200 Pi TRANSTIG ® INVERTER ARC WELDER Service Manual Revision No: AA Operating Features: Issue Date: March 31, 2008 Manual No.
WE APPRECIATE YOUR BUSINESS! Congratulations on your new Cigweld product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1300-654-674, or visit us on the web at www.cigweld.com.au.
! WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Transtig 200Pi Inverter Arc Welder Instruction Manual Number 0-4967 for: Catalog Number 700720 Published by: Thermadyne Industries, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.
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 ...................................................
TABLE OF CONTENTS TABLE OF CONTENTS (continued) SECTION 5: SERVICE .............................................................................................. 5-1 5.01 Routine Maintenance ...................................................................................... 5-1 5.02 Maintenance Diagram..................................................................................... 5-2 5.03 Basic Troubleshooting ....................................................................................
TABLE OF CONTENTS SECTION 7: MAINTENANCE ....................................................................................... 7-1 7.01 Subsystem Test and Replacement Procedures ............................................... 7-1 7.1.1 Preparation ............................................................................................ 7-1 7.1.2 Test and Replacement Parts List ........................................................... 7-1 7.02 Service Tools ............................................
SERVICE MANUAL TRANSTIG 200 Pi 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.
TRANSTIG 200 Pi SERVICE MANUAL WARNING WARNING FUMES AND GASES can be hazardous to your health. ARC RAYS can burn eyes and skin; NOISE can damage hearing. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 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. Keep your head out of the fumes. Do not breath the fumes. 1.
SERVICE MANUAL TRANSTIG 200 Pi 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.
TRANSTIG 200 Pi SERVICE MANUAL WARNING Engines can be dangerous. WARNING MOVING PARTS can cause injury. Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing. 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.
SERVICE MANUAL TRANSTIG 200 Pi 1. Keep cables close together by twisting or taping them. 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. 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: 2.
TRANSTIG 200 Pi SERVICE MANUAL 1.03 DECLARATION OF CONFORMITY Manufacturer: Address: CIGWELD 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.
SERVICE MANUAL TRANSTIG 200 Pi SECTION 2: INTRODUCTION 2.01 How To Use This Manual This Owner’s Manual applies to just specification or part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings.
TRANSTIG 200 Pi SERVICE MANUAL 2.04 Symbol Chart Note that only some of these symbols will appear on your model. On Single Phase Wire Feed Function Off Three Phase Wire Feed Towards Workpiece With Output Voltage Off.
SERVICE MANUAL TRANSTIG 200 Pi 2.05 Description The Cigweld Transtig 200 Pi is a self contained singlephase DC arc welding power source with Constant Current (CC) output characteristics.
TRANSTIG 200 Pi SERVICE MANUAL 2.06 Functional Block Diagrams Figure 2-2 illustrates the functional block diagram of the Transtig 200 Pi power source.
SERVICE MANUAL TRANSTIG 200 Pi 2.08 Specifications Parameter Power Source Part Number Cooling Welder Type Welding Power Source Mass Dimensions Manufactured to Australian Standard Number of Phases Nominal Supply Voltage Nominal Supply Frequency Protection Class Transtig 200Pi 700720 Fan Cooled Inverter Power Source 8kg H 260mm x W 130mm x L 320mm AS 60974.
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SERVICE MANUAL TRANSTIG 200 Pi SECTION 3: INSTALLATION 3.03 Electrical Input Connections 3.01 Environment The Transtig 200 Pi is designed for use in hazardous environments. Examples of environments with increased hazardous environments are: a. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts; b.
TRANSTIG 200 Pi 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 Pi The Welding Power Source must be: • Correctly installed, if necessary, by a qualified electrician.
SERVICE MANUAL TRANSTIG 200 Pi 3.05 High Frequency Introduction 3.06 High Frequency Interference 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.
TRANSTIG 200 Pi 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.
SERVICE MANUAL TRANSTIG 200 Pi SECTION 4: OPERATION 4.01 Transtig 200 Pi Controls 410 180 Art # A-08343 6 7 2 360 1 5 4 3 15 8 Figure 4-1: Transtig 200 Pi Power Source 1. Control Knob: This control sets the selected weld parameter, rotating it clockwise increases the parameter and is indicated on the digital meter. Pushing the knob inward displays the actual welding voltage. 2.
TRANSTIG 200 Pi SERVICE MANUAL ! CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal. 5. Gas Outlet: The Gas Outlet is a 5/8-18 UNF female gas fitting. 6. ON/OFF Switch: This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the Power Supply.
SERVICE MANUAL TRANSTIG 200 Pi 4.03 Weld Parameter Descriptions for Transtig 200 Pi Art # A-06032_AB Figure 4-3: Transtig 200 Pi Front Panel Parameter Description This parameter operates in TIG modes only and is used to get gas to the weld zone PRE-FLOW 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.
TRANSTIG 200 Pi SERVICE MANUAL Parameter Description 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 DOWN SLOPE CUR. This control is used to eliminate the crater that can form at the completion of a weld. This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to CRATER CUR. set the finish current for TIG.
SERVICE MANUAL TRANSTIG 200 Pi 4.
TRANSTIG 200 Pi SERVICE MANUAL Feature Voltage Reduction Device (VRD) Control Knob Self Diagnosis Using Error Codes Description Reduces the OCV when the power supply is not in use. Eliminates the need for add on voltage reducers and has no effect on arc starting. VRD fully complies to AS 60974.1 When Stick mode is selected the green VRD light is ON when not welding and red when welding. When in TIG modes VRD is off.
SERVICE MANUAL TRANSTIG 200 Pi 4.06 Set-Up for SMAW (STICK) and GTAW (TIG) Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short-term overload without adverse effects. The welding current range values should be used as a guide only.
TRANSTIG 200 Pi SERVICE MANUAL 4.07 Sequence of Operation NOTE Scroll Buttons are used to select the parameters to be set. The LED’s show which function is being adjusted on the weld sequence graph. Refer to Symbols Table located in the front of the manual for Symbol descriptions. Art # A-06034_AB 1 7 2 6 8 3 4 5 Figure 4-5: Transtig 200 Pi Front Panel 1. Pulse Function: Pressing this button enables the TIG current pulse functions. 5.
SERVICE MANUAL 4.08 Stick Welding TRANSTIG 200 Pi 4.09 HF TIG & Lift TIG Welding · Connect work lead to negative terminal · Connect work lead to positive terminal · Connect electrode lead to positive terminal · Connect TIG torch to negative terminal · Switch machine on · Switch machine on · Set weld current · Set WELD current. · Connect remote control device if required Use the Scroll Buttons to move to the parameter to be set.
TRANSTIG 200 Pi SERVICE MANUAL 4.10 Slope Mode Sequence Switch Open Switch Closed Initial Current Up Slope Switch Closed Weld Current Down Slope Preflow Final Current Switch Open Art # A-05069_AB Postflow Figure 4-6: Slope Mode Sequence 1) To start Slope sequence Close remote switch contacts. Once the welding arc is established the Power Source will maintain initial current setting as long as the remote switch contacts are closed.
SERVICE MANUAL TRANSTIG 200 Pi 4.12 Pulse Controls (Pulse Width) (Pulse Frequency) Art # A-05070 (Peak Current) (Base) Background Current Figure 4-7: Pulse Controls The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows: 1) Control puddle: size and fluidity (especially out of position). 2) Increase penetration 3) Travel speed control 4) Better consistent quality 5) Distortion on lighter or thinner materials.
TRANSTIG 200 Pi SERVICE MANUAL 4.13 Basic TIG Welding Guide 1. Electrode Polarity: Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece. 2. Tungsten Electrode Current Ranges: Electrode Diameter 0.040” (1.0mm) 1/16” (1.6mm) 3/32” (2.4mm) 1/8” (3.
SERVICE MANUAL TRANSTIG 200 Pi 5. Shielding Gas Selection: Alloy Aluminium & alloys Carbon Steel Stainless Steel Copper Shielding Gas Argon Argon Argon Argon Table 4-10: Shielding Gas Selection 6. TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe: Electrode Type & Diameter Thoriated 2% 3/32'' (2.4mm) Thoriated 2% 3/32'' (2.4mm) Thoriated 2% 3/32'' (2.
TRANSTIG 200 Pi SERVICE MANUAL 4.14 Basic Arc Welding Guide 1. Electrode Polarity: Stick electrodes are generally connected to the ‘+’ terminal and the work lead to the ‘-’ terminal but if in doubt consult the electrode manufacturers literature. 2. Effects of Stick Welding Various Materials: A. High tensile and alloy steels C. Cast Iron Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it.
SERVICE MANUAL TRANSTIG 200 Pi SECTION 5: SERVICE 5.01 Routine Maintenance The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment. ! WARNING Disconnect primary power at the source before opening the enclosure. Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge.
TRANSTIG 200 Pi SERVICE MANUAL 5.02 Maintenance Diagram Warning! Disconnect input power before maintaining. Maintain more often if used under severe conditions Each Use Visual check of torch Consumable parts Visual check of regulator and pressure Weekly Visually inspect the torch body and consumables Visually inspect the cables and leads.
SERVICE MANUAL TRANSTIG 200 Pi 5.03 Basic Troubleshooting ! WARNING There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an Accredited Cigweld Service Provider and you have had training in power measurements and troubleshooting techniques. If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Cigweld Service Provider for repair.
TRANSTIG 200 Pi SERVICE MANUAL 5.04 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique.
SERVICE MANUAL TRANSTIG 200 Pi Description 10 Arc flutters during TIG welding Possible Cause Remedy A Tungsten electrode is too A Select the right size large for the welding current electrode.
TRANSTIG 200 Pi SERVICE MANUAL 5.
SERVICE MANUAL TRANSTIG 200 Pi Description Possible Cause 4 Portions of the weld run do not A Small electrodes used on fuse to the surface of the metal or heavy cold plate edge of the joint B Welding current is too low C Wrong electrode angle Remedy A Use larger electrodes and preheat the plate B Increase welding current C Adjust angle so the welding arc is directed more into the base metal D Travel speed of electrode is D Reduce travel speed of too high electrode E Scale or dirt on joint surface E Clea
TRANSTIG 200 Pi SERVICE MANUAL Description 5 Non-metallic particles are trapped in the weld metal (slag inclusion) Possible Cause Remedy A Non-metallic particles may A If bad undercut is be trapped in undercut from present, clean slag out previous run and cover with a run from a smaller diameter electrode B Joint preparation too B Allow for adequate restricted penetration and room for cleaning out the slag C Irregular deposits allow slag C If very bad, chip or grind to be trapped out irregularities D Lac
SERVICE MANUAL TRANSTIG 200 Pi 5.
TRANSTIG 200 Pi Description 5 Gas flow won't shut off SERVICE MANUAL Possible Cause Remedy A Weld Mode (STD, SLOPE, A Strike an arc to complete REPEAT or SPOT ) was the weld cycle OR switch changed before POSTmachine off then on to FLOW gas time had finished reset solenoid valve sequence B Gas valve is faulty B Have an Accredited Cigweld Service Provider replace gas valve C Gas valve jammed open C Have an Accredited Cigweld Service Provider repair or replace gas valve D POST-FLOW control is set D Reduce
SERVICE MANUAL TRANSTIG 200 Pi 5.07 Power Source Error Codes Description Possible Cause 1 E01 error code A The Welding Power displayed. Source's duty cycle has Temperature been exceeded sensor TH1 B Fan ceases to operate (protects IGBTs) is greater than 80°C for about 1 C Air flow is restricted by second vents being blocked 2 E02 error code A The Welding Power displayed.
TRANSTIG 200 Pi SERVICE MANUAL Description Possible Cause Remedy 6 E94 error code The Welding Power Have an Accredited displayed. Source's temperature Cigweld Service Provider Temperature sensors have check or replace the sensor TH1 for malfunctioned temperature sensors IGBTs is an open circuit 7 E99 error code A Main on/off switch on A Turn on/off switch on displayed.
SERVICE MANUAL TRANSTIG 200 Pi 5.08 Voltage Reduction Device (VRD) 1. VRD Specification: Description Transtig 200 Pi VRD Open Circuit Voltage 15.3 to 19.8V VRD Resistance VRD Turn OFF Time Notes Open circuit voltage between welding terminals 148 to 193 ohms The required resistance between welding terminals to turn ON the welding power 0.2 to 0.3 seconds The time taken to turn OFF the welding power once the welding current has stopped Table 5-5: VRD Specification 2.
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SERVICE MANUAL TRANSTIG 200 Pi 6 ADVANCED TROUBLESHOOTING ADVANCED TROUBLESHOOTING If you are here, all of the troubleshooting suggestions in Section 5 - Basic Troubleshooting have either failed to resolve the faulty operation or have indicated that one or more of the subsystems within the power supply are defective. This section provides the information needed to take live measurements on the various subsystems within the power supply, and replace those subsystems that prove faulty.
TRANSTIG 200 Pi ADVANCED TROUBLESHOOTING 3) Loosen the screws on the front panel and the rear panel by turning them approximately two turns CCW. SERVICE MANUAL 5) Remove the side panels. NOTE DO NOT remove the screws completely. Figure 6-5: Remove Side Panel 6) Remove protection cover sheet by removing the plastic tabs. Figure 6-3: Loosen screws 4) Pull the front panel slightly forward and pull the rear panel slightly backward.
SERVICE MANUAL ADVANCED TROUBLESHOOTING 6.2 Verification and Remedy to the Indicated Error Codes NOTE The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete and then remove the cases to continue your inspection and repair (or maintenance) inside the power supply. As for the removal and installation of the case, Refer to section 6.1-1.
TRANSTIG 200 Pi ADVANCED TROUBLESHOOTING 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 6.
SERVICE MANUAL ADVANCED TROUBLESHOOTING TRANSTIG 200 Pi 6.2.7 E93 "Memory chip (EEPROM) error." 6.2.6 E04 "Torch Cable Failure" Cause The combined length of the torch cable and the work cable is too long. Cause Memory chip (EEPROM) on control PCB can not read/write weld parameters. Verification/Remedy Verification/Remedy a) Verify the rated duty cycle of the torch/work cable and the power supply. a) Replace Control Board PCB4 (WK-5549). • Refer to section 7.3.4 for the replacement of PCB4.
SERVICE MANUAL ADVANCED TROUBLESHOOTING 6.3 Verification and Remedy TRANSTIG 200 Pi 6.3.2 “Gas Valve Failure” (No Gas flow through unit) to Failures without Indication Codes Cause Occurs when the gas valve (SOL1) is defective, damaged or the driving voltage is incorrect. Refer to Note on Section 11.02. 6.3.1 “Cooling Fan (FAN1) Failure” (Fan is not rotating.) Cause Occurs when the cooling fan (FAN1) is defective, damaged or the driving voltage is incorrect.
TRANSTIG 200 Pi ADVANCED TROUBLESHOOTING 6.3.3 “No weld output” When in High Frequency TIG (HF TIG) mode, if the High Frequency is not generated (present), refer to “High Frequency Output Failure”. Refer to the page 6-7. Cause Occurs when the remote connector (CON1) or associated circuitry is defective, damaged, or the TIG torch cable is defective. Verification/Remedy CAUTION Read and understand this entire section before proceeding.
SERVICE MANUAL ADVANCED TROUBLESHOOTING b) Verify the connection between PCB5 (WK5448) and PCB4 (WK-5460). Verify that there is no omission of a loosening screws and connected harness between the PCB4 and PCB5. Replace PCB4 and PCB5 if necessary. Refer to the page 7-11, 12. 6.3.5 “High Frequency Output Failure” (Unit does not generate High Frequency.) TRANSTIG 200 Pi Verify there are no short circuits, burnt or broken wires between the HF UNIT1 and the R3 (R4).
TRANSTIG 200 Pi ADVANCED TROUBLESHOOTING 6.4 Fault Isolation Tests SERVICE MANUAL 6.5 Verification of the Power Input Circuitry 6.4.1 Preparation The following initial conditions must be met prior to starting any of the procedures in this section. 1) Connect the appropriate input voltage. (Check the name plate on the rear of the power supply for the proper input voltage.) NOTE Operate at ALL input voltages as noted on the nameplate on the rear panel when testing the power supply.
SERVICE MANUAL ADVANCED TROUBLESHOOTING TRANSTIG 200 Pi points U2 and V2 on the input switch, S1. The location of points U2 and V2 on switch S1 are indicated in Figure 6-7. 4) If this voltage is out of the operating range, which is ±10% (207~253VAC) of the rated voltage (230V), replace S1 following the process in section 12.3-4. 5) Verify the rectified output voltage of the primary diode, D1 using a DC voltmeter. (The capability of the voltmeter should be more than 400VDC.
TRANSTIG 200 Pi Test Point PCB6 TP1 TP2 TP3 ADVANCED TROUBLESHOOTING Reference PCB6 TP0 TP0 TP0 6.5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry ACCEPTABLE VALUE +5VDC +12VDC –12VDC CAUTION Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 6.4.1 "Preparation". Table 6-1: Checkpoints TP0-TP3 on PCB6 1) Verify the condition of the cooling fan, FAN1, using a DC voltmeter.
SERVICE MANUAL FAN1 Status Case 3 Inactive Case 4 Inactive Voltage measurement. (1PIN-2PIN of CN2 on PCB1) ADVANCED TROUBLESHOOTING TRANSTIG 200 Pi Remedy PCB1(WK-5713) Replace PCB1. Refer to the page 7-5. 4 Perform Below DC 18V “2. Verification of the Power Supply Voltage Test”. Refer to the page 6-9. Replace the DC 18 ~ 25V FAN1.Refer to the page 7-18.
TRANSTIG 200 Pi ADVANCED TROUBLESHOOTING 2) Refer to Table 11-5 and Figure 11-14 for the checkpoints on D1. COMPONENT TESTED Diode of D1 Diode of D1 TERMINALS Positive Negative lead lead 1, 2, 3 5 5 1, 2, 3 1, 2, 3 4 4 1, 2, 3 COMPONENT TESTED ACCEPTABLE VALUE 0.3 to 0.5V Open Open 0.3 to 0.5V Diode 1 of D2, and D3, Diode 2 of D2, and D3, SERVICE MANUAL TERMINALS ACCEPTABLE Positive Negative VALUE lead lead Anode Cathode 0.2 to 0.3V Cathode Anode Open Anode Cathode 0.2 to 0.
SERVICE MANUAL ADVANCED TROUBLESHOOTING TRANSTIG 200 Pi a) Verify the no-load voltage in STICK mode. TERMINALS ACCEPTABLE Positive Negative VALUE lead lead COMPONENT TESTED Collector-Emitter of Q1A~Q2C with PCB6 Collector-Emitter of Q3A~Q4C with PCB7 C CE CE C Open 0.2 to 0.5V CE E E CE Open 0.2 to 0.
TRANSTIG 200 Pi ADVANCED TROUBLESHOOTING 2) Press the Welding mode selection button to select HF TIG welding mode. 3) While depressing the Torch switch, verify the OCV using a DC voltmeter. (The capability of the voltmeter should be more than 100VDC.) The check point with a tester is the voltage between output terminal + and -. In TIG mode, the OCV ceases 3 seconds after you depress the torch switch. 4) The normal no-load voltage is approximately 65V.
SERVICE MANUAL TRANSTIG 200 Pi 7 MAINTENANCE 7.1 Subsystem Test and Replacement Procedures MAINTENANCE 7.1.1 Preparation This section provides specific procedures for verifying the operation and replacement of each subsystem within the power supply. Before undertaking any of these procedures, eliminate the obvious first-visually inspect the suspect subsystem for physical damage, overheating, and loose connections. 7.1.2 Test and Replacement Parts List 6 4 1 5 7 2 3 NO. DWG NO.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 10 8 2 9 3 11 1 6 13 12 5 4 7 NO. DWG NO. PARTS NAME REFERENCE PAGE PART NO. 1 C1 Capacitor 12-8 10-6510 2 C101-C102 Capacitor 12-21 W7001622 3 C103 Capacitor 12-24 W7001621 4 C2 Capacitor 12-25 W7001620 5 C.C.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 7 3 9 6 1 5 4 10 8 2 NO. DWG NO. REFERENCE PAGE PARTS NAME PARTNO.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 7.2 Service Tools 7.2.1 Tools and parts The tools and parts to be used for maintenance are shown by icons. Spanner Philips Head Screwdriver Long Nose Pliers C-Ring Pliers Soldering Copper (solder) Snap Band Silicon Compound 7.2.2 Notes of disassembly and assembly NOTE When removing the locking type connectors and board supporters, disengage the locking mechanism first and then disconnect them.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 7.3 Replacement Procedure 7.3.1 PCB1 (WK-5713) and Primary Diode D1 UVX[\ 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove the L102. [See section “7.3-18”] 3) Remove the screw and three cables. Cut the snap band. 3 3 2 1 4) Remove the terminal and Disconnect the three connectors CN1 (PCB4), CN101, 103 (PCB1). CN103 CN1 CN101 5) Remove the terminal.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 6) Remove the Gas Tube. Remove the two bolts, two toothed washers, and the terminal. 2 1 2 1 2 7) Remove the four screws and the Front Panel. 1 1 2 1 1 8) Remove the Gas Tube and the two cables.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 9) Remove the four screws and the Rear Panel. 1 1 2 1 1 10) Remove the four screws and the two cables. Disconnect the eight connectors CN1-8 on the PCB1. 1 2 2 CN3 CN2 CN1 CN4 CN5 CN6 CN8 CN7 11) Remove the four screws and Remove the PCB1 unit.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 12) Remove the Primary Diode D1 with the soldering iron from the PCB1. Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base. 2 1 3 7.3.2 PCB2 (WK-5417), Capacitor C1 and Resistor R1 VX[ 1) Remove the Side Panel. [See section "6.1-1"] 2) Remove the PCB1 and D1. [See section "7.3-1"] 3) Remove the PCB6 and PCB7. [See section “7.3-6, 3-7”] 4) Remove the screw and the cable.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 5) Remove the eight screws and the PCB2 unit. 1 1 1 1 2 6) Remove the screw and Remove the Capacitor C1 and Resistor R1 from the PCB2. Remove the two edge holders and the PCB2 Insulation Sheet from PCB2.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 7.3.3 PCB3 (WK-5609) and T1 “Transformer”V 1) Remove the Side Panel. [See section "6.1-1"] 2) Remove the CT1. [See section “7.3-10”] 3) Cut the snap band and Remove the cables. Disconnect the three connectors CN1-3 on the PCB3. Remove the three screws and the three cables. Remove the terminal. 2 CN2 4 CN1 4 CN3 1 4 3 4 3 3 4) Remove the 11 screws and PCB3 unit. Take care about the shape of the screw when you replace PCB3.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 7.3.4 PCB4 (WK-5449) V 1) Remove the Side Panel. [See section "6.1-1"] 2) Remove the Protection Cover. 2 2 3 1 3) Remove the Knob Cap. Holding the Knob down, loosen the screw and remove the Knob. 2 1 3 4) Disconnect the two connectors CN1,3 on the PCB4. Remove the four screws. Pull out the operation panel and bring it down.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 5) Remove the four screws. Remove the PCB4. 1 1 1 1 2 7.3.5 PCB5 (WK-5448) V 1) Remove the Side Panel. [See section "11.1-1"] 2) Remove the PCB4. [See section “12.3-4”] 3) Remove the three latches of Front Control Cover and then remove the PCB5. 1 1 2 When reinstalling the PCB5, engage two latches of Front Control Cover first.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 7.3.6 PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT” VX 1) Remove the Side Panel. [See section "6.1-1"] 2) Remove the four screws and two IGBT Spring Clips. Remove the cables from edge holder. 2 1 1 3) Disconnect the connector CN1 on the PCB6. Cut the lead of the Q1A-Q2C. Remember to install new Silicone Rubber Sheets where silicone compound (Shinetsu Silicone G-747 or equivalent) was spread when reinstalling the PCB6. Spread the silicone compound on IGBT.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 7.3.7 PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT” VZ 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove the four screws and two IGBT Spring Clips. Remove the cables from edge holder. 2 1 1 3) Disconnect the connector CN1 on the PCB6. Cut the lead of the Q3-Q4C. Remember to install new Silicone Rubber Sheets where silicone compound (Shinetsu Silicone G-747 or equivalent) was spread when reinstalling the PCB7. Spread the silicone compound on IGBT.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 7.3.8 D2 and D3 “Secondary Diode” V\ 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove PCB3 (WK-5569) and T1. [See section “7.3-3”] 3) Remove six screws and then detach the D2 and D3. Do not have the wrong direction of the diodes when reinstalling. Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base. 2 2 1 1 7.3.9 C.C.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 3) Remove the four screws and the Front Panel. 1 1 2 1 1 4) Remove the screw and then remove the cable. Remove the two terminals from HF. UNIT. Remove the terminal from PCB3. 1 3 2 3 5) Remove the C.C. and FCH1.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 7.3.10 CT1 “Hole Current Trans” V 1) Remove the Side Panel. [See section “11.1-1”] 2) Remove the bolts, the spring, and the washer. Remove the three screws and then remove the Output Bus Bar. 1 3 2 2 2 3) Remove the CT1. Disconnect the connector.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 7.3.11 FAN1 “Cooling Fan” UVX[ 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove the Gas Tube. Remove the two terminals and Cut the three snap bands. 2 2 2 2 1 1 3) Disconnect the connector CN2 on the PCB1 and Cut the snap band. 2 CN2 1 4) Remove the four screws and then open the Rear Panel.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 5) Remove the FAN1. Do not have the wrong direction of the fan when reinstalling. 7.3.12 HF UNIT1 “High Frequency Unit” V 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove the high frequency gap. Remove the four terminals. 3) Remove the two screws and the two washers. Detach the HF UNIT1.
TRANSTIG 200 Pi MAINTENANCE 7.3.13 SOL1 “Solenoid GAS Valve” V 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove the Gas Tube and two terminals. 1 2 3) Remove the C-ring and then detach the SOL1. When reinstalling, make sure that the C-ring seats in the solenoid valve groove.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 7.3.14 C101-C102 “Capacitor”, L101 “Ring Core” and S1 “Switch” V 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove the four screws and the six cables. Remove the one nut and one terminal. Remove the C101C102. 1 2 1 2 3 2 4 1 3) Cut off the snap band. Remove the L101 from the Input Cable. 1 3 2 4) Remove the two screws and then detach the S1.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 7.3.15 CON1 “Remote Receptacle” UV 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove the screw and then three ground cables. Cut the two snap bands. 3 3 2 1 3) Cut the snap band and disconnect connector CN1 on the PCB1. 1 CN1 2 4) Open the Panel Protects. Remove the two screws and the CON1.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 7.3.16 TH1 “Primary Thermistor” UV\ 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove the snap band. Disconnect the connector CN5 on the PCB1. Remove the screw and then detach the TH1. Before installing a new Thermistor, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base. 2 1 CN5 3 7.3.17 TH2 “Secondary Thermistor” UV\ 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove PCB3 unit. [See section “7.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 7.3.18 C103 “Capacitor” and L102 “Reactor” V 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove four screws, six terminals. Remove the C103 and L102. 2 2 1 Note : When C103 is installed again, it is a thing fixed to former place on PCB3 by RTV silicon rubber. 7.3.19 L103 “Reactor” VX[U 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove the L102. [See section “7.3-18”] 3) Cut off two snap bands and remove one screw, three terminals.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 4) Remove four screws and open the Rear Control Cover. 1 1 2 1 1 5) Remove one nut, one washer and two terminals. Remove the L103. 7.3.20 C2 “Capacitor” and R2 “Resistor” VX[Z 1) Remove the Side Panel. [See section “6.1-1”] 2) Remove the Gas Tube and the two cables.
TRANSTIG 200 Pi MAINTENANCE SERVICE MANUAL 3) Remove the four screws and open the Rear Panel. 1 1 2 1 1 4) Remove the CT1. [See section “7.3-10”] 5) Cut the snap band and remove the cables. Disconnect the three connectors CN1-3 on the PCB3. Remove the three screws and the three cables. Remove the terminal. 2 CN2 4 CN1 4 CN3 1 4 3 4 6) Remove the 11 screws and PCB3 unit. Take care about the shape of the screw when you replace PCB3.
SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi 7) Remove the screw and C2 unit. 1 2 8) Remove the C2 with the soldering iron from the R2.
TRANSTIG 200 Pi SERVICE MANUAL APPENDIX 1: OPTIONS AND ACCESSORIES Description 17 Series air cooled TIG torch (suitable for TransTig 200Pi) 26 Series air cooled TIG torch Part No.
SERVICE MANUAL TRANSTIG 200 Pi APPENDIX 2: PARTS LIST 1 Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Specificazztion or Assembly numbers.
TRANSTIG 200 Pi SERVICE MANUAL PARTS LIST No. 34 35 36 37 DWG No. R4-5 R6 S1 SOL1 Part No. W7001452 W7001451 W7001453 W7001604 Description Resistor, gen 3.1, IPS Resistor, gen 3.1, IPS Switch, gen 3.1, IPS Solenoid Valve, gen 3.1, IPS 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 T1 TH1, 2 W7001456 10-5228 W7001465 W7001466 W7001467 W7001331 W7001584 W7001598 10-6791 Transformer, gen 3.1, IPS Thermistor, gen 3.
SERVICE MANUAL TRANSTIG 200 Pi PARTS LIST No. 82 83 84 85 86 87 DWG No. Part No. W7001616 W7001609 W7001374 W7001618 10-2020 0-4955 Description Sheet, dust cover F, gen 3.1, IPS Sheet, dust cover R, gen 3.1, IPS Clip, g en 3.1, IPS Hose, Nylon, gen 3.1, IPS Plug, Output, g en 3.1, IPS Operating Manual, gen 3.1, IPS T ype & Rating E1B935200 E1B935600 # 74 NATURAL 4 T0425B Nylon Hose L=0.5m T RAK-SK50 Operating Manual QTY.
TRANSTIG 200 Pi SERVICE MANUAL PARTS LIST 20 19 62 18 78 21 17 34 16 22 62 34 4 68 15 81 14 64 68 80 79 63 22 62 62 33 9 76 79 60 82 61 1 10 60 39 31 79 79 30 3 83 39 64 35 75 71 6 38 5 7 11 32 27 25 70 28 12 77 73 72 A-5 26
SERVICE MANUAL TRANSTIG 200 Pi APPENDIX 3: CONNECTION WIRING GUIDE CONNECTION WIRING GUIDE APPENDIX 2 Connection Wiring Guide Destination A PCB2 CN2 l PCB3 CN3 B PCB2 CN3 l D1 C PCB3 CN1 l D1 D PCB3 CN2 l PCB17 E PCB3 CN7 l CT2 F G PCB3 CN11 l FAN1 SOL1 H PCB3 CN20 l PCB8 CN1 CN1 I PCB3 CN21 l PCB8 CN2 J PCB3 CN22 l PCB9 CN1 K PCB3 CN23 l PCB9 CN2 L PCB3 CN18 l PCB7 CN20 M PCB3 CN33 l PCB6 CN20 N PCB6 CN1 l HCT1 O PCB6 CN8 l TH
TRANSTIG 200 Pi SERVICE MANUAL CONNECTION WIRING GUIDE R CN3 CN21 CN17 PCB6 CN1 D CN20 N CN2 CN9 O M TH1 CN1 P CN2 E CT2 CN33 PCB10 SOL1 L J CN18 CN7 PCB7 CN15 K CN14 CON1 CN11 CN1 CN20 S FAN1 G PCB4 PCB11 T F CN1 CN8 U CN1 PCB17 A C CN1 I CN22 CN2 CN20 CN23 Q CN21 PCB9 H CN2 PCB3 TH2 CN1 PCB8 PCB16 CN3 PCB15 CN3 CN2 PCB2 CN1 CN6 B V CN4 HCT1 D1 PCB13 A-7
SERVICE MANUAL TRANSTIG 200 Pi APPENDIX 4: INTERCONNECT DIAGRAM INTERCONNECT DIAGRAM APPENDIX 3 INTERCONNECT DIAGRAM INTERCONNECT DIAGRAM G(6) P R(3) R2 TB2 TB5 TB4 N T(5) (2) EA N G2 E2 TB2 TB2 EA PCB17 Filter Circuit Board [WK-4917] PCB2 Link Circuit Board [WK-5482] SIDE CHASSIS 2 CN1 SIDE CHASSIS 1 1 2 3 4 5 1 2 REAR PANEL 1 2 3 4 SOL1 CN6 CN6 CN31 CN32 CN31 CN32 C2E CN1 CN4 G4 E4 1 2 3 4 PCB3 Control Souce PCB5 Circuit Board Conect Circuit Board [WK-5548] 1 2 3 4 5 6 [WK-5
TRANSTIG 200 Pi SERVICE MANUAL INTERCONNECT DIAGRAM T1 TB22 TB12 FCH1 PCB14 IGBT Snubber Circuit Board [WK-5570] Q13 D4 TB20 AC2 TB7 SH.DET+ AC1 PCB12 DIODE Snubber Circuit Board [WK-5615] CT2 G1 G1 PCB15 IGBT Gate E1 E1 Circuit Board [WK-3367] G2 G2 D5 TB21 E2 E2 G7 E7 D2 TB1 E8 G8 1 2 3 4 5 AC4 CT2 CT1 CN1 TO1 +Output Terminal TB2 + 1 2 3 4 5 Ground RY+15V /RY_ON 1 2 3 HCT1 CN3 SH.
SERVICE MANUAL TRANSTIG 200 Pi APPENDIX 5: DIODE TESTING BASICS DIODE TESTING BASIC APPENDIX 4 DIODE TESTING BASIC Testing of diode modules requires a digital Volt/ Ohmmeter that has a diode test scale.Locate the diode module to be tested.Remove cables from mounting studs on diodes to isolate them within the module.Set the digital volt/ohm meter to the diode test scale.Using figure 1 and 2, check each diode in the module.
CIGWELD LIMITED WARRANTY LIMITED WARRANTY: CIGWELD, A Thermadyne Company, hereafter, “CIGWELD” warrants to customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material.
Terms of Warranty – December 2007 1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply of goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including warranties as to merchantability and fitness for purpose) associated with the supply of goods and services.
Warranty Schedule – December 2007 These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of sale from the Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date CIGWELD delivered the product to the Accredited Distributor. Unless otherwise stated the warranty period includes parts and labour.
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.
Corporate Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 +61 3 9474 7488 FAX: Email: cigweldsales@cigweld.com.au www.cigweld.com.
