CIGWELD 200 Pi Transtig Service Manual

INVERTER ARC WELDER240 V5060HzINVERTER200 PiService ManualTRANSTIG®Revision No: AA Issue Date: March 31, 2008 Manual No.:

TRANSTIG 200 Pi SERVICE MANUAL1-4March 31, 2008 WARNINGEngines can be dangerous. WARNINGENGINE EXHAUST GASES can kill.Engines produce harmful exh

APPENDIX 4: INTERCONNECT DIAGRAMA-8APPENDIX 3 INTERCONNECT DIAGRAMINTERCO NNECT DIAG RAMINTERCONNECT DIAGRAMCN130CN131CN131 CN130CN132CN132S1GroundPCB

A-9TB7TB12TB21TB22TB20CT2PCB12DIODE SnubberCircuit Board[WK-5615]PCB10PanelCircuit Board[WK-5527]PCB11BoardEncoder[WK-5528]1 2 3 412CN23456CN11 2 3 4C

APPENDIX 5: DIODE TESTING BASICSA-10APPENDIX 4 DIODE TESTING BASICDIOD E TESTIN G BASICTesting of diode modules requires a digital Volt/Ohmmeter that

CIGWELD LIMITED WARRANTYLIMITED WARRANTY: CIGWELD, A Thermadyne Company, hereafter, “CIGWELD” warrants to customers ofits authorized distributors here

Terms of Warranty – December 20071. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supplyof goods

Warranty Schedule – December 2007These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of salefrom

GLOBAL CUSTOMER SERVICE CONTACT INFORMATIONThermadyne USA2800 Airport RoadDenton, Tx 76207 USATelephone: (940) 566-2000800-426-1888Fax: 800-535-0557Em

Corporate Headquarters71 Gower StreetPreston, Victoria, Australia, 3072Telephone: +61 3 9474 7400FAX: +61 3 9474 7488Email: cigweldsales@cig

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20081-5 WARNINGSTEAM AND PRESSURIZED HOTCOOLANT can burn face, eyes, and skin.The coolant in the radiator

TRANSTIG 200 Pi SERVICE MANUAL1-6March 31, 20081.03 DECLARATION OF CONFORMITYManufacturer: CIGWELDAddress: 71 Gower St, PrestonVictoria 3072AustraliaD

2-1March 31, 2008SERVICE MANUAL TRANSTIG 200 PiSECTION 2:INTRODUCTION2.01 How To Use This ManualThis Owner’s Manual applies to just specification orpa

2-2March 31, 2008TRANSTIG 200 Pi SERVICE MANUAL2.04 Symbol ChartNote that only some of these symbols will appear on your model.Gas Tungsten Arc Weldin

2-3March 31, 2008SERVICE MANUAL TRANSTIG 200 Pi2.05 DescriptionThe Cigweld Transtig 200 Pi is a self contained single-phase DC arc welding power sourc

2-4March 31, 2008TRANSTIG 200 Pi SERVICE MANUAL2.06 Functional Block DiagramsFigure 2-2 illustrates the functional block diagram of the Transtig 200 P

2-5March 31, 2008SERVICE MANUAL TRANSTIG 200 Pi2.08 SpecificationsParameter Transtig 200PiPower Source Part Number 700720Cooling Fan CooledWelder Type

2-6March 31, 2008TRANSTIG 200 Pi SERVICE MANUALTHIS PAGE LEFT INTENTIONALLY BLANK.

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20083-1SECTION 3: INSTALLATION3.03 Electrical Input Connections!WARNINGELECTRIC SHOCK can kill; SIGNIFICANTDC

WE APPRECIATE YOUR BUSINESS!Congratulations on your new Cigweld product. We are proud tohave you as our customer and will strive to provide you with t

TRANSTIG 200 Pi SERVICE MANUAL3-2March 31, 20083.04 Mains Supply Voltage RequirementsThe Mains supply voltage should be within ± 15% of the rated Main

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20083-33.05 High Frequency IntroductionThe importance of correct installation of highfrequency welding equipme

TRANSTIG 200 Pi SERVICE MANUAL3-4March 31, 20083.07 Duty CycleThe duty cycle of a welding power source is thepercentage of a ten (10) minute period th

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20084-1Art # A-083431804101234567836015Figure 4-1: Transtig 200 Pi Power SourceSECTION 4:OPERATION4.01 Transti

TRANSTIG 200 Pi SERVICE MANUAL4-2March 31, 2008 CAUTIONLoose welding terminal connections cancause overheating and result in the maleplug being fused

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20084-3 Parameter Description PRE-FLOW This parameter operates in TIG modes only and is used to get gas

TRANSTIG 200 Pi SERVICE MANUAL4-4March 31, 2008 Parameter Description DOWN SLOPE This parameter operates in TIG modes only and is used to set t

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20084-54.05 Power Source Features Feature Description New Digital Control Almost all welding parameters

TRANSTIG 200 Pi SERVICE MANUAL4-6March 31, 2008 Feature Description Reduces the OCV when the power supply is not in use. Eliminates the need for

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20084-74.06 Set-Up for SMAW (STICK) andGTAW (TIG)Conventional operating procedures apply when usingthe Welding

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

TRANSTIG 200 Pi SERVICE MANUAL4-8March 31, 20084.07 Sequence of OperationNOTEScroll Buttons are used to select the parameters to be set. The LED’s sh

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20084-94.08 Stick Welding· Connect work lead to negative terminal· Connect electrode lead to positive terminal

TRANSTIG 200 Pi SERVICE MANUAL4-10March 31, 20084.10 Slope Mode SequenceSwitchClosedSwitchOpenSwitchClosedSwitchOpenPreflow InitialCurrent UpSlopeWel

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20084-114.12 Pulse Controls(Pulse Width)(Pulse Frequency)(Peak Current) (Base)Background CurrentArt #

TRANSTIG 200 Pi SERVICE MANUAL4-12March 31, 20084.13 Basic TIG Welding Guide1. Electrode Polarity:Connect the TIG torch to the - / TORCH terminal and

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20084-135. Shielding Gas Selection: Alloy Shielding Gas Aluminium & alloys Argon Carbon Steel

TRANSTIG 200 Pi SERVICE MANUAL4-14March 31, 20084.14 Basic Arc Welding Guide1. Electrode Polarity:Stick electrodes are generally connected to the ‘+’

SERVICE MANUAL TRANSTIG 200 Pi5-1March 31, 2008SECTION 5:SERVICE5.01 Routine MaintenanceThe only routine maintenance required for the power supply is

TRANSTIG 200 Pi SERVICE MANUAL5-2March 31, 20085.02 Maintenance DiagramWarning! Disconnect input power before maintaining.Each UseVisual check of regu

SERVICE MANUAL TRANSTIG 200 Pi5-3March 31, 20085.03 Basic Troubleshooting!WARNINGThere are extremely dangerous voltages and power levels present insid

TABLE OF CONTENTSSECTION 1:ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ... 1-11.01 Arc Welding Hazards ...

TRANSTIG 200 Pi SERVICE MANUAL5-4March 31, 20085.04 TIG Welding ProblemsWeld quality is dependent on the selection of the correct consumables, mainten

SERVICE MANUAL TRANSTIG 200 Pi5-5March 31, 200810 Arc flutters during TIG welding A Tungsten electrode is too large for the welding currentA Select th

TRANSTIG 200 Pi SERVICE MANUAL5-6March 31, 20085.05 Stick Welding Problems1 Gas pockets or voids in weld metal (Porosity)A Electrodes are damp A Dry e

SERVICE MANUAL TRANSTIG 200 Pi5-7March 31, 20084 Portions of the weld run do not fuse to the surface of the metal or edge of the jointA Small electrod

TRANSTIG 200 Pi SERVICE MANUAL5-8March 31, 20085 Non-metallic particles are trapped in the weld metal (slag inclusion)A Non-metallic particles may be

SERVICE MANUAL TRANSTIG 200 Pi5-9March 31, 20085.06 Power Source Problems1 The welding arc cannot be establishedA The Primary supply voltage has not b

TRANSTIG 200 Pi SERVICE MANUAL5-10March 31, 20085 Gas flow won't shut off A Weld Mode (STD, SLOPE, REPEAT or SPOT) was changed before POST-FLOW g

SERVICE MANUAL TRANSTIG 200 Pi5-11March 31, 20085.07 Power Source Error CodesRemarksA The Welding Power Source's duty cycle has been exceededA Le

TRANSTIG 200 Pi SERVICE MANUAL5-12March 31, 2008Remarks6 E94 error code displayed. Temperature sensor TH1 for IGBTs is an open circuitThe Welding Powe

SERVICE MANUAL TRANSTIG 200 Pi5-13March 31, 20085.08 Voltage Reduction Device (VRD)1. VRD Specification: Description Transtig 200 Pi Notes VRD

TABLE OF CONTENTS (continued)TABLE OF CONTENTSSECTION 5:SERVICE ...

TRANSTIG 200 Pi SERVICE MANUAL5-14March 31, 2008THIS PAGE LEFT INTENTIONALLY BLANK.

6 ADVANCED TROUBLESHOOTING6 – 1ADVANCED TROUBLESHOOTINGIf you are here, all of the troubleshooting sugges-tions in Section 5 - Basic Troubleshooting h

6 – 23) Loosen the screws on the front panel and therear panel by turning them approximately twoturns CCW.NOTE DO NOT remove the screws completely.Fig

6 – 36.2Verification and Remedy to the Indicated Error CodesNOTE The capacitors inside the power supply will slowlydischarged after you turn off the s

6 – 4c) Verify the operation of the cooling fan, FAN1, and replace it if necessary. Verify the condition of FAN1. Verify that thereare no broken or c

6 – 5SERVICE MANUAL ADVANCED TROUBLESHOOTING TRANSTIG 200 Pi6.2.6 E04 "Torch Cable Failure"CauseThe combined length of

6 – 66.3Verification and Remedy to Failures without Indication CodesRefer to Note on Section 11.02.6.3.1 “Cooling Fan (FAN1) Failure” (Fan is not ro

6 – 76.3.3 “No weld output”When in High Frequency TIG (HF TIG) mode, if theHigh Frequency is not generated (present), refer to“High Frequency Output F

6 – 8b) Verify the connection between PCB5 (WK-5448) and PCB4 (WK-5460). Verify that there is no omission of a looseningscrews and connected harness

6 – 96.4Fault Isolation Tests6.4.1 PreparationThe following initial conditions must be met prior tostarting any of the procedures in this section.1) C

TABLE OF CONTENTSSECTION 7:MAINTENANCE ... 7-17.01 Subsystem Test

6 – 10points U2 and V2 on the input switch, S1.The location of points U2 and V2 on switchS1 are indicated in Figure 6-7. 4) If this voltage is out of

6 – 11Table 6-1: Checkpoints TP0-TP3 on PCB6Figure 11-11: Checkpoints CN2 on PCB1Table 6-2: Checkpoints CN2 on PCB13) If any of these voltages are not

6 – 12Table 6-3: Verification of the FAN1 At the time of a low output and standby, as forthis equipment, rotation of a fan becomes slow.Therefore, ex

6 – 132) Refer to Table 11-5 and Figure 11-14 forthe checkpoints on D1.Table 6-5: Tester checkpoints for D1Figure 6-14: Tester checkpoints in the D1

6 – 14Table 6-7: Tester checkpoints for Q1A-Q4CFigure 6-16: Tester checkpoints for Q1A-Q4C6.5.8 Verification of No-load Voltage (OCV)CAUTIONBefore p

6 – 152) Press the Welding mode selection buttonto select HF TIG welding mode.3) While depressing the Torch switch, verifythe OCV using a DC voltmeter

7 MAINTENANCE7 – 1MAINTENANCE7.1Subsystem Test and Replacement Procedures7.1.1 PreparationThis section provides specific procedures for verifying the

7 – 2NO. DWG NO. PARTS NAMEREFERENCEPAG EPART NO .1 C1 Capacitor 12-8 10-65102 C101-C102 Capacitor 12-21 W70016223 C

7 – 316921045378NO. DWG NO. PARTS NAMEREFERENCE PAG EPART NO .1 CON1 Remote Receptacle12-22 10-66272 CT1 Hall Current Trans12-17

7 – 47.2Service Tools7.2.1 Tools and partsThe tools and parts to be used for maintenance are shown by icons.7.2.2 Notes of disassembly and assemblyNOT

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20081-11.01 Arc Welding Hazards WARNINGELECTRIC SHOCK can kill.Touching live electrical parts can cause fata

7 – 57.3Replacement Procedure7.3.1 PCB1 (WK-5713) and Primary Diode D1 UVX[\1) Remove the Side Panel. [See section “6.1-1”]2) Remove the L102. [See se

7 – 66) Remove the Gas Tube. Remove the two bolts, two toothed washers, and the terminal.7) Remove the four screws and the Front Panel.8) Remove the G

7 – 79) Remove the four screws and the Rear Panel.10) Remove the four screws and the two cables. Disconnect the eight connectors CN1-8 on the PCB1.11)

7 – 812) Remove the Primary Diode D1 with the soldering iron from the PCB1. Before installing a new diode, apply a uniform coat of silicone compound

7 – 95) Remove the eight screws and the PCB2 unit.6) Remove the screw and Remove the Capacitor C1 and Resistor R1 from the PCB2. Remove the twoedge ho

7 – 107.3.3 PCB3 (WK-5609) and T1 “Transformer”V1) Remove the Side Panel. [See section "6.1-1"]2) Remove the CT1. [See section “7.3-10”]3)

7 – 117.3.4 PCB4 (WK-5449) V1) Remove the Side Panel. [See section "6.1-1"]2) Remove the Protection Cover.3) Remove the Knob Cap. Holding th

7 – 125) Remove the four screws. Remove the PCB4.7.3.5 PCB5 (WK-5448) V1) Remove the Side Panel. [See section "11.1-1"]2) Remove the PCB4. [

7 – 137.3.6 PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT” VX1) Remove the Side Panel. [See section "6.1-1"]2) Remove the four screws and two IGB

7 – 147.3.7 PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT” VZ1) Remove the Side Panel. [See section “6.1-1”]2) Remove the four screws and two IGBT Spring C

TRANSTIG 200 Pi SERVICE MANUAL1-2March 31, 2008 WARNINGARC RAYS can burn eyes and skin; NOISEcan damage hearing.Arc rays from the welding processpro

7 – 157.3.8 D2 and D3 “Secondary Diode” V\1) Remove the Side Panel. [See section “6.1-1”]2) Remove PCB3 (WK-5569) and T1. [See section “7.3-3”]3) Remo

7 – 163) Remove the four screws and the Front Panel.4) Remove the screw and then remove the cable. Remove the two terminals from HF. UNIT. Remove thet

7 – 177.3.10 CT1 “Hole Current Trans” V1) Remove the Side Panel. [See section “11.1-1”]2) Remove the bolts, the spring, and the washer. Remove the thr

7 – 187.3.11 FAN1 “Cooling Fan” UVX[1) Remove the Side Panel. [See section “6.1-1”]2) Remove the Gas Tube. Remove the two terminals and Cut the three

7 – 195) Remove the FAN1. Do not have the wrong direction of the fan when reinstalling.7.3.12 HF UNIT1 “High Frequency Unit”V1) Remove the Side Pane

7 – 207.3.13 SOL1 “Solenoid GAS Valve” V1) Remove the Side Panel. [See section “6.1-1”]2) Remove the Gas Tube and two terminals.3) Remove the C-ring

7 – 217.3.14 C101-C102 “Capacitor”, L101 “Ring Core” and S1 “Switch” V1) Remove the Side Panel. [See section “6.1-1”]2) Remove the four screws and the

7 – 227.3.15 CON1 “Remote Receptacle” UV1) Remove the Side Panel. [See section “6.1-1”]2) Remove the screw and then three ground cables. Cut the two s

7 – 237.3.16 TH1 “Primary Thermistor” UV\1) Remove the Side Panel. [See section “6.1-1”]2) Remove the snap band. Disconnect the connector CN5 on the P

7 – 247.3.18 C103 “Capacitor” and L102 “Reactor” V1) Remove the Side Panel. [See section “6.1-1”]2) Remove four screws, six terminals. Remove the C103

SERVICE MANUAL TRANSTIG 200 PiMarch 31, 20081-3 WARNINGWELDING can cause fire or explosion.Sparks and spatter fly off from the weldingarc. The fly

7 – 254) Remove four screws and open the Rear Control Cover.5) Remove one nut, one washer and two terminals. Remove the L103.7.3.20 C2 “Capacitor” and

7 – 263) Remove the four screws and open the Rear Panel.4) Remove the CT1. [See section “7.3-10”]5) Cut the snap band and remove the cables. Disconnec

7 – 277) Remove the screw and C2 unit.8) Remove the C2 with the soldering iron from the R2.121122SERVICE MANUALMAINTENANCETRANSTIG 200 Pi

APPENDIX 1: OPTIONS AND ACCESSORIES Description Part No. Details 17 Series air cooled TIG torch (suitable for TransTig 200Pi) 518710402 TIG

APPENDIX 2: PARTS LISTA-21Equipment IdentificationAll identification numbers as described in the Introduction chapter must be furnished when ordering

A-3.YTQgnitaR&epyTnoitpircseD.oNtraP.oNGWD.oN34 R4-5 W7001452 Resistor, gen 3.1, IPS MHS20A221KI 20W 220Ω 135 R6 W7001451 Resistor, gen 3.1, IPS M

A-450494742843644296969747459581341565385437428552575657240484524234367656646514955.YTQgnitaR&epyTnoitpircseD.oNtraP.oNGWD.oN82 W7001616 Shee

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APPENDIX 3: CONNECTION WIRING GUIDEA-6APPENDIX 2 Conne ction Wiring GuideCONNEC TIO N WIRING GUI DEDestinationA PCB2 CN2lPCB3 CN3B PCB2 CN3lD1C PCB3 C

A-7PCB10PCB9PCB8PCB11PCB7PCB6PCB4PCB3PCB2HCT1PCB13PCB16CN2CN1CN2CN1CN1CN20CN8CN9CN33CN21CN17CN1CN22CN11CN23CN20CN14CN15CON1CN3CN20CN21CN1CN2CN3CN4TH1T