ESAB TAF 800 / TAF 1250 User manual

0740 801 010 2008--10--09

Valid from Serial NO 615

TAF 800/ TAF 1250

AC

104

Service manual

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Rights reserved to al ter specifications without notice.

ENGLISH 3....................................................

ENGLISH

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TOCe

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

1.1 General 4..................................................................

1.2 Software versions 5.........................................................

1.3 Hardware versions 6.........................................................

2SAFETY 7...........................................................

3 COMPONENT DESCRIPTION (TAF 800/1250) 9.........................

4 CONNECTION DIAGRAM 10...........................................

4.1 From serial no. 615 10........................................................

4.2 From serial no. 835 12........................................................

4.3 From serial no. 310 14........................................................

4.4 From serial no. 624 (TAF 800) 16...............................................

4.5 From serial no. 624 (TAF 1250) 18.............................................

5 COMPONENT POSITIONS ON THE CIRCUIT BOARD 20..................

5.1 Circuit board (AP1) with part no: 0486 376 003 20................................

6 DESCRIPTION OF OPERATION 21.....................................

6.1 Circuit board AP1 -- Main features 21...........................................

6.2 Program monitoring 21........................................................

6.3 Setting of DIP switches 22.....................................................

8 MAINTENANCE (Diodes and Thyristors) 38.............................

8.1 Checking Diodes and Thyristors 38.............................................

8.2 Fitting New Diodes 38........................................................

8.3 Fitting New Thyristors 39......................................................

9 TEST DEVICE 40......................................................

10 STATIC CHARACTERISTICS 41........................................

11 Control cable diagram 42.............................................

11.1 Control cable TAF / 12pol -- PEH / 12pol 42......................................

11.2 Control cable TAF / 28pol -- PEH / 12pol 42......................................

CONNECTION INSTRUCTION 43..........................................

SPARE PARTS LIST 45...................................................

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1 READ THIS FIRST

1.1 General

This service manual is intended for use by technicians with electrical/electronic

training, for help in connection with fault --tracing and/or repair.

Use the connection diagram as a form of index for the description of operation and

the component description.

The circuit board is divided into numbered blocks, which are descr ibed individually in

more detail in the description of operation.

All component names in the connection diagram are listed in the component

description.

Note that there are different connection diagrams valid for different serial numbers.

This manual contains details of all design changes that have been made up to and

including July 2008.

For further inform a tion, see instruction manual “0456 513 xxx”.

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1.2 Software versions

From production start 97.07.04

LAF/TAF program (Flash, IC 6) 486525880

LAF/TAF 1.00A

From 99.01.01

LAF/TAF program (Flash, IC 6) 486525880

LAF/TAF 2.0

Strip welding and ESW welding.

Stainless steel setting. If this function is needed the power source board

486367001A in the LAF/TAF must be used.

Inch conversion.

From 00.02.29

LAF/TAF program (Flash, IC 6) 486525880

LAF/TAF 2.1

Improved wire creep speed LAF 1000ES

From 00.10.04

LAF/TAF program (Flash, IC 6) 486525880

LAF/TAF 2.4

Improved welding starts and welding

Safer detection of arc strike.

Changed sequence of weld start.

Faster engagement of the regulators.

Modified voltage regulation.

From 02.11.15

LAF/TAF program (Flash, IC 6) 486525880

LAF 4.0

Improved welding performance, better regulators.

Improved arc-- ignition.

Parallel connection of LAF

TAF 800 60% duty factor

Complete support for Weldoc. (Not in the Chinese version)

Gauging process added.

Calibration function. (Not in the Chinese version)

Program version 4.0 or 4.0C is needed.

From 03.04.14

LAF/TAF program (Flash, IC 6) 486525880

LAF/TAF 4.01

Increased wire creep speed.

Voltage regulations for analogue interface (PEI).

Program version from PEH 4.0, PEH 4.0C is needed.

From 04.01.01

LAF/TAF program (Flash, IC 6) 486525880

LAF/TAF 4.2

Added new alarm.

Improved regulation.

Program version from PEH 4.0, PEH 4.0C is needed.

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From 05.01.01

LAF/TAF program (Flash, IC 6) 486525880

LAF/TAF 4.3

Improved welding, analogue Interface.

Program version from PEH 4.0, PEH 4.0C is needed.

From 06.10.01

LAF/TAF program (Flash, IC 6) 486525880

LAF/TAF 5.0

Changed regulation, improved with dynamic characteristic.

Program version from PEH 5.0, PEH 5.0C is needed.

Require new hardware 486376005 for TAF.

From 08.07.30

LAF/TAF program (F lash, IC 6) 486525885

LAF/TAF 4.3M

This software adds possibility to choose settings for dynamic characteristics.

Program version from PEH 4.3M is needed.

Require new hardware 486376005 for TAF

1.3 Hardware versions

98.09.01 Circuit board 486368880 with component layout 496367001A

Software version LAF 2.0

Modification:

Hardware has been upgraded for improved stainless steel welding.

New transformer (T1) used.

Switch (IC 30) added for improved stainless steel welding (Function only accessible

together with software version LAF/TAF 2.0 and higher (see also comments for

software version LAF/TAF 2.0).

Improvements in voltage-- and current measuring (C11 and C21 added).

D39 and D40 added to improve max. output voltage from power source

03.05.22 Circuit board 486376880 with component layout 486375003

Software version from LAF/TAF2.4

Modification:

Added new reference, 0--10 V, for analogue reference.

06.10.01 Circuit board 486376880 with component layout 486375005

Software version from LAF/TAF 5 .0

Modification:

Improved welding characteristics.

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2SAFETY

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 precautions. Safety precautions

must meet the requirements that apply to this type of welding equipment. The following recommen-

dations 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 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 unauthorised 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 draughts

4. Personal safety equipment

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

clothing, safety gloves.

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.

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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 PRECAU-

TIONS 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 y our 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 y our 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!

WARNING

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.

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3 COMPONENT DESCRIPTION (TAF 800/1250)

Unless otherwise stated, the components listed below are those used in both

TAF 800 and TAF 1250.

AP1 Circuit board

AP2 Circuit board, EMC filter

C1 Capacitor

C2 Capacitor, 1.0 ìF

C4 Capacitor, 5,0 ìF

C5 Capacitor (Phase compensation)

FU1 F use, 16 A slow--blow

FU2 Automatic fuse: 20 A (serial no. 835 and 310)

15 A (serial no. 615)

HL1 Indicating lamp (white), for Power On indication.

HL2 Indicating lamp (yellow), for indication of excess temperature.

KM1 Main contactor.

KM2 Auxiliary contactor (see page 23)

L1 Inductor

M1 Fan

QF Main On/Off switch.

QS Emergency stop pushbutton

(from serial no. 310 the emergency stop has been removed)

R1 Resistor, 47 Ω

R2 Motstånd 15 Ω

RS1 Shunt (see page 25)

ST1 Thermal cutout (see page 25)

TM1 Main transformer.

TC1 Control power supply transformer, 42V, 900 VA

TC2 Transformer for synchronising pulses

V1 Thyristor 1050 A / 600 V (TAF 800)

1500 A / 500 V (TAF 1250)

XS3 Pole terminal for voltage measurement.

XS4 Burndy contact, 12--pole.

XT2 Terminal block.

Z1--Z3 Suppressor

Z4 Suppressor (valid for serial no. 615 and 835)

E01 Ferrite coil

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4 CONNECTION DIAGRAM

4.1 From serial no. 615

Connection block XT2 is connected for 400/415 V / 50 Hz, see the connection

instruction o n page 43.

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1. POWER SUPPLY

2. THERMAL OVERLOAD CUTOUT

3. SHUNT INPUT

4. SYNCHRONISING

5. ARC VOLTAGE

6. THYRISTOR FIRING CIRCUITS

7. COMMUNICATIONS INTERFACE

8. START/STOP

9. T EST INPUT

Numbers 1 -- 9 refer to the description of operation on pages 23--32.

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4.2 From serial no. 835

Connection block XT2 is connected for 400/415 V / 50 Hz, see the connection

instruction o n page 43.

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1. POWER SUPPLY

2. THERMAL OVERLOAD CUTOUT

3. SHUNT INPUT

4. SYNCHRONISING

5. ARC VOLTAGE

6. THYRISTOR FIRING CIRCUITS

7. COMMUNICATIONS INTERFACE

8. START/STOP

9. T EST INPUT

Numbers 1 -- 9 refer to the description of operation on pages 23--32.

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1

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4.3 From serial no. 310

Connection block XT2 is connected for 400/415 V / 50 Hz, see the connection

instruction o n page 43.

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1. POWER SUPPLY

2. THERMAL OVERLOAD CUTOUT

3. SHUNT INPUT

4. SYNCHRONISING

5. ARC VOLTAGE

6. THYRISTOR FIRING CIRCUITS

7. COMMUNICATIONS INTERFACE

8. START/STOP

9. T EST INPUT

Numbers 1 -- 9 refer to the description of operation on pages 23--32.

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4.4 From serial no. 624 (TAF 800)

Connection block XT2 is connected for 400/415 V / 50 Hz, see the connection

instruction o n page 44.

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1. POWER SUPPLY

2. THERMAL OVERLOAD CUTOUT

3. SHUNT INPUT

4. SYNCHRONISING

5. ARC VOLTAGE

6. THYRISTOR FIRING CIRCUITS

7. COMMUNICATIONS INTERFACE

8. START/STOP

9. T EST INPUT

Numbers 1 -- 9 refer to the description of operation on pages 23--32.

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4.5 From serial no. 624 (TAF 1250)

Connection block XT2 is connected for 400/415 V / 50 Hz, see the connection

instruction o n page 44.

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1. POWER SUPPLY

2. THERMAL OVERLOAD CUTOUT

3. SHUNT INPUT

4. SYNCHRONISING

5. ARC VOLTAGE

6. THYRISTOR FIRING CIRCUITS

7. COMMUNICATIONS INTERFACE

8. START/STOP

9. T EST INPUT

Numbers 1 -- 9 refer to the description of operation on pages 23--32.

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5 COMPONENT POSITIONS ON THE CIRCUIT BOARD

5.1 Circuit board (AP1) with part no: 0486 376 003

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ESAB TAF 800 / TAF 1250 User manual

ESAB TAF 800 / TAF 1250 User manual

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