ESAB Caddy Tig 2200i AC/DC User manual

GB
Valid for serial no. 803-xxx-xxxx, 843-xxx-xxxx0460 225 101 GB 20120731
Caddyâ
Tig 2200i AC/DC
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4...........................................................
2 INTRODUCTION 6...................................................
2.1 Equipment 6................................................................
2.2 Control panels 6............................................................
3 TECHNICAL DATA 6.................................................
4 INSTALLATION 8....................................................
4.1 Lifting instructions 8.........................................................
4.2 Location 8..................................................................
4.3 Mains power supply 8........................................................
5 OPERATION 9.......................................................
5.1 Connections and control devices 9............................................
5.2 Key to symbols 9............................................................
5.3 Connection to cooling unit 10..................................................
5.4 Turning on the power source 10................................................
6 MAINTENANCE 10....................................................
6.1 Inspection and cleaning 10....................................................
7 FAULT-TRACING 11..................................................
8 ORDERING SPARE PARTS 11.........................................
9 DISMANTLING AND SCRAPPING 11...................................
ASSEMBLY INSTRUCTIONS 13...........................................
DIAGRAM 14............................................................
ORDER NUMBER 16.....................................................
ACCESSORIES 17.......................................................

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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
requirements that apply to this type of equipment. The following recommendations should be ob
served 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 equip
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in
jury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding and cutting
2. The operator must ensure that:
Sno unauthorised 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.
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 precautions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
SInstall and earth the 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!
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.
ESAB can provide you with all necessary welding protection and accessories.
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2 INTRODUCTION
The Tig 2200i AC/DC is a TIG welding power source, which can also be used for
MMA welding. It can be used with alternating current (AC) or direct current (DC).
ESAB's accessories for the product can be found on page 97.
2.1 Equipment
The power source is supplied with a 5 m return cable, 3 m mains cable, carrying
strap, cable holder, shaft belt, instruction manual for power source and control panel.
2.2 Control panels
STA33 AC/DC STA34 AC/DC
See the separate instruction manual for a detailed description of the control panels.
Instruction manuals in other languages can be downloaded from the website,
www.esab.com.
3 TECHNICAL DATA
Tig 2200i AC/DC
Mains voltage 230V, $10%, 1∼50/60 Hz
Mains supply Zmax 0.28 ohm
Primary current
Imax TIG
Imax MMA
27 A
25 A
No load power
demand when in the enery-saving mode,
6.5 min. after welding
40 W
Setting range
TIG AC* / DC
MMA
3 - 220 A
4 - 160 A
Permissible load at TIG AC/DC
20% duty cycle
60% duty cycle
100% duty cycle
220 A / 18.8 V
150 A / 16.0 V
140 A / 15.6 V
Permissible load at MMA
30% duty cycle
60% duty cycle
100% duty cycle
160 A / 26.4 V
120 A / 24.8 V
110 A / 24.4 V
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Tig 2200i AC/DC
Ignition voltage (Upk)11.5 kV
Power factor at maximum current
TIG
MMA
0.99
0.99
Efficiency at maximum current
TIG
MMA
66 %
74 %
Open-circuit voltage TIG 55 - 60 V
Open-circuit voltage MMA
with VRD
55 - 60 V
< 35 V
Operating temperature -10 to + 40°C
Transportation temperature -20 to + 55°C
Constant sound pressure in open-circuit < 70 dB (A)
Dimensions, l x b x h 418 x 188 x 345 mm
Weight 15,7 kg
Shielding gas
max pressure
All types intended for TIG welding
5 bar
Insulation class transformer H
Enclosure class IP 23
Application class
*) The minimum current during AC welding depends on the alloy used for the aluminium plates and
their surface cleanliness.
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, Zmax
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.
CAUTION
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.
4.1 Lifting instructions
Install the carrying strap as illustrated
and lift the power source by the
strap.
4.2 Location
Position the welding power source such that its cooling air inlets and outlets are not
obstructed.
4.3 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 2200i AC/DC TIG MMA
Mains voltage 230 V 10 %,1230 V 10 %,1
Mains frequency 50 Hz 50 Hz
Mains cable area mm23G2.5 3G2.5
Phase current I RMS 14 A 15 A
Fuse
anti-surge
type C MCB
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 84. Read through before you start using the equipment!
5.1 Connections and control devices
1Connection for remote control unit 6Connection for return cable
2Control panel (see separate instruction
manual)
7Mains switch
3Connection for torch 8Mains cable
4Connection for gas to the torch 9Connection for shielding gas
5Connection for welding cable or torch
5.2 Key to symbols
MMA TIG Return clamp
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5.3 Connection to cooling unit
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 on page 93.
NOTE! Coolant must be topped up if
connecting a welding torch or connection
cables that are 4 meters in length or longer.
5.4 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 so that it 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.
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