ESAB Caddy Tig 1500i VRD User manual

Caddy®
Instruction manual
0460 826 374 GB 20190125
Valid for: serial no. Tig 1500i: 711-, 747-, 840-xxx-xxxx,
Tig2200i:747-xxx-xxxx
Tig 1500i VRD 
Tig2200iVRD

TABLE OF CONTENTS
0460 826 374 © ESAB AB 2019
1SAFETY ....................................................................................................... 4
1.1 Meaning of symbols ............................................................................... 4
1.2 Safety precautions ................................................................................. 4
2INTRODUCTION.......................................................................................... 7
2.1 Equipment ............................................................................................... 7
2.2 Control panels ........................................................................................ 7
3TECHNICAL DATA ...................................................................................... 8
4INSTALLATION............................................................................................ 10
4.1 Location................................................................................................... 10
4.2 Mains power supply ............................................................................... 10
5OPERATION ................................................................................................ 12
5.1 Connections and control devices ......................................................... 12
5.2 Key to symbols....................................................................................... 12
5.3 TIG (GTAW)-welding ............................................................................... 12
5.4 MMA (SMAW)-welding............................................................................ 13
5.5 Overheating protection .......................................................................... 13
5.6 Connection to cooling unit (only valid for Tig 2200i).......................... 13
5.7 Turning on the power source ................................................................ 13
6MAINTENANCE........................................................................................... 14
6.1 Inspection and cleaning......................................................................... 14
7TROUBLESHOOTING ................................................................................. 15
8ORDERING SPARE PARTS ........................................................................ 16
DIAGRAM ............................................................................................................ 17
ORDERING NUMBERS....................................................................................... 23
ACCESSORIES ................................................................................................... 24
Rights reserved to alter specifications without notice.

1 SAFETY
0460 826 374 -4- © ESAB AB 2019
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).
1.2 Safety precautions
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0460 826 374 -5- © ESAB AB 2019
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
0460 826 374 -6- © ESAB AB 2019
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
0460 826 374 -7- © ESAB AB 2019
2 INTRODUCTION
The Tig 1500i / 2200i is a TIG (GTAW) welding power source, which can also be used for
MMA (SMAW) welding. It supplies direct current (DC).
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
The power source is supplied with a 3 m (9.84ft) welding cable complete with a TIG-torch,
3m(9.84ft) return cable, 3 m (9.84 ft) mains cable, instruction manual for power source and
control panel, see Ordering information in the "ORDERING NUMBERS" chapter.
2.2 Control panels
TA33 TA34
See the separate instruction manual for a detailed description of the control panels.

3 TECHNICAL DATA
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3 TECHNICAL DATA
Tig 1500i Tig 2200i
Mains voltage 230V, ±10%, 1~ 50/60 Hz 230V, ±10%, 1~ 50/60 Hz
Mains supply Zmax 0.35 ohm Zmax 0.31 ohm
Primary current
ImaxTIG 14 A 25 A
ImaxMMA 22 A 26 A
No-load power demand when
in the energy-saving mode,
6.5 min. after welding
30 W 31 W
Setting range
TIG (GTAW) 3 A - 150 A 3 A - 220 A
MMA (SMAW) 4 A - 150 A 4 A - 170 A
Ignition voltage (Upk) 11.5 kV 11.5 kV
Permissible load at TIG (GTAW)
20% duty cycle 220 A / 18.8 V
25% duty cycle 150 A / 16.0 V
60% duty cycle 120 A / 14.8 V 150 A / 16.0 V
100% duty cycle 110 A / 14.4 V 140 A / 15.6 V
Permissible load at MMA (SMAW)
25% duty cycle 150 A / 26.0 V 170 A / 26.8 V
60% duty cycle 100 A / 24.0 V 130 A / 25.2 V
100% duty cycle 90 A / 23.6 V 110 A / 24.4 V
Power factor at maximum current
TIG (GTAW) 0.98 0.99
MMA (SMAW) 0.99 0.99
Efficiency at maximum current
TIG (GTAW) 77 % 73.0 %
MMA (SMAW) 80 % 77.9 %
Apparent powerat maximum
current
5.9kVA
Active powerat maximum
current
5.9kW
Open-circuit voltage TIG
(GTAW)
55-60 V 55-60 V
Open-circuit voltage MMA
(SMAW)
55-60 V 55-60 V
with VRD < 35 V < 35 V
No-load voltage
without VRD, U056V
with VRD, Ur22V

3 TECHNICAL DATA
0460 826 374 -9- © ESAB AB 2019
Tig 1500i Tig 2200i
Upk(with arc ignition unit, Tig) 10.7kV
Operating temperature -10 to + 40 °C
(+14to+104°F)
-10 to + 40 °C
(+14to+104°F)
Transportation temperature -20 to + 55 °C (-4 to + 131 °F) -20 to + 55 °C (-4 to + 131 °F)
Constant sound pressure in
open-circuit
< 70 dB (A) < 70 dB (A)
Dimensions, l × b × h 418 × 188 × 208 mm
(16.46×7.40 × 8.19 in.)
418 × 188 × 208 mm
(16.46×7.40 × 8.19 in.)
Dimensions, l × b × h
(including cooling unit)
418 × 188 × 345 mm
(16.46×7.40 × 13.58 in.)
Weight 9.2 kg (20.28 lb) Including cooling unit: 14 kg
(30.86 lb)
Including cooling unit, in
delivery mode: 19.4 kg (42.77
lb)
Shielding gas      
    
max pressure
All types intended for TIG
(GTAW) welding
5 bar (72.5 psi)
All types intended for TIG
(GTAW) welding
5 bar (72.5 psi)
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 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
electrical hazard.
Mains supply, Zmax
Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.

4 INSTALLATION
0460 826 374 - 10 - © ESAB AB 2019
4 INSTALLATION
The installation must be carried out by a professional.
NOTE!
Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit power
is greater than or equal to Sscmin at the interface point between the user's supply
and the public system. It is the responsibility of the installer or user of the equipment
to ensure, by consultation with the distribution network operator if necessary, that
the equipment is connected only to a supply with a short-circuit power greater than
or equal to Sscmin. Refer to the technical data in the TECHNICAL DATA chapter.
4.1 Location
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
4.2 Mains power supply
Check that the welding power source is connected to the
correct mains power supply voltage, and that it is protected by
the correct fuse size.
A protective earth connection must be made in accordance with
regulations.

Rating plate with supply connection data
Recommended fuse sizes and minimum cable area
Tig 1500i Tig 2200i
TIG (GTAW) MMA (SMAW) TIG (GTAW) MMA (SMAW)
Mains voltage 230 V ± 10%, 1~ 230 V ± 10%, 1~ 230 V ± 10%, 1~ 230 V ± 10%, 1~
Mains frequency 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz
Mains cable area
mm2
3G2.5 3G2.5 3G2.5 3G2.5
Phase current I1eff 9 A 11 A 11 A 14 A
Fuse
anti-surge 16 A 16 A 16 A 16 A
type C MCB 13 A 13 A 16 A 16 A

4 INSTALLATION
0460 826 374 - 11 - © ESAB AB 2019
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. For other regions, supply cables must be suitable for the
application and meet local and national regulations.

5 OPERATION
0460 826 374 - 12 - © ESAB AB 2019
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
5.1 Connections and control devices
1 Connection (+) for the return cable for TIG
(GTAW).
MMA (SMAW): for the return cable or the
welding cable.
6 Connection (-) for the TIG (GTAW)-torch
MMA (SMAW): return cable or welding
cable
2 Connection for the remote control unit,
only for control panel TA34
7 Mains switch
3 Control panel (see separate instruction
manual)
8 Mains cable
4 Connection for the TIG (GTAW)-torch 9 Connection for shielding gas
5 Connection for gas to the TIG
(GTAW)-torch
5.2 Key to symbols
MMA (SMAW) TIG (GTAW)
5.3 TIG (GTAW)-welding
Before using the Tig 1500i/2200i for TIG (GTAW) welding it must be equipped with:
• a TIG (GTAW) torch
• a cylinder of suitable welding gas
• a welding gas regulator (suitable gas regulator)

5 OPERATION
0460 826 374 - 13 - © ESAB AB 2019
• tungsten electrodes
• suitable filler metal, if necessary
5.4 MMA (SMAW)-welding
Connection of welding and return cable
The welding power source has two terminals, one plus and one minus pole, for the
connection of the welding and the return cable. Connect the welding cable to the pole
indicated on the package of the electrode to be used.
Connect the return cable to the other terminal. Fit the earth clamp of the return cable to the
work-piece and make sure there is good contact between the work-piece and the return
cable terminal on the welding power source.
5.5 Overheating protection
The power source has two thermal overload trips which operate if the internal temperature
becomes too high. A fault code is shown in the panel. They reset automatically when the
temperature has fallen.
5.6 Connection to cooling unit (only valid for Tig 2200i)
Only those persons who have appropriate electrical knowledge
(authorized personnel) may remove the safety plates to connect or
carry out service, maintenance or repair work on welding
equipment.
See installation instructions in the instruction manual for the cooling
unit.
5.7 Turning on the power source
Turn on the mains power by turning the mains switch to the ”1” position.
Turn the unit off by turning the switch to the ”0” position.
Whether the mains power supply is interrupted or the power unit is switched off in the normal
manner, welding data will be stored and is available next time the unit is started.

6 MAINTENANCE
0460 826 374 - 14 - © ESAB AB 2019
6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
Only those persons who have appropriate electrical knowledge (authorised personnel) may
remove the safety plates to connect or carry out service, maintenance or repair work on
welding equipment.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer attempts
any work to rectify any faults in the product during the warranty period.
6.1 Inspection and cleaning
Power source
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on: the welding process, arc times,
positioning of power source, and the surrounding environment. It is normally sufficient to blow
down the power source with dry compressed air (reduced pressure) once a year.
Clogged or blocked air inlets and outlets otherwise result in overheating.
Welding torch
The welding torch's wear parts should be cleaned and replaced at regular intervals in order
to achieve trouble-free welding.

7 TROUBLESHOOTING
0460 826 374 - 15 - © ESAB AB 2019
7 TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorised service
technician.
Type of fault Corrective action
No arc. • Check that the mains power supply switch is turned on.
• Check that the welding current supply and return
cables are correctly connected.
• Check that the correct current value is set.
• Check the mains power supply.
The welding current is
interrupted during welding.
• Check to see whether the thermal cut-outs have
tripped.
• Check the mains power supply fuses.
The thermal cut-out trips
frequently.
• Make sure that you are not exceeding the rated data
for the welding power source (i.e. that the unit is not
being overloaded).
• Make sure that the power source is clean.
Poor welding performance. • Check that the welding current supply and return
cables are correctly connected.
• Check that the correct current value is set.
• Check that the correct electrodes are being used.
• Check the gas flow.

8 ORDERING SPARE PARTS
0460 826 374 - 16 - © ESAB AB 2019
8 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Tig 1500i, Tig 2200i is designed and tested in accordance with the international and
European standards IEC/EN 60974-1,IEC/EN 60974-3 and IEC/EN 60974-10 Class A. It is
the obligation of the service unit which has carried out the service or repair work to make
sure that the product still conforms to the said standard.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see
esab.com. When ordering, please state product type, serial number, designation and spare
part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.

DIAGRAM
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DIAGRAM
Tig 1500i TA34

DIAGRAM
0460 826 374 - 18 - © ESAB AB 2019

DIAGRAM
0460 826 374 - 19 - © ESAB AB 2019
Tig 1500i TA33

DIAGRAM
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