ESAB Caddy Tig 1500i VRD User manual

GB
Valid for serial no. 828-xxx-xxxx0460 826 074 20120731
Caddyâ
Tig 1500i VRD
Tig 2200i VRD
Instruction manual

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Rights reserved to alter specifications without notice.
1 SAFETY 3...........................................................
2 INTRODUCTION 5...................................................
2.1 Equipment 5................................................................
2.2 Control panels 5............................................................
3 TECHNICAL DATA 5.................................................
4 INSTALLATION 7....................................................
4.1 Location 7..................................................................
4.2 Mains power supply 7........................................................
5 OPERATION 8.......................................................
5.1 Connections and control devices 8............................................
5.2 Key to symbols 8............................................................
5.3 Water connection 8..........................................................
5.4 TIG-welding 9..............................................................
5.5 MMA-svetsning 9...........................................................
5.6 Overheating protection 9.....................................................
5.7 Connection to cooling unit
(only valid for CaddytTig 2200i) 9............................................
5.8 Turning on the power source 9................................................
6 MAINTENANCE 10....................................................
6.1 Inspection and cleaning 10....................................................
7 FAULT-TRACING 10..................................................
8 ORDERING SPARE PARTS 11.........................................
9 DISMANTLING AND SCRAPPING 11...................................
DIAGRAM 12............................................................
ORDER NUMBER 18.....................................................
ACCESSORIES 19.......................................................

© ESAB AB 2008
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1 SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety pre
cautions. Safety precautions must meet the requirements that apply to this type of
welding 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 oper
ation of the welding 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 welding equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the equipment when it is
started up.
Sno-one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves. Note! Do not use safety gloves when replacing wire.
SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
CAUTION!
This product is solely intended for arc welding.
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WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding.
Ask for your employer's safety practices which should be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse 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.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
ESAB can provide you with all necessary welding protection and accessories.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Read and understand the instruction manual before
installing or operating.
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.
GB

© ESAB AB 2008
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2 INTRODUCTION
The Tig 1500i / 2200i is a TIG welding power source, which can also be used for
MMA welding. It can be used direct current (DC).
ESAB's accessories for the product can be found on page 19.
2.1 Equipment
The power source is supplied with a 3 m welding cable complete with a TIG-torch,
3 m return cable, 3 m mains cable, instruction manual for power source and control
panel, see Ordering information on page 18.
2.2 Control panels
STA33 STA34
See the separate instruction manual for a detailed description of the control panels.
3 TECHNICAL DATA
Tig 1500i Tig 2200i/2000iw
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
Imax MMA
14 A
22 A
24 A
25 A
No-load power
demand when in the energy-saving
mode, 6.5 min. after welding
30 W 30 W
Setting range
TIG
MMA
3 A - 150 A
4 A - 150 A
3 A - 220 A
4 A - 170 A
Ignition voltage (Upk)11.5 kV 11.5 kV
Permissible load at TIG
20% duty cycle
25% duty cycle
60% duty cycle
100% duty cycle
150 A / 16.0 V
120 A / 14.8 V
110 A / 14.4 V
220 A / 18.8 V
150 A / 16.0 V
140 A / 15.6 V
Permissible load at MMA
25% duty cycle
60% duty cycle
100% duty cycle
150 A / 26.0 V
100 A / 24.0 V
90 A / 23.6 V
170 A / 26.8 V
130 A / 25.2 V
110 A / 24.4 V
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Tig 2200i/2000iwTig 1500i
Power factor at maximum current
TIG
MMA
0.98
0.99
0.99
0.99
Efficiency at maximum current
TIG
MMA
77 %
80 %
75 %
81 %
Open-circuit voltage TIG 55-60 V 55-60 V
Open-circuit voltage MMA
with VRD
55-60 V
< 35 V
55-60 V
< 35 V
Operating temperature -10 to + 40°C-10 to + 40°C
Transportation temperature -20 to + 55°C-20 to + 55°C
Constant sound pressure in
open-circuit
< 70 dB (A) < 70 dB (A)
Dimensions, l x b x h 418 x 188 x 208 mm 418 x 188 x 208 mm
including the cooling unit -418 x 188 x 345 mm
Weight 9.2 kg 9.4 kg
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.
Mains supply, Zmax
Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.
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© ESAB AB 2008
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4 INSTALLATION
The installation must be executed by a professional.
Note!
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains supply, influence the
power quality of the grid. Therefore connection restrictions or requirements regarding the
maximum permissible mains impedance or the required minimum supply capacity at the interface
point to the public grid may apply for some types of equipment (see technical data). In this case it
is the responsibility of the installer or user of the equipment to ensure, by consultation with the
distrubution network operator if necessary, that the equipment may be connected.
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/2200iw
TIG MMA TIG MMA
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 mm23G2.5 3G2.5 3G2.5 3G2.5
Phase current I1eff 9 A 11 A 11 A 14 A
Fuse
anti-surge
type C MCB
16 A
13 A
16 A
13 A
16 A
16 A
16 A
16 A
NOTE! The mains cable areas and fuse sizes as shown above are in accordance with Swedish reg
ulations. Use the welding power source in ac cordance with the relevant national regulations.
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© ESAB AB 2008
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5 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
5.1 Connections and control devices
1Connection (+) for the return cable for
TIG.
MMA: for the return cable or the welding
cable.
7Mains switch
2Connection for the remote control unit,
only for control panel TA34
8Mains cable
3Control panel (see separate instruction
manual)
9Connection for shiedling gas
4Connection for the TIG-torch 10 Connection BLUE, with ELP* for cooling
water from the cooling unit
5Connection for gas to the TIG-torch 11 Connection RED for cooling water to the
cooling unit.
6Connection (-) for the TIG-torch
MMA: return cable or welding cable
12 Refilling of cooling water
* ESAB Logic Pump, see under 5.3
5.2 Key to symbols
MMA TIG
5.3 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.
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© ESAB AB 2008
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5.4 TIG-welding
Before using the Arc 1500i/2200i for TIG welding it must be equipped with:
Sa TIG torch
Sa cylinder of suitable welding gas
Sa welding gas regulator (suitable gas regulator)
Stungsten electrodes
Ssuitable filler metal, if necessary
5.5 MMA-svetsning
Connection of welding and return cable
The welding power source has two terminals, one plus and one minus pole, for the con
nection of the welding and the return cable. Connect the welding cable to the pole indi
cated 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.
5.6 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.
5.7 Connection to cooling unit
(only valid for CaddytTig 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.
5.8 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.
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© ESAB AB 2008
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6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
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.
CAUTION!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any faults.
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, placement, 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 FAULT-TRACING
Try these recommended checks and inspections before sending for an authorised
service technician.
Type of fault Corrective action
No arc. SCheck that the mains power supply switch is turned on.
SCheck that the welding current supply and return cables are
correctly connected.
SCheck that the correct current value is set.
SCheck the mains power supply.
The welding current is
interrupted during welding.
SCheck to see whether the thermal cut-outs have tripped.
SCheck the mains power supply fuses.
The thermal cut-out trips
frequently.
SMake sure that you are not exceeding the rated data for the
welding power source (i.e. that the unit is not being
overloaded).
SMake sure that the power source is clean.
Poor welding performance. SCheck that the welding current supply and return cables are
correctly connected.
SCheck that the correct current value is set.
SCheck that the correct electrodes are being used.
SCheck the gas flow.
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© ESAB AB 2008
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8 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB serviceman.
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. 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 may be ordered through your nearest ESAB dealer, see the last page of
this publication.
9 DISMANTLING AND SCRAPPING
Welding equipment primarily consists of steel, plastic and non-ferrous metals, and must
be handled according to local environmental regulations.
Coolant must also be handled according to local environmental regulations.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!
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© ESAB AB 2008
Diagram
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Tig 1500i TA34

© ESAB AB 2008
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© ESAB AB 2008
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Tig 1500i TA33

© ESAB AB 2008
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© ESAB AB 2008
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Tig 2200i TA33/TA34

© ESAB AB 2008
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Tig 1500i, Tig 2200i
© ESAB AB 2008
Order number
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Ordering no. Denomination Type
0460 450 870 Welding power source CaddyâTig 1500i, TA33, Australian version
incl. welding kit and torch TXH 150, 4 m
0460 450 871 Welding power source CaddyâTig 2200i, TA33, Australian version
incl. welding kit and Tig torch TXH 200, 4 m
0460 450 873 Welding power source CaddyâTig 2200i, TA34, Australian version
incl. welding kit and Tig torch TXH 200, 4 m
0460 450 874 Welding power source CaddyâTig 2200iw, TA33, Australian version
incl. welding kit and Tig torch TXH 250w, 4 m
0460 450 875 Welding power source CaddyâTig 2200iw, TA34, Australian version
incl. welding kit and Tig torch TXH 250w, 4 m
0460 447 074 Instruction manual Control panel, CaddyâTA33, TA34
0459 839 025 Spare parts list Welding power source, Tig 1500i, Tig 2200i, Tig 2200iw
0459 839 028 Spare parts list Control panel, CaddyâTA33
0459 839 028 Spare parts list Control panel, CaddyâTA34
Instruction manuals and the spare parts list are available on the Internet at www.esab.com

Tig 1500i, Tig 2200i
© ESAB AB 2008
Accessories
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Strap ................................... 0460 265 001
Cable holder ............................ 0460 265 002
Shoulder strap .......................... 0460 265 003
Trolley ......
for 5-10 litre gasbottle ..................... 0459 366 885
Trolley
for 20-50 litre gasbottle .................... 0459 366 886
Trolley
for 20-50 litre gasbottle ................... 0460 330 880

Tig 1500i, Tig 2200i
© ESAB AB 2008
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Tig torch
TXH 150 4 m ............................
TXH 150 8 m ............................
TXH 200 4 m ............................
TXH 200 8 m ............................
TXH 250w 4 m ...........................
TXH 250w 8 m ...........................
0460 011 842
0460 011 882
0460 012 840
0460 012 880
0460 013 840
0460 013 880
Tig torch
TXH 150r 4 m ...........................
TXH 150r 8 m ...........................
TXH 200r 4 m ...........................
TXH 200r 8 m ...........................
TXH 250wr 4 m ..........................
TXH 250wr 8 m ..........................
0462 011 842
0462 011 882
0462 012 840
0462 012 880
0462 013 840
0462 013 880
Remote control adapter RA12 12 pole ....
For analogue remote controls to CAN based
equipment.
Only with TA34
0459 491 910
Remote control unit MTA1 CAN ..........
MIG/MAG: wire feed speed and voltage
MMA: current and arc force
TIG: current, pulse and background current
Only with TA34
0459 491 880
Remote control unit M1 10Prog CAN ......
Choice of on of 10 programs
MIG/MAG: voltage deviation
TIG and MMA: current deviation
Only with TA34
0459 491 882
Remote control unit AT1 CAN ............
MMA and TIG: current
Only with TA34
0459 491 883
Remote control unit AT1 CF CAN .........
MMA and TIG: rough and fine setting of
current.
Only with TA34
0459 491 884