ESAB CaddyTig HF User manual

Brand: ESAB

Model: CaddyTig HF

Type: User manual

ESAB CaddyTig HF is a versatile and powerful welding machine that offers a wide range of features for both MMA and TIG welding tasks. With its compact and lightweight design, it's easy to take with you wherever you go. The CaddyTig HF provides precise arc control and excellent weld quality, making it ideal for a variety of applications, including fabrication, repair, and maintenance work.

0700 xxx xxx

020726

CaddyTig HF

Service manual

Cod. 92.08.00901

Edition: 07/02

Rev.: 1.0

How to contact Service Department:

part of this manual may be translated, reproduced or adapted

by any means (including photocopying, filming and microfil-

ming) without the written permission of Esab Welding

Equipment AB.

INDEX :

1) PURPOSE OF THE MANUAL . . . . . . . . . . . . . . . . . .3

2) WARNINGS, PRECAUTIONS, GENERAL

INFORMATION ON EXECUTING REPAIRS . . . . . . . .4

3) DIAGNOSTICS AND REPAIR INSTRUMENTS AND

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

4) TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . .6

5) DESCRIPTION OF MACHINE'S OPERATION

(BLOCK DIAGRAM) . . . . . . . . . . . . . . . . . . . . . . . . .7

6) WIRING AND CONNECTION DIAGRAM . . . . . . . . .8

7) DESCRIPTION OF DIAGNOSTIC INDICATIONS . . . .9

8) SET-UP PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . .10

9) DESCRIPTION OF BOARDS, REPLACING

INSTRUCTION, CURRENT CALIBRATION . . . . . . . . .12

10) AVAILABLE SPARE PARTS . . . . . . . . . . . . . . . . . . . . .24

1) PURPOSE OF THE MANUAL

The purpose of this manual is to furnish authorized service cen-

tres with essential information required to repair model CADDY

TIG HF.

To avoid serious personal injury or damage to property, it is vital

this manual be used by qualified technical personnel only.

Esab Welding Equipment AB declines all responsibility for any

injury or damage to property caused whilst repairs are being

carried out, including any injury or damage to property subse-

quent to the reading or putting into practice of the contents

hereof.

For a detailed description of installation, use and routine main-

tenance of the machine, refer to the "Owner's manual", which

must always be kept together with the machine.

To perform operations described herein, you will need a digital

multimeter and a clamp-on AC-DC ammeter together with

basic knowledge of how the machine works. A fundamental

grasp of electrical technology is also required.

Repair work consists in locating the faulty part - as this part is

included on the list of available spare parts - and in replacing it.

If a circuit board is faulty, repairs will consist in replacing the

board and not replacing the faulty electronic component on the

actual board.

Refrain from making any changes or performing any mainte-

nance work not contemplated herein.

Should the problem persist even after following the instructions

described herein, contact Esab Welding Equipment Service

Department or send the machine to Esab for relevant work.

Purpose of the manual 3

4 Warnings, precautions, general information on executing repairs

2) WARNINGS, PRECAUTIONS, GENERAL

INFORMATION ON EXECUTING REPAIRS

Imminent danger of serious bodily harm and dan-

gerous behaviours that may lead to serious bodily

harm.

lmportant advice to be followed in order to avoid

minor injuries or damage to property.

The notes preceded by this symbol are mainly

technical and facilitate operations.

Behaviour linked expressly to HF striking, which

might result in minor injuries or damage to pro-

perty (especially measuring instruments).

Repairs may be executed by qualified personnel only.

Before attempting any repairs, we advise you to read and under-

stand the information in this manual, especially in regard to safety

recommendations.

Do not carry out any repair unless another person is present who

can provide help in case of an accident.

To repair equipment, access is necessary to the internal parts of the

machine, and to obtain this, some protective panels have to be

removed. Therefore, some extra precautions are necessary, over and

above those applying to normal use of the machine for welding, in

order to prevent any damaged caused by contact with:

- Live parts

- moving parts

- parts at high temperature

- Live parts:

WARNING!: When accessing parts inside the

machine, remember that turning off the switch will

not prevent the danger of electric shocks. We the-

refore advise you to remove the plug and wait for

about a minute before attempting any job.

Further, as capacitors charged with high voltage may be pre-

sent, wait about a minute before working on the internal parts.

WARNING!: When taking measurements, remem-

ber that the measuring instruments themselves can

become live and, therefore, do not touch their

metal parts.

WARNING!: When TIG mode is selected with HF

start, the machine generates a series of high-volta-

ge pulses (approx. 10,000 V) to strike the welding

arc. Consequently, when diagnostic phases do not expressly

include an arc striking test in TIG mode with HF discharge,

you are recommended to disconnect FN1 & FN2 from Tig pc-

board (AP02).

Once repairs are done, remember to reconnect FN1 & FN2

before closing the machine case for the last time, and then

perform a number of welding tests, including a number of

starts in TIG HF mode.

- Moving parts:

WARNING!: Keep your hands well away from the

fan when the machine is connected to the power

supply. Make sure that the power plug is removed

and that the fan is idle before replacing it.

- Parts at high temperature:

WARNING!: When you have to handle internal

parts of the machine, remember that some could

be at high temperature. In particular, do not touch

cooling radiators.

Diagnostics and repair instruments and tools 5

3) DIAGNOSTICS AND REPAIR INSTRUMENTS

AND TOOLS

3.1)

Instruments for basic diagnostics

You will need:

- a multimeter with the following scale:

Ohms: in the range 0 to several Mohms

Diode test

Direct voltage (Vdc): from mVdc to 1000 Vdc

Alternating voltage (Vac): in the range 10 Vac to 700 Vac

NOTE: You are advised to use an instrument with an automatic

scale as, theoretically speaking, when the machine is faulty, it is

not possible to foresee the level of the electrical value to be

measured.

- a class 2.5 or higher clamp-on AC-DC ammeter with end of

scale 200A pk

- instead of the clamp-on ammeter, you can use a shunt with

a value of 60 mV @ 150 A.

NOTE:

- Remember that other shunts may do the job just as well,

though a greater capacity means less accuracy, whilst with

lower capacities, the measurement must be taken quickly or

the shunt will overheat.

Once inserted, the shunt is at welding potential

(watch out, above all, for discharges during striking

in TIG HF mode!)

- Nonetheless, in practical terms, a clamp-on ammeter is the

best choice.

3.2)

Tools for repairs

- complete set of open-ended spanners

- complete set of 6-point socket spanners

- complete set of flat-tip screwdrivers

- complete set of Phillips screwdrivers

- complete set of Allen keys

- a Phillips torque wrench for M3 screws with torque settings in

the range 1 to 3 Nxm accurate to 0.1 Nxm.

- a crimping tool for insulated wire terminals (blue, red and yellow)

- a pair of pliers for AMP contacts

- pliers and nippers commonly used with electronic components

- a larger pair of nippers for cutting small thicknesses of sheet

metal

- tongs (suitable size for closing gas pipe clamps)

- a soldering iron for electronic components with min. power 50 W

- portable DIY electric drill

3.3)

Conventions

We have adopted a convention whereby, when you are asked

to take a measurement between two points, such as a b,

the tip of the arrow always indicates where to apply the multi-

meter's red probe (a), whilst the black probe is applied to the

other end (b).

When the arrow between two measuring points is double (e.g.:

c d), the voltage to be measured is alternating (usually at

50 Hz) and, consequently, it does not matter what order the

multimeter's probes are applied in.

In drawings and tables, when a voltage measurement referring

to terminals of components such as diodes, BJTs, mosfets and

IGBTs appears, reference is made to the multimeter being used

in "diode test" mode (such measurements should always be

taken with the machine switched off, and usually give values in

the range +0.10… +0.90 Vdc). In this case, the relevant

symbol appears next to the value to be measured.

Junction measurement (multimeter in "diode test" mode)

Similarly, the following symbols will be used:

AC or DC voltage measurement (multimeter in voltmeter

mode)

Resistance measurement (multimeter in ohmmeter

mode)

Current measurement (clamp-on ammeter or shunt +

multimeter in millivoltmeter mode)

Frequency measurement (multimeter in Hz mode)

Measuring conditions (power source on/off, MMA/TIG opera-

ting mode etc.) are always clearly indicated next to the value to

be measured.

Connector pins are indicated with the name of the actual con-

nector followed by a slash and by the number of the pin; for

instance, CN1/2 indicates pin 2 of connector CN1.

Unless otherwise specified, all measurements should be taken

with the boards in their slots and connected

Remember that testing should always start with a

VISUAL INSPECTION!

Visual inspection reduces the time spent troubles-

hooting and points any subsequent tests in the

direction of the damaged part!

6 Technical data

4) TECHNICAL DATA

* When welding below 100 A in MMA a 10 A slow fuse is ade-

quate.

Performance MMA:

at 25% duty cycle

at 60% duty cycle

at 100% duty cycle

Performance TIG:

at 30% duty cycle

at 60% duty cycle

at 100% duty cycle

Setting range MMA/TIG

Open circuit voltage

MMA/TIG

Mains supply:

voltage

frequency

fuse

mains cable, area

Enclosure class

Application class

Dimensions L x W x H

Weight

Caddy TIG HF

150 A/26 V

115 A/24.6 V

100 A/24 V

150 A/16 V

125 A/15 V

110 A/14.4 V

5-150 A

95 V/104 V

230 V AC ±15%

50/60 Hz

16 A*

3x1,5 mm2

IP 23C

375 x 145 x 280 mm

5.9 kg

5) DESCRIPTION OF MACHINE'S OPERATION (BLOCK DIAGRAM) (fig. 1)

a) Master switch

b) Varistor

c) Emi input filter

d) Input rectifier

e) DC link capacitor

f) Zero Voltage Switching Phase Shifted Full Bridge Inverter

g) Primary current transformer

h) High frequency power transformer

i) Output rectifier

j) Voltage doubler

k) Shunt

l) Output filter

m) HF transformer

n) Arc striking unit

o) Switching auxiliary power supply

p) Syncronization unit

q) Inverter control unit

r) Microprocessor unit

Description of machine's operation (block diagram) 7

7) DESCRIPTION OF DIAGNOSTIC INDICATIONS (fig. 3)

The actual status of the equipment is reported to the operator via the LEDs and display of the front panel.

See the "Owner's manual" for meanings and use of the various controls as this section deals with diagnostic signals only.

Power Supply LED (GREEN)

Indicates machine on/off status. Always lit if the panel, and hence the machine, is powered correctly.

Alarm LED (YELLOW)

Indicates the equipment is in alarm status. Never lit unless there is a problem.

The display indicates the type of alarm in question by an error code.

Display

When the power source is switched on, the panel runs a "self-test" during which the display reads "150". Immediately afterwards,

the display indicates the control panel's software version (e.g. u01) for a moment.

The display indicates the welding parameters requested by the operator (with the aid of other keys) and as soon as the arc is struck,

it gives a readout, furnishing the real value of the current delivered.

When the yellow LED lights, flashing codes appear on the display to indicate an alarm status (in this status, only the two power and

alarm LEDs are lit):

* Note: in case of overtemperature or overload, resetting takes place automatically as soon as the unit has cooled down

for a while; due to fan action, cooling down is quicker if the machine is operating in stand-by mode (i.e. TIG mode selec-

ted, trigger released, no output voltage).

Generally speaking, once the causes of an alarm have been removed, the machine will resume operation as normal.

When checking fan, remember that Caddy TIG HF controls fan speed in order to minimize noise, energy consumption and exter-

nal powder suction: the higher is the internal temperature, the faster is the fan speed.

Caddy TIG HF has a built-in mains voltage compensation, which means that ±15% fluctuation in the supply voltage produces a

negligible variation in the welding current. No alarm is displayed if supply voltage exceed the limits above: if mains voltage goes

below 195, Vac machine just stop working; if mains voltage goes above 270Vac, varistor on AP03 could blow (see section 9.1 fur-

ther on). Avoid connecting the machine to supply voltage with fluctuations larger than ±15%.

Description of diagnostic indications 9

CODE

E01

E02

E03

E20

MEANING

Internal overtemperature*

Missed contact

Overload with respect to allowed

duty cycle*

Internal memory error

ACTION

Remove wrap-around, check heatsink temperature, check fan, check thermic

probe NTC on AP01 (see fig. 5)

Check short connection between CN4/4 & CN4/7 on AP01 (see fig. 2)

Let machine cool down for a while in stand-by mode: if E03 is still displayed, switch

the unit off and back on, then execute a MASTER RESET by parameter 99 (see sec-

tion 8.1 further on): if E20 is still displayed, AP01 pc-board must be changed.

Switch the unit off and back on, then execute a RESET by parameter 99 (see se-

ction 8.1 further on): if E20 is still displayed, AP01 pc-board must be changed.

8) SET-UP PARAMETERS

8.1) Setting up the unit

Front panel settings are complemented by others that can be edited in the Setup, which is accessed as follows (also see fig. 3 in

sect. 7):

- Switch the equipment on.

- Wait until "150" and then software release (e.g. "u01") is displayed

- Keep the "PARAMETERS" key pressed for at least 3 seconds.

- The display will read "0".

Now, by turning the encoder (knob on panel), you can set the value in the range "0" to "99" and by pressing the "PARAMETERS"

key, you can view the value of the associated parameter according to the data given in the table below:

- The value of the parameter selected during the previous step can be changed by turning the knob on the panel.

- We can see from the table above that some parameters do not really have a value associated: if we select one of these parame-

ters and press the "Parameters" key, the associated operation is performed (e.g. if we enter Setup, select parameter "2" and press

the "Parameters" key, factory settings are resumed for all parameters [RESET]).

- Parameters labelled as "not used" cannot be accessed, i.e. nothing happens when the "Parameters" key is pressed.

- To save changes made to parameters and exit the Setup menu, return to parameter "0" and press the "Parameters" key; otherwi-

se, switching the machine off directly will mean none of the changes will be saved, and the last confirmed parameter settings will

remain.

- Once you have exited Setup, regular operation is resumed, based on the new parameter settings (if any have been made).

Param.

Mode

TIG/MMA

TIG

MMA

Range

0.0 - 25.0s

0 - 500%

0.0 - 10.0 s

0 - 500%

0.0 - 25.0s

0 = 2T

1 = 4T

2 = MANUAL

PULSE

0 - 500%

0 = actual current

1 = actual voltage

2 = set current

0 -999

Pre-set value

0.1s

50%

0.0 s

50%

0.0s

80%

30%

500

Description/Meaning

Save & exit

Reset & return to pre-set values [RESET]

Pre-gas time(s)

Start current (% of welding current)

Slope-up time (s)

Second welding current value (% of welding current)

in TIG MANUAL PULSE

Final current (% of welding current)

Post-gas time (s). In 0.0 we have an automatic post-gas time

Trigger mode

....................…… not used parameter ……………………………..

Hot start (% of welding current)

Arc force (% of welding current)

....................…… not used parameter ……………………………..

Displayed quantity during welding

....................…… not used parameter ……………………………..

Access to output current calibration procedure (see sect. 9.2.3 further on)

....................…… not used parameter ……………………………..

Reset all parameters (only to be used when there are problems with the

non-volatile memory, see errors E20 in sect.7) [MASTER RESET]

10 Set-up parameters

8.2) TIG welding modes

Parameter n° 8 sets the trigger mode accordingly to what follows:

Two stroke TIG welding (2T)

1) 1

press of the trigger

- the gas flows for the pre-gas time

- the voltage is activated on the electrode

- the HF strikes the arc

- the current goes from the initial current to the welding current

in the slope-up time

- the current remain to the welding current

2) 1

release of the trigger

- the current goes from the welding current to the final current

in the slope-down time

- the arc switches off

- the gas flows for the post-gas time.

Four stroke TIG welding (4T)

1) 1

press of the trigger

- the gas flows for all this time

2) 1

release of the trigger

- the gas flows for the pre-gas time

- the voltage is activated on the electrode

- the HF strikes the arc

- the current goes from the initial current to the welding current

in the slope-up time

- the current remain to the welding value

3) 2

press of the trigger

- the current goes from the welding current to the final current

in the slope-down time

- the arc switches off

- the gas flows for the rest of this time

4) 2

release of the trigger

- the gas continues to flow for the post-gas time.

Manual Pulse

1) 1

press of the trigger

- the gas flows for the pre-gas time

- the voltage on the electrode is activated

- the HF strikes the arc

- the current remain at the initial current value

2) 1

release of the trigger

- the current goes from the initial current to the welding current

in the slope-up time

- the current remain to the welding value

2.1) 1

rapid press and release of the trigger

- the current goes without any ramp from the first welding cur-

rent (I1) to the second welding current (I2)

2.2) 2

rapid press and release of the trigger

- the current goes without any ramp from I2 to I1

2.3) 3

rapid press and release of the trigger

- the current goes without any ramp from I1 to I2 …and so on

3) 2

press of the trigger

- the current goes from the actual welding current to the final

current in the slope-down time

- the current remain to the final current

4) 2

release of the trigger

- the arc switches off

- the gas continues to flow for the post-gas time.

Set-up parameters 11

TIG WELDING (MANUAL PULSE)

CURRENT

TIME

I1 = START CURRENT (ADJ. 0-500% OF I2)

I2 = SET CURRENT (0-150 A)

I3 = FINAL CURRENT (ADJ. 0-500% OF I2)

I4 = PULSE CURRENT (MANUAL PULSE)

12 Description of boards, replacing instruction, current calibration

9) DESCRIPTION OF BOARDS, REPLACING INSTRUCTION, CURRENT CALIBRATION

The following sections illustrate regular work conditions of boards making up the power source, and furnish standard values for the

electrical measurements that can be taken at the main points of said boards.

All measurements indicated can be taken with a digital multimeter.

Remember that testing should always start with a VISUAL INSPECTION!

Visual inspection reduces the time spent troubleshooting and points any subsequent steps in the direction of the

damaged part!

Generally speaking, the following points should be inspected visually:

- input filter zone

- DC link electrolytic capacitors

- check for traces of fumes on the inside of the cover

- power and signal connections

- overall status of boards.

WARNING!: Unless otherwise specified, before taking measurements described in the following sections, discon-

nect HF connections (CN1 & CN2 in TIG pc-board AP02)!

Important note! When the machine is connected to the mains, the master switch is live regardless of its status (open

or closed). Consequently, you are recommended to unplug the unit before touching any of the parts inside!

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

Description of boards, replacing instruction, current calibration 13

9.1) Input filter board AP03 (fig. 4)

Filter pc-board AP03 contains a varistor

ZN1 guarding against supply overvoltage, an EMC filter circuitry and the DC link elec-

trolytic capacitors.

The filter basically consists in a network of capacitors and a shared inductor.

This circuit has the dual purpose of limiting the machine's radiofrequency emissions to levels prescribed by regulations, and making

the power source immune from similar problems caused by any electronic device connected to the same power supply.

A varistor ZN1 is inserted between the two power supply's input phases meaning that if you find an instantaneous voltage over

275Vac between terminals RV1 and RV2, the varistor instantly starts conducting so as to absorb a sufficient current spike to limit

the above-mentioned overvoltage. In this way, varistor ZN1 protects other parts of the machine from overvoltage characterized

by a limited energy content.

This process is actually non-destructive for the component if the energy delivered by the voltage spike is moderate, as is the case

with atmospheric discharges (lighting). If, on the other hand, overvoltage is considerable and prolonged, the varistor cannot dis-

sipate all associated energy and blows.

This happens, for instance, if the machine is accidentally connected to supply voltages over 275Vac, or if it is subjected to over-

voltage caused by inadequate or non-stabilized generating sets.

14 Description of boards, replacing instruction, current calibration

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

AP01 (fig. 5)

AP01

9.2) Main/power pc-board AP01, secondary rectifier, filter pc-board AP06

This pc-board contains the following circuits:

- auxiliary power supply

- power inverter

- welding current control

- microprocessor control of whole machine (front panel, torch trigger, gas, HF, fan, alarms,

welding logic).

The secondary power rectifier is located under AP01. A filter pc-board AP06 is assembled over

the rectifier terminal.

- Solder-jumper K1 causes a break in the internal auxiliary power supply circuit and is

normally closed

- Solder-jumper K2 enables a limitation of the power source's open circuit volta-

ge OCV, and is normally open (can be factory set only)

- Solder-jumper K3 causes a break in the inverter's power supply circuit and is

normally closed (it may be opened to test the power source; see below).

9.2.1) Testing of AP01, secondary rectifier, AP06

WARNING: varnish on the pc-board' surface could cause uncertain measure-

ments! Use pointed testing probes!

* Note1 Wait 10 minutes after switching off the power source before measuring R9A!

** Note2 Output rectifier testing doesn't require removing of AP06!

BEFORE TAKING MEASUREMENTS DESCRIBED BELOW, OPEN SOLDER-JUMPER K3 WITH

THE MACHINE UNPLUGGED!

WARNING!: Unless otherwise specified, before taking measurements described

in the following sections, disconnect HF connections (CN1 & CN2 in TIG pc-

board AP02)!

* Note1 RL1 closes a few seconds after the power source is switched on; the contact is in

parallel to PC1.

** Note2 In TIG LIFT 2T mode, with K3 open, L6...L9 leds are LIT UP only when trigger is

depressed.

TIG 2T = 2 STROKE TIG (see sect. 8.2)

Note: for greater ease of measurement, TP2 & CN4/7 are connected electrically

to the metal TAB of IC12, which is the electrical ground of the logic part of the pc-

board.

Functional part

Auxiliary power

supply

Pre-charge resistor

By-pass relay

Input rectifier

Thermic probe

Power inverter

Error code E02

(alarm)

Output rectifier **

AP06

Description of boards, replacing instruction, current calibration 15

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

Power source / Mode

OFF / -

Component

R9A *

MF2

PC1

RL1

Power module

CN4

DA **

DB **

Test point

S D

S G

COIL

1 5

3 5

7 1

7 3

9 10

11 12

17 18

19 20

25 26

14 13

16 14

21 23

23 24

CN4/4 CN4/7

A K

Value

+0.4 Vdc

+0.7 Vdc

150 ± 25%

@ 25°C

370

+0.5 Vdc

10 K ± 20%

@ 25°C

4.7 K

+0.4 Vdc

+0.2 Vdc

+0.5Vdc

Notes

Test point

ALT10 ALT20

+V -V

CN1/1 CN1/3

COIL

CONTACT

TP1 TP2

CN4/1 CN4/7

CN4/8 CN4/7

CN4/3 CN4/7

CN4/4 CN4/7

Functional part

Power supply "IN"

DC link

AP02 high voltage

power supply

By-pass relay *

Microproces.

power supply

Fan power supply

Negative power

supply

Positive power

supply

Inverter drivers **

AP02 gas valve out-

put command

AP02 auxiliary

power supply

AP02 trigger input

signal

E02 input signal

Power source / Mode

ON / -

ON / TIG LIFT 2T

(with trigger depres-

sed)

ON / TIG LIFT 2T

ON / -

Component

CN1

RL1

CN4

Value

~ 230Vac ± 15%

+ 325 Vdc ± 15%

+ 12Vdc

CLOSED

+ 5.0 ± 0.1 Vdc

LIT UP

+1.8 Vdc (while

trigger depressed);

+ 19Vdc (otherwise)

+19 ± 1.0 Vdc

+0 Vdc (while

trigger depressed);

+ 5Vdc (otherwise)

0 Vdc

Notes

BEFORE TAKING MEASUREMENTS DESCRIBED BELOW, WAIT 5 MINUTES AFTER SWIT-

CHING OFF THE POWER SOURCE AND - WITH THE MACHINE UNPLUGGED - CLOSE

SOLDER-JUMPER K3!

WARNING!: Unless otherwise specified, before taking measurements described

in the following sections, disconnect HF connections (CN1 & CN2 in TIG pc-

board AP02)!

* Note1 To obtain max fan speed, weld at least for 5 minutes @150A in stick mode.

Functional part

Fan power supply

Negative power

supply

Microproces.

power supply

Positive power

supply

Inverter drivers

AP02 HF output

command

Output voltage

feedback

OCV

Fan output com-

mand *

16 Description of boards, replacing instruction, current calibration

Test point

CN4/2 CN4/7

+Vout TP2

+ -

CN2/1 CN2/2

Power source / Mode

ON / MMA

(in MMA mode, with

K3 closed, L6...L9 leds

are always LIT UP).

ON / TIG HF 2T

ON / MMA

Component

CN4

OKC outlets

CN2

Value

LIT UP

44 ± 2 Hz (just for 1

second after trigger is

depressed);

+19 ± 1Vdc (other-

wise)

+95 ± 5 Vdc

+15Vdc

(@ max fan speed)

Notes

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

9.2.2) Replacing instructions for AP01 (fig. 6)

WARNING!

- Components sensitive to electrostatic discharges!

- Torque wrench settings:

POWER MODULE FASTENING TO HEAT SINK = MAX 2.2 Nx m / 19 lb x in

POWER MODULE FASTENING TO PC-BOARD = MAX 0.2 Nx m / 1.7 lb x in

- Always replace thermal interface with a new one!

In order to replace AP01 pc-board see following instructions:

1. Remove filter board AP06 from secondary rectifier.

2. Remove the connectors from the p.c. board and the flat cable on the front panel too. Unscrew the transformer connections (M1

& M2). Remove the four screws which keep the p.c. board and also the screws of the power module (S1, S2, S3, S4, S5, S6).

3. Remove AP01 p.c. board, complete with the capacitors board AP03.

4. Remove AP03 from AP01.

5. Remove the thermal interface (WARNING: IT CANNOT BE USED AGAIN).

6. Wipe by solvent the surfaces (the heat-sink and the power module of the new p.c. board).

7. Avoid to handle the thermal interface with bare hands. Otherwise, use the two protection sheets.

8. Check the integrity of new thermal interface (WARNING: A SIMPLE FOLD HARMS THE RELIABILITY).

9. Lay it on the heat-sink without the protection sheets.

10. Assembly AP03 on new AP01, executing the same operation as in point 4, in reverse order.

11. Remove the S7-S8-S9-S10 screws in the new p.c. board.

12. Place the new p.c. board on the heat-sink, using the new screws for the power module and respecting washers' polarity (see S1-

S2 screws below).

13. Tighten S1-S2 up to 2.0 - 2.2 N·m (17 - 19 lb·in).

14. Place and slightly turn the S7-S8-S9-S10 screws by max torque 0.2 N·m.

15. Tighten S3-S4-S5-S6 screws (follow this sequence).

16. Follow operation described in the above point 1 & 2 in reverse order to complete the replacing of the p.c. board.

Description of boards, replacing instruction, current calibration 17

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

18 Description of boards, replacing instruction, current calibration

9.2.3) Calibration procedure

In case of incorrect calibration performing and confirming, the machine will deliver a totally wrong current during

welding and damages could occur to the welding unit itself!

Grid load or striking a TIG arc is required to perform calibration!

Measurement of actual output current is required, too!

Once that AP01 or the shunt should have been replaced (see previous section 9.2.2 ), we may need to calibrate the current

delivered by the unit.

In order to perform the calibration, follow the statements below:

1. Be sure to have correctly replaced the damaged part and that the unit has been correctly repaired and closed up

2. Connect the unit to the mains

3. Switch the unit on

4. Enter setup (see section 8.1 above), select parameter n° 99 and perform a Master Reset: "RES" and then "0" are displayed

5. Go to parameter n°50 and press "Parameter" key: "500" is displayed

6. Turn the knob backwards until "358" is displayed and press "Parameters" key: "50" is displayed and actual calibration parame-

ter is thus accessible

7. Select parameter n°67 and press "Parameter" key: "tar" is displayed and then "60" is displayed

Output power is enabled now (OCV 105Vdc) !

8. Connect a grid load of about 0.02O 750W (60A @ 12V) or strike up a TIG arc by scratching the tungsten on the workpiece:

the generator starts delivering about 60A

9. Measure with an external clamp-on ammeter the actual delivered output current and adjust the knob until the value displayed

in the front panel of the unit equals the measured value

10. Press "parameter" key to confirm the calibration: "67" is displayed

11. Return to "0"

12. In order to exit without saving the new calibration value, just switch off the machine; otherwise skip to next point.

13. In order to save the new calibration, depress the "parameter" key: regular operation is resumed, based on the new calibrated

value.

In case of incorrect code input in issue # 6, the unit will stop working and "err" will be displayed: switching off and

back on of the unit will be required to resume normal operation. Then calibration procedure must be repeated from

the beginning!

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

Description of boards, replacing instruction, current calibration 19

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

9.2.4) Replacing instructions for secondary rectifier (fig. 7)

WARNING!

- Components sensitive to electrostatic discharges!

- Torque wrench settings:

POWER MODULE FASTENING TO HEAT SINK = MAX 2.2 N x m / 19 lb x in

POWER MODULE FASTENING TO PC-BOARD = MAX 0.2 N x m / 1.7 lb x in

DIODE MODULE FASTENING TO HEAT-SINK = MAX 1.5 N x m / 13 lb x in

COPPER BARS FASTENING TO DIODE MODULE = MAX 1.5 N x m / 13 lb x in

AP06 FASTENING TO DIODE MODULE = MAX 1.5 N x m / 13 lb x in

- Always replace thermal interface with a new one!

- Always use layer of thermal grease under diode module!

To replace secondary rectifier, AP01 pc-board must be removed, as described below:

1. Remove filter board AP06 from secondary rectifier.

2. Remove the connectors from the p.c. board and the flat cable on the front panel too. Unscrew the transformer connections (M1

& M2). Remove the four screws which keep the p.c. board and also the screws of the power module (S1, S2, S3, S4, S5, S6).

3. Remove AP01 p.c. board, complete with the capacitors board AP03.

4. Remove damaged diode module, without removing copper bars from power transformer.

5. Remove the thermal interface of power module (WARNING: IT CANNOT BE USED AGAIN).

6. Wipe by solvent the surfaces (the heat-sink and the power module).

7. Put some thermal grease under new diode module, then place in new diode module, reconnecting the copper bars.

8. Tigthen the screw of the diode module to heat-sink and to copper bars up to 1.5 N·m (13 lb·in).

9. Avoid to handle the thermal interface with bare hands. Otherwise, use the two protection sheets.

10. Check the integrity of new thermal interface (WARNING: A SIMPLE FOLD HARMS THE RELIABILITY).

11. Lay it on the heat-sink without the protection sheets.

12. Remove the S7-S8-S9-S10 screws in AP01 p.c. board.

13. Place AP01 on the heat-sink, using the old screws for the power module and respecting washers' polarity (see S1-S2 screws

below).

14. Tighten S1-S2 up to 2.0 - 2.2 N·m (17 - 19 lb·in).

15. Place and slightly turn the S7-S8-S9-S10 screws by max force 0.2 N·m.

16. Tighten S3-S4-S5-S6 screws (follow this sequence).

17. Follow operation described in the above point 1 & 2 in reverse order to complete the replacing of the secondary rectifier.

Note: when testing the single diode, +0.4Vdc should be read on the multimeter; but when the diode module is assembled

and connected to the power transformer, +0.2Vdc should be read (see section 9.2.1).

20 Description of boards, replacing instruction, current calibration

AP02 (fig. 8)

Unless otherwise specified, all measurements sholud be taken with the boards in their slots and connected accordingly

(UPPER VIEW)

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ESAB CaddyTig HF User manual

ESAB CaddyTig HF User manual

ESAB CaddyTig HF User manual

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