CIGWELD TRANSTIG 200 AC/DC Service Manual

200

Amp

240

V

1

50
60

Hz

INVERTER

TRANSTIG

®

INVERTER ARC WELDER

200 AC/DC

Service Manual

Revision No: AA Issue Date: January 17, 2008 Manual No.: 0-5001

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 please call
[phone], 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 a Global Brand of Arc Welding Products for
Thermadyne Industries Inc. We manufacture and supply to major
welding industry sectors worldwide including; Manufacturing,
Construction, Mining, Automotive, Aerospace, Engineering, Rural
and DIY/Hobbyist.

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

Above all, we are committed to develop technologically advanced
products to achieve a safer working environment 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 200 AC/DC Inverter Arc Welder
Operating Manual Number 0-5001 for:
Part Number 700719

Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermadyne.com

Copyright 2008 by
Thermadyne Industries Inc.

All rights reserved.

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

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

Publication Date: January 17, 2008

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

i

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 Parameter 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:

OPERATOR CONTROLS ............................................................................. 4-1

4.01 Transtig 200 AC/DC Controls .......................................................................... 4-1

4.02 Weld Process Selection for Transtig 200 AC/DC............................................. 4-3

4.03 Weld Parameter Descriptions for Transtig 200 AC/DC.................................... 4-4

4.04 Weld Parameters for Transtig 200 AC/DC....................................................... 4-6

4.05 Power Source Features ................................................................................... 4-7

SECTION 5:

SET-UP FOR SMAW (STICK) AND GTAW (TIG) .................................................. 5-1

SECTION 6:

SEQUENCE OF OPERATION........................................................................ 6-1

6.01 Stick Welding ................................................................................................. 6-2

6.02 AC or DC HF TIG Welding ............................................................................... 6-2

6.03 Slope Mode Sequence .................................................................................... 6-3

6.04 Slope Mode with Repeat Sequence ................................................................ 6-3

6.05 Pulse Controls ................................................................................................ 6-4

TABLE OF CONTENTS (continued)

TABLE OF CONTENTS

SECTION 7:

BASIC TIG WELDING GUIDE ....................................................................... 7-1

7.01 Explanation of “Fluttery Arc” when AC TIG Welding on Aluminum................. 7-1

7.02 Electrode Polarity ........................................................................................... 7-2

7.03 Tungsten Electrode Current Ranges ............................................................... 7-2

7.04 Tungsten Electrode Types ............................................................................... 7-2

7.05 Guide for Selecting Filler Wire Diameter ......................................................... 7-3

7.06 Shielding Gas Selection .................................................................................. 7-3

7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe .................. 7-3

7.08 Welding Parameters for Aluminum ................................................................ 7-4

7.09 Welding Parameters for Steel ......................................................................... 7-4

SECTION 8:

BASIC ARC WELDING GUIDE ..................................................................... 8-1

8.01 Electrode Polarity ........................................................................................... 8-1

8.02 Effects of Stick Welding Various Materials ..................................................... 8-1

SECTION 9:

ROUTINE MAINTENANCE .......................................................................... 9-1

SECTION 10:

BASIC TROUBLESHOOTING ...................................................................... 10-1

10.01 TIG Welding Problems................................................................................ 10-1

10.02 Stick Welding Problems ............................................................................. 10-4

10.03 Power Source Problems ............................................................................. 10-7

10.04 Power Source Error Codes ......................................................................... 10-9

10.04 Power Source Error Codes (con't)........................................................... 10-10

SECTION 11:

VOLTAGE REDUCTION DEVICE (VRD) ........................................................... 11-1

11.01 VRD Specification ....................................................................................... 11-1

11.02 VRD Maintenance ....................................................................................... 11-1

SECTION 12:

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

12.00 Introduction .................................................................................................. 6-1

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

12.1.1 Opening the Enclosure ........................................................................ 6-1

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

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

12.2.2 E02 "Over-Temperature at the secondary side" .................................... 6-4

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

12.2.4 E04 "Torch Cable Failure" ..................................................................... 6-4

12.2.5 E11 "Main Supply Over Voltage" .......................................................... 6-5

12.2.6 E12 "Main Supply Under Voltage" ........................................................ 6-5

12.2.7 E81 "Abnormal Input Voltage".............................................................. 6-5

12.2.8 E82 "Rated Voltage Selection Circuit abnormality" ............................... 6-5

TABLE OF CONTENTS

12.2.9 E83 "Abnormalities in Mains Supply Voltage Detection" ...................... 6-5

12.2.10 E85 "Pre-charge abnormality" ............................................................ 6-6

12.2.11 E94 "Thermistor malfunction" ............................................................ 6-6

12.2.12 E99 "Initial Power Receiving" ............................................................. 6-6

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

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

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

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

12.3.4 "Operating Panel Failure"...................................................................... 6-8

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

12.04 Fault Isolation Tests ...................................................................................... 6-9

12.4.1 Preparation .......................................................................................... 6-9

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

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

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

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

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

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

12.5.6 Verification of the secondary Diode (D2, D4, D5) .............................. 6-13

12.5.7 Verification of the primary IGBT (Q1-Q12) ........................................ 6-14

12.5.8 Verification of the secondary IGBT (Q13) .......................................... 6-14

12.5.9 Verification of No-load Voltage (OCV) ............................................... 6-15

SECTION 13:

MAINTENANCE ...................................................................................... 13-1

13.1 Maintenance List .......................................................................................... 13-1

13.2 Service Tools ................................................................................................ 13-5

13.2.1 Tools and parts .................................................................................. 13-5

13.2.2 Notes of disassembly and assembly ................................................. 13-5

13.3 Replacement Procedure ............................................................................... 13-6

13.3.1 PCB1 (WK-5477) ............................................................................... 13-6

13.3.2 PCB2 (WK-5596) ............................................................................... 13-7

13.3.3 PCB3 (WK-5548), PCB5 (WK-5551) ................................................. 13-9

13.3.4 PCB4 (WK-4819) ............................................................................. 13-10

13.3.5 PCB6 (WK-5549) ............................................................................. 13-10

13.3.6 PCB7 (WK-5550) ............................................................................. 13-11

13.3.7 PCB8 (WK-5479) (IGBT (Q1~Q6)) ................................................... 13-11

13.3.8 PCB9 (WK-5479) (IGBT (Q7~Q12)) ................................................. 13-12

13.3.9 PCB10 (WK-5527) ........................................................................... 13-13

13.3.10 PCB11 (WK-5528) ......................................................................... 13-13

13.3.11 PCB12 (WK-5615), Transformer (T1), Current Trans (CT2) .......... 13-15

13.3.12 PCB13 (WK-5569) ......................................................................... 13-18

13.3.13 PCB16 (WK-5499) ......................................................................... 13-19

13.3.14 PCB14 (WK-5570) ......................................................................... 13-19

13.3.15 PCB17 (WK-4917) ......................................................................... 13-20

13.3.16 PCB18 (WK-5861) ......................................................................... 13-21

TABLE OF CONTENTS (continued)

TABLE OF CONTENTS

13.3.17 Discharge Resistor (R3) ................................................................ 13-22

13.3.18 Current Limiting Resistor (R4, R5)................................................ 13-23

13.3.19 Resistor on High Frequency Unit (R6) ........................................... 13-24

13.3.20 Coupling Coil (CC1) ....................................................................... 13-24

13.3.21 Reactor (FCH1).............................................................................. 13-25

13.3.22 Primary Thermistor (TH1) ............................................................. 13-26

13.3.23 Secondary Thermistor (TH2) ......................................................... 13-26

13.3.24 Cooling Fan (FAN1) ....................................................................... 13-27

13.3.25 Solenoid Valve (SOL1)................................................................... 13-28

13.3.26 Main ON/OFF Switch (S1).............................................................. 13-29

13.3.27 Remote Connector (CON1) ............................................................ 13-29

13.3.28 High Freguency Unit (HF.UNIT1) ................................................... 13-31

13.3.29 Hall C.T. (HCT1) ............................................................................. 13-31

13.3.30 Primary Diode (D1) ....................................................................... 13-32

13.3.31 Secondary Diode (D2, D4, D5) ...................................................... 13-33

13.3.32 Secondary IGBT (Q13) (PCB15 (WK-3367)) ................................. 13-34

13.3.33 Reactor (L101) .............................................................................. 13-35

13.3.34 Earth Inductance (L103)................................................................ 13-35

APPENDIX 1: PARTS LIST ................................................................................ A-1

APPENDIX 2: CONNECTION WIRING GUIDE ........................................................... A-5

APPENDIX 3: DIODE TESTING BASICS .................................................................. A-7

APPENDIX 4: TRANSTIG 200 AC/DC ACCESSORIES .................................................. A-8

APPENDIX 5: TRANSTIG 200 AC/DC INTERCONNECTION DIAGRAM ............................... A-9

CIGWELD LIMITED WARRANTY

Terms of Warranty – January 2008

Warranty Schedule – January 2008

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

THIS PAGE LEFT INTENTIONALLY BLANK

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 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 AC/DC SERVICE MANUAL

1-2

January 17, 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

12

Medium 300 to 400 Amp 12

Over ¼ in., 6.4 mm

14

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 AC/DC

January 17, 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 AC/DC SERVICE MANUAL

1-4

January 17, 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 AC/DC

January 17, 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 AC/DC SERVICE MANUAL

1-6

January 17, 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.

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008

2-1

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

This Service 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 Transtig 200 AC/DC
Service 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.au.com

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.

TRANSTIG 200 AC/DC SERVICE MANUAL

2-2

January 17, 2008

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

On

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-04130

115V 15A

t

t1

t2

%

X

IPM

MPM

t

V

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

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

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008

2-3

2.05 Description

The Transtig 200 AC/DC is a self contained single­phase AC/DC arc welding power source with Constant
Current (CC) output characteristics. This unit is
equipped with a Digital Volt/Amperage Meter, gas
control valve, built in Sloper and Pulser, lift arc 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 retardant and
non-conductive plastic case.

(V)
OCV

5A 160A (A)

STICK Process

(V)
OCV

10V

25A 200A

(A)

LIFT TIG Process

(V)
OCV

5A

200A

(A)

HF TIG Process

Art # A-07443

Figure 2-1: Transtig 200 AC/DC Volt-Ampere curve

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.

TRANSTIG 200 AC/DC SERVICE MANUAL

2-4

January 17, 2008

2.06 Functional Block Diagrams

Figure 2-2 illustrates the functional block diagram of the 200 AC/DC-power supply.

Ma i n

Circuit

Switch

Fil ter

Input

Diode

Primary

Capacitor

DC Power

Voltage

Sensor

IGBT

Inverter

Thermal

Detec tor

To each control circuit

+/-15VDC +18VDC

+24VDC +5VDC

Trouble

Sensing

Circuit

Drive

Circuit

Torch Control

Connection

(CON1 )

circuit

Current

Adjustment

Referenc e

Adjustment &

Mode select Switches

Panel Circuit Board

Sequence

Control

Themal

Sensor

Circuit

Ma i n

Transformer

(PC B1 4)

Ou tpu t

Diodes

HF-UNIT

Control

Circ uit

Stick Mode

VRD

Sensing

Circuit

Lift Tig Mode

Outpu t Sh ort

Sensing

Circuit

Coupling

High

Coil

Frequ ency

Unit

Fan Control

Circuit

Gas Co ntrol

Circuit

Fan

Solenoid

Hall Current

Transformer

(HC T1 )

Out pu t

Induc tor

Thermal

Detector

+

-

+-

Input

Power

Secondary

DC Power

Voltage Sensor

To eac h control circuit

+/-12VDC +15VDC

Secondary

IGBT

Inverter

Drive

Circuit

Primary

Current

Sensor

Art # A-07267

Figure 2-2: Transtig 200 AC/DC Functional Block Diagram

2.07 Transporting Methods

This unit is 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.

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008

2-5

2.08 Parameter Specifications

Table 2-1: Parameter Specifications

Pa ramete r Tra nstig 200 AC/DC

Power Source Part Number700719

CoolingFan Cooled

Welder TypeInverter Power Source

Welding Power Source Mass19kg

DimensionsH 360mm x W 180mm x L 420mm

Manufactured to Australian StandardAS 60974.1-2006

Number of Phases1

Nominal Supply Voltage240V ±15%

Nominal Supply Frequency50Hz

Protection ClassIP23S

Standa rd Specifications (Applicable with factory fitted Supply Pl ug)

Pa ramete r Tra nstig 200 AC/DC

Welding Current Range5 - 200 Amps

Open Circuit Voltage65V

Factory Fitted Supply Plug Rating 15 Amps

Effective Input Current (I1eff) 15 Amps

Maximum Input Current (I1 max)36.7 Amps

Single Phase Generator Requirement8.8 KVA

Welding Output

(Quoted figures refer to MMAW output)

160A @ 15%, 26.4V

80A @ 60%, 23.2V

62A @ 100%, 22.5V

Welding Output

(Quoted figures refer to GTAW output)

200A @ 20%, 18.0V

130A @ 60%, 15.2V

100A @ 100%, 14.0V

Upgraded S pe cifica tions (Applicable wi th upgra de d S upply Pl ug)

Pa ramete r Tra nstig 200 AC/DC

Welding Current Range5 - 200 Amps

Open Circuit Voltage65V

Upgraded Supply Plug Rating Required 25 Amps

Effective Input Current (I1eff)23.2 Amps

Maximum Input Current (I1 max) 36.7 Amps

Single Phase Generator Requirement 8.8 KVA

Welding Output

(Quoted figures refer to MMAW output)

160A @ 40%, 26.4V

130A @ 60%, 25.2V

100A @ 100%, 24.0V

Welding Output

(Quoted figures refer to GTAW output)

200A @ 20%, 18.0V

130A @ 60%, 15.2V

100A @ 100%, 14.0V

TRANSTIG 200 AC/DC SERVICE MANUAL

2-6

January 17, 2008

NOTES

January 17, 2008

3-1

SERVICE MANUAL TRANSTIG 200 AC/DC

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 AC/DC is designed for use in
hazardous environments. Examples of environments
with increased hazardous conditions 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 conditions 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.

3-2

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

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 AC/DC

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.

Motor start fuses or thermal circuit breakers are recommended for this application.

Model

Mains Supply Lead Minimum 240V Mains Input Supply

Size (Factory Current Circuit Size Plug Current

Fitte d)

Rating

Transtig 200 AC/DC 2.5 mm

2

36.7 Amps 25A

Table 3-1: 240V Mains Current Circuit recommendations

January 17, 2008

3-3

SERVICE MANUAL TRANSTIG 200 AC/DC

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.

3-4

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

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
manufacturer's 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.

January 17, 2008

4-1

SERVICE MANUAL TRANSTIG 200 AC/DC

SECTION 4:

OPERATOR CONTROLS

4.01 Transtig 200 AC/DC Controls

Art # A-08341_AC

Figure 4-1: Transtig 200 AC/DC Power Source

1. Control Knob: This control sets the selected weld

parameter, rotating it clockwise increases the
parameter that 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.

Art # A-04984

21

543

678

12345678

5k Ohms

GND

Figure 4-2: 8-Socket Receptacle

Socket Pin Function

1 Earth (Ground)

Torch Switch Input (24V) to
(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)
4Not Used
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
8Not Used

2

Table 4-1: Socket Pin Functions

4-2

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

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.

CAUTION

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

5. Gas Outlet: Torch / Gas Terminal is an all-in-one

design of the Gas Outlet and the Negative Terminal.
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 may be 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.

January 17, 2008

4-3

SERVICE MANUAL TRANSTIG 200 AC/DC

4.02 Weld Process Selection for Transtig 200 AC/DC

Weld Mode

Weld Process

Selection

STICK

HF

TIG

LIFT

TIG

Description

STD

Yes Yes Yes

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

SLOPE

No Yes Yes

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

REPEAT

No Yes Yes

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

SPOT

No Yes No

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

PULSE ON/OFF

No Yes Yes Pulse operation in TIG Modes

Yes Yes Yes Selects AC or DC weld current

Operation

PANEL/REMOTE

Yes Yes Yes Selects mode of operation: Panel or Remote

Table 4-2: Weld Process selection versus Weld Mode for Transtig 200 AC/DC

4-4

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

4.03 Weld Parameter Descriptions for Transtig 200 AC/DC

Art # A-07237_AC

PRESS AND HOLD

Figure 4-3: Transtig 200 AC/DC Front Panel

Parameter Description

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

or

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

This parameter operates in TIG modes only and is used to provide 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

PRE-FLOW

Table 4-3: Transtig 200 AC/DC Front Panel Parameter Description

January 17, 2008

4-5

SERVICE MANUAL TRANSTIG 200 AC/DC

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

(BackgroundCurrent)

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

SPOT TIME

This parameter sets the duration of the

SPOT TIME

in

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.

AC FREQUENCY

This parameter operates in AC mode only and is used to set the
frequency for the AC weld current.

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

SLOPE

or

REPEAT

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

The SAVE/LOAD buttons are used to save and retrieve a total number of
5 programs into the 200AC/DC memory. Note: Press button for three
seconds to store settings.

WAVE BALANCE

This parameter is used for aluminum AC TIG mode and is used to set the
penetration to cleaning action ratio for the AC weld current. Generally

WAVE BALANCE

is set to 50% for AC

STICK

welding. The

WAVE

BALANCE

control changes the ratio of penetration to cleaning action of
the AC TIG welding arc. Maximum weld penetration is achieved when
the

WAVE BALANCE

control is set to 10%. Maximum cleaning of heavily

oxidised aluminium or magnesium alloys is achieved when the

WAVE

BALANCE

control is set to 65%.

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.

WAVE BALANCE=10%

Maximum Penetration and

reduced cleaning

WAVE BALANCE=50%

Balanced with 50% penetration

and 50% cleaning

WAVE BALANCE=65%

Maximum Cleaning and

reduced penetration

10%50% 65%

90%50% 35%

(+ )(+)(+)

(- )(-)(-)

Table 4-3: Transtig 200 AC/DC Front Panel Parameter Description (cont.)

4-6

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

4.04 Weld Parameters for Transtig 200 AC/DC

Weld HF

Parameter STICK 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.

5 to 185A 30A 1A No Yes Yes

UP SLOPE

0 to 15 sec 1 sec 0.1 sec No Yes Yes

PEAK CUR.

5 to 185A 120A 1A No Yes Yes

WELD CUR

(TIG)

WELD CUR (STICK)

5 to 160A 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

See

Table 6

AC FREQUENCY

15 to 150Hz 50Hz 1Hz Yes Yes Yes

WAVE BALANCE

10 to 65% 50% 1% Yes Yes Yes

DOWN SLOPE

0 to 25 sec 3 sec 0.1 sec No Yes Yes

CRATER CUR.

5 to 185A 30A 1A No Yes Yes

POST-FLOW

0.0 to 60 sec 10 sec 0.1 sec No Yes Yes

Weld Mode

Parameter

Range

Factory

Setting

Incremental

Unit

LIFT TIG

PULSE FREQ.

0.5 to 500Hz 100.0Hz No Yes Yes

5 to 185A 80A 1A No Yes Yes

Table 4-4: Weld Parameters for Transtig 200 AC/DC

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

January 17, 2008

4-7

SERVICE MANUAL TRANSTIG 200 AC/DC

4.05 Power Source Features

Feature Description

New Digital Control

• Almost all welding parameters are adjustable

Touch Panel Switches

• Touch switches eliminate mechanical damage

Front Control Cover

• Protects front panel controls

Digital Meter

• Displays selected weld parameter value

• 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

Intelligent Fan Control

• The intelligent cooling system is designed to reduce

dust and foreign material build-up, whilst providing
optimum cooling

• Fan speed reduces approximately 30 seconds after

machine is turned on

• Fan speed increases when internal components

reaches operating temperature

ON/OFF Switch

• Primary voltage Supply ON/OFF switch located on

rear panel

Voltage Reduction Device (VRD)

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.

Control Knob

• For the selected weld parameter, rotating the knob

clockwise increases the parameter

• Rotating the knob counter-clockwise 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.

Table 4-6: Power Source Features

4-8

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

Feature Description

Save/Load Function

• A total number of 5 programs can be saved into the 200

AC/DC memory.

SAVE

the Current Weld Parameters into Memory

• Press and HOLD the

SAVE

button for three seconds. Beep

will sound and the Digital Meter will show a number 1.

• Select a memory location by rotating the control knob,

1 to 5 is displayed on the meter.

• After selecting the desired memory location (i.e. 1 to 5),

press the right scroll button and the machine will give a
beep to confirm the weld parameters from the control panel
are saved.

LOAD

(retrieve) a Program to Control Panel

• Press and HOLD the

LOAD

button for three seconds. Beep

will sound and the Digital Meter display will show a number

1.

• Select a memory location by rotating the control knob,

1 to 5 is displayed on the meter.

After selecting the desired memory location (i.e. 1 to 5),
press the right scroll button and the machine will give a
beep to confirm the weld parameters are loaded onto the
control panel.

Table 4-6:Power Source Features (cont.)

January 17, 2008

5-1

SERVICE MANUAL TRANSTIG 200 AC/DC

SECTION 5:

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 5-1: Transtig 200 AC/DC Set-up

5-2

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

NOTES

January 17, 2008

6-1

SERVICE MANUAL TRANSTIG 200 AC/DC

SECTION 6:

SEQUENCE OF OPERATION

Scroll Buttons are used to select the parameters to be set. The LED’s show which function is
being adjusted on the weld sequence graph. Refer to the Symbols Table located in the front
of the manual for Symbol descriptions.

1

8

3

4

6

9

2

7

5

Art # A-07272_AC

PRESS AND HOLD

Figure 6-1: Transtig 200 AC/DC Front Panel

1. Pulse Function: Pressing this button enables the TIG current pulse functions.

2. Remote Current Function: Pressing this buttons enables remote current functions.

3. TIG Mode Functions: Pressing this button scrolls through the output TIG function modes (Standard,

Slope, Slope w/repeat, Spot).

4. 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.

5. Save/Load Buttons: By using the Save & Load buttons the operator can easily save up to five welding

parameter programs. The buttons must be pressed for three seconds to store the settings.

6. Control Knob: Allows the operator to adjust the output amperage within the entire range of the power

source and sets each parameter value.

7. Process Button: This button selects between STICK, HF TIG and Lift TIG mode.

8. Scroll Buttons: Used to select the parameters to be set. The LED’s show which function is being

adjusted on the Sequence Graph.

9. AC/DC Button: Selects between AC or DC welding output.

6-2

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

6.01 Stick Welding

· Connect work lead to negative terminal

· Connect electrode lead to positive terminal

· Switch machine on

· Set

AC

or DC weld current. If AC is selected then

set

AC FREQ

to 60Hz &

WAVE BALANCE

to 50%.

· Set Contractor

· 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

6.02 AC or DC HF TIG Welding

· Connect work lead to positive terminal

·

Connect TIG torch to gas terminal

·

Switch machine on

·

Set AC or DC weld current. If AC is selected then
set

AC FREQ

&

WAVE BALANCE

·

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

PRE-FLOW

time

· Set

HOT START

current

· Set

POST-FLOW

time

· Set

(WELD) PEAK CUR

current

· Set

POST-FLOW

time

Slope Mode Parameters if required

· Set

INITIAL 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

January 17, 2008

6-3

SERVICE MANUAL TRANSTIG 200 AC/DC

6.03 Slope Mode Sequence

Weld Current

Down

Slope

Up

Slope

Initial

Current

Switch
Closed

Switch
Open

Switch
Closed

Switch
Open

Preflow

Final

Current

Postflow

Art # A-04989

Figure 6-2: 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.

6.04 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 be 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.

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.

NOTE

Slope function operates with a Remote
ON/OFF device only

6-4

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

6.05 Pulse Controls

(Peak Current)

(Base)

Background

Current

(Pulse Width) (Pulse Frequency)

Art # A-04990

Figure 6-3: Pulse Controls

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

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

2) Increase penetration

3) Travel speed control

4) Better consistent quality

5) Decreased 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 remains 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.

January 17, 2008

7-1

SERVICE MANUAL TRANSTIG 200 AC/DC

SECTION 7:

BASIC TIG WELDING GUIDE

7.01 Explanation of “Fluttery Arc”
when AC TIG Welding on
Aluminum

The following will assist in understanding the
phenomenon of Arc Flutter, also referred to as Arc
Rectification.

The basic thesis is that the fluttering is caused by
lack of oxide in the weld pool.

The oxide layer on the plate reduced the energy for
electron emission. Electron emission from the weld
pool (DC+) causes the oxide layers to be disrupted,
the so-called “cleaning action”. However once the
cleaning action has produced a mirror like surface on
the weld pool, the effect of the oxide layer is limited
because the oxide layer has dissipated. This makes
electron emission from the weld pool more difficult
and increases the chance of arc instability.

This idea is supported by the observation that once
fluttering starts it can be made to stop by working
the arc away from the mirror like weld pool to an area
of oxide coated material. As soon as this is done the
arc settles back to a stable condition. So while the
arc is “consuming” oxide coated plate the instability
does not occur. But once the arc is stationary, the
pool becomes thoroughly “cleaned” by election
emission, the fluttering begins.

Tests conducted on various types of AC TIG power
sources, Fluttery Arc is not confined to one type of
power source or its' design, both conventional and
inverter types suffer from the same problem.

AC TIG on aluminum

1. The Problem: Arc appears unstable and pulses or flutters. ie. appears to rapidly change welding current

.

Conditions that accentuate arc flutter: Conditions that minimizes arc flutter:

• Cold work piece • Preheat the work piece

• Very short arc length • Increase the arc length

• Weld pool crater about 0.39” to 0.47”

(10 to 12mm) diameter

• Introduce filler rod material to the weld

pool, which introduces oxides

• Arc field in one spot to produce

“mirror” clean weld pool

• Move the weld pool around to introduce

oxides to the weld pool

• Increased cleaning action

i.e. Prolonged oxide emission from a
stationary weld pool increases the
likelihood of arc flutter

• Decrease the cleaning action by turning

the

WAVE BALANCE

to below 50% or

move the weld pool around

• Accentuated when tungsten running

near its current capacity, i.e. Molten ball
on end

• Use a larger diameter tungsten electrode

Table 7-1: Reduction of Arc Flutter

2. Conclusion: Fluttery Arc in AC TIG is a physical phenomenon independent of machine design.

7-2

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

7.02 Electrode Polarity

Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current
straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows
limited wear of the electrode since 70% of the heat is concentrated at the work piece.

7.03 Tungsten Electrode Current Ranges

Electrode Diameter AC Current (Amps) DC Current (Amps)

0.040” (1.0mm) 30 – 70 30 – 60
1/16” (1.6mm) 60 – 95 60 – 115
3/32” (2.4mm) 125 – 150 100 – 165

1/8” (3.2mm) 130 – 225 135 – 200
5/32” (4.0mm) 190 – 280 190 – 280
3/16” (4.8mm) 250 – 340 250 – 340

Table 7-2: Current ranges for various tungsten electrode sizes

7.04 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

Zirconated 1%

High quality AC welding of
aluminium, magnesium and
their alloys

Self cleaning, long life,
maintains balled end, high
current carrying capacity

White

Ceriated 2%

AC & 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 7-3: Tungsten Electrode Types

January 17, 2008

7-3

SERVICE MANUAL TRANSTIG 200 AC/DC

7.05 Guide for Selecting Filler Wire Diameter

NOTE

The filler wire diameter specified in Table 7-4 is a guide only, other diameter wires may be used
according to the welding application

AC Current Range DC Current Range

(Amps) (Amps)

1/16” (1.6 mm) 30-95 20 - 90
3/32” (2.4 mm) 125-160 65 - 115

1/8” (3.2 mm) 180-240 100 - 165

3/16” (4.8 mm) 220-320 200-350

Filler Wire Diameter

Table 7-4: Filler Wire Selection Guide

7.06 Shielding Gas Selection

Shielding Gas

Aluminium & alloys Welding Argon
Carbon Steel Welding Argon
Stainless Steel Welding Argon
Copper Welding Argon

Alloy

Table 7-5: Shielding Gas Selection

7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe

Current Range DC

Amperes

Thoriated 2%

3/32” (2.4 mm)

Thoriated 2%

3/32” (2.4 mm)

Thoriated 2%

3/32” (2.4 mm)

Electrode Type &

Diameter

Filler Rod for

Root Pass

Joint Preparation

120 - 170 Yes

100 - 160 Yes

90 - 130 No

Table 7-6: TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe

7-4

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

7.08 Welding Parameters for Aluminum

Filler Rod

Diameter

(if required)

0.040” 30-45 0.040” 1/16” Butt/Corner

1.0mm 35-50 1.0mm 1.6mm Lap/ Fillet

0.045” 40-60 0.040” 1/16” Butt/Corner

1.2mm 45-70 1.0mm 1.6mm Lap/ Fillet
1/16” 60-85 1/16” 1/16” Butt/Corner

1.6mm 70-95 1.6mm 1.6mm Lap/ Fillet

1/8” 3/32” 3/32”

3.2mm 2.4mm 2.4mm

1/8”

3.2mm

3/16” 180-225 1/8” 1/8” Butt/Corner

4.8mm 190-240 3.2mm 3.2mm Lap/ Fillet

¼” 240-280 3/16” 3/16” Butt/Corner

6.4mm 250-320 4.8mm 4.8mm Lap/ Fillet

125-150
130-160

Base Metal

Thickness

AC Current for

Aluminum

Tungsten

Electrode

Diameter

10

13

Joint Type

Butt/Corner

Lap/Fillet

5-7

5-7

7

10

Argon Gas
Flow Rate
Liters/min

Table 7-7: AC TIG Welding Parameters

7.09 Welding Parameters for Steel

Filler Rod

Diameter

(if required)

0.040” 35-45 20-30 0.040” 1/16” Butt/Corner

1.0mm 40-50 25-35 1.0mm 1.6mm Lap/ Fillet

0.045” 45-55 30-45 0.040” 1/16” Butt/Corner

1.2mm 50-60 35-50 1.0mm 1.6mm Lap/ Fillet
1/16” 60-70 40-60 1/16” 1/16” Butt/Corner

1.6mm 70-90 50-70 1.6mm 1.6mm Lap/ Fillet

1/8” 80-100 65-85 1/16” 3/32” Butt/Corner

3.2mm 90-115 90-110 1.6mm 2.4mm Lap/ Fillet
3/16” 115-135 100-125 3/32” 1/8” Butt/Corner

4.8mm 140-165 125-150 2.4mm 3.2mm Lap/ Fillet

¼” 160-175 135-160 1/8” 5/32” Butt/Corner

6.4mm 170-200 160-180 3.2mm 4.0mm Lap/ Fillet

Base Metal

Thickness

DC Current

for Mild

Steel

DC Current for

Stainless

Steel

Tungsten

Electrode

Diameter

7

10

10

Joint Type

Argon Gas

Flow Rate
Liters/min

5-7

5-7

7

Table 7-8: DC TIG Welding Parameters

January 17, 2008

8-1

SERVICE MANUAL TRANSTIG 200 AC/DC

SECTION 8:

BASIC ARC WELDING GUIDE

8.01 Electrode Polarity

Stick electrodes are generally connected to the ‘+’
terminal and the work lead to the ‘-’ terminal but if in
doubt consult the electrode manufacturers literature.

8.02 Effects of Stick Welding Various
Materials

High Tensile and Alloy Ateels

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.

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.

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 white­heart malleable, due to the porosity caused by gas
held in this type of iron.

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.

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.

8-2

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

Metals being

joined

Electrode Comments

Mild Steel 6013 Ideal electrodes for all general

purpose work. Features include
outstanding operator appeal, easy
arc starting and low spatter.

Mild Steel 7014 All positional electrode for use on

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.

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 resistant,
all hard-to-weld
jobs.

312-16 It will weld most problematic jobs

such as springs, shafts, broken
joints, mild steel to stainless and
alloy steel.
Not suitable for Aluminium.

Table 8-1: Types of Electrodes

January 17, 2008

9-1

SERVICE MANUAL TRANSTIG 200 AC/DC

SECTION 9:

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.

The unit should be wiped clean as necessary with solvents that are recommended for cleaning electrical
apparatus. Turn Power Switch to OFF before proceeding. Internal cleaning of the unit should be done every 6
months by an authorized CIGWELD Service Center to remove any accumulated dirt and dust. This may need
to be done more frequently under exceptionally dirty conditions.

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.

9-2

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

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

January 17, 2008

10-1

SERVICE MANUAL TRANSTIG 200 AC/DC

SECTION 10:

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.

10.01 TIG Welding Problems

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

Description Possible Cause Remedy

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.

Table 10-1: TIG Welding Problems

10-2

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

Description Possible Cause Remedy

6

Electrode melts when
arc is struck.

A

Electrode is connected to the
‘+’ terminal.

A

Connect the electrode to the
‘−’ terminal.

B

WAVE BALANCE

is greater

than 50%.

B

Reduced

WAVE BALANCE

to below 50% or increase

the electrode size.

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.

H

WAVE BALANCE

is set

above 50%.

H

Reduced

WAVE BALANCE

to below 50% or increase

the electrode size.

9 Poor weld finish. Inadequate shielding gas.

Increase gas flow or
check gas line for gas
flow problems.

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 Basic TIG Welding
Guide for ways to reduce
arc flutter.

Table 10-1 (continued): TIG Welding Problems

January 17, 2008

10-3

SERVICE MANUAL TRANSTIG 200 AC/DC

Description Possible Cause Remedy

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 welding 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 electrode type.
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.

Table 10-1 (continued): TIG Welding Problems

10-4

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

10.02 Stick Welding Problems

Description Possible Cause Remedy

1

Gas pockets or
voids in weld metal
(Porosity).

A
B
C

Electrodes are damp.
Welding current is too high.
Surface impurities such as oil,

grease, paint, etc.

A
B
C

Dry electrodes before use.
Reduce welding current.
Clean joint before welding.

2 Crack occurring in

weld metal soon
after solidification
commences.

A

B

C

Rigidity of joint.

Insufficient throat thickness.

Cooling rate is too high.

A

B

C

Redesign to relieve weld joint of
severe stresses or use crack
resistance electrodes.
Travel slightly slower to allow
greater build up in throat.
Preheat plate and cool slowly.

3 A gap is left by

failure of the weld
metal to fill the root
of the weld.

A
B

C

Welding current is too low.
Electrode too large for joint.

Insufficient gap.

A
B

C

Increase welding current
Use smaller diameter

electrode.
Allow wider gap.

D Incorrect sequence. D Use correct build-up sequence.

Table 10-2: Stick Welding Problems

Incorrect sequence

Insufficient
gap

Art # A-04991

Figure 10-1: Example of Insufficient Gap or Incorrect Sequence

January 17, 2008

10-5

SERVICE MANUAL TRANSTIG 200 AC/DC

Description Possible Cause Remedy

4 Portions of the weld

run do not fuse to the
surface of the metal
or edge of the joint.

A

B

Small electrodes used on heavy
cold plate.

Welding current is too low.

A

B

Use larger electrodes and
pre-heat the plate.

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.

Table 10-2 (continued): Stick Welding Problems

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

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

Lack of inter-run
fusion

Lack of root fusion

Art # A-04992

Figure 10-2: Example of Lack of Fusion

10-6

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

Description Possible Cause Remedy

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.

Table 10-2 (continued): Stick Welding Problems

Not cleaned, or
incorrect
electrode

Slag trapped in
undercut

Art # A-04993

Slag trapped in root

Figure 10-3: Examples of Slag Inclusion

January 17, 2008

10-7

SERVICE MANUAL TRANSTIG 200 AC/DC

10.03 Power Source Problems

Description Possible Cause Remedy

1 The welding arc

cannot be
established.

A

B

The Primary supply voltage has
not been switched ON.

The Welding Power Source
switch is switched OFF.

A

B

Switch ON the Primary
supply voltage.

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 can
not be achieved with
nominal Mains
supply voltage.

Defective control circuit. Have an accredited

CIGWELD Service Provider
repair the connection.

3 Welding current

reduces when
welding.

A

B

C

D
E

Loose welding cable
connections.

Incorrect welding cable size.

Improper input connections.

Poor electrode condition.
Wrong welding polarity.

A

B

C

D
E

Tighten all welding
cable connections.

Use proper size and
type of cable.

Refer to Section 2.05
Electrical Input Requirements.

Replace electrode.
Verify output torch

connections.

4 No gas flow when

the torch trigger
switch is depressed.

A
B

Gas hose is cut.
Gas passage contains
impurities.

A B Replace gas hose.

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.
D Torch trigger switch lead is

disconnected or switch/cable
is faulty.

D Reconnect lead or repair faulty

switch/cable.

Table 10-3: Power Source Problems

10-8

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

Description Possible Cause Remedy

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 Agent Provider or
replace the gas valve.

C Gas valve jammed open. C Have an accredited CIGWELD

Service Provider repair or
replace the gas valve.

D

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

POST-FLOW

gas

time had finished.

Do not change Weld Process

Mode before the

POST-FLOW

gas time had finished.

Table 10-3 (continued): Power Source Problems

January 17, 2008

10-9

SERVICE MANUAL TRANSTIG 200 AC/DC

10.04 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 E11 error code

displayed.
Over Primary
supply (input)
voltage at primary
capacitors is
exceeded for one
second.

Primary supply voltage
is greater than the
nominal voltage plus
10%.

Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the Primary
voltage.

Weld current
ceases. Buzzer
sounds constantly.
Error code E11
automatically will
reset when the
voltage reduces.

5 E12 error code

displayed.
Under mains
supply (input)
voltage warning
primary
capacitors is
reduced for one
second.

Mains supply voltage is
down to a dangerously
low level.

Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the Mains voltage.
Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the primary cable &
fuses.

Weld current
ceases. Buzzer
sounds constantly.
Error code E12 will
automatically reset
when the voltage
increases.

2

3

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.

Possible CauseDescription Remedy

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

1

10-10

January 17, 2008

TRANSTIG 200 AC/DC SERVICE MANUAL

10.04 Power Source Error Codes (con't)

Remarks

6 E14 error code

displayed.
Under mains
supply (input)
voltage warning
primary
capacitors is
reduced for one
second.

Mains supply voltage is
less than the nominal
operating voltage plus
10%.

Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the Mains voltage.

Weld current
available. Buzzer
sounds
intermittently. Error
code E14 will
autom atically reset
when the voltage
increases.

7 E81 error code

displayed.
Wrong Primary
supply (input)
voltage
connected.

When 3 phase machine
is first turned on with
the wrong Primary
supply (input) voltage
connected.

Have an Accredited
Cigweld Service Provider
check the Mains voltage.

No weld current is
available. Buzzer
sounds constantly.
Switch machine off.

8 E82 error code

displayed.
Link switch plug
not connected.

Link switch plug not
connected.

Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the connector plug
on input PCB.

No weld current is
available. Buzzer
sounds constantly.
Switch machine off.

9 E83 error code

displayed.
CPU checks
mains supply
(input) voltage
when the on/off
switch on rear
panel of machine
is turned ON.

The Primary supply
(input) voltage
fluctuates and is not
stable.

Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the connector plug
on the input PCB and the
Mains voltage.

No weld current is
available. Buzzer
sounds constantly.
Switch machine off
then o n to reset
E83 error.

10 E93 error code

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

Memory chip (EEPROM)
error.

Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the control PCB.

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

11 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.

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

Possible CauseDescription Remedy

12 E99 error code

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

January 17, 2008

11-1

SERVICE MANUAL TRANSTIG 200 AC/DC

SECTION 11:

VOLTAGE REDUCTION DEVICE (VRD)

11.01 VRD SPECIFICATION

Transtig

Description 200 AC/DC 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 11-1: VRD Specification

11.02 VRD MAINTENANCE

Routine inspection and testing (power source):

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

a. For transportable equipment, at least once every 3 months.

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 11-2: Periodic Tests

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

January 17, 2008

11-2

TRANSTIG 200 AC/DC SERVICE MANUAL

NOTES

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008

12-1

SECTION 12:

ADVANCED TROUBLE SHOOTING

12.00 Introduction

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 Cigweld 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.

12.01 System-Level Fault Isolation

If none of the suggestions provided in Section 5 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.

12.1.1 Opening the Enclosure

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

Figure 12-1: Switch OFF

CAUTION

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.

TRANSTIG 200 AC/DC SERVICE MANUAL

January 17, 2008

12-2

2) Remove all screws and nuts on the Side Panel.

Figure 12-2: Remove screws

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 12-3: 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 12-4: Loosen front and rear panels

5) Remove the Side Panel.

Figure 12-5: Remove side panel

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008

12-3

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

1

1

1

1

2

Figure 12-6: Remove PCB cover

NOTE

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

12.02 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. For
the removal and installation of the case,
refer to section 12.1.1.

NOTE

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

NOTE

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

12.2.1 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 3.07. Exceeding the duty cycle can damage
the unit and void the warranty. Refer to War­ranty section at the end of the manual 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 cleaning.

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 abnormal
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 13.3.24 for the replacement of
FAN1.

• Refer to section 12.5.3 for additional FAN1 tests.

d. Replace PCB6 (WK-5549).

• Refer to section 13.3.5 for the replacement of
PCB6.

TRANSTIG 200 AC/DC SERVICE MANUAL

January 17, 2008

12-4

12.2.2 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 3.07. 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
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 cleaning.

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 abnormal
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 13.3.24 for the replacement of
FAN1.

• Refer to section 12.5.3 for additional FAN1 tests.

d. Replace PCB6 (WK-5549).

• Refer to section 13.35 for the replacement of
PCB6.

12.2.3 E03 "Primary Over-Current Failure"

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 Section

2.08.

b. Verify the secondary diode (D2, D4 and D5).

• Refer to section 12.5.6 for the test.

• Refer to section 13.3.31 for the replacement.

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

• Refer to section 13.3.28 for the replacement of
HF.UNIT 1.

d. Verify the secondary IGBT (Q13).

• Refer to section 12.5.8 for the test.

• Refer to section 13.3.32 for the replacement.

e. Replace the Hall CT, HCT1.

NOTE

Pay special attention to the installed di­rection of HCT1. The Hall CT will not func­tion properly if installed in the incorrect
direction.

• Refer to section 13.3.29 for the replacement of
HCT1.

12.2.4 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 cycles 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.

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008

12-5

Refer to 2.9 for the recommended duty cycle.

b. Replace PCB6 (WK-5549) and PCB13 (WK-

5569).

• Refer to section 13.3.5 for the replacement of
PCB6.

• Refer to section 13.3.12 for the replacement of
PCB13.

12.2.5 E11 "Main Supply Over Voltage"

Cause

Main supply voltage occurs at about 275V or
more.

Verification/Remedy

a. Verify main supply voltage.

• Perform what is described in a section of “Veri­fication of the Power Supply Voltage”. Refer to
section 12.5.2.

b. Replace PCB4 (WK-4819).

• Verify PCB4 (WK-4819) and replace it if neces­sary. Refer to section 13.3.4.

12.2.6 E12 "Main Supply Under Voltage"

Cause

Main supply voltage occurs in about 150V or
less.

Verification/Remedy

a. Verify main supply voltage.

• Perform what is described in a section of “Veri­fication of the Power Supply Voltage”. Refer to
section 12.5.2.

b. Replace PCB4 (WK-4819).

• Verify PCB4 (WK-4819) and replace it if neces­sary. Refer to section 13.3.4.

12.2.7 E81 "Abnormal Input Voltage"

Cause

The detection circuitry of main supply voltage
is abnormal.

Verification/Remedy

a. Verify main supply voltage.

• Perform what is described in the section “Veri­fication of the Power Supply Voltage”. Refer to
section 12.5.2.

b. Confirm a secure connection of the harness wired

between CN2 on PCB3 (WK-5548) and CN1 on
PCB17 (WK-4917).

• Re-install the harness with a secure connection.

• Contact the manufacturer if you find any bro­ken connectors or a damaged wiring harness.

c. Verify PCB4 (WK-4819) and replace it if neces-

sary.

• Check whether there are any abnormalities on
the appearance of PCB4.

• Replace PCB4. Refer to section 13.3.4.

12.2.8 E82 "Rated Voltage Selection Circuit
abnormality"

Cause

Rated voltage selection circuit inside the Weld­ing Power Source is not functioning properly.

Verification/Remedy

a. Verify the wiring harness and connection of CN4

on PCB4 (WK-4819).

• Re-install the harness with a secure connection.

• Contact the manufacturer if you find any bro­ken connectors or damaged wiring harness.

b. Verify PCB4 (WK-4819) and replace it if neces-

sary.

• Check whether there are any abnormalities on
the appearance of PCB4.

• Replace PCB4. Refer to section 13.3.4.

12.2.9 E83 "Abnormalities in Mains Supply
Voltage Detection"

Cause

Abnormalities, such as an input voltage de­tection circuit

Verification/Remedy

a. Verify main supply voltage.

• Perform what is described in a section of “Veri­fication of the Power Supply Voltage”. Refer to
section 12.5.2.

b. Confirm a secure connection of the harness wired

between CN2 on PCB3 (WK-5548) and CN1 on
PCB17 (WK-4917).

• Re-install the harness with a secure connection.

• Contact the manufacturer if you find any bro­ken connectors or damaged wiring harness.

c. Verify PCB4 (WK-4819) and replace it if neces-

sary.

• Check whether there are any abnormalities on
the appearance of PCB4.

• Replace PCB4. Refer to section 13.3.4.

TRANSTIG 200 AC/DC SERVICE MANUAL

January 17, 2008

12-6

12.2.10 E85 "Pre-charge abnormality"

Cause

Due to malfunction inside the Welding Power
Source, primary capacitors are not charging
correctly.

Verification/Remedy

a. Verify the connection PCB2 (WK-5482) and the

rectified output voltage of the rectifier.

• Verify the connection between CN2 on PCB2 and
CN3 on PCB3.

• Confirm whether there is any breakage (blown,
burnt, cracked, etc.) of R4 and R5.

• Perform what is described in a section of “Veri­fication of the Power Supply Voltage”. Refer to
section 12.5.2.

b. Verify the primary diode (D1).

• Verify D1. Refer to section 12.5.2.3.

• Replace D1. Refer to section 13.3.30.

c. Verify the primary IGBT (Q1-Q12).

• Verify IGBT. Refer to section 12.5.2.5.

• Replace IGBT. Refer to section 13.3.7, 13.3.8.

d. Replace PCB2 (WK-5482) and PCB4 (WK-4819).

• Replace PCB2 and PCB4, when abnormalities
occur, even if you carry out the above-mentioned
verifications. Refer to section 13.3.2, 13.3.4.

12.2.11 E94 "Thermistor malfunction"

Cause

Thermistors for detecting temperature of in­ternal components have malfunctioned.

Verification/Remedy

a. Confirm a secure connection of the harness wired

between CN8-9 on PCB6 (WK-5549) and Ther­mistors (TH1, TH2).

• Re-install the harness with a secure connection.

• Contact the manufacturer if you find any bro­ken connectors or a damaged wiring harness.

b. Replace thermistors (TH1, TH2).

• Refer to section 13.3.22, 13.3.23.

c. Replace PCB6 (WK-5549).

• Refer to section 13.3.5.

12.2.12 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. Confirm a secure connection of the harness wired

between CN1 on PCB17 (WK-4917) and CN2 on
PCB3 (WK-5548).

• Re-install the harness with a secure connection.

• Contact the manufacturer if you find any bro­ken connectors or a damaged wiring harness.

b. Verify PCB4 (WK-4819) and replace it if neces-

sary.

• Confirm a secure connection of all harnesses
wired to PCB3 and PCB4.

• Replace PCB4. Refer to section 13.3.4.

c. Replace PCB6 (WK-5549).

• Refer to section 13.3.5.

12.03 Verification and Remedy to
Failures without Indication
Codes

Refer to Note on Section 12.02.

12.3.1 "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 cleaning.

• 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 bro­ken connectors or damaged wiring harnesses.

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008

12-7

• Replace the fan if there are any broken, cracked
or missing fan blades.

• Refer to section 13.3.24.

b. Verify the wiring harness between the cooling fan

(FAN1) and CN11 on PCB3 (WK-5548).

• Confirm a secure connection of the harness to
CN11 on PCB3.

c. Verify the drive circuitry of the cooling fan (FAN1)

on PCB3.

• Verify the drive circuitry of the cooling fan
(FAN1) on PCB3.

• Refer to section 12.5.3.

• Replace PCB3 if necessary.

• Refer to section 13.3.4.

12.3.2 "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. Confirm that TIG welding is selected on the weld-

ing mode.

• Do not change welding modes while welding.
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 the gas hose.

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

• Confirm 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 CN11 on PCB3 (WK-5548).

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

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

• Refer to section 12.5.4.

• Replace PCB3, when abnormal.

• Refer to section 13.3.3.

e. Replace the PCB6 (WK-5549).

• Refer to section 13.3.5.

12.3.3 "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 section

12.3.5..

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.)

• Confirm a secure between the remote connec­tor (CON1) and the TIG torch cable.

• Confirm a secure connection of the harness and
the connections between the remote connector
(CON1) and PCB7 (WK-5550) are all correct and
there are no open circuits.

• Contact the manufacture if you find any broken
connectors or damaged wiring harnesses.

• Confirm the proper pins-outs of the remote con­nector at the TIG Torch side. (Refer to section
in the Operating Manual.)

• Confirm that there is no open circuit on the re­mote connector at TIG Torch side.

• In equipment for remote control use, confirm
the pin specification of a connector. (Refer to
section Operating Manual.)

b. Verify the condition and connections of the weld-

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

• Confirm a secure connection of the welding
cable, stick rod holders, ground clamp and dinse
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 12.5.9 "Verification of No­load voltage (OCV)".

TRANSTIG 200 AC/DC SERVICE MANUAL

January 17, 2008

12-8

• 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 IGBT (Q13)

• Verification. Refer to section 12.5.7.

• Replacement. Refer to section 13.3.32.

2. Secondary diode (D2, D4, D5)

• Verification. Refer to section 12.5.6.

• Replacement. Refer to section 13.3.31.

3. Coupling coil (CC1)

• Replacement. Refer to section 13.3.20.

4. Reactor (FCH1)

• Replacement. Refer to section 13.3.21.

5. Transformer (T1)

• Replacement. Refer to section 13.3.11.

6. Primary IGBT (Q1-Q12)

• Verification. Refer to section 12.5.7.

• Replacement. Refer to section 13.3.7,

13.3.8.

7. Hall C.T. (HCT1)

• Replacement. Refer to section 13.3.29.

12.3.4 "Operating Panel Failure" (LED's do
not light properly or welding setting
cannot be established.)

Cause

Occurs when there is a connection failure among

PCB6 (WK-5549), PCB10 (WK-5527) and
PCB6 or PCB10 are defective.

Verification/Remedy

a. Verify the harness connection between CN21 on

PCB6 (WK-5549) and CN2 on PCB10 (WK- 5527).

• Confirm a secure connection of the harness and
the connections between CN21 on PCB6 (WK-

5549) and CN2 on PCB10 (WK-5527).

• Contact the manufacturer if you find any bro­ken connectors or damaged wiring harnesses.

b. Verify the connection between PCB5 (WK- 5551)

and PCB6 (WK-5549).

c. Replace PCB5 (WK-5551) and PCB6 (WK- 5549).

• Refer to section 13.3.4, 13.3.6.

d) Replace PCB6 (WK-5549) and PCB10 (WK-5527).

• Refer to section 13.3.6, 13.3.10.

12.3.5 "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 Unit

(HF UNIT1) and Coupling Coil (CC1).

• Verify the connection between the HF UNIT1 and
CC1; confirm that the quick-disconnect termi­nals are inserted onto the terminals of HF UNIT1
(TB5- TB6) correctly and completely.

• Confirm there are no short circuits, burnt or
broken wires at CC1.

• Replace CC1.

• Refer to section 13.3.20.

b. Verify the connection between High Frequency (HF

UNIT1) and the current limiting resistor (R2).

• Verify the connection between HF UNIT1 and
the current limiting resistor (R2), confirm that
the quick-disconnect terminals are inserted onto
the terminals of HF UNIT1 (TB3- TB4) correctly
and completely.

• Confirm there are no short circuits, burnt or
broken wires between the HF UNIT1 and the
current limiting resistor (R2).

c. Verify the connection between the terminals be-

tween AC1-AC2 (TB1-TB2).

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008

12-9

• Verify the connection between AC1-AC2, con­firm that the quick-disconnect terminals are in­serted onto the terminals of HF UNIT1 correctly
and completely.

• Confirm there are no short circuits, burnt or
broken wires between AC1 and AC2.

d. Verify and replace the Gap (GAP) of the High Fre-

quency Unit (HF UNIT1).

• Confirm that the GAP is connected to HF UNIT1
correctly and completely.

• Confirm 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.

• A setup of a gap is 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.

e. Verify and replace the Current limiting Resistor

(R6) on HF UNIT1.

• If R6 is defective (blown, burnt, cracked, etc.),
replace R6.

• Refer to section 13.3.19.

f. Replace the High Frequency Unit (HF UNIT1).

• Refer to section 13.3.28.

g. Replace PCB3 (WK-5548).

• Refer to section 13.3.4.

12.04 Fault Isolation Tests

12.4.1 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

12.1.1.

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

4. Place power supply MAIN CIRCUIT SWITCH (S1)
on rear of the 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 work piece or any
internal components while the unit is ac­tivated.

12.05 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 12. 4.1 "Preparation".

12.5.1 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. Measure
the point between lines U1 and W1 on the input
switch, S1. Measure the point between lines V1
and W1 on the input switch, S1. The location of
points U1, V1 and W1 on switch S1 are indicated
in Figure 6-7. When using a single-phase connec­tion, the voltage can be verified only between U1
and V1.

S1

U1

V1

W1

V2

U2

W2

Figure 6-7: Check points U1, U2, V1, V2, W1 and

W2

TRANSTIG 200 AC/DC SERVICE MANUAL

January 17, 2008

12-10

2. If the input voltage is out of the operating range
of the unit, which is 10% (187 ~ 253 /414 ~ 506
VAC) of the rated voltage (208, 230/ 460V), 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
points U2 and V2 on the input switch, S1.

• Using an AC voltmeter, measure between the
points U2 and W2 on the input switch, S1.

• Using an AC voltmeter, measure between the
points V2 and W2 on the input switch, S1.

The location of points U2, V2 and W2 on switch S1
are indicated in Figure 6-7. When using a single-phase
connection, the voltage can be verified only between
U2 and V2.

4. If this voltage is out of the operating range, which
is 10% (187~253/414~ 506VAC) of the rated volt­age (208, 230 / 460V), replace S1 following the
process in section 13.3.26.

5. Verify the rectified output voltage of the input di­ode, D1 using a DC voltmeter. (The capability of
the voltmeter should be more than 1000VDC.)
Using a DC voltmeter, measure between the points
1 (P) [+] and 2 (N) [-] on D1. Points 1 (P) and 2
(N) are on D1. See Figure 12.8. 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 (260 ~ 360 / 580
~ 720 VDC) following the process in section

13.3.30.

D1

1

2

Figure 6-8: The check points 1 (P) and 2 (N)

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 1000VDC.) Using a DC voltmeter, measure
between the points TB1 (P) [+] and TB2 (N) [-] on
PCB1 (WK-5477) Points TB1 (P) and TB2 (N) can
be found on the parts side of PCB1. See Figure 6-

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
(260 ~ 360 / 580 ~ 720 VDC).

PCB1

TB1
TB2

Figure 6-9: The check points TB1(P) and TB2(N)

7. After the replacement of D1, if the above voltage
is still abnormal, replace PCB1 (WK-5477).

12.5.2 Verification of 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 12. 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 PCB3 (WK-5548) and PCB6 (WK- 5549),
measure the voltages according to the following
table. The check points and the reference are ob­tainable on the top side of PCB6 (WK-5549). The
locations of points are indicated in Figure 6-10,
6-11.

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008

12-11

TP1

TP2

TP3

TP0

PCB6

Figure 6-10: Checkpoints TP0-TP3 on PCB6

Check Point Reference ACCEPTABLE

PCB3 PCB3 VALUE

Pin 1 on CN18 Pin 3 on CN18 +24VDC

Table 6-1: Checkpoints TP0-TP3 on PCB6

PCB3

CN18

pin 1

pin 3

Figure 6-11: Checkpoints CN18 on PCB3

3. If any of these voltages are not present or are be­low a 10% tolerance, replace PCB3 (WK-5548).
Refer to section 13.3.4.

12.5.3 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 12. 4.1 "Preparation".

1. Verify the condition of the cooling fan, FAN1, us-

ing 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.

PCB3

CN11

1pin

2pin

Figure 6-12: Verification of the FAN1

2. Using the measurement taken above, follow the

chart below for possible failure modes.

FAN1
Status

Voltage

measurement.

(1PIN-2PIN o f

CN11 on PCB3)

Remedy

Case

1

Rotati ng DC 18 ~ 25V

FAN1 drive circui t i s
normal.

Case

2

Rotating Below DC 18V

Replace P CB 3. Refer
to section 12.3.4.

Case

3

Inactive Below DC 18V

Replace P CB 3. Refer
to secti o n 1 2 .3.4 .4.
Perform “2".
Verfication of Power
Supply Voltage” Refer
to section 11.5.2.

Case

4

Inacti ve DC 18 ~ 25V

Replace t he FA N1.
Refer to section

12.3.24.

Table 6-3: Verification of the FAN1

TRANSTIG 200 AC/DC SERVICE MANUAL

January 17, 2008

12-12

• During low output and standby, fan rotation
becomes slower. Therefore, exact voltage mea­surement becomes impossible.

• When verifying the voltage, confirm that the AC
input voltage remains within the operating range
of the unit (the AC input does not drop below
180VAC).

12.5.4 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 in section 12. 4.1 "Preparation".

1. Verify the voltage between the PIN 3 (Positive [+])
and PIN 4 (Negative [-]) of connector CN11 on
PCB3 (WK-5548) while you press the torch switch
while in TIG Mode. (The capacity of the voltmeter
should be more than 50VDC.) The location of con­nector CN11 of PCB3 (WK- 5548) is indicated in
Figure 6-13. When you measure the above volt­age, do not remove the connector. Conduct the
measurement while the connector plug and re­ceptacle are still connected.

PCB3

CN11

pin 3

pin 4

Figure 6-13: Verification of the SOL1

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

Voltage

measurement.

(1PIN-2PIN of

Remedy

CN11 on PCB3)

Case 1

Below DC 18V

Replace PCB1. Refer
to section 12.3.1.

Case 2

DC 18 ~ 25V

Replace SOL1. Refer
to section 12.3.25.

Table 6-4: Verification of the SOL1

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

12.5.5 Verification of the primary Diode (D1)

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 12. 4.1 "Preparation".

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

2. Refer to Table 6-5 and Figure 6-14 for the check­points on D1.

TERMINALS

COMPONENT

TESTED

Positive

lead

Negative
lead

ACCEPTABLE

VALUE

3, 4, 5 0 0.3 to 0.5V

0 3, 4, 5 Open

Diode of D1

3, 4, 5 2 Open

2 3, 4, 5 0.3 to 0.5V

Thyristor of

D1

0
1

1
0

Open
Open

Table 6-5: Tester checkpoints for D1

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008

12-13

6

7

3
4
5

2
1

0

067

1

2

5

4

3

Figure 6-14: Tester checkpoints for D1 and showing

the connection diagram

12.5.6 Verification of the secondary Diode
(D2, D4, D5)

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 12. 4.1 "Preparation".

1. Verify the characteristic of the secondary diode,

D2, D4 and D5, using a diode tester.

2. Refer to Table 6-6 and Figure 6-15 for the check-

points on D2, D4 and D5.

TERMINALS

COMPONENT

TESTED

Positive

lead

Negative

lead

ACCEPTABLE

VALUE

Diode 1 of D2, Anode Cathode 0.2 to 0.3V

D4 and D5 Cathode Anode Open

Diode 2 of D2, Anode Cathode 0.2 to 0.3V

D4 and D5 Cathode Anode Open

Table 6-6: Tester checkpoints for D2, D4 and D5

Anode

Anode

Cathode

Cathode

Figure 6-15: Tester checkpoints in D2, D4 and D5

TRANSTIG 200 AC/DC SERVICE MANUAL

January 17, 2008

12-14

12.5.7 Verification of the primary IGBT (Q1­Q12)

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 12. 4.1 "Preparation".

1. Check whether there are any abnormalities in the
appearance of PCB8 and PCB9.

2. Verify the characteristic of the primary IGBT (Q1­Q12), using a diode tester.

3. Refer to Table 6-7 and Figure 6-16 for the check­points on PCB8 and PCB9.

TERMINALS

COMPONENT

TESTED

Positive

lead

Negative

lead

ACCEPTABLE

VALUE

C 1
C2E1

C2E1
C1

Open

0.2 to 0.5V

Collector­Emitter of Q13
(by PCB15
connector)

C2E1
E2

E2
C2E1

Open

0.2 to 0.5V

Table 6-7: Tester checkpoints for Q1-Q12

C

CE

E

PCB8

PCB9

Figure 6-16: Tester checkpoints in the Q1-Q12

12.5.8 Verification of the secondary IGBT
(Q13)

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 12. 4.1 "Preparation".

1. Check whether there are any abnormalities on the

appearance of PCB14.

2. Verify the characteristic of the secondary IGBT

(Q13), using a diode tester.

3. Refer to Table 6-8 and Figure 6-17 for the check-

points on Q13.

TERMINALS

COMPONENT

TESTED

Positive

lead

Negative

lead

ACCEPTABLE

VALUE

C 1
C2E1

C2E1
C1

Open

0.2 to 0.5V

Collector­Emitter of Q13
(by PCB15
connector)

C2E1
E2

E2
C2E1

Open

0.2 to 0.5V

Table 6-8: Tester checkpoints for Q13

C1

E2

C2E1

Figure 6-17: Tester checkpoints in the Q13

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008

12-15

12.5.9 Verification of No-load Voltage (OCV)

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 12. 4.1 "Preparation".

1. Verify the no-load voltage in STICK mode.

a. In STICK welding mode, mark and then turn

potentiometer VR1 on PCB6 (WK-5549) all
the way to the right and turn off the electric
shock protector function (Voltage-Reduction­Device, VRD).

b. Contactor function is put into the state of "ON"

pushing Function button. Refer to section 12.

!

WARNING

Electric shock hazard. The unit will gener­ate OCV immediately when contactor func­tion is put into the state of "ON pushing
Function button enabling STICK mode.

c. Verify the no-load voltage using a DC voltme-

ter. (The capability of the voltmeter should be
more than 100VDC.)

d. The normal no-load voltage is approximately

65V.

2. Verify the no-load voltage (OCV) in High Frequency
TIG mode.

!

WARNING

This welding mode produces high fre­quency and high voltage. Extra care shall
be taken to prevent electric shock.

3. 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 6-

18. To prevent electric shock, always wrap the
removed wire with electrical tape or other suit­able insulation.

Figure 6-18: Removal and installation from the HF

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

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

5. 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.

6. The normal no-load voltage is approximately 58­62V.

7. 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

8. Return connection with HF UNIT1 to the original
position.

TRANSTIG 200 AC/DC SERVICE MANUAL

January 17, 2008

12-16

THIS PAGE LEFT INTENTIONALLY BLANK

13 MAINTENANCE

MAINTENANCE

1

Maintenance List

8

9

1

4

5

2

3

6

7

No. DWG No. Parts name Reference page Part No.

1

PCB3 Print Circuit Board (WK-5548)

13-9

2

PCB10 Print Circuit Board (WK-5527)

13-13

3

PCB11 Print Circuit Board (WK-5528)

13-13

4

PCB12 Print Circuit Board (WK-5615)

13-15

5

PCB13 Print Circuit Board (WK-5569)

13-18

6

PCB14 Print Circuit Board (WK-5570)

13-19

7

PCB16 Print Circuit Board (WK-5499)

13-19

8

PCB17 Print Circuit Board (WK-4917)

13-20

9

PCB18 Print Circuit Board (WK-5861)

13-21

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-1

W7001314

W7001812
W7001320

W7001594

W7001433

W7001434

W7001324

10-6740

W7001602

13 MAINTENANCE

3

6

7

2

5

4

8

1

No. DWG No. Parts name Reference page Part No.

1

PCB1 Print Circuit Board (WK-5477)

1

3-6 W7001402

2

PCB2 Print Circuit Board (WK-5596)

1

3-7 W7001601

3

PCB4 Print Circuit Board (WK-4819)

13-10 10-6635

4

PCB5 Print Circuit Board (WK-5551)

1

3-10 W7001417

5

PCB6 Print Circuit Board (WK-5549)

1

3-10 W7001727

6

PCB7 Print Circuit Board (WK-5550)

1

3-11 W7001423

7

PCB8 (Q1~Q6)

Print Circuit Board (WK-5479) (Primary IGBT)

13-11 W7001318

8

PCB9 (Q7~Q12)

Print Circuit Board (WK-5479) (Primary IGBT)

13-12 W7001318

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-2

January 17, 2008

13 MAINTENANCE

9

5
4

6

3

12

10

11

2

7

1

8

No. DWG No. Parts name Reference page Part No.

1

CC1 Coupling Coil

1

3-24 W7001384

2

CT2 Current Trans

1

3-15 W7001304

3

D1

Primary

Diode

1

3-32 10-6628

4

D2 Secondary Diode

13-33 10-6629

5

D4 Secondary Diode

1

3-33 10-6629

6

D5 Secondary Diode

1

3-33 10-6629

7

FCH1 Reactor

1

3-31 W7001502

8

HCT1 Hall C. T.

1

3-25 10-5003

9

HF. UNIT High Freguency Unit

1

3-31 W7001399

10

L101 Reactor

1

3-35 W7001400

11

L103 Earth Inductance

13-35 W7001605

12

T1 Main Trans

1

3-15 W7001456

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-3

13 MAINTENANCE

8

6

5

9

7

2

4

11

10

1

3

No. DWG No. Parts name Reference page Part No.

1

CON1 Remote Connector

1

3-29 W7001595

2

FAN1 Cooling Fan

1

3-27 W7001307

3

Q13 (PCB15) Secondary IGBT (WK-3367)

1

3-34 10-6643

4

R3 Discharge Resistor

1

3-22 10-5137

5

R4 Current Limiting Resistor

1

3-23 W7001452

6

R5 Current Limiting Resistor

1

3-23 W7001452

7

R6 Resistor on High Frequency Unit

13-24 W7001451

8

S1 Main ON/OFF Switch

1

3-29 W7001453

9

SOL1 Solenoid Valve

1

3-28 W7001604

10

TH1 Primary Thermistor

13-26 10-5228

11

TH2 Secondary Thermistor

1

3-26 10-5228

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-4

January 17, 2008

13 MAINTENANCE

2

Service Tools

2.1 Tools and parts

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

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

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.

C-Ring Pliers

Long Nose
Pliers

Philips Head
Screwdriver

Spanner

(5.5, 8, 10, 17mm)

Snap Band

Silicon
Compound

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-5

13 MAINTENANCE

3

Replacement Procedure

3.1 PCB1 (WK-5477) UVX[\

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the PCB18 (WK-5861). [Reference page: 12-21]

3) Remove PCB2 (WK-5596). [Reference page: 12 - 7]

4) Remove the PCB8 (WK-5479). [Reference page: 12- 11]

5) Remove the PCB9 (WK-5479). [Reference page: 12- 12]

6) Remove the four screws. Pull out the Rear Control Cover and bring it down.

7) Remove the five screws and the PCB1 (WK-5477). Remove the two screws and two terminals.

8) Remove the four screws and remove the four terminals and 200V Input Bus Bar.

1

1

1

1

2

1

1

1

2

3

1

1

1

2

2

2

2

3

3

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-6

January 17, 2008

13 MAINTENANCE

3.2 PCB2 (WK-5596) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the PCB18 (WK-5861). [Reference page: 12-11]

3) Disconnect the 13 connectors.

4) Remove the four screws and two ground terminals.

5) Remove the PCB3, PCB4, PCB5, PCB6, and PCB7 unit and then disconnect the two connectors.

CN1

CN3

CN2

CN17

CN21

CN9

CN8

CN7

CN11

CN9

CN19

CN8

CN1

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-7

13 MAINTENANCE

Remove the Insulated Sheet.

6) Remove the three screws and seven terminals. Remove the PCB2 (WK-5596).

7) Disconnect the three connectors and two terminal from the PCB2 (WK-5596).

1

2

2

3

CN15

CN14

1

2

1

1

1

2

CN1

CN2

CN3

TB5

TB6

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-8

January 17, 2008

13 MAINTENANCE

3.3 PCB3 (WK-5548), PCB5 (WK-5551) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove PCB4 (WK-4819). [Reference page: 12 - 10]

3) Remove PCB6 (WK-5549). [Reference page: 12 - 10]

4) Remove PCB7 (WK-5550). [Reference page: 12 - 11]

5) Disconnect the 11 connectors.

6) Remove the four screws and then the two ground terminals. Remove the PCB3 and PCB5 unit.
Disconnect the two connectors.

7) Disconnect the one connector and remove the two screws, and then remove the PCB5 (WK-5551) from
the PCB3 (WK-5548).
Remove the one screw and one ground terminal from the PCB5 (WK-5551).

CN23

CN19

CN11

CN8

CN3

CN2

CN1

CN9

CN22

CN21

CN20

1

CN14

CN15

2

1

2

CN20

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-9

13 MAINTENANCE

8) Disconnect the two connectors from the PCB3 (WK-5548).

3.4 PCB4 (WK-4819) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the two screws and three connectors and remove the PCB4 (WK-4819).
Disconnect the one connector.

3.5 PCB6 (WK-5549) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Disconnect the six connectors.

CN33

CN18

2

CN4

1

CN6

CN5

CN4

CN21

CN20

CN8

CN9

CN17

CN1

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-10

January 17, 2008

13 MAINTENANCE

3) Remove the three screws and five connectors. Remove the PCB6 (WK-5549).

3.6 PCB7 (WK-5550) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the PCB6 (WK-5549). [Reference page: 12- 10]

3) Remove the two screws and three connectors. Remove the PCB7 (WK-5550).

3.7 PCB8 (WK-5479) (IGBT (Q1~Q6)) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the four screws and two IGBT Chassis.

CN27

CN30

CN31

CN32

CN18

CN32

CN31

CN30

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-11

13 MAINTENANCE

3) Remove the two connectors and three screws. Remove the PCB8 (WK-5479).

 Remember to install silicone rubber sheets when reinstalling the PCB8 (WK-5479).

3.8 PCB9 (WK-5479) (IGBT (Q7~Q12)) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the four screws and two IGBT Chassis.

3) Remove the two connectors and three screws. Remove the PCB9 (WK-5479).

 Remember to install silicone rubber sheets when reinstalling the PCB9 (WK-5479).

CN2

CN1

CN2

CN1

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-12

January 17, 2008

13 MAINTENANCE

3.9 PCB10 (WK-5527) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the PCB11 (WK-5528). [Reference page: 12-13]

3) Remove the three latches of Front Control Cover and then the PCB10 (WK-5527).

 When reinstalling the PCB10 (WK-5527), engage two latches of Front Control Cover first.

3.10 PCB11 (WK-5528) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the Protection Cover.

1

1

2

2

1

1

2

2

3

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-13

13 MAINTENANCE

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

4) Disconnect the one connector from the PCB10 (WK-5527). Remove the four screws. Pull out the Opera­tion Panel and bring it down.

5) Remove the one connector and two screws. Remove the PCB11 (WK-5528).
Remove the Encoder Cover from the PCB11 (WK-5528).

1

2

3

1mm

2

2

2

2

3

CN2

1

1

2

3

CN1

4

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-14

January 17, 2008

13 MAINTENANCE

3.11 PCB12 (WK-5615), Transformer (T1), Current Trans (CT2) VX[

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove PCB13 (WK-5569). [Reference page: 12- 18]

3) Disconnect the one connector and cut the one snap band.

4) Remove the one screw and one nut. Remove the two screws and remove the two terminals.

5) Open the Dust Cover Sheet. Remove the three screws and three terminals.

CN7

1

2

3

1

2

2

2

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-15

13 MAINTENANCE

6) Remove the 16 screws.

7) Remove the PCB12 and T1 unit.

8) Cut the one snap band and remove the Current Trans (CT2).

1

2

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-16

January 17, 2008

13 MAINTENANCE

9) Remove the Dust Cover Sheet. Extend the electrode and remove the T-D Bus Bar1, T-D Bus Bar2 and T
Center Bus Bar.

10) Remove the two PCB supporters and cushion.
Remove the four screws and remove the Main Trans (T1).

1

2

2

3

1

1

2

3

4

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-17

13 MAINTENANCE

3.12 PCB13 (WK-5569) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the Nylon Hose. Remove the four screws. Remove the two terminals and open the Rear Panel.

3) Disconnect the six connectors and remove the two screws and two terminals.

4) Remove the two screws and two PCB supporters and remove the PCB13 (WK-5569).

1

2

1

2

3

4

CN1

CN2

CN4

CN6

CN3

CN5

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-18

January 17, 2008

13 MAINTENANCE

3.13 PCB16 (WK-5499) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the Nylon Hose.

3) Disconnect the two connectors.
Remove the three PCB supporters and remove the PCB16 (WK-5499).

3.14 PCB14 (WK-5570) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the PCB16 (WK-5499). [Reference page: 12-19]

3) Remove the five screws and three terminals and remove the PCB14 (WK-5570).

2

1

CN1

CN3

1

1

2

1

1

1

1

2

2

2

3

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-19

13 MAINTENANCE

4) Remove the three PCB supporters from the PCB14 (WK-5570).

3.15 PCB17 (WK-4917) V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the four screws and four terminals.

3) Remove the four screws and then open the Rear Board.

1

1

2

2

1

1

1

1

2

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-20

January 17, 2008

13 MAINTENANCE

4) Disconnect the one connector.
Remove the two screws and one ground terminal and remove the PCB17 unit.

5) Remove the two screws and remove the S1 Bus Bar from the PCB17 (WK-4917).

3.16 PCB18 (WK-5861)V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the four screws and then remove the four cables.Remove the two screws. Remove the PCB18
(WK-5861).

1

2

2

3

4

CN1

1

2

1

1

2

2

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-21

13 MAINTENANCE

3.17 Discharge Resistor (R3)VX[

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the Nylon Hose. Remove the two bolts, two toothed washers, one washer, and one terminal.

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

4) Cut the one snap band and disconnect the one connector.

2

1

1

2

2

3

1

1

1

1

2

1

2

CN5

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-22

January 17, 2008

13 MAINTENANCE

5) Remove the one screw and one nut and remove the one terminal.

6) Remove the two screws and remove the Discharge Resistor (R3).

3.18 Current Limiting Resistor (R4, R5)V

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the PCB18 (WK-5861). [Reference page: 12-21]

3) Remove the PCB2 (WK-5596). [Reference page: 12-7]

4) Remove the one screw and remove the Current Limiting Resistor (R4, R5).

1

1

2

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-23

13 MAINTENANCE

3.19 Resistor on High Frequency Unit (R6) VX[

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Cut the one snap band and remove the two terminals. Remove the one screw and remove the Resistor
on High Frequency Unit (R6).

3.20 Coupling Coil (CC1) UV

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the Nylon Hose. Remove the two bolts, two toothed washers, one washer, and one terminal.

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

1

2

3

4

2

1

1

2

2

3

1

1

1

1

2

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-24

January 17, 2008

13 MAINTENANCE

4) Remove the two terminals. Remove the one screw and two terminals.

5) Remove the one screw and one nut. Remove the one screw and Coupling Coil (CC1).

3.21 Reactor (FCH1) UV

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the PCB16 (WK-5499). [Reference page: 12-19]

3) Remove the PCB14 (WK-5570). [Reference page: 12-19]

4) Remove the Coupling Coil (CC1). [Reference page: 12-24]

5) Remove the two posts, two screws and two nuts.

1

1

2

1

1

2

3

SERVICE MANUAL

TRANSTIG 200 AC/DC

January 17, 2008

13-25

13 MAINTENANCE

6) Remove the four screws and remove the Reactor (FCH1). Remove the Insulating Sheet.

3.22 Primary Thermistor (TH1) VX[\

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Cut the three snap bands. Disconnect the one connector.
Remove the one screw and then detach the Primary Thermistor (TH1).

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

747 or equivalent) on the base.

3.23 Secondary Thermistor (TH2) UVX[\

1) Remove the Side Panel. [Reference page: 11 - 1]

2) Remove the PCB13 (WK-5569). [Reference page: 12-18]

3) Remove the PCB12 (WK-5615). [Reference page: 12-15]

4) Remove the one screw and one nut and remove the bus bar.

1

1

2

3

CN8

TRANSTIG 200 AC/DC

SERVICE MANUAL

13-26

January 17, 2008