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March 31, 2008
TRANSTIG 200 Pi
SERVICE MANUAL
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Page 1: ...INVERTER ARC WELDER 240 V 50 60 Hz INVERTER 200 Pi Service Manual TRANSTIG Revision No AA Issue Date March 31 2008 Manual No 0 4967 Operating Features...
Page 2: ...to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide CIGWELD is the Market Leading Brand of A...
Page 3: ...298 5711 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...
Page 4: ...ctrical Input Connections 3 1 3 04 Mains Supply Voltage Requirements 3 2 3 05 High Frequency Introduction 3 3 3 06 High Frequency Interference 3 3 3 07 Duty Cycle 3 4 SECTION 4 OPERATION 4 1 4 01 Tran...
Page 5: ...eiving 6 4 6 2 6 E04 Torch Cable Failure 6 5 6 2 7 E93 Memory Chip EEPROM error 6 5 6 03 Verification and Remedy to Failures without Indication Codes 6 6 6 3 1 Cooling Fan FAN1 Failure Fan is not rota...
Page 6: ...7 15 7 3 9 C C Coupling Coil and FCH1 Reactor 7 15 7 3 10 CT1 Hole Current Trans 7 17 7 3 11 FAN1 Cooling Fan 7 18 7 3 12 HF UNIT1 High Frequency Unit 7 19 7 3 13 SOL1 Solenoid GAS Valve 7 20 7 3 14...
Page 7: ...ectrical 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 dam...
Page 8: ...ielding 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 o...
Page 9: ...emove 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 the...
Page 10: ...ch 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...
Page 11: ...isks 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 co...
Page 12: ...e 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 applicabl...
Page 13: ...n 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 contr...
Page 14: ...rease 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 Auxil...
Page 15: ...n Arc Welding GTAW Gas Tungsten Arc Welding Pulsed GTAW P Gas Tungsten Arc Welding Sloped GTAW S and Shielded Metal Arc Welding SMAW processes The power source is totally enclosed in an impact resista...
Page 16: ...nt Circuit Reference Adjustment Mode select Switch Panel Circuit Board Sequence Control Fan Control Circuit Fan Input Power Primary Circuit Sensor Gas Control Circuit Solenoid Coupling Coil High Frequ...
Page 17: ...meter Transtig 200Pi Welding Current Range 5 200 Amps Open Circuit Voltage 65V Upgraded Supply Plug Rating Required 25 Amps Effective Input Current I1eff 21 7 Amps Maximum Input Current I1 max 36 7 Am...
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Page 19: ...ive 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 loca...
Page 20: ...ith 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...
Page 21: ...iation 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 Sour...
Page 22: ...ycle 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...
Page 23: ...y 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...
Page 24: ...connects the Primary supply voltage to the equipment 8 Gas Inlet The Gas Inlet is a 5 8 18 UNF female gas fitting 4 02 Weld Process Selection for Transtig 200 Pi STICK HF TIG LIFT TIG STD SLOPE REPEAT...
Page 25: ...til 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 trig...
Page 26: ...n must remain depressed for 3 seconds in order to save or load the settings Table 4 3 continued Parameter Descriptions 4 04 Weld Parameters for Transtig 200 Pi Weld Parameter Parameter Range Factory S...
Page 27: ...ved into the 200 Pi memory SAVE the Current Weld Parameters into Memory Press and hold the SAVE button for 3 seconds Select a memory location by rotating the control knob 1 to 5 is displayed on the me...
Page 28: ...off For the selected weld parameter rotating the knob clockwise increases the parameter Rotating the knob counterclockwise decreases the parameter A selected weld parameter value can be adjusted at a...
Page 29: ...e 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...
Page 30: ...ed in this window Internal warnings such as over temperature low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen 4 Control Knob allows the...
Page 31: ...e on Set WELD current Connect remote control device A remote control device is required for use during LIFT TIG and HF TIG operation See section 3 01 section 2 Remote Control Socket for complete detai...
Page 32: ...pen 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...
Page 33: ...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 cu...
Page 34: ...ngsten Electrode Sizes 3 Tungsten Electrode Types Electrode Type Ground Finish Welding Application Features Color Code Thoriated 2 DC welding of mild steel stainless steel and copper Excellent arc sta...
Page 35: ...nless Steel Tungsten Electrode Diameter Filler Rod Diameter if required Argon Gas Flow Rate Liters min Joint Type 0 040 1 0mm 35 45 40 50 20 30 25 35 0 040 1 0mm 1 16 1 6mm 5 7 Butt Corner Lap Fillet...
Page 36: ...eavy sections necessary to give proper fusion of weld and base metal E Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications There are a gre...
Page 37: ...e enclosure Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge To clean the unit open the enclosure and use a vacuum cleaner to remove any accumulated...
Page 38: ...nspect 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...
Page 39: ...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 Weldi...
Page 40: ...e melts when arc is struck Electrode is connected to the terminal Connect the electrode to the terminal 7 Dirty weld pool A Electrode contaminated through contact with work piece or filler rod materia...
Page 41: ...nect 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 e...
Page 42: ...r use crack resistance electrodes B Insufficient throat thickness B Travel slightly slower to alloy greater build up in throat C Cooling rate is too high C Preheat plate and cool slowly 3 A gap is lef...
Page 43: ...ngle 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...
Page 44: ...rind 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 fro...
Page 45: ...d with nominal Mains supply voltage Defective control circuit Have an Accredited Cigweld Service Provider inspect then repair the welder 3 Welding current reduces when welding Poor work lead connectio...
Page 46: ...e 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 to 60 sec D Reduce POST FLOW time 6 The TIG electrode has been...
Page 47: ...ltage exceeds the secondary voltage specification TIG torch cable and or work lead are too long or leads are coiled Reduce the length of the TIG torch cable and or work lead or un coiled leads Weld cu...
Page 48: ...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 e...
Page 49: ...rtable equipment at least once every 3 months and b For fixed equipment at least once every 12 months The owners of the equipment shall keep a suitable record of the periodic tests NOTE A transportabl...
Page 50: ...TRANSTIG 200 Pi SERVICE MANUAL 5 14 March 31 2008 THIS PAGE LEFT INTENTIONALLY BLANK...
Page 51: ...ty subassembly should then be returned to Thermal Arc through established procedures WARNING Disconnect primary power at the source before dis assembling the power supply Frequently review the Importa...
Page 52: ...nel slightly backward The interlocking hooks of the side case covers can now be disengaged from the front and rear panels Figure 6 4 Loosen front and rear panels 5 Remove the side panels Figure 6 5 Re...
Page 53: ...rear airflow paths Cleaning and removing dust from the front and rear panels once every six months in a normal working envi ronment is recommended Extremely dusty environments will require more freque...
Page 54: ...ion properly if installed in the incorrect direction Refer to section 12 3 10 for the replacement of CT1 6 2 4 E94 Thermistor malfunction Cause Thermistors for detecting temperature of internal compon...
Page 55: ...commended total combined length of the torch and work cable is 50 feet Torch and work cable should not be coiled during welding operations Maintain the duty cycle of the power supply Refer to section...
Page 56: ...an FAN1 on PCB3 Refer to section 6 5 3 Replace PCB1 if necessary Refer to section 7 3 1 6 3 2 Gas Valve Failure No Gas flow through unit Cause Occurs when the gas valve SOL1 is defective damaged or th...
Page 57: ...nd the ground clamp Applies to all welding modes Verify a secure connection of the welding cable stick rod holders ground clamp and dense connectors and there are no open cir cuits c Verify the no loa...
Page 58: ...ct ter minals are inserted onto the terminals of HF UNIT1 TB5 TB6 correctly and completely Verify there are no short circuits burnt or bro ken wires at C C Replace C C Refer to the page 7 15 b Verify...
Page 59: ...ON Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described in section 6 4 1 Preparation 6 5 1 Verification of the AC input vol...
Page 60: ...nd TB2 N can be found on the parts side of PCB2 See Figure 11 9 The mea sured voltage should be approximately 1 4 times larger than input voltage measured in 1 above Replace diode D1 if the calculated...
Page 61: ...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 measure ment wh...
Page 62: ...measurement while the connector plug and receptacle are still con nected Figure 6 13 Verification of the SOL1 2 Using the measurement taken above follow the chart below for possible failure modes Tabl...
Page 63: ...4C CAUTION Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described at the beginning of an above section 1 Preparation Refer to...
Page 64: ...The capability of the voltmeter should be more than 100VDC 3 The normal no load voltage is approxi mately 65V b Verify the no load voltage OCV in High Fre quency TIG mode WARNING This welding mode pr...
Page 65: ...voltage between output termi nal and In TIG mode the OCV ceases 3 seconds after you depress the torch switch 4 The normal no load voltage is approxi mately 65V 5 Return the setting variable resister...
Page 66: ...heating and loose connections 7 1 2 Test and Replacement Parts List NO DWG NO PARTS NAME REFERENCE PAGE PARTNO 1 PCB1 Printed Circuit Board WK 5713 12 5 W7001626 2 PCB2 Printed Circuit Board WK 5714 1...
Page 67: ...620 5 C C Coupling Coil 12 15 W7001384 6 FCH1 Reactor 12 15 W7001502 7 HF UNIT High Freguency Unit 12 19 W7001399 8 L101 Ring Core 12 21 W7001623 9 L102 Reactor 12 24 W7001625 10 L103 Reactor 12 24 W7...
Page 68: ...10 5003 3 D1 Primary Diode 12 5 W7001481 4 D2 Secondary Diode 12 15 10 6629 5 D3 Secondary Diode 12 15 10 6629 6 FAN1 Cooling Fan 12 18 10 5227 7 S1 Switch 12 21 W7001453 8 SOL1 Solenoid GAS Valve 12...
Page 69: ...t 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 mainte nance or repair CAUTION Please note...
Page 70: ...e Panel See section 6 1 1 2 Remove the L102 See section 7 3 18 3 Remove the screw and three cables Cut the snap band 4 Remove the terminal and Disconnect the three connectors CN1 PCB4 CN101 103 PCB1 5...
Page 71: ...Tube Remove the two bolts two toothed washers and the terminal 7 Remove the four screws and the Front Panel 8 Remove the Gas Tube and the two cables 1 2 2 2 1 1 1 1 1 2 1 2 2 1 TRANSTIG 200 Pi MAINTE...
Page 72: ...el 10 Remove the four screws and the two cables Disconnect the eight connectors CN1 8 on the PCB1 11 Remove the four screws and Remove the PCB1 unit 1 1 1 1 2 1 2 2 CN2 CN1 CN4 CN5 CN6 CN3 CN8 CN7 1 1...
Page 73: ...compound Shinetsu Silicone G 747 or equivalent on the base 7 3 2 PCB2 WK 5417 Capacitor C1 and Resistor R1 VX 1 Remove the Side Panel See section 6 1 1 2 Remove the PCB1 and D1 See section 7 3 1 3 Re...
Page 74: ...s and the PCB2 unit 6 Remove the screw and Remove the Capacitor C1 and Resistor R1 from the PCB2 Remove the two edge holders and the PCB2 Insulation Sheet from PCB2 1 1 1 1 2 1 2 3 3 3 SERVICE MANUAL...
Page 75: ...hree screws and the three cables Remove the terminal 4 Remove the 11 screws and PCB3 unit Take care about the shape of the screw when you replace PCB3 5 Remove the two tap of T1 with the soldering iro...
Page 76: ...on Cover 3 Remove the Knob Cap Holding the Knob down loosen the screw and remove the Knob 4 Disconnect the two connectors CN1 3 on the PCB4 Remove the four screws Pull out the operation panel and brin...
Page 77: ...Side Panel See section 11 1 1 2 Remove the PCB4 See section 12 3 4 3 Remove the three latches of Front Control Cover and then remove the PCB5 When reinstalling the PCB5 engage two latches of Front Con...
Page 78: ...ove the cables from edge holder 3 Disconnect the connector CN1 on the PCB6 Cut the lead of the Q1A Q2C Remember to install new Silicone Rubber Sheets where silicone compound Shinetsu Silicone G 747 or...
Page 79: ...move the cables from edge holder 3 Disconnect the connector CN1 on the PCB6 Cut the lead of the Q3 Q4C Remember to install new Silicone Rubber Sheets where silicone compound Shinetsu Silicone G 747 or...
Page 80: ...rong direction of the diodes when reinstalling Before installing a new diode apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 7 3 9 C C Coupling Coil and FCH...
Page 81: ...s and the Front Panel 4 Remove the screw and then remove the cable Remove the two terminals from HF UNIT Remove the terminal from PCB3 5 Remove the C C and FCH1 1 1 1 1 2 3 3 1 2 1 2 2 TRANSTIG 200 Pi...
Page 82: ...move the Side Panel See section 11 1 1 2 Remove the bolts the spring and the washer Remove the three screws and then remove the Output Bus Bar 3 Remove the CT1 Disconnect the connector 1 3 2 2 2 1 2 S...
Page 83: ...1 1 2 Remove the Gas Tube Remove the two terminals and Cut the three snap bands 3 Disconnect the connector CN2 on the PCB1 and Cut the snap band 4 Remove the four screws and then open the Rear Panel 1...
Page 84: ...en 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 De...
Page 85: ...the Side Panel See section 6 1 1 2 Remove the Gas Tube and two terminals 3 Remove the C ring and then detach the SOL1 When reinstalling make sure that the C ring seats in the solenoid valve groove 1 2...
Page 86: ...section 6 1 1 2 Remove the four screws and the six cables Remove the one nut and one terminal Remove the C101 C102 3 Cut off the snap band Remove the L101 from the Input Cable 4 Remove the two screws...
Page 87: ...tion 6 1 1 2 Remove the screw and then three ground cables Cut the two snap bands 3 Cut the snap band and disconnect connector CN1 on the PCB1 4 Open the Panel Protects Remove the two screws and the C...
Page 88: ...inetsu Silicone G 747 or equivalent on the base 7 3 17 TH2 Secondary Thermistor UV 1 Remove the Side Panel See section 6 1 1 2 Remove PCB3 unit See section 7 3 3 3 Cut the three snap bands Disconnect...
Page 89: ...103 and L102 Note When C103 is installed again it is a thing fixed to former place on PCB3 by RTV silicon rubber 7 3 19 L103 Reactor VX U 1 Remove the Side Panel See section 6 1 1 2 Remove the L102 Se...
Page 90: ...Cover 5 Remove one nut one washer and two terminals Remove the L103 7 3 20 C2 Capacitor and R2 Resistor VX Z 1 Remove the Side Panel See section 6 1 1 2 Remove the Gas Tube and the two cables 2 1 1 1...
Page 91: ...e the cables Disconnect the three connectors CN1 3 on the PCB3 Remove the three screws and the three cables Remove the terminal 6 Remove the 11 screws and PCB3 unit Take care about the shape of the sc...
Page 92: ...7 27 7 Remove the screw and C2 unit 8 Remove the C2 with the soldering iron from the R2 1 2 1 1 2 2 SERVICE MANUAL MAINTENANCE TRANSTIG 200 Pi...
Page 93: ...tor only CIGWELD COMET argon flowmeter 0 15 lpm 301710 Flowmeter only CIGWELD COMET argon flowmeter 10 40 lpm 301711 Flowmeter only CIGWELD COMET argon regulator flowmeter 301526 Regulator flowmeter o...
Page 94: ...6629 Diode gen 3 1 IPS DBA200UA60 1 8 FAN1 W7001307 Fan gen 3 1 IPS 109E5724H507 DC 24V 16 8W 1 9 FCH1 W7001502 Inductor gen 3 1 IPS F3A285101 AC DC FCH 1 10 HCT1 10 5003 Sensor Current gen 3 1 IPS H...
Page 95: ...g n i R C 4 8 1 5 0 1 6 5 2 S 0 7 5 3 E B K A R T S P I 1 3 n e g F t u p t u O l a n i m r e T 0 6 6 6 0 1 7 5 58 N A Cable Input gen 3 1 IPS 132 10 3SOWBLKW R650 185ACDC 1 1 0 0 8 5 4 0 A B E S P I...
Page 96: ...7001616 Sheet dust cover F gen 3 1 IPS E1B935200 1 83 W7001609 Sheet dust cover R gen 3 1 IPS E1B935600 1 4 4 L A R U T A N 4 7 S P I 1 3 n e g p i l C 4 7 3 1 0 0 7 W 4 8 85 W7001618 Hose Nylon gen 3...
Page 97: ...25 20 19 21 18 17 81 14 22 62 62 62 62 22 68 68 16 15 80 63 4 34 34 33 10 64 11 32 12 38 83 35 39 61 76 60 60 79 79 82 79 64 9 31 75 1 27 71 70 77 73 72 26 28 79 30 3 78 TRANSTIG 200 Pi SERVICE MANUA...
Page 98: ...3 CN7 l CT2 F PCB3 CN11 l FAN1 G SOL1 H PCB3 CN20 l PCB8 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 PC...
Page 99: ...CN1 CN1 CN20 CN8 CN9 CN33 CN21 CN17 CN1 CN22 CN11 CN23 CN20 CN14 CN15 CON1 CN3 CN20 CN21 CN1 CN2 CN3 CN4 TH1 TH2 CN3 D1 PCB17 FAN1 SOL1 CN1 CN2 CN1 CT2 CN7 CN18 PCB15 CN6 CN1 CN2 V Q A B C H J M N R...
Page 100: ...rol Circuit Board WK 5549 CT2 CT1 SIDE CHASSIS 1 REAR PANEL E EA CN3 1 2 G1 E1 G2 E2 G3 E3 PCB5 Conect Circuit Board WK 5551 CN30 CN31 CN31 CN30 CN32 CN32 PCB7 Filter Circuit Board WK 5550 CN1 1 2 3 C...
Page 101: ...N1 1 2 3 4 P N CN2 1 2 P 21V PGND CN3 1 2 3 S 15V SG CN4 1 2 3 4 5 6 7 1 2 CN6 3 4 5 6 7 8 G7 E7 G8 E8 RY_ON R3 PCB13 Super Inpose Circuit Board WK 5569 HCT1 Output Terminal TO1 FCH1 PCB15 IGBT Gate C...
Page 102: ...ead to the anode positive of the diode and the negative lead to the cathode negative of the diode refer to Figure 13 1 A properly functioning diode will conduct in the forward bias direction and will...
Page 103: ...IAL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSI NESS INTERRUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELD with respect to any contract or...
Page 104: ...our Accredited Distributor in writing of its claim within seven 7 days of becoming aware of the basis thereof and at its own expense returning the goods which are the subject of the claim to CIGWELD...
Page 105: ...abour CIGWELD reserves the right to request documented evidence of date of purchase CIGWELD PROFESSIONAL INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR Transtig 200 Pi Transtig 200 AC DC Transarc 30...
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Page 107: ...1135 Fax 86 21 69171139 Thermadyne Utama Indonesia Kawasan Industri Jababeka JI Jababeka VI Blok P No 3 Cikarang Bekasi 17550 Indonesia Tel 62 21 893 6071 Fax 62 21 893 6067 6068 http www thermadyne c...
Page 108: ...Corporate Headquarters 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 FAX 61 3 9474 7488 Email cigweldsales cigweld com au www cigweld com au...
