CIGWELD TRANSTIG 200 AC/DC Bedienungsanleitung

200

Amp

240

INVERTER

TRANSTIG®

INVERTER ARC WELDER

200 AC/DC

Service Manual

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

Operating Features:

WE 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 please call

+61-3-9474-7400, or visit us on the web at www.cigweld.com.au.

This Operating Manual has been designed to instruct you on the

correct use and operation of your CIGWELD product. Your

satisfaction with this product and its safe operation is our ultimate

concern. Therefore please take the time to read the entire manual,

especially the Safety Precautions. They will help you to avoid

potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

CIGWELD is a Global Brand of Arc Welding Products for

Thermadyne Industries Inc. We manufacture and supply to major

welding industry sectors worldwide including; Manufacturing,

Construction, Mining, Automotive, Aerospace, Engineering, Rural

and DIY/Hobbyist.

We distinguish ourselves from our competition through market-

leading, dependable products that have stood the test of time. We

pride ourselves on technical innovation, competitive prices,

excellent delivery, superior customer service and technical support,

together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced

products to achieve a safer working environment for industry

operators.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing,

operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement,

the Manufacturer assumes no liability for its use.

Transtig 200 AC/DC Inverter Arc Welder

Operating Manual Number 0-5001 for:

Part Number 700719

Published by:

Thermadyne Industries Inc.

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermadyne.com

Thermadyne Industries Inc.

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

is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any

loss or damage caused by any error or omission in this Manual, whether such error

results from negligence, accident, or any other cause.

Publication Date: January 17, 2008

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS .................................... 1-1

1.01 Arc Welding Hazards ...................................................................................... 1-1

1.02 PRINCIPAL SAFETY STANDARDS .................................................................. 1-5

1.03 DECLARATION OF CONFORMITY ................................................................... 1-6

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identification................................................................................. 2-1

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 Symbol Chart ................................................................................................. 2-2

2.05 Description ..................................................................................................... 2-3

2.06 Functional Block Diagrams ............................................................................. 2-4

2.07 Transporting Methods .................................................................................... 2-4

2.08 Parameter Specifications ................................................................................ 2-5

SECTION 3:

INSTALLATION ...................................................................................... 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location ......................................................................................................... 3-1

3.03 Electrical Input Connections ........................................................................... 3-1

3.04 Mains Supply Voltage Requirements .............................................................. 3-2

3.05 High Frequency Introduction .......................................................................... 3-3

3.06 High Frequency Interference .......................................................................... 3-3

3.07 Duty Cycle ...................................................................................................... 3-4

SECTION 4:

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

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

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

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

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

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

SECTION 5:

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

SECTION 6:

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

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

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

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

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

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

TABLE OF CONTENTS (continued)

TABLE OF CONTENTS

SECTION 7:

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

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

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

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

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

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

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

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

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

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

SECTION 8:

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

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

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

SECTION 9:

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

SECTION 10:

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

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

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

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

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

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

SECTION 11:

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

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

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

SECTION 12:

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

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

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

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

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

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

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

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

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

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

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

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

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

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SECTION 13:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

TABLE OF CONTENTS (continued)

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

CIGWELD LIMITED WARRANTY

Terms of Warranty – January 2008

Warranty Schedule – January 2008

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

THIS PAGE LEFT INTENTIONALLY BLANK

SERVICE MANUAL TRANSTIG 200 AC/DC

January 17, 2008 1-1

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal

shocks or severe burns. The electrode and

work circuit is electrically live whenever the

output is on. The input power circuit and

machine internal circuits are also live when

power is on. In semiautomatic or automatic

wire welding, the wire, wire reel, drive roll

housing, and all metal parts touching the

welding wire are electrically live. Incorrectly

installed or improperly grounded equipment

is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body

protection.

3. Insulate yourself from work and ground using dry

insulating mats or covers.

4. Disconnect input power or stop engine before

installing or servicing this equipment. Lock input

power disconnect switch open, or remove line

fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment

according to its Owner’s Manual and national,

state, and local codes.

6. Turn off all equipment when not in use. Disconnect

power to equipment if it will be left unattended or

out of service.

7. Use fully insulated electrode holders. Never dip

holder in water to cool it or lay it down on the

ground or the work surface. Do not touch holders

connected to two welding machines at the same

time or touch other people with the holder or

electrode.

8. Do not use worn, damaged, undersized, or poorly

spliced cables.

9. Do not wrap cables around your body.

10.Ground the workpiece to a good electrical (earth)

ground.

11.Do not touch electrode while in contact with the

work (ground) circuit.

12.Use only well-maintained equipment. Repair or

replace damaged parts at once.

13.In confined spaces or damp locations, do not use

a welder with AC output unless it is equipped with

a voltage reducer. Use equipment with DC output.

14.Wear a safety harness to prevent falling if working

above floor level.

15.Keep all panels and covers securely in place.

SECTION 1:

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.

PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE

INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR

SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or

property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must

be learned through study and training before using this equipment. Some of these practices apply to equipment

connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive

training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the Australian Standard AS1674.2-2007 entitled: Safety in welding and allied

processes Part 2: Electrical. This publication and other guides to what you should learn before operating this

equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION,

MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

TRANSTIG 200 AC/DC SERVICE MANUAL

1-2 January 17, 2008

WARNING

ARC RAYS can burn eyes and skin; NOISE

can damage hearing.

Arc rays from the welding process

produce intense heat and strong ultraviolet

rays that can burn eyes and skin. Noise

from some processes can damage

hearing.

1. Wear a welding helmet fitted with a proper shade

of filter (see ANSI Z49.1 listed in Safety Standards)

to protect your face and eyes when welding or

watching.

2. Wear approved safety glasses. Side shields

recommended.

3. Use protective screens or barriers to protect others

from flash and glare; warn others not to watch

the arc.

4. Wear protective clothing made from durable,

flame-resistant material (wool and leather) and

foot protection.

5. Use approved ear plugs or ear muffs if noise level

is high.

WARNING

FUMES AND GASES can be hazardous to

your health.

Welding produces fumes and gases.

Breathing these fumes and gases can be

hazardous to your health.

1. Keep your head out of the fumes. Do not breath

the fumes.

2. If inside, ventilate the area and/or use exhaust at

the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied

respirator.

4. Read the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instruction for metals,

consumables, coatings, and cleaners.

5. Work in a confined space only if it is well ventilated,

or while wearing an air-supplied respirator.

Shielding gases used for welding can displace air

causing injury or death. Be sure the breathing air

is safe.

6. Do not weld in locations near degreasing, cleaning,

or spraying operations. The heat and rays of the

arc can react with vapors to form highly toxic and

irritating gases.

7. Do not weld on coated metals, such as galvanized,

lead, or cadmium plated steel, unless the coating

is removed from the weld area, the area is well

ventilated, and if necessary, while wearing an air-

supplied respirator. The coatings and any metals

containing these elements can give off toxic fumes

if welded.

Welding or Cutting

operation

Electrode size Metal Thickness

or Welding Current

Filter

shade

no.

Welding or Cutting operation Electrode size Metal

Thickness or Welding

Current

Filter

shade

no.

Torch soldering All 2

Torch brazing All 2 or 3 Non Ferrous base metal All 11

Ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding (TIG) All 12

Medium 1 – 6 in., 25 – 150 mm 4 or 5 Atomic Hydrogen welding All 12

Heavy Over 6 in., 150 mm 5 or 6 Carbon Arc welding All 12

Plasma arc Welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Carbon Arc Gouging

Medium 1/8 – 1/2 in., 3 – 12 mm 5 or 6 Light 12

Heavy Over 1/2 in., 12 mm 6 or 8 Heavy 14

Under 5/32 in., 4 mm 10 Light Under 300 Amp 9

Under 5/32 to ¼ in., 4 to 6.4mm 12 Medium 300 to 400 Amp 12

Over ¼ in., 6.4 mm 14 Heavy Over 400 Amp 14

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73

Plasma arc cutting

Oxygen cutting

Gas metal arc welding

Gas welding

Shielded metal-arc welding (stick) electrodes

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