Caddy Mig C160i and. C200i Demo handbook XA

Transcription

1 Caddy Mig C160i and C200i Demo handbook XA

2 CONTENTS How to make a successful demo Caddy Mig C160i preparations Welding with gasless wire Welding mild steel with gas Caddy Mig C200i preparations 6 Welding with gasless wire 8 Showing QSet 9 QSet with different thicknesses 10 QSet with different gases 11 QSet and arc stability 12 QSet for thick mild steel 13 Brazing with QSet 14 Aluminium welding with QSet 15 Caddy Mig with generator 16 How to make a successful demonstration! 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 for mild steel when using a Ø0,8 mm wire. With one knob you can set/change the welding dataa 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 keeps 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 CO 2 which is more economical. Seeing is believing! The best way for you to sell these machines is to show the respective automatic setting function in action and letting the customers try it themselves. This demonstration handbook will guide you in 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 breathing in the dangerous welding fumes by using smoke exhausts and personal protection equipment. 2

3 Preparation list for Caddy Mig C160i demonstration: y How to start and use the unit can be read in the Caddy Mig C160i instruction manual. If you do not have one, please downloadd from How to get started - preparations 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, Ø 0.8mm wire on spool with inner diameter 51mm, external diameter 200mm and width 55mm. Item number 35UE A spool of OK Autrod Ø0.8mm wire, on the same spool as specified above. Item number (1kg wire is included with each unit.) Get additional contact tips for Ø0.8mm wire, item number Get Gas: CO 2 and Mixed gas (e.g. 82% Ar/18% CO 2 ). Check status of liner: Steel liner for Ø0.8mm mild and stainless steel wire, item number (include ed as standard). liner (inside) contact tip Check rollers: Make sure the correct groove is selected for Ø0,8mm wire (see marking on side of feed roller). Replace roller if worn out. Feed roller (with groove): Pressure roller:

4 Caddy Mig C160i welding mild steel with gasless wire Overlap or fillet joint - M ild steel Wire: ESAB Coreshield 15, cored wire Ø0.8mm. Change polarity: Return lead on plus and MIG torch on minus. Gas: No gas Test plates: 2.0mm Plate thickness setting: Set knob to approx. 2/3 of the 2.0mm area. Heat adjustment knob: Set to middle position. 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 wire that builds a slag protection - needs no gas to weld a large variety of mild steels. 4

5 Caddy Mig C160i welding mild steel with gas Overlap or fillet joint - M ild steel Wire: Use the ESAB OK Autrod Ø0.8mm wire. Normal polarity: Return lead on minus and MIG torch on plus. Gas: CO 2 or Mixed gas (e.g. 82%Ar/18%C CO 2 ). Caddy Mig works superbly with CO 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 pos sition. Start to weld O 2. For more or less penetration - change heat adjustment knob setting. For different material thicknesses - change plate thickness setting knob. ESAB OK Autrod wire A high quality copper coated wire for excellent mild steel results in general construction. 5

6 Preparation list for Caddy Mig C200i demonstration: y How to start and use the unit can be read in the Caddy Mig C200i instruction manual. If you do not have one, please downloadd from How to get started - preparations Prepare test plates: Thicknesses: 1, 2, 4 and 6mm steel plates, 1mm galvanized 7μm car plate and 1.5mm aluminium plate. Suitable plate size approx: 60 X 200mm. Use ESAB consumables on spool with inner diameter 51mm, external diameter 200mm and width 55mm: Coreshield 15, for mild steel, Ø0.8mm, 4,5kg. Item number: 35UE OK Autrod 12.51, for mild steel, Ø0. 8mm, 5kg. Item number: OK Autrod 19.30, for brazing, Ø0.8mm, 5kg. Item number: OK Autrod 5183, for aluminium, Ø1..0mm, 2kg. Item number: Use correct liners: Steel liner for Ø mm mild steel and stainless steel wire, item number: Steel liner for Ø mm mild steel and stainless steel wire, item number: PTFE liner for Ø mm aluminium and brazing wire, item number: Use correct contact tips: For Ø0.8mm wire, item number For Ø1.0mm wire, item number liner (inside) contact tip 6

7 Preparation list for Cadd dy Mig C200i demo: Check rollers: Make sure the correc ct groove is selected for the wire you are using (see marking on side of feed roller). Replace roller if worn out. Feed roller (with groove): Pressure roller: Gas: Mild and low alloy steels use mixture of argon and fairly high quantities of carbon dioxide (e.g. 82/18) or use pure carbon dioxide, (which is cheaper than argon mixtures but speed is lower and considerably more fumes and spatter). 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 with small amounts of active gas, for ex. 1% Oxygen or 1-3% CO 2. Aluminium use 100% Argon. 7

8 Using the Caddy Mig C200i with gasless wire Overlap or fillet joint - Mild steel Wire: ESAB Coreshield 15, cored wire Ø0.8mm. Change polarity: Return lead on plus and MIG torch on minus. Gas: No gas. Plate: 2mm. Set to manual mode Wire feed speed: 7m/min (= 120A) Voltage: 18V Start welding QSet mode is not suitable for this wire Coreshield 15, gasless cored wire a wire that builds a slag protection - needs no gas to weld a large variety of mild steels. 8

9 Showing QSet Caddy Mig C200i welding mild steel Overlap joint - Mild steel, Ø0.8mm wire Wire: ESAB OK Autrod 12.51, Ø0.8mm. Normal polarity: Return lead on minus and MIG torch on plus. Gas: CO 2 or Mixed gas (e.g. 82/18). Plate: 2.0mm. Start with manual mode and ask the customer to try and find a good setting when you weld. Start welding Then show automatic setting with QSet : Destroy the former setting by turning the voltage up by 5-10V. Start welding and show the poor result Select QSet mode Check that material choice is set on Fe/Ss Turn plate thickness knob to 2.0mm Set QSet value to 0 Start welding and show that QSet is adjusting the settings automatically. Change QSet value to adjust heat input to show the different results in penetration. ESAB OK Autrod wire A high quality copper coated wire for excellent mild steel results in general construction. 9

10 QSet working with differe nt plate thicknesses Caddy Mig C200i welding mild steel 1. Fillet joint - Mild steel, 1.0mm plate Wire: ESAB OK Autrod 12.51, Ø0.8mm. Normal polarity: Return lead on minus and MIG torch on plus. Gas: 82% Argon / 18% CO 2 Plate: Mild Steel, 1.0mm. Plate thickness setting (WFS): 1.0mmm (4m/min). 2. Fillet joint - Mild steel, 2.0mm plate Wire: ESAB OK Autrod 12.51, Ø0.8mm. Normal polarity: Return lead on minus and MIG torch on plus. Gas: 82% Argon / 18% CO 2 Plate: Mild Steel, 2.0mm. Plate thickness setting (WFS): 2.0mmm (6.8m/min). This demo shows how easy it is to weld different plate thicknesses with QSet. - Just change the plate thickness setting. ESAB OK Autrod wire A high quality copper coated wire for excellent mild steel results in general construction. 10

11 QSet working with differe nt gases Caddy Mig C200i welding mild steel 1. Fillet joint - Mild steel, Mixed gas Wire: ESAB OK Autrod 12.51, Ø0.8mm. Normal polarity: Return lead on minus and MIG torch on plus. Gas: 82% Argon / 18% CO 2 Plate: Mild Steel, 2.0mm. Plate thickness setting (WFS): 2.0mmm (6.8m/min). 2. Fillet joint - Mild stee el, CO 2 Wire: ESAB OK Autrod 12.51, Ø0.8mmm Normal polarity: Return lead on minus and MIG torch on plus. Gas: CO 2 Plate: Mild Steel, 2.0mm. Plate thickness setting (WFS): 2.0mmm (6.8m/min). This demo shows that QSet automatically adjusts the settings for different gases. ESAB OK Autrod wire A high quality copper coated wire for excellent mild steel results in general construction. 11

12 QSet showing excellent arc stability Caddy Mig C200i welding mild steel Butt joint - Mild steel, 2.0mm plate Wire: ESAB OK Autrod 12.51, Ø0.8mm. Normal polarity: Return lead on minus and MIG torch on plus. Gas: 82% Argon / 18% CO 2 Plate: Mild Steel, 2.0mm. Plate thickness setting (WFS): 2.0mmm (6.3m/min). This demo shows that QSet gives excellent arc stability. ESAB OK Autrod wire A high quality copper coated wire for excellent mild steel results in general construction. 12

13 Caddy Mig C200i welding thick mild steel Fillet joint - Mild steel, 4.0mm plate Wire: ESAB OK Autrod 12.51, Ø0.8mm. Normal polarity: Return lead on minus and MIG torch on plus. Gas: 82% Argon / 18% CO 2 Plate: Mild Steel, 4.0mm. Plate thickness setting (WFS): 4.0mmm (9.8m/min). Fillet joint - Mild steel, 6.0mm plate Wire: ESAB OK Autrod 12.51, Ø0.8mm. Normal polarity: Return lead on minus and MIG torch on plus. Gas: 82% Argon / 18% CO 2 Plate: Mild Steel, 6.0mm. Plate thickness setting (WFS): 6.0mmm (12m/min). This demo shows the power of this small machine and the ability to weld thick plates. ESAB OK Autrod wire A high quality copper coated wire for excellent mild steel results in general construction. 13

14 QSet for easy brazing Caddy Mig C200i brazing galvanized steel Overlap joint - Galvanized plate (7μm car body) Wire: ESAB OK Autrod 19.30, Ø0.8mm. Normal polarity: Return lead on minus and MIG torch on plus. Gas: Argon + 1% O 2 (or pure Argon). Plate: Galvanized steel, 1.0mm. Plate thickness setting (WFS): 1.0mmm (5.2m/min) With one knob control and QSet you can easily find the optimal setting to braze without destroying the galvanized surface. ESAB OK Autrod for MIG/MAG brazing OK Autrod is alloyed with silicon and manganese and has good flow properties and wear resistance. The alloy is widely used in the joining of zinc- coated steel sheets in car body production. 14

15 Caddy Mig C200i welding Aluminium with QSet Overlap joint - Aluminium, 1.5mm plate Wire: ESAB OK Autrod 5183, Ø1.0mm. Normal polarity: Return lead on minus and MIG torch on plus. Gas: Pure Argon. Plate: Aluminium, 1.5mm. Plate thickness setting (WFS): 1.5mmm (8.5m/min). ESAB OK Autrod 5183 for aluminium welding A wire for marine and structural applications. 15

16 Caddy Mig C160i and C200i running off a generator Welding at full power off an automatic voltage 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 generator kva rating that is twice the power needed in the welding unit. Thanks to PFC we can use generator power very close to the calculated power. Some basic rules Do not have the welding unit connected when switching the generator on or off. Do not have the welding unit connected when the generator gives lower voltage than 230V plus/minus 15% (e.g. at low rpm s). Recommended generators (that we have tested Caddy Mig with): Honda EM65iS: max. 6,5kW inverter type, 95kg (priced at approximately 3700 ). Result: Excellent weld starts and overall performance. Honda EM5500CX: max. 5,5kW AVR, 88kg (approx ). Result: At high settings, starts are slightly worse than with the unit above, especially when welding with CO 2. Honda EM30: 2,6kW/3,0kVA cycloconverter, 31kg (approx ). Result: Works only for limited welding output max. 110A. 16

17 For your own notes: Welding positions Material Position Consumable: thickness mm mm diameter Gas: Plate thickness setting mm QSet value Wire feed speed m/min A Voltage V Material Position Consumable: thickness mm mm diameter Gas: Plate thickness setting mm QSet value Wire feed speed m/min A Voltage V 17