Help with Esab Caddy c200i parameters

admin

Hi guys my name is Ryan. I tend to get long winded, I'll do my best to keep my questions on track...Picked up a caddy mig c200i to use as a portable rig running off my generator. Did a test run from my generator, couldn't tell a difference from plugging in the wall-worked great. I used it for a couple indoor projects with .030 and c25, used the q-set and it ran great, tried the manual mode and could get it dialed in pretty good as well. My problem is with inner shield, I cant seem to find the right parameters. The q-set doesn't work on self shielded wire so I am using the manual mode. Best I can tell, manual mode does not let me select my amperage (which is what I am used to setting). I can set wire speed and volts, when I  start to weld the machine sets the amps. Not knowing where to start I used Millers calculator. Stated roughly 130 amps, 14 volts, and 260 ipm for 1/8" steel. That setting barely scratched the surface of the 1/8". Also, when I set my machine to 14 volts and 260 ipm it only gives me about 90 amps. I tried various settings all the way up to 19v, 429 imp, that gave me 120 amps. That ipm seems high to me but I dont know for sure. That setting gave one of the "better" looking welds but still pretty terrible. More importantly, EVERY combination I have tried gives me a very erratic arc that is extremely difficult to control. It is not smooth, it pulses- ztt., ztt., ztt., and tons of spatter. I have a $90 harbor freight 110v welder that I set on "high" and "6.2 wire speed" and it welds very smooth on 1/8", even with their cheapo self shielded wire...Any suggestions are greatly appreciated. Here are some more details and photos (photo 1-3 self shielded wire various settings. photo 4-5 test mig beads with c25 and q-set): Lincoln .030 NR 211NP wireElectrode Negative Inductance setting at 5 ( because I dont really know what it does so i chose the middle) Drive rollers adjusted properly
Reply:Have you changed the polarity on the welder when you changed to flux core?
Reply:Change the polarity.Your on DCEP thats why it mig welds nice.Switch your leads to DCEN and your FCAW wire will run better.
Reply:Yes I changed the polarity from MIG. Currently the ground cable goes to the + terminal.
Reply:ESAB told me to try starting at 20v and 300 ipm, should give about 140 amps. Working down from there if necessary.Would still appreciate any feedback from caddy owners. I can post results of ESAB's recommendations if anybody is interested.  Thanks, -ryan
Reply:No pro here, but I've never seen a FC weld approach the look of a Mig weld.  I, for one, don't think your FC welds look that bad or different from others I've seen.  They always look sh!tty.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:I hear ya, I'm not expecting a MIG bead. I was expecting a smoother easier to control arc from this ESAB unit though. I agree, the above welds might not look like total dog poop, but it was difficult to obtain even those results, and it was under ideal conditions- clamped down flat on my welding table inside with a place to steady my hand. I have a Miller 211 that runs flux core way better but I dont like hauling it around because its heavy. Last photo below is a flux core weld with my $90 harbor freight machine, same material, much better results. I still get the ztt. ztt. ztt. ztt. ztt. intermittent arc with every setting I have tried with the Caddy.
Reply:Turn your voltage down.. Inductance should not matter for spray. 5-6 is about all I use.. Don't crush the wire, since there is not a good flux-core drive wheel for the caddie tig. I used it in the Caddie tig 160 . .035 using coreshield 15. Excellent results, as good as any other machine I have used it in. Never tried it in the C-200 yet. if you are going to try Q-set. keep backing the trim down till you get better results. I probably would start out on manual, but I think Q-set should get you close enough..Last edited by Brand X; 09-25-2014 at 01:17 PM.Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Originally Posted by Brand XTurn your voltage down.. Inductance should not matter for spray. 5-6 is about all I use.. Don't crush the wire, since there is not a good flux-core drive wheel for the caddie tig. I used it in the Caddie tig 160 . .035 using coreshield 15. Excellent results, as good as any other machine I have used it in. Never tried it in the C-200 yet. if you are going to try Q-set. keep backing the trim down till you get better results. I probably would start out on manual, but I think Q-set should get you close enough..
Reply:Try the voltage in the 16 -17 range.ESAB Migmaster 250 Hobart Ironman 230Multimatic 215TWECO Fabricator 181i & 211iHH125EZ - nice little fluxcore only unitMaxstar 150 STH - very nice
Reply:First off, ignore Q-set and amps. Neither have anything to do with flux core. Set voltage and wire speed according to the data sheet for the wire you're using. A few examples:50 ipm, 13 - 14V150 ipm, 14 - 15V300 ipm, 18 - 19VAgain, Q-set on the ESAB machines and Auto-set on the Millers, are for hard wire only.JohnA few weldersA lot of hammersA whole lot of C-clamps
Reply:Basically the 160 is synergic full time, set wire feed, and trim the voltage. Very nice small wire self-shielded machine. Not the same as Q-set but close enough for the way the machine works. ( IMO)Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Thanks for advice guys. Turning down the voltage did help (photo1). I also read the data sheet for the wire and tried those combinations of wire speed vs. voltage. I cant get rid of the pop-pop-pop-pop-pop of the arc tough and still a lot of spatter. Appearance aside, I dont feel like I'm getting a strong weld, there is little penetration. Caddy is going back on the shelf for now, I'm out of scrap. I loaded it back up with solid .030 and tried some straight co2 for the first time, q-set, (even though q-set is meant for c25 i believe) it ran smooth as silk (photo2). Some photos below, not trying to compare the appearance of flux vs. gas just FYI. Loaded the same spool of flux core into my 211 and it ran very smooth, and it was on auto set (photo3). I'm no pro welder here so not the best beads in the world, just showing the huge difference between the machines.
Reply:Sorry to revive an old thread, but am having a very similar issue with the same machine, wire, and settings as the OP, was wondering if he ever found any resolution or if a new set of eyes might have some insight?
Reply:Originally Posted by NotInKSAnyMoreSorry to revive an old thread, but am having a very similar issue with the same machine, wire, and settings as the OP, was wondering if he ever found any resolution or if a new set of eyes might have some insight?
Reply:looks like a decent machine. flux core can be a deal breaker though!VictorPraxairAir LiquideMillerLincoln Electric