“MASTER? : MUREX® Transtig AC/DC 200 Technical Notes ne 2 8) SPECIFICATION @ ovrvur input Nominal voltage 200/380/415/440v Open circuit voltage Ac 69; 0C52v Phare Single Current range 5-200 amps AC/DC “Frequency so/6oHz Rated 100% duty cycle 96 amps 60% duty eycle 148 amps OTHER RELEVANT DATA 35% duty eyele 200 amps ——_—Rting specification Post-flow 0.5—30 secs 180700, 88638, 1979 Crate fit 05—10secs Insulation class, H (1800) Star current time 05-10 secs WEIGHT 135K9 Taeur ISeva Cuter BSA Ar &20y se Zarate SOAR Fase Carase Soy DIMENSIONS @ ve to variations which can occur in manufactured products, claimed performance, voltages, ratings, all capacities, Iessurements, dimensions and welts quoted are approximate only. Achievable capacities and ratings in use and Operation will depend upon coract installation use, aplication, maintenance and serie,MUREXS FAULT FINDING Equipment — Multimeter, 20kohm/v, or better — Unless otherwise specified, all voltages are measured from the electronie zero (negative welding current terminal) heck That the unit is connected for the correct supply voltage —That the mains supply is ive” ‘That all welding current cable’ connections and terminals are undamaged —That all controls on the front panel are correctly set, for MMA/TIG and with or without remote contro! device {local/remate contral) GENERAL Posible Faults Item Sympton Probable Cause Remedy T.__Thdcating lamp LPT dows nats, Fuse FST GA) Ras own Replace fuse. 11 the Tor Hows apm light andlor fon E does not mien? " @ sar Mains fire heck mains fuse, all connections and turminal Main transformer T1 faulty Remove the connections frm secondary terminal Block TB2. Measure the soltane between the upper an tower secondary connections: this should be 120v AG. this voltage not found replace the transform, 4 tncating lamp LP i Measure the voltoge between the conductors tasty Connected to LPI (048 and O86) ths should berddy AG. Ifthe Voltage i prevent replace the lam 2. Fuse FS1 (2A) blows a. Fan Ffeuty Remove connection 008 trom the electronic repnatedly tauipment power supply transformer trial block TB, terminal 8, and insulate the wie iFfuse FSt blows fans faulty. Measure the resistance of the rotor windings, which shoul be 138 ohm, I the rexitance dies appreciably ftom replace the fan, Reconnect ie 008 Electronic equipment Meature the voltages tthe transtorme termina power supply transformer block. "They shou be: 220" on TSS termina Fe tuity Sand. 1351 on TRS terminals 10 and 11 oron Te terminals 13-14, 16-17 and 19-20, 21V on TB terminals 22-20 and 28-24 it aharevltaper ae ot present replace ihe ttanstormer, €. Afaultonacireuit board ‘Replace orcult board. @. Relays RLG,RL2 anofor Replace the faulty ely LS ravi Cooling unit faulty Check the cooling unit and replace if necessary. 3. Mains fute blows when a, Faulty dode(s) or Check thyriators and/or dlodes as deribed Switch St (On/OH 8 thyristor tinder Malntanance turned on Tig WELDING Check That siten $2 is inthe TIG AC of T1G DC postions = That the correct shielding gas is being used, and at the correct flow rate. ‘That the gas supply hose is undamaged = That the TIG torch, welding cable, gas hose and control cable are undamaged = That the HF is set to Position 1 (Position 0 for scratch start) e — That 2 correctly-shaped thorium-alloy tungsten electrode is used for DC welding = That 2 rounded zirconiumrralloy tungsten wire is used for AC welding = That the TIG torch is connected to the correct terminal — That the return cable is undamaged and connected to the workpieceMUREKS tem Symptom Probable Cause Remedy 4. NOH spark for ignition a. Open circuit in the HF ‘check connections tocol L2, capacitors C1 oF TIG welding errs and C2 and HF cable to spark gap SG : WARNING: This is HIGH-VOLTAGE tuipment, and must be checked only inthe Unpowered sate Discharge the capacitors by Shorecircuiting them with screwdriver or Alacharge tik before working onthe equipment A fault inthe torch Shorvetruit terminals ¢ 8b on SK9 forthe Torch contact contact. Ifthe NF unit operates, replace the torch fwitgh, Check thatthe voltage ai terminal SK3 fs 15VDC. Circuit board PCB? is faulty __ Replace the circuit board 3 Nogs ®. Relay RL faulty Masse the voltage aorors ALS (between wires O17-012). If this is 42v AC. replace the relay ©. Hotes or hose connections urge the hore and torch with compressed blocked sir at raduced presure. Check thatthe hoses ae undamaged and not kinked «Gat control potentiometer Remove circut board plug PLA and V2 foulty measure the resistance between wie 037, and OV {connected to terminal D0) ‘Turing the potentiometer must vary this rexietance between 0 and about 1 Mohm, If this is not possible, replace the potentio- NB! When mesturing from terminal seove Contacts, the test probe must aot be rested down a0 fer that ¢ bad eontact may be caused 4. Cireut board PCB 2 is Replace circuit board faulty 6 Noslope-un.or incorrect a. Potentiometer AVA for Remove circuit board plug PLA and measure time slope-up seting faulty the velstanoe between wites 034 and O36, {connected to terminals DY and 06 respectively). Turing potentiometer RVS ‘must very the rsstanes between O hm and Shout § Kohm. If this s not posible, replace the potentiometer b. Circuit board PCB? is Replace circuit board faulty 7. Noslope-down,orincorect a. Potentiometer AVS for Remove circuit board plug PLA and measure time Slope-down adjustment the resitance betwean wires G24 and 035, istaulty (connected to terminals DY and DS). Turning potentiometer RV must vary the resistance fetween 0 ohm and about 5 Kohm, It this it not posible, replace the potentiometer, », Clreuit board Pee? is Replace ciruit boar. faulty 8. Noweldingcurent with Interruption inthe gas flow See item 5. ger-covled torch 8. Thermortst TH (onthe. Check tat there i circult between wires thyeistor bridge) andlor. O42 and084 (on terminal block T7 onthe TH2 fon the inductor) has Thysstor brie), tipped, due ether to high temperature orto a fou in the thermostat tel, e.Aithysstor'sfoulty Check the thyristors as described under Maintenance 4. Potentiomoter RVI for “Set S2tOMIMA and $3 to Local. Remove current setting is faulty, circuit board contact PL1 and check that there is circuit between wires 029 and 042, (connected to terminals Al and Aa respectively) It must be possible to vary the resistance between ohm and about 2.2 Kohm by means of potentiometer RV1.MURD& es? Item Symptom Probable Cause Remedy Para. 8 Continued Circuit board PCBI and/or Remove circuit board PCB2 and make a trial PoB2 faulty weld with a coated electrode (MMA). If the ower source works, replace circuit board PCB2 If the fault persists, replace circuit board PCB1 f. Oxidized electrode Prepare and clean the electrode see page 7 of the ‘operating manual. 9. No welding current with 2. Water supply pump fuse Replace the fuse water-cooled torch and faulty OCD1 cooling unit b. Water pump and/or relay Check the electrical connections to the pump. RL2 for the pump is/are ‘Measure the resistance of the pump motor, which faulty should be about 380 ohm, Measure the voltage fon wires 095 and 096, connected to terminals 13 and 14 respectively of relay RL2. This voltage should be 24v DC. If the voltage is present the relay is faulty and should be replaced, ©. Cooling water hoses and/ Check that the hoses are undamaged and not (oF connections blocked kinked. Check to see whether there is a blockage in the torch, If the fault remains, see Item 8, 8b and Bf. 10 Welding current is too low 2, Thyristor(s) faulty (Check thyristors as described under Maintenance. b. Circuit board{s) PCB As item Be. and/or PCB2 faulty "1 Welding current is too high 8, Thyristor(s) faulty Check thyristors as described under Maintenance. b. Open circuit in the shunt Remove circuit board plug PL1 ‘connections sand check that there is no break in wires 072 or 073, (connected to terminals 2 and 3 respectively} ©. Potentiometer RV1 for As item 8d, {current setting is faulty. 12, No base current (i.e. 2. Relay ALI for basecurrent Set switch $2 to the MMA, AC. difficulty in maintaining is faulty position, Measure the voltage between ‘the are and poor welding ‘wires 087 and 088 connected to characteristics with low AC terminals A and A2 respectively of welding currents) relay RL1. This should be 24v DC. the affirmative replace the relay. b. Resistor R1 for base Measure the resistance, which should current is faulty be 250hm. If not, replace the resistor. 13, HF spark isnotinterrupted —_._Diode(s) D1/D2 for base (Check the diodes as described under ‘when welding with DC. current is/are faulty Maintenance. (The arc is unstable, and welding current deviates from the set value) 14, Irregular or missing HF— a, Deposits on spark plug Clean spark plug, with wire brush. spark. SG Should problem remain, replace spark plug.METAL ARC WELDING Check ~ That switch $2 is in the MMA, AC or DC positions — That welding cables and electrode holder are undamaged r ) — That the return cable is undamaged and connected to the workpiece Probable Cause Remedy a, Thermostat TH1 (on the thyristor bridge) and/or ‘TH2 (on the inductor) has tripped, due either to high ‘temperature or to a fault in the thermostat itself. b. A thyristor is faulty ©. Potentiometer RV1 for current setting is faulty. rouit board PCB and/ ‘or PCB? faulty, As item Bb. Check the thyristors as described under Maintenance. As item 8d. As item Be. Item ‘Symptom 18. Nowelding current 16, Welding current is too low . Welding current is too high a. Thyristor(s) faulty b. Circuit board(s) PCBI and/or PCB2 faulty. a. Thyristor(s) faulty b. Open circuit in the shunt connections. ¢, Potentiometer RV1 for current setting is faulty. CCheck thyristors as described under Maintenance. As item Be, Check thyristors as described under Maintenance. As item 1, ‘As item 8d, EE Insulation and Continuity Test Yearly {or After a Long Period of Storage) Carry out an insulation resistance and continuity test as follows:— 1. Switeh off and isolate the main supply. . Using an insulation/reistance He ee ice ser on the ohms range, check for earth ontinuity. between che mains Iead earth terminal and all earthed components A reading of reo hme should be obtained, A simple bulb and battery may be Used if a meager or similar le not fvatlable, "The bulb should glow brightly if "continuity ssa factory. 3. Remove the two peb's from tireut by dlaconnecting PLI2.3 8:4. (The four ped plug 4. Wire together ‘R’ and ‘S'('U'&’'V"), mains input terminals(or the cable tends),to form a common junction. 5. Turn the ON/OFF switch to the ‘ON’ position. 6. Wire together the (—) and (+) output sockets, Using a 500V insulation tester (eg. megger) check for an insu: MAINTENANCE lation resistance of at least 2M ‘ohms betwoen: a. The input terminals ‘common junetion’ and the output terminals (paras. 4 & 6 above). b. The input terminals and each of the 10V, 21V-0-21V and 135V ae outputs of TRA, 8 Refit p.cib. connectors, reconnect to the mains supply and test the equipment before use. Overload Protection The overload protection thermostat’s are mounted on the thyristor br and choke and will interrupt the welding current when the rectifier is overloaded. The current will aut matically be reset when the unit is adequately cooled down. Hf the output is shut off, keep the mains switched on leaving the fan running to minimize the cooling time. ‘Schedule Maintenance Dai 1. Check all welding and electrical cables for signs of cracking or general deterioration. 2. Check that all electrical con. nections are condition. 3. Check the electrode holder for damage. Replace any suspect, partis). ALWAYS CHECK THE WELDING AREA DAILY FOR POSSIBLE SAFETY HAZARDS IF IN DOUBT in good physica! CONSULT YOUR SAFETY OFFICER. SbeMonthly 1. Switch off the unit and diseon- ect from the mains electrical supply. 2. Remove the top cover (retain the fixing screws). 3. Using a soft brush, remove any dust or dirt from the interior of the unit. If compressed air is Used to clean the unit the pressure must not exceed 2kg/em? (30Ib/ in2), and the air must be dry. CAUTION: Suitable eye and mouth protection should be worn. 4, Check the security of all com. ponents and connections. 5. Carry out an insulation and con: nuity test as detailed above, 6. Refit the covers,— bc POSITION — Ac POSITION T oy | Falls 2 z we wl] fr 38 36 ° & ¢ a 9 +34 [pa gB CB)sxe sil) se & (rss zy ev [teflon rs ac x6 Be 3 TI oie T Sé le? (HF) , oo dome my im on ae ty ost 1a & ooo @ cot el scp op ages ma (Gps! bt 1c Tia soePCB 1 Circuit° boo 6 8 os ” € a ‘ 9 eos o ° PCB 1 Board Layoutavert PCB 2 Board Layout‘= 6.4 +0.05mm xm] jex “My \ A Control Etctrode ‘4 Anode thet cathode Conduction —> Thyristor Fitting Instructions Replacing the thyristors When fitting a thyristor itis most important that the correct torque force be applied, and that the mating surface of the heat sink and the thyristor is absolutely clean and free from sharp edges. Smear the connecting surface of the heat sink with a very thin coating of heatsink compound or silicon ‘grease Fit the thyristor with the rectifier symbol on the thyristor facing in the direction shown opposite. The thyristor is centered by ‘means of a guide pin. First, tighten the nuts by hand, making sure that’ there is no play between washers and nuts. Then, using @ vernier caliper, measure the distance from the plate to the spring as shown. Finally, tighten the nuts alternatively with a wrench until the measurement is 6.4 * 0.08mm