ESAB Caddy Mig C200i User manual

Caddy®

Instruction manual

0440 001 001 GB 20200203 Valid for: serial no. 932-xxx-xxxx

Mig C200i

TABLE OF CONTENTS

0440 001 001 © ESAB AB 2020

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

1.1 Meaning of symbols ............................................................................... 4

1.2 Safety precautions ................................................................................. 4

2INTRODUCTION.......................................................................................... 7

2.1 Equipment ............................................................................................... 7

3TECHNICAL DATA ...................................................................................... 8

4INSTALLATION............................................................................................ 10

4.1 Lifting instruction ................................................................................... 10

4.2 Location................................................................................................... 10

4.3 Mains power supply ............................................................................... 10

5OPERATION ................................................................................................ 12

5.1 Connection and control devices ........................................................... 13

5.2 Operation................................................................................................. 13

5.2.1 Manual mode........................................................................................ 14

5.2.2 QSet mode ........................................................................................... 14

5.2.3 Unit of measurement ............................................................................ 15

5.3 Error codes ............................................................................................. 15

5.4 Inductance settings (Fe/SS) .................................................................. 16

5.5 Polarity change....................................................................................... 16

5.6 Wire feed pressure ................................................................................. 17

5.7 Replacing and inserting wire................................................................. 17

5.7.1 Changing the feed roller groove ........................................................... 18

5.8 Shielding gas .......................................................................................... 18

5.9 Overheating protection .......................................................................... 18

6MAINTENANCE........................................................................................... 19

6.1 Inspection and cleaning......................................................................... 19

6.2 Changing the wire liner.......................................................................... 19

7TROUBLESHOOTING ................................................................................. 20

8ORDERING SPARE PARTS ........................................................................ 21

DIAGRAM ............................................................................................................ 22

ORDERING NUMBERS....................................................................................... 23

WEAR PARTS...................................................................................................... 24

ACCESSORIES ................................................................................................... 25

Rights reserved to alter specifications without notice.

1 SAFETY

0440 001 001 -4- © ESAB AB 2020

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!

Means potential hazards which could result in personal injury or loss of life.

CAUTION!

Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer´s safety practices and

Safety Data Sheets (SDSs).

1.2 Safety precautions

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 observed in addition to the standard regulations that apply to

the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations which can

result in injury to the operator and damage to the equipment.

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

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

1 SAFETY

0440 001 001 -5- © ESAB AB 2020

4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions

when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or

wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding.

EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to

EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your

body between the torch and work cables. Never coil the torch or work

cable around your body. Keep welding power source and cables as

far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases

away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens

and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY

0440 001 001 -6- © ESAB AB 2020

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only

qualified people remove covers for maintenance and troubleshooting as

necessary. Reinstall panels or covers and close doors when service is

finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable

materials nearby.

• Do not use on closed containers.

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

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

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.

NOTE!

Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/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 has an assortment of welding accessories and personal protection equipment

for purchase. For ordering information contact your local ESAB dealer or visit us on

our website.

2 INTRODUCTION

0440 001 001 -7- © ESAB AB 2020

2 INTRODUCTION

Mig C200i 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 Ø0.6 to Ø1.0 mm. Pure argon, mixed

gas or pure C02may be used as shielding gases.

2.1 Equipment

The power source is supplied with:

• Instruction manual

•Welding torch MXLTM 180 (3 m, fixed)

• Return cable with clamp (3 m, fixed)

• Mains cable (3 m, fixed, with plug)

• Shoulder strap (see "Lifting instruction" section in "INSTALLATION" chapter).

• Gas hose with quick connection (4.5 m)

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of

this manual.

3 TECHNICAL DATA

0440 001 001 -8- © ESAB AB 2020

3 TECHNICAL DATA

Mig C200i

Mains voltage 230 V, 1 ~ 50/60 Hz

Permissible load at:

25 % duty cycle 180 A

60 % duty cycle 120 A

100 % duty cycle 100 A

Setting range 30 A - 200 A

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 - 12.0 m/min

Wire diameter:

Fe Ø 0.6 - 1.0

Cored wire Ø 0.8 - 1.0

Ss Ø 0.8 - 1.0

Al Ø 1.0

Max. diameter wire bobbin Ø200 mm

Continual sound pressure at no-load < 70 db

Dimensions l × w × h 449 × 198 × 347 mm

Weight 12 kg

Operating temperature -10 to +40°C

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 dioxide C02200 A

Mixed gas Ar/C02180 A

Self-shielded 120 A

Permitted load at 35 % duty cycle:

Carbon dioxide C02180 A

Mixed gas Ar/C02150 A

Self-shielded 100 A

Recommended gas flow 8 - 15 I/min

Wire diameter 0.6 - 1.0 mm

Weight 1.32 kg

3 TECHNICAL DATA

0440 001 001 -9- © ESAB AB 2020

Welding torch MXL 180

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/104°F, or below.

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 intended 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

0440 001 001 - 10 - © ESAB AB 2020

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" chapter). 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 such a way that its cooling air inlets and outlets are not

obstructed.

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.

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