ESAB Caddy Mig C200i Service Manual
Machine for mig/mag welding
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Summary of Contents for ESAB Caddy Mig C200i
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Page 1: Service Manual
R R R R Caddy Mig C200i Service manual 0349 300 095 101222 Valid for serial no. 932- -xxx- -xxxx... -
Page 2: Table Of Contents
READ THIS FIRST ..............INTRODUCTION . - Page 3 MAINTENANCE ..............Inspection and cleaning .
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Page 4: Read This First
READ THIS FIRST Maintenance and repair work should be performed by an experienced person, and electrical work only by a trained electrician. Use only recommended replacement parts. This service manual is intended for use by technicians with electrical/electronic training for help in connection with fault--tracing and repair. -
Page 5: Technical Data
TECHNICAL DATA Voltage 230 V, 1∼ 50/60 Hz Permissible load at 100% duty cycle 100 A 60 % duty cycle 120 A 25 % duty cycle 180 A Setting range (DC) 30 - - 200 A Open circuit voltage 60 V Open circuit power 15 W Efficiency... -
Page 6: Wiring Diagram
WIRING DIAGRAM Component description WARNING ! STATIC ELECTRICITY can damage circuit boards and electronic components. Observe precautions for handling electrostatic S S S S sensitive devices. Use proper static- -proof bags and boxes. S S S S WARNING ! High DC voltage may remain on the electrolytic capaci- tors on the power board. -
Page 7: Caddyr Mig C200I
Caddyr r r r Mig C200i Edition 101222 - - 7 - - s1Cad200... -
Page 8: Description Of Operation
DESCRIPTION OF OPERATION Caddyr Mig C200i is a set of following modules: power PCB -- AP1 control PCB -- AP2 MMC panel -- AP3 gas valve -- K1 wire feeding motor -- M1 fan -- M2 The power PCB contains all the track of energy conversion. It is supplied from the 230V 50/60Hz mains. - Page 9 Edition 101222 - - 9 - - s1Cad200...
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Page 10: Ap1:1. Emi Mains Filter
AP1:1. EMI mains filter The EMI mains filter contains capacitors and inductors intended for suppression of the common--mode interferences and the differential--mode interferences. The EMI filter contains following parts: L05, C1, L01, L02, C5, C8, C16. The resistors R30, R31 provides discharge path for the filter’s capacitors. AP1:2. -
Page 11: Ap1:6. Thermal Protection Sensors
Numbers of outlets of the power transformer. AP1:6. Thermal protection sensors The thermal protection sensors are placed inside the power modules (or module) and on the heatsink of the output rectifier. In the power module there are (is) NTC (negative temperature coefficient) non--linear sensor -- 22k @ 25_C, while on the output rectifier the PTC (positive temperature coefficient) 1,0 k @ 25_C linear sensor is installed. - Page 12 Edition 101222 - - 12 - - s1Cad200...
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Page 13: Ap2 Analogue Control Board
AP2 Analogue control board The analogue control PCB contains circuits connected to the input (high voltage, primary) and circuits connected to the output (low voltage, secondary). High Voltage Circuits High voltage circuits (primary side) are placed on the right part of the PCB and they are connected to the external circuits by means of the connector CN1. -
Page 14: Ap2:2H. Auxiliary Power Supply
PFC control is built on the specialised integrated circuit IC3. PFC control senses the DC bus voltage, input current (5,6 CN1) and input voltage, providing the constant 390...400V on the DC bus along with sinusoidal form of the input current. This goal is achieved by the control of the switch in the boost converter placed on the power PCB. - Page 15 The auxiliary power supply is built as flyback converter. Estimated maximum power of it is 25W. The most loaded output is the +24V secondary side. It provides the power for all low voltage control circuits and also power for the fan and the gas valve.
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Page 16: Ap2:3H. Thermal Protection On The Primary Side
AP2:3H. Thermal protection on the primary side As temperature sensors (sensor) are on the high voltage potential, the thermal protection circuit (fig. ) is placed on the high voltage side, then the 0/1 signal is transferred via the optocoupler IC2 with extended isolation, to the secondary circuits. - Page 17 The start signal from the welding torch is the basic input of the command system. As shown on the fig. the start signal can be disabled in several cases: thermal protection from the primary side (IC2), thermal protection form the secondary side (CN4.5,6), torch switch is pressed during the power up (charging of the C342, hold by the pressed switch) lack of the +24V_ENABLE signal...
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Page 18: Ap2:2L. Electromagnetic Valve
As shown, there is 0,2 gas pre--flow delay. The power source is kept on until the motor is running. AP2:2L. Electromagnetic valve The electromagnetic valve control works in a specific mode. As shown on the diagram the first 0,2 s coil of the valve is supplied from 24 volts d.c. -
Page 19: Ap2:3L. Short Arc Control
AP2:3L. Short arc control The voltage reference is proportional with different coefficients to: a. wire feed speed reference b. voltage on the Umin input c. voltage on the Upot input In the previous solution the source a. was replaced by the EMF -- voltage proportional to the actual wire feed speed, i.e. - Page 20 Voltage feedback is given on the CN4.1. Note that low voltage ground (GND_INV) is connected via CN4.2 to the power supply (+). It enables creation of the summing point in system with unipolar supply. Nevertheless the voltage feedback inverting amplifier gives the signal in opposite phase. This signal is delivered to the next inverting amplifier, which is not shown on the drawing.
- Page 21 The current reference signal IREF_IN from the voltage regulator is delivered via 2 diodes to the current input (COMP) of the PWM controller IC11. Diodes were applied to compensate voltage drop on diodes embedded in the IC11. Current feedback is provided by means of the current transformer TO02, placed on the power PCB.
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Page 22: Ap2:4L. Wire Feeder Motor Speed Controller
AP2:4L. Wire feeder motor speed controller The motor drive is supplied from the auxiliary winding on the main trafo as shown on the figure below. The wire speed motor controller is built on the peak current mode PWM controller IC. This IC does not provide the reference input, the internal reference is +2,5V. In this case the negative voltage feedback is provided in the form of the sourcing current, and the reference value is provided in the form of the sinking current. -
Page 23: Ap2 Components Layout
AP2 Components layout Edition 101222 - - 23 - - s1Cad200... -
Page 24: Ap3 Mmc Panel
AP3 MMC panel Man--machine communication panel (MMC) provides controls for process settings and machine operation, as well as feedback from the process and the machine condition. Physically, the MMC is printed circuit board (PCB) which consist of: microprocessor system, manual controls: pushbutton, rotary encoders LCD display The MMC is connected to the analog control PCB via connector CN1. - Page 25 Digital inputs Edition 101222 - - 25 - - s1Cad200...
- Page 26 Analog inputs Edition 101222 - - 26 - - s1Cad200...
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Page 27: Ap3:4. Microprocessor And Its Circuits
AP3:4. Microprocessor and its circuits The programming is available through the standard serial connector RS232, connected to CN4 via buffer PCB. Program updating can be carried out via this way. JTAG connector is not mounted. Edition 101222 - - 27 - - s1Cad200... -
Page 28: Ap3:5. Power Supplies
AP3:5. Power supplies The MMC panel is supplied from the 24V delivered by the power supply placed on the analog PCB. +5V power supply is built as the pulse buck converter. The integrated regulator VR2 together with the inductor L500 and the diode D520 composes a simple buck converter. -
Page 29: Ap3:6. Analog Outputs
AP3:6. Analog outputs All outputs are slow response PWM outputs. PWM signal are filtered and conditioned to the required level by means of the operational amplifiers. The di/dt output has a form of the sinking current source, where the npn transistor Q504 with resistor R570 in emitter is placed in the feedback of the operational amplifier. -
Page 30: Ap3:7. Digital Outputs
AP3:7. Digital outputs Digital outputs are created in form of the npn and pnp open collectors, connecting adequate output lines to ground and to +20V respectively. AP3:8. LCD display LCD display is connected directly to the microprocessor lines. Group lines are connected to the voltage dividers on resistors R587--594, which are necessary to create a.c. -
Page 31: Ap3 Components Layout
AP3 Components layout Edition 101222 - - 31 - - s1Cad200... -
Page 32: Service Instructions
SERVICE INSTRUCTIONS WARNING ! STATIC ELECTRICITY can damage circuit boards and electronic components. Observe precautions for handling electrostatic S S S S sensitive devices. Use proper static- -proof bags and boxes. S S S S What is ESD? A sudden transfer or discharge of static electricity from one object to another. ESD stands for Electrostatic Discharge. -
Page 33: Handling Of The Control Pcb
When the voltage is less then 50V a 1kW 0,5W resistor may be used for the final discharge. Handling of the control PCB Carefully put the control PCB in place. Try to avoid touching the wrong pins during placement of the PCB. The slit in the control PCB and the diode on the power PCB should help with positioning. -
Page 34: Assembly Of The Housing
ATTENTION! All primary and secondary circuits must be short--circuited to protect semiconductor devices. The insulation resistance between welding circuits (secondary circuits) and primary circuits should be more then 5M . It is recommended to carry out the insulation resistance test during periodical survey dependently on the environmental conditions, not less then once a year. -
Page 35: Fault Tracing
There are tongue--and--groove joints in the upper part of housing. To avoid damaging of the joint and achieve good connection, it is strongly recommended to follow the bolts insertion sequence presented on the drawing. Fault tracing Type of fault Actions Machine is dead. -
Page 36: General Failure Of The Power Block
General failure of the power block Failure in the power block frequently means the short--circuit of the DC bus. Unfortunately it causes an avalanche of further failures. Mechanism of the avalanche of failures is shown on the picture. DC bus short--circuit causes damage and disconnection of the shunt resistor inside the module. -
Page 37: Instructions
This chapter is an extract from the instructions for SAFETY Users of ESAB welding 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 welding equipment. The following recommen- dations should be observed in addition to the standard regulations that apply to the workplace. -
Page 38: Placing
Placing Position the welding power source such a way that its cooling air inlets and outlets are not obstructed. 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. -
Page 39: Operation
machine is protected against undervoltage. If the power supplied by the generator is not sufficient, the welding is interrupted by the undervoltage protection. Especially welding start could be disturbed. The generator should be replaced with a more powerful one or welding parameters be decreased if operator finds the welding process disturbed. -
Page 40: Operation
Operation Once the machine is turned--on, it is not powered instantly. Approximately 2 seconds after switching the machine on by means of the mains switch , the LCD display indicates that the machine is ready. The machine is protected against welding start during power on. If the torch pushbutton is pressed while the machine is being turned--on, the operation is disabled, until the torch button is released. - Page 41 QSett t t t mode A -- welding voltage B -- welding current C -- wire feed speed D -- workpiece thickness E -- QSett value F -- QSett value setting knob G -- Manual / QSett mode button H -- material selection / dynamics setting button I -- plate thickness setting knob...
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Page 42: Error Codes
suitable in most cases. The heat input setting is symbolised with a thermometer indicating hotter or colder settings. Error codes If an error occurs only the error code will be visible. Error No. Mnemo Description Action EPROM_CHSUM program related error Switch the machine OFF, wait Switch the machine OFF, wait POWER_SUPPLY_5V... -
Page 43: Polarity Change
Polarity change +/-- TERMINALS The machine is delivered with the welding wire connected to the plus pole. Some wires, e.g. gasless cored wires, are recommended to be welded with negative polarity (welding wire connected to the minus pole and return cable connected to the plus pole). -
Page 44: Wire Feed Pressure
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 insolated object, e.g. -
Page 45: Shielding Gas
wire through and terminate wire feeding instantly when the wire comes out of the current tip. WARNING! Do not keep the torch near the ears or the face during wire feeding, as this may result in personal injury. NOTE. Remember to use the correct contact tip in the torch for the wire diameter used. The torch is fitted with a contact tip for 0,8mm wire. -
Page 46: Maintenance
MAINTENANCE Regular maintenance is important for safe, reliable operation. Note! All guarantee undertakings from the supplier cease to apply if the customer himself attempts any work in the product during the guarantee period in order to rectify any faults. Inspection and cleaning Check regularly that the power source is free from dirt. -
Page 47: Ordering Of Spare Parts
Spare parts may be ordered through your nearest ESAB dealer, see the last page of this publication. -
Page 48: Notes
NOTES - - 48 - - notes... - Page 49 - - 49 - - notes...
- Page 50 ESAB subsidiaries and representative offices Europe NORWAY Asia/Pacific Representative offices AS ESAB AUSTRIA BULGARIA CHINA Larvik ESAB Ges.m.b.H ESAB Representative Office Shanghai ESAB A/P Tel: +47 33 12 10 00 Vienna- -Liesing Sofia Shanghai Fax: +47 33 11 52 03...
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Questions and answers
Esab caddy c200i with flashing screen and just stopped working after finishing a weld
The ESAB Caddy Mig C200i screen may flash and stop working after completing a weld due to a malfunction or safety protection being triggered. The machine is protected against welding start during power-on, and if the torch pushbutton is pressed while turning on, operation is disabled until the button is released. Malfunctions require expert assistance, and the device should not be used until inspected.
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@Mr. Anderson
can a esab caddy c200i be run on uk 110v and 240v supply on the same machine