ESAB Cadd Tig 1500i TA34 User manual

0740 800 186 Valid for serial no. 803--xxx--xxxx to 843--xxx--xxxx080826
Caddy t
Tig 1500i TA34
Tig 2200i TA33/TA34
Service manual

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Rights reserved to alter specifications without notice.
READ THIS FIRST 4.................................................................
INTRODUCTION 4...................................................................
TECHNICAL DATA 5.................................................................
WIRING DIAGRAM 6.................................................................
Component description 6..........................................................
Tig 1500i 8........................................................................
Tig 2200i 10........................................................................
DESCRIPTION OF OPERATION 12.....................................................
1 MMC module 12..................................................................
2AP1 Power supply board 13.......................................................
2AP1:1 Interference suppressor circuit 13............................................
2AP1:2 Primary circuit 14..........................................................
2AP1:3 Secondary circuit 15.......................................................
2AP1 Component positions 16....................................................
10AP1 TIG board 18................................................................
10AP1 Component positions 19....................................................
15AP1 Power board 20.............................................................
Charging circuit 20..................................................................
Power factor corrector (PFC) 20.......................................................
Gate driver stages 21................................................................
Switching circuit 21..................................................................
Supply to 2AP1 21..................................................................
15AP1 Component positions 22....................................................
15AP2 Secondary board 23.........................................................
15AP2 Component positions 23....................................................
20AP1 Control board 24............................................................
20AP1:1 Power supply 24...........................................................
20AP1:2 The CAN bus 26...........................................................
Starting sequence 26.......................................................
Communication interruptions 26.............................................
Terminating resistors 27....................................................
20AP1:3 Control panel interface circuits 27............................................
20AP1:4 Pulse width modulator 27...................................................
20AP1:5 Temperature monitoring 28..................................................
20AP1:6 Shunt and current control amplifier 28........................................
20AP1:7 Arc voltage feedback 29....................................................
20AP1:8 TIG functions 29...........................................................
20AP1:9 Welding process control 30.................................................
20AP1:10 Cooling unit control 31......................................................
20AP1 Component positions 32....................................................
REMOTE CONTROLS 33..............................................................
FAULT CODES 33....................................................................
Fault log 33........................................................................
Summary of fault codes 33.........................................................
Fault code description 34...........................................................
Power source 34....................................................................
SERVICE INSTRUCTIONS 36..........................................................
What is ESD? 36...................................................................
Service aid 36......................................................................
Checking the semiconductor module of 15AP1 38....................................
Checking rectifier and freewheel diodes 40..........................................
Checking the gate pulses 41........................................................
Soft starting 42....................................................................
Mounting components on the heat sink 44...........................................

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Rights reserved to alter specifications without notice.
INSTRUCTIONS 45...................................................................
SAFETY 45........................................................................
INSTALLATION 45..................................................................
Location 45........................................................................
Mains power supply 45.............................................................
OPERATION 46....................................................................
Connections and control devices 46.................................................
Water connection 47...............................................................
Overheating protection 47..........................................................
MAINTENANCE 47.................................................................
Inspection and cleaning 47.........................................................
FAULT--TRACING 48................................................................
SPARE PARTS 48....................................................................
NOTES 49...........................................................................

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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.
Use the wiring diagram as a form of index for the description of operation. The circuit
boards are divided into numbered blocks, which are described individually in more detail in
the description 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 page 48.
This manual contains details of design changes that have been made up to and including
August 2008.
The manual is valid for:
Tig 1500i TA34 and Tig 2200i TA33/TA34 with serial no. 803--xxx--xxxx, 828--xxx--xxxx, and
843--xxx--xxxx.
The Tig 1500i and Tig 2200i are designed and tested in accordance with international
and European standards IEC/EN 60974.
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.
INTRODUCTION
Design structure of the power source
Block diagram of the Tig 1500i and Tig 2200i
The power source is transistor--controlled, operating on the inverter principle. It consists of a
number of function modules, as shown in the block diagram above. Each module has a

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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.
15 Power module
This module is a single forward converter, operating at a switching frequency of 65 kHz.
All power semiconductors are built into modules.
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.
TECHNICAL DATA
Tig 1500i TA34 Tig 2200i TA33/TA34
Mains voltage 230V ±10%, 1∼50/60 Hz
Primary current
Imax TIG
Imax MMA
13.8 A
21.3 A
24.9 A
24.1 A
Mains supply Zmax 0.35 ohm Zmax 0.30 ohm
No--load power 30 W 30 W
Setting range TIG
MMA
3 -- 150 A
4 -- 150 A
3 -- 220 A
4 -- 170 A
Permissible load at TIG
20% duty cycle
25% duty cycle
60% duty cycle
100% duty cycle
--
150 A / 16 V
120 A / 14.8 V
110A/14.4V
220 A / 18.8 V
--
150 A / 16.0 V
110A/14.4V
Permissible load at MMA
25% duty cycle
60% duty cycle
100% duty cycle
150 A / 26 V
100 A / 24 V
90 A / 23.6 V
170 A / 26.8 V
130 A / 25.2 V
110A/24.4V
Power factor at maximum current
TIG
MMA
0.99
0.99
0.99
0.99
Efficiency at maximum current
TIG
MMA
76 %
80 %
75 %
81 %
Open--circuit voltage without VRD function
with VRD function
See page 29
<35V
See page 29
<35V
Operating temperature -- 1 0 t o + 4 0 ˚C-- 1 0 t o + 4 0 ˚C
Transportation temperature -- 2 0 t o + 5 5 ˚C-- 2 0 t o + 5 5 ˚C
Constant sound pressure in open--circuit <70dB(A) <70dB(A)
Dimensions, l x b x h without water cooler
with water cooler
418 x 188 x 208 mm 418 x 188 x 208 mm
418 x 188 x 345 mm

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Tig 2200i TA33/TA34Tig 1500i TA34
Weight without cooling unit
cooling unit with / without cooling water
9.2 kg 9.4 kg
6.7kg/4.5kg
Shielding gas
max pressure
All types intended for
TIG welding
5 bar
All types intended for
TIG welding
5 bar
Insulation class transformer H H
Enclosure class IP 23 IP 23
Application class
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading. The duty cycle is valid for 40˚C.
The duty cycle is valid for 40˚C ambient temperature.
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 designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
WIRING DIAGRAM
The power source is based on a number of function modules. These are described in the
component descriptions on the following pages. Wire numbers and component names in
the wiring diagram show to which module each component belongs.
Circuit boards within each module have names such as 15AP1 -- 15AP99.
15 = module association, 1--69
AP = circuit board
1 = individual identification number, 0--99
Components within modules are named in a similar way.
Component description
1MMC module: control panel and display board, see page 12.
2Mains module.
2AP1 Power supply board, see page 13.
2L1--2L8 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 page 18.

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10TV1 HF transformer.
10YV1 Gas valve, 230 V AC.
15 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 Shunt. 60 mV at 100 A.
15ST1 Thermal switch, fitted in the winding of main transformer 15TM1. See page 28.
15ST2 Thermal switch, fitted on the heat sink. See page 28.
15TM1 Main transformer.
20AP1 Controller circuit board. See the description on page 24.
20L1 Ferrite ring core.
CAUTION !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
SObserve precautions for handling electrostatic--
sensitive devices.
SUse proper static--proof bags and boxes.
ESD
Placement of the circuit boards

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Tig 1500i
with control panel TA34

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Tig 2200i
with control panels TA33 and TA34

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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.
The control panel is used for setting and displaying welding data. The welding data are
stored by the control board of the power 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.
STA33 STA34
Pushbuttons are used for parameter selection and a knob for parameter settings, current, time etc.

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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.
Circuit board 0487 631--880 is deliverd as spare part for all machines.
2AP1:1 Interference 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.

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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.
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.

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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.
-- 1 5 V
The voltage is controlled by VR2. It has a tolerance of ±0.75 V.
+13 VB (+12V CAN)
This voltage is unregulated. It has a tolerance of ±1.5 V.
Early warning power shut down
If the voltage goes low, output PS4 generates a warning signal to the
processor on circuit board 20AP1 (see page 24). Transistor Q6 switches off the
fan, 15EV1, at the same time.

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2AP1 Component positions
Power supply board 0487 064--884, used for the Tig 1500i
WARNING!
Dangerous voltage - mains voltage.

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Power supply board 0487 631--880, used for the Tig 2200i and as spare part
WARNING!
Dangerous voltage - mains voltage.

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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. It remains activated until the arc strikes, or
for a maximum of 0.5 seconds.
The voltage on the primary side of HF transformer 10TV1 is about 550 V. The secondary
voltage is about 11 kV if a 4 metre long welding torch is connected. If 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 is released and the gas post--flow time has elapsed, the gas valve is
deactivated.
TIG torch switch
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.

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10AP1 Component positions
WARNING!
Dangerous voltage - mains voltage.

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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.
The power module is a single forward converter,
operating at a switching frequency of 65 kHz.
The switch transistors are built into a
semiconductor module, PM1. See pages 38 to
40 and 41 to 43 for measurement instructions.
If the power board has failed, a replacement
board must be mounted in accordance with the
instructions on page 44.
The power board carries the 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. Thyristor TY1 short--circuits charge resistor R31 when the
machine is loaded. If TY1 did not conduct, resistor R31 would burn out when the unit is on
load.
Power factor corrector (PFC)
The aim with the power factor corrector is to keep the mains current sinusoidal and in phase
with the mains voltage. The PFC circuit holds the intermediate voltage at 365 V. At mains
currents above 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.