ESAB Caddy Mig C160i User manual

Valid for serial no. 924-xxx-xxxx0440 000 001GB 20120110

Caddy

Mig C160i

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 SAFETY 4...........................................................

2 INTRODUCTION 6...................................................

2.1 Equipment 6................................................................

3 TECHNICAL DATA 7.................................................

4 INSTALLATION 8....................................................

4.1 Lifting instruction 8..........................................................

4.2 Location 8..................................................................

4.3 Mains power supply 9........................................................

5 OPERATION 9.......................................................

5.1 Connection and control devices 10.............................................

5.2 Operation 11................................................................

5.3 Polarity change 11...........................................................

5.4 Wire feed pressure 12........................................................

5.5 Replacing and inserting wire 13................................................

5.5.1 Changing the feed roller groove 13.........................................

5.6 Shielding gas 13.............................................................

5.7 Overheating protection 13.....................................................

6 MAINTENANCE 14....................................................

6.1 Inspection and cleaning 14....................................................

6.2 Changing the wire liner 14.....................................................

7 FAULT TRACING 15..................................................

8 ORDERING OF SPARE PARTS 15......................................

DIAGRAM 16............................................................

ORDER NUMBER 17.....................................................

WEAR PARTS 18........................................................

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

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1 SAFETY

Users of ESAB 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 equipment. The following recommendations should be ob

served 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 equip

ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in

jury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding and cutting

2. The operator must ensure that:

Sno unauthorised person is stationed within the working area of the equipment when it is

started up.

Sno-one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from drafts

4. Personal safety equipment

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

clothing, safety gloves.

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

trapped or cause burns.

5. General precautions

SMake sure the return cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication 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 precautions when welding and

cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard

data.

ELECTRIC SHOCK - Can kill

SInstall and earth the unit in accordance with applicable standards.

SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

SKeep your head out of the fumes.

SUse 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.

SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect bystanders with suitable screens or curtains.

FIRE HAZARD

SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn bystanders of the risk.

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

PROTECT YOURSELF AND OTHERS!

WARNING

Do not use the power source for thawing frozen pipes.

CAUTION

This product is solely intended for arc welding.

CAUTION

Class A equipment is not intended for use in residential locations where

the electrical power is provided by the public low-voltage supply system.

There may be potential difficulties in ensuring electromagnetic

compatibility of class A equipment in those locations, due to conducted

as well as radiated disturbances.

CAUTION

Read and understand the instruction manual before

installing or operating.

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Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical and/or

electronic equipment that has reached the end of its life must be disposed of at a

recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain

information on approved collection stations.

For further information contact the nearest ESAB dealer.

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

2 INTRODUCTION

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

Mig C160i is a portable welding power source in a compact design, intended for

MIG/MAG welding.

It is possible to switch between welding with solid wire/shielding gas and welding

with selfshielded cored wire without gas.

The power source operates with wire diameters from ∅0.6 to ∅1.0 mm. Pure argon,

mixed gas or pure CO2may be used as shielding gases.

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

2.1 Equipment

The power source is supplied with:

SInstruction manual

SWelding gun MXL 180 (3m, fixed)

SReturn cable with clamp (3m, fixed)

SMains cable (3m, fixed, with plug)

SShoulder strap (see page 8)

SGas hose with quick connection (4.5m)

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3 TECHNICAL DATA

Power source Mig C160i

Mains voltage 230 V, 1∼50/60 Hz

Permissible load at

35 % duty cycle

60 % duty cycle

100 % duty cycle

150 A / 21.5 V

120 A / 20 V

100 A / 19 V

Setting range 30A / 15.5 V-160A / 22 V

Open circuit voltage 60 V

Open circuit power 15 W

Efficiency at maximum current 82%

Power factor at maximum current 0.99

Wire feed speed 2.0 - 11.0 m/min

Wire diameter

Cored wire

0.8 (0.6-1.0)

0.8-1.0

Max. diameter wire bobbin ∅200 mm

Continual sound pressure at no-load < 70 dB

Dimensions lxwxh 449 x 198 x 347 mm

Weight 12 kg

Operating temperature -10 to +40oC

Transportation temperature -20 to +55°C

Enclosure class IP 23C

Application classification

Welding torch MXL 180

Cooling Air/shielding gas

Permitted load at 20 % duty cycle

Carbon dioxideCO2

Mixed gas Ar/CO2

Self-shielded

200 A

180 A

120 A

Permitted load at 35 % duty cycle

Carbon dioxide CO2

Mixed gas Ar/CO2

Self-shielded

180 A

150 A

100 A

Recommended gas flow 8–15 l/min

Wire diameter 0.6 - 1.0 mm

Weight 1.32 kg

Length cable assembly 3.0 m

Standard control cable 2- pole

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at

a certain load without overloading. The duty cycle is valid for 40°C.

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Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP23C is designed for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

4 INSTALLATION

The installation must be carried out by a professional.

Note

Mains supply requirements

High power equipment may, due to the primary current drawn from the mains supply, influence the

power quality of the grid. Therefore connection restrictions or requirements regarding the

maximum permissible mains impedance or the required minimum supply capacity at the interface

point to the public grid may apply for some types of equipment (see technical data). In this case it

is the responsibility of the installer or user of the equipment to ensure, by consultation with the

distribution network operator if necessary, that the equipment may be connected.

4.1 Lifting instruction

The power source is lifted by the handle or by the shoulder strap, supplied with the

power source. The strap is fastened as shown in the picture below.

4.2 Location

Position the welding power source in such a way that its cooling air inlets and outlets

are not obstructed.

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4.3 Mains power supply

Check that the unit is connected to the correct mains power supply voltage, and that

it is protected by the correct fuse size. A protective earth connection must be made,

in accordance with regulations.

Rating plate with supply connection data

Recommended fuse sizes and minimum cable area

Mig C160i

Mains voltage 230 V ±15% 1∼ 50/60 Hz

Mains cable area 3G1.5 mm2

Phase current, Ieff 10 A

Fuse anti-surge 16 A

NOTE! The mains cable areas and fuse sizes as shown above are in accordance with Swedish

regulations. Use the power source in accordance with the relevant national regulations.

Extension cable

If needed, it is recommended to use an extension cable, 3x2.5 mm2,of a maximum

length of 50m.

Supply from power generators

The power source can be supplied from different types of generators. However,

some generators may not provide sufficient power for welding. The generators with

AVR, equivalent or better type of regulation with rated power 5.5...6.5 kW are

recommended to supply the power source within it's full capacity.

It is also possible to use generators with lower rated power, starting from 3.0kW, but

in that case the setting must be proportionally limited. The power source is protected

against undervoltage. If the power supplied by the generator is not sufficient, the

welding is interrupted. Especially the welding start could be disturbed. In case of

disturbed welding process, either adjust the welding parameters or change to a more

powerful generator.

5 OPERATION

General safety regulations for handling the equipment can be found on

page 4. Read through before you start using the equipment!

NOTE: When moving the equipment use intended handle. Never pull on the gun.

WARNING

Rotating parts can cause injury, take great care.

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WARNING

Assure that the side panels are closed during operation.

WARNING

Risk of crushing when replacing the wire bobbin!

Do not use safety gloves when inserting the welding wire between the feed rollers.

WARNING!

Lock the bobbin in order to prevent it from

sliding off the hub.

5.1 Connection and control devices

1Mains supply switch 6Knob for setting of material thickness

2Green indicating lamp, power supply ON 7Knob for arc correction

3Orange indicating lamp, overheating 8Connection for shielding gas

4Welding gun 9Mains cable

5Return cable

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