Esab Caddy Mig C200i - Gas Flow Problem?

[hjt350]

Hi,

I have a well used and looked after Esab Caddy MIG with an issue.

I set my flow rate on the regulator (Esab FE300), but the gas coming out the nozzle is half the indicated LPM. Measured with pea shooter.

If i test the flow rate straight from the bottle, its very accurate to the regulator dial.

If I test the flow rate from the machine BEFORE it goes into the gun/hose, its also correct to the regualtor.

If I then test at the nozzle, its dropped by around half the indicated LPM.

What could be my issue? Blockage somewhere? Leaking somewhere from machine to welding tip?

I have to set the regualtor extremely high to get the correct pressure at the gun and its getting annoying, any help would be mucho appreciated.

 

[Dutch Welder]

It could well be that the smallest diameter hose (i.e. the bottleneck) is in the torch hose.
If you are getting the required flow out at the nozzle and the welds look good, then it could very well be normal, as the other places you measured have a way larger bore hose to it.

 

[hjt350]

The smallest hose is definitely in the torch hose - it has a small brass fitting on the machine end.

I don't think that would make so much difference, and this is my 3rd of these machines and the only one with this issue?

 

[Dutch Welder]

Ah, that changes things a bit.
Can you try with a different torch package??
Maybe the gas line in it has a kink or there is some debris stuck in there.

 

[hotponyshoes]

Can you disconnect the torch gas outlet and test the flow there?

The solonide inside the machine probably has a gauze/mesh filter on the inlet side so that's where I'd look first if the flow coming out of the machine is low.

Possibly a filter on the gas inlet at the rear of the machine but I don't recall ever seeing one on an esab

 

[hjt350]

Can you disconnect the torch gas outlet and test the flow there?

The solonide inside the machine probably has a gauze/mesh filter on the inlet side so that's where I'd look first if the flow coming out of the machine is low.

Possibly a filter on the gas inlet at the rear of the machine but I don't recall ever seeing one on an esab

\
Thanks, have tried this.

The flow is perfect just before it goes into the gun, the middle photo above shows connection to gun, it all goes wrong after that

 

[hjt350]

Ah, that changes things a bit.
Can you try with a different torch package??
Maybe the gas line in it has a kink or there is some debris stuck in there.

I don't have anything here to test it with and I think the torch hose is one piece, there are compression fittings either end

 

[hotponyshoes]

Pull the liner out.
If you have overheated the torch at some stage it might have melted at the torch end.
Check the holes in the tip holder are clean.
Remove the tip holder and blow back down the torch cable from the torch end (with the machine end disconnected)

 

[hjt350]

Thanks very much, ill give it a go.

I have liner spares so will put some new stuff in as you say.

The gas line is delivered separately and looks non replaceable?

Not sure on that - I haven't disassembled one this far before

Thanks

 

[hjt350]

After giving all that go and blowing out the gas line in hose - replacing the liner, Ive still got the same situation.

No leaks at any fittings either - bit of a mystery to be honest how its dropping so much gas flow.

It's all back together now so will have to put up with it for now. Thanks