Related Manuals for ESAB Caddy Tig 1500i TA34
Summary of Contents for ESAB Caddy Tig 1500i TA34
- Page 1 Caddy™ Tig 1500i TA34 Tig 2200i TA33/TA34 Service manual 0740 800 186 GB 20160202 Valid for: serial no. 803- to 843-xxx-xxxx...
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Page 2: Table Of Contents
20AP1:9 Welding process control ..............32 20AP1:10 Cooling unit control................33 20AP1 Component positions................34 REMOTE CONTROLS ..................36 FAULT CODES ....................37 Fault log ......................37 Summary of fault codes ..................37 0740 800 186 © ESAB AB 2016... - Page 3 Checking rectifier and freewheel diodes ............43 Checking the gate pulses.................. 44 Soft starting ......................46 Mounting components on the heat sink ............47 SPARE PARTS ....................49 Rights reserved to alter specifications without notice. 0740 800 186 © ESAB AB 2016...
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Page 4: Read This First
On completion of service or repair work, it is the responsibility of the person(s) performing the work to ensure that the product still complies with the requirements of the above standard. 0740 800 186 - 4 - © ESAB AB 2016... -
Page 5: Introduction
20 Processor board module (controller module) This is the controller board, 20AP1, that monitors and controls the power source. The micro processor of the board comprises the welding data unit. 0740 800 186 - 5 - © ESAB AB 2016... -
Page 6: Technical Data
/ without cooling 6.7 kg / 4.5 kg water Shielding gas All types intended for TIG All types intended for TIG welding welding max pressure 5 bar 5 bar Insulation class transformer 0740 800 186 - 6 - © ESAB AB 2016... - Page 7 Equipment marked IP23 is intended for indoor and outdoor use. Application class The symbol indicates that the power source is designed for use in areas with increased electrical hazard. 0740 800 186 - 7 - © ESAB AB 2016...
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Page 8: Wiring Diagram
"Description of Operation". 15ST2 Thermal switch, fitted on the heat sink. See chapter "Description of Operation". 15TM1 Main transformer. 20AP1 Controller circuit board. See the description in chapter "Description of Operation". 0740 800 186 - 8 - © ESAB AB 2016... - Page 9 Ferrite ring core. CAUTION! STATIC ELECTRICITY can damage circuit boards and electronic components. • Observe precautions for handling electrostaticsensitive devices. • Use proper static-proof bags and boxes. Placement of the circuit boards 0740 800 186 - 9 - © ESAB AB 2016...
- Page 10 WIRING DIAGRAM Tig 1500i with control panel TA34 0740 800 186 - 10 - © ESAB AB 2016...
- Page 11 WIRING DIAGRAM 0740 800 186 - 11 - © ESAB AB 2016...
- Page 12 WIRING DIAGRAM Tig 2200i with control panels TA33 and TA34 0740 800 186 - 12 - © ESAB AB 2016...
- Page 13 WIRING DIAGRAM 0740 800 186 - 13 - © ESAB AB 2016...
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Page 14: Description Of Operation
0487 631-880 is used for the Tig 2200i. The difference between the two versions is the size of inductor L1. Circuit board 0487 631-880 is deliverd as spare part for all machines. 0740 800 186 - 14 - © ESAB AB 2016... -
Page 15: 2Ap1:1 Interference Suppressor Circuit
The mains voltage is filtered by the power supply board. Power board 15AP1 rectifies the mains voltage. TIG board 10AP1 uses the mains voltage for supply to the HF generator and the gas valve. 2AP1:2 Primary circuit 0740 800 186 - 15 - © ESAB AB 2016... -
Page 16: 2Ap1:3 Secondary Circuit
+5 V The voltage is controlled by VR3. It has a tolerance of ±0.25 V. -15 V The voltage is controlled by VR2. It has a tolerance of ±0.75 V. 0740 800 186 - 16 - © ESAB AB 2016... -
Page 17: 2Ap1 Component Positions
20AP1 (see section "20API Control board"). Transistor Q6 switches off the fan, 15EV1, at the same time. 2AP1 Component positions Power supply board 0487 064-884, used for the Tig 1500i WARNING! Dangerous voltage - mains voltage. 0740 800 186 - 17 - © ESAB AB 2016... -
Page 18: 10Ap1 Tig Board
Dangerous voltage - mains voltage. The relay contacts, the gas valve 10YV1, the HF generator TR2 and the primary side of transformer TR1 are connected to 230 V mains voltage. 0740 800 186 - 18 - © ESAB AB 2016... -
Page 19: 10Ap1 Component Positions
The secondary windings of transformer TR1 and rectifier bridge D3-D6 produce 24 V DC. This voltage energizes relay RE3 when the torch switch is closed. 10AP1 Component positions WARNING! Dangerous voltage - mains voltage. 0740 800 186 - 19 - © ESAB AB 2016... - Page 20 DESCRIPTION OF OPERATION 0740 800 186 - 20 - © ESAB AB 2016...
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Page 21: 15Ap1 Power Board
26 A the PFC does not work, the intermediate voltage is then 325 V or less. When the PFC is working properly the voltage across capacitor 15C1 is 365 V. 0740 800 186 - 21 - © ESAB AB 2016... -
Page 22: Gate Driver Stages
The switching transistors are integrated in the semiconductor module, PM1. Supply to 2AP1 The board supplies power supply board 2AP1 with 325 V DC (pins F1 and F3, connector 15XS1). 0740 800 186 - 22 - © ESAB AB 2016... -
Page 23: 15Ap1 Component Positions
Pin 1 marked P1 starts in the down-left corner and continuous anticlockwise around the semiconductor module. 15AP2 Secondary board The secondary board is fitted on the main transformer 15TM1, diode module 15D1 and inductor 15L1. 0740 800 186 - 23 - © ESAB AB 2016... - Page 24 When rectifier diode 15D1 conducts, the LC circuit charges up. The circuit is capable of temporarily maintaining a high arc voltage at low current, thus reducing the risk of arc extinction. Diode D1 prevents capacitor C3//C4 from going negative. 0740 800 186 - 24 - © ESAB AB 2016...
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Page 25: 15Ap2 Component Positions
Power source unit The control board has a machine ID, a hardware ID and a unit type number. To read this you need the ESAT service kit, see chapter "Service Instructions". 0740 800 186 - 25 - © ESAB AB 2016... -
Page 26: 20Ap1:1 Power Supply
E4. When the 5 and 2.5 V voltages are passing below their treshold values, the processor receives a reset signal from IC16. Fault code E4 is not displayed at normal power off. 0740 800 186 - 26 - © ESAB AB 2016... - Page 27 -15 V The -15 V power supply is monitored by the processor. +12 V CAN The +13 VB from 2AP1 is used to supply the CAN circuits of the equipment. 0740 800 186 - 27 - © ESAB AB 2016...
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Page 28: 20Ap1:2 The Can Bus
LED1 lights red. Then LED1, LED2 and LED3 lights green. When the board has been initiated, and the power source is in the application program, LED1 flashes continously with a green light. LEDs on circuit board 20AP1 0740 800 186 - 28 - © ESAB AB 2016... -
Page 29: Communication Interruptions
20AP1:4 Pulse width modulator The pulse width modulator determines the frequency and pulse time of the switching transistors' control pulses. IC3 controls the pulse frequency, the pulse time and inhibition of pulses. 0740 800 186 - 29 - © ESAB AB 2016... -
Page 30: 20Ap1:5 Temperature Monitoring
If the shunt is not connected to the circuit board, resistor R2 supplies about 1.4 to 1.9 V to the shunt input. This blocks the current control amplifier, i.e. the power source does not deliver any welding current. 0740 800 186 - 30 - © ESAB AB 2016... -
Page 31: 20Ap1:7 Arc Voltage Feedback
• When the current exceeds 8 A the hot start current is activated. • When the arc voltage exceeds 52 V, welding stops and the open-circuit voltage control is activated. 0740 800 186 - 31 - © ESAB AB 2016... -
Page 32: 20Ap1:8 Tig Functions
The process regulator control principle Hot start MMA Starting current, MMA welding mode 1. Phase 1, fixed starting current depending on the set current. 2. Phase 2, hot start = adjustable starting current. 0740 800 186 - 32 - © ESAB AB 2016... -
Page 33: 20Ap1:10 Cooling Unit Control
The pump is stopped if the water lock microswitch opens. Starting to weld: 1. The welder presses the welding torch trigger switch. 2. The water pump starts if the water lock microswitch is closed. 3. Welding starts. Stopping welding: 0740 800 186 - 33 - © ESAB AB 2016... -
Page 34: 20Ap1 Component Positions
The print number of the circuit board is used to identify the hardware version of the board. The print number is to the right in the component positions diagram above. (The print number is NOT the same as the ordering number of the board.) 0740 800 186 - 34 - © ESAB AB 2016... - Page 35 Power sources with serial no. 828-xxx-xxxx and 843-xxx-xxxx are delivered with version 2 of 20AP1. Spare parts: Version 2 of 20AP1 is delivered as spare part to all power sources. 0740 800 186 - 35 - © ESAB AB 2016...
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Page 36: Remote Controls
REMOTE CONTROLS REMOTE CONTROLS A number of remote control units can be connected to the power source, these are described in a separate service manual with filename 0740 800 170. 0740 800 186 - 36 - © ESAB AB 2016... -
Page 37: Fault Codes
Fault codes marked with an asterisk ( * ) are not displayed by the control panel. but they are stored in the fault log. To get access to the fault log use the ESAT service tool. See chapter "Service Instructions". 0740 800 186 - 37 - © ESAB AB 2016... -
Page 38: Fault Code Description
This test is preformed only on initiation after power-up. This fault does not disable any functions. Action: Restart the machine. If the fault persists, replace circuit board 20AP1, which carries the microprocessor chip. 0740 800 186 - 38 - © ESAB AB 2016... - Page 39 The control board is unable to process information from the other units at a sufficiently high speed. This fault is caused by abnormal loading of the microprocessor. Action: Turn off the mains power supply to reset the unit. 0740 800 186 - 39 - © ESAB AB 2016...
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Page 40: Service Instructions
We can offer a number of service tools that will simplify the service. Soft-starting tool SST 3 The soft-starting tool SST 3 is made for ESAB's single phase inverters and for 3-phase inverters with 250 A output current. Ordering no. 0459 534 881. - Page 41 The software update is made from a PC, it has to be managed by a trained serviceman. For this a PC program called ESAT, ESAB Software Administration Tool, is needed. The PC is connected to the welding equipment by a cable connector and a CAN reader. From the ESAT it is possible to update the software.
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Page 42: Checking The Semiconductor Module Of 15Ap1
The forward voltage drop must be 0.4 to 0.6 V. 4. PM1, diode D2: measure between the negative of capacitor 15C1 and terminal T2. The forward voltage drop must be 0.3 to 0.5 V. 0740 800 186 - 42 - © ESAB AB 2016... -
Page 43: Checking Rectifier And Freewheel Diodes
5. Use a multimeter in diode test position to measure the forward voltage drop of the two diodes: see the picture below. The voltage drop must be 0.3 to 0.5 V. 6. If the diode module has to be replaced, follow the instructions on page 44. 0740 800 186 - 43 - © ESAB AB 2016... -
Page 44: Checking The Gate Pulses
Circuit diagram and measuring points, circuit board 15AP2 Checking the gate pulses When checking the gate pulses, the power source can either be in soft-start mode or in normal operation mode. 0740 800 186 - 44 - © ESAB AB 2016... - Page 45 8. Measure the duration of the negative pulse. It must be 41 - 43 % of the cycle time, measured at a voltage level of -10 V. 9. The waveform of the pulses must be as shown below. Gate pulses from circuit board 20AP1 0740 800 186 - 45 - © ESAB AB 2016...
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Page 46: Soft Starting
SST 3 to terminal PS of power supply board 2AP1. 5. Connect the power source to the mains and turn on the mains switch. 6. Verify the output voltages from 2AP1, all LEDs on the SST 3 must light. 0740 800 186 - 46 - © ESAB AB 2016... -
Page 47: Mounting Components On The Heat Sink
2. Fit the board and tighten the screws to a torque of 2.5 Nm, and then further tighten them to 4.5 Nm. 3. Tighten the screws that connect transformer 15TM1 and capacitor 15C1 to circuit board 15AP1 to a torque of 4.5 Nm 0740 800 186 - 47 - © ESAB AB 2016... - Page 48 1. Clean the heat sink and apply thermal conducting paste to the thermal overload switch as described above. 2. Fit the thermal overload switch and tighten the screw to 2 Nm. 0740 800 186 - 48 - © ESAB AB 2016...
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Page 49: Spare Parts
The spare parts list is published in a separate document that can be downloaded from the Internet: www.esab.com Product Filename Tig 1500i 0459 839 025 Tig 2200i 0459 839 026 0740 800 186 - 49 - © ESAB AB 2016... - Page 50 ESAB subsidiaries and representative offices Europe NORWAY North and South America SOUTH KOREA AS ESAB ESAB SeAH Corporation AUSTRIA Larvik ARGENTINA Kyungnam ESAB Ges.m.b.H Tel: +47 33 12 10 00 CONARCO Tel: +82 55 269 8170 Vienna-Liesing Fax: +47 33 11 52 03...