ESAB Caddy Mig C160i User manual

GB
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.......................................................

© ESAB AB 2011
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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
Fe
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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