ESAB Caddy Tig 1500i User manual

GB
Valid for serial no. 803-xxx-xxxx to 927-xxx-xxxx0460 443 201 GB 20130412
Caddy
Tig 1500i
Tig 2200i
Instruction manual
®

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 5...........................................................
2 INTRODUCTION 7...................................................
2.1 Equipment 7................................................................
2.2 Control panels 7............................................................
3 TECHNICAL DATA 7.................................................
4 INSTALLATION 9....................................................
4.1 Location 9..................................................................
4.2 Mains power supply 9........................................................
5 OPERATION 10.......................................................
5.1 Connections and control devices 10............................................
5.2 Key to symbols 11............................................................
5.3 Water connection 11..........................................................
5.4 TIG-welding 11..............................................................
5.5 MMA-welding 11.............................................................
5.6 Overheating protection 11.....................................................
5.7 Connection to cooling unit
(only valid for CaddytTig 2200i) 11............................................
5.8 Turning on the power source 12................................................
6 MAINTENANCE 12....................................................
6.1 Inspection and cleaning 12....................................................
7 FAULT-TRACING 12..................................................
8 ORDERING SPARE PARTS 13.........................................
9 DISMANTLING AND SCRAPPING 13...................................
DIAGRAM 14............................................................
ORDER NUMBER 20.....................................................
ACCESSORIES 21.......................................................

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1 SAFETY
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
served in addition to the standard regulations that apply to the workplace.
jury 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
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
3. The workplace must:
be suitable for the purpose
be free from drafts
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 electrician.
Appropriate fire extinquishing equipment must be clearly marked and close at hand.
Lubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can beinjurious toyourself and others. Take precautions when weldingand
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
Install and earth the unit in accordance with applicable standards.
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
Insulate yourself from earth and the workpiece.
Ensure your working stance is safe.
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.
FIRE HAZARD
Sparks (spatter) can cause fire.Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
Warn 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
This product is solely intended for arc welding.
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 diculties in ensuring electromagnetic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
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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 21.
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 20.
Instruction manuals in other languages can be downloaded from the website,
www.esab.com.
2.2 Control panels
TA33 TA34
See the separate instruction manual for a detailed description of the control panels.
3 TECHNICAL DATA
Tig 1500i Tig 2200i/2200iw
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
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Tig 2200i/2200iwTig 1500i
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
Power factor at maximum current
TIG
MMA
0.98
0.99
0.99
0.99
Eciency at maximum current
TIG
MMA
77 %
80 %
75 %
81 %
Open-circuit voltage
with VRD
from serial number 843 & 927
55-60 V
< 35 V
55-60 V
< 35 V
Open-circuit voltage
from serial number 803
72 V 72 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
including the cooling unit
418 x 188 x 208 mm
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418 x 188 x 208 mm
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 or cut at
a certain load without overloading. The duty cycle is valid for 40°C.
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, Z max
Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.
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4 INSTALLATION
The installation must be carried out 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
distribution 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
regulations. Use the welding power source in accordance with the relevant national regulations.
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5 OPERATION
General safety regulations for handling the equipment can be found on
page 5. 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 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
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5.2 Key tosymbols
MMATIG
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.
5.4 TIG-welding
Before using the Tig 1500i/2200i for TIG welding it must be equipped with:
a TIG torch
a cylinder of suitable welding gas
a welding gas regulator (suitable gas regulator)
tungsten electrodes
suitable filler metal, if necessary
5.5 MMA-welding
Connection of welding and return cable
nection of the
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 Caddy 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.
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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.
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 attempts any
work to rectify any faults in the product during the guarantee 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, 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. 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.
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noitcaevitcerroCtluaffoepyT
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
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. 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.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/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.
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© ESAB AB 2013
Diagram
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Tig 1500i TA34

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© ESAB AB 2013
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Tig 1500i TA33

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© ESAB AB 2013
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Tig 2200i TA33/TA34

© ESAB AB 2013
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Tig 1500i, Tig 2200i
© ESAB AB 2013
Order number
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Ordering no. Product
0460 450 880 Caddy Tig 1500i, TA33 incl. 3 m MMA cable kit complete and Tig torch TXH 150, 4 m
0460 450 881 Caddy Tig 2200i, TA33 incl. 3 MMA cable kit complete and Tig torch TXH 200, 4 m
0460 450 882 Caddy Tig 1500i, TA34 incl. 3 m MMA cable kit complete and Tig torch TXH 150, 4 m
0460 450 883 Caddy Tig 2200i, TA34 incl. 3 m MMA cable kit complete and Tig torch TXH 200, 4 m
0460 450 884 Caddy Tig 2200iw, TA33 incl. water cooler CoolMini, 3 m MMA cable kit complete and
Tig torch TXH 250w, 4 m
0460 450 885 Caddy Tig 2200iw, TA34 incl. water cooler CoolMini, 3 m MMA cable kit complete and
Tig torch TXH 250w, 4 m
0460 450 890 Caddy Tig 1500i, TA33 incl. 3 return cable with clamp
0460 450 891 Caddy Tig 2200i, TA33 incl. 3 return cable with clamp
0460 450 892 Caddy Tig 1500i, TA34 incl. 3 return cable with clamp
0460 450 893 Caddy Tig 2200i, TA34 incl. 3 return cable with clamp
0460 450 894 Caddy Tig 2200iw, TA33 incl. 3 return cable with clamp
0460 450 895 Caddy Tig 2200iw, TA34 incl. 3 return cable with clamp
Filename Type Product
0460 447 074 Instruction manual Control panel, Caddy TA33, TA34
0459 839 125 Spare parts list Welding power source, Tig 1500i, Tig 2200i, Tig 2200iw
Instruction manuals and the spare parts list are available on the Internet at www.esab.com