ESAB CaddyTig HF User manual

Valid from serial no. 2170700 159 017 0219
CaddyTig HF
Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
Ïäçãßåò ÷ñÞóåùò
Instrukcja obs³ugi

2
SVENSKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DANSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
NORSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
SUOMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
DEUTSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
FRANÇAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
NEDERLANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
ESPAÑOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
ITALIANO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
PORTUGUÊS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
E HNIKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
POLSKI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Schema - Skema - Skjema - Johdotuskaavio - Diagram - Schaltplan -
Schéma - Esquema - - Schemat - . . . . . . . . . . . . . . . . . .133
Reservdelsförteckning - Reservedelsfortegnelse - Reservedeloversikt -
Varaosaluettelo - Spare parts list - Ersatzteilverzeichnis -
Liste de pièces détachées - Reserveonderdelenlijst -
Lista de repuestos - Esercizio - Lista de peças de reposição -
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135

43
11 DDIIRREECCTTIIVVEE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
22 SSAAFFEETTYY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
33 IINNTTRROODDUUCCTTIIOONN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
3.2 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
3.3 Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
44 IINNSSTTAALLLLAATTIIOONN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.1 Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.2 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.2.1 Mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.2.2 Connection of welding and return cable in MMA . . . . . . . . . . . . . . . . .48
4.2.3 Connection of TIG torch and return cable . . . . . . . . . . . . . . . . . . . . . . .48
55 OOPPEERRAATTIIOONN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
5.2 Overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.3 Mains voltage compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.4 Fan operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.5 Controls and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.6 Set-up menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
66 MMAAIINNTTEENNAANNCCEE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
6.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
77 FFAAUULLTT TTRRAACCIINNGG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
7.1 Possible faults and measures to take . . . . . . . . . . . . . . . . . . . . . . . . . . .51
88 OORRDDEERRIINNGG OOFF SSPPAARREE PPAARRTTSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
DDIIAAGGRRAAMM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
SSPPAARREE PPAARRTTSS LLIISSTT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135

DDEECCLLAARRAATTIIOONN OOFF CCOONNFFOORRMMIITTYY
EENNGGLLIISSHH
Esab Welding Equipment AB, S-695 81 Laxå, Sweden, gives its unreserved guarantee
that welding power source Caddy TIG HF having serial number 217 complies with stan-
dard EN 60974-1, in accordance with the requirements of directive 73/23/ EEA and
addendum 93/68/ EEA and standard EN 50199 in accordance with the requirements of
directive 89/336/ EEA and addendum 93/68/ EEA.
Laxå 97-09-10
Henry Selenius
Managing Director
Esab Weldin Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
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 workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the welding equip-
ment. 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:
• its operation
• location of emergency stops
• its function
• relevant safety precautions
• welding
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 draughts
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 mmaayy
oonnllyy bbee ccaarrrriieedd oouutt bbyy aa qquuaalliiffiieedd eelleeccttrriicciiaann..
• Appropriate fire extinquishing equipment must be clearly marked and close at hand.
• Lubrication and maintenance must nnoottbe carried out on the equipment during operation.
44
GB
1 DIRECTIVE
2 SAFETY

WARNING
AARRCC WWEELLDDIINNGG AANNDD CCUUTTTTIINNGG CCAANN BBEE IINNJJUURRIIOOUUSS TTOO YYOOUURRSSEELLFF AANNDD OOTTHHEERRSS.. TTAAKKEE PPRREECCAAUU--
TTIIOONNSS WWHHEENN WWEELLDDIINNGG.. AASSKK FFOORR YYOOUURR EEMMPPLLOOYYEERR''SS SSAAFFEETTYY PPRRAACCTTIICCEESS WWHHIICCHH SSHHOOUULLDD BBEE
BBAASSEEDD OONN MMAANNUUFFAACCTTUURREERRSS'' HHAAZZAARRDD DDAATTAA..
EELLEECCTTRRIICC SSHHOOCCKK -- CCaann kkiillll
• Install and earth the welding 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.
FFUUMMEESS AANNDD GGAASSEESS -- CCaann bbee ddaannggeerroouuss ttoo hheeaalltthh
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone
and the general area.
AARRCC RRAAYYSS -- CCaann iinnjjuurree eeyyeess aanndd bbuurrnn sskkiinn..
• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
• Protect bystanders with suitable screens or curtains.
FFIIRREE HHAAZZAARRDD
• Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NNOOIISSEE -- EExxcceessssiivvee nnooiissee ccaann ddaammaaggee hheeaarriinngg
• Protect your ears. Use ear defenders or other hearing protection.
• Warn bystanders of the risk.
MMAALLFFUUNNCCTTIIOONN -- CCaallll ffoorr eexxppeerrtt aassssiissttaannccee iinn tthhee eevveenntt ooff mmaallffuunnccttiioonn..
RREEAADD AANNDD UUNNDDEERRSSTTAANNDD TTHHEE IINNSSTTRRUUCCTTIIOONN MMAANNUUAALL BBEEFFOORREE IINNSSTTAALLLLIINNGG OORR OOPPEERRAATTIINNGG..
PPRROOTTEECCTT YYOOUURRSSEELLFF AANNDD OOTTHHEERRSS!!
WWAARRNNIINNGG!!
Read and understand the instruction manual
before installing or operating.
45
GB

GB
46
3 INTRODUCTION
Caddy TIG HF is a welding power source based on the inverter technique, intended for
welding with coated electrodes (MMA welding) and with infusible tungsten electrode in
inert gas (TIG welding).
Caddy TIG HF is especially designed for high quality TIG welding due to a specific device
that allows the striking of the arc without touching the metal surface with the electrode.
33..11 TTeecchhnniiccaall ddaattaa
Performance MMA:
at 25% duty cycle
at 60% duty cycle
at 100% duty cycle
Performance TIG:
at 30% duty cycle
at 60% duty cycle
at 100% duty cycle
Setting range MMA/TIG
Open circuit voltage MMA/TIG
Mains supply:
voltage
frequency
fuse
mains cable, area
Enclosure class
Application class
Dimensions L x W x H
Weight
CCaaddddyy TTIIGG HHFF
150 A/26 V
115 A/24.6 V
100 A/24 V
150 A/16 V
125 A/15 V
110 A/14.4 V
5-150 A
95 V/104 V
230 V AC ±15%
50/60 Hz
16 A*
3x1,5 mm2
IP 23C
375 x 145 x 280 mm
5.9 kg
*When welding below 100 A in MMA a 10 A slow fuse is adequate..
DDuuttyy ccyyccllee
The duty cycle refers to the time in per cent of a ten-minute period that you can weld
at a certain load without overloading the welding power source.
EEnncclloossuurree ccllaassss
The IIPPcode indicates the enclosure class, i. e. the degree of protection against pene-
tration by solid objects or water. Equipment marked IIPP
2233CCis designed for indoor and
outdoor use.
AApppplliiccaattiioonn ccllaassss
The symbol indicates that the power source is designed for use in areas where
there is an increased electrical hazard.

GB
47
33..22 EEqquuiippmmeenntt
The welding power source is delivered with mains cable (3 metres).
33..33 FFiieelldd ooff aapppplliiccaattiioonn
The power source supplies direct current, which allows you to weld most alloyed and
non-alloyed steels, stainless steels and cast iron.
MMMMAA wweellddiinngg
Selecting the MMA welding with the selection switch and the led indication on the front
panel, coated electrodes from Ø1.6 mm to Ø 3.25 mm and also many Ø 4,00 mm can
be welded.
TTIIGG--wweellddiinngg
TIG welding is particularly useful when high quality standards are required and when
welding thin sheet.
Before using the Caddy TIG HF for TIG welding, it must be equipped with a TIG torch
with trigger switch, a cylinder of argon, an argon regulator, tungsten electrodes and, if
necessary, suitable filler metal.
Selecting the TIG process, in order to strike the arc, you only need to put the tip of the
tungsten electrode near the workpiece and to press the trigger switch; an high frequency
(HF) discharge will strike the arc.
When the TIG LIFT START welding process has been selected the arc ignition is obte-
ned touching the workpiece with the tip of the tungsten electrode, pressing the trigger
switch and lifting the electrode gently to estabilish the arc. In this way the short circuit
current is maintained to a minimum level, in order to prevent the wear of the tungsten
electrode, and to reduce contamination of tungsten in the weld pool.
WWAARRNNIINNGG
This product is intended for industrial use and for repair and maintenance welding.
In domestic or office environment this product may cause radio interference.
It is the responsibility of the user to take adequate precautions.
44..11 PPllaacciinngg
Place the machine so that there is nothing to prevent the cooling air from passing through it.
44..22 CCoonnnneeccttiioonn
44..22..11MMaaiinnss ccoonnnneeccttiioonn
The rating plate, including connection data, is placed underneath the units.
Connect the welding power source to an earthed mains terminal.
Make sure the welding power source is connected for the correct mains voltage and pro-
perly fused.
•Mains voltage 230 V ±15%
•Mains frequency 50-60 Hz
•Fuse, slow 16 A
•Mains cable, area 3 x 1,5 mm2
4 INSTALLATION

GB
48
44..22..22CCoonnnneeccttiioonn ooff wweellddiinngg aanndd rreettuurrnn ccaabbllee iinn MMMMAA
The welding power source has two power terminals, one plus and one minus pole, for the
connection 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.
44..22..33CCoonnnneeccttiioonn ooff TTIIGG ttoorrcchh aanndd rreettuurrnn ccaabbllee
Connect the power connector of the torch to the minus pole terminal of the power source.
Connect the signal and the gas male connectors of the torch to the corresponding fema-
le connectors on the front side of the welding power source.
Connect the gas hole from the gas cylinders to the gas connector on the rear side of the
machine.
GGeenneerraall ssaaffeettyy rreegguullaattiioonnss ffoorr tthhee hhaannddlliinngg ooff tthhee eeqquuiippmmeenntt ccaann bbee ffoouunndd oonn ppaaggee 3366..
RReeaadd tthhrroouugghh bbeeffoorree yyoouu ssttaarrtt uussiinngg tthhee eeqquuiippmmeenntt!!
55..11SSttaarrtt--uupp
•Make sure that the mains cable is properly connected.
•Make sure that the welding cable or the connectors of the TIG torch and the earth
clamp are properly connected.
•Start the welding power source by setting the mains switch to position 1.
•Select the welding process you want pressing on the process selection switch.
Electrode welding process
TIG LIFT START process
TIG HF START process.
Light on the corresponding led confirm the choise.
•Set the welding current, using the knob on the front panel of the power source and
reading the current on the display.
Follow the instructions on the electrode package for the recommended welding
current in MMA welding.
In TIG welding the current must be appropriate to the workpiece and the welding
requirements.
For reducing the final crater in the weld pool is possible to select the ramp-down
function with the selection switch on the right of the front panel and to change its
value with the knob. After some seconds the control return to the welding current.
5 OPERATION

GB
55..22OOvveerrllooaadd pprrootteeccttiioonn
Caddy TIG HF is provided with a thermal cut-out to prevent overheating of the welding
power source. In the event of overload the supply voltage is interrupted, the yellow led on
the front goes on and an error code starts blinking on the display accordingly to the follow:
E01 = overtemperature
E03 = overload with respect to allowed duty cycle
In case of error E01 or E03 resetting takes place automatically as soon as the welding
power source has cooled down.
Error code E20 could also be displayed; in that case switch off and on again the machi-
ne: if E20 is still displayed, call Service.
55..33MMaaiinnss vvoollttaaggee ccoommppeennssaattiioonn
Caddy TIG HF both has mains voltage compensation, which means that + 15% fluc-
tuation in the supply voltage produces a negligible variation in the welding voltage.
55..44 FFaann ooppeerraattiioonn
In order to reduce noise, no load consumption and metallic powder movement, Caddy
TIG HF has a special device that control the fan velocity; the higher is the internal tem-
perature the faster is the fun speed.
55..55 CCoonnttrroollss aanndd ccoonnnneeccttiioonnss
1. Control panel
2. Knob for adjusting the welding parameters
3. Green indicating led (correct mains connection)
4. Yellow indicating led (overheating)
5. Selection switch: MMA mode (light on led); TIG LIFT START mode (light on
led); TIG HF START mode (light on led)
6. Welding parameters and set up switch
7. Green led (welding current is selected)
8. Green led (ramp down time is selected)
9. Display
10. Terminal, minus pole, for connecting welding or return cable or TIG torch.
11. Terminal, plus pole, for connecting welding or return cable
12. Torch switch connector
13. Torch gas connector
14. Input gas connector for the gas hole from the argon cylinder
15. Mains switch
49

GB
50
55..66 SSeett--uupp mmeennuu
Pressing the set-up button for 2s you access to the set-up menu confirmed by a central
"0" on the display.
Via the knob you vary the set-up line, via the set up button you confirm the required line,
via the knob you vary the parameter value, an so on.
If line "1" is confirmed with the button you return to the factory-set values.
If line "0" is confirmed with the button you quit set-up and you save the parameters you
have changed.
Here is the complete list of the set-up parameters:
NN..WWeellddiinngg MMooddeeDDeessccrriippttiioonn
0 TIG/MMA Save and exit
1 TIG/MMA Reset and return to pre-set values
2 TIG Pre-gas time (s), 0.0s-25.0s. Pre-set value = 0.1s
3 TIG Start current (% of welding current), 0% - 500%.
Pre-set value= 50%.
4 TIG Slope-up time (s), 0.0s-10.0 s. Pre-set value = 0.0s.
5 TIG The second welding current value (%of welding current) in TIG
MANUAL PULSE, 0-500%. Pre-set value = 50%.
6 TIG Final current (%of welding current), 0-500%. Pre-set value = 50%.
7 TIG Post-gas time (s). 0.0-25.0. In 0.0 you have an automatic Post-
gas time. Pre-set value = 0.0s.
8 TIG Trigger modes, 0=2T, 1=4T, 2=MANUAL PULSE. Pre-set value = 0.
10 MMA Hot-start (% added to welding current), 0-500%. Pre-set value = 80%.
11 MMA Arc-force (% added to welding current), 0-500%. Pre-set value = 30%.
CURRENT
MMMMAA WWEELLDDIINNGGTTIIGG
WWEELLDDIINNGG ((MMAANNUUAALL PPUULLSSEE))
TIME
CURRENT
TIME
Approx = 1 s
I1 = HOT START (ADJ. 0-500% OF I2 + I2)
I2 = SET CURRENT (0-150 A)
I1 = START CURRENT (ADJ. 0-500% OF I2)
I2 = SET CURRENT (0-150 A)
I3 = FINAL CURRENT (ADJ. 0-500% OF I2)
I4 = PULSE CURRENT (MANUAL PULSE)

77..11 PPoossssiibbllee ffaauullttss aanndd mmeeaassuurreess ttoo ttaakkee
When ordering a spare part, please state the type and serial number of the machine as
well as number of the spare part, according to the spare parts list.
This will simplify dispatch and ensure you get the right part.
TTyyppee ooff ffaauulltt
No arc is generated by the welding
power source.
The welding current is interrupted in the
course of welding.
The thermal cut-out trips frequently.
Poor welding result.
MMeeaassuurree
•Make sure the mains switch is on.
•Check that the welding and return
cables are properly connected.
•Make sure the welding current set is
correct.
•Verify that the welding process is cor-
rectly selected
•Check if the thermal cut-out has trip-
ped (the yellow indicating led on the
front panel is on).
•Check the mains fuse.
•Check that the filter is not packed with
dust.
•Check that the ratings of the welding
power source have not been exceeded
(overload of the power source).
•Check that the welding and return
cables are properly connected.
•Make sure the welding current set is
correct.
•Check that there is nothing wrong with
the electrodes.
•Verify that the welding process is cor-
rectly selected
8 ORDERING OF SPARE PARTS
7 FAULT TRACING
66..11 CClleeaanniinngg
Normally it is sufficient to blow the welding power source clean regularly using dry com-
pressed air (reduced pressure), and to clean the filter in the front regularly.
In dusty and dirty environment the welding power source should be cleaned at shorter
intervals.
GB
51
6 MAINTENANCE