ESAB TA34 AC/DC User manual

Caddy®

Instruction manual

0460 227 174 GB 20131022 Valid from program version 1.20

TA34 AC/DC

TABLE OF CONTENTS

0460 227 174 © ESAB AB 2013

1 INTRODUCTION................................................................................................... 3

1.1 Useful information about the welding product .................................................3

1.2 Control panel ........................................................................................................ 3

2 TIG WELDING....................................................................................................... 5

2.1 Settings ................................................................................................................. 5

2.2 Symbol and Function explanations....................................................................6

2.3 Hidden TIG functions......................................................................................... 12

3 MMA WELDING.................................................................................................. 14

3.1 Settings ............................................................................................................... 14

3.2 Symbol and Function explanations..................................................................14

3.3 Hidden MMA functions ......................................................................................15

4 WELDING DATA MEMORY ................................................................................ 17

5 FAULT CODES ................................................................................................... 18

5.1 List of fault codes .............................................................................................. 18

5.2 Fault code descriptions..................................................................................... 18

6 ORDERING SPARE PARTS ............................................................................... 21

ORDERING NUMBERS.............................................................................................22

Rights reserved to alter specifications without notice.

1 INTRODUCTION

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1 INTRODUCTION

The manual describes the use of TA34 AC/DC control panel.

For general information about operation see instruction manual for the power source.

When mains power is supplied the unit runs a self diagnosis of

the LEDs and the display, the program version is displayed and

in this example the program version is 0.18.

NOTE!

Differences in the panel function may occur, depending on in which product it is

installed.

Instruction manuals in other languages can be downloaded from the Internet: www.esab.com

1.1 Useful information about the welding product

The power source is equipped with the function True AC rating (TIG).

"True AC rating" means the average current can be maintained in the event of variations in

inductance and resistance in the welding circuit. This is the result of active process control,

which compensates for the inductance present in the welding circuit.

The process is optimised so that the energy in the arc will correspond to the set welding

current selected for AC (alternating current). Process optimisation normally leads to welding

being possible at a lower set current value (than with previous power sources) thanks to

reduced losses in the welding circuit.

For the best possible oxide break-up and a long tungsten electrode life for AC TIG, we

recommend a negative AC balance (-70%), which is also the basic setting on delivery. It is

possible to reduce the weld pool penetration for AC TIG by reducing the heat exchange by

lowering the AC balance. The minimum AC balance value is -50%, see tables 1-3 on page 8

for recommended current ranges. This primarily facilitates welding of weaker/thinner material

dimensions.

1.2 Control panel

1 INTRODUCTION

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1. Knob for setting data (current, voltage, percentage, seconds, or frequency)

2. Display

3. Choice of welding method TIG or MMA

4. Pushbutton for selection of TIG-welding with:

• Alternating current AC

• Direct current DC -

• Direct current DC - with pulsing

Pushbutton for selection of MMA-welding with:

• Alternating current AC

• Direct current DC -

• Direct current DC +

5. Choice of start HF start or LiftArc

™

6. Choice of 2-stroke or 4-stroke

7. Setting from panel , program change with torch trigger switch

or connecting remote control unit

8. Display of VRD function (reduced open-circuit voltage) is active or inactive

NOTE!

This function works for power sources where it is implemented.

9. Indication of which parameter is shown in the display (current, voltage, percentage,

seconds or frequency)

10. Display of measurement value for current (A) or voltage (V) during welding.

11. Indication of selected setting parameter, see section "Symbol and Function

explanations".

The right-hand button is also used for hidden functions.

12. Buttons for weld data memory settings, see section "Welding data memory".

Measured value in the display for arc voltage V, and welding current A, is arithmetic average

value = rectified average value.

2 TIG WELDING

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2 TIG WELDING

2.1 Settings

TIG without pulsing AC/DC and TIG with pulsing DC

Function Setting range In steps of: Default

value

HF/LiftArc

™1)

HF or LiftArc

™

LiftArc

™

2/4 stroke

2 stroke or 4 stroke - 2 stroke

Gas pre flow time

0-5 s 0.1 s 0.5 s

Slope up-time 0-10 s 0.1 s 0.0 s

Slope down time 0-10 s 0.1 s 1.0 s

Gas post flow time 0-25 s 0.1 s 10.0 s

Current

4 - max

1 A 60 A

Active panel OFF or ON - ON

Changing trigger data OFF or ON - OFF

Remote control unit OFF or ON - OFF

Min current

0-99% - 0 %

VRD - - -

These functions cannot be changed while welding is in progress.

These functions are hidden Tig functions, see description in section "Hidden TIG

functions".

The setting range is dependent on the power source used.

TIG with AC

Function Setting range In steps of: Default

value

Balance setting 50 - 98 %* 1 % 50 %

Frequency setting 10 - 152 Hz 1 - 3 Hz 65 Hz

Electrode preheating

automatic

manual



80 - 120 ms



15 - 100 ms



Depending on frequency setting.

These functions are hidden TIG functions, see description in section "Hidden TIG

functions".

TIG with pulsing DC

Function Setting range In steps of: Default

value

Pulse current

4 - max

1 A 60 A

Pulse time

Micro pulse

0.01 - 2.5 s

0.001 - 0.250 s



0.01 s

0.001 s



1.0 s

2 TIG WELDING

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Function Setting range In steps of: Default

value

Background current

4 - max

1 A 20 A

Background time

Micro pulse

0.01 - 2.5 s

0.001 - 0.250 s



0.01 s

0.001 s



1.0 s

These functions are hidden TIG functions, see description in section "Hidden TIG

functions".

The setting range is dependent on the power source used.

2.2 Symbol and Function explanations

TIG welding

TIG welding melts the metal of the workpiece, using an arc struck from a

tungsten elec- trode, which does not melt itself. The weld pool and the electrode

are protected by shielding gas.

AC, Alternating current

The advantage of an alternating current is good oxide break-up capacity when

welding light metals (aluminium, magnesium and their alloys).

Direct current

A higher current produces a wider weld pool, with better penetration into the

workpiece

Pulsed current (only DC)

Pulsing is used for improved control of the weld pool and the solidification

process. The pulse frequency is set so slow that the weld pool has time to

solidify at least partially between each pulse. In order to set pulsing, four

parameters are required: pulse current, pulse time, background current and

background time.

Parameter settings

1. Slope up 6. Slope down

2. Welding current 7. Gas post flow time

3. Pulse time 8. Balance

4. Background current 9. Frequency

5. Background time 10. Electrode preheating

2 TIG WELDING

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Slope up

The slope up function means that, when the TIG arc strikes, the current rises

slowly to the set value. This provides `gentler' heating of the electrode, and gives

the welder a chance to position the electrode properly before the set welding

current is reached.

Pulse current

The higher of the two current values in the event of pulsed current.

A. Current D. Background current

B. Time E. Pulse time

C. Background time F. Pulse current

TIG welding with pulsing.

Pulse time

The time the pulse current is on during a pulse period.

Background current

The lower of the two current values in the event of pulsed current.

Background time

Time for background current which, along with the time for pulse current, gives the pulse

period.

Slope down

TIG welding uses “slope down”, by which the current falls 'slowly' over a

controlled time, to avoid craters and/or cracks, when a weld is finished.

Gas post-flow

This controls the time during which shielding gas flows after the arc is

extinguished.

Balance

Setting the balance between the positive (+) electrode and negative (-) electrode

half period during alternating current welding (AC).

Lower balance value produces more heat on the electrode and better oxide

break-up on the workpiece.

Higher balance value produces more heat to the workpiece and better

penetration.

2 TIG WELDING

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Frequency

Lower frequency (alternating current) transfers more heat to the workpiece and

produces a wider weld pool.

Higher frequency produces a narrower arc with higher arc force (narrower weld

pool).

HF start

The HF start function strikes the arc by means of a spark from the electrode to

the workpiece as the electrode is brought closer to the workpiece.

Automatic preheating of electrode with AC

The preheating function is designed to provide a stable arc and a safe start in a

balanced manner. The electrode preheating time is controlled by a

preprogrammed time in relation to the set welding current. It is possible to set

(finetune) the automatic preheating when on the outer area of the electrode's

current range, see recommended current range below.

The setting range for preheating is 80 - 120 ms, where 100 ms is equal to the

basic value (value on delivery).

Current ranges for electrode WP (pure tungsten)

Max A AC - 50% Balance Max A AC - 70% Balance

A. Welding current A B. Electrode diameter (mm)

Table 1 - Recommended current ranges for electrode selection WP = Green Colour coding

and classification names as per ISO 6848:2004

2 TIG WELDING

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Current ranges for electrode WC20 (WCe2)

Max A AC - 50% Balance Max A AC - 70% Balance

A. Welding current A B. Electrode diameter (mm)

Table 2 - Recommended current ranges for electrode selection WC20 = Grey Colour coding

and classification names as per ISO 6848:2004

Current ranges for electrode WLa 15/Gold Plus (70% AC Balance)

I max A AC

A. Welding current A B. Electrode diameter (mm)

Table 3 - Recommended current ranges for electrode selection WLa15 = Gold Colour coding

and classification names as per ISO 6848:2004



2 TIG WELDING

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Deactivation of automatic preheating of electrode

In hidden TIG functions automatic preheating can be deactivated for a manual setting from

15 - 100 ms for adjustment in specific instances. When switching from an automatic to a

manual setting, the previous autogenerated value for preheating is used and a preferred

value is selected using the knob.

LiftArc™

The LiftArc™ function strikes the arc when the electrode is brought into contact

with the workpiece and then lifted away from it.

Striking the arc with the LiftArc™ function:

1. The electrode is touched on to the workpiece.

2. The trigger switch is pressed, and a low current starts to flow.

3. The welder lifts the electrode from the workpiece: the arc strikes, and the current rises

automatically to the set value.

2 stroke

A. Gas pre-flow C. Slope down

B. Slope up D. Gas post-flow

Functions when using 2 stroke control of the welding torch.

In the 2 stroke control mode, pressing the TIG torch trigger switch (1) starts gas pre-flow (if

used) and strikes the arc. The current rises to the set value (as controlled by the slope up

function, if in operation). Releasing the trigger switch (2) reduces the current (or starts slope

down if in operation) and extinguishes the arc. Gas post-flow follows if it is in operation.

2 TIG WELDING

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4 stroke

A. Gas pre-flow C. Slope down

B. Slope up D. Gas post-flow

Functions when using 4 stroke control of the welding torch.

In the 4 stroke control mode, pressing the trigger switch (1) starts gas pre-flow (if used). At

the end of the gas pre-flow time, the current rises to the pilot current (a few ampere), and the

arc is struck. Releasing the trigger switch (2) increases the current to the set value (with

slope up, if in use). When the trigger switch is pressed in (3) the current returns to the set

pilot current (with 'slope down' if in use).

When the trigger switch is released again (4) the arc is extinguished and any gas post flow

occurs.

Active panel

Settings are made from the control panel.

Changing trigger data

This function permits changing between different welding data memories by a

double press on the trigger of the welding gun. Only applies for TIG welding.

Remote control unit

Settings are made from the remote control unit.

The remote control unit must be connected to the remote control unit socket on

the equipment before activation. When the remote control unit is activated the

panel is inactive.

Voltage Reducing Device (VRD)

The VRD function ensures that the open-circuit voltage does not exceed 35 V

when welding is not being carried out. This is indicated by a lit VRD LED.

The VRD function is blocked when the system senses that welding has started.

If the VRD function is activated and the open-circuit voltage exceeds the 35 V

limit, this is indicated by an error message (16) appearing in the display and

welding cannot be started whilst the error message is displayed.

Contact an authorised ESAB service technician to activate the function.

2 TIG WELDING

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2.3 Hidden TIG functions

There are hidden functions in the control panel.

To access the functions, press for 5 seconds. The display shows a letter and a value.

Select function by pressing the right arrow. The knob is used to change the value of the

selected function.

To exit hidden functions, press for 5 seconds.

Function Settings

A = gas pre-flow 0 - 5 s

l = min current 0 - 99 %

L = automatic start pulse/electrode

preheating

0 = OFF; 1 = ON

P = start pulse value on delivery 70A at setting 60A

b = micro pulse (only in DC) 0 = OFF; 1 = ON

Gas pre-flow

This controls the time during which shielding gas flows before the arc is struck.

Min current

Used to set the minimum current for the remote control.

If the max current is 100 A and the min current is to be 50 A, set the concealed function min

current to 50%.

If the max current is 100 A and the min current is to be 90 A, set the min current to 90%.

This function also applies when setting background current with pulsed TIG.

Electrode preheating

In the function automatic start pulse/electrode preheating (L), electrode preheating is only

activated in AC. This function is used to achieve a stable arc rapidly, and preheating extends

the service life of the electrode.

Start pulse

NOTE!

To activate manual start pulse (P), the function (L) must first be deactivated in the

hidden function, select (0 = OFF).

Start pulse produces a safe, controlled start and is balanced and adapted to the electrode

diameter and set welding current.

2 TIG WELDING

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Micro pulse

In order to select micro pulse, the machine must be in the pulsed current function .

The value for pulse time and background current is normally 0.01-2.50 seconds. By using

the micro pulse, the time can go down to 0.001 seconds. When the micro pulse function is

active, times that are shorter than 0.25 seconds are shown in the display without decimal

points.

3 MMA WELDING

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3 MMA WELDING

3.1 Settings

Function Setting range In steps of: Default

value

Current

16 - max. A

1 A 100 A

Hotstart

0 - 99 1 0

Arc force

0 - 99 1 5

Drop welding

0=OFF or 1=ON - OFF

Welding regulator 1=OFF or 0=ON - ON

Active panel OFF or ON - ON

Remote control unit OFF or ON - OFF

Min current

0 - 99 % - 0 %

VRD - - -

These functions are hidden functions, see description in section "Hidden MMA functions".

The setting range is dependent on the power source used.

3.2 Symbol and Function explanations

MMA welding

MMA welding may also be referred to as welding with coated electrodes. Striking

the arc melts the electrode, and its coating forms protective slag.

During MMA welding, it is possible to weld with reversed polarity without reconnection of

welding cables on the power source.

Select MMA welding and then press

• AC, for alternating current

• DC (-) for direct current with negative polarity on the electrode

• No LED is on, for direct current with positive polarity on the electrode

Active panel

Settings are made from the control panel.

Remote control unit

Settings are made from the remote control unit.

The remote control unit must be connected to the remote control unit socket on

the equipment before activation. When the remote control unit is activated the

panel is inactive.

3 MMA WELDING

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Voltage Reducing Device (VRD)

The VRD function ensures that the open-circuit voltage does not exceed 35 V

when welding is not being carried out. This is indicated by a lit VRD LED.

The VRD function is blocked when the system senses that welding has started.

If the VRD function is activated and the open-circuit voltage exceeds the 35 V

limit, this is indicated by an error message (16) appearing in the display and

welding cannot be started whilst the error message is displayed.

Contact an authorised ESAB service technician to activate the function.

3.3 Hidden MMA functions

There are hidden functions in the control panel.

To access the functions, press for 5 seconds. The display shows a letter and a value.

Select function by pressing the right arrow. The knob is used to change the value of the

selected function.

To exit hidden functions, press for 5 seconds.

Function Settings

C = Arc Force 0 - 99 %

d = drop welding 0 = OFF; 1 = ON

F = welding regulator type ArcPlus™ 0 = OFF; 1 = ON

H = Hotstart 0 - 99 %

I = min current 0 - 99 %

Arc force

The arc force is important in determining how the current changes in response to

a change in the arc length. A lower value gives a calmer arc with less spatter.

Drop welding

Drop welding can be used when welding with stainless electrodes. The function involves

alternately striking and extinguishing the arc in order to achieve better control of the supply

of heat. The electrode needs only to be raised slightly to extinguish the arc.

Welding regulator ArcPlus™

Welding regulator ArcPlus™ is a new type of control that produces a more intense, more

concentrated and calmer arc. It recovers more quickly after a spot short-circuit, which

reduces the risk of the electrode becoming stuck.

• ArcPlus™ (0) is recommended for a basic electrode.

• ArcPlus™ (1) is recommended for a rutile electrode.

Hot start

Hot start increases the weld current for an adjustable time at the start of welding,

thus reducing the risk of poor fusion at the beginning of the joint.

3 MMA WELDING

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Min current

Used to set the minimum current for the remote control unit.

If the max current is 100 A and the min current is to be 50 A, set the hidden function min

current to 50%.

If the max current is 100 A and the min current is to be 90 A, set the min current to 90%.

4 WELDING DATA MEMORY

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4 WELDING DATA MEMORY

Two different welding data programs can be stored in the control panel memory.

Press button or for 5 seconds to store the welding data in the memory. The

welding data is stored when the green indicator lamp starts to flash.

To switch between the different welding data memories press button or

The welding data memory has a back-up battery so that the settings remain even if the

machine has been switched off.

5 FAULT CODES

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5 FAULT CODES

The fault code is used to indicate that a fault has occurred in the equipment. It is indicated in

the display by an E followed by a fault code number.

A unit number is displayed to indicate which unit has generated the fault.

Fault code numbers and unit numbers are shown alternately.

If several faults have been detected only the code for the last occurring fault is displayed.

Press any function button or turn the knob to remove the fault indication from the display.

NOTE!

If the remote control is activated, deactivate the remote control by pressing

to remove the fault indication.

5.1 List of fault codes

U 0 = welding data unit U 2 = power source U 5 = AC-unit

U 1 = cooling unit U 4 = remote control unit

5.2 Fault code descriptions

Code Description

E 4

U 0

U 5

5 V power supply low

The power supply voltage is too low.

The current welding process is stopped and starting is prevented.

Action: Turn off the mains power supply to reset the unit. Send for a service

technician if the fault persists.

E 6

U 1

U 2

U 5

High temperature

The thermal overload cut-out has tripped.

The current welding process is stopped and cannot be restarted until the temperature

has fallen.

Action: Check that the cooling air inlets or outlets are not blocked or clogged with

dirt. Check the duty cycle being used, to make sure that the equipment is not being

overloaded.

E 7

U 5

High temperature

The thermal overload cut-out has tripped.

The current welding process is stopped and cannot be restarted until the temperature

has fallen.

Action: Check that the cooling air inlets or outlets are not blocked or clogged with

dirt. Check the duty cycle being used, to make sure that the equipment is not being

overloaded.

E 8

U 1

U 5

Faulty 24 V/15 V supply voltage

The supply voltage is too high or too low.

The current welding process is stopped and starting is prevented.

Action: Turn off the mains power supply to reset the unit. Send for a service

technician if the fault persists.

5 FAULT CODES

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Code Description

E 9

U 1

U 5

Faulty 24 V/15 V supply voltage

The supply voltage is too high or too low.

The current welding process is stopped and starting is prevented.

Action: Turn off the mains power supply to reset the unit. Send for a service

technician if the fault persists.

E 12

U 0

U 1

U 4

U 5

Communication error (warning)

Less serious interference on the CAN bus.

Action: Check that there are no faulty units connected on the CAN bus. Check the

cables. Send for a service technician if the fault persists.

E 14

U 0

Communication error (bus off)

Serious interference on the CAN bus.

Action: Check that there are no faulty units connected on the CAN bus. Check the

cables. Send for a service technician if the fault persists.

E 15

U 0

Communication problems (lost message)

The system's CAN bus has been overloaded.

Action: Send for a service technician if the fault persists.

E 16

U 2

High open-circuit voltage VRD

Open circuit voltage has been too high.

Action: Turn off the mains power supply to reset the unit. Send for a service

technician if the fault persists.

E 19

U 0

Memory error

Content of existing memory is incorrect. Basic data will be used.

Action: Turn off the mains power supply to reset the unit. Send for a service

technician if the fault persists.

E 20

U 2

High inductance in the welding circuit

The power source cannot produce the desired current because the measured

inductance in the welding circuit is too high. The fault indication is reset if the

inductance reading receives a sufficiently low value at weld start. Resetting can also

be achieved by turning off the power.

Action: Use shorter welding cables and ensure that the cables are not coiled up.

Place the welding cable and connector cable next to each other. If possible, the

inductance can be reduced by welding with a shorter arc.

Send for a service technician if the fault persists.

E 25

U 0

Lost contact with AC-unit

The control panel has lost contact with the AC unit.

The current welding process stops.

Action: Send for a service technician if the fault persists.

5 FAULT CODES

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Code Description

E 26

U 0

Program operating fault

Something has prevented the processor from performing its normal tasks in the

program.

The program restarts automatically. The current welding process will be stopped.

This fault does not disable any functions.

Action: Send for a service technician if the fault persists.

E 29

U 0

U 1

No cooling water flow

The flow monitor switch has tripped.

The current welding process is stopped and starting is prevented.

Action: Check the cooling water circuit and the pump.

E 41

U 0

Lost contact with the cooling unit

The welding data unit has lost contact with the cooling unit. The welding process

stops.

Action: Check the wiring. If the fault persists, send for a service technician.

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ESAB TA34 AC/DC User manual

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