ESAB Caddy Tig 2200i AC/DC User manual

ESAB Caddy Tig 2200i AC/DC User manual

Caddy®

Tig 2200i AC/DC

Instruction manual

0460 225 301 GB 20180920 Valid for: serial no. 711-, 747-xxx-xxxx

TABLE OF CONTENTS

3 4 1 2

SAFETY

.......................................................................................................

1.1

Meaning of symbols

...............................................................................

1.2

Safety precautions

.................................................................................

INTRODUCTION

..........................................................................................

2.1

Equipment

...............................................................................................

2.2

Control panels

........................................................................................

TECHNICAL DATA

......................................................................................

INSTALLATION

............................................................................................

4.1

Lifting instructions

.................................................................................

4.2

Location

...................................................................................................

4.3

Mains power supply

...............................................................................

5 6

OPERATION

................................................................................................

5.1

Connections and control devices

.........................................................

5.2

5.3

5.4

Key to symbols

.......................................................................................

Connection to cooling unit

....................................................................

Turning on the power source

................................................................

MAINTENANCE

...........................................................................................

6.1

Inspection and cleaning

.........................................................................

7

TROUBLESHOOTING

.................................................................................

8

ORDERING SPARE PARTS

........................................................................

ASSEMBLY INSTRUCTIONS

..............................................................................

DIAGRAM

............................................................................................................

ORDERING NUMBERS

.......................................................................................

ACCESSORIES

...................................................................................................

8

10

10 10 10

4

4 4

7

7 7

16

17

18

19

21

22

12

13 13

14 14

15

15

Rights reserved to alter specifications without notice.

0460 225 301 © ESAB AB 2018

1 SAFETY

1 SAFETY

1.1

Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

WARNING!

Means potential hazards which could result in personal injury or loss of life.

CAUTION!

Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual and follow all labels, employer´s safety practices and Safety Data Sheets (SDSs).

1.2

Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be 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 equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment.

1.

2.

3.

Anyone who uses the equipment must be familiar with: ○ its operation ○ location of emergency stops ○ its function ○ relevant safety precautions ○ welding and cutting or other applicable operation of the equipment 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 or work is started with the equipment The workplace must: ○ be suitable for the purpose ○ be free from drafts 0460 225 301

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1 SAFETY 4.

5.

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 General precautions: ○ Make sure the return cable is connected securely ○ Work on high voltage equipment

may only be carried out by a qualified electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at hand ○ Lubrication and maintenance must

not

be carried out on the equipment during operation

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding.

EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to EMF: ○ Route the electrode and work cables together on the same side of your body. Secure them with tape when possible. Do not place your body between the torch and work cables. Never coil the torch or work cable around your body. Keep welding power source and cables as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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1 SAFETY

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only qualified people remove covers for maintenance and troubleshooting as necessary. Reinstall panels or covers and close doors when service is finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.

NOTE!

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2012/19/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information contact your local ESAB dealer or visit us on our website.

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2 INTRODUCTION

2 INTRODUCTION

The Tig 2200i AC/DC is a TIG welding power source, which can also be used for MMA welding. It can be used with alternating current (AC) or direct current (DC).

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual.

2.1

Equipment

The power source is supplied with a 5 m return cable, 3 m mains cable, carrying strap, cable holder, shaft belt, instruction manual for power source and control panel.

2.2

Control panels

• TA33 AC/DC • TA34 AC/DC See the separate instruction manual for a detailed description of the control panels.

Instruction manuals in other languages can be downloaded from the Internet: www.esab.com

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3 TECHNICAL DATA

3 TECHNICAL DATA

Mains voltage Primary current

I max : MMA

Tig 2200i AC/DC, From serial no. 747-xxx-xxxx

230V, 10%, 1~ 50/60 Hz 25 A TIG No-load power (idle state)

Setting range:

MMA TIG, AC* / DC 28 A 41 W 4 A/20 V–160 A/26.4 V 3 A/10 V–220 A/18.8 V

Values of the conventional load: TIG

(duty cycle at 40 °C/104 °F ambient temperature): 20% 60% 220 A / 18.8 V 150 A / 16.0 V 100% 140 A / 15.6 V

MMA

(duty cycle at 40 °C/104 °F ambient temperature): 30% 60% 100%

Power factor

at maximum current (I 2 ): MMA TIG

Efficiency

at maximum current (I 2 ): MMA 160 A / 26.4 V 120 A / 24.8 V 110 A / 24.4 V 0.99

0.99

73 % 65 % 6.4 kVA TIG

Apparent power

at max current (I 2 )

Active power

at max current (I 2 )

U 0

No-load voltage

U r

No-load voltage with VRD

U pk

(with arc ignition unit, Tig)

Working temperature Continual sound pressure at no-load Dimensions l×w×h Dimensions l×w×h

with cooler

Weight Weight

with cooler

Isolation class transformer Enclosure class

6.3 KW 58 V 25 V 10.7 kV -10 to +40 °C (+14 to +104 °F) < 70 dB(A) 418×188×345 mm (16.46×7.40×13.58 in.) 418×188×496 mm (16.46×7.40×19.53 in.) 15.7 kg (34.61 lbs) 22.1 kg (48.72 lbs) H IP23 0460 225 301

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3 TECHNICAL DATA

Tig 2200i AC/DC, From serial no. 747-xxx-xxxx Application class Restrictive use

Class A *) The minimum current during AC welding depends on the alloy used for the aluminium plates and their surface cleanliness.

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a certain load without overloading. The duty cycle is valid for 40 °C / 104 °F, or below.

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 intended for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased electrical hazard.

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4 INSTALLATION

4 INSTALLATION

The installation must be carried out by a professional.

CAUTION!

This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the user's responsibility to take adequate precautions.

4.1

Lifting instructions

Install the carrying strap as illustrated and lift the power source by the strap.

4.2

Location

Position the welding power source such that its cooling air inlets and outlets are not obstructed.

4.3

Mains power supply

NOTE!

Mains supply requirements

This equipment complies with IEC 61000-3-12 provided that the short-circuit power is greater than or equal to S power greater than or equal to S scmin scmin at the interface point between the user's supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit . Refer to the technical data in the TECHNICAL DATA chapter.

Check that the welding power source is connected to the correct mains power supply voltage, and that it is protected by the correct fuse size.

A protective earth connection must be made in accordance with regulations.

Rating plate with supply connection data

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© ESAB AB 2018

4 INSTALLATION

Recommended fuse sizes and minimum cable areas Tig 2200i AC/DC

Mains voltage Mains cable area Primary current I max Phase current I 1eff Fuse Anti-surge Type C MCB 230 V ±10%, 1~ 50/60 Hz 3×2.5 mm 2 28 A 15 A 16 A 16 A

NOTE!

The mains cable areas and fuse sizes as shown above are in accordance with Swedish regulations. For other regions, supply cables must be suitable for the application and meet local and national regulations.

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5 OPERATION

5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY" chapter of this manual. Read it through before you start using the equipment!

                                                        0460 225 301

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© ESAB AB 2018

5 OPERATION 3 4 5

5.1

1 2

Connections and control devices

Connection for remote control unit Control panel (see separate instruction manual) Connection for torch Connection for gas to the torch Connection for welding cable or torch 6 7 8 9 Connection for return cable Mains switch Mains cable Connection for shielding gas                                            

5.2

Key to symbols

MMA        TIG        Return clamp 0460 225 301

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5 OPERATION

5.3

Connection to cooling unit

Only those persons who have appropriate electrical knowledge (authorised personnel) may remove the safety plates to connect or carry out service, maintenance or repair work on welding equipment.

See installation instructions in chapter "INSTALLATION".

NOTE!

Coolant must be topped up if connecting a welding torch or connection cables that are 4 meters in length or longer.

5.4

Turning on the power source

Turn on the mains power by turning the mains switch to the ”1” position.

Turn the unit off by turning the switch to the ”0” position.

Whether the mains power supply is interrupted or the power unit is switched off in the normal manner, welding data will be stored so that it is available next time the unit is started.

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© ESAB AB 2018

6 MAINTENANCE

6 MAINTENANCE

NOTE!

Regular maintenance is important for safe and reliable operation.

Only those persons who have appropriate electrical knowledge (authorised personnel) may remove the safety plates to connect or carry out service, maintenance or repair work on welding equipment.

CAUTION!

All warranty undertakings from the supplier cease to apply if the customer attempts any work to rectify any faults in the product during the warranty period.

6.1

Inspection and cleaning

Power source

Check regularly that the welding power source is not clogged with dirt How often and which cleaning methods apply depend on: the welding process, arc times, placement, and the surrounding environment. It is normally sufficient to blow down the power source with dry compressed air (reduced pressure) once a year.

Clogged or blocked air inlets and outlets otherwise result in overheating.

Welding torch

• The wear parts of the welding torch should be cleaned and replaced at regular intervals in order to achieve trouble-free wire feed. Blow the wire guide clean regularly and clean the contact tip.

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7 TROUBLESHOOTING

7 TROUBLESHOOTING

Try these recommended checks and inspections before sending for an authorised service technician.

No arc.

Type of fault

The welding current is interrupted during welding.

The thermal cut-out trips frequently.

Poor welding performance.

Corrective action

• 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.

• Check to see whether the thermal cut-outs have tripped.

• Check the mains power supply fuses.

• Make sure that you are not exceeding the rated data for the welding power source (i.e. that the unit is not being overloaded).

• 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.

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© ESAB AB 2018

8 ORDERING SPARE PARTS

8 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.

Tig 2200i AC/DC is designed and tested in accordance with the international and European standards

IEC/EN 60974-1

,

60974-3

and

IEC/EN 60974-10 Class A

product still conforms to the mentioned standards.

. It is the obligation of the service unit which has carried out the service or repair work to make sure that the Spare parts and wear parts can be ordered through your nearest ESAB dealer, see esab.com

. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list. This facilitates dispatch and ensures correct delivery.

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ASSEMBLY INSTRUCTIONS

ASSEMBLY INSTRUCTIONS

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© ESAB AB 2018

DIAGRAM

DIAGRAM

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© ESAB AB 2018

DIAGRAM 0460 225 301

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© ESAB AB 2018

ORDERING NUMBERS

ORDERING NUMBERS

Ordering no.

Denomination

0460 150 881 Welding power source 0460 150 880 Welding power source 0460 150 882 Welding power source 0460 150 883 Welding power source 0460 150 884 Welding power source

Type

Caddy® Tig 2200i, AC/DC, TA33 AC/DC Caddy® Tig 2200i, AC/DC, TA34 AC/DC Caddy® Tig 2200i, AC/DC, TA33 AC/DC, MMA cable kit complete and Tig torch TXH201 4 m Caddy® Tig 2200i, AC/DC, TA34 AC/DC, MMA cable kit complete and Tig torch TXH201 4 m Caddy® Tig 2200i, AC/DC, TA34 AC/DC, MMA cable kit complete and Tig torch TXH251 4 m, Water cooler CoolMini, 2-wheel trolley

Filename Denomination Product

0459 839 013 Spare parts list 0460 226 Welding power source, Tig 2200i AC/DC Instruction manual Control panel, Caddy® TA33 AC/DC 0460 227 Instruction manual Control panel, Caddy® TA34 AC/DC Instruction manuals and the spare parts list are available on the Internet at: www.esab.com

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© ESAB AB 2018

ACCESSORIES

ACCESSORIES

0459 491 910 Remote control adapter RA12    12 pole For analogue remote controls to CAN based equipment.

0459 491 880 0459 491 882 0459 491 883 Remote control unit MTA1 CAN MIG/MAG: wire feed speed and voltage MMA: current and arc force TIG: current, pulse and background current Remote control unit M1 10Prog CAN Choice of one of 10 programs MIG/MAG: voltage deviation TIG and MMA: current deviation Remote control unit AT1 CAN MMA and TIG: current 0459 491 884 Remote control unit AT1 CF CAN MMA and TIG: rough and fine setting of current.

0700 006 884 0700 006 885 Welding cable kit Return cable kit     0459 544 880 0459 554 881 0459 554 882 0459 554 883 0459 554 884 Remote cable CAN 4 pole - 12 pole 5 m 10 m 15 m 25 m 0.25 m 0460 225 301

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© ESAB AB 2018

ACCESSORIES 0460 265 001 Strap 0460 265 002 Cable holder 0460 265 003 Shoulder holder    0459 366 885 Trolley for 5-10 litre gasbottle    0460 330 880 Trolley for 20-50 litre gasbottle 0700 300 552 0700 300 561 Tig torch TXH 201 4 m Tig torch TXH 251w 4 m 0460 315 880 Foot pedal TI Foot CAN 0460 144 880 Cooling unit CoolMini 0460 225 301

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© ESAB AB 2018

For contact information visit esab.com

ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 http://manuals.esab.com

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