ESAB Caddyt Arc 150i Service Manual

0740 800 161 Valid for serial no. 316--xxx--xxxx to 620--xxx--xxxx061205

Caddyt Arc 150i
Caddyt Tig 150i
Origot Tig 150i

Service manual

S0740 800 161/E061205/P66

-- 2 --TOCe

Rights reserved to alter specifications without notice.

READ THIS FIRST 4.................................................................

INTRODUCTION 4...................................................................

TECHNICAL DAT A 5.................................................................

WIRING DIAGRAM 6.................................................................

Component description 6..........................................................

CaddyTig 150, CaddyArc 150, OrigoTig 150 8.......................................

DESCRIPTION OF OPERATION 10.....................................................

1AP1 Control panel 10..............................................................

CaddyArc 150 10...................................................................

CaddyTig 150 11....................................................................

OrigoTig 150 12.....................................................................

1AP2 Display board 12.............................................................

2AP1 Power supply board 14.......................................................

2AP1:1 Interference suppressor circuit 14............................................

2AP1:2 Primary circuit 14..........................................................

2AP1:3 Secondary circuit 15.......................................................

2AP1 Component positions 16....................................................

10AP1 TIG board 18................................................................

10AP1 Component positions 19....................................................

15AP1 Power board 20.............................................................

Charging circuit 20..................................................................

Supply to 2AP1 21..................................................................

Gate driver stages 21................................................................

Switching circuit 21..................................................................

15AP1 Component positions 22....................................................

15AP2 Secondary board 23.........................................................

15AP2 Component positions 23....................................................

20AP1 Control board 24............................................................

20AP1:1 Power supply 24...........................................................

20AP1:2 Control panel interface circuits 26............................................

LED display driver 27......................................................

Rotary encoder input 28....................................................

Push button filters 28.......................................................

20AP1:3 Remote control input 29....................................................

20AP1:4 Pulse width modulator 29...................................................

20AP1:5 Temperature monitoring 29..................................................

20AP1:6 Shunt and current control amplifier 30........................................

20AP1:7 Arc voltage monitoring 31...................................................

20AP1:8 TIG functions 31...........................................................

20AP1:9 Welding process control 32.................................................

Hot start MMA 32..........................................................

20AP1:10 Machine type configuration 33...............................................

20AP1 Component positions 34

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

FAULT CODES 36....................................................................

Version 1 of circuit board 20AP1 36.................................................

Version 2 of circuit board 20AP1 37.................................................

SERVICE FUNCTIONS 38.............................................................

Version 1 of circuit board 20AP1 38.................................................

Version 2 of circuit board 20AP1 41.................................................

SERVICE INSTRUCTIONS 44..........................................................

What is ESD? 44...................................................................

Special tools 44....................................................................

Dismantling CaddyArc and CaddyTig 45.............................................

Soft starting 46....................................................................

Checking rectifier and freewheel diodes 48..........................................

Checking the gate pulses 49........................................................

Checking the semiconductor module 50.............................................

Mounting components on the heat sink 51...........................................

S0740 800 161/E061205/P66

-- 3 --TOCe

Rights reserved to alter specifications without notice.

INSTRUCTIONS 52...................................................................

SAFETY 52........................................................................

INSTALLATION 52..................................................................

CaddyArc 150 53.....................................................................

OPERATION 53....................................................................

Connections and control devices 53.................................................

Control panel 53...................................................................

Remote control unit 53.............................................................

Overheating protection 53..........................................................

MMA WELDING 54.................................................................

Settings 54........................................................................

Hidden functions 54................................................................

TIG WELDING 55...................................................................

MAINTENANCE 55.................................................................

Cleaning the dust filter 55..........................................................

CaddyTig 150 56.....................................................................

OPERATION 56....................................................................

Connections and control devices 56.................................................

Control panel 56...................................................................

Remote control unit 57.............................................................

Overheating protection 57..........................................................

TIG WELDING 57...................................................................

Settings 57........................................................................

Hidden TIG functions 59............................................................

MMA WELDING 60.................................................................

Settings 60........................................................................

Hidden MMA functions 60..........................................................

WELDING DATA MEMORY 61.......................................................

MAINTENANCE 61.................................................................

Cleaning the dust filter 61..........................................................

OrigoTig 150 62......................................................................

OPERATION 62....................................................................

Connections and control devices 62.................................................

Control panel 62...................................................................

Overheating protection 62..........................................................

TIG WELDING 63...................................................................

Settings 63........................................................................

MMA WELDING

64.................................................................

MAINTENANCE 64.................................................................

SPARE PARTS 64....................................................................

NOTES 65...........................................................................

S0740 800 161/E061205/P66

-- 4 --

ct27d1

READ THIS FIRST

Maintenance and repair work should be performed by an experienced person, and
electrical work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault--tracing and repair.

Use the wiring diagram as a form of index for the description of operation. The circuit
board is divided into numbered blocks, which are described individually in more detail in
the description of operation. All component names in the wiring diagram are listed in the
component description.

This manual contains details of all design changes that have been made up to and
including November 2006.

The manual is valid for:
CaddyArc 150, CaddyTig 150 and OrigoTig 150 with serial no. 316--xxx--xxxx,
328--xxx--xxxx, 341--xxx--xxxx, 405--xxx--xxxx, 613--xxx--xxxx.
Caddyt Arc 150i, Caddyt Tig 150i and Origot Tig 150i with serial no. 620--xxx--xxxx.

The CaddyArc 150, CaddyTig 150, OrigoTig 150, Caddyt Arc 150i, Caddyt Tig 150i
and Origot Tig 150i 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

The Power sources are renamed:

New name Old name

Caddyt Arc 150i CaddyArc 150
Caddyt Tig 150i CaddyTig 150
Origot Tig 150i OrigoTig 150

The power module of the power source is a single forward converter, operating at a
switching frequency of 65 kHz. IGBT transistors are used as the switching elements. All
power semiconductors are built into modules.

Schematic diagram of the power source

S0740 800 161/E061205/P66

-- 5 --

ct27d1

TECHNICAL DAT A

CaddyTig 150
CaddyArc 150

OrigoTig 150

Mains voltage 230 V ±10% 1∼ 50/60 Hz 230 V ±10% 1∼ 50/60 Hz
Fuse (delayed--action) 16 A 16 A
Primary current I

max

36 A 36 A

Primary current I

eff

21 A 21 A

Voltage/current range

(TIG)
(MMA)

3 A / 10 V --150 A / 16 V
4 A / 20 V --150 A / 26 V

3 A / 10 V --150 A / 16 V
4 A / 20 V --150 A / 26 V

Maximum permissible load at TIG

35% duty cycle
60% duty cycle

100% duty cycle

150 A / 16 V
120 A / 15 V

95 A / 14 V

150 A / 16 V
120 A / 15 V

95 A / 14 V

Maximum permissible load at MMA

25% duty cycle
35% duty cycle
60% duty cycle

100% duty cycle

150 A / 26 V
140 A / 25.

5 V

1 10 A / 24.

5 V

90 A / 23.

5 V

150 A / 26 V
140 A / 25.

5 V

1 10 A / 24.

5 V

90 A / 23.

5 V

Power factor at maximum current 0.62 0.62
Efficiency at maximum current 77 % 77 %
Open--circuit voltage 71 -- 78 V 71 -- 78 V
Open--circuit voltage Caddy Arc VRD 20 V --
Operating temperature -- 1 0 ˚C--+40˚C -- 1 0 ˚C till + 40˚C
Constant A-- weighed sound pressure <70 db <70 db
Dimensions, l x b x h 394 x 267 x 274 mm 380 x 180 x 300 mm
Weight CaddyTig 10 kg

CaddyArc 9 kg

9kg

Enclosure class IP 23C IP 23C
Application class

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer­tain load without overloading.

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

S0740 800 161/E061205/P66

-- 6 --

ct27d1

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.

Wires/cables within modules are marked 100 -- 6999.
Circuit boards within each module have names such as 20AP1 -- 20AP99.

15 = module association, 1--69
AP = circuit board
1 = individual identification number, 0--99

Components within modules are named in a similar way.

WARNING !

STATIC ELECTRICITY can damage circuit
boards and electronic components.

S Observe precautions for handling electrostatic--

sensitive devices.

S Use proper static--proof bags and boxes.

ESD

Component description

1 MMC module.

1AP1 Control panel (MMC panel).

1AP2 Display board.

2 Mains module.

2AP1 Power supply board.

2L1 2 ferrite rings. The yellow/green cable must be wound two turns through the

ferrite rings.

2L2 Ferrite ring.

2QF1 Mains switch.

2XS1 Flat pin sockets. Important: to obtain a proper electric connection, the complete

cord set must be replaced if the sockets have to be replaced.

10 TIG module. Only CaddyTig 150 and OrigoTig 150.

10AP1 TIG board.

10TV1 HF transformer.

10YV1 Gas valve, 230 V AC.

S0740 800 161/E061205/P66

-- 7 --

ct27d1

15 Power module.

15AP1 Power board.

15AP2 Secondary board.

15C1 Smoothing capacitor, 1000 uF.

15D1 Diode module with rectifier and freewheel diodes.

15EV1 Fan.

15L1 Inductor.

15RS1 Shunt. 60 mV at 100 A.

15ST1 Thermal switch, fitted in the winding of main transformer 15TM1. See page 29.

15ST2 Thermal switch, fitted on the heat sink. See page 29.

15TM1 Main transformer.

20AP1 Controller circuit board.

29XS5 Remote control socket. Only CaddyArc 150 and CaddyTig 150.

S0740 800 161/E061205/P66

-- 8 --

ct27d1

CaddyTig 150, CaddyArc 150, OrigoTig 150

S0740 800 161/E061205/P66

-- 9 --

ct27d1

S0740 800 161/E061205/P66

-- 1 0 --

ct27d1

DESCRIPTION OF OPERATION

This description of operation describes the function of circuit boards and other components
in the power source. It is divided into sections, numbered to correspond to the circuit board
numbers and divisions into function blocks.

1AP1 Control panel

The control board processes the control signals to/from the control panel. See the
description on page 26.

When the machine is switched on, the LEDs of the control panel and the display segments
are tested by the software. The display then shows the machine type and software version.

Some of the LEDs of the control panel may gleam very weak when they are off, this is no
fault. An activated LED lights with a clear light.
The control panel LEDs and the display segments can be tested by service functions, see
pages 38 to 43.

CaddyArc 150

A

E

L

A1

A2

A3 A4

X1

D2

F

D1

D3 D4

K

A1

A2

A3

A4

1

8

7

5

6

D1

D2

D3

D4

4

Green LEDs, except D2 (yellow)

X1

GREEN LED

24

FEA

17

16

12

23

K L

21

22

Buttons

Control panel, CaddyArc 150

S0740 800 161/E061205/P66

-- 1 1 --

ct27d1

CaddyTig 150

A

B

C

D

E

H

G

K

J

L

A1

A2

A3

A5

A6

B1

A7

B2

B5

C1

C2

C3 C5

C6

C7

C4

D4 D5D3

D1

D2

B6 B7

F

X1

C1

C2

C3

C4

C5

C7

C6

B1

B2

B7

A1

A2

A3

A5

A7

A6

D1

D5

B6

B5

D4

D3

D2

4

3

2

1

11

10

9

8

7

5

6

Green LEDs, except D2 (yellow)

X1

GREEN LED

L24KJHGFEDCBA

22

21

20

19

18

17

16

15

14

13

12

23

Buttons

Control panel, CaddyTig 150

S0740 800 161/E061205/P66

-- 1 2 --

ct27d1

OrigoTig 150

A

C

D

E

A1

A2

A6 B1

B3

A7

B2

B4

B5

F

X1

2

1

11

10

9

8

7

5

6

B1

B2

B3

B4

A1

A2

A7

A6

B5

Green LEDs, except B5 (yellow)

X1

GREEN LED

24

FEDCBA

23

17

16

15

14

13

12

Buttons

Control panel, OrigoTig 150

1AP2 Display board

Component positions of the display board

S0740 800 161/E061205/P66

-- 1 3 --

ct27d1

Circuit diagram of the display board

The display segments can be tested by a service function, see pages 38 to 43.

S0740 800 161/E061205/P66

-- 1 4 --

ct27d_2

2AP1 Power supply board

The power supply board filters the mains voltage and generates internal supply voltages for
the machine.

2AP1:1 Interference suppressor circuit

WARNING! Dangerous voltage -- mains voltage.

The mains voltage is filtered by the power supply board. Power board 15AP1
rectifies the mains voltage. TIG board 10AP1 uses the mains voltage for
supply to the HF generator and the gas valve.

2AP1:2 Primary circuit

WARNING! Dangerous voltage -- mains voltage.

The primary circuit is supplied with 325 V DC from the power board, 15AP1.
S1 is a fuse with high rupturing capacity.

S0740 800 161/E061205/P66

-- 1 5 --

ct27d_2

Transistor Q5 is the switching element in a switched voltage supply. The
secondary voltage, +24 V, is sensed by IC2 and controlled by IC1.

The isolation voltage of transformer T1 and optocoupler IC3 is 4 kV.

2AP1:3 Secondary circuit

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 V.

-- 1 5 V

The voltage is controlled by VR2. It has a tolerance of ±0.75 V.

+13 VB

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.

S0740 800 161/E061205/P66

-- 1 6 --

ct27d_2

2AP1 Component positions

WARNING! Dangerous voltage -- mains voltage.

S0740 800 161/E061205/P66

-- 1 7 --

page

S0740 800 161/E061205/P66

-- 1 8 --

ct27d_10

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.

Circuit diagram of the TIG functions of the CaddyTig and OrigoTig

The processor on circuit board 20AP1 controls the HF generator and gas valve. They can
be tested by service functions, see pages 38 to 43.

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 0.7 seconds.

The 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.

The torch switch can be tested by a service function, see pages 38 to 43.

S0740 800 161/E061205/P66

-- 1 9 --

ct27d_10

10AP1 Component positions

WARNING! Dangerous voltage -- mains voltage.

S0740 800 161/E061205/P66

-- 2 0 --

ct27d_15

WARNING!
Dangerous voltage -- mains voltage.
Never make any measurements on this
board when the machine is connected to
the mains supply.

15AP1 Power board

The power module is a single forward converter, operating at a switching frequency of
65 kHz. IGBT transistors are used as the switching elements. See page 49 and 50 for
screen traces of waveforms and measurement instructions.

If the power board has failed, a replacement board must be mounted in accordance with the
instructions on page 51.

The power board carries the mains rectifier, the charging circuit, the switching circuit and the
gate circuit.
The mains rectifier and the switching transistors are integrated in a semiconductor module,
PM1, which is part of the power board.

Charging circuit

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 power
source is on load.