ESAB LTT 150 User manual

LTT 150
Caddy Tig 150
Welding rectifier
Service manual
0740 800 120
9804
LIST OF CONTENTS
Page
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION DIAGRAM LTT 150 . . . . . . . . . . . . . . . . . . .
FUNCTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD CHARACTERISTIC . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
4
5
6
14
17
19
22
23
24
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . .
24
25
26
27
28
28
SPARE PARTS LIST LTT 150 . . . . . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
34
READ THIS FIRST
This service manual is intended for use by technicians with appropriate electro--technical
training when carrying out fault--tracing and repair work.
The connection diagram can be used as a Contents for the function and component
descriptions. The connection diagram is divided into numbered blocks, which are used to
identify the various parts in the function description.
The manual contains details of all design changes up to and including April 1998.
WARNING!
The components in the machine are at mains voltage.
Never make any measurements inside the machine when it is
energised in the normal manner.
ESAB reserves the right to change specifications without prior notice
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The LTT 150 is designed and tested in accordance with the international
EN 60 974--1 (IEC 974--1) standard.
After service or repair, it is the responsibility of the person, company, section etc.
that have/has performed the work to make sure that the product does not depart
from the requirements of the above standard.
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
S
Install and earth the welding unit in accordance with applicable standards.
S
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S
Insulate yourself from earth and the workpiece.
S
Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S
Keep your head out of the fumes.
S
Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and
the general area.
ARC RAYS -- Can injure eyes and burn skin.
S
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S
Protect your ears. Use ear defenders or other hearing protection.
S
Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
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COMPONENT DESCRIPTION
WARNING!
The components in this machine are at mains voltage.
Never make measurements in the machine while it is energised in the normal
manner. Read and comply with the fault-- tracing instructions on page 19.
AP01
Circuit board, power section, see the function description.
AP02
Circuit board, control electronics, see the function description.
AP03
Circuit board with EMC filter and rectifier bridge, see the diagram and
description on page 6 - 7.
C01
Capacitor, decoupling.
EV01
Cooling fan, 230 V AC.
L01 - L11
Ferrite ring for interference suppression (EMC).
QF01
Mains On/Off switch.
RP01
Potentiometer for current setting. This potentiometer is of insulated
construction, and may be replaced only by the potentiometer listed in the
spare parts list.
SA01
Welding mode selector switch (MMA / TIG).
ST01
Thermal overload switch. See the description on page 11.
V01
Rectifier bridge.
V03
LED, orange. See the description on page 11.
XS01
Sleeve connector.
1 -- 6
The figures below relate to the corresponding function descriptions.
Headings and page numbers are shown here.
Page
1 POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER SUPPLY, AP01
POWER SUPPLY, AP02
POWER SUPPLY FOR STARTING
2 OPEN--CIRCUIT VOLTAGE MONITORING . . . . . . . . . . . . . . . . . . 8
3 START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STARTING SEQUENCE, MMA
STARTING SEQUENCE, TIG
4 PULSE WIDTH MODULATOR / GATE DRIVING . . . . . . . . . . . . 10
5 THERMAL SWITCH / LOW--VOLTAGE MONITOR . . . . . . . . . . 11
6 CURRENT SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7 WELDING METHOD SELECTION . . . . . . . . . . . . . . . . . . . . . . . . 12
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CONNECTION DIAGRAM LTT 150
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FUNCTION DESCRIPTION
This description refers to the circuit diagram on page 5.
WARNING! The components in the machine are at mains voltage.
Never make measurements in the machine when it is energised in
the normal manner.
Read and follow the fault-- tracing instructions on page 19.
1
POWER SUPPLY
POWER SUPPLY, AP01
Power supply circuit board AP01 is supplied at two different voltages:
S
Rectified mains voltage, about +330 V to the switch transistors.
Power supply voltage from AP02: +22 V, tolerance 22--26V, power
supply to the gate drive circuit boards.
The winding on TR2 that is marked 1 TURN provides pulses to TY1,
which short--circuits charging resistor R25 about one second after
power--up.
S
Interference suppression is partly by ferrite rings around wires and partly
by twisting wire pairs. Most of the suppression is provided by the EMC
filter.
Cooling fan EV01 is supplied with 230V AC immediately after the EMC
filter via contacts I1 and I2, and starts when the main switch, QF01, is
turned on.
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POWER SUPPLY, AP02
Contact C6 on AP02 is supplied at +40V, tolerance 38--49V, which is then
converted to the following voltages:
+22V, tolerance 22--26V, for supplying the gate drive boards on AP01.
+10V, tolerance 10--11V, used internally on AP02 and for supply to
potentiometer RP01 (current setting).
+15V, tolerance 15--17.5V, used internally on AP02.
If a short circuit should occur in any of the diodes D13, D18 or D22, the
+40V supply will be too low to supply AP02.
POWER SUPPLY TO AP02 WHEN STARTING
When the mains power supply is turned on, AP02 is supplied from rectifier
bridge V01, the voltage from which is reduced by ten resistors R1--R10,
connected in parallel. This power supply is used during the starting
procedure, which takes about one second. The power supply is then taken
from the winding marked ’2 TURNS’ on the welding transformer via diodes
D1--D4.
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2
OPEN--CIRCUIT VOLTAGE SENSING
Optocoupler IC4 senses the open--circuit voltage. On open circuit, current
flows through the LED and the transistor conducts. Shorting the welding
electrode to the workpiece interrupts the current through the LED. The
threshold value for activation of IC4 is about 50V output voltage from the
machine. The optocoupler output is connected to AP02.
The open--circuit voltage from the machine is 70--90V in MMA mode and
50--60V in TIG mode.
3
START
STARTING SEQUENCE, MMA
Block diagram for AP02 when MMA welding
Turning switch SA01 to the MMA position connects contacts E6 and E7,
giving a hot start. The open--circuit voltage drops as soon as the electrode
short--circuits to the workpiece. AP02 receives a signal from optocoupler
IC4 via contacts C3 and C4.
The current reference is increased for about 0,5 seconds during hot starting.
The magnitude and duration of this boost depends on the current setting.
For the current setting of 150 A, the starting current is about 205A.
The starting current is proportional to the set value of the current.
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STARTING SEQUENCE, TIG
Block diagram, AP02, for scrape starting
With switch SA01 in the TIG position:
S
Contacts E6 - E7 are open, disconnecting hot start.
S
Contacts E3 -- E6 are closed, thus engaging open--circuit voltage
monitoring for TIG via optocoupler and the control circuit on AP02.
The open--circuit voltage is 50 - 60 V.
S
Strike a pilot arc by scraping the electrode on the workpiece. The
welding pistol trigger switch must not be pressed while doing this.
S
The pilot arc draws a current of 18 - 20 A. The minimum reference
signal has priority over all other input signals to the control amplifier.
The pilot current flow until the pistol trigger switch is pressed.
Block diagram for AP02 during welding
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S
Pressing the pistol trigger switch opens optocoupler IC3 and the
current rises to the set value. Releasing the trigger switch drops the
current to the pilot current value. To extinguish the arc, lift the
welding pistol away from the workpiece.
S
The pistol switch is galvanically insulated from other circuits via
optocoupler IC3. The power supply to the pistol switch is taken from a
separate winding on main transformer TR2: see the main connection
diagram on page 5.
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4
PULSE WIDTH MODULATOR / GATE DRIVING
Input signals to the pulse width modulator
The PWM circuit controls the length of the gate pulses and thus the average
value of the welding current. The thermal overload switch and the
low--voltage monitor can turn off the pulses: with no pulses from the pulse
width modulator, there is no welding current.
The pulse width modulator controls the frequency and pulse duration of the
gate pulses to the MOSFET transistors. The pulse frequency is set to
70.5kHz ±0.5kHz. The maximum pulse factor is 41.6%--42.2%. The
proportion between pulse time and frequency depends on each of them,
which means that they must both be correctly adjusted.
Do NOT make measurements when the machine is being
powered from the mains.
See CHECKING AP02 on page 20.
Gate driving
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5
THERMAL OVERLOAD SWITCH / LOW VOLTAGE MONITOR
THERMAL OVERLAOD SWITCH
The thermal overload switch, ST01, which is fitted in the end of a heat sink,
interrupts the gate pulses if the temperature exceeds 75C ±5%. LED V03
on the front panel lights to indicate that it has operated. The switch resets
automatically when the temperature has fallen to 55C ±5%..
LOW--VOLTAGE MONITOR
The low--voltage monitor interrupts the welding current if the voltage from
rectifier V01 drops below about 220V DC. The signal to the monitor is
taken via contact B3. Operation of the monitor is indicated by LED V03 on
the front panel. See the circuit diagram above.
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6
CURRENT MEASUREMENT
Current transformer TR3, which has a ratio of 1:100, measures the current
in the primary winding of the main transformer. The secondary of the
current transformer is connected to AP02 via contacts J2 and J3.
The voltage is measured and the actual value of the welding current is
calculated. It is compared with the set value, and the difference is used to
control the reference to the PWM circuit, which controls the welding
current to the required set value.
HIGH--SPEED CURRENT LIMIT
The purpose of this current limit is instantaneously to interrupt the transistor
pulse if the welding current exceeds the permissible peak value. Control is
automatic, and operates for as long as the peak current is too high.
7
WELDING METHOD SELECTION
Switch SA01 selects the required welding method. See the description
under Item 3, START, on page 8.
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DISMANTLING
WARNING! The components in the machine are at mains voltage
REMOVING THE CASING
It is important, when dismantling the machine, to note the positions of the parts, in order to
be sure of correct re--assembly.
1.
Disconnect the machine from the mains supply.
2.
Disconnect the welding current and return cables from the front of the machine.
3.
Using a Torx screwdriver, remove the four screws from the underside of the case. The
screwdriver can be ordered from ESAB: see SERVICE TOOLS on page 30.
4.
Starting from the back, separate the two halves of the case and then lift the upper half
straight up.
5.
Remove the lower wires, from upper circuit board AP03, from the mains switch in the
cover. Remove the yellow/green wire from AP03.
6.
Remove the rear grille from the lower half of the case.
7.
Disconnect sleeve connectors A, D1--D2 and E from the control board (AP02). The
wires to these connectors come from the cover.
8.
Pull the fan forward and fold it out of the way.
9.
Remove the four screws at the front and rear edges of the power circuit board AP01.
10. Unscrew the nuts holding the current busbars and bend the bars out of the way.
11. Lift the power unit out of the lower half of the case.
When working on the power unit, place it such that it cannot be damaged.
Component positions on circuit board AP02
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Component positions on circuit board AP03
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REMOVING POWER CIRCUIT BOARD AP01
Component positions, circuit board AP01
1.
Remove the 11 nuts on the top of the machine.
2.
Remove all the contacts on AP03 and contacts A, B, C, D and E on AP02.
3.
Remove the bridge rectifier, the fan and circuit boards AP02 and AP03.
4.
Remove the 11 screws from the
slots in the heat sinks.
5.
Turn the machine upside down.
6.
Remove the springs (2) that
hold the board in position by
inserting a screwdriver (1)
between each spring and the
heat sink.
7.
Unscrew the four socket--head
screws in the bottom of the
board, and remove transformer
TR2 and inductor L2.
8.
Unsolder the wires (blue) to the
start1 and start2 thyristor
controls.
Removal/refitting of circuit board AP01
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FITTING
FITTING CIRCUIT BOARD AP01
When fitting the heat sinks, apply thermal compound to the heat sinks of the secondary side
and contact oil to the heat sinks of the primary side. Use only thermal compound and contact
oil recommended by ESAB, see SERVICE TOOLS on page 30.
1.
Fit the transformer and inductor.
2.
Solder the start1 and start2 wires back into position.
3.
Remove all traces of old varnish on the heat sink contact surfaces (3) if the old ones are
being refitted. Polish them with fine abrasive paper (P600). See the figure on the
previous page.
4.
Heat sinks, primary side: apply a thin layer of contact oil to the contact surfaces.
5.
Heat sinks, secondary side: apply a thin layer of thermal compound to the contact
surfaces.
6.
Place the circuit board (2) on the heat sinks, and then fit a spring at each corner by
pressing it down with a screwdriver (4). See the figure on the previous page. Fit the rest
of the springs.
Note: make sure that the springs are fitted over the components that are to contact the
heat sinks. Always use new springs when re--assembling.
7.
Turn the machine over and insert the screws in the slots.
8.
Place circuit boards AP02 and AP03 and the diode bridge in position.
9.
Fit the wires and contacts. See ’Fitting AP02 and AP03’.
10. Screw the circuit boards and diode bridge into position.
11. Using a straightedge, check that the heat sinks are parallel with each other and at the
same height.
Aligning the heat sinks using a straightedge
FITTING POTENTIOMETER RP01
When replacing this potentiometer, the connections must face upwards.
For safety reasons, fit only a potentiometer with an insulated shaft.
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FITTING THE CONTACTS TO AP03
Contact
Wire
A1, A2
Blue (2--TURNS from TR2)
A3
009 black (+40 V DC)
C
010 from welding negative
D1
Yellow/green
F1
003
F2
004
G1
006
G2
005
J1
007
J2
008
I1, I2
230 V to the fan
FITTING THE CONTACTS TO AP02
Contact
Wire
A1 -- A3
To potentiometer
A4
011 to LED
A5
012 to LED
A6 -- A7
To the thermal overload switch
B1 -- B3
From AP01
C1 -- C7
From AP01
D1 -- D2
From connector XS01
D3 -- D4
From AP01
E3, E6, E7 From switch SA01
FITTING THE CASE
Fit the case in the reverse order to that of removal. Take care to ensure good contact between
the busbars and the OKC connectors.
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FAULT TRACING
Measuring the open--circuit voltage:
1.
Remove the positive and negative welding current cables from the machine.
2.
Connect the mains supply plug to the mains and measure the voltage at the welding
terminals with a multimeter. The value must be between 70--90V in MMA mode and
50--60V in TIG mode. It is not affected by the potentiometer.
This is the only measurement that may be made when the unit is connected to the mains
power supply. Never make any measurements in the machine when it is connected to
the mains power supply in the normal way.
Now make sure that the mains cable is not connected to the mains power supply.
Dismantle the machine as described by items 1--7 on page 14.
Check:
1.
Diode bridge V01: check the diodes with a multimeter.
2.
Charging resistor R25 on AP01: measure between J1 on AP03 and the heat sink not
having a copper strip. The value must be about 22τΚ
3.
The switching transistors: measure across the large heat sinks, using the multimeter in
the diode test position, with the positive connection on the heat sink having a copper
strip. The value must be 0.3 - 0.5 V.
Measuring with reverse polarity will indicate a higher value, which will rise as a result of
charging up capacitors. If a value of less than 0.3 V is found, it indicates that a transistor
has failed.
4.
The welding and freewheel diodes: measure the resistance across the current busbars,
with the positive terminal of the multimeter to the negative on the machine and the
instrument negative to the machine positive. Then reverse the connections and
re--measure. Both values must be about 2.3 kτ. Measuring using the diode test position
will give measured values of about 0.4 V and about 1.2 V respectively.
5.
Capacitors C12 - C14 on AP01: measure using the negative terminal of the multimeter
to contact AP03:J2 and the positive to the heat sink without a copper strip. The value
must be about 1500←F.
Heat sinks and busbars to the OKC connector
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Circuit board AP03
WARNING: The mains cable must be disconnected from the supply.
Never make any measurements in the machine when it is connected to the mains power
supply in the normal way.
CHECKING AP02
Follow items 1 to 5 under the headline SOFT STARTING below.
Turn circuit boards AP02 and AP03 so that the contacts on AP02 are accessible. Remove
contact C (7--pole) from AP02. Connect 30V DC between contacts C1 and C6 on circuit
board AP02; positive to C6 and negative to C1.
Measure the voltages on the E connector, relative to C1 (= 0 V). The link between B3 and E2
disables the undervoltage protection.
a.
E2: +10 V, tolerance 10--11 V.
b.
E4: +15 V, tolerance 15--17.5 V. With link B3--E2 connected: 12.2 V.
c.
E5: +22 V, tolerance 22--26 V. With link B3--E2 connected: 20 V.
d.
Measuring the PWM pulses: The thermal overload switch must be connected, or contacts
A6--A7 be linked in order to obtain gate pulses.
Using an oscilloscope, measure the pulses from the PWM circuit across C1 and C2.
Frequency and duty cycle for the pulses are to be found on page 10. The edges of the
pulses need to be square (not rounded).
If the measurements above are within the tolerances AP02 is OK. Reassemble the contacts
and check that they are correctly connected.
SOFT STARTING
Three connectors are needed for making the links and measurements on circuit board AP02.
See under the heading SERVICE TOOLS on page 30 for their order number.
1.
Dismantle the machine in accordance with Items 1 - 7 on page 14.
2.
Place the fan so that it cannot short--circuit the busbars.
3.
Remove circuit boards AP02 and AP03. Remove thermal overload switch contacts
A6--A7 from AP02.
4.
Remove contact B (3--pole) from AP02. Connect contact B3 to contact E2, which
disables the low--voltage monitoring function.
5.
Replace the thermal overload switch connections on A6--A7.
6.
Replace circuit boards AP02 and AP03, but do not screw them into position.
7.
Connect AP03:A3 to the positive on V01, or short--circuit one of resistors R1--R10 on
AP03 by fitting a jumper.
8.
Connect 30V from a DC power supply to AP03; positive to G1 and negative to G2.
Or connect to plus and minus on V01.
9.
Measure the voltage between the busbars. The value must be about 7.5 V.
The current from the DC power supply is about 0.4A.
10. Remove the thermal overload switch connections (A6--A7). The current must now drop
to not more than 0.1A.
If the measurements above are within the tolerances, reassemble the machine and make a test
weld.
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Test and connection points on circuit board AP03
Test and connection points on circuit board AP02
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TECHNICAL DATA
MMA
TIG
Performance:
at 25% duty cycle
at 35% duty cycle
at 60% duty cycle
at 100% duty cycle
150 A / 26 V
140 A / 26 V
110 A / 25 V
90 A / 24 V
150 A / 16 V
140 A / 16 V
120 A / 15 V
100 A / 14 V
Setting range
13--150 A
15--150 A
Open circuit voltage
70--90 V
50--60 V
Mains supply:
voltage
frequency
fuse
mains cable, area
230 V AC
50/60 Hz
16 A*
3x1.5 mm2**
230 V AC
50/60 Hz
16 A*
3x1.5 mm2**
Enclosure class
IP 23
IP 23
Dimensions L x W x H
375 x 145 x 280 mm
375 x 145 x 280 mm
Weight
6.7 kg
6.7 kg
Application class
*When welding below 100 A a 10 A slow fuse is adequate..
**Power cable ratings complies with Swedish regulations..
Duty cycle
The duty cycle refers to the time in per cent of a ten--minute period that you can weld at a
certain load without overloading the welding power source.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by
solid objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.
Application class
The symbol
indicates that the power source is designed for use in areas where there is an
increased electrical hazard.
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LOAD CHARACTERISTIC
Load characteristic, LTT 150
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INSTRUCTIONS
INSTRUCTIONS
This chapter contains an extract from the instruction manual for LTT 150.
INTRODUCTION
Note!
This product is solely intended for arc welding.
Caddy Tig is a DC welding power source that uses inverter technology and is intended for
TIG welding and welding with coated electrodes (MMA welding).
Equipment
Caddy Tig 150 is supplied with:
S
Mains cable (3 metres)
S
Return cable with earth clamp (2.5 metres)
Field of application
TIG welding is particularly useful when high quality standards are required and when
welding thin sheet.
Before using the Caddy for TIG welding it must be equipped with a TIG torch
(HW 20 ARVSW--3,8m), and gas valve, a cylinder of argon, an argon regulator, tungsten
electrodes and, if necessary, suitable filler metal.
The best method to use is the touch start, where you gently stroke the tungsten electrode
against the workpiece to establish the arc.
Caddy Tig 150 both supply direct current, which allows you to weld most alloyed and
non--alloyed steels, stainless steels and cast iron.
Caddy Tig lets you weld with coated electrodes from 1.6 mm to 3.25 mm diameter.
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INSTRUCTIONS
INSTALLATION
WARNING
This product is intended for repair and maintenance welding
In domestic or office environment this product may cause radio interference.
It is the responsibility of the user to take adequate precautions.
Placing
Place the machine so that there is nothing to prevent the cooling air from passing through it.
Mains connection
The rating plate including connection data is placed on the underside of the welding power
source.
Connect the welding power source to an earthed mains terminal. Make sure the welding
power source is connected for the correct mains voltage and properly fused.
S
Mains voltage 230 V
S
Mains frequency 50--60 Hz
S
Fuse, slow rupture 16 A
S
Mains cable, area 3 x 1,5 mm2
Connection of welding and return cable
TIG
For TIG welding, the torch is connected
to the negative terminal and the control
cable is connected to the socket on the
front panel. Connect the return cable to
the positive terminal, and the gas hose to
the regulator on the gas bottle.
MMA
The welding power source has two
terminals, one plus and one minus pole,
for the connection of the welding and
the return cable. Connect the welding
cable to the pole indicated on the
package of the electrode to be used.
Return cable
Attach the return cable clamp to the workpiece and make sure there is good contact between
the workpiece and the socket for the return cable on the power source.
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INSTRUCTIONS
OPERATION
Start--up
TIG
S Connect the TIG torch and return cable.
S Connect the shielding gas to the torch.
S Set the toggle switch on the front of the power source to the TIG setting.
S Switch on the power source by setting the power switch to setting 1.
S Set the welding current using the knob on the front of the power source. Use the
recommended welding current range shown on the electrode packaging.
S Strike the arc without pressing the trigger, then press the trigger and allow the current to
rise to the preset value.The RK function allows you to control the heat input by pressing
or releasing the trigger.
MMA
S Make sure that the cables and the earth clamp are properly connected.
S Start the welding power source by setting the mains switch to position 1.
S Set the welding current, using the knob on the front panel of the power source. Follow
the instructions on the electrode package for the recommended welding current.
Overload protection
Caddy Tig 150 are provided with a thermal cut--out to prevent overheating of the welding
power source. In the event of overload the supply voltage is interrupted and the orange lamp
on the front goes on. Resetting takes place automatically as soon as the welding power source
has cooled down.
Mains voltage compensation
Caddy Tig 150 both have mains voltage compensation, which means that ±10% fluctuation
in the supply voltage produces only ±0.2% variation in the welding voltage.
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-- 26 --
INSTRUCTIONS
Controls and connections
6
1
2
7
5
3
4
1.
2.
3.
4.
5.
6.
7.
Orange indicating lamp (overheating)
Knob for adjusting the welding current
Terminal, minus pole, for connecting welding or return cable
Terminal, plus pole, for connecting welding or return cable
Mains switch
Toggle switch
Sleeve socket for connecting torch
MAINTENANCE
Note:
All warrantly undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
Cleaning
Normally it is sufficient to blow the welding power source clean regularly using dry
compressed air (reduced pressure), and to clean the filter in the front regularly.
In dusty and dirty environment the welding power source should be cleaned at shorter
intervals.
cltt1de3
-- 27 --
INSTRUCTIONS
FAULT TRACING
Possible faults and measures to take
Type of fault
Measure
The current will rise to the preset value
S
Check that the pin connector is connected
to the front of the machine.
S
Replace the torch if necessary.
Start--up is violent.
S
Check that the toggle switch is set to TIG.
No arc is generated by the welding power source.
S
Make sure the mains switch is on.
S
Check that the welding and return cables
are properly connected.
S
Make sure the welding current set is correct.
S
Check if the thermal cut--out has tripped (the
orange indicating lamp on the front panel is
on).
S
Check the mains fuse.
S
Check that the filter is not packed with dust.
S
Check that the ratings of the welding power
source have not been exceeded (overload
of the power source).
S
Check that the welding and return cables
are properly connected.
S
Make sure the welding current set is correct.
S
Check that there is nothing wrong with the
electrodes.
The welding current is interrupted in the course
of welding.
The thermal cut--out trips frequently.
Poor welding result.
ORDERING OF SPARE PARTS
Spare parts are ordered through your nearest ESAB representative, see back cover. When ordering spare parts, please state machine type and number as well as designation and spare part
number as shown in the spare parts list on page 29.
This will simplify dispatch and ensure you get the right part.
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-- 28 --
SPARE PARTS LIST LTT 150
SPARE PARTS LIST LTT 150
Edition 980529
Ordering no.
Denomination
Notes
0457 329 880
LTT 150
Mains voltage 230V
0588 000 776
Tig Torch
HW 20--ARVSW--3.8 m
0457 051 880
Return cable
Complete
0457 049 001
Electrode holder
cltt1se1
-- 29 --
SPARE PARTS LIST LTT 150
C = component designation in the circuit diagram
Item
no.
Qty
100
1
0456 538 001 Cover
101
1
0456 539 001 Inner grating
102
1
0457 487 001 Cover
103
1
0456 192 882 Mains cable
104
1
0193 307 104 Cable clamp
105
1
0193 317 001 Switch
106
1
0212 602 208 Nut
107
1
0468 208 001 Strap
108
2
0456 572 001 Clamp
109
1
0321 475 885 Knob
110
1
0193 995 501 Potentiometer
RP01
111
1
0455 201 002 Light--emitting diode
V03
112
1
0456 541 001 Front grating
113
1
0456 574 001 Filter
114
2
0366 306 881 Connector
115
2
0160 362 005 Nut
116
1
0194 034 002 Ferrite ring cores
L02
4
0194 494 003 Ferrite ring cores
L08 -- L11
117
1
0194 061 002 Toggle switch
SA01
118
1
0457 420 880 Sleeve terminal
119
1
0538 500 902 Sleeve terminal
Ordering no.
Denomination
Notes
Lower part
Upper part
QF01
OKC 25
Complete with C02 and C03
XS01
XS01
SERVICE TOOLS
Qty
Ordering no.
1
0192 058 106
Contact oil
To be used when mounting the heat sinks
1
0193 260 062
Connector
3--pole, to be used on contact B on AP02
1
0193 260 066
Connector
7--pole to be used on contact C on AP02
1
0193 260 068
Connector
9--pole to be used on contact E on AP02
1
0457 488 001
Torx screw driver
For dismantlig the machine
cltt1se1
C
Denomination
Notes
-- 30 --
SPARE PARTS LIST LTT 150
cltt1se1
-- 31 --
SPARE PARTS LIST LTT 150
C = component designation in the circuit diagram
Item
no.
Qty
200
1
0193 316 208 Rectifier bridge
201
1
0486 457 880 Printed circuit board
202
1
0486 509 880 Printed circuit board
AP02
203
1
0365 539 001 Fan
EV01
204
1
0457 875 881 Printed circuit board
Item 205, 23 springs are included
205
23
0457 002 001 Spring
Included in item 204
206
3
0193 965 019 Capacitor
400V, 470 μF included in AP01
207
1
0194 017 117
9W, 22W included in AP01
208
1
0468 940 002 Thermal switch
209
1
0457 044 001 Cover
210
1
0457 232 001 Heat sink
211
1
0457 232 002 Heat sink
212
1
0456 576 080 Heat sink
213
1
0456 576 075 Heat sink
214
1
0456 699 060 Heat sink
215
1
216
Ordering no.
Denomination
Notes
C
V01
EMC
Resistor
AP03
AP01
75_C
ST01
0456 568 880 Transformer
Main transformer
TR2*
1
0456 569 880 Inductor
Welding current inductor*
217
1
0320 805 884 Capacitor
218
1
0457 081 001 Angle
219
2
0457 265 001 Insulation
220
4
0457 254 001 Spacer
221
2
0456 575 002 Bus bar
222
6
0193 494 003 Ferrite cores
C01
L01, L03 -L07
*Items 215 and 216 are mounted on item 204, but they are not included in item 204
cltt1se1
-- 32 --
SPARE PARTS LIST LTT 150
cltt1se1
-- 33 --
NOTES
notes
-- 34 --
notes
-- 35 --
ESAB subsidiaries, representative offices and agents
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 N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 726 80 05
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
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: +49 212 298 204
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 2 97 96 81
Fax: +39 2 97 28 91 81
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.z.o.o
Warszaw
Tel: +48 22 813 99 63
Fax: +48 22 813 98 81
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 1 837 1527
Fax: +351 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 Ibérica S.A.
Alcobendas (Madrid)
Tel: +34 91 661 55 80
Fax: +34 91 661 51 83
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: +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: +55 31 333 43 33
Fax: +55 31 361 31 51
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 & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
Asia/Pacific
AUSTRALIA
ESAB Australia Pty Ltd
Ermington
Tel: +61 2 9647 1232
Fax: +61 2 9748 1685
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 01 88
Fax: +62 21 461 29 29
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: +65 861 43 22
Fax: +65 861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyung--Nam
Tel: +82 551 2 89 81 11
Fax: +82 551 289 88 63
THAILAND
ESAB (Thailand) Ltd
Samutprakarn
Tel: +66 2 393 60 62
Fax: +66 2 748 71 11
UNITED ARAB EMIRATES
ESAB Middle East
Dubai
Tel: +971 4 338 88 29
Fax: +971 4 338 87 29
Representative offices
ALGERIA
ESAB Algeria
Alger
Tel: +213 2 67 24 93
Fax: +213 2 68 32 90
IRAN
Kavosh Azmoon
Teheran
Tel: +98 21 884 39 14
Fax: +98 21 884 13 46
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 211 75 02
RUSSIA-- CIS
ESAB Representative Office
Moscow
Tel: +7 095 93 79 820
Fax: +7 095 93 79 580
ESAB Representative Office
St Petersburg
Tel: +7 812 325 6688
Fax: +7 812 325 6685
Agents
For addresses and phone
numbers to our agents, please
contact ESAB International AB,
Sweden
EUROPE
Cyprus, Greece, Malta
AFRICA
Angola, Cameron, Ethiopia,
Gabon, Ghana, Kenya, Liberia,
Morocco, Mocambique, Nigeria,
Senegal, South Africa, Tanzania,
Togo, Tunisia, Zambia, Zimbabwe
ASIA
Bahrain, Hongkong, Israel,
Japan, Jordania, Korea, Kuwait,
Lebanon, New Guinea, Oman,
Pakistan, The Philippines,
Quatar, Saudi Arabia,
Sri Lanka, Syria, Taiwan,
Turkey, Vietnam, Yemen
LATIN AMERICA
Bolivia, Chile,
Colombia, Costa Rica, Curacao,
Equador, El Salvador,
Guatemala, Honduras, Jamaica,
Paraguay, Peru, Trinidad,
Uruguay, Venezuela
BULGARIA
INTESA
Sofia
Tel: +359 2 980 17 15
Fax: +359 2 980 08 42
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 6539 7124
Fax: +86 21 6543 6622
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ESAB Welding Equipment AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
Fax +46 584 123 08
www.esab.com
990922