ESAB Caddy Tig 1500i VRD, Caddy Tig 2200i VRD Instruction Manual

GB

Valid for serial no. 828-xxx-xxxx0460 826 074 20120731

Caddy

â

Tig 1500i VRD
Tig 2200i VRD

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 SAFETY 3...........................................................

2 INTRODUCTION 5...................................................

2.1 Equipment 5................................................................

2.2 Control panels 5............................................................

3 TECHNICAL DATA 5.................................................

4 INSTALLATION 7....................................................

4.1 Location 7..................................................................

4.2 Mains power supply 7........................................................

5 OPERATION 8.......................................................

5.1 Connections and control devices 8............................................

5.2 Key to symbols 8............................................................

5.3 Water connection 8..........................................................

5.4 TIG-welding 9..............................................................

5.5 MMA-svetsning 9...........................................................

5.6 Overheating protection 9.....................................................

5.7 Connection to cooling unit

(only valid for Caddyt Tig 2200i) 9............................................

5.8 Turning on the power source 9................................................

6 MAINTENANCE 10....................................................

6.1 Inspection and cleaning 10....................................................

7 FAULT-TRACING 10..................................................

8 ORDERING SPARE PARTS 11.........................................

9 DISMANTLING AND SCRAPPING 11...................................

DIAGRAM 12............................................................

ORDER NUMBER 18.....................................................

ACCESSORIES 19.......................................................

© ESAB AB 2008

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1 SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety pre
cautions. Safety precautions must meet the requirements that apply to this type of
welding 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 oper
ation of the welding 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. Anyone who uses the welding equipment must be familiar with:

S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding

2. The operator must ensure that:

S no unauthorized person is stationed within the working area of the equipment when it is

started up.

S no-one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose
S be free from drafts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves. Note! Do not use safety gloves when replacing wire.

S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.

CAUTION!

This product is solely intended for arc welding.

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WARNING

Read and understand the instruction manual before installing or operating.

Arc welding and cutting can be injurious to yourself and others. Take precausions 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 take fumes and gases away 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 earmuffs or other hearing protection.
S Warn bystanders of the risk.

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

PROTECT YOURSELF AND OTHERS!

ESAB can provide you with all necessary welding protection and accessories.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Read and understand the instruction manual before
installing or operating.

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.

GB

© ESAB AB 2008

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2 INTRODUCTION

The Tig 1500i / 2200i is a TIG welding power source, which can also be used for
MMA welding. It can be used direct current (DC).

ESAB's accessories for the product can be found on page 19.

2.1 Equipment

The power source is supplied with a 3 m welding cable complete with a TIG-torch,
3 m return cable, 3 m mains cable, instruction manual for power source and control
panel, see Ordering information on page 18.

2.2 Control panels

S TA33 S TA34

See the separate instruction manual for a detailed description of the control panels.

3 TECHNICAL DATA

Tig 1500i Tig 2200i/2000iw

Mains voltage 230V, $10%, 1∼ 50/60 Hz 230V, $10%, 1∼ 50/60 Hz

Mains supply Z

max

0.35 ohm Z

max

0.31 ohm

Primary current

I

max

TIG

I

max

MMA

14 A
22 A

24 A
25 A

No-load power

demand when in the energy-saving
mode, 6.5 min. after welding

30 W 30 W

Setting range

TIG
MMA

3 A - 150 A
4 A - 150 A

3 A - 220 A
4 A - 170 A

Ignition voltage (Upk) 11.5 kV 11.5 kV

Permissible load at TIG

20% duty cycle
25% duty cycle
60% duty cycle
100% duty cycle

150 A / 16.0 V
120 A / 14.8 V
110 A / 14.4 V

220 A / 18.8 V

150 A / 16.0 V
140 A / 15.6 V

Permissible load at MMA
25% duty cycle

60% duty cycle
100% duty cycle

150 A / 26.0 V
100 A / 24.0 V
90 A / 23.6 V

170 A / 26.8 V
130 A / 25.2 V
110 A / 24.4 V

GB

© ESAB AB 2008

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Tig 2200i/2000iwTig 1500i

Power factor at maximum current

TIG
MMA

0.98

0.99

0.99

0.99

Efficiency at maximum current

TIG
MMA

77 %
80 %

75 %
81 %

Open-circuit voltage TIG 55-60 V 55-60 V

Open-circuit voltage MMA

with VRD

55-60 V
< 35 V

55-60 V
< 35 V

Operating temperature -10 to + 40° C -10 to + 40° C

Transportation temperature -20 to + 55° C -20 to + 55° C

Constant sound pressure in
open-circuit

< 70 dB (A) < 70 dB (A)

Dimensions, l x b x h 418 x 188 x 208 mm 418 x 188 x 208 mm

including the cooling unit - 418 x 188 x 345 mm

Weight 9.2 kg 9.4 kg

Shielding gas

max pressure

All types intended for TIG
welding

5 bar

All types intended for TIG
welding

5 bar

Insulation class transformer H H

Enclosure class IP 23 IP 23
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 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 indicates that the power source is designed for use in areas with increased
electrical hazard.

Mains supply, Z

max

Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.

GB

© ESAB AB 2008

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4 INSTALLATION

The installation must be executed by a professional.

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.

4.1 Location

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

4.2 Mains power supply

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

Recommended fuse sizes and minimum cable area

Tig 1500i Tig 2200i/2200iw

TIG MMA TIG MMA

Mains voltage 230 V 10 %,1230 V 10 %,1230 V 10 %,1230 V 10 %,

1

Mains frequency 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz
Mains cable area mm

2

3G2.5 3G2.5 3G2.5 3G2.5

Phase current I

1eff

9 A 11 A 11 A 14 A

Fuse

anti-surge
type C MCB

16 A
13 A

16 A
13 A

16 A
16 A

16 A
16 A

NOTE! The mains cable areas and fuse sizes as shown above are in accordance with Swedish reg
ulations. Use the welding power source in ac cordance with the relevant national regulations.

GB

© ESAB AB 2008

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5 OPERATION

General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!

5.1 Connections and control devices

1 Connection (+) for the return cable for

TIG.
MMA: for the return cable or the welding
cable.

7 Mains switch

2 Connection for the remote control unit,

only for control panel TA34

8 Mains cable

3 Control panel (see separate instruction

manual)

9 Connection for shiedling gas

4 Connection for the TIG-torch 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 the TIG-torch

MMA: return cable or welding cable

12 Refilling of cooling water

* ESAB Logic Pump, see under 5.3

5.2 Key to symbols

MMA TIG

5.3 Water 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.

GB

© ESAB AB 2008

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5.4 TIG-welding

Before using the Arc 1500i/2200i for TIG welding it must be equipped with:

S a TIG torch
S a cylinder of suitable welding gas
S a welding gas regulator (suitable gas regulator)
S tungsten electrodes
S suitable filler metal, if necessary

5.5 MMA-svetsning

Connection of welding and return cable

The welding power source has two terminals, one plus and one minus pole, for the con
nection of the welding and the return cable. Connect the welding cable to the pole indi
cated on the package of the electrode to be used.

Connect the return cable to the other terminal. Fit the earth clamp of the return cable
to the work-piece and make sure there is good contact between the work-piece and the
return cable terminal on the welding power source.

5.6 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.

5.7 Connection to cooling unit

(only valid for Caddyt Tig 2200i)

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.

See installation instructions in the instruction manual
for the cooling unit.

5.8 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 and is available next time the unit is
started.

GB

© ESAB AB 2008

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6 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.

CAUTION!

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.

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 welding torch's wear parts should be cleaned and replaced at regular intervals in
order to achieve trouble-free welding.

7 FAULT-TRACING

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

Type of fault Corrective action

No arc. S Check that the mains power supply switch is turned on.

S Check that the welding current supply and return cables are

correctly connected.

S Check that the correct current value is set.
S Check the mains power supply.

The welding current is
interrupted during welding.

S Check to see whether the thermal cut-outs have tripped.
S Check the mains power supply fuses.

The thermal cut-out trips
frequently.

S Make sure that you are not exceeding the rated data for the

welding power source (i.e. that the unit is not being
overloaded).

S Make sure that the power source is clean.

Poor welding performance. S Check that the welding current supply and return cables are

correctly connected.

S Check that the correct current value is set.
S Check that the correct electrodes are being used.
S Check the gas flow.

GB

© ESAB AB 2008

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8 ORDERING SPARE PARTS

Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.

Tig 1500i, Tig 2200i is designed and tested in accordance with the international and
European standards IEC/EN 60974-1, IEC/EN 60974-3 and IEC/EN 60974-10. It is the
obligation of the service unit which has carried out the service or repair work to make
sure that the product still conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.

9 DISMANTLING AND SCRAPPING

Welding equipment primarily consists of steel, plastic and non-ferrous metals, and must
be handled according to local environmental regulations.
Coolant must also be handled according to local environmental regulations.

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.

By applying this European Directive you will improve the environment and human
health!

GB

© ESAB AB 2008

Diagram

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Tig 1500i TA34

© ESAB AB 2008

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© ESAB AB 2008

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Tig 1500i TA33

© ESAB AB 2008

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© ESAB AB 2008

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Tig 2200i TA33/TA34

© ESAB AB 2008

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Tig 1500i, Tig 2200i

© ESAB AB 2008

Order number

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Ordering no. Denomination Type

0460 450 870 Welding power source Caddyâ Tig 1500i, TA33, Australian version

incl. welding kit and torch TXH 150, 4 m

0460 450 871 Welding power source Caddyâ Tig 2200i, TA33, Australian version

incl. welding kit and Tig torch TXH 200, 4 m

0460 450 873 Welding power source Caddyâ Tig 2200i, TA34, Australian version

incl. welding kit and Tig torch TXH 200, 4 m

0460 450 874 Welding power source Caddyâ Tig 2200iw, TA33, Australian version

incl. welding kit and Tig torch TXH 250w, 4 m

0460 450 875 Welding power source Caddyâ Tig 2200iw, TA34, Australian version

incl. welding kit and Tig torch TXH 250w, 4 m

0460 447 074 Instruction manual Control panel, Caddyâ TA33, TA34

0459 839 025 Spare parts list Welding power source, Tig 1500i, Tig 2200i, Tig 2200iw

0459 839 028 Spare parts list Control panel, Caddyâ TA33

0459 839 028 Spare parts list Control panel, Caddyâ TA34

Instruction manuals and the spare parts list are available on the Internet at www.esab.com

Tig 1500i, Tig 2200i

© ESAB AB 2008

Accessories

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Strap ................................... 0460 265 001

Cable holder ............................ 0460 265 002

Shoulder strap .......................... 0460 265 003

Trolley ......

for 5-10 litre gasbottle ..................... 0459 366 885

Trolley

for 20-50 litre gasbottle .................... 0459 366 886

Trolley

for 20-50 litre gasbottle ................... 0460 330 880

Tig 1500i, Tig 2200i

© ESAB AB 2008

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Tig torch

TXH 150 4 m ............................

TXH 150 8 m ............................

TXH 200 4 m ............................

TXH 200 8 m ............................

TXH 250w 4 m ...........................

TXH 250w 8 m ...........................

0460 011 842
0460 011 882
0460 012 840
0460 012 880
0460 013 840
0460 013 880

Tig torch

TXH 150r 4 m ...........................

TXH 150r 8 m ...........................

TXH 200r 4 m ...........................

TXH 200r 8 m ...........................

TXH 250wr 4 m ..........................

TXH 250wr 8 m ..........................

0462 011 842
0462 011 882
0462 012 840
0462 012 880
0462 013 840
0462 013 880

Remote control adapter RA12 12 pole ....

For analogue remote controls to CAN based
equipment.

Only with TA34

0459 491 910

Remote control unit MTA1 CAN ..........

MIG/MAG: wire feed speed and voltage
MMA: current and arc force
TIG: current, pulse and background current

Only with TA34

0459 491 880

Remote control unit M1 10Prog CAN ......

Choice of on of 10 programs
MIG/MAG: voltage deviation
TIG and MMA: current deviation

Only with TA34

0459 491 882

Remote control unit AT1 CAN ............

MMA and TIG: current

Only with TA34

0459 491 883

Remote control unit AT1 CF CAN .........

MMA and TIG: rough and fine setting of
current.

Only with TA34

0459 491 884

Tig 1500i, Tig 2200i

© ESAB AB 2008

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Welding cable kit ........................

Return cable kit .........................

0700 006 884

0700 006 885

Remote cable CAN 4 pole - 12 pole

5 m.....................................

10 m....................................

15 m....................................

25 m....................................

0.25 m ..................................

Only with TA34

0459 544 880
0459 554 881
0459 554 882
0459 554 883
0459 554 884

Foot pedal TI Foot CAN ..................

Only with TA34

0460 315 880

Cooling unit CoolMini

Assembly kit ...........................

Only for Tig 2200i

0460 144 880
0460 509 880

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p

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p

www.esab.com

110915© ESAB AB

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna-Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]

BULGARIA

ESAB Kft Representative Office
Sofia
Tel/Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Herlev
Tel: [phone]
Fax: [phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel: [phone]
Fax: [phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel: [phone]
Fax: [phone]

ITALY

ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: [phone]
Fax: [phone]

THE NETHERLANDS

ESAB Nederland B.V.
Amersfoort
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel: [phone]
Fax: [phone]

POLAND

ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Romania Trading SRL
Bucharest
Tel: [phone]
Fax: [phone]

RUSSIA

LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel: [phone]
Fax: [phone]

SPAIN

ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel: [phone]
Fax: [phone]

ESAB international AB
Gothenburg
Tel: [phone]
Fax: [phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

UKRAINE

ESAB Ukraine LLC
Kiev
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem-MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

AUSTRALIA

ESAB South Pacific
Archerfield BC QLD 4108
Tel: [phone]
Fax: [phone]

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

JAPAN

ESAB Japan
Tokyo
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
USJ
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]

Africa

EGYPT

ESAB Egypt
Dokki-Cairo
Tel: [phone]
Fax: [phone]

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd
Durbanvill 7570 - Cape Town
Tel: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com