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CIGWELD Transtig 220 AC/DC Service Manual Download Page 1

Art # A-12276

220AC/DC

300AC/DC

Service Manual

Revision: 

 AB

 

               Issue Date: 

March 4, 2014                          

Manual No:

 0-5292

Operating Features: 

TRANSTIG

welDING MAChINe

Summary of Contents for Transtig 220 AC/DC

Page 1: ...Art A 12276 220AC DC 300AC DC Service Manual Revision AB Issue Date March 4 2014 Manual No 0 5292 Operating Features TRANSTIG welding machine...

Page 2: ...y will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide CIGWELD is the Market Lea...

Page 3: ...d by CIGWELD Pty Ltd 71 Gower Street Preston Victoria Australia 3072 www cigweld com au Copyright 2013 2014 by CIGWELD All rights reserved Reproduction of this work in whole or in part without written...

Page 4: ...age Requirements 3 3 3 07 Electromagnetic Compatibility 3 4 SECTION 4 OPERATION 4 1 4 01 TRANSTIG 220AC DC and 300AC DC Power Source Controls Indicators and Features 4 1 4 02 Setup for TIG GTAW Weldin...

Page 5: ...n DC Bus Voltage Monitoring 6 7 6 09 Welding Output Voltage Monitoring 6 8 6 10 Remote Control Interface 6 9 6 11 Water Cooler Interface 6 10 6 12 Primary Supply Current Monitoring 6 10 6 13 TRANSTIG...

Page 6: ......

Page 7: ...rkpiece 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 co...

Page 8: ...Process Approximate Range of Welding Current in Amps Minimum Shade Number of Filter s Manual Metal Arc Welding covered electrodes MMAW Less than or equal to 100 8 100 to 200 10 200 to 300 11 300 to 40...

Page 9: ...or fire 1 Protect yourself and others from flying sparks and hot metal 2 Do not weld where flying sparks can strike flam mable material 3 Remove all flammables within 10M of the welding arc If this i...

Page 10: ...e 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 Ge...

Page 11: ...hlet 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 Stan d...

Page 12: ...re used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard Only qualified persons shoul...

Page 13: ...ts such as drive rolls Have only qualified persons remove doors panels covers or guards for maintenance as necessary Keep hands hair loose clothing and tools away from moving parts Reinstall doors pan...

Page 14: ...unica tions equipment Have only qualified persons familiar with electronic equipment install test and service H F producing units The user is responsible for having a qualified electrician promptly co...

Page 15: ...r 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 inst...

Page 16: ...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 Con...

Page 17: ...d that such re pairs be carried out by appropriately qualified persons approved by CIGWELD Advice in this regard can be obtained by contacting an Accredited CIGWELD Distributor This equipment or any o...

Page 18: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE INTRODUCTION 2 4 Manual 0 5292 Notes...

Page 19: ...uty cycle period the following example is used Suppose a Welding Power Source is designed to operate at a 40 duty cycle 170 amperes at 26 8 volts This means that it has been designed and built to prov...

Page 20: ...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 oper...

Page 21: ...subjected to abnormal vibration or shock E In areas not exposed to direct sunlight or rain F Place at a distance of 300mm or more from walls or similar that could restrict natural air flow for coolin...

Page 22: ...the premises 3 07 Electromagnetic Compatibility WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation A Installatio...

Page 23: ...endations 3 Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level 4 Equipotential Bonding Bonding of all...

Page 24: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE INSTALLATION OPERATION AND SETUP 3 6 Manual 0 5292 Notes...

Page 25: ...in receptacle is used to connect a trigger switch or remote control to the welding Power Source circuitry To make connections align keyway insert plug and rotate threaded collar fully clockwise The so...

Page 26: ...ical components are at Mains voltage potential 6 Mains Supply Lead The Transtig 220AC DC is fitted with a heavy duty 15 Amp mains supply lead and plug The Transtig 300AC DC is fitted with a heavy duty...

Page 27: ...Potentiometers Wiper 5 Remote Control 5k ohm Potentiometers Minimum 6 Remote Control Enable Short to common to enable remote control 7 Common 8 Remote 2T short to common to select remote control activ...

Page 28: ...ing in GTAW TIG mode the power source will remain activated until the selected downslope time has elapsed 16 2T normal indicator light This light will illuminate when the power source is in GTAW 2T we...

Page 29: ...t to preview mode 2 welding is recommenced in which case actual welding amperage will be displayed or 3 a period of 10 seconds elapses following the completion of welding in which case the unit will r...

Page 30: ...n the Digital Volt meter Display 35 Hz frequency indicator light This light will illuminate when Hz frequency is being shown on the Digital Volt meter Display 36 percentage indicator light This light...

Page 31: ...is selected 47 AC Balance indicator light This light will illuminate when the AC Balance Welding Parameter is selected 48 Crater Current indicator light This light will illuminate when the Crater Cur...

Page 32: ...ed in the bayonet terminal D Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below The TIG torch will require a trigger switch to operate in...

Page 33: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE Manual 0 5292 4 9 OPERATION A 12037 10 17 Figure 4 6 Setup for TIG Welding...

Page 34: ...17 button Welding Type Welding Type Selection DC HF TIG AC Lift TIG DC Lift TIG AC HF TIG Then select a Welding Mode by pressing the WELDING MODE 10 button Welding Mode Welding Mode Selection 2T Norm...

Page 35: ...GTAW operating modes are available AC welding output mode The AC Led 21 will illuminate DC Negative welding output mode The DC Negative Led 19 will illuminate HF AC welding output mode The HF Led 18 a...

Page 36: ...recommended Welding Current AC Amps are dependent on the type of electrode and on the AC Balance Parameter setting Parameter Range LED Code Left Display Parameter Value Right Display Factory Setting...

Page 37: ...d 0 99 20 Crater Current AE This parameter operates in GTAW modes only This is the current at the end of the down slope current ramp The welding current will remain at the Crater Current value until t...

Page 38: ...r Transtig 220AC DC Transtig 300AC DC Set this parameter to the tungsten electrode size being used 1 0 3 2 1 0 4 0 2 4 AC frequency This parameter operates in AC mode only and is used to set the frequ...

Page 39: ...AC GTAW welding arc Maximum weld penetration is achieved when the AC BALANCE is set to 10 Maximum cleaning of heavily oxidised aluminium or magnesium alloys is achieved when the WAVE BALANCE is set to...

Page 40: ...gnition to provide stabilisation of the arc A different peak current is saved for each selected tungsten electrode diameter 10 200 100 Plus terminal Correction Ignition using the positive welding term...

Page 41: ...meter Led 42 and mm LED 30 are illuminated Use the Multi Function Control 24 to adjust the Electrode size being used Press and hold the WELDING MODE 10 button then press the SAVE 54 button Press the B...

Page 42: ...onic jobs are saved it will not be possible to select any TipTronic jobs Use the BACK button 22 or FORWARD button 22 to switch between TipTronic jobs and all main parameters A 12041 Figure 4 9 Tip Tro...

Page 43: ...e SAVE button 54 The display will how the Job Number identification the job set and job number Use the Multi Function Control 24 to select the job set number and the job number Press the GAS button 52...

Page 44: ...ding current flows from the power source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection C Sel...

Page 45: ...2042_AB Figure 4 10 Setup for Manual Arc Welding First select Stick Mode by pressing the Welding Mode 10 button Welding Type Welding Mode Selection Stick Mode Then select Welding Type by pressing the...

Page 46: ...e Electrode size being used Press the BACK button 22 or FORWARD button 23 so the Hot Start Amps Led 41 and Led 36 are illuminated Use the Multi Function Control 24 to adjust the Hot Start Amps percent...

Page 47: ...parameters to the electrode size being used 1 5 4 0 1 5 5 0 2 5 Hot Start AS This parameter operates in MMAW mode and is used to improve the start characteristics for stick electrodes by adding curre...

Page 48: ...n during welding these settings can be adjusted and changed Parameter Range LED Code Left Display Parameter Value Right Display Factory Setting Arc Dynamic Arc Force Arc Force is effective in MMAW Mod...

Page 49: ...tch the power off to the unit to save the settings Menu item Range LED Code Left Display Parameter Value Right Display Factory Setting C02 Water Pump Error Message Display Set this to ON if a water co...

Page 50: ...ll from the Power Source until the trigger is pressed This provides the greatest level of safety for the operator and is mandatory on some work sites While the Dead Man Switch function greatly increas...

Page 51: ...will now output the VRD volts and the VRD led will be lit 3 Touch the MMAW Stick Electrode to the work and commence welding as usual 4 Release the trigger and continue welding 5 Press and release the...

Page 52: ...gure 4 15 Soft Reset Master Reset WARNING All saved TipTronic jobs will be erased All welding and secondary parameters will be restored to the factory setting Press and hold the BACK button 22 Press t...

Page 53: ...LED s and meter displays will light up for approximately 4 seconds A 12048 Figure 4 17 Control Panel Test Fan Test Press and hold the BACK button 22 Press the WELDING TYPE button 17 The fan will run f...

Page 54: ...et Connection interface Press and hold the FORWARD button 22 Press the WELDING TYPE button 17 The Water Cooler Net Connection type will run for approximately 30 seconds If there is an error or no pump...

Page 55: ...W E L D S e r v i c e Provider check the power source PFC Input Stage PFC Input Stage is Faulty Have an Accredited C I G W E L D S e r v i c e Provider check the power source EEProm checksum error Com...

Page 56: ...water cooler Water cooled GTAW torch connected Check the Net Connection water cooler cable and the water cooler Use a gas cooled torch S e c o n d a r y O v e r Voltage Initial Voltage is too high Hav...

Page 57: ...r v i c e Provider check the power source HF Ignition Faulty HF Ignition Faulty Have an Accredited C I G W E L D S e r v i c e Provider check the power source Mains Supply Under Voltage Mains Supply...

Page 58: ...an dangerously propel a loose part 3 DO NOT remove the regulator from a cylinder without first closing the cylinder valve and releasing gas in the regulator high and low pressure chambers 4 DO NOT use...

Page 59: ...the outlet hose firmly and attach down stream equipment 5 To protect sensitive down stream equipment a separate safety device may be necessary if the regulator is not fitted with a pressure relief de...

Page 60: ...scharge from regulator by opening the downstream valve Bleed welding grade shielding gas into a well ventilated area and away from any ignition source Turn adjusting screw counter clockwise until the...

Page 61: ...on the end of the cable to the 8 pin receptacle on the front of the welding machine To complete the connection align the keyway insert the plug and rotate the threaded collar fully clockwise Foot Con...

Page 62: ...m the unit will be 50 Should 100 output be required the respective front panel control must be set to 100 or maximum in which case the remote device will then be able to control between 1 100 output T...

Page 63: ...C then goes on to a much smaller main transformer than in a conventional power supply The AC is then rectified to extremely smooth DC The diagram to the below shows the basic electrical wiring of a DC...

Page 64: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE THEORY OF OPERATION 5 2 Manual 0 5292 Notes...

Page 65: ...l fuse Have an Accredited CIGWELD Service Provider check primary circuit 3 Error Code E01 is displayed and unit will not commence welding when the torch trigger switch is depressed Duty cycle of power...

Page 66: ...ges from airflow ducts Replace fan Check fan wiring header is plugged securely into Control board Check fan wiring is not damaged Allow unit to cool with fan run ning until over temperature light exti...

Page 67: ...006330 Transtig 300ac dc Table 6 2 Power Source Faults 6 03 Advanced Troubleshooting If the problem cannot be solved by the basic external troubleshooting guide the Power Source covers will have to be...

Page 68: ...t present in these units can cause burning or arcing of PCB transformers switches or rectifier when a failure occurs Carefully inspect all components within these units Look in particular for the foll...

Page 69: ...ture Sensor Inverter Transformer E01 03 E13 03 Temperature Sensor EMC Mains Filter E01 05 E13 04 Table 6 3 TRANSTIG 220AC DC Temperature Sensor Error Codes TRANSTIG 300AC DC Sensor Error Code for Over...

Page 70: ...al control power supplies for the whole power source Art A 12278 Figure 6 3 Control Board Power Supply Monitoring If an internal supply voltage is out of range the power source will stop and the error...

Page 71: ...Mains Voltage Limit Uvp DC Bus Voltage Limit Uz Error Code During Start Up 280 VAC 414 VDC E02 mains over voltage During Normal Operation or During Standby 440 VAC 490 VDC E02 mains over voltage Durin...

Page 72: ...he control board Art A 12280 Figure 6 5 Welding Output Voltage Monitoring During the start up sequence if the offset voltage of the shunt resistor is too high the error code E15 00 is displayed After...

Page 73: ...The Remote Control Interface is for connecting a hand or foot remote control It is also possible to use the interface for simple automation Art A 12281 Figure 6 6 Remote Control Interface If there is...

Page 74: ...If the flow rate is less than 0 3 l m or no water cooler is connected the power source will stop and the error code E05 will be displayed Art A 12283 Figure 6 7 Water Cooler Interface 6 12 Primary Sup...

Page 75: ...rd should be replaced Art A 12290 Figure 6 9 Main Control PCB TRANSTIG 220AC DC LED LED state and function 1 green Indicates the internal CPLD processor is ok This LED may be ON OFF or FLASHING 2 gree...

Page 76: ...y Voltage X15 2 X15 1 3 15 VDC Internal 24 VDC Supply X5 7 X5 9 17 37 VDC Internal 15 VDC Supply X15 2 X5 9 12 20 VDC Internal 5VDC Supply X4 5 X5 9 4 8 5 2 VDC Temperature Sensor Inverter Transformer...

Page 77: ...Troubleshooting Primary Inverter PFC PCB W7006306 This board comprises the PFC input stage the main DC Bus capacitance the input current sensor as well as the inverter bridge power module IGBT s Art...

Page 78: ...ad connects to Measurement IGBT Gate 1 4 3 47k 10 IGBT Gate 2 11 10 47k 10 IGBT Gate 3 18 19 47k 10 IGBT Gate 4 26 27 47k 10 Temperature Sensor Power Module 15 16 68k at 25 C IGBT 1 31 7 0 2 0 9 VDC I...

Page 79: ...d comprises the secondary rectifier and the IGBT s for polarity selection and AC DC output Art A 12288 Figure 6 12 Secondary Rectifier PCB TRANSTIG 220AC DC Output Diode and Polarity Selection IGBT in...

Page 80: ...k 10 IGBT Gate 3 18 19 47k 10 IGBT Gate 4 26 27 47k 10 Temperature Sensor Power Module 15 16 68k at 25 C IGBT 1 31 7 0 2 0 9 VDC IGBT 1 7 31 1k IGBT 2 7 13 0 2 0 9 VDC Table 6 10 Secondary Rectifier B...

Page 81: ...resetting the mains power does not clear the fault the board should be replaced LED LED state and function 1 green Indicates the internal CPLD processor is ok This LED may be ON OFF or FLASHING 2 gree...

Page 82: ...X10 2 X10 3 320 VDC 10 Fan 1 Supply Voltage X11 2 X11 1 3 15 VDC Fan 2 Supply Voltage X13 2 X13 1 3 15 VDC Fan 3 Supply Voltage X15 2 X15 1 3 15 VDC Internal 24 VDC Supply X5 7 X5 9 17 37 VDC Internal...

Page 83: ...00 AC DC POWER SOURCE Manual 0 5292 6 19 Troubleshooting EMC PCB NEFI 1300 W7006324 This board comprises the mains EMC filter as well as the soft start circuitry Art A 12292 Art A 12293 Figure 6 16 EM...

Page 84: ...bleshooting 6 20 Manual 0 5292 Primary Inverter PCB W7006322 This board comprises the main DC Bus capacitance the input current sensor as well as the inverter bridge power module IGBT s Art A 12294 Fi...

Page 85: ...o Measurement IGBT Gate 1 1 2 47k 10 IGBT Gate 2 8 7 47k 10 IGBT Gate 3 13 14 47k 10 IGBT Gate 4 20 19 47k 10 Temperature Sensor Power Module 21 22 22k at 25 C IGBT 1 3 4 17 18 9 10 0 2 0 9 VDC IGBT 1...

Page 86: ...re 6 19 Secondary Rectifier PCB TRANSTIG 300AC DC WARNING In the positions where the cables are attached the LONGER screws must be used The rest of the screws are the SHORT ones DAMAGE to the power de...

Page 87: ...GBT B E 47k 10 IGBT E C 0 2 0 9 VDC IGBT C E 1k Diode A1 K1 0 2 0 9 VDC Diode A2 K2 0 2 0 9 VDC Diode K1 A1 1k Diode K2 A2 1k Table 6 14 Secondary Rectifier Board Mmeasuring Points TRANSTIG 300AC DC D...

Page 88: ...URCE Troubleshooting 6 24 Manual 0 5292 6 15 Main Circuit Description Transtig 220AC DC Art A 12297 Figure 6 22 Main Circuit Description Transtig 220AC DC Transtig 300AC DC Art A 12298 Figure 6 23 Mai...

Page 89: ...m the transformer is rectified by the output diodes to DC This DC is controlled by the PWM of the primary side IGBT transistors and is filtered by an inductor before connecting to the welding output t...

Page 90: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE Troubleshooting 6 26 Manual 0 5292 Notes...

Page 91: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE Manual 0 5292 7 1 KEY SPARE PARTS SECTION 7 KEY SPARE PARTS 7 01 220AC DC Power Source A 12051_AB Figure 7 1 Transtig 220AC DC Spare Parts...

Page 92: ...Primary Inverter 8 W7006307 PCB Display 9 W7006308 PCB NEFI NTC 10 W7006309 Transformer Inverter 11 W7006310 Switch On Off 12 W7006311 Rectifier Bridge Mains Supply 13 W7006314 Cable Assy 8 pin remot...

Page 93: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE Manual 0 5292 7 3 KEY SPARE PARTS 7 02 300AC DC Power Source A 12052_AB Figure 7 2 Transtig 300AC DC Spare Parts...

Page 94: ...7006307 PCB Display 9 W7006324 PCB NEFI 1300 10 W7006325 Transformer Control 11 W7006326 Transformer Inverter 12 W7006327 Switch On Off 3 pole 13 W7006328 Rectifier Bridge B6 36A Mains Supply 14 W7006...

Page 95: ...10 4 TR2 TR1 LP1 X1 X5 X8 1 X8 2 F1 C1 X7 2 X7 1 R1 X11 1 X11 2 M1 M X13 1 X13 2 M2 M X15 1 X15 2 M3 M X4 X3 X17 1 1 X17 2 2 X17 3 3 X17 4 4 X17 5 5 X17 6 6 X17 7 7 X17 8 8 X17 9 9 X17 10 10 X18 3 3 X...

Page 96: ...9 9 X17 10 10 X18 3 3 X18 4 4 X5 X3 I1 2 stroke I 0 extern Y1 X12 2 X12 1 L1 X18 2 2 X18 1 1 X4 X1 L1 2 L2 6 L3 10 Q1 L2 L3 LP2 LP3 A4 AC AC AC 3 LP2A LP3A A1 X1 X2 3 A5 X10 3 X12 3 X3 1 X3 2 X12 4 X...

Page 97: ...d 646757 Electrode holder Work Lead Set 5m 400A 50mm DINSE 646325 Electrode Holder Work Lead Set 8m 400A 50mm DINSE 646763 Electrode Holder w Deadman Switch Work Lead Set 8m 400A 50mm DINSE 301526 Com...

Page 98: ...TRANSTIG 220AC DC AND 300AC DC POWER SOURCE APPENDIX A 4 Manual 0 5293 Notes...

Page 99: ...R CONSEQUENTIAL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSINESS INTERRUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of CIGWELD with respect to any...

Page 100: ...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 101: ...POWER SOURCE WARRANTY PERIOD PARTS LABOUR Original main power magnetics 3 Year 2 Year Original main power rectifiers printed circuit boards and power switch semiconductors 2 Year 2 Year All other cir...

Page 102: ...rn of goods to Cigweld or our Nominated Accredited Distributor Accredited Service Provider are the responsibility of the consumer This warranty is given Cigweld Pty Ltd A B N 56007226815 71 Gower Stre...

Page 103: ...1257 224800 PT Victor Technologies Utama Indonesia Jl Angsana II Blok AE No 28 Delta Silicon I Cikarang Sukaresmi Bekasi 17550 Indonesia Tel 62 21 8990 6095 Fax 62 21 8990 6096 1867 http www Victortec...

Page 104: ...Asia Pacific Regional Headquarters 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 FAX 61 3 9474 7391 Email enquiries cigweld com au www cigweld com au...

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