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.......................................................

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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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© ESAB AB 2011
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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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© ESAB AB 2011
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5.2 Operation
The power source is not powered instantly when the mains switch (1) is turned on.
After approximately 2 seconds the green lamp (2) indicates that the power source is
ready.
If the welding gun trigger is pressed while the power source is being turned on, the
operation is disabled, until the trigger is released. This is also indicated by the
orange lamp (3).
The main knob (6) is scaled in mm and ga. The numbers point out recommended
thicknesses of the mild steel workpiece to be welded with 0.8 mm wire. This knob
simultaneously adjusts both the wire feed speed and the average output voltage.
The knob (7) sets the arc length correction or i.e. the voltage correction.
The return cable (5) must be reliably connected to the workpiece or to the welding
table.
The side panel covering the wire feeder must be closed prior to welding.
The power source is instantly switched with the mains switch (1).
5.3 Polarity change
+/- TERMINALS
The power source is delivered with the welding wire connected to the plus pole.
Some wires, e.g. shelfshielded cored wires, are recommended to be welded with
negative polarity. Negative polarity means that the wire is connected to the minus
pole and the return cable to the plus pole. Check the recommended polarity for the
welding wire you want to use.
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The polarity can be changed as follows:
1. Switch off the power source and disconnect the mains cable.
2. Open the side panel.
3. Bend the rubber covers back to give access to the +/- terminals.
4. Remove the nuts and washers. Note the correct order of the washers.
5. Change the position of the cables to the desired polarity (see marking).
6. Install the washers in correct order and tighten the nuts to spanner tightness.
7. Make sure the rubber covers are covering the +/- terminals.
5.4 Wire feed pressure
Start by making sure that the wire moves smoothly through the wire guide. Then
set the pressure of the wire feeder's pressure rollers. It is important that the
pressure is not too great.
Fig 1 Fig 2
To check that the feed pressure is set correctly, you can feed out the wire against
an insulated object, e.g. a piece of wood.
When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feed
rollers should slip.
If you hold the gun approx. 50 mm from the piece of wood, the wire should be
fed out and bend (fig. 2).
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5.5 Replacing and inserting wire
SOpen the side panel.
SPlace the spool on the hub and secure it with the lock.
SDisconnect the pressure arm by folding it sidewards, the pressure roller slides
away.
SStraighten out the new wire 10-20 cm. File away burrs and sharp edges from the
end of the wire before inserting it into the wire feeder.
SMake sure that the wire goes properly into the feed roller groove and into the
outlet nozzle and the wire liner.
SSecure the pressure arm.
SClose the side panel.
Feed the wire through the welding gun until it comes out through the nozzle. This
operation should be carried out carefully, as the wire is ready for welding and an
unintentional arc may occur. Keep the gun off conducting parts during feeding the
wire through and terminate wire feeding instantly when the wire comes out.
See Technical Data, chapter 3, for suitable wire dimensions for each wire type.
Use only ∅200mm spools. Note! ∅100mm/1kg spools are not applicable.
WARNING!
Do not keep the welding gun near the ears or the face during the wire feeding,
as this may result in personal injury.
5.5.1 Changing the feed roller groove
The power source is delivered with the feed roller set for ∅0.8/1.0mm welding wire. If
you want to use it for ∅0.6mm wire you must change groove in the feed roller.
1. Fold back the pressure arm to release the pressure roller.
2. Switch on the power source and press the gun trigger to position the feed roller
so that the locking screw is visible.
3. Switch off the power source.
4. Use a 2mm Allen key to open the locking screw about half a turn.
5. Pull the feed roller off the shaft and turn it around. See marking on the side of the
feed roller for suitable wire diameters.
6. Put the roller back on the shaft and make sure it goes all the way in. You may
need to turn the roller to position the locking screw over the flat surface of the
shaft.
7. Tighten the locking screw.
5.6 Shielding gas
A mixture of carbon dioxide and argon or pure carbon dioxide can be used as
shielding gases.
5.7 Overheating protection
Overheating is indicated by lamp (3). A thermal overload fuse protects the unit against
overheating by disabling the welding if overheating occurs. The fuse resets automati
cally when the unit has cooled.
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6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer attempts any
work to rectify any faults in the product during the guarantee period.
6.1 Inspection and cleaning
Power source
SCheck regularly that the power source is free from dirt.
SHow often and which cleaning methods apply depend on: the welding process,
arc times, placement, and the surrounding environment. It is normally sufficient
to blow the dust out of the power source with dry compressed air (reduced
pressure) once a year.
SClogged or blocked air inlets and outlets otherwise result in overheating.
Welding gun
SThe welding gun's wear parts should be cleaned and replaced at regular
intervals in order to achieve trouble-free wire feed. Blow the wire guide clean
regularly and clean the contact tip.
6.2 Changing the wire liner
A. Loosen the fixing screw and take the roller off the axle.
B. Loosen the adaptor nut, straighten the gun cable and remove the liner.
C. Insert the replacement liner into the straightened cable until it touches the contact
tip.
D. Lock the liner with adaptor nut. Cut excess of liner so it sticks 7mm out of the tip
adaptor.
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7 FAULT TRACING
Try these recommended checks and inspections before sending for an authorised
service technican.
Type of fault Actions
No arc SCheck that the mains power supply switch is turned on.
SCheck that the welding current supply and return cables are
correctly connected.
SCheck that correct current value is set.
Welding current is interrupted
during welding
SCheck whether the overheating protection has tripped.
(indicated by the orange lamp on the front).
SCheck the main power supply fuses.
The overheating protection
trips frequently
SCheck to see whether the air inlet or outlet are clogged.
SMake sure that you are not exceeding the rated data for the
power source (i.e. that the unit is not being overloaded).
Poor welding performance SCheck that the welding current supply and return cables are
correctly connected.
SCheck that the correct current value is set.
SCheck that the correct welding wires are being used.
SCheck the main power supply fuses.
SCheck if proper rollers are applied and if the pressure of the
wire feeder's pressure rollers is properly set.
8 ORDERING OF SPARE PARTS
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Mig C160i is designed and tested in accordance with the international and European
standards 60974-1, 60974-5 and 60974-10. It is the obligation of the service unit which
has carried out the service or repair work to make sure that the product still conforms
to the said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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© ESAB AB 2011
Diagram
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Mig C160i
© ESAB AB 2011
Order number
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Ordering no. Denomination Type Notes
0349 310 850 Welding power source Caddy®Mig C160i, CE (Europe) 230 V, 1∼50/60 Hz
0349 300 556 Spare parts list

Mig C160i
© ESAB AB 2011
Wear parts
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Item Denomination Ordering no. Notes
AGas nozzle
Gas nozzle/Tip insulator MXL
0700 200 054
0700 200 105
BContact tip
0700 200 063
0700 200 064
0700 200 065
0700 200 066
W 0.6 M6x25
W 0.8 M6x25
W 0.9 M6x25
W 1.0 M6x25
CNozzle spring 0700 200 078
DTip adaptor 0700 200 072
E
Wire liner
O-ring
0700 200 085
0700 200 087
0700 200 091
W 0.6-0.8 Steel for Fe and Ss wire
W 0.9-1.2 Steel for Fe and Ss wire
W 0.9-1.2 PTFE for Al and CuSi wire
O-ring 3.5/IDX 1.8 (3.5x1.8mm)
Black nitrile rubber
FFeed roller 0349 311 890 W 0.6/0.8-1.0 V-groove
GPressure roller 0349 312 062
HInlet nozzle 0455 049 002 W 0.6-1.0
The feed rollers are marked with wire dimension in mm and inch.

Mig C160i
© ESAB AB 2011
Accessories
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Trolley with gas shelf .....................
(incl. fixing kit for machine)
0459 366 887

www.esab.com
110915© ESAB AB
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: [phone]
Fax: [phone]
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: [phone]
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]
DENMARK
Aktieselskabet ESAB
Herlev
Tel: [phone]
Fax: [phone]
FINLAND
ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: [phone]
Fax: [phone]
GERMANY
ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]
ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]
HUNGARY
ESAB Kft
Budapest
Tel: [phone]
Fax: [phone]
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: [phone]
Fax: [phone]
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: [phone]
Fax: [phone]
NORWAY
AS ESAB
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Tel: [phone]
Fax: [phone]
POLAND
ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]
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Lisbon
Tel: [phone]
Fax: [phone]
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ESAB Romania Trading SRL
Bucharest
Tel: [phone]
Fax: [phone]
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LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]
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ESAB Slovakia s.r.o.
Bratislava
Tel: [phone]
Fax: [phone]
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: [phone]
Fax: [phone]
ESAB international AB
Gothenburg
Tel: [phone]
Fax: [phone]
SWITZERLAND
ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]
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ESAB Ukraine LLC
Kiev
Tel: [phone]
Fax: [phone]
North and South America
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CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]
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ESAB S.A.
Contagem-MG
Tel: [phone]
Fax: [phone]
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ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]
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ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]
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AUSTRALIA
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Archerfield BC QLD 4108
Tel: [phone]
Fax: [phone]
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Shanghai
Tel: [phone]
Fax: [phone]
INDIA
ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]
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Jakarta
Tel: [phone]
Fax: [phone]
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Tokyo
Tel: [phone]
Fax: [phone]
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ESAB (Malaysia) Snd Bhd
USJ
Tel: [phone]
Fax: [phone]
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Singapore
Tel: [phone]
Fax: [phone]
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Kyungnam
Tel: [phone]
Fax: [phone]
UNITED ARAB EMIRATES
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Dubai
Tel: [phone]
Fax: [phone]
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: [phone]
Fax: [phone]
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd
Durbanvill 7570 - Cape Town
Tel: [phone]
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com