CIGWELD TRANSTIG 200 User manual

200
Amp
240
V
1
50
60
Hz
INVERTER
TRANSTIG®
INVERTER ARC WELDER
200 AC/DC
Service Manual
Revision No: AB Issue Date: January 10, 2014 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
[phone], 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
Victor Technologies International Inc. 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:
Victor Technologies International Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.victortechnologies.com
Copyright 2014 by
Victor Technologies International Inc.
All rights reserved.
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
Revision Date: January 10, 2014
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
i

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 ................................................................12-1
12.00 Introduction.................................................................................................. 12-1
12.01 System-Level Fault Isolation......................................................................... 12-1
12.1.1 Opening the Enclosure....................................................................... 12-1
12.02 Verification and Remedy to the Indicated Error Codes.................................. 12-3
12.2.1 E01 "Over-Temperature at the primary side"....................................... 12-3
12.2.2 E02 "Over-Temperature at the secondary side"................................... 12-4
12.2.3 E03 "Primary Over-Current Failure".................................................... 12-4
12.2.4 E04 "Torch Cable Failure".................................................................... 12-4
12.2.5 E11 "Main Supply Over Voltage"......................................................... 12-5
12.2.6 E12 "Main Supply Under Voltage" ...................................................... 12-5
12.2.7 E81 "Abnormal Input Voltage"............................................................ 12-5
12.2.8 E82 "Rated Voltage Selection Circuit abnormality" ............................. 12-5
12.2.9 E83 "Abnormalities in Mains Supply Voltage Detection"..................... 12-5
12.2.10 E85 "Pre-charge abnormality" .......................................................... 12-6
12.2.11 E94 "Thermistor malfunction" .......................................................... 12-6
12.2.12 E99 "Initial Power Receiving" ........................................................... 12-6

TABLE OF CONTENTS
12.03 Verification and Remedy to Failures without Indication Codes...................... 12-6
12.3.1 "Cooling Fan (FAN1) Failure" (Fan is not rotating.) ............................. 12-6
12.3.2 "Gas Valve Failure" (No Gas flow through unit) .................................. 12-7
12.3.3 "No Weld Output" ............................................................................... 12-7
12.3.4 "Operating Panel Failure" ................................................................... 12-8
12.3.5 "High Frequency Output Failure"......................................................... 12-8
12.04 Fault Isolation Tests ...................................................................................... 12-9
12.4.1 Preparation ........................................................................................ 12-9
12.05 Verification of the Power Input Circuitry ....................................................... 12-9
12.5.1 Verification of the AC Input Voltage using an AC Voltmeter............... 12-9
12.5.2 Verification of Power Supply Voltage............................................... 12-10
12.5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry ...................... 12-11
12.5.4 Verification of the Gas Valve, SOL1, Drive Circuitry......................... 12-12
12.5.5 Verification of the primary Diode (D1) ............................................. 12-12
12.5.6 Verification of the secondary Diode (D2, D4, D5) ............................ 12-13
12.5.7 Verification of the primary IGBT (Q1-Q12)....................................... 12-14
12.5.8 Verification of the secondary IGBT (Q13)......................................... 12-14
12.5.9 Verification of No-load Voltage (OCV).............................................. 12-15
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
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

TABLE OF CONTENTS (continued)
TABLE OF CONTENTS
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

TABLE OF CONTENTS (continued)
TABLE OF CONTENTS
THIS PAGE LEFT INTENTIONALLY BLANK

SERVICE MANUAL TRANSTIG 200 AC/DC
1-1 Manual No. 0-5001
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 weld-
ing 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.
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.
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
Manual No. 0-5001 1-2
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.
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 work-
piece, 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 (10.7 m) of the welding
arc. If this is not possible, tightly cover them with approved
covers.
4. Be alert that welding sparks and hot materials from welding
can easily go through small cracks and openings to adjacent
areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area
as practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock and fire
hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire
at contact tip when not in use.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73
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 Gas metal arc welding
Torch brazing All 2 or 3 Non Ferrous base metal All 11
Oxygen cutting 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
Gas welding 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
Shielded metal-arc welding (stick) electrodes Plasma arc cutting
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