Caddy®
Mig C160i
Instruction manual
0440 000 096 GB 20200203
Valid for: serial no. 406-xxx-xxxx
TABLE OF CONTENTS
1
SAFETY
1.1 Meaning of symbols
1.2 Safety precautions
2
INTRODUCTION
2.1 Equipment
3
TECHNICAL DATA
4
INSTALLATION
4.1 Lifting instruction
4.2 Location
4.3 Mains power supply
5
OPERATION
5.1 Connections and control devices
5.2 Operation
5.3 Polarity change
5.4 Wire feed pressure
5.5 Replacing and inserting wire
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7
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12
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15
5.5.1 Changing the feed roller groove ........................................................... 15
5.6 Shielding gas
5.7 Overheating protection
6
MAINTENANCE
6.1 Inspection and cleaning
6.2 Changing the wire liner
7
TROUBLESHOOTING
8
ORDERING SPARE PARTS
DIAGRAM
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ORDERING NUMBERS
WEAR PARTS
ACCESSORIES
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Rights reserved to alter specifications without notice.
0440 000 096 © ESAB AB 2020
1 SAFETY
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
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© ESAB AB 2020
1 SAFETY
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.
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NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
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© ESAB AB 2020
1 SAFETY
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.
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© ESAB AB 2020
2 INTRODUCTION
2 INTRODUCTION
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 Ø0.6 to Ø1.0 mm. Pure argon, mixed
gas or pure CO2may be used as shielding gases.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
The power source is supplied with:
• Instruction manual
• Welding torch MXL 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)
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© ESAB AB 2020
3 TECHNICAL DATA
3 TECHNICAL DATA
Power source Mig C160i
Mains voltage 230 V, 1 ~ 50/60 Hz
Permissible load at
35 % duty cycle 150 A / 21.5 V
60 % duty cycle 120 A / 20 V
100 % duty cycle 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 Ø200 mm
Continual sound pressure at no-load < 70 db (A)
Dimensions l × w × h 449 x 198 x 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 CO
Mixed gas Ar/CO
2
2
200 A
180 A
Self-shielded
Permitted load at 35 % duty cycle
Carbon dioxide CO
Mixed gas Ar/CO
2
2
Self-shielded
120 A
180 A
150 A
100 A
Recommended gas flow 8 - 15 I/min
Wire diameter 0.6 - 1.0 mm
Weight 1.32 kg
Length cable assembly 3.0 m
Standard control cable 2-pole
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© ESAB AB 2020
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