ESAB Caddyt Tig 150i User manual

GB
Valid for serial no. 620--xxx--xxxx0459 262 201 060523
Tig 150i
Tig 200i
OrigotTA33
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 5...................................................
3.1 Equipment 5................................................................
4 TECHNICAL DATA 5.................................................
5 INSTALLATION 6....................................................
5.1 Placing 6...................................................................
5.2 Rating plate 6...............................................................
5.3 Mains power supply 7........................................................
6 OPERATION 8.......................................................
6.1 Connections and control devices 8............................................
6.2 Control panel TA33 9........................................................
6.3 Overheating protection 9.....................................................
7 WELDING 10.........................................................
7.1 TIG welding 10...............................................................
7.2 MMA welding 12.............................................................
8 MAINTENANCE 12....................................................
9 FAULT TRACING 13...................................................
9.1 Fault codes 13...............................................................
10 ORDERING SPARE PARTS 13..........................................
DIAGRAM 14............................................................
DIAGRAM 16............................................................
ORDERING NUMBER 18.................................................
ACCESSORIES 19.......................................................

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1DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-
ing power source Tig 150i / Tig 200i from serial number 620 complies with standard IEC/EN 60974--1
/--3, in accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and
with standard IEC/EN 60974--10 in accordance with the requirements of directive (89/336/EEC) and
addendum (93/68/EEC).
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------
Kent Eimbrodt
Global Director Equipment and Automation
ESAB AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2006--05--22
2SAFETY
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 precautions. 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 work-
place.
All work must be carried out by trained personnel well--acquainted with the operation of the welding equipment. Incorrect oper-
ation 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.
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.
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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 PRECAU-
TIONS 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!
Read and understand the instruction manual before installing
or operating.
Do not use the power source for thawing frozen pipes.
WARNING!
This product is solely intended for arc welding.
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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3 INTRODUCTION
The Tig 150i/Tig 200i is a welding current power source intended for use with
coated electrodes (MMA welding) and TIG welding.
3.1 Equipment
The Tig 150i/Tig 200i is supplied with a mains cable and an instruction manual.
ESAB’s accessories for the product can be found on page 19.
4 TECHNICAL DATA
Tig 150i Tig 200i
Mains voltage 230V, 1∼50/60 Hz 230V, 1∼50/60 Hz
Fuse (delayed--action) 16 A 20 A
Primary current Imax 36 A 36 A
Primary current Ieff 21 A 21 A
Voltage/current range
(TIG)
(MMA) 3 A / 10 V --150 A / 16 V
4 A / 20 V --150 A / 26 V 3 A / 10 V -- 200 A / 18 V 4 A / 20 V -- 150 A / 27 V
Maximum permissible load at TIG
25% duty cycle
35% duty cycle
60% duty cycle
100% duty cycle
150 A / 16 V
120 A / 15 V
95 A / 14 V
200 A / 18 V
180 A / 17 V
140 A / 15,5 V
110A/14,5V
Maximum permissible load at MMA
25% duty cycle
35% duty cycle
60% duty cycle
100% duty cycle
150 A / 26 V
140 A / 25,5 V
110A/24,5V
90 A / 23,5 V
150 A / 26 V
140 A / 25,5 V
110A/24,5V
90 A / 23,5 V
Power factor at maximum current 0,62 0,62
Efficiency at maximum current 77 % 79 %
Open--circuit voltage 71 -- 78 V 71 -- 78 V
Operating temperature -- 1 0 ˚C--+40˚C-- 1 0 ˚C--+40˚C
Constant A--weighed sound pressure <70 db <70 db
Dimensions, l x b x h 380 x 180 x 300 mm 380 x 180 x 300 mm
Weight 9kg 9kg
Enclosure class IP 23C IP 23C
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.
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.
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4.1 Parameter setting
Settings Setting range In steps of: Default value
Welding method TIG or MMA -- TIG
2/4--stroke 2strokeor4stroke -- 2--stroke
HF / Lift ArctHF or LiftArct-- HF
Slope down time 0--10 s 0.1 s 1.0 s
Gas post--flow 0--25 s 0.1 s 2.0 s
Current TIG Tig 150I 3 -- 150 A 1A 100 A
Current TIG Tig 200I 3 -- 200 A 1A 100 A
Current MMA Tig 150I 3 -- 150 A 1A 60 A
Current MMA Tig 200I 4 -- 150 A 2A 100 A
5 INSTALLATION
The installation must be executed by a professional.
WARNING!
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.
Note!
Connect the power source to the electricity mains with a network impedance of 0.210 ohm or lower. If the
network impedance is higher, there is a risk of flicker in the illuminators.
5.1 Placing
Place the power source so that its cooling air inlets and outlets are not obstructed.
5.2 Rating plate
The rating plate is located on the underside of the power source or on the rear plate.
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5.3 Mains power supply
Make sure that the welding power source is connected to the correct supply voltage
and that it is protected by the correct fuse rating. The standards for the country in
question must be complied with as regards the mains cable area. A protective earth
connection must be made in accordance with regulations.
5.3.1 Recommended fuse sizes and minimum cable areas
Tig 150i Tig 200i
Mains voltage 230 V ¦10 %, 1--phase 230 V ¦10 %, 1--fas
Mains frequency 50--60 Hz 50--60 Hz
Fuse (delayed--action)
85A 35% duty cycle MMA
120A 20% duty cycle MMA
150A 25% duty cycle MMA
10 A
16 A
20 A*)
10 A
16 A
20 A
Mains cable, area 3x2.5mm
23x2,5 mm2
Welding cable, area MMA 16 mm216 mm2
Welding cable, area TIG 16 mm225 mm2
*) NOTE! The mains plug is approved for maximum 16A.
North American version: Mains cable is approved for maximun 18 A.
Australian- version: The mains cable plug is approved for maximum 15A.
Note!
The cable area and fuse rating above comply with Swedish regulations. Use the welding power source
in accordance with the relevant national regulations.
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6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
6.1 Connections and control devices
Make sure that the welding power source is connected to the correct supply voltage
and that it is protected by the correct fuse rating.
1Mains switch 6TIG torch connection (--)
2Connection (gas bottle connector) 7Connection for return cable (--) MMA
3Mains cable 8Welding cable connection (+) MMA
Connection for return cable (+) TIG
4Connection for the TIG torch 9Control panel (see 6.2)
5TIG torch gas connection
7and 8are used for welding current supply and return cable connection during MMA
welding
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6.2 Control panel TA33
The power source checks the LEDs and all segments in the display when main
switch is turned on. The machine type and program version are also displayed.
AMains voltage (green) LED BData display
COverheating (yellow) LED DKnob for setting data.
Increase (+) or Decrease (--) selected by
the function pushbuttons
6.2.1 Panel function symbols (E -- G)
TIG TIG HF 2--stroke
MMA LiftArct4--stroke
GSlope down F. Gas post--flow
6.3 Overheating protection
The welding power source has a thermal overload trip which operates if the
temperature becomes too high, interrupting the welding current and lighting a
yellow indicating lamp on the front of the power source. The thermal overload trip
resets automatically when the temperature has fallen.
7 WELDING
7.1 TIG welding
During TIG welding, the return cable must be connected to (+) and the TIG torch to
(--). If they are connected in reverse, the tungsten electrode will melt.
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7.1.1 2--stroke
Gas pre--flow Slope
up Slope down Gas post--flow
Functions when using 2--stroke control of the welding torch.
In the 2--stroke control mode, pressing the trigger switch starts gas pre--flow (if
used) and strikes the arc (1). The current rises to the set value (as controlled by the
slope up function, if in operation). Releasing the trigger switch (2) reduces the
current (or starts slope down if in operation) and extinguishes the arc. Gas
post--flow follows if it is in operation.
7.1.2 4--stroke
Gas pre--flow Slope
up Slope down Gas post--flow
Functions when using 4--stroke control of the welding torch.
In the 4--stroke control mode, pressing the trigger switch starts gas pre--flow (if
used) (1). At the end of the gas pre--flow time, the current rises to the pilot level (a
few ampere), and the arc is struck. Releasing the trigger switch (2) increases the
current to the set value (with slope up, if in use). At the end of welding, the welder
presses the trigger switch again (3), which reduces the current to pilot level again
(with slope down, if in use). Releasing the switch again (4) extinguishes the arc and
starts gas post--flow.
7.1.3 HF
The HF function strikes the arc by means of a spark from the tungsten electrode to
the workpiece as the electrode is brought closer to the workpiece.
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7.1.4 LiftArct
The lift arc function strikes the arc when the electrode is brought into contact with the
workpiece and then lifted away from it.
Striking the arc with the Lift Arc function. Step 1: the electrode is touched on to the workpiece. Step
2: the trigger switch is pressed, and a low current starts to flow. Step 3: the welder lifts the torch
from the workpiece: the arc strikes, and the current rises automatically to the set value.
7.1.5 Gas post--flow
This controls the time during which shielding gas flows after the arc is extinguished.
7.1.6 Slope down
TIG welding uses slope down, by which the current falls ’slowly’ over a controlled
time, to avoid craters and/or cracks when a weld is finished.
Current
A higher current produces a wider weld pool, with better penetration into the
workpiece.
The current set value can be changed irrespective of which menu is displayed. This
value is displayed in the main menu only.
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cmha2p10
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7.2 MMA welding
Tig 150i/Tig 200i gives direct current, and you can weld most metals to alloy and
non--alloy steel, stainless steel and cast iron.
The Tig 150i allows you to weld most coated electrodes from ∅1.6 to ∅3.25.
The Tig 200i allows you to weld most coated electrodes from ∅1.6 to ∅4.0.
MMA welding may also be referred to as welding with coated electrodes. Striking the arc
melts the electrode, and its coating forms protective slag.
If, when striking the arc, the tip of the electrode is pressed against the metal, it im-
mediately melts and sticks to the metal, rendering continued welding impossible.
Therefore, the arc has to be struck in the same way that you would light a match.
Quickly strike the electrode against the metal, then raise it so
as to give an appropriate arc length (approx. 2 mm). If the arc
is too long, it will crackle and spit before finally going out com-
pletely.
If you are working on a welding bench, check before attempting
to strike the arc that residual waste metal, pieces of electrode
or other objects do not insulate the part to be welded.
Once the arc has been struck, move the electrode from left to
right. The electrode must be at an angle of 60˚to the metal in
relation to the direction of welding.
When you want to weld wide beads, or when you want the weld
to be so thick that you have to weld in a number of layers, how-
ever, you have to use lateral movements.
8 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Note!
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.
The Tig 150i/Tig 200i requires little maintenance. In normal cases, it is sufficient to
blow it clean using dry compressed air once a year, but this should be done more
often if it is set up in a dusty, dirty area.
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9 FAULT TRACING
Try these recommended checks and inspections before sending for an authorised
service technician.
Type of fault 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.
The thermal overload trips ope-
rate frequently.
SCheck whether the thermal overload trips have operated
(indicated by the yellow lamp on the front panel).
SCheck the main power supply fuses.
The thermal overload trip opera-
tes 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).
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.
9.1 Fault codes
The Tig 150i/Tig 200i comes with built--in fault monitoring. If a fault occurs, a code is
shown in the display.
If any of these fault codes (Exx) reappears once the unit has been restarted, the
welding power source should be sent to an authorised ESAB service workshop for
repair.
10 ORDERING SPARE PARTS
Tig 150i/Tig 200i is designed and tested in accordance with the international and Euro-
pean standards IEC/EN 60974--1, 60974--3 and 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 pro-
duct still conforms to the said standard.
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
GB

Diagram
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Tig150i

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Tig150i

Diagram
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Tig200i

-- 1 7 --
Tig200i

Tig 150i, Tig 200i
Edition 060523
Ordering number
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Tig150i/200i
Ordering no. Denomination Type Notes
0459 200 881 Welding power source OrigotTig 150i, TA33 for 230 V
mains voltage
0459 200 887 Welding power source OrigotTig 150I, TA33 for 230 V
mains voltage Australian version
0459 200 883 Welding power source OrigotTig 200i, TA33 for 230 V
mains voltage
0459 262 990 Spare part list OrigotTig 150i / OrigotTig 200i

Edition 060523
Tig 150i, Tig 200i
Accessories
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Access
MMA welding and return cable kit
(”crocodile” type holder) 0349 501 078................
MMA welding and return cable kit
(”screwe” type holder) 0349 501 079.................
Shoulderstrap 0459 368 880....................................
Trolley small gas bottle 0459 366 880....................................
Tig Torch
(BTF 150 OKC25 0458 218 890.....................

ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]
www.esab.com
060517
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Prague
Tel: [phone]
Fax: [phone]
DENMARK
Aktieselskabet ESAB
Herlev
Tel:[phone]
Fax:[phone]
FINLAND
ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]
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ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]
GERMANY
ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]
GREAT BRITAIN
ESAB Group (UK) Ltd
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Tel: [phone]
Fax: [phone]
ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]
HUNGARY
ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]
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ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]
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Tel: [phone]
Fax: [phone]
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AS ESAB
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Tel:[phone]
Fax:[phone]
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Tel: [phone]
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Fax: [phone]
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Tel:[phone]
Fax:[phone]
SPAIN
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Tel: [phone]
Fax: [phone]
SWEDEN
ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]
ESAB international AB
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Tel:[phone]
Fax:[phone]
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ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]
North and South America
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CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]
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ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]
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ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]
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ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]
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ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]
INDIA
ESAB India Ltd
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Fax: [phone]
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ESAB Japan
Tokyo
Tel: [phone]
Fax:[phone]
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ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax:[phone]
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ESAB Asia/Pacific Pte Ltd
Singapore
Tel:[phone]
Fax: [phone]
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ESAB SeAH Corporation
Kyungnam
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Fax: [phone]
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Dubai
Tel: [phone]
Fax: [phone]
Representative offices
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Tel/Fax: [phone]
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ESAB Egypt
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Fax: [phone]
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ESAB Representative Office
Bucharest
Tel/Fax: [phone]
RUSSIA
LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]
LLC ESAB
St Petersburg
Tel: [phone]
Fax: [phone]
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com