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Summary of Contents for ESAB Cadd Tig 1500i TA34
- Page 1 Caddy Tig 1500i TA34 Tig 2200i TA33/TA34 Service manual 0740 800 186 080826 Valid for serial no. 803- -xxx- -xxxx to 843- -xxx- -xxxx...
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Page 2: Table Of Contents
READ THIS FIRST ..............INTRODUCTION . - Page 3 INSTRUCTIONS ..............SAFETY .
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Page 4: Read This First
READ THIS FIRST Maintenance and repair work should be performed by an experienced person, and electrical work only by a trained electrician. Use only recommended replacement parts. This service manual is intended for use by technicians with electrical/electronic training for help in connection with fault--tracing and repair. -
Page 5: Technical Data
module number, which is always included as the first part of the name/identification of components in the module. The modules have the following main functions: 1 MMC module Control panel and display board. 2 Mains module Mains switch, mains interference suppressor and power supply board. 10 TIG module Torch switch interface, HF unit, gas valve. -
Page 6: Wiring Diagram
Tig 1500i TA34 Tig 2200i TA33/TA34 Weight without cooling unit 9.2 kg 9.4 kg cooling unit with / without cooling water 6.7 kg / 4.5 kg Shielding gas All types intended for All types intended for TIG welding TIG welding max pressure 5 bar 5 bar... - Page 7 10TV1 HF transformer. 10YV1 Gas valve, 230 V AC. Power module. 15AP1 Power board, see page 20. 15AP2 Secondary board, see page 23. 15C1 Smoothing capacitor, 1000 uF. 15D1 Diode module with rectifier and freewheel diodes. 15EV1 Fan. 15L1 Inductor. 15L2 PFC Inductor (Power Factor Corrector) 15RS1...
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Page 8: Tig 1500I
Tig 1500i with control panel TA34 S0740 800 186/E080826/P50 - - 8 - - ct34_00... - Page 9 S0740 800 186/E080826/P50 - - 9 - - ct34_00...
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Page 10: Tig 2200I
Tig 2200i with control panels TA33 and TA34 S0740 800 186/E080826/P50 - - 10 - - ct34_00... - Page 11 S0740 800 186/E080826/P50 - - 11 - - ct34_00...
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Page 12: Description Of Operation
DESCRIPTION OF OPERATION This description of operation describes the function of circuit boards and other components in the equipment. It is divided into sections, numbered to correspond to the circuit board numbers and divisions into function blocks. 1 MMC module The MMC module consists of an operator’s control panel and a display board. -
Page 13: 2Ap1 Power Supply Board
2AP1 Power supply board The power supply board filters the mains voltage and generates internal supply voltages for the machine. There are two versions of the power supply board: 0487 064--884 is used for the Tig 1500i and 0487 631--880 is used for the Tig 2200i. The difference between the two versions is the size of inductor L1. -
Page 14: 2Ap1:2 Primary Circuit
2AP1:2 Primary circuit WARNING! Dangerous voltage - mains voltage. The primary circuit is supplied with 325 V DC from the power board, 15AP1. S1 is a fuse with high rupturing capacity. Transistor Q5 is the switching element in a switched voltage supply. The secondary voltage, +24 V, is sensed by IC2 and controlled by IC1. -
Page 15: 2Ap1:3 Secondary Circuit
2AP1:3 Secondary circuit The secondary circuit delivers the following voltages: +24 V The voltage is controlled by IC1 on the primary side. It has a tolerance of ±0.6 V. +5 V The voltage is controlled by VR3. It has a tolerance of ±0.25 V. - -15 V The voltage is controlled by VR2. -
Page 16: 2Ap1 Component Positions
2AP1 Component positions Power supply board 0487 064- -884, used for the Tig 1500i WARNING! Dangerous voltage - mains voltage. S0740 800 186/E080826/P50 - - 16 - - ct34_02... - Page 17 Power supply board 0487 631- -880, used for the Tig 2200i and as spare part WARNING! Dangerous voltage - mains voltage. S0740 800 186/E080826/P50 - - 17 - - ct34_02...
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Page 18: 10Ap1 Tig Board
10AP1 TIG board WARNING! 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. The processor on circuit board 20AP1 controls the HF generator and gas valve. HF generator When the welding torch switch is operated, and the open--circuit voltage is over 50 V, relay RE2 closes and turns on the HF generator, TR2. -
Page 19: 10Ap1 Component Positions
10AP1 Component positions WARNING! Dangerous voltage - mains voltage. S0740 800 186/E080826/P50 - - 19 - - ct33_10... -
Page 20: 15Ap1 Power Board
15AP1 Power board WARNING! Dangerous voltage - mains voltage. Never make any measurements on this board when the machine is connected to the mains supply. CAUTION! There are different versions of the power board available. See the spare parts list to find the correct spare part for the machine. -
Page 21: Gate Driver Stages
Gate driver stages Transformer TR1 is a gate driver transformer for galvanic isolation of the drive circuits from controller board 20AP1. Switching circuit 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). -
Page 22: 15Ap1 Component Positions
15AP1 Component positions Pin positions of the semiconductor module: (Seen from the component side of the board). Pin 1 marked P1 starts in the down--left corner and continuous anticlockwise around the semiconductor module. S0740 800 186/E080826/P50 - - 22 - - ct33_15_1... -
Page 23: 15Ap2 Secondary Board
15AP2 Secondary board The secondary board is fitted on the main transformer 15TM1, diode module 15D1 and inductor 15L1. Diode module 15D1 comprises two diodes, rectifier and freewheel diode. During the time interval between two voltage pulses from transformer 15TM1, the freewheel diode maintain the welding current from inductor 15L1. -
Page 24: 20Ap1 Control Board
20AP1 Control board The processor on the control board monitors and controls the various functions of the power source. The control board is used in combi mode. In combi mode the board handles the control of the power source, the welding data unit and the MMC panel. If the circuit board is faulty, it must be replaced. - Page 25 The voltage on terminal PS4 is normally about 24 V, when this drops below 20 V, pin 14 of IC6 goes low, providing the processor with a low power supply voltage signal. The processor then stores current data and generates fault code E4.
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Page 26: 20Ap1:2 The Can Bus
20AP1:2 The CAN bus Bus communication circuits to and from the control board A standardised communication (CAN -- Controller Area Network) bus is used for communication between the units of the machine. Communication speed is 400 kbit/s. The +12V_CAN and 0V_CAN power supply is unregulated and is galvanically isolated from other parts of the control board. -
Page 27: Terminating Resistors
All screen connections must be sound. Check the screen connections of the CAN cabling. Good contact with the chassis connections from/to the circuit boards and suppressor capacitors. See the main circuit diagram. The connection cable between units. Check that the correct type of cable is being used. -
Page 28: 20Ap1:5 Temperature Monitoring
20AP1:5 Temperature monitoring The thermal overload switches, 15ST1 and 15ST2, are normally closed. Terminal T2 of the circuit board is at 0 V. 15ST2, which is fitted on the heat sink, opens at 75 _C. 15ST1, which is fitted in the winding of the main transformer, 15TM1, opens at 130 _C. If either of the switches operates, the power source is stopped, fault code E06 is displayed. -
Page 29: 20Ap1:7 Arc Voltage Feedback
20AP1:7 Arc voltage feedback This circuit measures and scales the arc voltage to a suitable level for the processor. 64 V arc voltage produces a voltage signal of 5.0 V at the cathode of diode D13. Open- -circuit voltage control Version 1 of 20AP1: The open--circuit voltage control holds the voltage at about 70 V. -
Page 30: 20Ap1:9 Welding Process Control
HF TIG start See: 10AP1 TIG board, on page 18. 20AP1:9 Welding process control The processor inputs are the set values of welding data and the arc voltage. The processor also calculates a set value signal for welding current, and supplies this to the current control amplifier. -
Page 31: 20Ap1:10 Cooling Unit Control
20AP1:10 Cooling unit control Starting the welding equipment The welding data unit senses whether the water lock microswitch, 5S2, is closed or not. If it is closed, a command to start the pump is generated, and a relay in the cooler starts the pump and the fan. If welding does not start within 6.5 minutes, the pump is stopped. -
Page 32: 20Ap1 Component Positions
20AP1 Component positions Version 2 of the control board 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.) Version 1 of 20AP1: Print numbers up to and including 487343--004. -
Page 33: 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. FAULT CODES Fault codes are used in order to indicate and identify a fault in the equipment. Fault log All faults that occur when using the welding equipment are documented as error messages in the fault log. -
Page 34: Fault Code Description
Code Description Welding Power Remote data source control unit unit *28 Stack overflow *40 Incompatible units 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 page 37. - Page 35 Code Description, power source High temperature The temperature monitoring circuit has operated. The power source is stopped, and cannot be restarted until the circuit has reset. See also page 28. Possible causes: Overloading, fan not working properly, cooling air inlets or outlets blocked or obstructed or dirt on the heat exchanger.
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Page 36: 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 37 The software update is made from a PC, it has to be managed by a trained serviceman. For this a computer 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 in power source, wire feeder and control panel.
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Page 38: Checking The Semiconductor Module Of 15Ap1
Checking the semiconductor module of 15AP1 Measuring points for the semiconductor module, PM1 Disconnect the machine from the mains and follow the instructions below. Measurements 2 -- 6: Use a multimeter in diode test position to measure the diodes. Measure with the positive and negative of the multimeter connected as shown in the picture above. - Page 39 PM1, diode D3: measure between the positive of capacitor 15C1 and terminal T2. The forward voltage drop must be 0.3 to 0.5 V. PM1, diode D1: measure between the positive of capacitor 15C1 and terminal L2. The forward voltage drop must be 0.3 to 0.5 V. PM1, transistor Q2: measure the resistance between source, the positive of capacitor 15C1, and gate, pin 19 of the module.
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Page 40: Checking Rectifier And Freewheel Diodes
Checking rectifier and freewheel diodes Disconnect the machine from the mains. Dismantle the housing of the machine. Use a Torx key no. T25 to unscrew and remove five screws from circuit board 15AP2. The screws are marked on the picture below, Bend out the circuit board so that it has no contact with the connections of the diode module. -
Page 41: Checking The Gate Pulses
Checking the gate pulses When checking the gate pulses, the machine can either be in soft--start mode or in normal operation mode. Special equipment To measure the gate pulses, you need a gate pulse load. This is included in soft--starting tool SST 3, which is described on page 36. -
Page 42: Soft Starting
Soft starting We recommend soft starting of the machine after replacing control circuit board 20AP1, power supply board 2AP1 and circuit boards or components in the power module. Soft starting supplies the power module with a low voltage in order to avoid injury to persons or damage to components. - Page 43 Disconnect connector 15XS3 (supply to the fan) from terminal E of circuit board 2AP1. Connect the 24 V DC input of the SST 3 to terminal E of circuit board 2AP1. Connect the 24 V DC output of the SST 3 to terminals N1 and N2 of power board 15AP1.
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Page 44: Mounting Components On The Heat Sink
Mounting components on the heat sink Thermal paste Apply thermal conducting paste to the components before fitting them to the heat sink. Start by cleaning the heat sink, and then apply a very thin, even layer of thermal paste to the contact surfaces of the components. -
Page 45: Safety
INSTRUCTIONS This chapter is an extract from the instruction manual for the Tig 1500i TA34, Tig 2200i TA33 and Tig 2200i TA34. SAFETY CAUTION! Read and understand the instruction manual before installing or operating. INSTALLATION The installation must be executed by a professional. Location Position the welding power source such that its cooling air inlets and outlets are not obstructed. -
Page 46: Operation
11 Connection RED for cooling water to the cooling unit. 6 Connection (--) for TIG--torch 12 Refilling of cooling water MMA: for return cable or welding cable * ESAB Logic Pump, see ’Water connection’ below S0740 800 186/E080826/P50 - - 46 - - ct34i1... -
Page 47: Water Connection
Water connection The cooling unit is equipped with a detection system ELP (ESAB Logic Pump) which checks that the water hoses are connected. When connecting a water--cooled TIG torch cooling starts. Overheating protection The power source has two thermal overload trips which operate if the internal temperature becomes too high. -
Page 48: Spare Parts
Check that the correct current value is set. Check that the correct electrodes are being used. Check the gas flow. 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... -
Page 49: Notes
NOTES S0740 800 186/E080826/P50 - - 49 - - notes... - Page 50 ESAB subsidiaries and representative offices Europe Asia/Pacific Representative offices NORWAY AS ESAB AUSTRIA BULGARIA CHINA Larvik ESAB Ges.m.b.H ESAB Representative Office Shanghai ESAB A/P Tel: +47 33 12 10 00 Vienna- -Liesing Sofia Shanghai Fax: +47 33 11 52 03...
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