ESAB Caddy Mig C200i

  1. Rich. Member

    Messages:
    24
    Newcastle UK
    Hi all,

    I picked up an ESAB C200i welder a few months ago, i was told it wasnt operational and he was quoted £700 to fix it. So, took it home, opened it up and low and behind, the LCD panel was disconnected on the front. Reconnected it, it booted straight back up and welded perfectly on gasless wire (As perfectly as a gasless wire weld can be).

    I then swapped it out for some proper Esab 12.51 Autrod wire in, reversed the polarity in the machine (Then reversed it back as the previous user apparently hadn't bothered), connected up some pure C02 and low and behold, it welded like it was set to about 50 amps. I can just get away with a weld on some 0.8-1mm plate when cranked up to 19v. It states its welding at 190a on the screen (Photo attached of the display whilst welding).

    So i took some readings, and it turns out open circuit voltage is 44.4v (Service manual states it should be 58v), and DC bus voltage is around 310-320v from memory, again manual states it should be 390-400V. Im assuming this is my problem.

    My next question is, how do i fault find this further. The control PCB controls the buck boost controller on the power pcb to regulate the DC bus voltage, but without knowing what the control specs are supposed to be, how do i diagnose between a faulty control pcb and a faulty power pcb?

    All components seem to be intact, caps all look good. Machine generally doesnt look like its had much use.

    The two photos show LCD display whilst welding, and an example of a gasless weld on the left, VS the same settings with the gas wire on the right.

    Thanks in advance
    Rich
     
    • ESAB 2.jpg
    • ESAB 1.jpg
  2. Brad93

    Brad93 M J B Engineering

    Messages:
    6,818
    Location:
    Essex
    Turn Q set off
     
  3. Rich. Member

    Messages:
    24
    Newcastle UK
    Tried that unfortunately and no difference i either Qset or manual
     
  4. Bobbes Member

    Messages:
    136
    Location:
    Maarssen / Netherlands
    Your PFC controller is broken. This is a complete white block on the PCB. This part is not seperatly to by. Only a complete board is available.
     
  5. Rich. Member

    Messages:
    24
    Newcastle UK
    Had a feeling this might be the case. Its the part sitting under the large heatsink on the power board? It is referenced to on this page https://translate.google.com/transl...oda.pl/rtvforum/topic3357107.html&prev=search.

    He did state that he managed to make a non integrated part which i might investigate. The power board is £550+VAT which makes it not economical to repair.

    The main thing i dont understand is why it seems to weld fine on gasless?

    Rich
     
  6. Davidcardiff Member

    Messages:
    108
    Location:
    Kildare . Ireland
    Screen only says 6v which isn’t enough for 10mpm
    Turn off q set and set it manually
    What size wire are you using
     
  7. Rich. Member

    Messages:
    24
    Newcastle UK
    The voltage was set to 19v, this is just the feedback. Manual or qset makes no real difference. I can get something resembling a weld on some 4mm plate with voltage set at full and wire speed at about 4-5mpm but its still cold.

    Wire size 0.8mm.

    Thanks
    Rich
     
    Davidcardiff likes this.
  8. Rich. Member

    Messages:
    24
    Newcastle UK
    Hi all,

    been thinking about this a little more. If it is infact the PFC/ buck boost controller thats broken, does anyone have a good explanation why it would weld fine on gasless but not on normal wire?

    Thanks
    Rich
     
  9. willie.macleod

    willie.macleod Member

    Messages:
    54
    Location:
    Western Isles, Scotland
    Your weld appears better with gasless because DCEN gives you more a bit more heat in the electrode compared to DCEP, I think that's all your seeing here.
     
    Rich. likes this.
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