Tig 2200i AC/DC Caddyt Service manual 0740 800 179 071123 Valid for serial no.
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the semiconductor module of 15AP1 . . . . . . . . . . . . . . . . .
READ THIS FIRST Maintenance and repair work should be performed by an experienced person, and electrical work only by a trained electrician. Use only recommended replacement parts. This service manual is intended for use by technicians with electrical/electronic training for help in connection with fault--tracing and repair. Use the wiring diagram as a form of index for the description of operation.
The power source is transistor--controlled, operating on the inverter principle. It consists of a number of function modules, as shown in the block diagram above. Each module has a module number, which is always included as the first part of the name/identification of components in the module. The modules have the following main functions: 1 MMC module Control panel and display board. 2 Mains module Mains interference suppressor, mains switch, auxiliary transformer, contactor.
Tig 2200i AC/DC Operating temperature --10 to + 40˚C Transportation temperature --25 to + 55˚C Constant sound pressure in open--circuit < 70 dB (A) Dimensions, l x b x h 418 x 188 x 345 mm Weight 15.7 kg Shielding gas All types intended for TIG welding max pressure 5 bar Insulation class transformer H Enclosure class Application class IP 23 *) The minimum current during AC welding depends on the alloy used for the aluminium plates and their surface cleanliness.
2QF1 Mains switch. 2XS1 Flat pin sockets. Important: to obtain a proper electric connection, the complete cord set must be replaced if the sockets have to be replaced. 10 TIG module. 10AP1 TIG board. 10TV1 HF transformer. 10YV1 Gas valve, 230 V AC. 15 Power module. 15AP1 Power board. 15AP2 Secondary board. 15C1 Smoothing capacitor, 2200 uF. 15D1 Diode module with rectifier and freewheel diodes. 15EV1 Fan. 15L1 Inductor. 15L2 PFC Inductor (Power Factor Corrector) 15RS1 Shunt.
Tig 2200i AC/DC ct33_00 -- 8 -- S0740 800 179/E071123/P64
ct33_00 -- 9 -- S0740 800 179/E071123/P64
DESCRIPTION OF OPERATION This description describes the function of circuit boards and other components in the power source. It is divided into sections, numbered to correspond to the circuit board numbers and divisions into function blocks. 1 MMC module The MMC module consists of an operator’s control panel and a display board. The control panel is used for setting and displaying welding data. The welding data are stored by the control board of the power source.
2AP1 Power supply board The power supply board filters the mains voltage and generates internal supply voltages for the machine. 2AP1:1 Interference suppressor circuit WARNING! Dangerous voltage - mains voltage. The mains voltage is filtered by the power supply board. Power board 15AP1 rectifies the mains voltage. TIG board 10AP1 uses the mains voltage for supply to the HF generator and the gas valve. 2AP1:2 Primary circuit WARNING! Dangerous voltage - mains voltage.
Transistor Q5 is the switching element in a switched voltage supply. The secondary voltage, +24 V, is sensed by IC2 and controlled by IC1. The isolation voltage of transformer T1 and optocoupler IC3 is 4 kV. +15V A Internal power supply to 2AP1 and power supply to the PFC circuits of the power board, 15AP1. The voltage is controlled by VR1, it has a tolerance of ±0.75V.
Early warning power shut down If the voltage goes low, output PS4 generates a warning signal to the processor on circuit board 20AP1 (see page 27). Transistor Q6 switches off the fan, 15EV1, at the same time. 2AP1 Component positions WARNING! Dangerous voltage - mains voltage.
10AP1 TIG board WARNING! Dangerous voltage - mains voltage. The relay contacts, the gas valve 10YV1, the HF generator TR2 and the primary side of transformer TR1 are connected to 230 V mains voltage. The processor on circuit board 20AP1 controls the HF generator and gas valve. HF generator When the welding torch switch is operated, and the open--circuit voltage is over 50 V, relay RE2 closes and turns on the HF generator, TR2. It remains activated until the arc strikes, or for a maximum of 0.7 seconds.
10AP1 Component positions WARNING! Dangerous voltage - mains voltage.
15AP1 Power board WARNING! Dangerous voltage - mains voltage. Never make any measurements on this board when the machine is connected to the mains supply. The power module is a single forward converter, operating at a switching frequency of 65 kHz. IGBT transistors are used as the switching elements. See pages 44 to 47 and 53 to 55 for measurement instructions. If the power board has failed, a replacement board must be mounted in accordance with the instructions on page 56.
Gate driver stages Transformer TR1 is a gate driver transformer for galvanic isolation of the drive circuits from controller board 20AP1. Switching circuit The switching transistors are integrated in the semiconductor module, PM1. Supply to 2AP1 The board supplies power supply board 2AP1 with 325 V DC (pins F1 and F3, connector 15XS1).
15AP1 Component positions Pin positions of the semiconductor module: (Seen from the component side of the board). Pin 1 marked P1 starts in the down--left corner and continuous anticlockwise around the semiconductor module.
15AP2 Secondary board The secondary board is fitted on the main transformer 15TM1, diode module 15D1 and inductor 15L1. Diode module 15D1 comprises two diodes, rectifier and freewheel diode. During the time interval between two voltage pulses from transformer 15TM1, the freewheel diode maintain the welding current from inductor 15L1. If the diode module has failed, a replacement module must be fitted in accordance with the instructions on page 56.
18AP1 AC control board Sections 18AP1:1 to 18AP1:6 refer to the wiring diagram on page 8. The processor on the AC control board monitors the temperature in the AC power modules. The AC control commands are generated by the processor on circuit board 20AP1 and executed by the local processor. Circuit board identity The AC control board has a machine ID, a hardware ID and a unit type number. To read this you need the ESAT service kit, see page 43.
18AP1:2 CAN bus Bus communication circuits The circuit board includes a driver for the CAN bus, IC17, which handles the communication with the other units of the system. Starting sequence On power--up, the board’s CAN controller reads the bus speed from the micro processor: 400 kbit/s. The light--emitting diodes D30, D31 and D32 displays the starting sequence from power--up: D30 lights red. Then D30, D31 and D32 lights green.
18AP1:3 Temperature monitoring Principle diagram of the temperature monitoring circuits The temperature monitoring circuit senses the temperature of the IGBT modules, IC1 and IC2, that are fitted to circuit board 18AP2. Two NTC resistors, NTC_IC1 and NTC_IC2, are used as sensors. The output of the monitoring circuit is sensed by the processor, which in turn stops the machine if overtemperature occurs. If the temperature exceeds 110 _C the power source is stopped.
18AP1:5 Fan power supply The fan is supplied at 24 V DC from the power supply board, 18AP1:6 Switch driver See also 18AP2:1 Switching circuits on page 25. The gate signals can be measured on circuit board 18AP2. See page 50 for test instructions.
18AP1 ct33_18 Component positions -- 24 -- S0740 800 179/E071123/P64
18AP2 AC power board Sections 18AP2:1 to 18AP2:3 refer to the wiring diagram on page 8. 18AP2:1 Switching circuits The circuit board carries two IGBT modules IC1 and IC2, with 2 IGBTs each. In the description below the IGBTs are named IGBT1, IGBT2, IGBT3 and IGBT4. The IGBTs are controlled by the processor. All IGBTs are conducting during the starting sequence of the power source (mains switch power on). MMA IGBT1 and IGBT4 are conducting.
18AP2:2 Temperature monitoring See 18AP1:3 on page 22. 18AP2:3 Fan power supply See 18AP1:5 on page 23.
20AP1 Control board The processor on the control board monitors and controls the various functions of the power source. The control board is used in combi mode. In combi mode the board handles the control of the power source, the welding data unit and the MMC panel. If the circuit board is faulty, it must be replaced. After replacing the circuit board, soft--start the machine. See the instructions on page 54.
The voltage on terminal PS4 is normally about 24 V, when this drops below 20 V, pin 14 of IC6 goes low, providing the processor with a low power supply voltage signal. The processor then stores current data and generates fault code E4. When the 5 and 2.5 V voltages are passing below their treshold values, the processor receives a reset signal from IC16. Fault code E4 is not displayed at normal power off +15V and +20V Voltage regulator VR2 produces an output voltage of +20 ±1.
20AP1:2 The CAN bus Bus communication circuits to and from the control board A standardised communication (CAN -- Controller Area Network) bus is used for communication between the units of the machine. Communication speed is 400 kbit/s. The +12V_CAN and 0V_CAN power supply is unregulated and is galvanically isolated from other parts of the control board. The shell of the CAN--connectors and the shield of the CAN cables are connected to 0V_CAN. GND in the diagram is connected to the power source chassis.
S All screen connections must be sound. Measure the resistance between the shell of the CAN connector connected to 20AP1 and the shell of CAN connector XP55 connected to 18AP1. There must be a short circuit between those two end points. S Good contact with the chassis connections from/to the circuit boards and suppressor capacitors. See the main circuit diagram. S The connection cable between units. Check that the correct type of cable is being used.
20AP1:5 Temperature monitoring The thermal overload switches, 15ST1 and 15ST2, are normally closed. Terminal T2 of the circuit board is at 0 V. 15ST2, which is fitted on the heat sink, opens at 75 _C. 15ST1, which is fitted in the winding of the main transformer, 15TM1, opens at 130 _C. If either of the switches operates, the power source is stopped, fault code E06 is displayed. The power source cannot be restarted until it has cooled sufficiently for the switch(es) to reclose.
20AP1:7 Arc voltage feedback This circuit measures and scales the arc voltage to a suitable level for the processor. 64 V arc voltage produces a voltage signal of 5.0 V at the cathode of diode D13. TIG The open--circuit voltage control is inactive in the TIG welding mode. The open--circuit voltage is about 110 V. Arc voltages below 45 V are defined as welding. Output voltage is produced only when TIG welding is in progress.
20AP1:9 Welding process control The processor inputs are the set values of welding data and the arc voltage. The processor also calculates a set value signal for welding current, and supplies this to the current control amplifier. The process regulator control principle Current Hot start MMA Peak current Adjustable starting current Set current 1 2 Starting current, MMA welding mode 1. Phase 1, fixed starting current depending on the set current. 2. Phase 2, hot start = adjustable starting current.
20AP1:10 Cooling unit control Starting the welding equipment 1. 2. 3. The welding data unit senses whether the water lock microswitch, 5S2, is closed or not. If it is closed, a command to start the pump is generated, and a relay in the cooler starts the pump and the fan. If welding does not start within 6.5 minutes, the pump is stopped. The pump is stopped if the water lock microswitch opens. Starting to weld 1. 2. 3. The welder presses the welding torch trigger switch.
20AP1 ct33_20 Component positions -- 35 -- S0740 800 179/E071123/P64
REMOTE CONTROLS A number of remote control units can be connected to the power source, these are described in a separate service manual with filename 0740 800 170. FAULT CODES Fault codes are used in order to indicate and identify a fault in the equipment. Fault log All faults that occur when using the welding equipment are documented as error messages in the fault log. When the fault log is full, the oldest message will automatically erase when the next fault occurs.
Description Code Welding data unit 20 High inductance in the welding circuit Power source Remote AC control unit unit x *22 Transmitter buffer overflow x x x *23 Receiver buffer overflow x x x *25 Lost contact with AC unit x *26 Program operating fault x *28 Stack overflow x x x *40 Incompatible units x Fault codes marked with an asterisk ( * ) are not displayed by the control panel. but they are stored in the fault log. To get access to the fault log use the ESAT service tool.
Code Description, power source 4 5 V power supply too low The unregulated power supply voltage (+24 V) is too low: the smoothing capacitors cannot keep the voltage up enough for the processor to continue to operate. The processor stops all normal activities, expecting to be shut down. Action: Turn off the mains power supply to reset the unit. If the fault persists, check the power supply to circuit board 20AP1. 6 High temperature The temperature monitoring circuit has operated.
AC unit Code Description, AC unit 1 EPROM check sum error -- program memory error Check sum test of the program memory, which is run only when initiating the unit after power--up. This fault does not disable any functions. The program memory is damaged. This is a serious fault, that can have unforeseen effects. Action: Restart the machine. If the fault persists, load new software via ESAT. If the fault still persists, replace circuit board 18AP1, which carries the memory chip.
Code Description, AC unit 12 Communication error (warning) The load on the system CAN bus is temporarily too high, or there is electric noise on the bus. Action: Check the equipment to ensure that only one remote control unit is connected. See also section 20AP1:3 ’The CAN bus’ on pages 29 to 30. 13 High temperature external The temperature monitoring circuit has operated. The power source is stopped, and cannot be restarted until the circuit has reset.
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SERVICE INSTRUCTIONS WARNING ! STATIC ELECTRICITY can damage circuit boards and electronic components. ESD S Observe precautions for handling electrostatic-sensitive devices. S Use proper static--proof bags and boxes. What is ESD? A sudden transfer or discharge of static electricity from one object to another. ESD stands for Electrostatic Discharge. How does ESD damage occur? ESD can cause damage to sensitive electrical components, but is not dangerous to people.
Antistatic service kit Ordering no. 0740 511 001 The kit makes it easier to protect sensitve components from electrostatic discharge. Contents: S A conductive mat (size 610 x 610 mm) S A 1.5 metre long ground cable with a crocodile clip S An adjustable wrist strap and cable with an inbuilt protective resistor Antistatic service kit ESAT service kit Ordering no. 0458 847 880 The software update is made from a PC, it has to be managed by a trained serviceman.
Checking the semiconductor module of 15AP1 Measuring points for the semiconductor module, PM1 Disconnect the machine from the mains and follow the instructions below. Measurements 2 -- 6: Use a multimeter in diode test position to measure the diodes. Measure with the positive and negative of the multimeter connected as shown in the picture above. The main transformer must be connected to terminals T1 and T2. 1. Resistor R31 (and thyristor TY1 in parallel): measure the resistance of R31.
5. PM1, diode D3: measure between the positive of capacitor 15C1 and terminal T2. The forward voltage drop must be 0.3 to 0.5 V. 6. PM1, diode D1: measure between the positive of capacitor 15C1 and terminal L2. The forward voltage drop must be 0.3 to 0.5 V. 7. PM1, transistor Q2: measure the resistance between source, the positive of capacitor 15C1, and gate, pin 19 of the module. The resistance must be higher than 500 kohm. 8.
emptypage0 -- 46 -- S0740 800 179/E071123/P64
Checking rectifier and freewheel diodes 1. Disconnect the machine from the mains. 2. Dismantle the housing of the machine. 3. Use a Torx key no. T25 to unscrew and remove five screws from circuit board 15AP2. The screws are marked on the picture below, 4. Bend out the circuit board so that it has no contact with the connections of the diode module. 5. Use a multimeter in diode test position to measure the forward voltage drop of the two diodes: see the picture below. The voltage drop must be 0.
Checking the IGBT modules of AC power board 18AP2 Disconnect the machine from the mains and follow the instructions below. The numbers of the instructions refer to the diagrams on this and next page. Before measuring: disconnect connector 18XS3 from terminal CN1 and the positive and negative voltage supply bars from the circuit board. 1. Use a multimeter in diode test position. Measure with the positive and negative of the multimeter connected as shown in the pictures.
Component positions AC power board 18AP2, measuring points IGBT modules ct33f3acpwr -- 49 -- S0740 800 179/E071123/P64
Checking the gate signals to AC power board 18AP2 The gate voltage is +15 V when the IGBTs are conducting. The gate voltage is --10 V when the IGBTs are open. Measure the gate voltage across varistors D4, D6, D12 and D16. Measuring points a and b in the diagram. 1. Switch on the machine 2. Select MMA mode and positive polarity. IGBT1 and IGBT4 must be conducting. 3. Select MMA mode and negative polarity. IGBT2 and IGBT3 must be conducting.
Component positions AC power board 18AP2, measuring points gate signals ct33f3acpwr -- 51 -- S0740 800 179/E071123/P64
emptypage -- 52 -- S0740 800 179/E071123/P64
Checking the gate pulses When checking the gate pulses, the machine can either be in soft--start mode or in normal operation mode. Special equipment To measure the gate pulses, you need a gate pulse load. This is included in soft--starting tool SST 1, which is described on page 42. Instructions 1. Disconnect the machine from the mains. 2. Disconnect connector 20XS5 from terminal G on control board 20AP1. 3. Connect the gate pulse test cable of the SST 1 to terminal G on control board 20AP1.
Soft starting We recommend soft starting of the machine after replacing control circuit board 20AP1, power supply board 2AP1 and circuit boards or components in the power module. Soft starting supplies the power module with a low voltage in order to avoid injury to persons or damage to components. It is a good idea to use soft starting when fault tracing. Special equipment To soft--start the machine you need soft--starting tool SST 1, this is described on page 42. Instructions 1.
8. Disconnect connector 15XS3 (supply to the fan) from terminal E of circuit board 2AP1. Connect the 24 V DC input of the SST 1 to terminal E of circuit board 2AP1. 9. Connect the 24 V DC output of the SST 1 to terminals N1 and N2 of power board 15AP1. Circuit connections and measuring points for soft starting 10. Switch on the machine and set it to MMA mode. 11. Check that the DC voltage across smoothing capacitor 15C1 is 22--24 V. 12.
Mounting components on the heat sink Thermal paste Apply thermal conducting paste to the components before fitting them to the heat sink. Start by cleaning the heat sink, and then apply a very thin, even layer of thermal paste to the contact surfaces of the components. The purpose of the paste is to fill out any hollows in the surfaces of the components and the heat sink. Those parts of the component and the heat sink that are in true metallic contact may already have good thermal contact.
15ST2 18AP2: IC1, IC2, Thermal overload switch 1. Clean the heat sink and apply thermal conducting paste to the thermal overload switch as described above. 2. Fit the thermal overload switch and tighten the screw to 2 Nm. AC power board with IGBT modules 1. Clean the heat sink and apply thermal conducting paste as described above. 2. Fit the power board with the two IGBT modules to the heat sink. 3. Tighten the screws, that secure the modules to the heat sink, to a torque of 2.
INSTRUCTIONS This chapter is an extract from the instruction manual for the Tig 2200i AC/DC. SAFETY CAUTION! Read and understand the instruction manual before installing or operating. INSTALLATION The installation must be executed by a professional. Lifting instructions Install the carrying strap as illustrated and lift the power source by the strap. Location Position the welding power source such that its cooling air inlets and outlets are not obstructed.
OPERATION Connections and control devices 1 2 3 4 5 Connection for remote control unit Control panel (see separate instruction manual) Connection for torch switch Connection for gas to the torch Connection for welding cable or torch 6 7 Connection for return cable Mains switch 8 9 Mains cable Connection for shielding gas Key to symbols MMA ct33i TIG Return clamp -- 59 -- S0740 800 179/E071123/P64
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 so that it is available next time the unit is started. MAINTENANCE Regular maintenance is important for safe, reliable operation.
Water cooler, assembly instructions 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.
FAULT--TRACING Try these recommended checks and inspections before sending for an authorised service technician. Type of fault No arc. Corrective action S S Check that the mains power supply switch is turned on. Check that the welding current supply and return cables are correctly connected. Check that the correct current value is set. Check the mains power supply. The welding current is interrupted during welding. S S Check to see whether the thermal cut--outs have tripped.
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