CIGWELD 300Pi Service manual

300 Pi
TRANSTIG
®
INVERTER ARC WELDER
Service Manual
Revision: AA
Operating Features:
Issue Date: June 30, 2008
Manual No.: 0-5005
415
V
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
+1300 654 674, 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 Market Leading Brand of Arc Equipment, Gas
Equipment and Filler Metals for Thermadyne Industries Inc. We are
a mainline supplier to major welding industry sectors in the Asia
Pacific and emerging global markets including; Manufacturing,
Construction, Mining, Automotive, Engineering, Rural and DIY.
We distinguish ourselves from our competition through marketleading, 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 300 Pi Inverter Arc Welder
Service Manual Number 0-5005 for:
Part Number 700722
Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 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 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: June 30, 2008
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 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:
OPERATION ........................................................................................... 4-1
4.01 Transtig 300 Pi Controls ................................................................................. 4-1
4.02 Weld Process Selection for Transtig 300 Pi .................................................... 4-2
4.03 Weld Parameter Descriptions for Transtig 300 Pi ........................................... 4-3
4.04 Weld Parameters for Transtig 300 Pi .............................................................. 4-4
4.05 Power Source Features................................................................................... 4-5
4.06 Set-Up for SMAW (STICK) and GTAW (TIG) ................................................... 4-7
4.07 Sequence of Operation ................................................................................... 4-7
4.08 Stick Welding ................................................................................................. 4-8
4.09 HF TIG & Lift TIG Welding .............................................................................. 4-8
4.10 Slope Mode Sequence .................................................................................... 4-9
4.11 Slope Mode with Repeat Sequence ................................................................ 4-9
4.12 Pulse Controls .............................................................................................. 4-10
4.13 Basic TIG Welding Guide .............................................................................. 4-11
4.14 Basic Arc Welding Guide .............................................................................. 4-13
SECTION 5:
SERVICE .............................................................................................. 5-1
5.01 Routine Maintenance ...................................................................................... 5-1
5.02 Basic Troubleshooting .................................................................................... 5-1
5.03 Maintenance Diagram..................................................................................... 5-2
5.04 TIG Welding Problems ................................................................................... 5-3
TABLE OF CONTENTS
TABLE
OF CONTENTS
(continued)
5.05 Stick Welding
Problems
.................................................................................
5-5
5.06 Power Source Problems ................................................................................. 5-8
5.07 Power Source Error Codes ............................................................................. 5-9
5.08 Voltage Reduction Device (VRD) .................................................................. 5-11
SECTION 6:
ADVANCED TROUBLESHOOTING .................................................................. 6-1
6.01 System-Level Fault Isolation ........................................................................... 6-1
6.1.1 Opening the Enclosure ................................................................................... 6-1
6.02 Verification and Remedy to the Indicated Error Codes ................................... 6-3
6.2.1 E01 “Over-Temperature at the primary side” ................................................ 6-3
6.2.2 E02 “Over-Temperature at the secondary side” ............................................ 6-4
6.2.3 E03 “Transformer Over-Current Failure” ....................................................... 6-4
6.2.4 E04 “Torch Cable Failure” ............................................................................. 6-5
6.2.5 E11 “Main Supply Over Volt-age” .................................................................. 6-5
6.2.6 E12 “Main Supply Under Volt-age” ................................................................ 6-5
6.2.7 E81 “Wrong Main Supply Voltage” ................................................................ 6-5
6.2.8 E82 “Rated Voltage Selection Circuit abnormality” ........................................ 6-6
6.2.9 E83 “Abnormalities in Mains Supply Voltage Detection” ............................... 6-6
6.2.10 E85 “Pre-charge abnormality” ..................................................................... 6-6
6.2.11 E94 “Thermistor malfunction” ..................................................................... 6-7
6.2.12 E99 “Initial Power Receiving” ...................................................................... 6-7
6.03 Verification and Remedy to Failures without Indication Codes ....................... 6-7
6.3.1 “Cooling Fan (FAN1) Failure” (Fan is not rotating.) ........................................ 6-7
6.3.2 ”No Weld Output” .......................................................................................... 6-8
6.3.3 ”Operating Panel Failure” ............................................................................... 6-9
6.04 Fault Isolation Tests ...................................................................................... 6-10
6.4.1 Preparation .................................................................................................. 6-10
6.05 Verification of the Power Input Circuitry ....................................................... 6-11
6.5.1 Verification of the AC Input Voltage using an AC voltmeter ......................... 6-11
6.5.2 Verification of the Power Supply Voltage ..................................................... 6-12
6.5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry .................................. 6-13
6.5.4 Verification of the Gas Valve, SOL1, Drive Circuitry ..................................... 6-14
6.5.5 Verification of the Primary Diode (D1) ......................................................... 6-14
6.5.6 Verification of the Secondary Diode (D2-D7) ............................................... 6-15
6.5.7 Verification of the Primary IGBT (Q1-Q24) .................................................. 6-15
6.5.8 Verification of the Secondary IGBT (Q25-Q26) ............................................ 6-16
6.5.9 Verification of No-load Volt-age (OCV) ........................................................ 6-16
SECTION 7:
MAINTENANCE ....................................................................................... 7-1
7.01 Subsystem Test and Replacement Procedures ............................................... 7-1
7.1.1 Preparation .................................................................................................... 7-1
7.1.2 Test and Replacement Parts List ................................................................... 7-1
7.02 Service Tools .................................................................................................. 7-5
7.2.1 Tools and parts .............................................................................................. 7-5
7.2.2 Notes of disassembly and assembly .............................................................. 7-5
7.03 Replacement Procedure ................................................................................. 7-6
7.3.1 PCB1(WK-5493) ............................................................................................ 7-6
7.3.2 PCB2 (WK-5597) ........................................................................................... 7-7
TABLE OF CONTENTS
7.3.3 PCB3 (WK-5548), PCB7 (WK-5550) .............................................................. 7-8
7.3.4 PCB4 (WK-4819) ......................................................................................... 7-10
7.3.5 PCB5 (WK-5551) ......................................................................................... 7-10
7.3.6 PCB6 (WK-5549) ......................................................................................... 7-10
7.3.7 PCB8, PCB9 (WK-5479) and Q1-Q12 “Primary IGBT” ................................. 7-11
7.3.8 PCB10, PCB11 (WK-5479) and Q13-Q24 “Primary IGBT” ........................... 7-12
7.3.9 PCB12 (WK-5527) ....................................................................................... 7-12
7.3.10 PCB13 (WK-5528) ..................................................................................... 7-13
7.3.11 PCB14 (WK-5594) <T1 “Main Transformer”> ............................................ 7-14
7.3.12 PCB15 (WK-5606) ..................................................................................... 7-15
7.3.13 PCB20 (WK-5499) ..................................................................................... 7-16
7.3.14 PCB21 (WK-4917) ..................................................................................... 7-16
7.3.15 PCB22 (WK-5022) ..................................................................................... 7-18
7.3.16 Current Limiting Resistor (R6) .................................................................. 7-18
7.3.17 Resistor (R7, R8) ...................................................................................... 7-19
7.3.18 Reactor (FCH1) .......................................................................................... 7.21
7.3.19 Primary Thermistor (TH1) ......................................................................... 7-22
7.3.20 Secondary Thermistor (TH2) ..................................................................... 7-23
7.3.21 Cooling Fan (FAN1) .................................................................................... 7-23
7.3.22 Main ON/OFF Switch (S1) .......................................................................... 7-25
7.3.23 Input Voltage Switch (S2) .......................................................................... 7-26
7.3.24 Remote Socket (CON1) ............................................................................. 7-27
7.3.25 Hall Current Sensor (HCT1) ....................................................................... 7-28
7.3.26 Primary Diode (D1) ................................................................................... 7-29
7.3.27 Secondary Diode (D2, D4, D5 and D7) ...................................................... 7-30
7.3.28 Current Trans (CT2, CT3) ........................................................................... 7-31
7.3.29 Ring Core (L1) ........................................................................................... 7-32
7.3.30 Ring Core (L105) ....................................................................................... 7-34
7.3.31 Reactor (L101) .......................................................................................... 7-35
7.3.32 Reactor (L102) .......................................................................................... 7-36
7.3.33 Reactor (L103) .......................................................................................... 7-37
APPENDIX 1: PARTS LIST ................................................................................ A-1
APPENDIX 2: CONNECTION WIRING GUIDE ........................................................... A-6
APPENDIX 3: INTERCONNECT DIAGRAM ............................................................... A-8
APPENDIX 4: DIODE TESTING BASICS ................................................................. A-10
APPENDIX 5: OPTIONS AND ACCESSORIES .......................................................... A-11
CIQWELD LIMITED WARRANTY
Terms of Warranty – January 2008
Warranty Schedule – January 2008
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
SERVICE MANUAL
TRANSTIG 300 Pi
SECTION 1:
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE
INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR
SERVICING THIS EQUIPMENT.
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 AS1674.2-2006 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.
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.
June 30, 2008
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.
1-1
TRANSTIG 300 Pi
SERVICE MANUAL
WARNING
WARNING
FUMES AND GASES can be hazardous to
your health.
ARC RAYS can burn eyes and skin; NOISE
can damage hearing.
Welding produces fumes and gases.
Breathing these fumes and gases can be
hazardous to your health.
Arc rays from the welding process
produce intense heat and strong ultraviolet
rays that can burn eyes and skin. Noise
from some processes can damage
hearing.
1. Keep your head out of the fumes. Do not breath
the fumes.
1. 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. If inside, ventilate the area and/or use exhaust at
the arc to remove welding fumes and gases.
2. Wear approved safety glasses. Side shields
recommended.
4. Read the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals,
consumables, coatings, and cleaners.
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.
3. If ventilation is poor, use an approved air-supplied
respirator.
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 airsupplied respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73
Welding or Cutting Electrode size Metal Thickness
operation
or Welding Current
Torch soldering
All
Filter
shade
no.
2
Torch brazing
All
2 or 3
Oxygen cutting
Electrode size Metal
Thickness or Welding
Current
Filter
shade
no.
All
All
11
12
Gas metal arc welding
Non Ferrous base metal
Ferrous base metal
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
Gas welding
Light
Under 1/8 in., 3 mm
4 or 5
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
1-2
Welding or Cutting operation
Carbon Arc Gouging
Plasma arc cutting
Under 5/32 in., 4 mm
Under 5/32 to ¼ in., 4 to 6.4mm
10
12
Light
Medium
Over ¼ in., 6.4 mm
14
Heavy
Under 300 Amp
300 to 400 Amp
9
12
Over 400 Amp
14
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding
arc. The flying sparks and hot metal, weld
spatter, hot workpiece, and hot equipment
can cause fires and burns. Accidental
contact of electrode or welding wire to
metal objects can cause sparks,
overheating, or fire.
1. Protect yourself and others from flying sparks and
hot metal.
2. Do not weld where flying sparks can strike
flammable material.
3. Remove all flammables within 35 ft (10.7 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.
WARNING
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal.
As welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to
treat them carefully.
1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position
by chaining them to a stationary support or
equipment cylinder rack to prevent falling or
tipping.
3. Keep cylinders away from any welding or other
electrical circuits.
4. Never allow a welding electrode to touch any
cylinder.
5. Use only correct shielding gas cylinders,
regulators, hoses, and fittings designed for the
specific application; maintain them and associated
parts in good condition.
6. Turn face away from valve outlet when opening
cylinder valve.
7. Keep protective cap in place over valve except
when cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas
cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
June 30, 2008
1-3
TRANSTIG 300 Pi
SERVICE MANUAL
WARNING
Engines can be dangerous.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated
areas.
2. If used in a closed area, vent engine exhaust
outside and away from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Stop engine before installing or connecting
unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting
as necessary.
4. To prevent accidental starting during
servicing, disconnect negative (-) battery
cable from battery.
5. Keep hands, hair, loose clothing, and tools
away from moving parts.
6. Reinstall panels or guards and close doors
when servicing is finished and before starting
engine.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near
any sparks or open flames.
3. Allow engine to cool before fueling. If possible,
check and add fuel to cold engine before beginning
job.
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
4. Do not overfill tank — allow room for fuel to
expand.
Batteries contain acid and generate explosive gases.
5. Do not spill fuel. If fuel is spilled, clean up before
starting engine.
1. Always wear a face shield when working on a
battery.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when working
on a battery.
4. Do not use welder to charge batteries or jump start
vehicles.
5. Observe correct polarity (+ and –) on batteries.
1-4
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
1. Keep cables close together by twisting or
taping them.
WARNING
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and skin.
The coolant in the radiator can be very hot
and under pressure.
1. Do not remove radiator cap when engine is hot.
Allow engine to cool.
2. Arrange cables to one side and away from the
operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far
away from body as practical.
ABOUT PACEMAKERS:
2. Wear gloves and put a rag over cap area when
removing cap.
The above procedures are among those
also normally recommended for
pacemaker wearers. Consult your doctor
for complete information.
3. Allow pressure to escape before completely
removing cap.
1.02 PRINCIPAL SAFETY STANDARDS
WARNING
This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals know to the State of
California to cause birth defects and, in
some 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 General
Conclusions Section of the U.S. Congress, Office of
Technology Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background
Paper, OTA-BP-E-63 (Washington, DC: U.S.
Government Printing Office, May 1989): “...there is
now a very large volume of scientific findings based
on experiments at the cellular level and from studies
with animals and people which clearly establish that
low frequency magnetic fields and interact with, and
produce changes in, biological systems. While most
of this work is of very high quality, the results are
complex. Current scientific understanding does not
yet allow us to interpret the evidence in a single
coherent framework. Even more frustrating, it does
not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear sciencebased advice on strategies to minimize or avoid
potential risks.”
To reduce magnetic fields in the workplace, use the
following procedures.
June 30, 2008
Safety in Welding and Cutting, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910,
from Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet 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,
Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye
and Face Protection, ANSI Standard Z87.1, from
American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B,
from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
Safety in welding and allied processes Part 2:
Electrical, AS1674.2-2007 from SAI Global Limited,
www.saiglobal.com
1-5
TRANSTIG 300 Pi
SERVICE MANUAL
1.03 DECLARATION OF CONFORMITY
Manufacturer:
Address:
CIGWELD
71 Gower St, Preston
Victoria 3072
Australia
Description of equipment: Welding Equipment (GMAW, MMAW, GTAW). Including, but not limited to CIGWELD
Transtig 200 Pi, Transtig 200 AC/DC, Transarc 300 Si, Transtig 300 Pi, Transtig 300 AC/DC, Transmig 400 i and
associated accessories.
Serial numbers are unique with each individual piece of equipment and details description, parts
used to manufacture a unit and date of manufacture.
The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive
73/23/EU, as recently changed in Directive 93/68/EU and to the National legislation for the enforcement of the
Directive.
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) applicable to arc welding equipment - generic emissions and
regulations.
• EN60974-1 applicable to welding equipment and associated accessories.
• AS60974.1 applicable to welding equipment and associated accessories.
Extensive product design verification is conducted at the manufacturing facility as part of the routine design
and manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is
incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design
specifications.
CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance,
ultra safe operation and world class quality for more than 30 years and will continue to achieve excellence.
1-6
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
This Service Manual applies to just specification or
part numbers listed on page i.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotations are easily
recognized as follows:
!
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information
concerning certain operating procedures.
Additional copies of this manual may be purchased
by contacting CIGWELD at the address and phone
number for your location listed in the inside back cover
of this manual. Include the Owner’s Manual number
and equipment identification numbers.
Electronic copies of this manual can also be
downloaded at no charge in Acrobat PDF format by
going to the CIGWELD web site listed below and
clicking on the Literature Library link:
2.02 Equipment Identification
The unit’s identification number (specification 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 control panel
such as gun and cable assemblies is identified only
by the specification or part number printed on the
shipping container. Record these numbers on the
bottom of page i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against
the invoice to make sure it is complete and inspect
the equipment for possible damage due to shipping.
If there is any damage, notify the carrier immediately
to file a claim. Furnish complete information
concerning damage claims or shipping errors to the
location in your 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 installation site before uncrating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to uncrate the unit.
CAUTION
The products applicable to this Service
Manual are manufactured in various
configurations for differing global
requirements. Some specifications and
and electrical data quoted within this
Service Manual may not be applicable to
all products and regions. For this reason
due caution and care must be exercised
when using this Service Manual.
http://www.cigweld.com.au
June 30, 2008
2-1
TRANSTIG 300 Pi
SERVICE MANUAL
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Single Phase
Wire Feed Function
Off
Three Phase
Wire Feed Towards
Workpiece With
Output Voltage Off.
Dangerous Voltage
Three Phase Static
Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
115V 15A
2-2
X
%
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
Line Connection
Touch Start (GTAW)
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
t
Spot Time
Preflow Time
t1
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
Burnback Time
IPM
Inches Per Minute
MPM
Meters Per Minute
Voltage Input
Art # A-04130
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
2.05 Description
The CIGWELD Transtig 300 Pi is a three-phase DC
arc welding power source with Constant Current (CC)
output characteristics. This unit is equipped with a
Digital Volt/Amperage Meter, gas control valve, built
in Sloper and Pulser, lift arc starter, and highfrequency arc starter for use with Gas Tungsten Arc
Welding (GTAW), Gas Tungsten Arc Welding-Pulse
(GTAW-P), Gas Tungsten Arc Welding-Sloped (GTSWS), and Shielded Metal Arc Welding (SMAW)
processes. The power source is totally enclosed in
an impact resistant, flame resistant and nonconductive plastic case.
(V)
OCV
1A
160A
(A)
STICK Process
NOTE
Volt-Ampere curves show the maximum
Voltage and Amperage output capabilities
of the welding power source. Curves of
other settings will fall between the curves
shown.
(V)
OCV
Art # A-06027
10V
25A
200A
(A)
LIFT TIG Process
(V)
OCV
1A
200A
(A)
HF TIG Process
Figure 2-1: Transtig 300 Pi Volt-Ampere Curves
June 30, 2008
2-3
TRANSTIG 300 Pi
SERVICE MANUAL
2.06 Functional Block Diagrams
Figure 2-2 illustrates the functional block diagram of the Transtig 300 Pi-power supply.
Input
Power
Main
Circuit
Switch
Input
Diode
Filter
Capacitor
DC Power
Primary
Voltage
Sensor
IGBT
Inverter
Thermal
Detector
Main
Transformers
(T1)
Hall Current
Transformer
(HCT1)
Output
Diodes
Output
Inductor
To each control circuit
+/-12VDC +18VDC
+24VDC +5VDC
Trouble
Sensing
Circuit
Thermal
Sensor
Circuit
Drive
Circuit
HF Unit
Control
Circuit
Stick Mode Lift Tig Mode
VRD
Output Short
Sensing
Sensing
Circuit
Circuit
Primary
Circuit
Sensor
High
Frequency
Unit
Sequence
Control
Torch Control
Connection
(CON1)
Coupling
Coil
Current
Reference
Adjustment
Adjustment &
Circuit
Mode select Switch
Fan Control
Circuit
Gas Control
Circuit
Fan
Solenoid
Panel Circuit Board
Art # A-06029
Figure 2-2: Transtig 300 Pi Functional Block Diagram
2.07 Transporting Methods
These units are equipped with a handle for carrying purposes.
!
WARNING
ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors
from de-energized supply line before moving the welding power source.
!
WARNING
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Lift unit with handle on top of case.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a proper skid before transporting.
2-4
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
2.08 Specifications
Parameter
Transtig 300Pi
Power Source Part Number
700722
Cooling
Fan Cooled
Welder Type
Inverter Power Source
Welding Power Source Mass
24kg
Dimensions
H 420mm x W 210mm x D 450mm
Maunfactured to Australian Standard
AS 60974.1-2006
Number of Phases
3
Nominal Supply Voltage
415V ±15%
Nominal Supply Frequency
50Hz
Open Circuit Voltage
65V
Welding Current Range
5 - 300 Amps
Effective Input Current (I1eff)
14.1 Amps
Maximum Input Current (I1max)
22.3 Amps
Three Phase Generator Requirement
16 KVA
0
300A @ 40%, 32.0V
Welding Output, 40 C, 10 min.
250A @ 60%, 30.0V
(quoted figures refer to MMAW
180A @ 100%, 27.2V
output)
0
300A @ 40%, 22.0V
Welding Output 40 C, 10 min.
250A @ 60%, 20.0V
(Quoted figures refer to GTAW output)
180A @ 100%, 17.2V
Protection Class
IP23S
Table 2-1: Specifications
Cigweld continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the
specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of
equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above
specifications due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured
components, installation location and conditions and local power grid supply conditions.
June 30, 2008
2-5
TRANSTIG 300 Pi
SERVICE MANUAL
THIS PAGE LEFT INTENTIONALLY BLANK
2-6
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
SECTION 3:
INSTALLATION
3.03 Electrical Input Connections
3.01 Environment
The Transtig 300 Pi is designed for use in hazardous
environments. Examples of environments with
increased hazardous conditions are:
a. In locations in which freedom of movement is
restricted, so that the operator is forced to perform
the work in a cramped (kneeling, sitting or lying)
position with physical contact with conductive
parts;
b. 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 locations where humidity or
perspiration considerably reduces the skin
resistance of the human body and the insulation
properties of accessories.
!
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT
DC VOLTAGE is present after removal of
input power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input
power employing lockout/tagging procedures.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
Environments with hazardous conditions do not
include places where electrically conductive parts in
the near vicinity of the operator, which can cause
increased hazard, have been insulated.
3.02 Location
Be sure to locate the welder according to the following
guidelines:
· In areas, free from moisture and dust.
· Ambient temperature between 0 degrees C to
40 degrees C.
· In areas, free from oil, steam and corrosive
gases.
· In areas, not subjected to abnormal vibration
or shock.
· In areas, not exposed to direct sunlight or rain.
· Place at a distance of 12” (304.79mm) or more
from walls or similar that could restrict natural
airflow for cooling.
!
WARNING
CIGWELD advises that this equipment be
electrically connected by a qualified
electrician.
June 30, 2008
3-1
TRANSTIG 300 Pi
SERVICE MANUAL
3.04 Mains Supply Voltage Requirements
The Mains supply voltage should be within ± 15% of the rated Mains supply voltage. Too low a voltage may
cause the fuse or circuit breaker to rupture due to the increased primary current. Too high a supply voltage will
cause the Power Source to fail.
415V Mains Current Circuit Requirements for the Transtig 300 Pi
The Welding Power Source must be:
• Correctly installed, if necessary, by a qualified electrician.
• Correctly earthed (electrically) in accordance with local regulations.
• Connected to the correct size 415V Mains Current Circuit as per the Specifications
!
WARNING
CIGWELD advises that this equipment be electrically connected by a qualified electrical tradesperson.
The following 415V Mains Current Circuit recommendations are required to obtain the maximum welding
current and duty cycle from this welding equipment:
Motor start fuses or thermal circuit breakers are recommended for this application.
Model
Transtig 300 Pi
Minimum 415V Mains
Current Circuit Size
22.3 Amps
Table 3-1: 415V Mains Current Circuit Recommendations
3-2
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
3.05 High Frequency Introduction
3.06 High Frequency Interference
The importance of correct installation of high
frequency welding equipment cannot be
overemphasized. Interference due to high frequency
initiated or stabilized arc is almost invariably traced
to improper installation. The following information is
intended as a guide for personnel installing high
frequency welding machines.
Interference may be transmitted by a high frequency
initiated or stabilized arc welding machine in the
following ways:
!
WARNING: EXPLOSIVES
The high frequency section of this machine
has an output similar to a radio transmitter.
The machine should NOT be used in the
vicinity of blasting operations due to the
danger of premature firing.
!
WARNING: COMPUTERS
It is also possible that operation close to
computer installations may cause
computer malfunction.
1. Direct Radiation: Radiation 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 Source will prevent
direct radiation if the equipment is properly
grounded.
2. Transmission via the Supply Lead: Without
adequate shielding and filtering, high frequency
energy may be fed to the wiring within the
installation (mains) by direct coupling. The energy
is then transmitted by both radiation and
conduction. Adequate shielding and filtering is
provided in the Power Source.
3. Radiation from Welding Leads: Radiated
interference from welding leads, although
pronounced in the vicinity of the leads, diminishes
rapidly with distance. Keeping leads as short as
possible will minimize this type of interference.
Looping and suspending of leads should be
avoided where possible.
4. Re-radiation from Unearthed Metallic Objects:
A major factor contributing to interference is reradiation from unearthed metallic objects close
to the welding leads. Effective grounding of such
objects will prevent re-radiation in most cases.
June 30, 2008
3-3
TRANSTIG 300 Pi
SERVICE MANUAL
3.07 Duty Cycle
The duty cycle of a welding power source is the
percentage of a ten (10) minute period that it can be
operated at a given output without causing
overheating and damage to the unit. If the welding
amperes decrease, the duty cycle increases. If the
welding amperes are increased beyond the rated
output, the duty cycle will decrease.
!
WARNING
Exceeding the duty cycle 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.
3-4
CAUTION
Continually exceeding the duty cycle
ratings can cause damage to the welding
power source and will void the
manufactures warranty.
NOTE
Due to variations that 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 operation will depend upon correct
installation,
use,
applications,
maintenance and service.
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
SECTION 4:
OPERATION
4.01 Transtig 300 Pi Controls
410
180
Art # A-06031_AB
7
6
2
360
1
5
4
3
15
8
Figure 4-1: Transtig 300 Pi Power Source
1. Control Knob: This control sets the selected weld
parameter, rotating it clockwise increases the
parameter and is indicated on the digital meter.
Pushing the knob inward displays the actual
welding voltage.
2. Remote Control Socket: The 14 pin Remote
Control Socket is used to connect remote current
control devices to the welding Power Source. To
make connections, align keyway, insert plug, and
rotate threaded collar fully clockwise.
E
Art # A-07653_AB
B
A B C D E F G H I J K L M N
C
A
K
L
D
J
E
A
B
C
D
I
N
M
Socket
Pin
H
E
G
F
5k ohms
Front view of 14
Socket Receptacle
Figure 4-2: 14-Socket Receptacle
3. Positive Terminal: Welding current flows from
the Power Source via heavy duty Dinse type
terminal. It is essential, however, that the male
plug is inserted and turned securely to achieve a
sound electrical connection.
G
Function
Torch Switch Input (24V) to (connect
pins A & B to turn on welding current).
Torch Switch Input (0V) to energize
weld
current (connect pins A & B to turn on
welding current).
5k ohm (maximum) connection to 5k
ohm remote control potentiometer.
Zero ohm (minimum) connection to 5k
ohm remote control potentiometer.
Wiper arm connection to 5k ohm
remote control potentiometer.
Mains Earth.
F,H,I,J,
Not Used.
K,L
OK to move current detect signal for
M
robotics applications.
OK to move current detect signal for
N
robotics applications.
Table 4-1: Socket Pin Functions
4. Negative Terminal: Welding current flows from
the Power Source via heavy duty Dinse type
terminal. It is essential, however, that the male
plug is inserted and turned securely to achieve a
sound electrical connection.
June 30, 2008
4-1
TRANSTIG 300 Pi
SERVICE MANUAL
!
CAUTION
Loose welding terminal connections can
cause overheating and result in the male
plug being fused in the bayonet terminal.
WARNING
When the welder is connected to the
Primary supply voltage, the internal
electrical components may be at 400V
potential with respect to earth.
5. Gas Outlet: The Gas Outlet is a 5/8-18 UNF female
gas fitting.
6. ON/OFF Switch: This switch connects the Primary
supply voltage to the inverter when in the ON
position. This enables the Power Supply.
7. Input Cable: The input cable 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 300 Pi
Weld Process Selection
Weld Mode
STICK HF TIG LIFT TIG
Description
Yes
Yes
Yes
2T operation in TIG Modes using remote devices
to control contactor & current
No
Yes
Yes
4T operation in TIG Modes with crater fill using a
remote contactor device to control sequence.
No
Yes
Yes
4T operation in TIG Modes with repeat operation
and crater fill using a remote contactor device.
No
Yes
No
2T operation spot welding in HF TIG using a
remote contactor device.
No
Yes
Yes
Pulse operation in TIG Modes
STD
SLOPE
REPEAT
SPOT
PULSE ON/OFF
Table 4-2: Weld Process Selection Versus Weld Mode for Transtig 300 Pi
4-2
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
4.03 Weld Parameter Descriptions for Transtig 300 Pi
Art # A-07847_AD
PRESS AND HOLD
Figure 4-3: Transtig 300 Pi Front Panel
Parameter
Description
This parameter operates in TIG modes only and is used to get gas to the weld zone
PRE-FLOW prior to striking the arc, once the torch trigger switch has been pressed. This control
is used to dramatically reduce weld porosity at the start of a weld.
This parameter operates in all weld modes except Lift TIG mode and is used to heat
up the weld zone in TIG modes or improve the start characteristics for stick
HOT START electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the
BASE (WELD) current. e.g. HOT START current = 130 amps when BASE (WELD) =
100 amps & HOT START = 30 amps
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to
INITIAL CUR. set the start current for TIG. The Start Current remains on until the torch trigger
switch is released after it has been depressed.
This parameter operates in TIG modes only and is used to set the time for the weld
UP SLOPE current to ramp up, after the torch trigger switch has been pressed then released,
from INITIAL CUR to PEAK or BASE current
PEAK CUR. This parameter sets the PEAK weld current when in PULSE mode
This parameter sets the TIG WELD current in STD , SLOPE , REPEAT and
WELD
SPOT modes when PULSE is off. This parameter also sets the STICK weld current.
BASE
This parameter sets the Background current when in Pulse TIG mode.
(Background
Current)
SPOT TIME
PULSE
WIDTH
PULSE FREQ.
This parameter sets the duration of the SPOT TIME in HF TIG mode only
This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK
weld current when the PULSE is on.
This parameter sets the PULSE FREQUENCY when the PULSE is on.
Table 4-3: Transtig 300 Pi Parameter Descriptions
June 30, 2008
4-3
TRANSTIG 300 Pi
SERVICE MANUAL
Parameter
Description
This parameter operates in TIG modes only and is used to set the time for the weld
current to ramp down, after the torch trigger switch has been pressed, to CRATER
DOWN SLOPE
CUR. This control is used to eliminate the crater that can form at the completion of a
weld.
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to
CRATER CUR. set the finish current for TIG. The CRATER Current remains on until the torch trigger
switch is released after it has been depressed.
This parameter operates in TIG modes only and is used to adjust the post gas flow
POST-FLOW time once the arc has extinguished. This control is used to dramatically reduce
oxidation of the tungsten electrode.
The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs
into the 300 Pi memory. Note: Press and hold button for three seconds to store
settings.
Table 4-3 (continued): Parameter Descriptions
4.04 Weld Parameters for Transtig 300 Pi
Weld Mode
Weld
Parameter
Parameter Range
PRE-FLOW
HOT START
INITIAL CUR.
UP SLOPE
PEAK CUR.
WELD CUR (TIG)
WELD CUR (STICK)
SPOT TIME
PULSE WIDTH
PULSE FREQ.
DOWN SLOPE
CRATER CUR.
POST-FLOW
0.0 to 1.0 sec
0 to 70A
5 to 300A
0 to 15 sec
5 to 300A
5 to 300A
5 to 300A
0.5 to 5.0 sec
15 to 80%
0.5 to 500Hz
0 to 25 sec
5 to 40A
0.0 to 60 sec
Factory
Setting
0 sec
20A
30A
1 sec
120A
80A
80A
2 sec
50%
100.0Hz
3 sec
30A
10 sec
Incremental
Unit
0.1 sec
1A
1A
0.1 sec
1A
1A
1A
0.1 sec
1%
See Table 4-5
0.1 sec
1A
0.1 sec
STICK
No
Yes
No
No
No
No
Yes
No
No
No
No
No
No
HF
TIG
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
LIFT
TIG
Yes
No
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Table 4-4: Weld Parameters for Transtig 300 Pi
PULSE FREQ. Range
0.5 to 20Hz
20 to 100Hz
100 to 500Hz
Incremental Unit
0.1Hz
1Hz
5Hz
Table 4-5: PULSE FREQ. Range and Incremental Units
4-4
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
4.05 Power Source Features
Feature
Digital Control
Touch Panel Switches
Front Control Cover
Digital Meter
ON/OFF switch
Save/Load Function
Description
•Almost all welding parameters are adjustable
•Touch switches eliminate mechanical damage
•Protects front panel controls
•Displays selected weld parameter value
•Displays weld current when welding
•Displays weld current for 20 seconds after weld has
been completed
•A selected weld parameter value can be adjusted at any
time even while welding
•Primary voltage Supply ON/OFF switch located on rear
panel
•A total number of 5 programs can be saved into the
200 Pi memory
SAVE the Current Weld Parameters into Memory
•Press the SAVE button
•Select a memory location by rotating the control knob, 1
to 5 is displayed on the meter
•After selecting the desired memory location (ie 1 to 5),
press the right scroll button and the machine will give a
been to confirm the weld parameters from the control
panel are saved. Note: Press and hold the Save button for
three seconds to store settings.
LOAD (retrieve) a Program to Control Panel
•Press the LOAD button
•Select a memory location by rotating the control knob, 1
to 5 is displayed on the meter
•After selecting the desired memory location (i.e. 1 to 5),
press the right scroll button and the machine will give a
been to confirm the weld parameters from the weld
parameters are loaded. Note: Press and hold the Load
button for three seconds to store settings.
Table 4-6: Power Source Features
June 30, 2008
4-5
TRANSTIG 300 Pi
SERVICE MANUAL
Feature
Voltage Reduction Device (VRD)
Control Knob
Self Diagnosis Using Error Codes
Description
Reduces the OCV when the power supply is not in use.
Eliminates the need for add on voltage reducers and has
no effect on arc starting.
•VRD fully complies to AS 60974.1
•When Stick mode is selected the green VRD light is ON
when not welding and red when welding.
•When in TIG modes VRD is off.
•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 any
time even while welding
•Pushing the knob in displays actual arc voltage.
•An error code is displayed on the Digital Meter when a
problem occurs with Primary supply voltage or internal
component problems. Refer to troubleshooting guide.
Table 4-6 (continued): Power Source Features
4-6
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
4.06 Set-Up for MMAW (STICK) and
GTAW (TIG)
Conventional operating procedures apply when using
the Welding Power Source, i.e. connect work lead
directly to work piece and electrode lead is used to
hold electrode. Wide safety margins provided by the
coil design ensure that the Welding Power Source
will withstand short-term overload without adverse
effects. The welding current range values should be
used as a guide only. Current delivered to the arc is
dependent on the welding arc voltage, 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 current range values
as a guide, then finally adjust the current setting to
suit the application.
!
`
WARNING
Before connecting the work clamp to the
work and inserting the electrode in the
electrode holder make sure the Primary
power supply is switched off.
CAUTION
Art # A-07843
Figure 4-4: Transtig 300 Pi Set-Up
Remove any packaging material prior to
use. Do not block the air vents at the front
or rear or sides of the Welding Power
Source.
CAUTION
DO NOT change the Weld Mode or Weld
Process Mode until after POST-FLOW time
has finished.
June 30, 2008
4-7
TRANSTIG 300 Pi
SERVICE MANUAL
4.07 Sequence of Operation
NOTE
Scroll Buttons are used to select the parameters to be set. The LED’s show which function is being
adjusted on the weld sequence graph. Refer to Symbols Table located in the front of the manual for
Symbol descriptions.
1
Art # A-07848_AD
6
2
7
PRESS AND HOLD
3
5
4
Figure 4-5: Transtig 300 Pi Front Panel
1. Pulse Function: Pressing this button enables the TIG current pulse functions.
2. Scroll Buttons: Used to select the parameter to be set. The LED’s show which function is being adjusted on
the weld sequence graph.
3. Digital LED Display: Welding amperage and parameter values are displayed 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 operator to adjust the output amperage within the entire range of the power
source, also used to set each parameter value. Pushing the knob inward displays the actual welding voltage.
5. Process Button: This button selects between STICK, Lift or HF TIG mode.
6. Remote Control Button: This button selects between the front panel and a connected remote device.
7. Save/Load Button: By using the Save & Load buttons the operator can easily save up to 5 welding parameter
program. Note: Press and hold Save/Load button for three seconds to store settings.
4-8
June 30, 2008
SERVICE MANUAL
4.08 Stick Welding
TRANSTIG 300 Pi
4.09 HF TIG & Lift TIG Welding
· Connect work lead to negative terminal
· Connect work lead to positive terminal
· Connect electrode lead to positive terminal
· Connect TIG torch to negative terminal
· Switch machine on
· Switch machine on
· Set weld current
· Set WELD current.
· Connect remote control device if required
Use the Scroll Buttons to move to the parameter to
be set. The LED will show which function is being
adjusted on the weld sequence graph. Use the control
knob to adjust each parameter.
· Set HOT START
· Set WELD current
Commence welding
· 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 details
of the remote device.
Use the Scroll Buttons to move to the parameter to
be set. The LED will show which function is being
adjusted on the weld sequence graph. Use the control
knob to adjust each parameter.
· Set PRE-FLOW time
· Set HOT START current
· Set POST-FLOW time
· Set WELD current
· Set POST-FLOW time
Slope Mode Parameters if required
· Set INITIAL CUR current
· Set UP SLOPE time
· Set (WELD) PEAK CUR current
· Set BASE current
· Set DOWN SLOPE time
· Set CRATER CUR current
Pulse Mode parameters if required
· Set PULSE WIDTH % for PEAK CURRENT
· Set PEAK CURRENT
· Set PULSE FREQ
Commence welding
June 30, 2008
4-9
TRANSTIG 300 Pi
SERVICE MANUAL
4.10 Slope Mode Sequence
Switch
Open
Switch
Closed
Initial
Current
Up
Slope
Switch
Closed
Weld Current
Preflow
Figure 4-6: Slope Mode Sequence
1) To start Slope sequence Close remote switch
contacts. Once the welding arc is established the
Power Source will maintain initial current setting
as long as the remote switch contacts are closed.
a) In the HF TIG mode, after Preflow time High
Frequency is present at the torch. When the
torch is positioned close to the work the
welding current will transfer to the work and
establish the arc at the initial current setting.
b) In the Lift TIG mode, after Preflow time Lift
Start current is present at the torch. When
the electrode is touched to the work and lifted
off, the welding arc is established at the initial
current setting.
Down
Slope
Final
Current
Switch
Open
Art # A-05069_AB
Postflow
2) Open 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 Switch: Welding current decreases
to final current setting. Once final welding current
is reached the power source will maintain final
current setting as long as the remote switch
contacts are closed.
4) Open Remote Switch: Welding arc stops and post
flow begins.
4.11 Slope Mode with Repeat Sequence
The repeat function is operated during the down slope cycle of the Slope Sequence and is active through the
down slope period only. During the down slope period by opening the Remote Switch contacts the current will
increase back to weld current. Within the Down Slope period the repeat function can operated as many times
as desired. To continue slope cycle and end slope sequence close remote switch contacts and allow weld
current to reach final current setting. Once final current setting is reached opening the Remote Switch again
will turn off the welding arc and post flow begins.
4-10
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
4.12 Pulse Controls
(Pulse Width)
(Pulse Frequency)
Art # A-05070
(Peak Current)
(Base)
Background Current
Figure 4-7: Pulse Controls
The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows:
1) Control puddle: size and fluidity (especially out of position).
2) Increase penetration
3) Travel speed control
4) Better consistent quality
5) Distortion on lighter or thinner materials.
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) current
periods, cooling and solidification take place. Pulse Width is the time in one cycle the current stays at the peak
current setting. Pulse Frequency measured in Hertz is the number of cycles per second the current travels
between peak and background current settings. It is as if the foot rheostat were moved up and down to
increase and decrease the welding current on a regular basis. The faster you moved the foot rheostat up and
down the faster the frequency.
June 30, 2008
4-11
TRANSTIG 300 Pi
SERVICE MANUAL
4.13 Basic TIG Welding Guide
1. Electrode Polarity:
Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current
straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows
limited wear of the electrode since 70% of the heat is concentrated at the work piece.
2. Tungsten Electrode Current Ranges:
Electrode Diameter
0.040” (1.0mm)
1/16” (1.6mm)
3/32” (2.4mm)
1/8” (3.2mm)
5/32” (4.0mm)
3/16” (4.8mm)
DC Current (Amps)
30 – 60
60 – 115
100 – 165
135 – 200
190 – 280
250 – 340
Table 4-7: Current Ranges for Various Tungsten Electrode Sizes
3. Tungsten Electrode Types:
Electrode Type
(Ground Finish)
Welding Application
Features
DC welding of mild steel,
Thoriated 2% stainless steel and copper.
Ceriated 2%
DC welding of mild steel,
stainless steel, copper,
aluminium, magnesium and
their alloys
Excellent arc starting, Long
life, High current carrying
capacity.
Longer life, More stable arc,
Easier starting, Wider current
range, Narrower more
concentrated arc.
Color
Code
Red
Grey
Table 4-8: Tungsten Electrode Types
4. Guide for Selecting Filler Wire Diameter:
Filler Wire Diameter
1/16” (1.6 mm)
3/32” (2.4 mm)
1/8” (3.2 mm)
3/16” (4.8 mm)
DC Current Range (Amps)
20 - 90
65 - 115
100 - 165
200-350
Table 4-9: Filler Wire Selection Guide
NOTE
The filler wire diameter specified in Table 4-9 is a guide only, other diameter wires may be used
according to the welding application.
4-12
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
5. Shielding Gas Selection:
Alloy
Shielding Gas
Aluminium & alloys
Carbon Steel
Stainless Steel
Copper
Argon
Argon
Argon
Argon
Table 4-10: Shielding Gas Selection
6. TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe:
Electrode Type
& Diameter
Thoriated 2%
3/32'' (2.4mm)
Thoriated 2%
3/32'' (2.4mm)
Thoriated 2%
3/32'' (2.4mm)
Current Range
DC Amperes
Fillet Rod for
Root Pass
120-170
Yes
100-160
Yes
90-130
No
Joint
Preparation
Table 4-11: TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
DC Current
for
Stainless
Steel
0.040”
35-45 40- 20-30 251.0mm
50
35
0.045”
45-55 50- 30-45 351.2mm
60
50
1/16”
60-70 70- 40-60 501.6mm
90
70
1/8”
80-100 90- 65-85 903.2mm
115
110
3/16”
115-135
100-125
4.8mm
140-165
125-150
160-175
135-160
¼” 6.4mm
170-200
160-180
DC Current
Base Metal
for Mild
Thickness
Steel
Tungsten
Filler Rod Argon Gas
Electrode Diameter (if Flow Rate
Diameter
required) Liters/min
0.040”
1.0mm
0.040”
1.0mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
1/16”
1.6mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
5/32”
4.0mm
5-7
5-7
7
7
10
10
Joint Type
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Table 4-12: DC TIG Welding Parameters
June 30, 2008
4-13
TRANSTIG 300 Pi
SERVICE MANUAL
4.14 Basic Arc Welding Guide
1. Electrode Polarity:
Stick electrodes are generally connected to the ‘+’
terminal and the work lead to the ‘-’ terminal but if in
doubt consult the electrode manufacturers literature.
2. Effects of Stick Welding Various Materials:
A. High tensile and alloy steels
C. Cast Iron
Most types of cast iron, except white iron, are
weldable. White iron, because of its extreme
brittleness, generally cracks when attempts
are made to weld it. Trouble may also be
experienced when welding white-heart
malleable, due to the porosity caused by gas
held in this type of iron.
D. Copper and alloys
The two most prominent effects of welding
these steels are the formation of a hardened
zone in the weld area, and, if suitable
precautions are not taken, the occurrence in
this zone of under-bead cracks. Hardened
zone and under-bead cracks in the weld area
may be reduced by using the correct
electrodes, preheating, using higher current
settings, using larger electrodes sizes, short
runs for larger electrode deposits or
tempering in a furnace.
B. Manganese steels
The effect on manganese steel of slow cooling
from high temperatures is to embrittle it. For
this reason it is absolutely essential to keep
manganese steel cool during welding by
quenching after each weld or skip welding to
distribute the heat.
Metals being joined
Electrode
Mild steel
6013
Mild steel
7014
Cast iron
99% Nickel
Stainless steel
318L-16
Copper, Bronze,
Brass, etc.
Bronze 5.7
ERCUSI-A
High Alloy Steels,
Dissimilar Metals,
Crack Resistance. All
Hard-To-Weld Jobs.
312-16
The most important factor is the high rate of
heat conductivity of copper, making
preheating of heavy 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 great number of
electrodes used for specialized industrial
purposes which are not of particular interest
for everyday general work. These include
some low hydrogen types for high tensile
steel, cellulose types for welding large
diameter pipes, etc. The range of electrodes
dealt with in this publication will cover the vast
majority of applications likely to be
encountered; are all easy to use and all will
work on even the most basic of welding
machines.
Comments
Ideal electrodes for all general purpose work. Features
include out standing operator appeal, easy arc starting and
low spatter.
All positional electrode for use on mild and galvanized steel
furniture, plates, fences, gates, pipes and tanks etc.
Especially suitable for vertical-down welding.
Suitable for joining all cast irons except white cast iron.
High corrosion resistance. Ideal for dairy work, etc. On
stainless steels.
Easy to use electrode for marine fittings, water taps and
valves, water trough float arms, etc. Also for joining copper to
steel and for bronze overlays on steel shafts.
It will weld most problematical jobs such as springs, shafts,
broken joins mild steel to stainless and alloy steels. Not
suitable for Aluminum.
Table 4-13: Types of Electrodes
4-14
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
SECTION 5:
SERVICE
5.01 Routine Maintenance
The only routine maintenance required for the power
supply is a thorough cleaning and inspection, with
the frequency depending on the usage and the
operating environment.
!
WARNING
Disconnect primary power at the source
before opening the enclosure. Wait at least
two minutes before opening the enclosure
to allow the primary capacitors to
discharge.
5.02 Basic Troubleshooting
!
WARNING
There are extremely dangerous voltages
and power levels present inside this
product. Do not attempt to open or repair
unless you are an Accredited CIGWELD
Service Agent and you have had training
in power measurements and
troubleshooting techniques.
If major complex subassemblies are faulty, then the
Welding Power Source must be returned to an
Accredited CIGWELD Service Agent for repair.
The basic level of troubleshooting is that which can
be performed without special equipment or
knowledge.
To clean the unit, open the enclosure and use a
vacuum cleaner to remove any accumulated dirt and
dust. The unit should also be wiped clean, if necessary;
with solvents that are recommended for cleaning
electrical apparatus.
CAUTION
Do not blow air into the power supply
during cleaning. Blowing air into the unit
can cause metal particles to interfere with
sensitive electrical components and cause
damage to the unit.
June 30, 2008
5-1
TRANSTIG 300 Pi
SERVICE MANUAL
5.03 Maintenance Diagram
Warning!
Disconnect input power before maintaining.
Maintain more often if used under severe conditions
Each Use
Visual check of torch
Consumable parts
Visual check of
regulator and pressure
Weekly
Visually inspect the torch
body and consumables
Visually inspect the
cables and leads.
Replace as needed
3 Months
Replace all
broken parts
Clean
exterior
of power supply
6 Months
Bring the unit to an authorized
CIGWELD Service Provider
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.
Art # A-07681_AC
5-2
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
5.04 TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper
welding technique.
1
2
3
4
5
Description
Excessive bead build-up or poor
penetration or poor fusion at edges
of weld
Weld bead too wide and flat or
undercut at edges of weld or
excessive burn through
Weld bead too small or insufficient
penetration or ripples in bead are
widely spaced apart
Weld bead too wide or excessive
bead build-up or excessive
penetration in butt joint
Uneven leg length in fillet joint
Possible Cause
Welding current is too low
Welding current is too high
Remedy
Increase weld current
and/or faulty joint
preparation
Decrease weld current
Travel speed too fast
Reduce travel speed
Travel speed too slow
Increase travel speed
Wrong placement of filler
rod
6 Electrode melts when arc is struck
Electrode is connected to
the '+' terminal
7 Dirty weld pool
A Electrode contaminated
through contact with work
piece or filler rod material
B Gas contaminated with air
8 Electrode melts or oxidizes when
an arc is struck
9 Poor weld finish
Re-position filler rod
A
B
A No gas flowing to welding
region
A
B Torch is clogged with dust
C Gas hose is cut
D Gas passage contains
impurities
B
C
D
E Gas regulator turned off
F Torch valve is turned off
G The electrode is too small
for the welding current
E
F
G
Inadequate shielding gas
Connect the electrode to
the '-' terminal
Clean the electrode by
grinding off the
contaminates
Check gas lines for cuts
and loose fitting or
change gas cylinder
Check the gas lines for
kinks or breaks and gas
cylinder contents
Clean torch
Replace gas hose
Disconnect gas hose from
torch then raise gas
pressure and blow out
impurities
Turn on
Turn on
Increase electrode
diameter or reduce the
welding current
Increase gas flow or
check gas line for gas
flow problems
Table 5-1: TIG Welding Problems
June 30, 2008
5-3
TRANSTIG 300 Pi
SERVICE MANUAL
Description
10 Arc flutters during TIG welding
Possible Cause
Remedy
A Tungsten electrode is too
A Select the right size
large for the welding current electrode. Refer to Basic
TIG Welding Guide
B Absence of oxides in the
B Refer to Basic TIG
weld pool
Welding Guide for ways to
reduce arc flutter
11 Welding arc cannot be established A Work clamp is not
A Connect the work clamp
connected to the work piece to the work piece or
or the work/torch leads are
connect the work/torch
not connected to the right
leads to the right welding
terminals
terminals
B Torch lead is disconnected B Connect it to the '-'
terminal
C Select the right flow rate,
C Gas flow incorrectly set,
change cylinders or turn
cylinder empty or the torch
torch valve on
valve is off
12 Arc start is not smooth
A Tungsten electrode is too
A Select the right size
large for the welding current electrode. Refer to Basic
TIG Welding Guide
B Select the right size
B The wrong electrode is
electrode. Refer to Basic
being used for the welding
TIG Welding Guide
job
C Gas flow rate is too high
C Select the correct rate for
the welding job. Refer to
Basic TIG Welding Guide
D Incorrect shielding gas is
D Select the right shielding
being used
gas. Refer to Basic TIG
Welding Guide
E Poor work clamp
E Improve connection to
connection to work piece
work piece
Table 5-1 (continued): TIG Welding Problems
5-4
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
5.05 Stick Welding Problems
Description
Possible Cause
1 Gas pockets or voids in weld metal A Electrodes are damp
(Porosity)
B Welding current is too high
C Surface impurities such as
oil, grease, paint, etc
2 Crack occurring in weld metal soon A Rigidity of joint
after solidification commences
3 A gap is left by failure of the weld
metal to fill the root of the weld
Remedy
A Dry electrodes before use
B Reduce welding current
C Clean joint before welding
A Redesign to relieve weld
joint of severe stresses or
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
A Welding current is too low A Increase welding current
B Electrode too large for joint B Use smaller diameter
electrode
C Insufficient gap
C Allow wider gap
D Incorrect sequence
D Use correct build-up
sequence
Table 5-2: STICK Welding Problems
Art # A-05866_AB
Incorrect Sequence
Insufficient Gap
Figure 5-1: Example of Insufficient Gap or Incorrect Sequence
June 30, 2008
5-5
TRANSTIG 300 Pi
SERVICE MANUAL
Description
Possible Cause
4 Portions of the weld run do not
A Small electrodes used on
fuse to the surface of the metal or
heavy cold plate
edge of the joint
B Welding current is too low
C Wrong electrode angle
Remedy
A Use larger electrodes and
preheat the plate
B Increase welding current
C Adjust angle so the
welding arc is directed
more into the base metal
D Travel speed of electrode is D Reduce travel speed of
too high
electrode
E Scale or dirt on joint surface E Clean surface before
welding
Table 5-2 (continued): STICK Welding Problems
Lack of fusion caused by dirt,
electrode angle incorrect,
rate of travel too high
Art # A-05867_AB
Lack of inter-run fusion
Lack of side fusion,
scale dirt, small electrode,
amperage too low
Lack of root fusion
Figure 5-2: Example of Lack of Fusion
5-6
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
Description
5 Non-metallic particles are trapped
in the weld metal (slag inclusion)
Possible Cause
Remedy
A Non-metallic particles may A If bad undercut is
be trapped in undercut from present, clean slag out
previous run
and cover with a run from
a smaller diameter
electrode
B Allow for adequate
B Joint preparation too
restricted
penetration and room for
cleaning out the slag
C Irregular deposits allow slag C If very bad, chip or grind
to be trapped
out irregularities
D Use smaller electrode with
D Lack of penetration with
sufficient current to give
slag trapped beneath weld
adequate penetration. Use
bead
suitable tools to remove
all slag from corners
E Rust or mill scale is
E Clean joint before welding
preventing full fusion
F Wrong electrode for position F Use electrodes designed
in which welding is done
for position in which
welding is done,
otherwise proper control
of slag is difficult
Table 5-2 (continued): STICK Welding Problems
Art # A-05868
Slag trapped in
undercut
Not cleaned, or incorrect electrode
Slag trapped in root
Figure 5-3: Examples of Slag Inclusion
June 30, 2008
5-7
TRANSTIG 300 Pi
SERVICE MANUAL
5.06 Power Source Problems
Description
1 The welding arc cannot be
established
2
3
4
5
6
Possible Cause
Remedy
A The Primary supply voltage A Switch ON the Primary
has not been switched ON
supply voltage
B The Welding Power Source B Switch ON the Welding
switch is switched OFF
Power Source
C Loose connections
C Have an Accredited
internally
Cigweld Service Provider
repair the connection
Maximum output welding current
Defective control circuit
Have an Accredited
cannot be achieved with nominal
Cigweld Service Provider
Mains supply voltage
inspect then repair the
welder
Welding current reduces when
Poor work lead connection
Ensure that the work lead
welding
to the work piece
has a positive electrical
connection to the work
piece
No gas flow when the torch trigger A Gas hose is cut
A Replace gas hose
switch is depressed
B Gas passage contains
B Disconnect gas hose from
impurities
the rear of Power Source
then raise gas pressure
and blow out impurities
C Gas regulator turned off
C Turn gas regulator on
Gas flow won't shut off
A Weld Mode (STD, SLOPE,
A Strike an arc to complete
REPEAT or SPOT ) was
the weld cycle OR switch
changed before POSTmachine off then on to
FLOW gas time had finished reset solenoid valve
sequence
B Gas valve is faulty
B Have an Accredited
Cigweld Service Provider
replace gas valve
C Gas valve jammed open
C Have an Accredited
Cigweld Service Provider
repair or replace gas valve
D POST-FLOW control is set D Reduce POST-FLOW time
to 60 sec.
The TIG electrode has been
Do not change Weld
The Weld Process Mode
contaminated due to the gas flow
Process Mode before the
(STICK, HF TIG or LIFT TIG )
shutting off before the
was changed before POSTPOST-FLOW gas time had
programmed POST-FLOW time has FLOW gas time had finished
finished
elapsed
Table 5-3: Power Source Problems
5-8
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
5.07 Power Source Error Codes
Description
1 E01 error code
displayed.
Temperature
sensor TH1
(protects IGBTs)
is greater than
80°C for about 1
second.
2 E02 error code
displayed.
Temperature
sensor TH2
(protects IGBTs)
is greater than
90°C for about 1
second.
3 E03 error code
displayed.
Primary (input)
current too high.
Possible Cause
Remedy
A The Welding Power
A Let Power Source cool
Source's duty cycle has
down then keep within its
been exceeded.
duty cycle.
B Fan ceases to operate. B Have an Accredited
Cigweld Service Provider
investigate.
C Air flow is restricted by C Unblock vents then let
vents being blocked.
Power Source cool down.
A The Welding Power
A Let Power Source cool
Source's duty cycle has
down then keep within its
been exceeded.
duty cycle.
B Fan ceases to operate. B Have an Accredited
Cigweld Service Provider
investigate.
C Air flow is restricted by C Unblock vents then let
vents being blocked.
Power Source cool down.
A Primary current too high A Reduce length of welding
because welding arc is
arc
too long
B Mains supply voltage is B Have an Accredited
more than 10% below
Cigweld Service Provider
nominal voltage
or a qualified electrician
check for low Mains
voltage.
4 E11 error code
Primary supply voltage
Have an Accredited
displayed.
is greater than the
Cigweld Service Provider
Over Primary
nominal voltage plus
or a qualified electrician
supply (input)
10%.
check the Primary
voltage at primary
voltage.
capacitors is
exceeded for one
second.
5 E12 error code
Mains supply voltage is
Have an Accredited
displayed.
down to a dangerously
Cigweld Service Provider
Under mains
low level.
or a qualified electrician
supply (input)
check the Mains voltage.
voltage warning
Have an Accredited
primary
Cigweld Service Provider
capacitors is
or a qualified electrician
reduced for one
check the primary cable &
second.
fuses.
Remarks
Weld current
ceases. Buzzer
sounds constantly.
E01 resets when
TH1 decreases to
70°C for about 30
seconds.
Weld current
ceases. Buzzer
sounds constantly.
E02 resets when
TH2 decreases to
70°C for about 30
seconds.
Weld current
ceases. Buzzer
sounds constantly.
Switch machine off
then on to reset
E03 error.
Weld current
ceases. Buzzer
sounds constantly.
Error code E11
automatically will
reset when the
voltage reduces.
Weld current
ceases. Buzzer
sounds constantly.
Error code E12 will
automatically reset
when the voltage
increases.
Table 5-4: Power Source Error Codes
June 30, 2008
5-9
TRANSTIG 300 Pi
Description
6 E14 error code
displayed.
Under mains
supply (input)
voltage warning
primary
capacitors is
reduced for one
second.
7 E81 error code
displayed.
Wrong Primary
supply (input)
voltage
connected.
8 E82 error code
displayed.
Link switch plug
not connected.
SERVICE MANUAL
Possible Cause
Mains supply voltage is
less than the nominal
operating voltage plus
10%.
Remedy
Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the Mains voltage.
When 3 phase machine
is first turned on with
the wrong Primary
supply (input) voltage
connected.
No weld current is
Have an Accredited
Cigweld Service Provider available. Buzzer
check the Mains voltage. sounds constantly.
Switch machine off.
Link switch plug not
connected.
Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the connector plug
on input PCB.
Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the connector plug
on the input PCB and the
Mains voltage.
The Primary supply
9 E83 error code
(input) voltage
displayed.
fluctuates and is not
CPU checks
stable.
mains supply
(input) voltage
when the on/off
switch on rear
panel of machine
is turned ON.
Memory chip (EEPROM)
Have an Accredited
10 E93 error code
error.
Cigweld Service Provider
displayed.
or a qualified electrician
Memory chip
check the control PCB.
(EEPROM) on
control PCB can
not read/write
weld parameters.
Have an Accredited
The Welding Power
11 E94 error code
Cigweld Service Provider
Source's temperature
displayed.
check or replace the
sensors have
Temperature
temperature sensors.
malfunctioned.
sensor TH1 for
IGBTs is an open
circuit.
12 E99 error code A Main on/off switch on
A Turn on/off switch on.
displayed.
machine has been
Mains supply
turned off.
(input) voltage
B Have an Accredited
B Mains supply (input)
has been turned
Cigweld Service Provider
voltage has been turned
off, but control
or a qualified electrician
off.
circuit has power
check the Main voltage
from the primary
and fuses.
capacitors.
5-10
Remarks
Weld current
available. Buzzer
sounds
intermittently. Error
code E14 will
automatically reset
when the voltage
increases.
No weld current is
available. Buzzer
sounds constantly.
Switch machine off.
No weld current is
available. Buzzer
sounds constantly.
Switch machine off
then on to reset
E83 error.
Weld current is
ceases. Buzzer
sounds constantly.
Switch machine off.
Weld current
ceases. Buzzer
sounds constantly.
Switch machine off.
Weld current
ceases. Buzzer
sounds constantly.
Must switch
machine off then
on to reset E99
error.
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
5.08 Voltage Reduction Device (VRD)
1. VRD Specification:
Description
VRD Open Circuit Voltage
VRD Resistance
VRD Turn OFF Time
Transtig 300 Pi
Notes
15.3 to 19.8V Open circuit voltage between
welding terminals.
148 to 193 ohms The required resistance between
welding terminals to turn ON the
welding power.
0.2 to 0.3
The time taken to turn OFF the
seconds
welding power once the welding
current has stopped.
Table 5-5: VRD Specification
2. VRD Maintenance:
Routine inspection and testing (power source):
An inspection of the power source, an insulation
resistance test and an earth resistance test shall be
carried out.
a) For transportable 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 transportable power source is any
equipment that is not permanently
connected and fixed in the position in
which it is operated.
June 30, 2008
In addition to the above tests and specifically in
relation to the VRD fitted to this machine, the following
periodic tests should also be conducted by an
accredited CIGWELD service provider.
Description
VRD Open
Circuit Voltage
VRD Turn ON
Resistance
VRD Turn OFF
Time
Required Parameters
Less than 20V; at Vin=240V
Less than 200 ohms
Less than 0.3 seconds
Table 5-6: Periodic Tests
If this equipment is used in a hazardous location or
environments with a high risk of electrocution then
the above tests should be carried out prior to entering
this location.
5-11
TRANSTIG 300 Pi
SERVICE MANUAL
NOTES
5-12
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
6 ADVANCED TROUBLESHOOTING
ADVANCED TROUBLESHOOTING
If you are here, all of the troubleshooting suggestions in Section 8-Basic Troubleshooting have
either failed to resolve the faulty operation or have
indicated that one or more of the subsystems
within the power supply are defective. This section
provides the information needed to take live measurements on the various subsystems within the
power supply, and replace those subsystems that
prove faulty.
CAUTION
Troubleshooting and repairing this unit is a process, which should be undertaken only by those
familiar with high voltage/high power electronic
equipment.
6.01 System-Level Fault Isolation
If none of the suggestions provided in Section 8
have solved the problem or corrected the faulty
operation, the next step is to isolate one or more of
the internal subassemblies that may be defective.
CAUTION
Perform all steps in each procedure, in sequence.
Skipping portions of procedures, or performing
steps out of sequence can result in damage to the
unit, and possible injury, or worse, to the operator.
6.1.1 Opening the Enclosure
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have training in
power electronics, measurement and troubleshooting techniques.
Under no circumstances are field repairs to be
attempted on printed circuit boards or other subassemblies of this unit. Evidence of unauthorized
repairs will void the factory warranty. If a subassembly is found to be defective by executing any of
the procedures in this Service Manual, the subassembly should be replaced with a new one. The
faulty subassembly should then be returned to
Thermal Arc through established procedures.
WARNING
Disconnect primary power at the source before disassembling the power supply. Frequently review
the "Important Safety Precautions" in section 1.02.
Be sure the operator is equipped with proper
gloves, clothing and eye and ear protection. Make
sure no part of the operator's body comes into contact with the work piece or any internal components
while the unit is activated.
June 30, 2008
1) Confirm that the switch of power supply and
the switch on switchboard (distribution panel)
are all OFF.
Figure 6-1: Switch OFF
CAUTION
The capacitors inside the power supply will slowly
discharged after you turn off the switch of the
power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete.
6-1
TRANSTIG 300 Pi
SERVICE MANUAL
ADVANCED TROUBLESHOOTING
2) Remove all screws and nuts on the side covers.
4) Pull the front panel slightly forward and pull the
rear panel slightly backward. The interlocking
hooks of the side case covers can now be disengaged from the front and rear panels.
Figure 6-2: Remove screws
3) Loosen the screws on the front panel and the
rear panel by turning them approximately two
turns CCW.
Figure 6-4: Loosen front and rear panels
5) Remove the side covers.
Figure 6-3: Loosen screws
NOTE
DO NOT remove the screws completely.
Figure 6-5: Remove Side covers
6-2
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
ADVANCED TROUBLESHOOTING
6) Remove protection cover sheet by removing
the plastic tabs.
6.2.1 E01 "Over-Temperature at
the primary side"
Cause
Occurs when an over-temperature condition of the
primary IGBT is detected.
Verification/Remedy
a) Unit may be in thermal shutdown mode.
Review the rated duty cycle of the unit per
section 3.8. Exceeding the duty cycle can
damage the unit and void the warranty. Refer
also to section 1.6 for additional information.
b) Verify the ventilating condition.
Figure 6-6: Remove PCB cover
NOTE
When you re-assemble the parts, conduct the
above process backwards.
6.02 Verification and Remedy
to the Indicated Error Codes
NOTE
The capacitors inside the power supply will slowly
discharged after you turn off the switch of the
power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete and then remove the cases to
continue your inspection and repair (or maintenance) inside the power supply. As for the removal
and installation of the case, refer to section 6.1.1.
NOTE
During the "Verification/Remedy" procedures
below, follow the alphabetical sequence (a, b, c...)
and proceed with your verification and confirmation.
Maintain a clear and unobstructed distance
of more than 30cm in the front and more that
50cm in the rear of the unit for ventilation purposes.
Verify and maintain clean, dust free, front and
rear airflow paths. Cleaning and removing
dust from the front and rear panels once
every six months in a normal working environment is recommended. Extremely dusty
environments will require more frequent
cleanings.
c) Verify the operation of the cooling fan, FAN1,
and replace it if necessary.
Verify the condition of FAN1. Verify that there
are no broken or cracked fan blades and that
FAN1 is not producing any abnormal sounds.
If broken or cracked FAN1 blades, or abnormal sounds are emanating from FAN1,
replace FAN1.
Verify the operation of the cooling fan and
replace it if the condition of FAN1 is inactive.
Follow the instruction in section.
Refer to section 7.3.21 for the replacement
of FAN1.
Refer to section 6.5.3 for additional FAN1
tests.
d) Replace PCB6 (WK-5549).
NOTE
After you confirm and replace all spare parts and
components, confirm that there are no damaged
harnesses or connectors, uninstalled or loose
screws.
June 30, 2008
Refer to section 7.3.6 for the replacement of
PCB6.
6-3
TRANSTIG 300 Pi
SERVICE MANUAL
ADVANCED TROUBLESHOOTING
6.2.2 E02 "Over-Temperature at
the secondary side"
Cause
6.2.3 E03 "Transformer
Over-Current Failure"
Cause
Occurs when an over-temperature condition of the
secondary IGBT and diode are detected.
Occurs when excessive current is detected flowing into the primary side of the main transformer.
Verification/Remedy
Verification/Remedy
a) Unit may be in thermal shutdown mode.
a) Confirm the operation of the machine within
the rated specification.
Review the rated duty cycle of the unit per
section 3.8. Exceeding the duty cycle can
damage the unit and void the warranty.
b) Verify the ventilating condition.
Maintain a clear and unobstructed distance
of more than 30cm in the front and more that
50cm in the rear of the unit for ventilation purposes.
Verify and maintain clean, dust free, front and
rear airflow paths. Cleaning and removing
dust from the front and rear panels once
every six months in a normal working environment is recommended. Extremely dusty
environments will require more frequent
cleanings.
c) Verify the operation of the cooling fan, FAN1,
and replace it if necessary.
Refer to the specification data sheet in Section 3.9.
b) Verify the secondary diode (D2, D4, D5 and
D7).
Refer to section 6.5.6 for the test and
replacement of D2, D4, D5 and D7.
c) Replace the Hall CT, HCT1.
Refer to section 7.3.29 for the replacement
of HF.UNIT 1.
NOTE
Pay special attention to installed direction of HCT1.
The Hall CT will not function properly if installed in
the incorrect direction.
Refer to section 7.3.27 for the replacement
of HCT1.
Verify the condition of FAN1. Verify that there
are no broken or cracked fan blades and that
FAN1 is not producing any abnormal sounds.
d) Verify the H.F. unit (HF. UNIT1).
If broken or cracked FAN1 blades, or abnormal sounds are emanating from FAN1,
replace FAN1.
(300 Pi & 300 AC/DC only)
Refer to section 7.3.26 for the replacement
of HF.UNIT 1.
Verify the operation of the cooling fan and
replace it if the condition of FAN1 is inactive.
Follow the instruction in section.
Refer to section 7.3.21 for the replacement
of FAN1.
Refer to section 6.5.3 for addition FAN1
tests.
d) Replace PCB6 (WK-5549).
Refer to section 7.3.6 for the replacement of
PCB6.
6-4
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
ADVANCED TROUBLESHOOTING
6.2.4 E04 "Torch Cable Failure"
Cause
6.2.6 E12 "Main Supply Under Voltage"
Cause
The combined length of the torch cable and the
work cable is too long.
Main supply voltage occurs at about 150V or less.
Verification/Remedy
Verification/Remedy
a) Verify the rated duty cycle of the torch/work
cable and the power supply.
a) Verify main supply voltage.
Only use appropriate sized torch cables
(length and capacity). The recommended
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 3.8 for the recommended
duty cycle.
b) Replace PCB6 (WK-5549)
Refer to section 7.3.6 for the replacement of
PCB6.
6.2.5 E11 "Main Supply Over Voltage"
Cause
Main supply voltage occurs in about 275V or
more.
Verification/Remedy
a) Verify main supply voltage.
Perform what is described in a section of
"Verification of the Power Supply Voltage".
Refer section 6.5.2.
b) Replace PCB4 (WK-4819)
Verify PCB4 (WK-4819) and replace it if necessary. Refer to section 7.3.4.
Perform what is described in a section of
"Verification of the Power Supply Voltage".
Refer to section 6.5.2
b) Replace PCB4 (WK-4819)
Replace PCB4, when abnormalities occur,
even if carries out the above-mentioned verifications. Refer to section 7.3.4.
6.2.7 E81 "Wrong Main Supply
Voltage"
Cause
The detection circuitry of main supply voltage is
abnormality.
Verification/Remedy
a) Verify main supply voltage.
Perform what is described in a section of
"Verification of the Power Supply Voltage".
Refer to section 6.5.2.
b) Confirm a secure connection of the harness
wired between CN2 on PCB3 (WK-5548) and
CN1 on PCB21 (WK-4917)
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken connectors or damaged wiring harness.
When the PCB fixed screw is loosening, it
fastens certainly.
c) Verify PCB4 (WK-4819) and replace it if necessary
Check whether there are any abnormalities
on the appearance of PCB4.
Replace PCB4. Refer to section 7.3.4.
June 30, 2008
6-5
TRANSTIG 300 Pi
SERVICE MANUAL
ADVANCED TROUBLESHOOTING
6.2.8 E82 "Rated Voltage Selection
Circuit abnormality"
Cause
Rated voltage selection circuit inside the Welding
Power Source is not functioning properly.
c) Verify PCB4 (WK-4819) and replace it if necessary.
Check whether there are any abnormalities
on the appearance of PCB4.
Replace PCB4. Refer to section 7.3.4.
6.2.10 E85 "Pre-charge abnormality"
Verification/Remedy
a) Verify the wiring harness and connection of
CN4 on PCB4 (WK-4819).
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken connectors or damaged wiring harness.
When the PCB fixed screw is loosening, it
fastens certainly.
b) Verify PCB4 (WK-4819) and replace it if necessary.
Check whether there are any abnormalities
on the appearance of PCB4.
Replace PCB4. Refer to section 7.3.4.
6.2.9 E83 "Abnormalities in Mains
Supply Voltage Detection"
Cause
Abnormalities, such as an input voltage detection
circuit.
Cause
Due to a malfunction inside the Welding Power
Source, primary capacitors are not charging correctly.
Verification/Remedy
a) Verify the connection PCB2 (WK-5597) and
the rectified output voltage of the rectifier.
Verify the connection between CN2 on PCB2
and CN3 on PCB3.
Confirm whether there is any breakage
(blown, burnt, cracked, etc.) of R18 on PCB2.
Perform what is described in a section of
"Verification of the Power Supply Voltage".
Refer to section 6.5.2.
b) Verify the primary diode (D1).
Verify D1. Refer to section 6.5.5.
Replace D1. Refer to section 7.3.28.
c) Verify the primary IGBT (Q1-Q24).
Verify IGBT. Refer to section 6.5.7.
Replace IGBT. Refer to section 7.3.7, 7.3.8.
Verification/Remedy
a) Verify main supply voltage.
Perform what is described in a section of
"Verification of the Power Supply Voltage".
Refer to section 6.5.2.
d) Replace PCB2 (WK-5597) and PCB4
(WK-4819).
Replace PCB2 and PCB4, when abnormalities
occur, even if you carry out the above-mentioned
verifications. Refer to section 7.3.2, 7.3.4.
b) Confirm a secure connection of the harness
wired between CN2 on PCB3 (WK-5548) and
CN1 on PCB21 (WK-4917).
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken connectors or damaged wiring harness.
6-6
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
ADVANCED TROUBLESHOOTING
6.2.11 E94 "Thermistor malfunction"
Cause
Thermistors for detecting temperature of internal
components have malfunctioned.
Verification/Remedy
a) Confirm a secure connection of the harness
wired between CN8-9 on PCB6 (WK-5549)
and Thermistors (TH1, TH2).
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken connectors or damaged wiring harness.
b) Replace thermistors (TH1, TH2).
Refer to section 7.3.19, 7.3.20.
c) Replace PCB6 (WK-5549).
Refer to section 7.3.6.
6.2.12 E99 "Initial Power Receiving"
Cause
Occurs when the initial AC power received signal
has not reached the CPU. This error occurs normally during the power "OFF" sequence of the
unit.
Verification/Remedy
a) Confirm a secure connection of the harness
wired between CN1 on PCB21 (WK-4917) and
CN2 on PCB3 (WK-5548).
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken connectors or damaged wiring harness.
b) Verify PCB4 (WK-4819) and replace it if necessary.
Confirm a secure connection of all the harnesses wired to PCB3 and PCB4.
Replace PCB4. Refer to section 7.3.4.
c) Replace PCB6 (WK-5549).
Refer to section 7.3.6.
6.03 Verification and Remedy to
Failures without Indication
Codes
6.3.1 "Cooling Fan (FAN1) Failure"
(Fan is not rotating.)
Cause
Occurs when the cooling fan (FAN1) is defective,
damaged or the driving voltage is incorrect.
Verification/Remedy
a) Verify the cooling fan (FAN1).
Inspect the condition of the fan blades and all
peripheral parts. Clean the fan blades and all
peripheral parts if covered with dust. Cleaning and removing dust from the fan blades
once every 6 months in a normal environment is recommended. Extremely dusty
environments will require more frequent
cleanings.
Verify that there are no wiring harnesses
entangled inside the fan, confirm that the harnesses do not have any brakes in the wire or
damaged connectors.
Replace wiring harnesses if you find any broken connectors or damaged wiring harnesses.
Replace the fan if there are any broken,
cracked or missing fan blades.
Refer to section 7.3.21.
b) Verify the wiring harness between the cooling
fan (FAN1) and CN11 on PCB3 (WK-5548).
Confirm a secure connection of the harness
to CN11 on PCB3.
c) Verify the drive circuitry of the cooling fan
(FAN1) on PCB3.
Verify the drive circuitry of the cooling fan
(FAN1) on PCB3.
Refer to section 6.5.3.
Replace PCB3 if necessary.
Refer to section 7.3.3.
June 30, 2008
6-7
TRANSTIG 300 Pi
SERVICE MANUAL
ADVANCED TROUBLESHOOTING
6.3.3 "No Weld Output"
When in High Frequency TIG (HF TIG) mode, if the
High Frequency is not generated (present), refer to
"High Frequency Output Failure". Refer to page
6-9.
Cause
Occurs when the remote connector (CON1) or
associated circuitry is defective, damaged, or the
TIG torch cable is defective.
Verification/Remedy
Caution
Read and understand this entire section before
proceeding. Extreme personal harm and test
equipment damage will occur if the procedures are
not performed accurately.
a) Verify the remote connector (CON1).
(Applies to LIFT TIG and High Frequency TIG
(HF TIG) mode.)
Confirm a secure between the remote connector (CON1) and the TIG torch cable.
Confirm a secure connection of the harness
and the connections between the remote
connector (CON1) and PCB7 (WK-5550) are
all correct and there are no open circuits.
Contact the manufacture if you find any broken connectors or damaged wiring harnesses.
Confirm the proper pin-outs of the remote
connector at the TIG Torch side. (Refer to
the Operating Manual.)
Confirm that there is no open circuit on the
remote connector at TIG Torch side.
In equipment for remote control use, confirm
the pin specification of a connector. (Refer to
the Operating Manual.)
b) Verify the condition and connections of the
welding cable, the stick rod holders and the
ground clamp. (Applies to all welding modes.)
Confirm a secure connection of the welding
cable, stick rod holders, ground clamp and
dense connectors and there are no open circuits.
6-8
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
ADVANCED TROUBLESHOOTING
c) Verify the no-load voltage (OCV).
(Applies to STICK, High Frequency TIG (HF
TIG) mode.)
Refer to the section "Verification of No-load
voltage (OCV)" in section 6.5.9.
If performing the "No-Load Voltage Failure"
procedure does not rectify the failure, perform the following tests in the sequence
below. Replace any defective components
found.
1. Secondary diode (D2, D4, D5 and D7).
Verification. Refer to section 6.5.6.
Replacement. Refer to section 7.3.29.
2. Reactor (FCH1)
Replacement. Refer to section 7.3.18.
3. PCB14 (T1)
Replacement. Refer to section 7.3.11.
4. PCB8-PCB11 (Q1~Q24)
Verification. Refer to section 6.5.7.
Replacement. Refer to section 7.3.7,
7.3.8.
5. Hall C.T. (HCT1)
Replacement. Refer to section 7.3.27.
d) Replacement. Refer to section 7.3.
6.3.4 "Operating Panel Failure"
(LED's do not light properly
or welding setting cannot be
established.)
Cause
Occurs when there is a connection failure among
PCB6 (WK-5549), PCB12 (WK-5527) and PCB6
or PCB12 are defective.
Verification/Remedy
a) Verify the harness connection between CN21
on PCB6 (WK-5549) and CN2 on PCB12
(WK-5527).
Confirm a secure connection of the harness
and the connections between CN21 on PCB6
(WK-5549) and CN2 on PCB12 (WK-5527).
Contact the manufacture if you find any broken connectors or damaged wiring harnesses.
June 30, 2008
b) Verify the connection between PCB6
(WK-5549) and PCB12 (WK-5527).
c) Replace PCB6 (WK-5549) and PCB12
(WK-5527).
Refer to section 7.3.6, 7.3.9.
d) Verify the connection between PCB5
(WK-5551) and PCB6 (WK-5549).
e) Replace PCB5 (WK-5551) and PCB6
(WK-5549).
Refer to section 7.3.5, 7.3.6.1
6.3.5 "High Frequency Output Failure" (Unit does not generate
High Frequency.)
Cause
Occurs when the HF. unit (HF UNIT1) is defective
or blown.
Verification/Remedy
Caution
Read and understand this entire section before
proceeding. Extreme personal harm and test
equipment damage will occur if the procedures are
not performed accurately. The unit will generate a
High Voltage component that can cause extreme
personal harm and test equipment damage.Capacitors installed inside the Welding Power Source are
electrically charged for a while after the Mains ON/
OFF switch or distribution panel switch has been
turned off. Before inspecting the inside of the Welding Power Source, leave it for about 5 min. after
switching off power for discharging the capacitors,
and then remove the top and side panels.
a) Verify the connection between High Frequency
(HF UNIT1) and Coupling Coil (CC1).
Verify the connection between the HF UNIT1
and CC1; confirm that the quick-disconnect
terminals are inserted onto the terminals of
HF UNIT1 (TB5-TB6) correctly and completely.
Confirm there are no short circuits, burnt or
broken wires at CC1.
Replace CC1.
Refer to section 7.3.17.
6-9
TRANSTIG 300 Pi
SERVICE MANUAL
ADVANCED TROUBLESHOOTING
b) Verify the connection between High Frequency
(HF UNIT1) and the current limiting resistor
(R2).
Verify the connection between HF UNIT1 and
the current limiting resistor (R2), confirm that
the quick-disconnect terminals are inserted
onto the terminals of HF UNIT1 (TB3-TB4)
correctly and completely.
Confirm there are no short circuits, burnt or
broken wires between the HF UNIT1 and the
current limiting resistor (R2).
c) Verify the connection between the terminals
between AC1-AC2 (TB1-TB2).
Verify the connection between AC1-AC2,
confirm that the quick-disconnect terminals
are inserted onto the terminals of HF UNIT1
correctly and completely.
Confirm there are no short circuits, burnt or
broken wires between AC1 and AC2.
d) Verify and replace the Gap (GAP) of the High
Frequency (HF UNIT1).
Confirm that the GAP is connected to HF
UNIT1 correctly and completely.
Confirm there is no dust or foreign debris
between the space of the GAP.
If there are any abnormalities observed with
the GAP, replace the GAP.
A setup of a gap is 1.0mm.
In the case of a gap 1.0mm or more, high frequency voltage and a period increase.
In the case of a gap 1.0mm or less, high frequency voltage and a period decrease.
6.04 Fault Isolation Tests
6.4.1 Preparation
The following initial conditions must be met
prior to starting any of the procedures in this
section.
1) Connect the appropriate input voltage.
(Check the name plate on the rear of the
power supply for the proper input voltage.)
NOTE
Operate at all input voltages as noted on the nameplate on the rear panel when testing the power supply.
2) Remove the side covers. Refer to the section 6-01.
3) Close primary power source wall disconnect switch or circuit breaker.
4) Place power supply MAIN CIRCUIT
SWITCH (S1) on rear of the unit in the ON
position.
WARNING
Dangerous voltage and power levels are present
inside this unit. Be sure the operator is equipped
with proper gloves, clothing and eye and ear protection. Make sure no part of the operator's body
comes into contact with the work piece or any internal components while the unit is activated.
e) Verify and replace the Current limiting Resistor
(R6) on HF UNIT1.
If R6 is defective (blown, burnt, cracked,
etc.), replace R6.
Refer to section 7.3.15.
f) Replace the High Frequency (HF UNIT1).
Refer to section 7.3.26.
g) Replace PCB3 (WK-5548).
Refer to section 7.3.3.
6-10
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
ADVANCED TROUBLESHOOTI
6.05 Verification of the Power
Input Circuitry
? Using an AC voltmeter, measure between
the points U2 and V2 on the input switch, S1.
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
section 6.4.1 " Preparation" on page 6-10.
6.5.1 Verification of the AC Input
Voltage using an AC voltmeter.
1) Verify input voltage (Phase-to Phase) using an
AC voltmeter. (The capability of the voltmeter
should be more than 600VAC). Measure the
point between lines U1 and V1 on the input
switch, S1.Measure the point between lines U1
and W1 on the input switch, S1. Measure the
point between lines V1 and W1 on the input
switch, S1. The location of points U1, V1 and
W1on switch S1 are indicated in Figure 6-7.
When using a single-phase connection, the
voltage can be verified only between U1 and
V1.
U2
S1
? Using an AC voltmeter, measure between
the points U2 and W2 on the input switch, S1.
? Using an AC voltmeter, measure between
the points V2 and W2 on the input switch, S1.
The location of points U2, V2 and W2 on
switch S1are indicated in Figure 6-7. When
using a single-phase connection, the voltage
can be verified only between U2 and V2.
4) If this voltage is out of the operating range,
which is ±10% (187 ? 253/414 ? 506 VAC) of
the rated voltage (208, 230/460V), replace S1
following the process in section 7.3.23.
5) Verify the rectified output voltage of the input
diode, D1 using a DC voltmeter. (The capability
of the voltmeter should be more than
1000VDC.) Using a DC voltmeter, measure
between the points 1 (P) [+] and 2 (N) [-] on D1.
Points 1 (P) and 2 (N) are on D1. See Figure
6-8. The measured voltage should be approximately 1.4 times larger than input voltage measured in #1 above. Replace diode D1 if the
calculated measurement is not within the coresponding range (260 ? 360/580 ? 720 VDC)
following the process in section 7.3.28.
V2
W2
U1
3) Verify input voltage after the input switch (S1)
using an AC voltmeter. (The capability of the
voltmeter should be more than 600VAC.)
V1
1
2
0
D1
W1
Figure 6-7: Check points U1, U2, V1, V2, W1 and W2
2) If the input voltage is out of the operating range
of the unit, which is ±10% (187 ? 253/414 ? 506
VAC) of the rated voltage (208, 230/460V),
verify the available power capacity at the
installed site. If the input voltage is within the
operating range, recheck the input voltage
while welding, as welding may cause the input
voltage to decrease to a value below the operating range of the unit.
June 30, 2008
Figure 6-8: The check points 1 (P) and 2 (N)
6-11
TRANSTIG 300 Pi
SERVICE MANUAL
ADVANCED TROUBLESHOOTING
6) Verify bus voltage (the voltage of the
electrolytic capacitor after rectification) using a
DC Voltmeter. The capacity of the DVM should
be more than 1000VDC.
Measure between the output studs C and E on
PCB8 (WK5479), PCB9 (WK5479), PCB10
(WK5479) and PCB11 (WK5479).
The measured voltage should be approximately
1.4 times larger than the input voltage measured
in step 1 (above), except when running at 460V
where the bus voltage will be shared across all
boards, i.e., each board receiving 0.7 times the
input voltage measured in step 1 (above).
Replace diode D1 if the calculated measurement
is not within the corresponding range (260 ~
360/580 ~ 720VDC). Follow the process in
7.3.28.
TB4(N)
2) On the PCB3 (WK-5548) and PCB6 (WK5549), measure the voltages according to the
following table. The check points and the reference are obtainable on the solder side of
PCB4 (WK-4819). The locations of points are
indicated in Figure 6-10, 6-11.
TP3 TP1
TP0
TP2
PCB6
TB1(P)
Figure 6-10: Checkpoints TP0-TP3 on PCB6
PCB2
Figure 6-9: The check points TB1(P) and TB2(N)
Check Point
PCB6
Reference
PCB6
ACCEPTABLE
VALUE
TP1
TP0
+5VDC
TP2
TP0
+15VDC
TP3
TP0
-15VDC
Table 6-1: Checkpoints TP0-TP3 on PCB6
7) After the replacement of D1, if the above voltage is still abnormal, replace PCB1
(WK-5493).
1pin
3pin
PCB3
6.5.2 Verification of the Power Supply Voltage
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".
1) Verify Power Supply voltage using an DC voltmeter. (The capability of the voltmeter should
be more than 50VDC.) Operate at all input voltages as noted on the nameplate on the rear
panel when testing the power supply.
6-12
CN18
Figure 6-11: Checkpoints CN18 on PCB3
Check Point
PCB3
Pin 1 on CN18
Reference
PCB3
Pin 3 on CN18
ACCEPTABLE
VALUE
+24VDC
Table 6-2: Checkpoints CN18 on PCB3
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
ADVANCED TROUBLESHOOTING
3) If any of these voltages are not present or
are below a 10% tolerance, replace the
PCB3 (WK-5548). Refer to section 7.3.3.
6.5.3 Verification of the Cooling
Fan, FAN1, Drive Circuitry
2) Using the measurement taken above, follow
the chart below for possible failure modes.
FAN1
Status
Case 1 Rotating
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
section 6.4.1 " Preparation" on page 6-10.
1) Verify the condition of the cooling fan, FAN1,
using a DC voltmeter. (The capability of the
voltmeter should be more than 50VDC.) Using
a DC voltmeter, measure between PIN 1 (Positive [+]) 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 measurement while the connector plug and receptacle
are still connected.
1pin
2pin
PCB3
CN11
Case 2 Rotating
Case 3 Inactive
Case 4 Inactive
Voltage
measurement.
(1PIN-2PIN of
CN11 on PCB3)
Remedy
FAN1 drive circuit
is normal.
Replace PCB3.
Below DC 18V Refer to section
7.3.3.
Replace PCB3.
Refer to section
7.3.3.
DC 18 a 25V
4
Perform
Below DC 18V
"Verification of the
Power Supply
Voltage".
Refer to section
6.5.2.
Replace the FAN1.
DC 18 a 25V Refer to section
7.3.21.
Table 6-3: Verification of the FAN1
At the time of a low output and standby, as
for this equipment, rotation of a fan becomes
slow. Therefore, exact voltage measuring
becomes impossible. Perform the check of
voltage in the state of abnormalities.
When verifying the voltage, confirm that the
AC input voltage remain within the operating
range of the unit. (The AC input does not
drop below 180VAC).
Figure 6-12: Verification of the FAN1
June 30, 2008
6-13
TRANSTIG 300 Pi
SERVICE MANUAL
ADVANCED TROUBLESHOOTING
6.5.4 Verification of the Gas Valve,
SOL1, Drive Circuitry
CAUTION
6.5.5 Verification of the primary
Diode (D1)
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
section 6.4.1 " Preparation" on page 6-10.
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
section 6.4.1 " Preparation" on page 6-10.
1) Verify the voltage between the PIN 3 (Positive
[+]) and PIN 4 (Negative [-]) of connector CN11
on PCB3 (WK-5548) while you press the torch
switch while in TIG Mode. (The capacity of the
voltmeter should be more than 50VDC.) The
location of connector CN11 of PCB3 (WK5548) is indicated in Figure 6-13. When you
measure the above voltage, do not remove the
connector. Conduct the measurement while
the connector plug and receptacle are still connected.
1) Verify the characteristic of the primary diode,
D1, using a diode tester.
2) Refer to Table 6-5 and Figure 6-14 for
the checkpoints on D1.
COMPONENT
TESTED
Diode of D1
Diode of D1
Thyristor of D1
3pin
4pin
PCB3
Gate of D1
TERMINALS
Positive Negative
lead
lead
3, 4, 5
0
0
3, 4, 5
3, 4, 5
2
2
3, 4, 5
0
1
1
0
6
7
ACCEPTABLE
VALUE
0.3 to 0.5V
Open
Open
0.3 to 0.5V
Open
Open
52 +3, ±3ohms
Table 6-5: Tester checkpoints in D1
CN11
Figure 6-13: Verification of the SOL1
3
Case 1
Case 2
Remedy
Below DC 18V
Replace PCB1.
Refer to the page 7-23.
DC 18 a 25V
Replace SOL1.
Refer to the page 7-23.
0
1
2
0
Table 6-4: Verification of the SOL1
3) When verifying the voltage, confirm that the AC
input voltage remain within the operating range
of the unit.
(The AC input does not drop below 180VAC).
6-14
4
67
D1
2) Using the measurement taken above, follow
the chart below for possible failure modes.
Voltage
measurement.
(PIN 1-PIN 2 of
CN11 on PCB3)
5
6 7
1
5
4
3
2
Figure 6-14: Tester checkpoints for D1 showing the
interconnection diagrams
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
ADVANCED TROUBLESHOOTING
6.5.6 Verification of the secondary
Diode (D2-D7)
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
section 6.4.1 " Preparation" on page 6-10.
1) Verify the characteristic of the secondary
diode, D2-D7, using a diode tester.
2) Refer to Table 6-6 and Figure 6-15 for
the checkpoints on D2-D7.
COMPONENT
TESTED
Diode 1 of
D2-D7
Diode 2 of
D2-D7
TERMINALS
Positive Negative
lead
lead
Anode
Cathode
Cathode
Anode
Anode
Cathode
Cathode
Anode
ACCEPTABLE
VALUE
1) Check whether there are any abnormalities on
the appearance of PCB8-PCB11.
2) Verify the characteristic of the primary IGBT
(Q1-Q24), using a diode tester.
3) Refer to Table 6-7 and Figure 6-16 for
the checkpoints on PCB8-PCB11.
TERMINALS
COMPONENT
TESTED
Positive Negative
lead
lead
ACCEPTABLE
VALUE
Collector-Emitter
of Q1aQ12 with
PCB8 and PCB9
C
CE
CE
C
Open
0.2 to 0.5V
Collector-Emitter
of Q13aQ24 with
PCB10 and PCB11
CE
E
E
CE
Open
0.2 to 0.5V
Table 6-7: Tester checkpoints in the Q1-Q24
0.2 to 0.3V
Open
0.2 to 0.3V
Open
Table 6-6: Tester checkpoints for D2-D7
PCB10
D4
C
Diode 1
Anode
CE
PCB11
E
Diode 2
Anode
D2
D7
Cathode
Cathode
TRO_0031
D5
Figure 6-15: Tester checkpoints for D2-D7
PCB8
PCB9
C
CE
E
6.5.7 Verification of the primary
IGBT (Q1-Q24)
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 section
6.04.
June 30, 2008
Figure 6-16: Tester checkpoints for Q1-Q24
6-15
TRANSTIG 300 Pi
SERVICE MANUAL
ADVANCED TROUBLESHOOTING
6.5.8 Verification of the secondary
IGBT (Q25-Q26)
CAUTION
6.5.9 Verification of No-load Voltage (OCV)
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
section 6.4.1 " Preparation" on page 6-10.
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 tsection
6.04.
1) Check whether there are any abnormalities on
the appearance of PCB17.
a. Verify the no-load voltage in STICK mode.
2) Verify the characteristic of the secondary IGBT
(Q25-Q26), using a diode tester.
3) Refer bellow Table 6-8 and Figure 6-17 for
the checkpoints on Q25-Q26.
1) In STICK welding mode, mark and then
turn potentiometer VR1 on PCB6 (WK5549) all the way to the right and turn off
the electric shock protector function (Voltage-Reduction-Device, VRD).
2) Contactor function is put into the state of
on pushing Function button.
TERMINALS
COMPONENT
TESTED
Positive
lead
Negative
lead
ACCEPTABLE
VALUE
WARNING
Collector-Emitter
of Q25
(By PCB18
connection)
C1
C2E1
C2E1
C1
Open
0.2 to 0.5V
Collector-Emitter
of Q26
(By PCB19
connection)
C2E1
E2
E2
C2E1
Open
0.2 to 0.5V
Table 6-8: Tester checkpoints for Q25-Q26
Electric shock hazard. The unit will generate OCV
immediately when contactor function is put into the
state of on pushing Function button at STICK
mode.
3) Verify the no-load voltage using a DC voltmeter.
(The capability of the voltmeter should be
more than 100VDC.)
4) The normal no-load voltage is approximately 65V.
C2E1
Q25
Q26
E2
C1
Figure 6-17: Tester checkpoints in the Q25-Q26
6-16
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
ADVANCED TROUBLESHOOTING
b. Verify the no-load voltage (OCV) in High Frequency TIG mode.
WARNING
This welding mode produces high frequency and
high voltage. Extra care shall be taken to prevent
electric shock.
1) When in HF TIG mode, the unit will generate high voltage. To prevent personal harm
and test equipment damage, mark and
then remove the indicated wire from the HF
UNIT1 shown in Figure 6-18. To prevent
electric shock, always wrap the removed
wire with electrical tape or other suitable
insulation.
HF. UNIT1
Figure 6-18: Removal and installation
from the HF UNIT1
(To disable the operation of the HF unit.)
2) Press the Welding mode selection button
to select HF TIG welding mode.
3) While depressing the Torch switch, verify
the OCV using a DC voltmeter. (The capability of the voltmeter should be more than
100VDC.) The check point with a tester is
the voltage between output terminal + and
-. In TIG mode, the OCV ceases 3 seconds
after you depress the torch switch.
4) The normal no-load voltage is approximately 65V.
5) Return the setting variable resister (VR1)
to the original position. (Return to the position recorded by "a. 1)" clause.)
• fully clockwise:
VRD ON
• fully counter-clockwise: VRD OFF
6) Return connection with HF UNIT1 to the
original position.
June 30, 2008
6-17
TRANSTIG 300 Pi
SERVICE MANUAL
7 MAINTENANCE
7.01 Subsystem Test and Replacement Procedures
7.1.1 Preparation
This section provides specific procedures for verifying the operation and replacement of each subsystem
within the power supply.
Before undertaking any of these procedures, eliminate the obvious first-visually inspect the suspect subsystem
for physical damage, overheating, and loose connections.
7.1.2 Test and Replacement Parts List
9
3
2
4
5
6
1
7
8
No.
DWG No.
Parts name
Reference page
Part No.
1
PCB2
Print Circuit Board (WK-5597)
7- 8
W7001678
2
PCB3
Print Circuit Board (WK-5548)
7- 9
W7001314
3
PCB4
Print Circuit Board (WK-4819)
7- 11
10-6635
4
PCB5
Print Circuit Board (WK-5551)
7- 11
W7001417
5
PCB7
Print Circuit Board (WK-5550)
7- 9
W7001423
6
PCB12
Print Circuit Board (WK-5527)
7- 14
W7001319
7
PCB13
Print Circuit Board (WK-5528)
7- 15
W7001320
8
PCB14
Print Circuit Board (WK-5594)
7- 16
W7001321
9
PCB21
Print Circuit Board (WK-4917)
7- 18
10-6740
7-1
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
10
11
8
9
2
5
1
6
3
4
7
No.
DWG No.
Parts name
Reference page
Part No.
1
CON1
Remote Socket
7- 29
W7001666
2
D1
Primary Diode
7- 31
10-6628
3
D2
Secondary Diode
7- 32
10-6629
4
D4
Secondary Diode
7- 32
10-6629
5
D5
Secondary Diode
7- 32
10-6629
6
D7
Secondary Diode
7- 32
10-6629
7
HF.UNIT1
High Frequency Unit
8
L101
Reactor
7- 37
W7001670
9
L102
Reactor
7- 38
W7001672
10
S1
Main ON/OFF Switch
7- 27
10-6857
11
S2
Input Voltage Switch
7- 28
June 30, 2008
7- 29
W7001399l
10-5222
7-2
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
8
2
7
3
11
12
4
9
5
13
14
15
10
6
1
No.
DWG No.
1 CC1
Parts name
Coupling Coil
Reference page
7- 23
Part No.
W7001382
2
CT2
Current Trans
7- 33
W7001304
3
CT3
Current Trans
7- 33
4
FAN1
Cooling Fan
7- 25
W7001304
W7001307
5
FCH1
Reactor
7- 23
W7001653
6
HCT1
Hall Current Sensor
7- 30
10-5003
7
L1
Ring Core
7- 34
W7001309
8
L103
Reactor
7- 39
W7001605
9
L105
Ring Core
7- 36
W7001400
10
R6
Current Limiting Resistor
7- 20
W7001451
11
R7
Resistor
7- 21
W7001325
12
R8
Resistor
7- 21
W7001325
13
SOL1
Solenoid Valve
7- 26
W7001604
14
TH1
Primary Thermistor
7- 24
15
TH2
Secondary Thermistor
7- 25
10-5228
10-5228
7-3
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
7.02 Service Tools
7.2.1 Tools and parts
The tools and parts to be used for maintenance are shown by icons.
Spanner
Philips Head
Screwdriver
Long Nose
Pliers
C-Ring Pliers
Snap Band
Silicon
Compound
7.2.2 Notes of disassembly and assembly
NOTE
When removing the locking type connectors and board supporters, disengage the locking mechanism first
and then disconnect them.
Locking type connectors and board supporters are indicated in this manual using the following symbols;
black star marks for locking connectors and white star marks for locking board supports.
NOTE
During your maintenance or repair, please cut 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 maintenance or repair.
CAUTION
Please note that you remove each connector, grasp and pull out by the connector part only. Do not pull the
harness (cable) part.
WARNING
The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete.
June 30, 2008
7-4
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
7.03 Replacement Procedure
7.3.1 PCB1 (WK-5493) UVX[\
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the PCB2 (WK-5597). [Reference page : 7-8]
3) Remove the Primary Diode (D1). [Reference page : 7-31]
4) Remove the Current Trans (CT2/CT3). [Reference page : 7-33]
5) Remove the Nylon Hose. Remove the two bolts, and one terminal.
Remove the four screws and open the front cabinet.
2
3
1
3
4
2
3
3
1
2
6) Remove the two screws and three terminals from the PCB1 (WK-5493).
7) Remove the Reactor (L1). [Reference page : 7-34]
7-5
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
8) Remove the 18 screws and remove the PCB1 (WK-5493).
2
1
1
7.3.2 PCB2 (WK-5597) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the screw and then disconnect the four ground terminals. Disconnect the 19 connectors.
CN7
CN17
CN4
CN1
CN7
1
CN3
CN2
2
CN22
CN23
CN8
CN21
CN19
CN1
2
CN9
CN21
CN20 CN9
CN8
CN11
3) Remove the four screws. Remove the PCB3, PCB4, PCB5, PCB6, and PCB7 unit.
Disconnect the three connectors.
CN1
2
CN15
CN16
CN2
CN13
June 30, 2008
1
7-6
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
4) Remove the six screws, three terminals and three connectors.
CN1
CN2
CN3
5) Remove the two PCB supporters and then the PCB2 (WK-5597) and insulation sheet.
7.3.3 PCB3 (WK-5548), PCB7 (WK-5550) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the PCB4 (WK-4819). [Reference page : 7-11]
3) Remove the PCB6 (WK-5549). [Reference page : 7-11]
4) Remove the PCB5 (WK-5551). [Reference page : 7-11]
5) Disconnect the 11 connectors from the PCB3 (WK-5548).
CN21
CN20
CN9
CN23
CN22
CN11
CN8
CN19
CN1
CN2
7-7
CN3
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
6) Remove the screw and then the four ground terminals. Remove the four screws and then remove the
PCB3 and PCB7 unit. Disconnect the three connectors from the PCB7 (WK-5550).
1
2
CN14
CN15
CN13
3
7) Disconnect the one connector and remove the two screws, and then remove the PCB7 (WK-5550) from
the PCB3 (WK-5548). Remove one screw and one ground terminal from the PCB7 (WK-5550).
CN20
1
2
8) Disconnect the two connectors from the PCB3 (WK-5548).
CN18
CN33
June 30, 2008
7-8
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
7.3.4 PCB4 (WK-4819) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Disconnect the two connectors. Remove the two screws and three connectors and remove the PCB4
(WK-4819) from the PCB3 (WK-5548).
1
2
CN7
CN4
CN5
CN4
CN6
7.3.5 PCB5 (WK-5551) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the PCB6 (WK-5549). [Reference page : 7-11]
3) Remove the two screws and three connectors. Remove the PCB5 (WK-5551) from the PCB3 (WK5548).
CN30
CN31
CN32
7.3.6 PCB6 (WK-5549) V
1) Remove the Side Panel. [Reference page :6-1]
2) Disconnect the six connectors.
CN21
CN17
CN1
CN9
CN8
CN20
7-9
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
3) Remove the three screws and five connectors. Remove the PCB6 (WK-5549) from the PCB5 (WK-5551)
and PCB7 (WK-5550).
CN27
CN18
CN32
CN30
CN31
7.3.7 PCB8, PCB9 (WK-5479) and Q1-Q12 “Primary IGBT” V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the eight screws and four device clips. Remove the four connectors and six screws.
Remove the PCB8 (WK-5479) and PCB9 (WK-5479).
Remember to install Silicone Rubber Sheets where silicone compound (Shinetsu silicone G-747 or
equivalent) was spread when reinstalling the PCB8 and PCB9. Spread the silicone compound on
IGBT.
CN1
CN2
2
2 CN1
CN2
1
Silicone rubber sheets
3
June 30, 2008
7-10
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
7.3.8 PCB10, PCB11 (WK-5479) and Q13-Q24 “Primary IGBT” V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the eight screws and four device clips.
Remove the four connectors and six screws. Remove the PCB10 (WK-5479) and PCB11 (WK-5479).
Remember to install Silicone Rubber Sheets where silicone compound (Shinetsu silicone G-747 or equivalent) was spread when reinstalling the PCB10 and PCB11. Spread the silicone compound on IGBT.
CN2
CN1
CN1
2 CN2
1
Silicone rubber sheets
3
7.3.9 PCB12 (WK-5527) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the PCB13 (WK-5528). [Reference page :7-15]
3) Remove the three latches of Front Control Cover and then the PCB12 (WK-5527).
2
1
1
When reinstalling the PCB12 (WK-5527), engage two latches of Front Control Cover first.
1
2
7-11
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
7.3.10 PCB13 (WK-5528) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the Protection Cover.
2
2
3
1
3) Remove the Knob Cap. Holding the Knob down, loosen the screw and remove the Knob.
2
1mm
1
3
4) Disconnect the one connector from the PCB12 (WK-5527).
Remove the nut, washer and terminal. Remove the four screws.
Pull out the Operation Panel and bring it down.
1
3
2
3
CN2
4
3
3
June 30, 2008
7-12
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
5) Remove the one connector and two screws. Remove the PCB13 (WK-5528) and Encoder Cover.
2
4
1
CN1
3
7.3.11 PCB14 (WK-5594) <T1 “Main Transformer”> UVX[
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the Coupling Coil (CC1). [Reference page : 7-23]
3) Remove the PCB20 (WK-5499). [Reference page : 7-18]
4) Remove the Reactor (FCH1). [Reference page : 7-23]
5) Remove the two screws and the T-CC Bus Bar from the front side.
6) Remove the Nylon Hose and two terminals of SOL1. Remove the four screws and open the Rear Panel.
3
2
3
4
1
3
1
2
3
7-13
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
7) Remove the four screws from the PCB1 (WK-5477). Remove the seven terminals.
The cables is drawn out.
2
2
1
8) Remove the four screws and then two cables from bottom. Remove the two screws and then drags out
the PCB14 (WK-5594) and D Bus Bar1, D Bus Bar2, D Bus Bar3, D Bus Bar4 and Dust Cover Sheet
(Rear). Remove the four screws and then remove the D Bus Bar1, D Bus Bar2, D Bus Bar3, D Bus Bar4
and Dust Cover Sheet (Rear) form PCB14.
1
2
3
7.3.12 PCB15 (WK-5606) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the Nylon Hose and two terminals of SOL1.
3) Open the Dust sheet. Remove the eight screws. Remove the two PCB supporters and remove the
PCB15 (WK-5606).
3
1
2
3
June 30, 2008
2
7-14
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
7.3.13 PCB20 (WK-5499) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove one screw and one terminal. Remove one bolt, toothed washer, washer and terminal. Remove
one screw, nut and the Output Bus Bar. Disconnect one connector from HCT1.
4
3
1
CN1
5
2
3) Disconnect the two connectors.
Remove the four PCB board supporters and then remove the PCB20 (WK-5499).
1
CN1
1
CN3
2
2
3
7.3.14 PCB21 (WK-4917) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the six screws from the S1 and remove the six terminals.
2
1
2
1
7-15
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
3) Remove the four screws and then open the Rear Board.
1
1
2
1
1
4) Disconnect the one connector. Remove the two screws and one ground terminal.
Remove the PCB21 (WK-4917).
3
2
1
CN1
2
5) Remove the three screws and the S1 Bus Bar from the PCB21 (WK-4917).
June 30, 2008
7-16
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
7.3.15 PCB22 (WK-5022) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Disconnect one connector.
Remove the four screws and one terminal. Remove the PCB22 (WK-5022).
2
1
CN1
2
3
3) Remove three board supports.
7.3.16 Current Limiting Resistor (R6) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the HF.UNIT1 [Reference page : 6-15]
3) Cut the cable. Remove one screw and then remove the Current Limiting Resistor (R6).
2
1
7-17
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
7.3.17 Resistor (R7, R8) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove four screws and three terminals.
3) Cut off one snap band and disconnect one connector. Remove the one screw.
2
3
1
CN1
4) Remove two screws and remove the PCB22 unit.
1
2
1
June 30, 2008
7-18
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
5) Remove four screws and open the Rear Panel.
1
1
2
1
1
6) Remove four screws and six terminals. Remove the Resistors (R7 and R8).
1
1
2
1
7-19
2
1
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
7.3.18 Reactor (FCH1)
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the Nylon Hose. Remove the two bolts, and one terminal.
Remove the four screws and open the Front Panel.
2
3
1
3
4
2
3
3
1
2
3) Remove one screw, one nut and two terminals. Remove one screw, one nut and one terminal.
1
3
2
1
2
3
4) Remove four screws and remove the Reactor (FCH1).
1
2
1
June 30, 2008
7-20
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
7.3.19 Primary Thermistor (TH1)
1) Remove the Side Panel. [Reference page : 6-1]
2) Disconnect the one connector CN8 on the PCB6. Remove the one screw and then detach the Primary
Thermistor (TH1).
Before installing a new therminstor, apply a uniform coat of silicone compound (Shinetsu Silicone G747 or equivalent) on the base.
1
CN8
2
7-21
3
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
7.3.20 Secondary Thermistor (TH2) VX[\
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the PCB16 (WK-5569). [Reference page : 7-16]
3) Cut the three snap bands and disconnect the one connector CN9 on the PCB6. Remove the one screw
and Secondary Thermister (TH2).
Before installing a new therminstor, apply a uniform coat of silicone compound (Shinetsu Silicone G747 or equivalent) on the base.
1
1
1
2
CN9
4
3
7.3.21 Cooling Fan (FAN1) VX[
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel.
3
2
3
4
1
3
1
2
3
June 30, 2008
7-22
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
3) Cut the one snap band and disconnect the one connector CN11 on the PCB3.
CN11
4) Remove the two screws and detach the Cooling Fan (FAN1).
7-23
AIR FLOW
ROTATION
Do not have the wrong direction of the fan when reinstalling.
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
7.3.22 Main ON/OFF Switch (S1)
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the six screws and six terminals.
2
1
2
1
3) Remove the two screws and detach the Main ON/OFF Switch (S1). Remove the three posts.
June 30, 2008
7-24
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
7.3.23 Input Voltage Switch (S2) UV
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the six screws and six terminals.
2
1
2
1
3) Remove the four screws, and open the Rear Board.
1
1
2
1
1
4) Disconnect the one connector CN4 on the PCB4.
Remove the two screws and two nuts and then remove the Input Voltage Switch (S2).
CN4
7-25
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
7.3.24 Remote Socket (CON1)
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the Ring Core (L105). [Reference page : 7-36]
3) Disconnect the three connectors CNB-15 on the PCB7. Remove the one screw and one ground terminals.
2
CN13
1
CN15
1
CN14
1
4) Remove the two screws and remove the Remote Socket (CON1).
2
1
June 30, 2008
7-26
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
7.3.25 Hall Current Sensor (HCT1)
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove one screw and one terminal. Remove one bolt. toothed washer, washer and terminal. Remove
one screw. nut and the Output Bus Bar. Disconnect one connector from HCT1.
4
3
1
CN1
5
2
3) Remove the one screw and detach the Hall Current Sensor (HCT1) from the Output Bus Bar.
1
2
7-27
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
7.3.26 Primary Diode (D1) V\
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the PCB3 (WK-5548). [Reference page : 7-9]
3) Remove four screws and three terminals.
4) Cut off one snap band and disconnect one connector. Remove the one screw.
2
3
1
CN1
5) Remove two screws and remove the PCB22 unit.
1
2
1
June 30, 2008
7-28
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
6) Remove the six screws and 14 terminals. Remove the two screws and then detach the Primary Diode
(D1).
Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or
equivalent) on the base.
1
2
1
7.3.27 Secondary Diode (D2, D4, D5 and D7) V\
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the PCB15 (WK-5606). [Reference page : 7-17]
3) Remove one screw and one nut. Remove 20 screws and two terminals. Remove the D Bus Bar, D Bus
Bar1, D Bus Bar2, D Bus Bar3 and D Bus Bar4.
4
2
1
3
2
2
1
2
4) Remove the eight screws and then detach the Secondary Diodes (D2, D4, D5, D7).
Do not have the wrong direction of the diodes when reinstalling.
Before installing a new diodes, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or
equivalent) on the base.
D4
D2
D7
D5
7-29
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
7.3.28 Current Trans (CT2, CT3) VX[
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove four screws and three terminals.
3) Cut off one snap band and disconnect one connector. Remove the one screw.
2
3
1
CN1
4) Remove two screws and remove the PCB22 unit.
1
2
1
June 30, 2008
7-30
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
5) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel.
3
2
3
4
1
3
1
2
3
6) Cut the three snap bands and remove the connector from the PCB3 (WK-5548). Remove two screws
and three terminals from the PCB1 (WK-5493). Cut two snap bands and remove the Current Trans (CT2,
CT3).
5
5
3
3
1
1
4
1
2
CN7
7.3.29 Ring Core (L1) VX[
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove four screws and three terminals.
7-31
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
3) Cut off one snap band and disconnect one connector. Remove the one screw.
2
3
1
CN1
4) Remove two screws and remove the PCB22 unit.
1
2
1
5) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel.
3
2
3
4
1
3
1
2
3
June 30, 2008
7-32
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
6) Remove the two screws and three terminals. Cut the snap band and remove the Ring Core (L1).
1
1
3
2
7.3.30 Ring Core (L105) V
1) Remove the Side Panel. [Reference page : 6-1]
2) Remove the Protection Cover.
2
2
3
1
3) Remove the four screws. Pull out the Operation Panel and bring it down.
1
1
2
1
7-33
1
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
4) Cut the snap band remove the Ring Core (L105).
7.3.31 Reactor (L101)VU
1) Remove the Side Panel. [Reference page: 9-1]
2) Remove four screws and three terminals.
1
2
3) Remove four screws and open the rear panel. Remove one nut, one washer and one terminal. Remove
the Reactor (L101).
1
1
3
2
1
1
June 30, 2008
7-34
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
4) Remove harness from the Reactor (L101).
The harness is rolled three times at the installation.
7.3.32 Reactor (L102) VX[
1) Remove the Side Panel. [Reference page: 9-1]
2) Remove four screws and three terminals.
3) Cut off one snap band and disconnect one connector. Remove the one screw.
2
3
1
CN1
7-35
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
MAINTENANCE
4) Remove two screws and remove the PCB22 unit.
1
2
1
5) Remove six screws, nine terminals and remove the Reactor (L102).
2
1
3
7.3.33 Reactor (L103) VX[
1) Remove the Side Panel. [Reference page: 9-1]
2) Remove one screw and two terminals.
June 30, 2008
7-36
TRANSTIG 300 Pi
SERVICE MANUAL
MAINTENANCE
) Remove four screws and open the rear panel. Remove one nut, one washer and one terminal.
1
1
3
2
1
1
4) Cut off one snap band. Remove the Reactor (L103).
1
7-37
2
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
APPENDIX 1 PARTS LIST
1 Equipment Identification
All identification numbers as described in the Introduction chapter must be furnished when ordering parts
or making inquiries. This information is usually found on the nameplate attached to the equipment. Be
sure to include any dash numbers following the Part or Assembly numbers.
2 How To Use This Parts List
The Parts List is a combination of an illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are
listed except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc.,
and permanently attached items which are soldered, riveted, or welded to other parts. The part descriptions may be indented to show part relationships. To determine the part number, description, quantity, or
application of an item, simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List.
PART NUMBER:
TRANSTIG 300 Pi
700722
No. DWG No. Part No.
Description
1
CC1
W7001382 Coupling Coil, gen 3.1, IPS
2
CON1
W7001666 Connector, remote, gen 3.1, IPS
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21
22
23
June 30, 2008
CT2-3
D1
D2,4,5,7
FAN1
FCH1
HCT1
HF.UNIT1
L1
L101
L102
L103
L105
PCB1
PCB2
PCB3
PCB4
PCB5
PCB6
PCB6
PCB7
PCB8-11
W7001304
10-6628
10-6629
W7001307
W7001687
10-5003
W7001399
10-6633
W7001309
W7001670
W7001672
W7001605
W7001400
W7001312
W7001313
W7001314
10-6635
W7001417
W7001737
W7001736
W7001423
W7001318
Transformer, gen 3.1, IPS
Diode, gen 3.1, IPS
Diode, gen 3.1, IPS
Fan, gen 3.1, IPS
Inductor, gen 3.1, IPS
Sensor, Current, gen 3.1, IPS
HF, Unit, gen 3.1, IPS
HF, Gap, gen 3.1, IPS
Reactor, gen 3.1, IPS
Reactor, gen 3.1, IPS
Reactor, gen 3.1, IPS
Reactor, gen 3.1, IPS
Reactor, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, 400TS, gen 3.1, IPS
PCB, 300TS, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
Additional Information
F3A073800 300A AC CC
MS3102A20-27S (NIC) 14P (with Wiring
Assembly)
F2A503001 CT 1:40
DFA50BA160
DBA200UA60
109E5724H507 DC 24V 16.8W
F3A285700 DC TIG FCH
HC-TN200V4B15M 200A 4V
HF.UNIT (WK-4840 U04)
U0A601100
GP-7
DFR47ZMD
F2A734000
SNG-25B-600
ZCAT-3035-1330
WK-5493 U01 MAIN PCB
WK-5597 U01 LINK PCB
WK-5548 U01 DDC PCB
WK-4819 U01 DETECT PCB
WK-5551 U01 CONECT PCB
WK-5549 U05-4 DC CTRL PCB
WK-5549 U5-3 DC CTRL PCB
WK-5550 U01 FILTER PCB
WK-5479 U01 GATE PCB (with
IRGP20B60PD)
QTY.
1
1
2
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
A-1
TRANSTIG 300 Pi
SERVICE MANUAL
TRANSTIG 300 Pi PARTS LIST
A-2
No.
24
25
26
27
28
29
30
31
32
33
34
35
36
DWG No.
PCB12
PCB13
PCB14
PCB15
PCB20
PCB21
PCB22
R2
R6
R7-8
S1
S2
SOL1
Part No.
W7001811
W7001320
W7001321
W7001322
W7001324
10-6740
W7001677
W7001449
W7001451
W7001325
10-6857
10-5222
W7001604
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
TH1,2
10-5228
W7001472
W7001329
W7001330
W7001331
W7001332
W7001656
10-6791
W7001336
W7001686
W7001338
W7001339
W7001340
W7001689
10-6733
W7001345
W7001513
W7001511
W7001690
10-5184
10-6660
N/A
10-6795
W7001349
W7001350
W7001351
W7001352
W7001353
10-6665
10-6666
W7001685
Additional Information
WK-5527 U09 PANEL PCB
WK-5528 U01 ENCODER PCB
WK-5594 U01 TRANS PCB
WK-5606 U01 DIODE SNUBBER PCB
WK-5499 U01 FILTER PCB
WK-4917 U04 INPUT FILTER PCB
WK-5022 B U01 FILTER2_PCB
ERG3SJ220H 3W 22Ω
MHS20A101KI 20W 100Ω
MHS20A151JI 20W 150OHM
DCP-103SR100C-480V 3P-480V
SDKGA4-A-1-A
5505NBR1.5 DC24V 11VA/10W (with
Gas Inlet and PC4-02)
Thermistor, gen 3.1, IPS
ERTA53D203 20kΩ/25°CB=3950K
Panel, Front, gen 3.1, IPS
E0D004801
Panel, Rear, gen 3.1, IPS
E0D004901
Label, Side, gen 3.1, IPS
E0D005207
Case, Front, gen 3.1, IPS
E0C346000
Board, Front, gen 3.1, IPS
JEA496001
Cover, Rear, gen 3.1, IPS
JDA173300
Cover, Encoder, gen 3.1, IPS
EBA514400
Cover, PCB, gen 3.1, IPS
E1B547900(with Dustcover Sheet)
Label, Name, gen 3.1, IPS
N4A933200 (300TS)
Label, Name, gen 3.1, IPS
N4A933300 (400TS)
Label, Side, gen 3.1, IPS
N4A785200
Label, 1 Warning, gen 3.1, IPS
N1B029700
Label, 2 Warning, gen 3.1, IPS
N1B029800
Label, terminal output, gen 3.1,IPS N4A670700
Label, Gas Input, gen 3.1, IPS
N4A040700
Label, Switch, gen 3.1, IPS
N4A919100
Label, VRD, gen 3.1, IPS
N4A918800
Label, VRD, gen 3.1, IPS
N4A598700
Outlet, Gas, gen 3.1, IPS
E5A925600 (with PC4-02)
C-Ring, gen 3.1, IPS
Terminal, Output, gen 3.1, IPS
TRAK-BE35-70S
Cable, Input, gen 3.1, IPS
H07RN-F#1600106 4# X L=3.9m
Clamp, Input, gen 3.1, IPS
EBA156800
Heatsink, gen 3.1, IPS
E1B895000
Heatsink, gen 3.1, IPS
E1B870100
Spring Clip,IGBT, gen 3.1, IPS
E1B850100
Chassis, PCB1, gen 3.1, IPS
J5B017500
Chassis, gen 3.1, IPS
J3C356600
Knob, gen 3.1, IPS
2621603
Knob Cap, gen 3.1, IPS
3021104
Cover, Protector, gen 3.1, IPS
N1B036500 (300TS)
Description
PCB, WK5527 U09,GEN3.1,IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
Resistor, gen 3.1, IPS
Resistor, gen 3.1, IPS
Resistor, gen 3.1, IPS
Switch, gen 3.1, IPS
Switch, gen 3.1, IPS
Solenoid Valve, gen 3.1, IPS
QTY.
1
1
1
1
1
1
1
2
1
2
1
1
1
2
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
2
1
1
2
1
8
1
1
1
1
1
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
TRANSTIG 300 Pi PARTS LIST
No. DWG No.
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
June 30, 2008
Part No.
W7001357
W7001358
W7001645
W7001360
W7001361
W7001362
W7001363
W7001364
10-6868
W7001646
W7001367
W7001671
W7001673
W7001368
W7001369
W7001370
W7001371
W7001643
W7001373
W7001374
W7001375
W7001377
10-6681
10-2020
0-4995
W7001334
Description
Sheet, rubber, gen 3.1, IPS
Post, 1(M5), gen 3.1, IPS
Bus Bar, D, gen 3.1, IPS
Bus Bar, T-D, gen 3.1, IPS
Bus Bar, 1 D, gen 3.1, IPS
Bus Bar, 2 D, gen 3.1, IPS
Bus Bar, 3 D, gen 3.1, IPS
Bus Bar, 4 D, gen 3.1, IPS
Bus Bar, S1, gen 3.1, IPS
Bus Bar, Output, gen 3.1, IPS
Bus Bar, T-CC, gen 3.1, IPS
Bus Bar, input, gen 3.1, IPS
Chassis, PCB22, gen 3.1, IPS
Post, Output, gen 3.1, IPS
Insulated Board, gen 3.1, IPS
Insulation Sheet, gen 3.1, IPS
Insulation Sheet, gen 3.1, IPS
Cover, Protector, gen 3.1, IPS
Cover, Protector, gen 3.1, IPS
Clip, gen 3.1, IPS
Cover, CON1, gen 3.1, IPS
Edge protect, gen 3.1, IPS
Hose, Nylon, gen 3.1, IPS
Plug, Output, gen 3.1, IPS
Operating Manual, gen 3.1, IPS
Cover, Protector, gen 3.1, IPS
Additional Information
E DA227700
EBA643600 (M5-M5)
E CA903300
E DA003800
E DA046900
E DA047000
E DA047100
E DA047200
E CA321000
E CA904000
E DA047300
E DA069200
J5 B 3 4 8 0 0 0
E CA867900
E 1B872000
E 1B859700
E DA079800
E 1B933000
E 1B933100
# 74 NATURAL
1070500-20 (with String)
E H18U
T0425B Nylon Hose L=0.5m
T RAK-SK50
Operating Manual
E 0C299200
QTY.
4
3
1
4
1
1
1
1
3
1
1
1
1
2
2
1
1
1
1
4
1
2
1
1
1
1
A-3
TRANSTIG 300 Pi
SERVICE MANUAL
TRANSTIG 300 Pi PARTS LIST
53
43
49
46
34
48
35
29
70
88
40
77
70
77
60
39
59
52
14
25
42
45
24
57
41
68
36
66
67
54
6
47
40
44
55
47
91
38
15
50
82
2
48
89
56
58
57
A-4
58
82
51
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
TRANSTIG 300 Pi PARTS LIST
3
30
11
4 90
13
12
90
3
21
19
20
33
16
81
18
33
84
80
22
63
17
64
63
23
61
23
61
69
85
69
23
37
65
83
63
23
26
63
62
7
79
83
5
5
28
72
5
1
72
65
9
73
86
74
75
37
76
32
71
10
31
87
27
78
8
June 30, 2008
A-5
TRANSTIG 300 Pi
SERVICE MANUAL
APPENDIX 2 CONNECTION WIRING GUIDE
Destination
A
B
C
D
E
PCB2
PCB2
PCB2
PCB3
PCB3
CN1
CN2
CN3
CN1
CN2
F
PCB3
CN7
PCB3
CN11
PCB3
PCB3
PCB3
PCB3
PCB3
PCB3
PCB4
PCB6
PCB6
PCB6
CN20
CN21
CN22
CN23
CN18
CN33
CN4
CN1
CN8
CN9
S
PCB6
CN17
T
U
V
W
X
PCB6
CN21
CN13
CN14
CN15
CN1
G
H
I
J
K
L
M
N
O
P
Q
R
A-6
PCB7
PCB12
PCB4
PCB3
D1
D1
PCB21
CT2
CT3
FAN1
SOL1
PCB8
PCB8
PCB10
PCB9
PCB7
PCB6
S2
HCT1
TH1
TH2
PCB16
PCB20
PCB12
CN4
CN3
CN1
CN1
CN2
CN1
CN2
CN20
CN20
CN4
CN3
CN2
CON1
PCB13
CN1
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
TRANSTIG 300 Pi CONNECTION WIRING GUIDE
CT2
CT3
CN17
CN21
X
T
CN1
PCB6
F
CN1
CN2
O
P
CN1
CN20
CN8
PCB21
CN9
PCB13
S2
N
K
CN1
CN4
E
PCB12
CN1
PCB4
L
CN2
CN1
CN2
CN22
CN7
CN23
PCB10
C
A
CN2
CN3
D
CN1
CN33
CN11
PCB7
CN13
U
CN15
W
V
D1
B
PCB11
CN18
CN20
CN3
CN14
FAN1
PCB3
G
M
CN2
SOL1
H
PCB2
CN1
S
I
CN21
CON1
HCT1
CN1
CN20
J
PCB20
PCB9
PCB8
CN3
TH2
June 30, 2008
CN2
CN1
CN2
TH1
R
Q
A-7
TRANSTIG 300 Pi
SERVICE MANUAL
APPENDIX 3 INTERCONNECT DIAGRAM
INTERCONNECT DIAGRAM
TB13
UB3
TB14
TB15
P
G
E
C
E
PCB8
Main
Circuit
Board
[WK-5493]
P
R(3)
TB1
G1
E1
R2
S(4)
1
2
3
R2
1 2 3 4 5
REAR
PANEL
TB4
G6
E6
C
K
L
D
N
M
E
1
2
F
EC
E
C
Q7
TB5
UB1
TB6
TB7
C
Q19
G
E
E
PCB11 C
Q20
C
CE
Q8
IGBT
Gate G
Circuit E
Board C
[WK-5479]
Q9
1
2
3
G7
Q10 E7
E
C
1
2
3
Q12
G
Q21
G
E
C
Q22
G
E
C
Q23
G
E
C
Q24
G
E
E3
G3
E
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
CN21
CN22
CN23
CN20
CN9
CN8
1 2
1 2 3
1 2
CN18
1 2 3
1
2
3
4
E7
G7
E1
G1
G8
E8
G
E6
G6
CN7
Q11
PCB6
Control
Circuit Bord
[WK-5549]
PCB7
Filter
Circuit Board
[WK-5550]
Q18
E
CN2
1
2
3
4
E
C
CT1
CT2
CT3
CT4
CN17 CN18
TB0 CN17 CN18
EB
1
2
3
A-8
1
2
3
G
E
C
CN20
CN14
CN11
H
G
1
2
3
4
CN131 CN132 CN130
CN131 CN132 CN130
1
2
CN27
3
4
CN27
5
I
CN1
CN4
CN30
CN30
CN15
B
CON1
J
CN32
CN32
CN13
A
E
PCB3
Control
Souce
PCB5
Connect Circuit Board Circuit Board 1 2 3 4 5 6
[WK-5548]
[WK-5551]
CN31
CN31
A : Contactor Control /+24VDC
B : Contactor Control /Contactor Clouser To"A"
C : 0 To +10Vdc Output To Remote Control
D : Remote Control Circuit Common
E : 0 To +10Vdc Intput From Remote Control
F : Not Used
G : Chassis Ground
H : Not Used
I : Not Used
J : Not Used
K : Not Used
L : Not Used
M : OK to Move(Current Detect Signal)
N : OK to Move(Current Detect Signal)
L105
CN6
CN6
Q17
G
G
IGBT G
Gate
Circuit E
Board C
[WK-5479]
1 2 3
PCB4
CN7
Detect
Circuit Board
[WK-4819]
CN5
CN5
SOL1
E
G5
E5
FAN1
+
1
2
3
4
TB20
CN3
1
2
3
4
-
G
CN2
CN2
Q6
G
CN20
R2
C
CE
1 2 3 4 5
CN4
P
C
TB19
TB4
CN1
1
2
3
4
5
6
E
C
1
2
3
4
E3
PCB9 C
1 2 3
N
TB18
CN1
1 2 3
Q5 G3
E4
G4
1 2
Q16
G
E8
G8
1
2
3
4
5
CN1
SIDE CHASSIS 1
G
E
C
CN19
1 2 3
1 2 3
CN17
CE Filter
Circuit Board
[WK-5022]
1
2
3
Q15
TB3
PCB2
Link
Circuit Board
[WK-5597]
TB1 PCB22
Q14
IGBT
Gate G
Circuit E
Board C
[WK-5479]
G4
E2
G2
+
TB3
CN1
CN1
PCB21
E Filter
Circuit
Board
[WK-4917]
E
PCB10 C
G
E
E5
G5
Ground
CN2
L103
E
Q4 E4
G
E
C
TB2
TB12
Q13
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
CN33
TH2
TH1
P+21V
PGND
GND
TB2
1
2
3
4
G
Q3
G
E
C
CN2
GND
G2
E2
N
C
CE
Q2
G
E
C
N
T(5) (2)
C
TB11
CN21
(0)
TB1
TB10
CN1
L101
Q1
IGBT
Gate G
Circuit E
Board C
[WK-5479]
CN1
G(6)
L102
C
CE
PCB1
K(7)
S1
C
CN1
+
(1)
CN1
1
2
D1
CN2
CN3
APPENDIX 3 INTERCONNECT DIAGRAM
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
CT2
CT1
TB7
TB33
+15
-15
IS
GND
AC1
4
123
AC2
PCB14
TRANS
Board
[WK-5594]TB35
PCB15
DIODE Snubber
Circuit Board
[WK-5606]
D5
SH.DET+
TRANSTIG 300 Pi INTERCONNECT DIAGRAM
TO1
+Output
Terminal
HCT1
TB21
TB34
CT2
D7
TB8
UB2
L1
D2
TB30
TB16
1
2
3
TB31
FCH1
CN3
RY+15V
/RY_ON
TB22
PCB20
Filter Circuit
Board
[WK-5499] SIDE CHASSIS 3
Torch/Gas
CC1
Terminal
D4
AC4
TB17 CT3
Ground
CN1
TB32
TO2
CC2
SH.DET-
CT4
CT3
+
1 2 3 4 5
UB4
-Output
Terminal
CC1
R1
HF.UNIT1
AC1
R2
R2
AC3
R6
AC3
SH.DET+
SH.DET-
AC2
AC4
AC3
EB
AC1
1 2 3 4 5
1 2 3 4 5 6 7 8 9
CN8
CN9
FRONT
PANEL
EB
+
/RY_ON
PCB12
Panel
Circuit Board
[WK-5527]
1
2
3
4
5
6
+15
-15
IS
GND
June 30, 2008
SIDE CHASSIS 2
PCB13
Encoder
Board
[WK-5528]
CN2
RY+15V
Ground
R7
UB1
UB2
R8
CN1
CN1
UB3
UB4
1 2 3 4
1 2 3 4
A-9
TRANSTIG 300 Pi
SERVICE MANUAL
APPENDIX 4 DIODE TESTING BASICS
DIODE TESTING BASIC
APPENDIX 4 DIODE Testing Basic
Testing of diode modules requires a digital Volt/
Ohmmeter that has a diode test scale.
1. Locate the diode module to be tested.
2. Remove cables from mounting studs on diodes
to isolate them within the module.
3. Set the digital volt/ohm meter to the diode test
scale.
4. Using figure 1 and 2, check each diode in the
module. Each diode must be checked in both
the forward bias (positive to negative) and
reverse bias (negative to positive) direction.
5. To check the diode in the forward bias direction, connect the volt/ohm meter positive lead
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 indicate between 0.3
and 0.9 volts.
VR
COM
A
Forward Bias
Diode Conducting
Anode
Cathode
Figure 13-1: Forward bias diode test
6. To check the diode in the reverse bias direction, reverse the meter leads (refer to Figure
13-1). A properly functioning diode will block
current flow in the reverse bias direction, and
depending on the meter function, will indicate
an open or "OL".
7. If any diode in the module tests as faulty,
replace the diode module.
8. Reconnect all cables to the proper terminals.
VR
COM
A
Reverse Bias
Diode Not Conducting
Cathode
Anode
Figure 13-2: Reverse bias diode test
A-10
June 30, 2008
SERVICE MANUAL
TRANSTIG 300 Pi
APPENDIX 5 TRANSTIG 300 Pi ACCESSORIES
Description
17 Series air cooled TIG torch
(suitable for TransTig 200Pi)
26 Series air cooled TIG torch
Part No.
518710402
200 Amp lead set, 5 metre
646323
Details
TIG torch with 4 metre cable & remote
current control
TIG torch with 4 metre cable & remote
current control
1 x 5m work lead; 1 x 5m electrode holder
400 Amp lead set, 8 metre
646325
OTD 10/4013
OTD 10/2004
OTD 10/4014
OTD 10/2005
OTD 10/4016
OTD 10/2007
301527
1 x 8m work lead; 1 x 8m electrode holder
200Pi, 200AC/DC slider only
300Pi, 300AC/DC, 400i slider only
200Pi, 200AC/DC hand pendant only
300Pi, 300AC/DC, 400i hand pendant only
200Pi, 200AC/DC
300Pi, 300AC/DC, 400i
Regulator only
301710
Flowmeter only
301711
Flowmeter only
301526
705700
Regulator/flowmeter only
VAF-4 wirefeeder, 8m interconnection,
operating manual
VS212 wirefeeder, operating manual
MIG torch with 3.6m cable, T4 connection
Welding helmet, 2 x spare cover lenses,
product bag, operating manual
Welding helmet, 2 x spare cover lenses,
product bag, operating manual
Welding helmet, 2 x spare cover lenses,
product bag, operating manual
Slide controller
Hand pendant
Foot controller
CIGWELD COMET argon regulator
CIGWELD COMET argon flowmeter
0-15 lpm
CIGWELD COMET argon flowmeter
10-40 lpm
CIGWELD COMET argon
regulator/flowmeter
VAF-4 Wirefeeder (for 400i ONLY)
VS212 Voltage sensing wirefeeder
Tweco® 4 MIG Torch
ArcMaster Pro Auto-darkening
Helmet, 9-13 – blue
ArcMaster Pro Auto-darkening
Helmet, 9-13 – blue with graphic
ArcMaster Pro Auto-darkening
Helmet, 9-13 – black with graphic
June 30, 2008
538720401
W3512006
717201
454294
454295
454296
A-11
CIGWELD LIMITED WARRANTY
LIMITED WARRANTY: CIGWELD, A Thermadyne Company, hereafter, “CIGWELD” warrants to customers of
its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or
material. Should any failure to conform to this warranty appear within the time period applicable to the CIGWELD
products as stated below, CIGWELD shall, upon notification thereof and substantiation that the product has
been stored, installed, operated, and maintained in accordance with CIGWELD’s specifications, instructions,
recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at CIGWELD’s sole option, of any
components or parts of the product determined by CIGWELD to be defective.
CIGWELD MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN
LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: CIGWELD SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL,
INDIRECT OR 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 contract, or anything done in connection therewith such as the performance or breach
thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by
CIGWELD whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall
not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No
employee, agent, or representative of CIGWELD is authorized to change this warranty in any way or grant any
other warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES
ARE USED WHICH IN CIGWELD’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY
CIGWELD PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD
TO PURCHASER BY NON-AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend
more than the time stated plus one year from the date CIGWELD delivered the product to the authorized
distributor.
Terms of Warranty – January 2008
1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply
of goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain
situations to the benefit of various conditions, warranties, guarantees, rights and remedies (including
warranties as to merchantability and fitness for purpose) associated with the supply of goods and services. A consumer should seek legal advice as to the nature and extent of these protected interests. In
some circumstances, the supplier of goods and services may legally stipulate that the said conditions,
warranties, guarantees, rights and remedies are limited or entirely excluded. The warranties set out in
Clause 2 shall be additional to any nonexcludable warranties to which the Customer may be entitled pursuant to any statute.
2. Subject to Clause 3. CIGWELD gives the following warranties to the Customer:
Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantable
quality and reasonably fit for the purpose for which they are supplied by CIGWELD.
CIGWELD will repair or, at its option, replace those of the goods which, upon examination, are found by
CIGWELD to be defective in workmanship and/or materials.
CIGWELD reserves the right to request documented evidence of date of purchase.
3. The Warranty in Clause 2;
Is conditional upon:
The Customer notifying CIGWELD or 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 or nominated Accredited Distributor/Accredited Service Provider. The goods
being used in accordance with the Manufacturer’s Operating Manuals, and under competent supervision.
Does not apply to:
Obsolete goods sold at auction, second-hand goods and prototype goods.
Breakdown or malfunction caused by accident, misuse or normal wear and tear.
Repairs or replacement made other than by CIGWELD or Accredited Service Providers, unless by prior
arrangement with CIGWELD.
Replacement parts or accessories which may affect product safety or performance and which are not
manufactured, distributed or approved by CIGWELD.
4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supply
of goods which are not of a kind ordinarily acquired for personal, domestic or household use or consumption to any one or more of the following (the choice of which shall be at the option of CIGWELD).
The replacement of the goods or the supply of equivalent goods.
The repair of goods.
The payment of cost of replacing the goods or acquiring equivalent goods.
The payment of the cost of having goods repaired.
5. Except as provided in Clauses 2 to 4 above, to the extent permitted by statute, CIGWELD hereby excludes
all liability for any loss, damage, death or injury of any kind whatsoever occasioned to the Customer in
respect of the supply of goods including direct, indirect, consequential or incidental loss, damage or injury
of any kind.
Warranty Schedule – January 2008
These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of sale
from the Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date CIGWELD delivered the product to
the Accredited Distributor. Unless otherwise stated the warranty period includes parts and labour. 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 300 Si, Transtig 300 Pi, Transtig 300 AC/DC,
Transmig 400 i
Original Main Power Magnetics ..............................................................................................................
3 years
2 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors....................
All other circuits and components including, but not limited to, relays, switches, contactors,
solenoids, fans, electric motors..................................................................................................
2 years
2 years
1 year
1 year
Please note that the information detailed in this statement supersedes any prior published data produced by
CIGWELD.
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
Thermadyne Asia Sdn Bhd
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: sales@thermalarc.com
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Canada
Cigweld, Australia
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Europe
Thermadyne Italy
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
Thermadyne International
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
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.com
Asia Pacific Regional Headquarters
71 Gower Street
Preston, Victoria, Australia, 3072
Telephone: +61 3 9474 7400
+61 3 9474 7488
FAX:
Email: cigweldsales@cigweld.com.au
www.cigweld.com.au