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ESAB Caddy Tig 1500i TA34, Service Manual

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TABLE OF CONTENTS

0740 800 186

© ESAB AB 2016

READ THIS FIRST

................................................................................................

4

INTRODUCTION

...................................................................................................

5

TECHNICAL DATA

...............................................................................................

6

WIRING DIAGRAM

...............................................................................................

8

DESCRIPTION OF OPERATION

........................................................................

14

1 MMC module

....................................................................................................

14

2AP1 Power supply board

.................................................................................

14

2AP1:1 Interference suppressor circuit ............................................................ 15
2AP1:2 Primary circuit...................................................................................... 15
2AP1:3 Secondary circuit................................................................................. 16
2AP1 Component positions.............................................................................. 17

10AP1 TIG board

................................................................................................

18

10AP1 Component positions............................................................................ 19

15AP1 Power board

...........................................................................................

21

Charging circuit ................................................................................................ 21
Power factor corrector (PFC) ........................................................................... 21
Gate driver stages............................................................................................ 22
Switching circuit ............................................................................................... 22
Supply to 2AP1 ................................................................................................ 22
15AP1 Component positions............................................................................ 23

15AP2 Secondary board

....................................................................................

23

15AP2 Component positions............................................................................ 25

20AP1 Control board

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25

20AP1:1 Power supply..................................................................................... 26
20AP1:2 The CAN bus..................................................................................... 28

Starting sequence .......................................................................................... 28
Communication interruptions ......................................................................... 29
Terminating resistors ...................................................................................... 29

20AP1:3 Control panel interface circuits .......................................................... 29
20AP1:4 Pulse width modulator ....................................................................... 29
20AP1:5 Temperature monitoring .................................................................... 30
20AP1:6 Shunt and current control amplifier ................................................... 30
20AP1:7 Arc voltage feedback......................................................................... 31
20AP1:8 TIG functions ..................................................................................... 32
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

Summary of Contents for Caddy Tig 1500i TA34

Page 1: ...Caddy Service manual 0740 800 186 GB 20160202 Valid for serial no 803 to 843 xxx xxxx Tig 1500i TA34 Tig 2200i TA33 TA34 ...

Page 2: ...itching circuit 22 Supply to 2AP1 22 15AP1 Component positions 23 15AP2 Secondary board 23 15AP2 Component positions 25 20AP1 Control board 25 20AP1 1 Power supply 26 20AP1 2 The CAN bus 28 Starting sequence 28 Communication interruptions 29 Terminating resistors 29 20AP1 3 Control panel interface circuits 29 20AP1 4 Pulse width modulator 29 20AP1 5 Temperature monitoring 30 20AP1 6 Shunt and curr...

Page 3: ...ce 38 SERVICE INSTRUCTIONS 40 What is ESD 40 Service aid 40 Checking the semiconductor module of 15AP1 42 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 ...

Page 4: ...iption of operation Component names in the wiring diagram are listed in the component description Use the spare parts list as a guide to where the components are located in the equipment The spare parts list is published as a separate document see the SPARE PARTS chapter in this manual The manual is valid for Tig 1500i TA34 and Tig 2200i TA33 TA34 with serial no 803 xxx xxxx 828 xxx xxxx and 843 x...

Page 5: ...n 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 15 Power module This module is a single forward converter operating at a switching frequency of 65 kHz All power semiconductors are built into ...

Page 6: ...5 2 V 100 duty cycle 90 A 23 6 V 110 A 24 4 V Power factor at maximum current TIG 0 99 0 99 MMA 0 99 0 99 Efficiency at maximum current TIG 76 75 MMA 80 81 Open circuit voltage without VRD function with VRD function See Chapter Description of operation 35 V See Chapter Description of operation 35 V Operating temperature 10 to 40 C 10 to 40 C Transportation temperature 20 to 55 C 20 to 55 C Constan...

Page 7: ...can weld or cut at a certain load without overloading The duty cycle is valid for 40 C 104 F or below Enclosure class The IP code indicates the enclosure class i e the degree of protection against penetration by solid objects or water 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...

Page 8: ... Ferrite ring cores 2QF1 Mains switch 2XS1 Flat pin sockets Important to obtain a proper electric connection the complete cord set must be replaced if the sockets have to be replaced 10 TIG module 10AP1 TIG board see chapter Description of Operation 10TV1 HF transformer 10YV1 Gas valve 230 V AC 15 Power module 15AP1 Power board see chapter Description of Operation 15AP2 Secondary board see chapter...

Page 9: ...016 20L1 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 ...

Page 10: ...WIRING DIAGRAM 0740 800 186 10 ESAB AB 2016 Tig 1500i with control panel TA34 ...

Page 11: ...WIRING DIAGRAM 0740 800 186 11 ESAB AB 2016 ...

Page 12: ...WIRING DIAGRAM 0740 800 186 12 ESAB AB 2016 Tig 2200i with control panels TA33 and TA34 ...

Page 13: ...WIRING DIAGRAM 0740 800 186 13 ESAB AB 2016 ...

Page 14: ...wer source The control panels are described in separate instruction and service manuals TA33 intended for MMA and DC TIG welding without pulsing TA34 intended for MMA and DC TIG welding with pulsing TA33 TA34 Pushbuttons are used for parameter selection and a knob for parameter settings current time etc 2AP1 Power supply board The power supply board filters the mains voltage and generates internal...

Page 15: ...e suppressor circuit WARNING Dangerous voltage mains voltage 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 ...

Page 16: ...ed by IC1 The isolation voltage of transformer T1 and optocoupler IC3 is 4 kV 15V A Internal power supply to 2AP1 and power supply to the PFC circuits of the power board 15AP1 The voltage is controlled by VR1 it has a tolerance of 0 75V 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 ...

Page 17: ...rning power shut down If the voltage goes low output PS4 generates a warning signal to the processor on circuit board 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 ...

Page 18: ...31 880 used for the Tig 2200i and as spare part WARNING Dangerous voltage mains voltage 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 ...

Page 19: ...the welding torch is 16 metre long the HF spark is about 8 kV Due to electromagnetic interference regulations the energy in the HF ignition spark is limited and so the HF spark weakens with increasing length of the torch The HF ignition is satisfactory for welding torches up to 16 metres Gas valve When the torch switch is operated relay RE1 closes and energizes the gas valve When the torch switch ...

Page 20: ...DESCRIPTION OF OPERATION 0740 800 186 20 ESAB AB 2016 ...

Page 21: ... mains rectifier the charging circuit the PFC circuit the gate circuits and the switching circuits The mains rectifier the switching transistors and parts of the charge and PFC circuits are integrated in a semiconductor module PM1 which is part of the power board Charging circuit When the mains power supply is turned on the rectified mains voltage charges smoothing capacitor 15C1 via resistor R31 ...

Page 22: ... 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 23: ...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 15AP2 Secondary board The secondary board is fitted on the main transformer 15TM1 diode module 15D1 and inductor 15L1 ...

Page 24: ...ode module has failed a replacement module must be fitted in accordance with the instructions in chapter Service Instructions Inductor L1 forms an LC circuit with C3 C4 and D1 to reduce the risk of arc extinction at low welding currents 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 ...

Page 25: ...ulty it must be replaced After replacing the circuit board soft start the power source See the instructions in chapter Service Instructions There are two hardware versions of the control board see section Component Positions of this chapter NOTE The spare part boards have different ordering numbers for the Tig 1500i TA34 Tig 2200i TA33 and Tig 2200i TA34 see the spare parts list Circuit board iden...

Page 26: ...e changed by ESAT The ID numbers of the different control panels are TA33 machine ID 37 TA34 machine ID 20 Hardware ID 4 Unit type 0 20AP1 1 Power supply 5 V and 2 5 V IC6 monitors the 24 V voltage supply to the 5 V regulator on circuit board 2AP1 IC16 monitors the 5 and 2 5 V supplies Regulator VR4 supplies the processor with 2 5 V The voltage on terminal PS4 is normally about 24 V when this drop...

Page 27: ...age Voltage divider R70 R75 supplies 2 6 V to the processor This provides a signal that the power supply is available Voltage regulator VR1 produces an output voltage of 15 V and this together with the 15 V supply powers the analogue circuits 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 ...

Page 28: ...ulated and is galvanically isolated from other parts of the control board The shell of the CAN connectors and the shield of the CAN cables are connected to 0V CAN GND in the diagram is connected to the power source chassis Voltage regulator VR5 supplies a 5 V power supply to the CAN circuits on 20AP1 Starting sequence On power up the board s CAN controller reads in the bus speed from the micro pro...

Page 29: ...h 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 Check that each signal is being carried by the correct core CAN H and CAN L must be carried by the twinned pair Terminating resistors In order to avoid communication interference the ends of the CAN bus mus...

Page 30: ...ich 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 The power source cannot be restarted until it has cooled sufficiently for the switch es to reclose 20AP1 6 Shunt and current control amplifier The shunt produces 60 mV at a welding c...

Page 31: ...nction deactivated See the component positions diagram in section Component Positions of this chapter for identification of circuit board versions TIG The open circuit voltage is about 90 V Arc voltages above 45 V are defined as no welding Output voltage is produced only when TIG welding is in progress If the open circuit voltage arc voltage is above 45 V for more than 100 milliseconds the open ci...

Page 32: ...creases decreases to the set current HF TIG start See 10AP1 TIG board on page section 10AP1 TIG board of this chapter 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 The process regulator control principle Hot start MMA ...

Page 33: ...elding mode the peak current is three times the set value but the duration is shorter at only 50 ms The hot start current phase 2 above is engaged for 240 milliseconds It is set in per cent of the set current but does never exceed the peak current 20AP1 10 Cooling unit control Starting the welding equipment 1 The welding data unit senses whether the water lock microswitch 5S2 is closed or not 2 If...

Page 34: ...s always flowing Microswitch 5S2 in the water lock connector closes when a cooling water hose is connected to the blue water connector on the front of the cooling unit The pump stops if the switch opens 20AP1 Component positions Version 2 of the control board There are two hardware versions of the control board See section 20AP1 7 Arc voltage feedback of this chapter for description of the differn...

Page 35: ...Power sources with serial no 803 xxx xxxx are delivered with version 1 of 20AP1 Version 2 of 20AP1 Print numbers from 487343 005 and there above 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 ...

Page 36: ...MOTE CONTROLS 0740 800 186 36 ESAB AB 2016 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 ...

Page 37: ...e which unit has generated the fault The following unit numbers are used U0 welding data unit U2 power source U4 remote control unit Summary of fault codes Cod e Description Welding data unit Power source Remote control unit 1 Memory error EPROM x x x 2 Memory error RAM x x 3 Memory error external RAM x x 4 5 V power supply x 6 High temperature x 8 Power supply 1 x 9 Power supply 2 x 12 Communicat...

Page 38: ...e error 4 Memory hardware error This is an unlikely cause for the error First try to restart equipment again to clear the error If that does not clear the error then perform a general reset of the equipment and restart twice to clear the error If the error still persists then replace circuit board 20AP1 Power source Code Description power source 1 EPROM check sum error program memory error Check s...

Page 39: ...s or outlets blocked or obstructed or dirt on the heat exchanger 12 Communication error warning The load on the system CAN bus is temporarily too high or there is electric noise on the bus Action Check that all units are correct connected to the CAN bus See also section 20AP1 2 The CAN bus in chapter Description of Operation 15 Lost messages The bus CAN controller indicates that a message has been...

Page 40: ...tive materials e g fabrics or insulators e g plastics generate and hold static charge so you should not bring unnecessary nonconductive items into the work area It is obviously difficult to avoid all such items so various means are used to drain off any static discharge from persons to prevent the risk of ESD damage This is done by simple devices wrist straps connected to ground and conductive sho...

Page 41: ...nd a CAN reader From the ESAT it is possible to update the software ESAT also contains service functions by which it is possible to control change or read the different functions of the equipment For the installation and use of the ESAT you need a PC with operating system Windows The ESAT service kit contents CAN adapter with connection cables CD with software Instruction manual for ESAT USB2CAN f...

Page 42: ...istor R31 and thyristor TY1 in parallel measure the resistance of R31 It must be 12 ohm on some boards the resistance of R31 is 6 8 or 10 ohm which are also approved values 2 PM1 diode P1D measure between resistor R31 and terminal N1 PM1 diode P2D measure between resistor R31 and terminal N2 The forward voltage drop must be 0 4 to 0 6 V 3 PM1 diode N1D measure between the negative of capacitor 15C...

Page 43: ...l T2 and gate pin 14 of the module The resistance must be higher than 500 kohm Circuit diagram and measuring points for the semiconductor module Checking rectifier and freewheel diodes 1 Disconnect the power source from the mains 2 Dismantle the housing of the power source 3 Use a Torx key no T25 to unscrew and remove five screws from circuit board 15AP2 The screws are marked on the picture below ...

Page 44: ...ESAB AB 2016 Measuring points circuit board 15AP2 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 ...

Page 45: ...he gate pulse test cable of the SST 3 to terminal G on control board 20AP1 Measuring connection for the gate pulses 4 Switch on the power source 5 Connect an oscilloscope to the SST 3 with the probe to terminal G2 and the screen to terminal G1 of SST 3 6 Set the machine to MMA welding mode 7 Measure the pulse frequency It must be 65 kHz 1kHz 8 Measure the duration of the negative pulse It must be ...

Page 46: ...ed earlier in this chapter Instructions 1 Disconnect wires 1501 1502 1503 1504 red and yellow from circuit boards 2AP1 and 15AP1 see the circuit diagram below Disconnections prior to soft starting 2 Connect the 230 V AC input of the SST 3 to terminals B2 and B4 on circuit board 2AP1 3 Connect the 325 V DC output of the SST 3 to terminals F1 and F3 on circuit board 2AP1 The SST 3 connected to 2AP1 ...

Page 47: ...en the power source is in normal operating mode See Power factor corrector in chapter Description of Operation 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 The purpose of the past...

Page 48: ...ibed above 2 Fit the module and tighten the screws to a torque of 2 5 Nm and then further tighten them to 4 5 Nm 3 Tighten the connections to circuit board 15AP2 to 4 5 Nm 4 Tighten the screws that connect transformer 15TM1 and inductor 15L1 to circuit board 15AP2 to a torque of 4 5 Nm CAUTION Incorrectly fitted components can cause failure Do not tighten the screws to more than 4 5 Nm 15ST2 Therm...

Page 49: ...0740 800 186 49 ESAB AB 2016 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 ...

Page 50: ...34 91 878 3600 Fax 34 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel 46 31 50 95 00 Fax 46 31 50 92 22 ESAB International AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB Europe GmbH Neuhof Business Center Neuhofstr 4 Tel 41 1 741 25 25 Fax 41 1 740 30 55 UKRAINE ESAB Ukraine LLC Kiev Tel 38 044 501 23 24 Fax 38 044 575 21 88 North and South America ARGENTINA CONARCO Buenos ...

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