ESAB Caddy Tig 2200i AC/DC Service Manual

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Instruction manual (32 pages)

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Esab 2200i caddy E12 keeps coming up u5 and u2 aswell

Summary of Contents for ESAB Caddy Tig 2200i AC/DC

Page 1 Tig 2200i AC/DC Caddyt Service manual 0740 800 179 071123 Valid for serial no. 718- -xxx- -xxxx...
Page 2: Table Of Contents
READ THIS FIRST ..............INTRODUCTION .
Page 3 SERVICE INSTRUCTIONS ............What is ESD? .
Page 4: Read This First
READ THIS FIRST Maintenance and repair work should be performed by an experienced person, and electrical work only by a trained electrician. Use only recommended replacement parts. This service manual is intended for use by technicians with electrical/electronic training for help in connection with fault--tracing and repair.
Page 5: Technical Data
The power source is transistor--controlled, operating on the inverter principle. It consists of a number of function modules, as shown in the block diagram above. Each module has a module number, which is always included as the first part of the name/identification of components in the module.
Page 6: Wiring Diagram
Tig 2200i AC/DC Operating temperature --10 to + 40˚C Transportation temperature --25 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 All types intended for TIG welding max pressure...
Page 7 2QF1 Mains switch. 2XS1 Flat pin sockets. Important: to obtain a proper electric connection, the complete cord set must be replaced if the sockets have to be replaced. TIG module. 10AP1 TIG board. 10TV1 HF transformer. 10YV1 Gas valve, 230 V AC. Power module.
Page 8: Tig 2200I Ac/Dc
Tig 2200i AC/DC S0740 800 179/E071123/P64 - - 8 - - ct33_00...
Page 9 S0740 800 179/E071123/P64 - - 9 - - ct33_00...
Page 10: Description Of Operation
DESCRIPTION OF OPERATION This description describes the function of circuit boards and other components in the power source. It is divided into sections, numbered to correspond to the circuit board numbers and divisions into function blocks. 1 MMC module The MMC module consists of an operator’s control panel and a display board. The control panel is used for setting and displaying welding data.
Page 11: 2Ap1 Power Supply Board
2AP1 Power supply board The power supply board filters the mains voltage and generates internal supply voltages for the machine. 2AP1:1 Interference suppressor circuit WARNING! Dangerous voltage - mains voltage. The mains voltage is filtered by the power supply board. Power board 15AP1 rectifies the mains voltage.
Page 12: 2Ap1:3 Secondary Circuit
Transistor Q5 is the switching element in a switched voltage supply. The secondary voltage, +24 V, is sensed by IC2 and controlled by IC1. The isolation voltage of transformer T1 and optocoupler IC3 is 4 kV. +15V A Internal power supply to 2AP1 and power supply to the PFC circuits of the power board, 15AP1.
Page 13: 2Ap1 Component Positions
Early warning power shut down If the voltage goes low, output PS4 generates a warning signal to the processor on circuit board 20AP1 (see page 27). Transistor Q6 switches off the fan, 15EV1, at the same time. 2AP1 Component positions WARNING! Dangerous voltage - mains voltage.
Page 14: 10Ap1 Tig Board
10AP1 TIG board WARNING! Dangerous voltage - mains voltage. The relay contacts, the gas valve 10YV1, the HF generator TR2 and the primary side of transformer TR1 are connected to 230 V mains voltage. The processor on circuit board 20AP1 controls the HF generator and gas valve. HF generator When the welding torch switch is operated, and the open--circuit voltage is over 50 V, relay RE2 closes and turns on the HF generator, TR2.
Page 15: 10Ap1 Component Positions
10AP1 Component positions WARNING! Dangerous voltage - mains voltage. S0740 800 179/E071123/P64 - - 15 - - ct33_10...
Page 16: 15Ap1 Power Board
15AP1 Power board WARNING! Dangerous voltage - mains voltage. Never make any measurements on this board when the machine is connected to the mains supply. The power module is a single forward converter, operating at a switching frequency of 65 kHz. IGBT transistors are used as the switching elements.
Page 17: Gate Driver Stages
Gate driver stages Transformer TR1 is a gate driver transformer for galvanic isolation of the drive circuits from controller board 20AP1. Switching circuit The switching transistors are integrated in the semiconductor module, PM1. Supply to 2AP1 The board supplies power supply board 2AP1 with 325 V DC (pins F1 and F3, connector 15XS1).
Page 18: 15Ap1 Component Positions
15AP1 Component positions Pin positions of the semiconductor module: (Seen from the component side of the board). Pin 1 marked P1 starts in the down--left corner and continuous anticlockwise around the semiconductor module. S0740 800 179/E071123/P64 - - 18 - - ct33_15_1...
Page 19: 15Ap2 Secondary Board
15AP2 Secondary board The secondary board is fitted on the main transformer 15TM1, diode module 15D1 and inductor 15L1. Diode module 15D1 comprises two diodes, rectifier and freewheel diode. During the time interval between two voltage pulses from transformer 15TM1, the freewheel diode maintain the welding current from inductor 15L1.
Page 20: 18Ap1 Ac Control Board
18AP1 AC control board Sections 18AP1:1 to 18AP1:6 refer to the wiring diagram on page 8. The processor on the AC control board monitors the temperature in the AC power modules. The AC control commands are generated by the processor on circuit board 20AP1 and executed by the local processor.
Page 21: 18Ap1:2 Can Bus
18AP1:2 CAN bus Bus communication circuits The circuit board includes a driver for the CAN bus, IC17, which handles the communication with the other units of the system. Starting sequence On power--up, the board’s CAN controller reads the bus speed from the micro processor: 400 kbit/s.
Page 22: 18Ap1:3 Temperature Monitoring
18AP1:3 Temperature monitoring Principle diagram of the temperature monitoring circuits The temperature monitoring circuit senses the temperature of the IGBT modules, IC1 and IC2, that are fitted to circuit board 18AP2. Two NTC resistors, NTC_IC1 and NTC_IC2, are used as sensors. The output of the monitoring circuit is sensed by the processor, which in turn stops the machine if overtemperature occurs.
Page 23: 18Ap1:5 Fan Power Supply
18AP1:5 Fan power supply The fan is supplied at 24 V DC from the power supply board, 18AP1:6 Switch driver See also 18AP2:1 Switching circuits on page 25. The gate signals can be measured on circuit board 18AP2. See page 50 for test instructions.
Page 24: 18Ap1 Component Positions
18AP1 Component positions S0740 800 179/E071123/P64 - - 24 - - ct33_18...
Page 25: 18Ap2 Ac Power Board
18AP2 AC power board Sections 18AP2:1 to 18AP2:3 refer to the wiring diagram on page 8. 18AP2:1 Switching circuits The circuit board carries two IGBT modules IC1 and IC2, with 2 IGBTs each. In the description below the IGBTs are named IGBT1, IGBT2, IGBT3 and IGBT4. The IGBTs are controlled by the processor.
Page 26: 18Ap2:2 Temperature Monitoring
18AP2:2 Temperature monitoring See 18AP1:3 on page 22. 18AP2:3 Fan power supply See 18AP1:5 on page 23. 18AP2 Component positions S0740 800 179/E071123/P64 - - 26 - - ct33_18...
Page 27: 20Ap1 Control Board
20AP1 Control board The processor on the control board monitors and controls the various functions of the power source. The control board is used in combi mode. In combi mode the board handles the control of the power source, the welding data unit and the MMC panel. If the circuit board is faulty, it must be replaced.
Page 28 The voltage on terminal PS4 is normally about 24 V, when this drops below 20 V, pin 14 of IC6 goes low, providing the processor with a low power supply voltage signal. The processor then stores current data and generates fault code E4.
Page 29: 20Ap1:2 The Can Bus
20AP1:2 The CAN bus Bus communication circuits to and from the control board A standardised communication (CAN -- Controller Area Network) bus is used for communication between the units of the machine. Communication speed is 400 kbit/s. The +12V_CAN and 0V_CAN power supply is unregulated and is galvanically isolated from other parts of the control board.
Page 30: Terminating Resistors
All screen connections must be sound. Measure the resistance between the shell of the CAN connector connected to 20AP1 and the shell of CAN connector XP55 connected to 18AP1. There must be a short circuit between those two end points. Good contact with the chassis connections from/to the circuit boards and suppressor capacitors.
Page 31: 20Ap1:5 Temperature Monitoring
20AP1:5 Temperature monitoring The thermal overload switches, 15ST1 and 15ST2, are normally closed. Terminal T2 of the circuit board is at 0 V. 15ST2, which is fitted on the heat sink, opens at 75 _C. 15ST1, which is fitted in the winding of the main transformer, 15TM1, opens at 130 _C. If either of the switches operates, the power source is stopped, fault code E06 is displayed.
Page 32: 20Ap1:7 Arc Voltage Feedback
20AP1:7 Arc voltage feedback This circuit measures and scales the arc voltage to a suitable level for the processor. 64 V arc voltage produces a voltage signal of 5.0 V at the cathode of diode D13. The open--circuit voltage control is inactive in the TIG welding mode. The open--circuit voltage is about 110 V.
Page 33: 20Ap1:9 Welding Process Control
20AP1:9 Welding process control The processor inputs are the set values of welding data and the arc voltage. The processor also calculates a set value signal for welding current, and supplies this to the current control amplifier. The process regulator control principle Hot start MMA Peak current Adjustable starting current...
Page 34: 20Ap1:10 Cooling Unit Control
20AP1:10 Cooling unit control Starting the welding equipment The welding data unit senses whether the water lock microswitch, 5S2, is closed or not. If it is closed, a command to start the pump is generated, and a relay in the cooler starts the pump and the fan. If welding does not start within 6.5 minutes, the pump is stopped.
Page 35: 20Ap1 Component Positions
20AP1 Component positions S0740 800 179/E071123/P64 - - 35 - - ct33_20...
Page 36: Remote Controls
REMOTE CONTROLS A number of remote control units can be connected to the power source, these are described in a separate service manual with filename 0740 800 170. FAULT CODES Fault codes are used in order to indicate and identify a fault in the equipment. Fault log All faults that occur when using the welding equipment are documented as error messages in the fault log.
Page 37: Fault Code Description
Code Description Welding Power Remote data source control unit unit unit 20 High inductance in the welding circuit *22 Transmitter buffer overflow *23 Receiver buffer overflow *25 Lost contact with AC unit *26 Program operating fault *28 Stack overflow *40 Incompatible units Fault codes marked with an asterisk ( * ) are not displayed by the control panel.
Page 38 Code Description, power source 5 V power supply too low The unregulated power supply voltage (+24 V) is too low: the smoothing capacitors cannot keep the voltage up enough for the processor to continue to operate. The processor stops all normal activities, expecting to be shut down.
Page 39: Ac Unit
AC unit Code Description, AC unit EPROM check sum error - - program memory error Check sum test of the program memory, which is run only when initiating the unit after power--up. This fault does not disable any functions. The program memory is damaged. This is a serious fault, that can have unforeseen effects. Action: Restart the machine.
Page 40 Stack overflow The stack memory is full. This fault should never occur in reality: the fault code is intended as an aid during development work. Contact ESAB if the fault does occur. S0740 800 179/E071123/P64 - - 40 - -...
Page 41 S0740 800 179/E071123/P64 - - 41 - - ct33f1...
Page 42: Service Instructions
We can offer a number of service tools that will simplify the service. Soft- -starting tool SST 1 The soft--starting tool SST 1 is made for ESAB’s single phase inverters. It can be ordered from ESAB, ordering no. 0459 534 880.
Page 43 The software update is made from a PC, it has to be managed by a trained serviceman. For this a computer program called ESAT, ESAB software administration tool, is needed. The PC is connected to the welding equipment by a cable connector and a CAN reader. From the ESAT it is possible to update the software in power source, wire feeder and control panel.
Page 44: Checking The Semiconductor Module Of 15Ap1
Checking the semiconductor module of 15AP1 Measuring points for the semiconductor module, PM1 Disconnect the machine from the mains and follow the instructions below. Measurements 2 -- 6: Use a multimeter in diode test position to measure the diodes. Measure with the positive and negative of the multimeter connected as shown in the picture above.
Page 45 PM1, diode D3: measure between the positive of capacitor 15C1 and terminal T2. The forward voltage drop must be 0.3 to 0.5 V. PM1, diode D1: measure between the positive of capacitor 15C1 and terminal L2. The forward voltage drop must be 0.3 to 0.5 V. PM1, transistor Q2: measure the resistance between source, the positive of capacitor 15C1, and gate, pin 19 of the module.
Page 46 S0740 800 179/E071123/P64 - - 46 - - emptypage0...
Page 47: Checking Rectifier And Freewheel Diodes
Checking rectifier and freewheel diodes Disconnect the machine from the mains. Dismantle the housing of the machine. Use a Torx key no. T25 to unscrew and remove five screws from circuit board 15AP2. The screws are marked on the picture below, Bend out the circuit board so that it has no contact with the connections of the diode module.
Page 48: Checking The Igbt Modules Of Ac Power Board 18Ap2
Checking the IGBT modules of AC power board 18AP2 Disconnect the machine from the mains and follow the instructions below. The numbers of the instructions refer to the diagrams on this and next page. Before measuring: disconnect connector 18XS3 from terminal CN1 and the positive and negative voltage supply bars from the circuit board.
Page 49 Component positions AC power board 18AP2, measuring points IGBT modules S0740 800 179/E071123/P64 - - 49 - - ct33f3acpwr...
Page 50: Checking The Gate Signals To Ac Power Board 18Ap2
Checking the gate signals to AC power board 18AP2 The gate voltage is +15 V when the IGBTs are conducting. The gate voltage is --10 V when the IGBTs are open. Measure the gate voltage across varistors D4, D6, D12 and D16. Measuring points a and b in the diagram.
Page 51 Component positions AC power board 18AP2, measuring points gate signals S0740 800 179/E071123/P64 - - 51 - - ct33f3acpwr...
Page 52 S0740 800 179/E071123/P64 - - 52 - - emptypage...
Page 53: Checking The Gate Pulses
Checking the gate pulses When checking the gate pulses, the machine can either be in soft--start mode or in normal operation mode. Special equipment To measure the gate pulses, you need a gate pulse load. This is included in soft--starting tool SST 1, which is described on page 42.
Page 54: Soft Starting
Soft starting We recommend soft starting of the machine after replacing control circuit board 20AP1, power supply board 2AP1 and circuit boards or components in the power module. Soft starting supplies the power module with a low voltage in order to avoid injury to persons or damage to components.
Page 55 Disconnect connector 15XS3 (supply to the fan) from terminal E of circuit board 2AP1. Connect the 24 V DC input of the SST 1 to terminal E of circuit board 2AP1. Connect the 24 V DC output of the SST 1 to terminals N1 and N2 of power board 15AP1.
Page 56: Mounting Components On The Heat Sink
Mounting components on the heat sink Thermal paste Apply thermal conducting paste to the components before fitting them to the heat sink. Start by cleaning the heat sink, and then apply a very thin, even layer of thermal paste to the contact surfaces of the components.
Page 57 15ST2 Thermal overload switch Clean the heat sink and apply thermal conducting paste to the thermal overload switch as described above. Fit the thermal overload switch and tighten the screw to 2 Nm. 18AP2: AC power board with IGBT modules IC1, IC2, Clean the heat sink and apply thermal conducting paste as described above.
Page 58: Instructions
INSTRUCTIONS This chapter is an extract from the instruction manual for the Tig 2200i AC/DC. SAFETY CAUTION! Read and understand the instruction manual before installing or operating. INSTALLATION The installation must be executed by a professional. Lifting instructions Install the carrying strap as illustrated and lift the power source by the strap.
Page 59: Operation
OPERATION Connections and control devices Connection for remote control unit Connection for return cable Control panel (see separate instruction Mains switch manual) Connection for torch switch Mains cable Connection for gas to the torch Connection for shielding gas Connection for welding cable or torch Key to symbols Return clamp S0740 800 179/E071123/P64...
Page 60: Turning On The Power Source
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.
Page 61: Water Cooler, Assembly Instructions
Water cooler, assembly instructions 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. S0740 800 179/E071123/P64 - - 61 - - ct33i...
Page 62: Fault- -Tracing
Check that the correct electrodes are being used. Check the gas flow. SPARE PARTS The spare parts list is published in a separate document that can be downloaded from the internet: www.esab.com Product Filename 0459 839 013 Tig 2200i AC/DC...
Page 63 S0740 800 179/E071123/P64 - - 63 - - ct33i...
Page 64 ESAB subsidiaries and representative offices Europe Asia/Pacific Representative offices NORWAY AS ESAB AUSTRIA BULGARIA CHINA Larvik ESAB Ges.m.b.H ESAB Representative Office Shanghai ESAB A/P Tel: +47 33 12 10 00 Vienna- -Liesing Sofia Shanghai Fax: +47 33 11 52 03...