Tig 1500i TA34 Tig 2200i TA33/TA34
Contents
1. 15 2 bo a eT 15AP2 N2 DI BF TA 1 3 1 FN 365V DC c12 e RE 15 81 5 RIA OVA JTUL TS 197 1 i N R15 325V DC N R16 7 1504 mt R17 025 is Li 15L2 S a BA BA BY BY B1 cao B2 Circuit diagram and measuring points for the semiconductor module ct33f3semi 39 50740 800 186 E090407 P50 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 69 on the picture below 4 Bend out the circuit board so that it has no contact with the connections of the diode module 5 Use a multimeter in diode test position to measure the forward voltage drop of the two diodes see the picture below The voltage drop must be 0 3 to 0 5 V 6 If the diode module has to be replaced follow the instructions on page 44 15AP2 Secondary board Circuit diagram and measuring points circuit board 15AP2 ch31f3diode 40 S07402. Soft Starling 22 Mounting components on the heat sink Rights reserved to alter specifications without notice TOCe 2 Sua 36 50740 800 186 E090407 P50 INSTRUCTIONS ciiam e teh xem nm oh Rm RD gn ih eO RO ee GO AX om eeu elas 45 SAFETY manne net ties RE TUNER ee PENES EN EE S E EAR 45 INSTALLATION A 45 LOCATION ME M 45 Mains power supply ssssssss 45 OPEHATION Me I ea a asi DELIS 46 Connections and control devices 46 Water connection 4 ssssssssseress 47 Overheating protection 44 sssssssssssssssss 47 LX agi bred 47 Inspection and cleaning 47 FAULT TRAGING i 2 2 6 hii Ade un Dnm eee 48 SPARE PARTS Risa e Er En Era ee nee ie EMEN 48 NOTES cL E 49 Rights reserved to alter specifications without notice TOCe 3 50740 800 186 E090407 P50 READ THIS FIRST Maintenance and repair work should be performed by an experienced person and electrical work only by a trained electrician
3. 20AP1 Control board 20AP1 1 Power supply 20AP1 2 The CAN bus Starting sequence Communication interruptions Terminating resistors 20AP1 3 Control panel interface circuits 20AP1 4 Pulse width modulator 20AP1 5 Temperature monitoring 20AP1 6 Shunt and current control amplifier 20AP1 7 Arc voltage feedback 20AP1 8 TIG functions 20AP1 9 Welding process control 20AP1 10 Cooling unit control 20AP1 Component positions REMOTE CONTROLS FAULT CODES vise cert eee hots Be eee aes Fault 00 22 324224 ni dee dia Summary of fault codes Fault code description POWET SOUFCE ics te Puce he SERVICE INSTRUCTIONS Whats ESD ina EN Service aid rere Checking the semiconductor module of 15AP1 Checking rectifier and freewheel diodes Checking the gate pulses
4. 6 e 2022 2024 5 5XS4 230V AC not connected 15ST2 15ST1 To 5XS4 Heatsink Transformer 15XS3 RED 15EV1 E3 BLACK PS1 OV PS2 OV ps3 Early warn PS4 2021 2023 2022 2024 1516 5V PSS 20XS5 JE 20XS1 24V PS6 Not connected PS7 GND Not connected PS8 CAN H OVB PS9 CANL Welding process 13VB PS10 control 12V CAN 20 54 OV CAN 20XS3 51 51 20 1 6 60mv 100A 52 PS2 OV Control board PS3 OV PS4 Early warn PS5 PS6 PS7 PS8 0V TIG1 PS9 OVB Start OV TIG2 PS10 13VB 0 1 Gas on 0 TIG4 24 TIGS MMC module 1X 81 21 82 3 10X53 MMC1 MMC34 1012 230V AC from 2AP1 7011 41 7013 5 54 2 ct34_00 10 5XS1 Connectors 5XS1 5XS2 5XS4 and cabling are only fitted to machines with cooling unit 5XS2 1 8 1 10 To cooling unit S0740 800 186 E090407 P50 From mains connection 215 1515 1516 2908 CAN Remote 20XS25 K The remote connection is only fitted to machines with control panel TA34 L D E 1031 1031 10XS1 10XS4 MT 10AP1 10V 025 TIG board zn 027 4 1515 1021 4 From 2AP1 230V AC 1023 4 29XS4 TIG torch 001 002 4 003 6 004 6 005 4 10 52 ct34 00 11 50740 800 186 90407 50 DESCRIPTION OF OPERATION This description of operation describes the function o
5. 12 Communication error warning The load on the system CAN bus is temporarily too high or there is electric noise on the bus Action See section 20AP1 2 The CAN bus on pages 26 to 27 15 Lost messages The bus CAN controller indicates that a message has been lost No functions are disabled by this fault Action Check that all units are correct connected to the CAN bus See also section 20AP1 2 CAN bus on pages 26 to 27 16 High open circuit voltage VRD The open circuit voltage has been too high Action Turn off the mains power supply to reset the unit If the fault persists check the arc voltage feedback see page 29 22 Transmitter buffer overflow The control board is unable to transmit information to the other units at a sufficiently high speed Action A break in the bus line can cause this fault Check the CAN cabling Turn off the mains power supply to reset the unit 23 Receiver buffer overflow The control board is unable to process information from the other units at a sufficiently high speed This fault is caused by abnormal loading of the microprocessor Action Turn off the mains power supply to reset the unit ct34f1 35 50740 800 186 090407 50 SERVICE INSTRUCTIONS CAUTION STATIC ELECTRICITY can damage circuit boards and electronic components e Observe precautions for handling electrostatic sensitive devices Use proper
6. 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 arc voltage feedback thod select method select PROCESS CONTROL current reference current feedback The process regulator control principle Hot start MMA _ Peak current Current Adjustable starting current Set current Starting current MMA welding mode 1 Phase 1 fixed starting current depending on the set current 2 Phase 2 hot start adjustable starting current MMA normal welding mode In the MMA normal welding mode the welding current is briefly increased at the start of welding The peak current phase 1 in the diagram above is engaged for 150 milliseconds The peak current is twice the normal welding current up to 150 A i e twice the set value subject to a maximum of 210 A for the Tig 1500i and 240 A for the Tig 2200i The hot start current phase 2 above is engaged for 1 5 seconds It is set in per cent of the set current but does never exceed the peak current MMA drop welding mode In the MMA drop welding mode the peak current is three times the set value but the duration is shorter at only 50 ms The hot start current phase 2 above is engaged for 240 milliseconds It is set in per cent of the set current but does never e
7. 41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 455 31 2191 4333 Fax 455 31 2191 4440 CANADA ESAB Group Canada Inc Missisauga Ontario Tel 1 905 670 02 20 Fax 1 905 670 48 79 MEXICO ESAB Mexico S A Monterrey Tel 52 8 350 5959 Fax 52 8 350 7554 USA ESAB Welding amp Cutting Products Florence SC Tel 1 843 669 44 11 Fax 1 843 664 57 48 Asia Pacific CHINA Shanghai ESAB A P Shanghai Tel 86 21 2326 3000 Fax 86 21 6566 6622 INDIA ESAB India Ltd Calcutta Tel 91 33 478 45 17 Fax 91 33 468 18 80 INDONESIA P T ESABindo Pratama Jakarta Tel 62 21 460 0188 Fax 62 21 461 2929 JAPAN ESAB Japan Tokyo Tel 81 45 670 7073 Fax 81 45 670 7001 MALAYSIA ESAB Malaysia Snd Bhd USJ Tel 603 8023 7835 Fax 603 8023 0225 SINGAPORE ESAB Asia Pacific Pte Ltd Singapore Tel 65 6861 43 22 Fax 65 6861 31 95 SOUTH KOREA ESAB SeAH Corporation Kyungnam Tel 82 55 269 8170 Fax 82 55 289 8864 UNITED ARAB EMIRATES ESAB Middle East FZE Dubai Tel 971 4 887 21 11 Fax 971 4 887 22 63 Representative offices BULGARIA ESAB Representative Office Sofia Tel Fax 359 2 974 42 88 EGYPT ESAB Egypt Dokki Cairo Tel 20 2 390 96 69 Fax 20 2 393 32 13 ROMANIA ESAB Representative Office Bucharest Tel Fax 40 1 322 36 74
8. Caddy Tig 15001 Tig 22001 Service manual 0740 800 186 090407 Valid for serial no 803 to 843 READ THIS FIRST eta INTRODUCTION remet eke TECHNICAL IRR vee ean ee EIS WIRING Component description TiQ 1500L LLLI imus 118 22001 5 2 ae ue DESCRIPTION OF OPERATION 1 MMC module lI vau I bee 2AP1 Power supply board 2AP1 1 Interference suppressor circuit 2AP1 2 Primary circuit 2AP1 3 Secondary circuit 2AP1 Component positions 10AP1 TIG bo trd 2 nn 10AP1 Component positions 15AP1 Power board Charging circuit Power factor corrector Gate driver stages Switching circuit aes eme due S pply to 2APT mapa Waianae 15AP1 Component positions 15AP2 Secondary board 15AP2 Component positions
9. RUSSIA LLC ESAB Moscow Tel 7 095 543 9281 Fax 7 095 543 9280 LLC ESAB St Petersburg Tel 7 812 336 7080 Fax 7 812 336 7060 Distributors For addresses and phone numbers to our distributors in other countries please visit our home page www esab com ESAB AB SE 695 81 LAXA SWEDEN Phone 46 584 81 000 www esab com 081016
10. Tig 1500 and Tig 2200 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 ct34_00 4 50740 800 186 E090407 P50 module number which is always included as the first part of the name identification of components in the module The modules have the following main functions 1 MMC module Control panel and display board 2 Mains module Mains switch mains interference suppressor and power supply board 10 TIG module Torch switch interface HF unit gas valve 15 Power module This module is a single forward converter operating at a switching frequency of 65 kHz All power semiconductors are built into modules 20 Processor board module controller module This is the controller board 20AP1 that monitors and controls the power source The micro processor of the board comprises the welding data unit TECHNICAL DATA Mains voltage Primary current Imax TIG Imax Mains supply No load power Setting range TIG MMA Permissible load at TIG 20 duty cycle 25 duty cycle 60 duty cycle 100 duty cycle Permissible load at MMA 25 duty cycle 60 duty cycle 100 duty cycle Power factor at maximum current Open circuit voltage without VRD function with VRD function Operating temperature Transportation temperature Constant sound pressure in open circuit Dimensio
11. be activated or deactivated by the ESAT see page 37 Note Spare part boards are delivered with the VRD function deactivated See the component positions diagram on page 32 for identification of circuit board versions TIG The open circuit voltage is about 90 V Arc voltages above 45 V are defined as no welding Output voltage is produced only when TIG welding is in progress If the open circuit voltage arc voltage is above 45 V for more than 100 milliseconds the open circuit voltage control is activated and then the output voltage is shut down MMA power source generates the actual open circuit voltage see Open circuit voltage control above e Touch the electrode to the workpiece When the open circuit voltage goes below 45 V 16 V when VRD is active the open circuit voltage control is disabled e When the current exceeds 8 A the hot start current is activated e When the arc voltage exceeds 52 V welding stops and the open circuit voltage control is activated TIG functions LiftArc TIG start e Touch the electrode on to the workpiece e Press the torch trigger The power source produces a current of about 6 e the electrode from the workpiece The arc strikes and the current increases to 30 A e When the arc voltage exceeds 8 V the current increases decreases to the set current 29 50740 800 186 090407 50 20AP1 9 ct34 20 HF TIG start See 10AP1 TIG board on page 18
12. connector on the front of the cooling unit The pump stops if the switch opens 31 50740 800 186 E090407 P50 20AP1 Component positions pl 13 ZN N MMC Cl Ce CI5 Co 99 853 FE e F serra EE EE oa e TI m SEE BE rofl GE lake R57 6 Ej mE C29 si Y w nann JA 6 Lez gg Des Am 7 7 1 EUM CIO 112 R204 Q 63 AARNE 21636363 A 1 585 al NE e f P830 a dc CRE VRD 487343 005 2 151 H coo s D30 Version 2 of the control board There are two hardware versions of the control board See page 29 for description of the differnce in function between the two versions The print number of the circuit board is used to identify the hardware version of the board The print number is to the right in the component positions diagram above The print number is NOT the same as the ordering number of the board Version 1 of 20AP1 Print numbers up to and including 487343 004 Power sources with serial no 803 xxx xxxx are delivered with version 1 of 20AP1 Version 2 of 20AP1 Print numbers from 487343 005 and there above Power sources with serial no 828 and 843 xxx xxxx are de
13. static proof bags and boxes What is ESD A sudden transfer or discharge of static electricity from one object to another ESD stands for Electrostatic Discharge How does ESD damage occur ESD can cause damage to sensitive electrical components but is not dangerous to people ESD damage occurs when an ungrounded person or object with a static charge comes into contact with a component or assembly that is grounded A rapid discharge can occur causing damage This damage can take the form of immediate failure but it is more likely that system performance will be affected and the component will fail prematurely How do we prevent ESD damage ESD damage can be prevented by awareness If static electricity is prevented from building up on you or on anything at your work station then there cannot be any static discharges Nonconductive materials e g fabrics or insulators e g plastics generate and hold static charge so you should not bring unnecessary nonconductive items into the work area It is obviously difficult to avoid all such items so various means are used to drain off any static discharge from persons to prevent the risk of ESD damage This is done by simple devices wrist straps connected to ground and conductive shoes Work surfaces carts and containers must be conductive and grounded Use only antistatic packaging materials Overall handling of ESD sensitive devices should be minimized to prevent damage Servic
14. voltage in order to avoid injury to persons or damage to components It is a good idea to use soft starting when fault tracing Special equipment To soft start the machine you need soft starting tool SST 3 this is described on page 36 Instructions 1 Disconnect wires 1501 1502 1503 1504 red and yellow from circuit boards 2AP1 and 15AP1 see the circuit diagram below 15AP1 Power board 20F1 2AP1 T 2x81 Power supply L1 2 A1 B2 PF 01222 0 n 230V AC N 202 A2 gt BA 502 N2 230 V B5 Pu disconnect 2 dEXED n rmm 1503 N 3259 DOF 504 2 N 15 55 15 57 Disconnections prior to soft starting 2 Connect the 230 V AC input of the SST 3 to terminals B2 and 4 on circuit board 2AP1 3 Connect the 325 V DC output of the SST 3 to terminals F1 and on circuit board 2AP1 The SST 3 connected to 2AP1 4 Disconnect connector 20XS4 from terminal PS of power supply board 2AP1 Connect the voltage test cable of the SST 3 to terminal PS of power supply board 2AP1 5 Connect the power source to the mains and turn on the mains switch Verify the output voltages from 2AP1 all LEDs on the SST 3 must light Switch off the machine Disconnect the voltage test cable and reconnect connector 20XS4 to terminal PS of circuit board 2AP1 ct34f3soft 42 S0740 800 186 E090407 P50 8 Disco
15. 13VB PS10 control 12V CAN 20XS4 OV CAN 1 MMC module 1 81 ct34_00 20XS3 PS1 PS2 PS3 PS4 PS5 PS6 PS7 PS8 PS9 ov ov Early warn OVB PS10 13VB Control board OV TIG1 Start OV TIG2 HF on 0V TIG3 MMC1 Gas on TIG4 24V TIGS 3 19 28 MMC34 not connected 50740 800 186 E090407 P50 1515 1516 10YV1 X 1515 From 2AP1 230V AC ct34 00 2998 CAN Remote 20X525 A 4 K E 3 L 2 H1 E 1031 1031 10 51 10AP1 TIG board 10AP1 Part B 29XS4 TIG torch A Tu 1011 50740 800 186 090407 50 Tig 2200i with control panels TA33 and TA34 2QF1 214 215 11 402 apium PAPE 2 51 ower supply 230 VAC 202 gt 1501 230V AC 1502 0 216 217 J 203 15 52 15 51 F3 3 1503 C F1 15XS6 215 8 325V DC 325V DC a F1 3 1504 C 15VA fm Red 15VA e ENTE OVA C3 Yellow XK emi 9 15 58 15 57 o 10XS5 Di D2 E1 E2 A1 A2 A3 A4 8 8 7011 2 1021 7 To 10AP1 e b 7012 j 025 TlG board 19X95 15 54 Y 20 52 2021 2023
16. 2 A1 N 202 230 R53 R52 H R42 e o 0 U il 2 2 Z LL A2 N J 1502 m 2AP1 8 15 1 Power supply board B5 203 WARNING Dangerous voltage mains voltage The mains voltage is filtered by the power supply board Power board 15AP1 rectifies the mains voltage TIG board 10AP1 uses the mains voltage for supply to the HF generator and the gas valve ct34_02 13 50740 800 186 90407 50 2AP1 2 Primary circuit 15XS1 15 62 rar me 325 V DC fe HE 1503 ai 15AP1 Power QV 24V 1 5 12 1 59 er 10 6 8 7 OVA 2AP1 Power supply board WARNING Dangerous voltage mains voltage The primary circuit is supplied with 325 V DC from the power board 15AP1 1 is a fuse with high rupturing capacity Transistor Q5 is the switching element in a switched v
17. 341 47 50740 800 186 090407 50 FAULT TRACING Try these recommended checks and inspections before sending for an authorised service technician 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 thermal cut out trips Make sure that you are not exceeding the rated data for the frequently 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 SPARE PARTS The spare parts list is published in a separate document that can be downloaded from the internet www esab com Product Filename Tig 1500i 0459 839 025 Tig 2200i 0459 839 026 341 48 50740 800 186 090407 50 NOTES notes 49 50740 800 186 E090407 P50 ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges m b H Vienna Liesing Tel 43 1 888 25 11 Fax 43 1 888 25 11 85 BELGIUM S A ESAB Brussels Tel 32 2 745 11 00 Fax 32 2 745 11 28 THE CZECH REPUBLIC ESAB VAMBERK s r o Vamberk Te
18. 8 Processor H4 C6 X COMP X lt Ye 2 16 IC SENSE1 Early warning T power shut 7 7 SENSE2 MR down SENSES RESET n BND RESET d R197 r C111 P Processor KHR IC6 monitors the 24 V voltage supply to the 5 V regulator on circuit board 2AP1 1C16 monitors the 5 and 2 5 V supplies Regulator VR4 supplies the processor with 2 5 V ct34_20 24 50740 800 186 090407 50 ct34 20 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 When the 5 and 2 5 V voltages are passing below their treshold values the processor receives a reset signal from IC16 Fault code E4 is not displayed at normal power off 15 V and 20 V Processor 20AP1 Control board Voltage regulator VR2 produces an output voltage of 20 1 0 V which supplies the pulse width modulator output stage Voltage divider R70 R75 supplies 2 6 V to the processor This provides a signal that the power supply is available Voltage regulator VR1 produces an ou
19. 800 186 E090407 P50 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 3 which is described on page 36 Instructions Disconnect the machine from the mains 2 Disconnect connector 20XS5 from terminal G on control board 20AP1 Connect the gate pulse test cable of the SST 3 to terminal G on control board 20AP1 Control board 20AP1 20XS5 20 52 2021 K A1 Measuring connection for the gate pulses 4 Switch on the machine 5 Connect an oscilloscope to the SST 3 with the probe to terminal G2 and the screen to terminal G1 of SST 3 Set the machine to MMA welding mode Measure the pulse frequency It must be 65 kHz 1kHz Measure the duration of the negative pulse It must be 41 43 96 of the cycle time measured at a voltage level of 10 V 9 The waveform of the pulses must be as shown below Freq 65 27kHz Duty 43 26 4 8 12 16 20 24 28 32 36 ps Gate pulses from circuit board 20AP1 ct33f3gate 41 50740 800 186 90407 50 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
20. 90407 50 Recommended fuse sizes and minimum cable area Tig 1500i Tig 2200i 2200iw TIG MMA TIG MMA Mains voltage 230 V 10 96 230 V 10 96 230 V 10 96 230 V 1 10 96 1 50 60 Hz 1 50 60 Hz 1 50 60 Hz 1 50 60 Hz Mains cable area 3G2 5 3G2 5 3G2 5 3G2 5 Phase current 9 1A 11 5A 11 5 A 13 4 A Fuse anti surge 16A 16A 16A 16A type C MCB 13A 13A 16A 16A 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 OPERATION General safety regulations for the handling of the equipment can be found in the instruction manual Read through before you start using the equipment Connections and control devices 1 Connection 7 Mains switch TIG for return cable welding cable or return cable 2 Connection for the remote control unit 8 Mains cable 3 Control panel see separate instruction 9 Connection for shiedling gas manual 4 Connection for the TIG torch trigger switch 10 Connection BLUE with ELP for cooling water from the cooling unit 5 Connection for gas to the TIG torch 11 Connection RED for cooling water to the cooling unit 6 Connection for TIG torch 12 Refilling of cooling water MMA for return cable or welding cable ESAB Logic Pump see Water connection below AH 0877 ct34i1 46 50740 800 186 090407 50 W
21. A the PFC does not work the intermediate voltage is then 325 V or less When the PFC is working properly the voltage across capacitor 15C1 is 365 V ct33 15 1 20 S0740 800 186 E090407 P50 15AP1 Power board D7 08 019 15 2 1 451 1 15AP2 T2 al E 15 1 ou 365V DC 1 15 51 15XS2 1 1503 325V DC P F3 1504 Fim 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 ct33_15 1 21 50740 800 186 90407 50 15AP1 Component positions 4 JE LHI Pin positions of the semiconductor module Seen from the component side of the board Pin 1 marked P1 starts in the down left corner a
22. Lost messages 16 High open circuit votage 1 2 3 4 8 9 12 15 X 16 X x x MEE MN MEN MTS cat ct34f1 33 S0740 800 186 E090407 P50 Code Description Welding data unit incompatible uns x Fault codes marked with an asterisk are not displayed by the control panel but they are stored in the fault log To get access to the fault log use the ESAT service tool See page 37 Fault code description This manual describes the fault codes for the power source The fault codes for the other units are described in the manuals for these units Note The welding data unit is operated by the processor of the control board in the power source The fault codes for the welding data unit are described in the service manual for the control panel Power source Code Description power source 1 EPROM check sum error program memory error Check sum test of the program memory which is run only when initiating the power source 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 If the fault persists load new software via ESAT If the fault still persists replace circuit board 20AP1 which carries the memory chip 2 Microprocessor RAM error The microprocessor is unable to read write from to a particular memory add
23. 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 Use the wiring diagram as a form of index for the description of operation The circuit boards are divided into numbered blocks which are described individually in more detail in the description of operation Component names in the wiring diagram are listed in the component description Use the spare parts list as a guide to where the components are located in the equipment The spare parts list is published as a separate document see page 48 This manual contains details of design changes that have been made up to and including March 2009 The manual is valid for 15001 and Tig 22001 TA33 TA34 with serial no 803 828 and 843 The 1500i and 22001 are designed and tested in accordance with international and European standards IEC EN 60974 On completion of service or repair work it is the responsibility of the person s performing the work to ensure that the product still complies with the requirements of the above standard INTRODUCTION Design structure of the power source 15AP2 Secondary board ENS 2AP1 239 Power supply 10 1 TIG board 1 1 gt lt Gas valve Remote connection Block diagram of the
24. ater 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 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 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 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 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
25. ault code E06 is displayed The power source cannot be restarted until it has cooled sufficiently for the switch es to reclose 20AP1 6 Shunt and current control amplifier 20AP1 Processor Processor Control board Shunt Amplifier 15V 85 0127 C50 AOFS 15 88 Ov Current control 1 amplifier 82 R15 R22 PWM HE ov ov The shunt produces 60 mV at a welding current of 100 A The shunt response is linear to the welding current If the shunt is not connected to the circuit board resistor R2 supplies about 1 4 to 1 9 V to the shunt input This blocks the current control amplifier i e the power source does not deliver any welding current ct34 20 28 50740 800 186 E090407 P50 20AP1 7 20AP1 8 ct34 20 Arc voltage feedback ida Arc voltage sensing No load voltage control 5 57 15XS8 515 S5 Shunt RED S2 Welding 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 Open circuit voltage control Version 1 of 20AP1 The open circuit voltage control holds the voltage at about 70 V Version 2 of 20AP1 The open circuit voltage control holds the voltage at 46 60 When the VRD voltage reducing device function is active the open circuit voltage is lt 35 19 26 The VRD function can only
26. converter operating at a switching frequency of 65 kHz The switch transistors are built into a semiconductor module PM1 See pages 38 to 40 and 41 to 43 for measurement instructions If the power board has failed a replacement board must be mounted in accordance with the instructions on page 44 The power board carries the mains rectifier the charging circuit the PFC circuit the gate circuits and the switching circuits The mains rectifier the switching transistors and parts of the charge and PFC circuits are integrated in a semiconductor module PM1 which is part of the power board Charging circuit OVA Yellow 15XS6 Mains switch 2 1 1 A G1 20AP1 G2 2AP1 Mains filter 20XS5 2021 Power actor correction M Under voltage protection Mains current imit N1 A1 2022 A2 Gate pulse driver When the mains power supply is turned on the rectified mains voltage charges smoothing capacitor 15C1 via resistor R31 Thyristor TY1 short circuits charge resistor R31 when the machine is loaded If TY1 did not conduct resistor R31 would burn out when the unit is on load Power factor corrector PFC The aim with the power factor corrector is to keep the mains current sinusoidal and in phase with the mains voltage The PFC circuit holds the intermediate voltage at 365 V At mains currents above 26
27. dicates that the power source is designed for use in areas with increased electrical hazard WIRING DIAGRAM The power source is based on a number of function modules These are described in the component descriptions on the following pages Wire numbers and component names in the wiring diagram show to which module each component belongs Circuit boards within each module have names such as 15AP1 15AP99 15 module association 1 69 AP circuit board 1 individual identification number 0 99 Components within modules are named in a similar way Component description 1 MMC module control panel and display board see page 12 2 Mains module 2AP1 Power supply board see page 13 2L1 2L8 Ferrite ring cores 2QF1 Mains switch 2 51 Flat pin sockets Important to obtain a proper electric connection the complete cord set must be replaced if the sockets have to be replaced 10 TIG module 10AP1 TIG board see page 18 ct34_00 6 50740 800 186 E090407 P50 10TV1 10YV1 15 15AP1 15AP2 15C1 15D1 15EV1 15L1 15L2 15RS1 15ST1 15ST2 15TM1 20AP1 20L1 HF transformer Gas valve 230 V AC Power module Power board see page 20 Secondary board see page 23 Smoothing capacitor 1000 uF Diode module with rectifier and freewheel diodes Fan Inductor PFC Inductor Power Factor Corrector Shunt 60 mV at 100 A Thermal switch fitted in the winding of main transformer 15TM1 See page 28 Thermal
28. e aid We can offer a number of service tools that will simplify the service Soft starting tool SST 3 The soft starting tool SST 3 is made for ESAB s single phase inverters and for 3 phase inverters with 250 A output current Ordering no 0459 534 881 The SST 3 is replacing the SST 1 which only can be used for the single phase inverters The tool includes Soft starting rectifier cable set voltage test board gate pulse load and shunt voltage resistor for single phase inverters with analogue control board Arc 151i A31 Arc 152i A31 and OrigoArc For the 3 phase machines there are soft starting voltage adapter with current limit and temperature switch jumper cpo2f2 36 S0740 800 186 E090407 P50 Antistatic service kit Ordering no 0740 511 001 The kit makes it easier to protect sensitve components from electrostatic discharge Contents e conductive mat size 610 x 610 mm e 1 5 metre long ground cable with a crocodile clip e adjustable wrist strap and cable with an inbuilt protective resistor Antistatic service kit ESAT service kit The software update is made from a PC it has to be managed by a trained serviceman For this a PC 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 ESAT also contains service functions by which it is possible to co
29. e terminating resistors Power source Unit no 2 Remote control Unit no 4 Control panel interface circuits See the service manual for the TA33 and TA34 control panels filename 0740 800 180 Pulse width modulator 20AP1 Control board 20V 20 55 20 52 a G1 Je 2021 0 A1 G2 J 2022 X A2 eo aea a a The pulse width modulator determines the frequency and pulse time of the switching transistors control pulses controls the pulse frequency the pulse time and inhibition of pulses The pulse frequency is 65 kHz 1kHz with a maximum pulse width of 43 44 of the cycle width See page 41 for screen traces of waveforms and measurement instructions Transistor Q5 controls the primary winding of the pulse transformer on circuit board 15AP1 27 50740 800 186 E090407 P50 20AP1 5 Temperature monitoring 20 51 20xs2 15AP1 Power board 13 2023 lt A3 T2 2024 A4 Processor 21 20 1 Control board D1 D2 E1 2 15XS5 15XS4 15812 15511 Heatsink Transformer The thermal overload switches 15ST1 and 15ST2 are normally closed Terminal T2 of the circuit board is at O 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 f
30. e voltage on the primary side of HF transformer 10TV1 is about 550 V The secondary voltage is about 11 kV if a 4 metre long welding torch is connected If the welding torch is 16 metre long the HF spark is about 8 kV Due to electromagnetic interference regulations the energy in the HF ignition spark is limited and so the HF spark weakens with increasing length of the torch The HF ignition is satisfactory for welding torches up to 16 metres Gas valve When the torch switch is operated relay RE1 closes and energizes the gas valve When the torch switch is released and the gas post flow time has elapsed the gas valve is deactivated TIG torch switch The secondary windings of transformer TR1 and rectifier bridge D3 D6 produce 24 V DC This voltage energizes relay RE3 when the torch switch is closed ct33 10 18 50740 800 186 E090407 P50 10AP1 ct33 10 Component positions WARNING Dangerous voltage mains voltage TIG board part B GNDI 9 TIG board part A 19 50740 800 186 90407 50 15AP1 Power board WARNING Gate pulse Dangerous voltage mains voltage driver Never make any measurements on this board when the machine is connected to the mains N PN supply 15V Alm C1 M1 PFC CAUTION There are different versions of the power board available See the spare parts list to find the correct spare part for the machine The power module is a single forward
31. f circuit boards and other components in the equipment 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 The welding data are stored by the control board of the power source The control panels are described in separate instruction and service manuals TA33 intended for MMA and DC TIG welding without pulsing TA34 intended for MMA and DC TIG welding with pulsing TA33 Caddy Caddy ev e mm Aly Pushbuttons are used for parameter selection and a knob for parameter settings current time etc ct34 01 12 50740 800 186 E090407 P50 2AP1 Power supply board The power supply board filters the mains voltage and generates internal supply voltages for the machine There are two versions of the power supply board 0487 064 884 is used for the Tig 1500i and 0487 631 880 is used for the Tig 2200i The difference between the two versions is the size of inductor L1 Circuit board 0487 631 880 is deliverd as spare part for all machines 2AP1 1 Interference suppressor circuit 10 85 10 84 D3 1023 B7 230V AC 10AP1 D1 1021 B5 TIG board Cut FOE c 230V 51 3 Cooling 5 unit 2QF1 2x81 L1
32. hts red Then LED1 LED2 and LEDS lights green When the board has been initiated and the 31 5 power source is in the application program LED1 flashes continously with a green light LEDs on circuit board 20AP1 Communication interruptions If the CAN bus fails the control panel will normally generate a fault message Check the following points in the event of problems with CAN communications e The terminating resistor The CAN bus resistance must lie the range 50 130 ohm the optimum value is 60 ohm To check the resistance turn off the power source and measure the resistance between pins L and K in connector socket XS25 26 S0740 800 186 E090407 P50 20AP1 3 20AP1 4 ct34 20 e All screen connections must be sound Check the screen connections of the CAN cabling e Good contact with the chassis connections from to the circuit boards and suppressor capacitors See the main circuit diagram e connection cable between units Check that the correct type of cable is being used Check that each signal is being carried by the correct core CAN H and CAN L must be carried by the twinned pair Terminating resistors In order to avoid communication interference the ends of the CAN bus must be terminated by resistive loads Welding data unit Unit no 0 Unit no LS 120 ohm 120 ohm where where CAN low Principle diagram of the CAN bus and connecting up of th
33. ic contact may already have good thermal contact Mount the components as described below See the spare parts list for the order number for thermal paste roller and roller handle Use only the paste recommended by us Fitting instructions 15AP1 Power board with semiconductor module 1 Clean the heat sink and apply thermal conducting paste to the semiconductor module as described above 2 Fitthe board and tighten the screws to a torque of 2 5 Nm and then further tighten them to 4 5 Nm 3 Tighten the screws that connect transformer 15TM1 and capacitor 15C1 to circuit board 15AP1 to a torque of 4 5 Nm CAUTION Incorrectly fitted components can cause failure Do not tighten the screws to more than 4 5 Nm Note f capacitor 15C1 or transformer 15TM1 have to be replaced the power board must be removed and then refitted as described above 15D1 Diode module 1 Clean the heat sink and apply thermal conducting paste to the diode module as described above 2 Fitthe module and tighten the screws to a torque of 2 5 Nm and then further tighten them to 4 5 Nm 3 Tighten the connections to circuit board 15AP2 to 4 5 Nm 4 Tighten the screws that connect transformer 15TM1 and inductor 15L1 to circuit board 15AP2 to a torque of 4 5 Nm CAUTION Incorrectly fitted components can cause failure Do not tighten the screws to more than 4 5 Nm 15ST2 Thermal overload switch 1 Clean the heat sink and apply thermal conducting pa
34. l 420 2 819 40 885 Fax 420 2 819 40 120 DENMARK Aktieselskabet ESAB Herlev Tel 45 36 30 01 11 Fax 45 36 30 40 03 FINLAND ESAB Oy Helsinki Tel 358 9 547 761 Fax 358 9 547 77 71 FRANCE ESAB France S A Cergy Pontoise Tel 33 1 30 75 55 00 Fax 33 1 30 75 55 24 GERMANY ESAB GmbH Solingen Tel 49 212 298 0 Fax 49 212 298 218 GREAT BRITAIN ESAB Group UK Ltd Waltham Cross Tel 44 1992 76 85 15 Fax 44 1992 71 58 03 ESAB Automation Ltd Andover Tel 44 1264 33 22 33 Fax 44 1264 33 20 74 HUNGARY ESAB Kft Budapest Tel 36 1 20 44 182 Fax 36 1 20 44 186 ITALY ESAB Saldatura S p A Mesero Mi Tel 39 02 97 96 81 Fax 39 02 97 28 91 81 THE NETHERLANDS ESAB Nederland B V Amersfoort Tel 31 33 422 35 55 Fax 31 33 422 35 44 NORWAY AS ESAB Larvik Tel 47 33 12 10 00 Fax 47 33 11 52 03 POLAND ESAB Sp zo o Katowice Tel 48 32 351 11 00 Fax 48 32 351 11 20 PORTUGAL ESAB Lda Lisbon Tel 351 8 310 960 Fax 4351 1 859 1277 SLOVAKIA ESAB Slovakia s r o Bratislava Tel 421 7 44 88 24 26 Fax 421 7 44 88 87 41 SPAIN ESAB Ib rica S A Alcal de Henares MADRID Tel 34 91 878 3600 Fax 434 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel 46 31 50 95 00 Fax 46 31 50 92 22 ESAB international AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax
35. livered with version 2 of 20AP1 Spare parts Version 2 of 20AP1 is delivered as spare part to all power sources ct34 20 32 50740 800 186 090407 50 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 When the fault log is full the oldest message will automatically erase when the next fault occurs Only the most recent fault message is displayed on the control panel To read the entire fault log the machine must be connected to the ESAT see service tools on page 37 Faults are monitored detected in two ways by test routines that are run on initiation and by functions that can detect a fault when it occurs The control panel displays a unit number to indicate which unit has generated the fault The following unit numbers are used UO welding data unit U2 power source U4 remote control unit Summary of fault codes Code Description Welding Power data source control unit i 7 8 Memory eror EPROM Memory enon RAM e MemoyemrexemiRAM apsvpwrapy 1 ighememue 1 e mwesmpys e Communication enor waring 15
36. nd continuous anticlockwise around the semiconductor module ct33 15 1 22 S0740 800 186 E090407 P50 15AP2 Secondary board The secondary board is fitted on the main transformer 15TM1 diode module 15D1 and inductor 15L1 15TM1 25 1 2 Secondary board 1511 Diode module 1501 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 If the diode module has failed a replacement module must be fitted in accordance with the instructions on page 44 Inductor L1 forms an LC circuit with C3 C4 and D1 to reduce the risk of arc extinction at low welding currents When rectifier diode 15D1 conducts the LC circuit charges up The circuit is capable of temporarily maintaining a high arc voltage at low current thus reducing the risk of arc extinction Diode D1 prevents capacitor C3 C4 from going negative 15AP2 Component positions O c8 C4 a 01 ch31_15 2 23 50740 800 186 90407 50 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 cont
37. nent positions Y2 Lei 878 A o 36 CS DI 25 2111 zx R8 Power supply board 0487 064 884 used for the Tig 1500i WARNING Dangerous voltage mains voltage ct34 02 16 50740 800 186 90407 50 c E Power supply board 0487 631 880 used for the Tig 2200i and as spare part WARNING Dangerous voltage mains voltage ct34 02 17 50740 800 186 E090407 P50 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 TIG3 J 1003 C L ov 10 55 10XS4 D1 1021 BS 230V AC D3 1023 B7 2AP1 5V 10XS3 10 52 TIG23 1002 X A2 TIG1 1001 A1 The processor on circuit board 20AP1 controls the HF generator and gas valve Secondary board 29XS4 TIG torch D2J 2901 A 2902 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 It remains activated until the arc strikes or for a maximum of 0 5 seconds Th
38. nnect connector 15XS3 supply to the fan from terminal E of circuit board 2AP1 Connect the 24 V DC input of the SST 3 to terminal E of circuit board 2AP1 9 Connect the 24 V DC output of the SST 3 to terminals N1 and N2 of power board 15AP1 15AP2 Secondary 2QF1 Power supply 230 24V 1 OV 15 1 Circuit connections and measuring points for soft starting 10 Switch on the machine and set it to MMA mode 11 Check that the DC voltage across smoothing capacitor 15C1 is 22 24 V 12 Check that the DC voltage at the welding terminals is about 6 7 V 13 If all the measurements are as described above reconnect the wires to restore the power source to normal operation mode and make a test weld The PFC circuits are not active in soft starting mode To check that the PFC is working properly measure the intermediate voltage when the machine is in normal operating mode See Power factor corrector on page 20 ct34f3soft 43 S0740 800 186 E090407 P50 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 The purpose of the paste is to fill out any hollows in the surfaces of the components and the heat sink Those parts of the component and the heat sink that are in true metall
39. ns x b x h without water cooler with water cooler ct34 00 230V 10 1 50 60 Hz 13 8A 21 3A Zmax 0 35 ohm 30 W 3 150 A 4 150 A 150 A 16V 120 14 8 V 110A 14 4V 150 A 26 100 A 24V 90 23 6 0 99 0 99 76 96 80 96 29 35 10to 40 C 20 to 55 C lt 70 dB A 418 x 188 x 208 mm 24 9 A 24 1 A Zmax 0 30 ohm 30 W 3 220 A 4 170A 220 A 188V 150 16 0 V 110A 14 4 V 170A 26 8V 130A 252V 110A 24 4 V 0 99 0 99 75 96 81 See page 29 lt 35V 10 to 40 C 20 to 55 C lt 70 dB A 418 x 188 x 208 mm 418 x 188 x 345 mm 50740 800 186 E090407 P50 Weight without cooling unit 9 2 kg 9 4 kg cooling unit with without cooling water 6 7 kg 4 5 kg Shielding gas All types intended for All types intended for TIG welding TIG welding max pressure 5 bar 5 bar Insulation class transformer H H Enclosure class IP 23 IP 23 Application class 5 S 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 The duty cycle is valid for 40 C The duty cycle is valid for 40 C ambient temperature 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 S in
40. ntrol change or read the different functions of the equipment For the installation and use of the ESAT you need a PC with operating system Windows The ESAT service kit contents e adapter with connection cables e with software e Instruction manual for ESAT Ordering no 0458 847 880 for connection to the print port of the PC 0458 847 881 USB2CAN for connection to the USB port of the PC cpo2f2 37 50740 800 186 E090407 P50 Checking the semiconductor module of 15AP1 5 4 gt 500 kohm LLE P14 p NI 2222 PEGS UE 6 D Measuring points for the semiconductor module PM1 30 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 The main transformer must be connected to terminals T1 and T2 1 Resistor R31 and thyristor TY1 in parallel measure the resistance of R31 It must be 12 ohm on some boards the resistance of R31 is 6 8 or 10 ohm which are also approved values 2 1 diode P1D measure between resistor R31 and terminal 1 PM1 diode P2D measure between resistor R31 and terminal N2 The forward voltage drop must be 0 4 to 0 6 V 3 PM1 diode N1D measure between the negative of capacito
41. oltage 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 15VA Internal power supply to 2AP1 and power supply to the PFC circuits of the power board 15AP1 The voltage is controlled by VR1 it has a tolerance of 0 75V ct34_02 14 50740 800 186 E090407 P50 2AP1 3 Secondary circuit 2AP1 Power supply 15EV1 PS4 J PS4 m Early warning power shut down PS6 J C 56 m 24V PS3 PS3 PS2 PS2 PS9 PS9 20XS4 20XS3 The secondary circuit delivers the following voltages 24 V The voltage is controlled by IC1 on the primary side It has a tolerance of 0 6 V 5 V The voltage is controlled by VR3 It has a tolerance of 0 25 15 The voltage is controlled by VR2 It has a tolerance of 0 75 V 13 VB 12V CAN This voltage is unregulated It has a tolerance of 1 5 V 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 24 Transistor Q6 switches off the fan 15EV1 at the same time ct34_02 15 50740 800 186 E090407 P50 2AP1 Compo
42. r 15C1 and terminal N1 PM1 diode N2D measure between the negative of capacitor 15C1 and terminal N2 The forward voltage drop must be 0 4 to 0 6 V 4 PM1 diode D2 measure between the negative of capacitor 15C1 and terminal T2 The forward voltage drop must be 0 3 to 0 5 V ct33f3semi 38 50740 800 186 E090407 P50 5 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 6 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 7 PM1 transistor Q2 measure the resistance between source the positive of capacitor 15C1 and gate pin 19 of the module The resistance must be higher than 500 kohm 8 PM1 transistor Q3 measure the resistance between source terminal T2 and gate pin 14 of the module The resistance must be higher than 500 kohm 15 1 E 3 Power board JTUL R24 R27 3 X 04 R19 D7 029 027 D28 Ag M V BA Dr e l Dig TR2 TR3 OVA TN nmm 9 E3 EN 1 82 827 20 50 03 22 2009 2524 T kohm 4 4 4 9
43. ress in its internal memory This test is preformed only on initiation after power up This fault does not disable any functions Action Restart the machine If the fault persists replace circuit board 20AP1 which carries the microprocessor chip 3 Error in external RAM Read write test of the processor s internal external RAM This test is preformed only as part of initiation after power up The microprocessor is unable to read write from to a particular memory address in its external memory This fault does not disable any functions Action Restart the machine If the fault persists replace circuit board 20AP1 which carries the microprocessor chip 4 5V 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 Action Turn off the mains power supply to reset the unit If the fault persists check the power supply to circuit board 20AP1 ct34f1 34 S0740 800 186 E090407 P50 Code Description power source High temperature The temperature monitoring circuit has operated The power source is stopped and cannot be restarted until the circuit has reset See also page 28 Possible causes Overloading fan not working properly cooling air inlets or outlets blocked or obstructed or dirt on the heat exchanger
44. rol of the power source the welding data unit and the MMC panel If the circuit board is faulty it must be replaced After replacing the circuit board soft start the power source See the instructions on page 42 There are two hardware versions of the control board see page 32 Note The spare part boards have different ordering numbers for the Tig 1500 Tig 2200 TA33 and 2200 see the spare parts list Circuit board identity Power source unit The control board has a machine ID a hardware ID and a unit type number To read this you need the ESAT service kit see page 37 e machine ID defines which type of power source the board is intended for hardware ID shows design and type of circuit board e unit type is used for identification on the CAN bus The ID numbers of the power sources are Tig 1500i Tig 2200i Machine ID 35 Machine ID 36 Hardware ID 4 Hardware ID 4 Unit type 2 Unit type 2 Welding data unit and MMC The machine ID for the MMC part of the control board determines which type of control panel that is used The machine ID can be changed by ESAT The ID numbers of the different control panels are TA33 machine ID 37 TA34 machine ID 19 Hardware ID 4 Unit type 0 20AP1 1 Power supply 5 V and 432 5 V 2AP1 Power supply 20AP1 Control board 5V RIS e R193 184 R16
45. ste to the thermal overload switch as described above 2 Fitthe thermal overload switch and tighten the screw to 2 Nm ct34a1heat 44 50740 800 186 E090407 P50 INSTRUCTIONS This chapter is an extract from the instruction manual for the Tig 15001 Tig 2200i TA33 and Tig 2200i TA34 SAFETY CAUTION Read and understand the instruction manual before installing or operating INSTALLATION The installation must be executed by a professional Location Position the welding power source such that its cooling air inlets and outlets are not obstructed Mains power supply 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 distrubution network operator if necessary that the equipment may be connected 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 341 45 50740 800 186
46. switch fitted on the heat sink See page 28 Main transformer Controller circuit board See the description on page 24 Ferrite ring core CAUTION STATIC ELECTRICITY can damage circuit boards and electronic components e Observe precautions for handling electrostatic sensitive devices e Use proper static proof bags and boxes 15AP1 ct34 00 15AP2 Placement of the circuit boards 50740 800 186 E090407 P50 Tig 1500i with control panel TA34 2QF1 15AP1 24 215 11 42 2 1 2xS1 Power suppl 230 VAC 202 ET A gt 1501 230 gt 1502 218 2L7 3 203 15XS2 15 51 Gnd 4 F3 fm 1503 1 15XS6 325V DC 325V DC 213 214 F1 15 4 2 S umb 15VA fm J Red m 1 15VA 2 _ 8 S OVA C3 31 Yellow XK emi 4 15 58 15 57 9 10 55 Di D2 A1 2 A4 not connected d gt 1023 TIG board 15XS5 15XS4 I Y 20 52 2021 2023 8 8 2022 2024 1919 not connected 15ST2 15ST1 Heatsink Transformer 15XS3 15 1 BLACK PS1 OV PS2 OV ps3 Early warn PS4 2021 2023 2022 2024 1516 5V PSS 20 85 1 1 20xs1 A 24V PS6 Not connected PS7 Not connected PS8 CANH OVB PS9 2 Welding process
47. tput voltage of 15 V and this together with the 15 V supply powers the analogue circuits Processor The 15 V power supply is monitored by the processor 12 V_CAN 12V_CAN PS10 The 13 VB from 2AP1 is used to supply the CAN circuits of the equipment This supply is referred to as 12 V_CAN its neutral point CAN is separated from the electronic neutral 0 The tolerance of the voltage is 11 5 to 14 5 V 25 50740 800 186 090407 50 20AP1 2 The CAN bus ct34 20 12V_CAN 12V_CAN Remote 20XS25 N m or x 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 equipment Communication speed is 400 kbit s The 12V CAN and OV CAN power supply is unregulated and is galvanically isolated from other parts of the control board The shell of the CAN connectors and the shield of the CAN cables are connected to OV CAN GND in the diagram is connected to the power source chassis Voltage regulator VR5 supplies a 5 V power supply to the CAN circuits on 20AP1 Starting sequence On power up the board s CAN controller reads in the bus speed from the micro processor 400 kbit s The circuit board displays the starting sequence from power up LED1 lig
48. xceed the peak current 30 50740 800 186 E090407 P50 20AP1 10 Cooling unit control 20AP1 Control board From processor Power on pump and fan To processor Not used To processor Flow guard To processor ELP detection ct34 20 5 Cooling unit 24V Pump fan 230V AC Not used 24V Starting the welding equipment 1 The welding data unit senses whether the water lock microswitch 5S2 is closed or not 2 If it is closed a command to start the pump is generated a relay the cooler starts the pump and the fan 3 If welding does not start within 6 5 minutes the pump is stopped The pump is stopped if the water lock microswitch opens Starting to weld 1 The welder presses the welding torch trigger switch 2 The water pump starts if the water lock microswitch is closed 3 Welding starts Stopping welding 1 The welder releases the trigger switch 2 Welding stops 3 The water pump continues to run for a further 6 5 minutes If welding is restarted while the pump is still running the pump will continue to run as required i e the 6 5 minute shutdown countdown is interrupted Flow guard can not be installed in the CoolMini The flow guard input is jumpered with wire 541 in the cooler the behaviour is as if the cooling water is always flowing Microswitch 5S2 in the water lock connector closes when a cooling water hose is connected to the blue water
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