Caddy® Mig C160i and Demo handbook d C200i

Caddy® Mig C160i and Demo handbook d C200i
Caddy® Mig C160i and
d C200i
Demo handbook
XA00150720
CONTENTS
How to make a successful demo
Caddy® Mig C160i preparations
Welding with gasless wire
Welding mild steel with gas
Caddy® Mig C200i preparations
g with g
gasless wire
Welding
Showing QSet™
es
QSet™ with different thicknesse
QSet™ with different gases
QSet™ and arc stability
QSet™ for thick mild steel
Brazing with QSet™
Aluminium welding with QSet™
Caddy® Mig with generator
2
3
4
5
6
8
9
10
11
12
13
14
15
16
How to make a successful de
emonstration!
The Caddy® Mig C160i and C200i are very easy to use MIG/MAG welding units with one knob
settings.
Caddy® Mig C160i has a built in synergic line
e for mild steel when using a Ø0,8
Ø0 8 mm wire
wire. With
one knob you can set/change the welding data
a for different material thicknesses.
Caddy® Mig C200i has ESAB’s intelligent QSet™ function. This function automatically sets
the best welding parameters for the arc and ke
eeps the same arc length independent of the
stick-out, resulting in higher quality and making life easier for the welder.
Caddy® Mig works excellent with CO2 which iss more economical.
Seeing is believing!
The best way for you to sell these machine
es is to show the respective automatic setting
function in action and letting the customerrs try it themselves.
This demonstration handbook will guide you in
n what to do, and how to do it, to make a good
®
and professional demonstration of the Caddy Mig C160i and C200i.
It describes some ideal applications for you to demonstrate the versatility of the machines.
As always, be sure to avoid breathiing in the dangerous welding fumes
by using smoke exhausts and personal
p
protection equipment.
2
Preparation list for Caddy
y®
Mig C160i demonstration:
How to start and use the unit can be re
ead in
®
the Caddy Mig C160i instruction manual. If
you do not have one, please download
d from
www.esab.com.
b
How to get started - prepara
ations
Prepare mild steel test plates:
• Thicknesses : 1, 2, 3 and 4 mm
• Size, approx: 60 x 200 mm
Get the consumables:
• A spool of ESAB Coreshield 15,
15 Ø0.8mm
0 8mm wire on spool with inner
diameter 51mm, external diameterr 200mm and width 55mm. Item number
35UE084630.
• A spool of OK Autrod 12.51 Ø0.8m
mm wire, on the same spool as specified
above. Item number 1251084600. (1kg wire is included with each unit.)
Get additional contact tips for Ø0.8
8mm wire, item number 0700200064.
Get Gas: CO2 and Mixed gas (e.g. 82%
8
Ar/18% CO2).
Check status of liner: Steel liner forr Ø0.8mm mild and stainless steel wire,
item number 0700200085 (include
ed as standard).
standard)
liner (inside)
contact tip
Check rollers: Make sure the correc
ct groove is selected for Ø0,8mm wire
(see marking on side of feed roller). Replace roller if worn out.
Feed roller (with groove): 034931189
90 Pressure roller: 0349312062
90.
3
Caddy® Mig C160i welding mild steel with gasless wire
Overlap or fillet joint - Mild steel
Wire: ESAB Coreshield 15, cored wire Ø0
0.8mm.
Change polarity: Return lead on plus and
d MIG torch on minus.
G
Gas:
N gas
No
Test plates: 2.0mm
Plate thickness setting: Set knob to app
prox. 2/3 of the 2.0mm area.
Heat adjustment
j
knob: Set to middle p
pos
sition.
Start to weld
For more or less penetration - change
heat adjustment knob setting.
For different material thicknesses change plate thickness setting knob.
Coreshield 15, gasless cored wire – a wiire that builds a slag protection - needs
no gas to weld a large variety of mild ste
eels.
4
Caddy® Mig C160i welding mild steel with gas
Overlap or fillet joint - Mild steel
Wire: Use the ESAB OK Autrod 12.51 Ø0
0.8mm wire.
Normal polarity: Return lead on minus an
nd MIG torch on plus.
Gas: CO2 or Mixed gas (e
(e.g.
g 82%Ar/18%C
CO2).
)
Caddy® Mig works superbly with CO
O2.
Test plates: 1, 2 , 3 or 4 mm.
Plate thickness setting: Set knob to the plate thickness you plan to weld.
Heat adjustment knob: Set to middle possition
sition.
Start to weld
For more or less penetration - change
heat adjustment knob setting.
For different material thicknesses change plate thickness setting knob.
ESAB OK Autrod 12.51 wire – A high qua
ality copper coated wire for excellent mild
steel results in general construction.
5
Preparation list for Caddy
y®
Mig C200i demonstration:
How to start and use the unit can be re
ead in
®
the Caddy Mig C200i instruction manual. If
you do not have one, please download
d from
www.esab.com.
How to get started - prepara
ations
Prepare test plates:
• Thicknesses: 1,
1 2,
2 4 and 6mm steel plates,
plates 1mm galvanized 7μm car plate
and 1.5mm aluminium plate.
• Suitable plate size approx: 60 X 200
0mm.
Use ESAB consumables on spool with
w inner diameter 51mm, external
diameter 200mm and width 55mm:
• Coreshield 15, for mild steel, Ø0.8m
mm, 4,5kg. Item number: 35UE084630
• OK Autrod 12.51, for mild steel, Ø0.8mm, 5kg. Item number: 1251084600
• OK Autrod 19.30, for brazing, Ø0.8m
mm, 5kg. Item number: 1930084600
• OK Autrod 5183, for aluminium, Ø1..0mm, 2kg. Item number: 1816104620
Use correct liners:
• Steel liner for Ø0.6-0.8mm mild stee
el and stainless steel wire, item number:
0700200085
• Steel liner for Ø0.9-1.2mm mild stee
el and stainless steel wire, item number:
0700200087
• PTFE liner for Ø0.9-1.2mm aluminiu
um and brazing wire, item number:
0700200091
Use correct contact tips:
• For Ø0.8mm wire, item number 070
00200064
• For Ø1.0mm wire, item number 070
00200066
liner (inside)
contact tip
6
Preparation list for Cadd
dy® Mig C200i demo:
Check rollers: Make sure the correcct groove is selected for the wire you
are using (see marking on side of fee
ed roller). Replace roller if worn out.
Feed roller (with groove): 034931189
90. Pressure roller: 0349312062.
Gas:
• Mild and low alloy steels – use mixture of argon and fairly high
quantities of carbon dioxide (e.g. 82
2/18) or use pure carbon dioxide,
(which is cheaper than argon mixtu
ures but speed is lower and
considerably more fumes and spattter). No gas is needed with
Coreshield 15.
• High alloyed and Stainless steels – use a mixture of Argon with very
small percentage (1-2%) of carbon dioxide or oxygen.
• Mig brazing – use 100% Argon or Argon
A
with small amounts of active
gas, for ex. 1% Oxygen or 1-3% CO
O2.
• Aluminium – use 100% Argon.
7
Using the Caddy® Mig C200
0i with gasless wire
Overlap or fillet joint - Mild
M steel
Wire: ESAB Coreshield 15, cored wire Ø0.8mm.
Change polarity: Return lead on plus and MIG torch on minus.
Gas: No gas.
gas
Plate: 2mm.
Set to manual mode
Wire feed speed: 7m/min (= 120A)
Voltage: 18V
Start welding
QSet™ mode is not suitable for this wirre
Coreshield 15, gasless cored wire – a wiire that builds a slag protection - needs no
gas to weld a large variety of mild steels.
8
Showing QSet™
QSet
Caddy® Mig C200i welding mild
m steel
Overlap joint - Mild steel, Ø0.8mm wire
Wire: ESAB OK Autrod 12.51, Ø0.8mm
m.
Normal polarity: Return lead on minus
s and MIG torch on plus.
Gas: CO2 or Mixed gas (e.g.
(e g 82/18)
82/18).
Plate: 2.0mm.
Start with manual mode and ask the customer
c
to
try and find a good setting when you weld.
Start welding
Then show automatic setting with QSet™:
Q
Destroy the former setting by turning th
he voltage up by 5-10V.
Start welding and show the poor res
sult
Select QSet™ mode
• Check that material choice is set on Fe/Ss
F
• Turn plate thickness knob to 2.0mm
• Set
S t QSet™
QS t™ value
l tto 0
Start welding – and show that QSet™ is adjusting the settings
automatically.
Change
g Q
QSet™ value to adjust
j
heat inp
put to show the different results in
penetration.
ESAB OK Autrod 12.51 wire – A high qua
ality copper coated wire for excellent mild
steel results in general construction.
9
QSet working with different plate thicknesses
QSet™
Caddy® Mig C200i welding mild steel
1. Fillet joint - Mild stee
el, 1.0mm plate
Wire: ESAB OK Autrod 12.51, Ø0.8mm
m.
Normal polarity: Return lead on minus
s and MIG torch on plus.
Gas: 82% Argon / 18% CO2
Plate: Mild Steel, 1.0mm.
Set to QSet™ mode
m (4m/min).
Plate thickness setting (WFS): 1.0mm
QSet™ value: 0
2 Fill
2.
Fillet jjoint
i - Mild stee
el,
l 2
2.0mm
0
plate
l
Wire: ESAB OK Autrod 12.51, Ø0.8mm
m.
Normal polarity: Return lead on minus
s and MIG torch on plus.
Gas: 82% Argon / 18% CO2
Plate: Mild Steel, 2.0mm.
Set to QSet™ mode
m (6.8m/min).
Plate thickness setting (WFS): 2.0mm
QSet™ value: 0
This demo shows how easy it is
to weld different plate thicknesses
with QSet.™ - Just change the
plate thickness setting.
ESAB OK Autrod 12.51 wire – A high qua
ality copper coated wire for excellent mild
steel results in general construction.
10
QSet working with different gases
QSet™
Caddy® Mig C200i welding mild steel
1. Fillet joint - Mild stee
el, Mixed gas
Wire: ESAB OK Autrod 12.51, Ø0.8mm
m.
Normal polarity: Return lead on minus
s and MIG torch on plus.
Gas: 82% Argon / 18% CO2
Plate: Mild Steel, 2.0mm.
Set to QSet™ mode
Plate thickness setting (WFS): 2.0mm
m (6.8m/min).
QSet™ value: 0
2 Fill
2.
Fillett jjoint
i t - Mild stee
t el,
l CO2
Wire: ESAB OK Autrod 12.51, Ø0.8mm
m
Normal polarity: Return lead on minus
s and MIG torch on plus.
Gas: CO2
Plate: Mild Steel, 2.0mm.
Set to QSet™ mode
m (6.8m/min).
Plate thickness setting (WFS): 2.0mm
QSet™ value: 0
This demo shows that QSet™
automatically adjusts the settings
for different gases.
ESAB OK Autrod 12.51 wire – A high qua
ality copper coated wire for excellent mild
steel results in general construction.
11
Q
QSet™
showing
g excellent arc
a stability
y
Caddy® Mig C200i welding mild
m steel
Butt joint - Mild steel, 2.0mm
2
plate
Wire: ESAB OK Autrod 12.51, Ø0.8mm.
Normal polarity: Return lead on minus and MIG torch on plus.
Gas: 82% Argon / 18% CO2
Plate: Mild Steel, 2.0mm.
Set to QSet™ mode
m (6.3m/min).
Plate thickness setting (WFS): 2.0mm
QSet™ value: 0
This demo shows that QSet™
gives excellent arc stability
stability.
ESAB OK Autrod 12.51 wire – A high qua
ality copper coated wire for excellent mild
steel results in general construction.
12
Caddy® Mig C200i welding thick mild steel
Fillet joint - Mild steel, 4.0mm
4
plate
Wire: ESAB OK Autrod 12.51, Ø0.8mm.
Normal polarity: Return lead on minus and MIG torch on plus.
Gas: 82% Argon / 18% CO2
Plate: Mild Steel, 4.0mm.
Set to QSet
QSet™ mode
Plate thickness setting (WFS): 4.0mm
m (9.8m/min).
QSet™ value: 0
Fillet joint - Mild steel, 6.0mm
6
plate
Wire: ESAB OK Autrod 12.51, Ø0.8mm.
Normal polarity: Return lead on minus and MIG torch on plus.
Gas: 82% Argon / 18% CO2
Plate: Mild Steel, 6.0mm.
Set to QSet
QSet™ mode
Plate thickness setting (WFS): 6.0mm
m (12m/min).
QSet™ value: 0
This demo shows the power of
this small machine and the ability
to weld thick plates.
ESAB OK Autrod 12.51 wire – A high qua
ality copper coated wire for excellent mild
steel results in general construction.
13
QSet™
QS
t™ for
f easy brazing
b i
Caddy® Mig C200i brazing galvanized
g
steel
Overlap joint - Galvanizzed plate (7μm car body)
Wire: ESAB OK Autrod 19.30, Ø0.8mm
m.
Normal polarity: Return lead on minus
s and MIG torch on plus.
Gas: Argon + 1% O2 (or pure Argon).
Plate: Galvanized steel, 1.0mm.
Set to QSet™ mode
m (5.2m/min)
Plate thickness setting (WFS): 1.0mm
QSet™ value: 0
With one knob control and QSet™ you can
easily find the optimal setting to braze
without destroying the galvanized surface.
ESAB OK Autrod 19.30 for MIG/MAG brazing
b
OK Autrod 19.30 is alloyed
y with silicon and manganese
g
and has g
good flow
properties and wear resistance. The alloy is widely used in the joining of zinccoated steel sheets in car body productio
on.
14
Caddy® Mig C200i welding Aluminium
A
with QSet™
Overlap joint - Aluminiu
um, 1.5mm plate
Wire: ESAB OK Autrod 5183, Ø1.0mm
m.
Normal polarity: Return lead on minus
s and MIG torch on plus.
Gas: Pure Argon.
Plate: Aluminium, 1.5mm.
Set to QSet™ mode
m (8.5m/min).
Plate thickness setting (WFS): 1.5mm
QSet™ value: 0
ESAB OK Autrod 5183 for aluminium welding
A wire for marine and structural applications.
15
Caddy® Mig C160i and C200i running off a generator
Welding at full power off an automatic voltage
v
regulated (or inverter) generator
requires at least 5,5 kVA. The largerr the generator the better the starts (poor
starts if power is too low). Weld with limited capacity if using smaller generator.
Normally you would demand a generato
or kVA rating that is twice the power needed
in the welding unit. Thanks to PFC we
w can use generator power very close to
the calculated power.
Some basic rules
• Do not have the welding unit connec
cted when switching the generator on or off.
• Do not have the welding unit connec
cted when the generator gives lower voltage
than 230V plus/minus 15% (e.g. at lo
ow rpm’s).
Recommended generators (that we have
h
tested Caddy® Mig with):
•Honda EM65iS: max. 6,5kW inverter ty
ype, 95kg
(priced at approximately 3700 €).
€)
Result: Excellent weld starts and overalll performance.
•Honda EM5500CX: max. 5,5kW AVR, 88kg
8
(approx 1900 €).
(approx.
€)
Result: At high settings, starts are slighttly worse than with the
unit above, especially when welding witth CO2.
•Honda EM30: 2,6kW/3,0kVA cycloconv
verter, 31kg
(
(approx.
1600€)
1600€).
o
– max. 110A.
Result: Works only for limited welding output
16
For your own notes:
Weldiing positions
Material _______________
_
Position ________
Consumable: ________
thickness_____ mm
____mm
mm diameter
_____________
Gas: _________________
Plate thickness setting ___
___mm
QSet™ value_____
Wire feed speed _____m/m
min ____A Voltage ____V
Material _______________
_
Position ________
C
Consumable:
bl ________
thickness_____ mm
____mm diameter
di
t
_____________
Gas: _________________
Plate thickness setting ___
___mm
QSet™ value_____
Wire feed speed
p
_____m/m
min ____A Voltage
g ____V
17
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising