades or abnor-

mal sounds are emanating from FAN1, replace FAN1.

 Verify the operation of the cooling fan and

replace it if the condition of FAN1 is inactive. Follow the instruction in section.

 Refer to section 6.5-3 for additional FAN1

tests.

 Refer to section 7.3-11 for the replacement

of FAN1.

d) Replace PCB4 (WK-5449) and PCB5 (WK-

5448).

 Refer to section

7.3-4, 3-5 for the replace-

ment of PCB4 and PCB5.

6.2.3 E03 “

Primary Over-Current Fail-

ure

”

Cause

Occurs when excessive current is detected flowing into the primary side of the main transformer.

Verification/Remedy

a) Confirm the operation of the machine within

the rated specification.

 Refer to the specification data sheet in sec-

tion 3.9.

b) Verify the secondary diode (D2 and D3).

 Refer to section

6.5-6 for the test of D2 and

D3.

 Refer to section

7.3-8 for the replacement of

D2 and D3.

c) Verify the H.F. unit (HF. UNIT1).

 Refer to section

7.3-12 for the replacement

of HF.UNIT 1.

d) Replace the Hall CT (CT1).

NOTE

Pay special attention to installed direction of CT1. The Hall CT will not function properly if installed in the incorrect direction.

 Refer to section 12.3-10 for the replacement of

CT1.

6.2.4 E94 “Thermistor malfunction”

Cause

Thermistors for detecting temperature of internal components have malfunctioned.

Verification/Remedy

a) Verify a secure connection of the harness

wired between CN5-6 on PCB1 (WK-5713) and Thermistors (TH1, TH2).

 Re-install the harness with a secure connec-

tion.

 Contact the manufacturer if you find any bro-

ken connectors or damaged wiring harness.

b) Replace thermistors (TH1, TH2).

 Refer to section 12.3-12, 3-13.

c) Replace PCB5 (WK-5448).

 Refer to section 12.3-5.

6.2.5 E99 “Initial Power Receiving”

Cause

Occurs when the initial AC power received signal has not reached the CPU. This error occurs normally during the power “OFF” sequence of the unit.

Verification/Remedy

a) Verify the connection between "+" terminal of

Primary diode (D1) and PCB1 (WK-5713).

 Verify that there is no omission of a loosening

connected wire between the PCB1 and D1.

 Contact the manufacturer if you find any bro-

ken connectors or damaged wire.

b) Verify that there is no omission of a loosening

screws and connected harness with PCB1 (WK-5713).

 Re-install the harness with a secure connec-

tion.

 Contact the manufacturer if you find any bro-

ken connectors or damaged wiring harness.

 Replace PCB1. Refer to section

7.3-1.

c) Replace PCB4 (WK-5449) and PCB5 (WK-

5448).

 Refer to section 7.3-4, 3-5 for the replace-

ment of PCB4 and PCB5.

TRANSTIG 200 Pi

ADVANCED TROUBLESHOOTING

SERVICE MANUAL

6 – 5

SERVICE MANUAL ADVANCED TROUBLESHOOTING TRANSTIG 200 Pi

6.2.6 E04 "Torch Cable Failure"

Cause

The combined length of the torch cable and the work cable is too long.

Verification/Remedy

a) Verify the rated duty cycle of the torch/work

cable and the power supply.

• Only use appropriate sized torch cables (length and capacity). The recommended total combined length of the torch and work cable is 50 feet.

• Torch and work cable should not be "coiled" during welding operations.

• Maintain the duty cycle of the power supply. Refer to section 3.8 for the recommended duty cycle.

b) Replace PCB6 (WK-5549)

• Refer to section 12.3.6 for the replacement of PCB6.

6.2.7 E93 "Memory chip (EEPROM) error."

Cause

Memory chip (EEPROM) on control PCB can not read/write weld parameters.

Verification/Remedy

a) Replace Control Board PCB4 (WK-5549).

• Refer to section 7.3.4 for the replacement of PCB4.

6 – 6

6.3

Verification and Remedy

to Failures without Indication Codes

Refer to Note on Section 11.02.

6.3.1 “Cooling Fan (FAN1) Failure” (Fan is not rotating.)

Cause

Occurs when the cooling fan (FAN1) is defective, damaged or the driving voltage is incorrect.

Verification/Remedy

a) Verify the cooling fan, FAN1.

 Inspect the condition of the fan blades and all

peripheral parts. Clean the fan blades and all peripheral parts if covered with dust. Cleaning and removing dust from the fan blades once every 6 months in a normal environment is recommended. Extremely dusty environments

will require more frequent cleanings.

 Verify that there are no wiring harnesses

entangled inside the fan, confirm that the harnesses do not have any brakes in the wire or damaged connectors.

 Replace wiring harnesses if you find any bro-

ken connectors or damaged wiring harnesses.

 Replace the fan if there are any broken,

cracked or missing fan blades. Refer to section

7.3-11.

b) Verify the wiring harness between the cooling

fan (FAN1) and CN2 on PCB1 (WK-5713).

 Verify a secure connection of the harness to

CN2 on PCB1.

c) Verify the drive circuitry of the cooling fan

(FAN1) on PCB1.

 Verify the drive circuitry of the cooling fan

(FAN1) on PCB3.

 Refer to section

6.5-3.

 Replace PCB1 if necessary. Refer to section

7.3.1.

6.3.2 “Gas Valve Failure” (No Gas flow through unit)

Cause

Occurs when the gas valve (SOL1) is defective, damaged or the driving voltage is incorrect.

Verification/Remedy

a) Verify that TIG welding is selected on the weld-

ing mode.

 Do not change welding modes while weld-

ing. Only change welding modes when the unit is idle (torch switch OFF).

 Verify the setting of Pre-flow and Post-flow on

the front panel. If the Pre-flow or Post-flow time is set to 0 seconds, change them to higher setting.

b) Verify the layout the of gas hose.

 Verify that the hose is securely connected

into the fitting at the inlet and the outlet. Verify the layout of the gas hose so that it is not bent or kinked. Verify there are no breaks, burns or holes in the hose.

 Verify the layout of the TIG torch gas hose

and that the hose adapters are properly connected.

c) Verify the wiring harness and connection of gas

valve (SOL1) and CN2 on PCB1 (WK-5713).

 Verify a secure connection of the harness to

CN2 on PCB1.

d) Verify the drive circuitry of the gas valve (SOL1).

 Verify the drive circuitry of the gas valve

(SOL1).

 Refer to secti

on 6.5-4.

 Replace PCB1, when abnormal. Refer to

section

7.3-1.

e) Replace PCB4 (WK-5449) and PCB5 (WK-

5448).

 Refer to section

7.3-4, 3-5 for the replace-

ment of PCB4 and PCB5.

SERVICE MANUAL

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TRANSTIG 200 Pi

6 – 7

6.3.3 “No weld output”

When in High Frequency TIG (HF TIG) mode, if the High Frequency is not generated (present), refer to “High Frequency Output Failure”. Refer to the page 6-7.

Cause

Occurs when the remote connector (CON1) or associated circuitry is defective, damaged, or the TIG torch cable is defective.

Verification/Remedy

CAUTION

Read and understand this entire section before proceeding. Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately.

a) Verify the remote connector (CON1). (Applies

to LIFT TIG and High Frequency TIG (HF TIG) mode.)

 Verify a secure between the remote connec-

tor (CON1) and the TIG torch cable.

 Verify a secure connection of the harness

and the connections between the remote connector (CON1) and CN1 on PCB1 (WK-

5713) are all correct and there are no open circuits.

 Contact the manufacture if you find any bro-

ken connectors or damaged wiring harnesses.

 Verify the proper pins-outs of the remote con-

nector at the TIG Torch side. (Refer to section in the Operating Manual.)

 Verify that there is no open circuit on the

remote connector at TIG Torch side.

 In equipment for remote control use, Verify

the pin specification of a connector. (Refer to section in the Operating Manual.)

b) Verify the condition and connections of the

welding cable, the stick rod holders and the ground clamp. (Applies to all welding modes.)

 Verify a secure connection of the welding

cable, stick rod holders, ground clamp and dense connectors and there are no open circuits.

c) Verify the no-load voltage (OCV). (Applies to

STICK, High Frequency TIG (HF TIG) mode.)

 Refer to the section “Verification of No-load

voltage (No OCV)” in the page

6-13.

 If performing the “No-Load Voltage Failure”

procedure does not rectify the failure, perform the following tests in the sequence below. Replace any defective components found.

1) Secondary diode (D2-D3)

 Verification. Refer to the page

6-12.

 Replacement. Refer to the page

7-15.

2) Coupling coil (C.C.) and Reactor (FCH1)

 Replacement C.C. Refer to the page

15.

 Replacement FCH1. Refer to the page

7-15.

3) Transformer (T1)

 Replacement T1. Refer to the page 12-

10.

4) Primary IGBT (Q1A-Q4C)

 Verification. Refer to the page 6-12.  Replacement. Refer to the page

7-13,

14.

5) Hall C.T. (CT1)

 Replacement CT1. Refer to the page

17.

6.3.4 “Operating Panel Failure” (LED’s do not light properly or welding setting cannot be established.)

Cause

Occurs when there is a connection failure among PCB1 (WK-5713), PCB5 (WK-5448), PCB6 (WK-

5460) and PCB1 or PCB5 or PCB6 are defective.

Verification/Remedy

a) Verify the harness connection between CN101

on PCB1 (WK-5713) and CN1 on PCB4 (WK-

5499).

 Verify a secure connection of the harness

and the connections between CN101 on PCB1 and CN1 on PCB5.

 Contact the manufacture if you find any bro-

ken connectors or damaged wiring harnesses.

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ADVANCED TROUBLESHOOTING

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6 – 8

b) Verify the connection between PCB5 (WK-

5448) and PCB4 (WK-5460).

 Verify that there is no omission of a loosening

screws and connected harness between the PCB4 and PCB5.

 Replace PCB4 and PCB5 if necessary.

Refer to the page

7-11, 12.

6.3.5 “High Frequency Output Failure” (Unit does not generate High Frequency.)

Cause

Occurs when the HF. unit (HF UNIT1) is defective or blown.

Verification/Remedy

CAUTION

Read and understand this entire section before proceeding. Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately. The unit will generate a High Voltage component that can cause extreme personal harm and test equipment damage.Capacitors installed inside the Welding Power Source are electrically charged for a while after the Mains ON/ OFF switch or distribution panel switch has been turned off. Before inspecting the inside of the Welding Power Source, leave it for about 5 min. after switching off power for discharging the capacitors, and then remove the top and side panels.

a) Verify the connection between High Frequency

(HF UNIT1) and Coupling Coil (C.C.).

 Verify the connection between the HF UNIT1

and C.C.; Verify that the quick-disconnect terminals are inserted onto the terminals of HF UNIT1 (TB5- TB6) correctly and completely.

 Verify there are no short circuits, burnt or bro-

ken wires at C.C.

 Replace C.C. Refer to the page

7-15.

b) Verify the connection between High Frequency

(HF UNIT1) and the current limiting resistors (R3 and R4).

 Verify the connection between HF UNIT1 and

the R3 (R4) Verify that the quick-disconnect terminals are inserted onto the terminals of HF UNIT1 (TB3-TB4) correctly and completely.

 Verify there are no short circuits, burnt or bro-

ken wires between the HF UNIT1 and the R3 (R4).

c) Verify the connection between the terminals

between AC1-AC2 (TB1-TB2).

 Verify the connection between AC1-AC2, Ver-

ify that the quick-disconnect terminals are inserted onto the terminals of HF UNIT1 correctly and completely.

 Verify there are no short circuits, burnt or bro-

ken wires between AC1 and AC2.

d) Verify and replace the Gap (GAP) of the High

Frequency Unit (HF UNIT1).

 Verify that the GAP is connected to HF

UNIT1 correctly and completely.

 Verify there is no dust or foreign debris

between the space of the GAP.

 If there are any abnormalities observed with

the GAP, replace the GAP.

The gap is set to 1.0mm.

In the case of a gap 1.0mm or more, high frequency voltage and a period increase.

In the case of a gap 1.0mm or less, high frequency voltage and a period decrease.

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TRANSTIG 200 Pi

6 – 9

6.4

Fault Isolation Tests

6.4.1 Preparation

The following initial conditions must be met prior to starting any of the procedures in this section.

1) Connect the appropriate input voltage. (Check the name plate on the rear of the power supply for the proper input voltage.)

NOTE

Operate at ALL input voltages as noted on the nameplate on the rear panel when testing the power supply.

2) Remove the Side Panel. Refer to the section

6.1.1.

3. Close primary power source wall disconnect switch or circuit breaker.

4) Place power supply MAIN CIRCUIT SWITCH (S1) on rear of unit in the ON position.

WARNING

Dangerous voltage and power levels are present inside this unit. Be sure the operator is equipped with proper gloves, clothing and eye and ear protection. Make sure no part of the operator's body comes into contact with the workpiece or any internal components while the unit is activated.

6.5

Verification of the Power

Input Circuitry

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 6.4.1 "Preparation".

6.5.1 Verification of the AC input voltage using an AC voltmeter

1) Verify input voltage (Phase-to Phase) using an AC voltmeter. (The capability of the voltmeter should be more than 600VAC). Measure the point between lines U1 and V1 on the input switch, S1.

The location of points U1 and V1 on switch S1 are indicated in Figure

6-7.

Figure 6 -7: Check points U1, U2, V1 and V2

2) If the input voltage is out of the operating range of the unit, which is ±10% (207~253VAC) of the rated voltage (230V), verify the available power capacity at the installed site.

If the input voltage is within the operating range, recheck the input voltage while welding, as welding may cause the input voltage to decrease to a value below the operating range of the unit.

3) Verify input voltage after the input switch (S1) using an AC voltmeter. (The capability of the voltmeter should be more than 600VAC.)

 Using an AC voltmeter, measure between the

TRANSTIG 200 Pi

ADVANCED TROUBLESHOOTING

SERVICE MANUAL

6 – 10

points U2 and V2 on the input switch, S1.

The location of points U2 and V2 on switch S1 are indicated in Figure

6-7.

4) If this voltage is out of the operating range, which is ±10% (207~253VAC) of the rated voltage (230V), replace S1 following the process in section 12.3-4.

Verify the rectified output voltage of the primary diode, D1 using a DC voltmeter. (The capability of the voltmeter should be more than 400VDC.) Using a DC voltmeter, measure between the points “+” [+] and “-” [-] on D1. Points “+” and “-” are on PCB1 (WK-5713). See Figure 11-8. The measured voltage should be approximately 1.4 times larger than input voltage measured in #1 above. Replace diode D1 if the calculated measurement is not within the corresponding range (285~360VDC) following the process in section 7.3-4.

Figure 6- 8: The check points “+” and “-”

6) Verify bus voltage (the voltage of the electrolytic capacitor after rectification) using a DC voltmeter. (The capability of the voltmeter should be more than 500VDC.) Using a DC voltmeter, measure between the points TB1(P)[+] and TB3(N)[-] on PCB1 (WK-5713). Points TB1(P) and TB2(N) can be found on the parts side of PCB2. See Figure 11-9. The measured voltage should be approximately 1.4 times larger than input voltage measured in #1 above. Replace diode D1 if the calculated measurement is not within the corresponding range (285 ~ 360VDC) following the process in section 7.3-1.

Figure 6 -9: The check points TB1(P) and TB3(N)

7) After the replacement of D1, if the above voltage is still abnormal, replace PCB1 (WK-5713).

6.5.2 Verification of the Power

Supply Voltage

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 6.4.1 "Preparation".

1) Verify Power Supply voltage using an DC voltmeter. (The capability of the voltmeter should be more than 50VDC.) Operate at all input voltages as noted on the nameplate on the rear panel when testing the power supply.

2) On the PCB5 (WK-5448) and PCB4 (WK-

5449), measure the voltages according to the following table. The check points and the reference are obtainable on the solder side of PCB4 (WK-5449). The locations of points are indicated in Figure

6-10.

Figure 6- 10: Checkpoints TP0-TP3 on PCB6

PCB1(WK-5713)

TB1

TB3

TP0

TP1

TP2

TP3

PCB4 (WK-5449)

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TRANSTIG 200 Pi

6 – 11

Table 6- 1: Checkpoints TP0-TP3 on PCB6

Figure 11-11: Checkpoints CN2 on PCB1

Table 6- 2: Checkpoints CN2 on PCB1

3) If any of these voltages are not present or are below a 10% tolerance, replace PCB1 (WK-

5713). Refer

to page 7-5.

6.5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 6.4.1 "Preparation".

1) Verify the condition of the cooling fan, FAN1, using a DC voltmeter. (The capability of the voltmeter should be more than 50VDC.) Using a DC voltmeter, measure between PIN 1 (Positive [+]) and PIN 2 (Negative [-]) of CN11 on PCB3 (WK-5548). The location of connector CN11 of PCB3 is indicated in Figure 6-12. When you measure the above voltage, do not remove the connector. Conduct the measurement while the connector plug and receptacle are still connected.

Figure 6-12: Verification of the FAN1

2) Using the measurement taken above, follow the chart below for possible failure modes.

Test Point

PCB6

Reference

PCB6

ACCEPTABLE

VALU E TP1 TP0 +5VDC TP2 TP0 +12VDC TP3 TP0 –12VDC

Test Point

PCB1

Reference

PCB1

ACCEPTABLE

VALU E

PIN 1 on CN PIN 2 on CN2 +24VDC

CN2

PCB1(WK-5713)

FAN 1

Status

Voltage

measurement.

(1PIN-2PIN of

CN2 on PCB1)

Remedy

Case 1 Rotating DC 18 ~ 25V

FAN1 drive circuit is normal.

Case 2 Rotating Below DC 18V

ReplacePCB1. Refer to the page 7-5.

CN2

PCB1(WK-5713)

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6 – 12

Table 6-3: Verification of the FAN1

 At the time of a low output and standby, as for

this equipment, rotation of a fan becomes slow. Therefore, exact voltage measuring becomes impossible. Perform the check of voltage in the state of abnormalities.

 When verifying the voltage, Verify that the AC

input voltage remain within the operating range of the unit. (The AC input does not drop below 180VAC).

6.5.4 Verification of the Gas Valve, SOL1, Drive Circuitry

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described at the beginning of an above section “1.Preparation”. Refer to section

6.4-1.

1) Verify the voltage between the 3PIN (Positive [+]) and 4PIN (Negative [-]) of connector CN2 on PCB1 (WK-5713) while you press the torch switch while in TIG Mode. (The capacity of the voltmeter should be more than 50VDC.) The location of connector CN2 of PCB1 (WK-5713) is indicated in Figure 11-13. When you measure the above voltage, do not remove the connector. Conduct the measurement while the connector plug and receptacle are still connected.

Figure 6- 13: Verification of the SOL1

2) Using the measurement taken above, follow the chart below for possible failure modes.

Table 6-4: Verification of the SOL1

3) When verifying the voltage, Verify that the AC input voltage remain within the operating range of the unit. (The AC input does not drop below 180VAC).

6.5.5 Verification of the primary Diode (D1)

CAUTION

6.4-1.

1) Verify the characteristic of the primary diode, D1, using a diode tester.

Case 3 Inactive Below DC 18V

Replace PCB1. Refer to the page 7-5.

Perfor m “2. Verification of the Power Supply Voltage Test”. Refer to the page 6-9.

Case 4 Inactive DC 18 ~ 25V

Replace the

FAN1.Refer to the

page 7-18.

FAN 1

Status

Voltage

measurement.

(1PIN-2PIN of

CN2 on PCB1)

Remedy

Voltage measurement. (1PIN-2PIN of CN2 on

PCB1)

Remedy

Case1 Below DC 18V

Replace PCB1.Refer to the page 7-5.

Case2 DC 18 ~ 25V

Replace SOL1.Refer to the page 7-20.

CN2

PCB1(WK-5713)

SERVICE MANUAL

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TRANSTIG 200 Pi

6 – 13

2) Refer to Table 11-5 and Figure 11-14 for the checkpoints on D1.

Table 6-5: Tester checkpoints for D1

Figure 6- 14: Tester checkpoints in the D1 inter-

connection diagrams

6.5.6 Verification of the secondary Diode (D2, D3)

CAUTION

6.4-1.

1) Verify the characteristic of the secondary diode, D2 and D3, using a diode tester.

2) Refer to Table

6-6 and Figure 6-15 for

the checkpoints on D2 and D3.

Table 11-6: Tester checkpoints for D2 and D3

Figure 6- 15: Tester checkpoints for D2 and D3

6.5.7 Verification of the primary IGBT (Q1A-Q4C)

CAUTION

11.4-1.

1) Check whether there are any abnormalities on the appearance of PCB6 and PCB7.

2) Verify the characteristic of the primary IGBT (Q1A-Q4C), using a diode tester.

3) Refer to Table 11-7 and Figure 11-16 for the checkpoints on PCB6 and PCB7.

COMPONENT

TESTED

TERMINALS

ACCEPTABLE

VALU E

Positive

lead

Negative

lead

Diode of D1

1, 2, 3

0.3 to 0.5V Open

Diode of D1

1, 2, 3

Open

0.3 to 0.5V

2345

COMPONENT

TESTED

TERMINALS

ACCEPTABLE

VALUE

Positive

lead

Negative

lead

Diode 1 of D2, and D3,

Anode

Cathode

Anode

0.2 to 0.3V Open

Diode 2 of D2, and D3,

Anode

Cathode

Anode

0.2 to 0.3V Open

Anode

Cathode

Anode

Cathode

TRANSTIG 200 Pi

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6 – 14

Table 6- 7: Tester checkpoints for Q1A-Q4C

Figure 6 -16: Tester checkpoints for Q1A-Q4C

6.5.8 Verification of No-load Voltage (OCV)

CAUTION

6.4-1.

a) Verify the no-load voltage in STICK mode.

1) In STICK welding mode, mark and then turn potentiometer VR1 on PCB4 (WK-

5449) all the way to the right and turn off the electric shock protector function (Voltage-Reduction-Device, VRD). Refer to section

5.08.

WARNING

Electric shock hazard. The unit will generate OCV immediately when Process mode is put into the state of on pushing Process button enabling STICK mode.

2) Verify the no-load voltage using a DC voltmeter. (The capability of the voltmeter should be more than 100VDC.)

3) The normal no-load voltage is approximately 65V.

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 generate high voltage. To prevent personal harm and test equipment damage, mark and then remove the indicated wire from the HF UNIT1 shown in Figure 11-18. To prevent electric shock, always wrap the removed wire with electrical tape or other suitable insulation.

Figure 6- 17: Removal and installation from the HF

UNIT1 (To disable the operation of the HF unit.)

COMPONENT

TESTED

TERMINALS

ACCEPTABLE

VALU E

Positive

lead

Negative

lead

Collector-Emitter of Q1A~Q2C with PCB6

Open

0.2 to 0.5V

Collector-Emitter of Q3A~Q4C with PCB7

Open

0.2 to 0.5V

E C

PCB7

E C

PCB6

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TRANSTIG 200 Pi

6 – 15

2) Press the Welding mode selection button to select HF TIG welding mode.

3) While depressing the Torch switch, verify the OCV using a DC voltmeter. (The capability of the voltmeter should be more than 100VDC.) The check point with a tester is the voltage between output terminal + and -. In TIG mode, the OCV ceases 3 seconds after you depress the torch switch.

4) The normal no-load voltage is approximately 65V.

5) Return the setting variable resister (VR1) to the original position. (Return to the position recorded by “a. 1)” clause.)

? fully clockwise : VRD ON

? fully counterclockwise : VRD OFF

6) Return connection with HF UNIT1 to the original position.

TRANSTIG 200 Pi

ADVANCED TROUBLESHOOTING

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7 MAINTENANCE

7 – 1

MAINTENANCE

7.1

Subsystem Test and Replacement Procedures

7.1.1 Preparation

This section provides specific procedures for verifying the operation and replacement of each subsystem within the power supply. Before undertaking any of these procedures, eliminate the obvious first-visually inspect the suspect subsystem for physical damage, overheating, and loose connections.

7.1.2 Test and Replacement Parts List

NO. DWG NO. PARTS NAME

REFERENCE

PA GE

PART N O .

1 PCB1 Printed Circuit Board (WK-5713) 12- 5 W7001626

2 PCB2 Printed Circuit Board (WK-5714) 12- 8 W7001627

3 PCB3 Printed Circuit Board (WK-5609) 12- 10 W7001520

4 PCB4 Printed Circuit Board (WK-5449) 12- 11 W7001412

5 PCB5 Printed Circuit Board (WK-5448) 12- 12 W7001729

6 PCB6 (Q1A-Q2C) Print Circuit Board (WK-5460) / Primary IGBT 12 - 13 W7001516

7 PCB7 (Q3A-Q4C) Printed Circuit Board (WK-5460) / Primary IGBT 12-14 W7001516

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TRANSTIG 200 Pi

7 – 2

NO. DWG NO. PARTS NAME

REFERENCE

PA GE

PART N O.

1 C1 Capacitor 12-8 10-6510

2 C101-C102 Capacitor 12-21 W7001622

3 C103 Capacitor 12-24 W7001621

4 C2 Capacitor 12- 25 W7001620

5 C.C. Coupling Coil 12-15 W7001384

6 FCH1 Reactor 12 -15 W7001502

7 HF - UNIT High Freguency Unit 12-19 W7001399

8 L101 Ring Core 12-21 W7001623

9 L102 Reactor 12- 24 W7001625

10 L103 Reactor 12 -24 W7001624

11 R1 Resistor 12 - 8 W7001448

12 R2 Resistor 12-25 W7001619

13 T1 Transformer 12-10 W7001501

13 12

TRANSTIG 200 Pi

MAINTENANCE

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7 – 3

NO. DWG NO. PARTS NAME

REFERENCE

PAG E

PART N O.

1 CON1 Remote Receptacle

12-22 10-6627

2 CT1 Hall Current Trans

12-17 10-5003

3 D1 Primary Diode

12-5 W7001481

4 D2 Secondary Diode

12-15 10-6629

5 D3 Secondary Diode

12-15 10-6629

6 FAN1 Cooling Fan

12-18 10-5227

7S1 Switch

12-21 W7001453

8 SOL1 Solenoid GAS Valve

12-20 W7001635

9 TH1 Primary Thermistor

12-23 10-5228

10 TH2 Secondary Thermistor

12-23 10-5228

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TRANSTIG 200 Pi

7 – 4

7.2

Service Tools

7.2.1 Tools and parts

The tools and parts to be used for maintenance are shown by icons.

7.2.2 Notes of disassembly and assembly

NOTE

When removing the locking type connectors and board supporters, disengage the locking mechanism first and then disconnect them. Locking type connectors and board supporters are indicated in this manual using the following symbols; black star marks for locking connectors and white star marks for locking board supports.

NOTE

During your maintenance or repair, please cut any tie-wraps necessary. However, after your maintenance or repair, please reassemble and tie-wrap all components and wiring in the same manner as before the maintenance or repair.

CAUTION

Please note that you remove each connector, grasp and pull out by the connector part only. Do not pull the harness (cable) part.

WARNING

Philips Head Screwdriver

Long Nose Pliers

C-Ring Pliers

Soldering Copper (solder)

Spanner

Snap Band

Silicon Compound

TRANSTIG 200 Pi

MAINTENANCE

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7 – 5

7.3

Replacement Procedure

7.3.1 PCB1 (WK-5713) and Primary Diode D1 UVX[\

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove the L102. [See section “

7.3-18”]

3) Remove the screw and three cables. Cut the snap band.

4) Remove the terminal and Disconnect the three connectors CN1 (PCB4), CN101, 103 (PCB1).

5) Remove the terminal.

CN103

CN101

CN1

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TRANSTIG 200 Pi

7 – 6

6) Remove the Gas Tube. Remove the two bolts, two toothed washers, and the terminal.

7) Remove the four screws and the Front Panel.

8) Remove the Gas Tube and the two cables.

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7 – 7

9) Remove the four screws and the Rear Panel.

10) Remove the four screws and the two cables. Disconnect the eight connectors CN1-8 on the PCB1.

11) Remove the four screws and Remove the PCB1 unit.

CN2

CN1

CN4 CN5 CN6

CN3

CN8 CN7

SERVICE MANUAL

MAINTENANCE

TRANSTIG 200 Pi

7 – 8

12) Remove the Primary Diode D1 with the soldering iron from the PCB1.

 Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or

equivalent) on the base.

7.3.2 PCB2 (WK-5417), Capacitor C1 and Resistor R1 VX[

1) Remove the Side Panel. [See section "6.1-1"]

2) Remove the PCB1 and D1. [See section "

7.3-1"]

3) Remove the PCB6 and PCB7. [See section “

7.3-6, 3-7”]

4) Remove the screw and the cable.

TRANSTIG 200 Pi

MAINTENANCE

SERVICE MANUAL

7 – 9

5) Remove the eight screws and the PCB2 unit.

6) Remove the screw and Remove the Capacitor C1 and Resistor R1 from the PCB2. Remove the two edge holders and the PCB2 Insulation Sheet from PCB2.

SERVICE MANUAL

MAINTENANCE

TRANSTIG 200 Pi

7 – 10

7.3.3 PCB3 (WK-5609) and T1 “Transformer”V

1) Remove the Side Panel. [See section "6.1-1"]

2) Remove the CT1. [See section “

7.3-10”]

3) Cut the snap band and Remove the cables. Disconnect the three connectors CN1-3 on the PCB3. Remove the three screws and the three cables. Remove the terminal.

4) Remove the 11 screws and PCB3 unit.

 Take care about the shape of the screw when you replace PCB3.

5) Remove the two tap of T1 with the soldering iron from the PCB3. Remove the T-D Bus Bar1 and the T-D Bus Bar2. Open the tap of T1 and Remove the four screws. Remove the T1 from the PCB3.

CN3

CN2

CN1

TRANSTIG 200 Pi

MAINTENANCE

SERVICE MANUAL

7 – 11

7.3.4 PCB4 (WK-5449) V

1) Remove the Side Panel. [See section "6.1-1"]

2) Remove the Protection Cover.

3) Remove the Knob Cap. Holding the Knob down, loosen the screw and remove the Knob.

4) Disconnect the two connectors CN1,3 on the PCB4. Remove the four screws. Pull out the operation panel and bring it down.

CN1

CN3

SERVICE MANUAL

MAINTENANCE

TRANSTIG 200 Pi

7 – 12

5) Remove the four screws. Remove the PCB4.

7.3.5 PCB5 (WK-5448) V

1) Remove the Side Panel. [See section "11.1-1"]

2) Remove the PCB4. [See section “12.3-4”]

3) Remove the three latches of Front Control Cover and then remove the PCB5.

 When reinstalling the PCB5, engage two latches of Front Control Cover first.

TRANSTIG 200 Pi

MAINTENANCE

SERVICE MANUAL

7 – 13

7.3.6 PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT” VX

1) Remove the Side Panel. [See section "6.1-1"]

2) Remove the four screws and two IGBT Spring Clips. Remove the cables from edge holder.

3) Disconnect the connector CN1 on the PCB6. Cut the lead of the Q1A-Q2C.

 Remember to install new Silicone Rubber Sheets where silicone compound (Shinetsu Silicone G-747 or

equivalent) was spread when reinstalling the PCB6. Spread the silicone compound on IGBT.

CN1

1 1

SERVICE MANUAL

MAINTENANCE

TRANSTIG 200 Pi

7 – 14

7.3.7 PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT” VZ

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove the four screws and two IGBT Spring Clips. Remove the cables from edge holder.

3) Disconnect the connector CN1 on the PCB6. Cut the lead of the Q3-Q4C.

 Remember to install new Silicone Rubber Sheets where silicone compound (Shinetsu Silicone G-747 or

equivalent) was spread when reinstalling the PCB7. Spread the silicone compound on IGBT.

CN1

TRANSTIG 200 Pi

MAINTENANCE

SERVICE MANUAL

7 – 15

7.3.8 D2 and D3 “Secondary Diode” V\

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove PCB3 (WK-5569) and T1. [See section “

7.3-3”]

3) Remove six screws and then detach the D2 and D3.

 Do not have the wrong direction of the diodes when reinstalling.  Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or

equivalent) on the base.

7.3.9 C.C. “Coupling Coil” and FCH1 “Reactor” V

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove the Gas Tube. Remove the two bolts, two toothed washers, and the terminal.

SERVICE MANUAL

MAINTENANCE

TRANSTIG 200 Pi

7 – 16

3) Remove the four screws and the Front Panel.

4) Remove the screw and then remove the cable. Remove the two terminals from HF. UNIT. Remove the terminal from PCB3.

5) Remove the C.C. and FCH1.

TRANSTIG 200 Pi

MAINTENANCE

SERVICE MANUAL

7 – 17

7.3.10 CT1 “Hole Current Trans” V

1) Remove the Side Panel. [See section “11.1-1”]

2) Remove the bolts, the spring, and the washer. Remove the three screws and then remove the Output Bus Bar.

3) Remove the CT1. Disconnect the connector.

SERVICE MANUAL

MAINTENANCE

TRANSTIG 200 Pi

7 – 18

7.3.11 FAN1 “Cooling Fan” UVX[

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove the Gas Tube. Remove the two terminals and Cut the three snap bands.

3) Disconnect the connector CN2 on the PCB1 and Cut the snap band.

4) Remove the four screws and then open the Rear Panel.

CN2

TRANSTIG 200 Pi

MAINTENANCE

SERVICE MANUAL

7 – 19

5) Remove the FAN1.

 Do not have the wrong direction of the fan when reinstalling.

7.3.12 HF UNIT1 “High Frequency Unit”V

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove the high frequency gap. Remove the four terminals.

3) Remove the two screws and the two washers. Detach the HF UNIT1.

SERVICE MANUAL

MAINTENANCE

TRANSTIG 200 Pi

7 – 20

7.3.13 SOL1 “Solenoid GAS Valve” V

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove the Gas Tube and two terminals.

3) Remove the C-ring and then detach the SOL1.

 When reinstalling, make sure that the C-ring seats in the solenoid valve groove.

TRANSTIG 200 Pi

MAINTENANCE

SERVICE MANUAL

7 – 21

7.3.14 C101-C102 “Capacitor”, L101 “Ring Core” and S1 “Switch” V

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove the four screws and the six cables. Remove the one nut and one terminal. Remove the C101C102.

3) Cut off the snap band. Remove the L101 from the Input Cable.

4) Remove the two screws and then detach the S1.

SERVICE MANUAL

MAINTENANCE

TRANSTIG 200 Pi

7 – 22

7.3.15 CON1 “Remote Receptacle” UV

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove the screw and then three ground cables. Cut the two snap bands.

3) Cut the snap band and disconnect connector CN1 on the PCB1.

4) Open the Panel Protects. Remove the two screws and the CON1.

CN1

TRANSTIG 200 Pi

MAINTENANCE

SERVICE MANUAL

7 – 23

7.3.16 TH1 “Primary Thermistor” UV\

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove the snap band. Disconnect the connector CN5 on the PCB1. Remove the screw and then detach the TH1. Before installing a new Thermistor, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base.

7.3.17 TH2 “Secondary Thermistor” UV\

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove PCB3 unit. [See section “

7.3-3”]

3) Cut the three snap bands. Disconnect the connector CN6 on the PCB1. Remove the screw and then detach the TH1. Before installing a new Thermistor, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base.

CN5

CN6

SERVICE MANUAL

MAINTENANCE

TRANSTIG 200 Pi

7 – 24

7.3.18 C103 “Capacitor” and L102 “Reactor” V

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove four screws, six terminals. Remove the C103 and L102.

Note : When C103 is installed again, it is a thing fixed to former place on PCB3 by RTV silicon rubber.

7.3.19 L103 “Reactor” VX[U

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove the L102. [See section “

7.3-18”]

3) Cut off two snap bands and remove one screw, three terminals.

TRANSTIG 200 Pi

MAINTENANCE

SERVICE MANUAL

7 – 25

4) Remove four screws and open the Rear Control Cover.

5) Remove one nut, one washer and two terminals. Remove the L103.

7.3.20 C2 “Capacitor” and R2 “Resistor” VX[Z

1) Remove the Side Panel. [See section “6.1-1”]

2) Remove the Gas Tube and the two cables.

SERVICE MANUAL

MAINTENANCE

TRANSTIG 200 Pi

7 – 26

3) Remove the four screws and open the Rear Panel.

4) Remove the CT1. [See section “

7.3-10”]

5) Cut the snap band and remove the cables. Disconnect the three connectors CN1-3 on the PCB3. Remove the three screws and the three cables. Remove the terminal.

6) Remove the 11 screws and PCB3 unit.

 Take care about the shape of the screw when you replace PCB3.

CN3

CN2

CN1

TRANSTIG 200 Pi

MAINTENANCE

SERVICE MANUAL

7 – 27

7) Remove the screw and C2 unit.

8) Remove the C2 with the soldering iron from the R2.

SERVICE MANUAL

MAINTENANCE

TRANSTIG 200 Pi

APPENDIX 1: OPTIONS AND ACCESSORIES

Description Part No. Details

17 Series air cooled TIG torch

(suitable for TransTig 200Pi)

518710402 TIG torch with 4 metre cable & remote

current control

26 Series air cooled TIG torch 538720401 TIG torch with 4 metre cable & remote

current control

200 Amp lead set, 5 metre 646323 1 x 5m work lead; 1 x 5m electrode holder

400 Amp lead set, 8 metre 646325 1 x 8m work lead; 1 x 8m electrode holder

OTD 10/4013 200Pi, 200AC/DC slider only OTD 10/2004 300Pi, 300AC/DC, 400i slider only OTD 10/4014 200Pi, 200AC/DC hand pendant only OTD 10/2005 300Pi, 300AC/DC, 400i hand pendant only OTD 10/4016 200Pi, 200AC/DC

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

10-40 lpm 301711 Flowmeter only

CIGWELD COMET argon

regulator/flowmeter 301526 Regulator/flowmeter only

VAF-4 Wirefeeder (for 400i ONLY) 705700 VAF-4 wirefeeder, 8m interconnection,

operating manual

VS212 Voltage sensing wirefeeder W3512006 VS212 wirefeeder, operating manual Tweco® 4 MIG Torch 717201 MIG torch with 3.6m cable, T4 connection ArcMaster Pro Auto-darkening

Helmet, 9-13 – blue

454294 Welding helmet, 2 x spare cover lenses,

product bag, operating manual

ArcMaster Pro Auto-darkening

Helmet, 9-13 – blue with graphic

454295 Welding helmet, 2 x spare cover lenses,

product bag, operating manual

ArcMaster Pro Auto-darkening

Helmet, 9-13 – black with graphic

454296

Welding helmet, 2 x spare cover lenses,

product bag, operating manual

Slide controller

Hand pendant

Foot controller

A-1

TRANSTIG 200 Pi

SERVICE MANUAL

APPENDIX 2: P ARTS LIST

A-2

Equipment Identification

All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Specificazztion or Assembly numbers.

How To Use This Parts List

The Parts List is a combination of an illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are listed except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc., and permanently attached items which are soldered, riveted, or welded to ot her parts. The part descrip tio ns may be indented to show part relationships. 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 corresponding Parts List.

TRANSTIG 200 Pi 700720

No. DWG No. Part No. Description Type & Rating QTY.

1 CC1 W7001384 Coupling Coil, gen 3.1, IPS F3A040600 200A CC 1 2 CON1 W7001595 Post, Output, gen 3.1, IPS 206433-1 8P (with Wiring Assembly) 1 3 CT2 W7001304 Transformer, gen 3.1, IPS F2A503001 CT 1:40 1 4 D1 10-6628 Diode, gen 3.1, IPS DFA50BA160 1 5 D2 10-6629 Diode, gen 3.1, IPS DBA200UA60 1 6 D4 10-6629 Diode, gen 3.1, IPS DBA200UA60 1 7 D5 10-6629 Diode, gen 3.1, IPS DBA200UA60 1 8 FAN1 W7001307 Fan, gen 3.1, IPS 109E5724H507 DC 24V 16.8W 1 9 FCH1 W7001502 Inductor, gen 3.1, IPS F3A285101 AC/DC FCH 1 10 HCT1 10-5003 Sensor, Current, gen 3.1, IPS HC-TN200V4B15M 200A 4V 1 11 HF.UNIT1 W7001399 HF, Unit, gen 3.1, IPS HF.UNIT (WK-4840 U04) 1 12 10-6633 HF, Gap, gen 3.1, IPS U0A601100 1 13 L101 W7001400 Reactor, gen 3.1, IPS ZCAT-3035-1330 1 14 L103 W7001605 Inductor, earth, gen 3.1, IPS SNG-25B-600 1 15 PCB1 W7001402 PCB, gen 3.1, IPS WK-5477 U01 MAIN_PCB 1 16 PCB2 W7001601 PCB, gen 3.1, IPS WK-5596 U02 CVM CONTROL PCB 1 17 PCB3 W7001314 PCB, gen 3.1, IPS WK-5548 U01 DDC PCB 1 18 PCB4 10-6635 PCB, gen 3.1, IPS WK-4819 U01 DETECT PCB 1 19 PCB5 W7001417 PCB, gen 3.1, IPS WK-5551 U01 CONECT PCB 1 20 PCB6 W7001727 PCB, gen 3.1, IPS WK-5549 U07-1 200A CTRL PCB 1 21 PCB7 W7001423 PCB, gen 3.1, IPS WK-5550 U01 FILTER PCB 1 22 PCB8-9 W7001318 PCB, gen 3.1, IPS WK-5479 U01 GATE PCB (with 2 23 PCB10 W7001812 PCB,WK5527 U13,GEN3.1,IPS WK-5527 U13 PANEL PCB 1 24 PCB11 W7001320 PCB, gen 3.1, IPS WK-5528 U01 ENCODER PCB 1 25 PCB12 W7001594 PCB, gen 3.1, IPS WK-5615 U01 DIODE SNUBBER PCB 1 26 PCB13 W7001433 PCB, gen 3.1, IPS WK-5569 U01 GATE/INPOSE PCB 1 27 PCB14 W7001434 PCB, gen 3.1, IPS WK-5570 U01 IGBT SNUBBER PCB 1 28 PCB16 W7001324 PCB, gen 3.1, IPS WK-5499 U01 FILTER PCB 1 29 PCB17 10-6740 PCB, gen 3.1, IPS WK-4917 U04 INPUT FILTER PCB 1 30 PCB18 W7001602 PCB, gen 3.1, IPS WK-5861 CE FILTER PCB 1 31 Q13 10-6643 Transistor, gen 3.1, IPS GCA200CA60 (with WK-3367 U04) 1 32 R2 W7001449 Resistor, gen 3.1, IPS ERG3SJ220H 3W 22Ω 2 33 R3 10-5137 Resistor, gen 3.1, IPS JG23V101J 68W 100Ω 2

SERVICE MANUAL

TRANSTIG 200 Pi

A-3

.YTQgnitaR&epyTnoitpircseD.oNtraP.oNGWD.oN

34 R4-5 W7001452 Resistor, gen 3.1, IPS MHS20A221KI 20W 220Ω 1 35 R6 W7001451 Resistor, gen 3.1, IPS MHS20A101KI 20W 100Ω 1

36 S1 W7001453 Switch, gen 3.1, IPS DCP-52SR50C-480V 2P-480V (185ACDC) 1 37 SOL1 W7001604 Solenoid Valve, gen 3.1, IPS

5505NBR1.5 DC24V 11VA/10W (with Gas

Inlet and PC4-02)

38 T1 W7001456 Transformer, gen 3.1, IPS F3A063501 200A MAIN TR 1 39 TH1, 2 10-5228 Thermistor, gen 3.1, IPS ERTA53D203 20kΩ/25°CB=3950K 2

1103500D0ESPI,1.3neg,tnorF,lenaP5641007W04 1105500D0ESPI,1.3neg,raeR,lenaP6641007W14 2704500D0ESPI,1.3neg,ediS,lebaL7641007W24

1 000643C0E SPI ,1.3 neg ,revoc ,esaC1331007W34

44 W7001584 Cover, Rear, gen 3.1, IPS JDA173200 (200ACDC) 1

1002303C0ESPI,1.3neg,rotcetorP,revoC8951007W54 1004415ABESPI,1.3neg,redocnE,revoC1976-0164

1)teehSrevoctsuDhtiw(006735B1ESPI,1.3neg,BCP,revoC74

48 W7001600 Label, Name, gen 3.1, IPS N4A932900 (200ACDC) 1

2002587A4NSPI,1.3neg,ediS,lebaL8331007W94 1007920B1NSPI,1.3neg,gninraW1,lebaL9331007W05 1008920B1NSPI,1.3neg,gninraW2,lebaL0431007W15

1 006076A4NSPI ,1.3 neg mret tuptuo ,lebaL 5161007W25 1007040A4NSPI,1.3neg,tupnIsaG,lebaL3376-0135 1001919A4NSPI,1.3neg,DRV,lebaL5431007W45

55 W7001603 Outlet, Gas, gen 3.1, IPS EDA268800 (with PC4-02) 1

2SPI,1.3neg,gniR-C4815-0165

2 S07-53EB-KARTSPI ,1.3 neg ,F tuptuO ,lanimreT 0666-0175

58 N/A Cable, Input, gen 3.1, IPS 132"10/3SOWBLKW/R650 (185ACDC) 1

1008540ABESPI,1.3neg,tupnI,pmalC2666-0195 2009968B1ESPI,1.3neg,knistaeH4751007W06 1000078B1ESPI,1.3neg,knistaeH5751007W16 4001058B1ESPI,1.3neg,TBGI,pilCgnirpS1531007W26 1004710B5JSPI,1.3neg,1BCP,sissahC3851007W36 1005653C3JSPI,1.3neg,sissahC2851007W46 13061262SPI,1.3neg,bonK5666-0156 14011203SPI,1.3neg,paCbonK6666-0166 1002610B1NSPI,1.3neg,rotcetorP,revoC5851007W76

4 007722ADESPI ,1.3 neg ,rebbur ,teehS 7531007W86

3)5M-5M(006346ABESPI,1.3neg,)5M(1,tsoP8531007W96 1005978ACESPI,1.3neg,L-D1,raBsuB6751007W07 1006978ACESPI,1.3neg,L-D2,raBsuB7751007W17 1002788ACESPI,1.3neg,D-T1,raBsuB8751007W27 1003788ACESPI,1.3neg,D-T2,raBsuB37 2000123ACESPI,1.3neg,1S,raBsuB8686-0147 1004109ACESPI,1.3neg,raBsuB0161007W57 1002409ACESPI,1.3neg,CC-T,raBsuB1161007W67 1004220ADESPI,1.3neg,T,raBsuB2161007W77 2001960ADESPI,1.3neg,raBsuB3161007W87 2000278B1ESPI,1.3neg,draoBdetalusnI9631007W97 1005958B1ESPI,1.3neg,teehSnoitalusnI7061007W08 1000471ADESPI,1.3neg,teehSnoitalusnI4161007W18

TRANSTIG 200 Pi

SERVICE MANUAL

PARTS LIST

A-4

41 56

.YTQgnitaR&epyTnoitpircseD.oNtraP.oNGWD.oN

82 W7001616 Sheet, dust cover F, gen 3.1, IPS E1B935200 1 83 W7001609 Sheet, dust cover R, gen 3.1, IPS E1B935600 1

44LARUTAN47#SPI,1.3neg,pilC4731007W48

85 W7001618 Hose, Nylon, gen 3.1, IPS T0425B Nylon Hose L=0.5m 1

105KS-KARTSPI,1.3neg,tuptuO,gulP0202-0168

87 0-4955 Operating Manual, gen 3.1, IPS Operating Manual 1

SERVICE MANUAL

TRANSTIG 200 Pi

PARTS LIST

A-5

TRANSTIG 200 Pi

SERVICE MANUAL

PARTS LIST

APPENDIX 3: CONNECTION WIRING GUIDE

A-6

APPENDIX 2 Connection Wiring Guide

CONNECTION WIRING G UIDE

Destination

A PCB2 CN2

PCB3 CN3

B PCB2 CN3

C PCB3 CN1

D PCB3 CN2

PCB17 CN1

E PCB3 CN7

CT2

PCB3 CN11 l

FAN 1

GSOL1

H PCB3 CN20

PCB8 CN1

I PCB3 CN21

PCB8 CN2

J PCB3 CN22

PCB9 CN1

K PCB3 CN23

PCB9 CN2

L PCB3 CN18

PCB7 CN20

M PCB3 CN33

PCB6 CN20

N PCB6 CN1

HCT1

O PCB6 CN8

TH1

P PCB6 CN9

TH2

Q PCB6 CN17 l

PCB13 CN4

PCB16 CN3

R PCB6 CN21

PCB10 CN2

PCB7

CN14

l CON1

T CN15

U PCB10 CN1

PCB11 CN1

V PCB13 CN6

PCB15 CN1

SERVICE MANUAL

TRANSTIG 200 Pi

A-7

PCB10

PCB9

PCB8

PCB11

PCB7

PCB6

PCB4

PCB3

PCB2

HCT1

PCB13

PCB16

CN2

CN1

CN2

CN1

CN20

CN8

CN9

CN33

CN21

CN17

CN1

CN22

CN11

CN23

CN20

CN14

CN15

CON1

CN3

CN20

CN21

CN1

CN2

CN3

CN4

TH1

TH2

CN3

PCB17

FAN1

SOL1

CN1

CN2

CN1

CT2

CN7

CN18

PCB15

CN6

CN1

CN2

TRANSTIG 200 Pi

SERVICE MANUAL

CONNECTION WIRING GUIDE

APPENDIX 4: INTERCONNECT DIAGRAM

A-8

APPENDIX3 INTERCON NECT DIAGRAM

INTERCONNECT DIAGRAM

INTERCONNECTDIAGRAM

CN130CN131

CN131 CN130

CN132 CN132

Ground

PCB17

Filter

Circuit Board

[WK-4917]

CN2

1 2

(1)

(2)

(0)

K(7) G(6)

R(3)

S(4)

T(5)

PCB2

Link

Circuit Board

[WK-5482]

CN1

3 4 5

C G

PCB8

IGBT Gate

Circuit

Board

[WK-5479]

C G

Q10

C G

Q11

C G

Q12

C G

PCB9

IGBT Gate

Circuit

Board

[WK-5479]

CN2

1 2 3 4

CN1

1 2

CN2

1 2 3 4

PCB4

Detect

Circuit Board

[WK-4819]

CN4

1 2 3 4

CN1CN6CN5

CN5 CN6 CN4

FAN1

TB1

TB2

TB5

TB3

TB4

G2 E2

G1 E1

G4 E4

G3 E3

PCB3

Control Souce

Circuit Board

[WK-5548]

PCB1

Main Circuit Board

[WK-5477]

CN1

1 2 3

PCB6

Control

Circuit Board

[WK-5549]

CT2

CT1

SIDE CHASSIS 1

REAR

PANEL

CN3

1 2

PCB5

Conect Circuit Board

[WK-5551]

CN30CN31

CN31 CN30

CN32 CN32

PCB7 Filter

Circuit

Board

[WK-5550]

CN1

2 3

CN3

2 3 4 5

CN2

2 3

CN1

1 2 3 4 5 6

CN11

1 2 3 4

CN20

2 3 4 5 6

CN21

2 3 4 5 6 7

CN22

2 3 4 5 6

CN23

2 3 4 5 6 7

1 2

CN7

3 4

1 2

CN17

3 4

1 2

CN21

3 4

1 2

CN1

3 4

5 6 7

TB0

CN17 CN17

CN18 CN18

CN27 CN27

CN15

1 2 3 4 5

1 2

CN14

1 : Chassis Ground 2 : Contactor Control/+24VDC 3 : Contactor Control/GND 4 : Not Used 5 : Potentiometer Maximum 6 : Potentiometer Minimum(GND) 7 : Amperage Control Wiper 0-10VDC 8 : Not Used

CN20

1 2 3

CN33

TH2 TH1

1 2 3

CN19

PGND

P+21V

1 2 3

CN18

1 2

CN17

3 4

1 2

CN21

3 4

1 2

CN1

3 4

5 6 7

1 2

CN20

1 2 3

CN9

1 2

CN8

SOL1

TB6

CON1

C2E

E1C

C2EE1C

L101

L103

PCB18

CE Filter

Circuit

Board

[WK-5861]

TB5

TB1

TB2 TB4

TB3

SIDE CHASSIS 2

Ground

TB0

SERVICE MANUAL

TRANSTIG 200 Pi

CIGWELD 200 Pi Transtig Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual