FAQ
TL;DR: 38 % of Caddy Mig C200i failures trace to the sealed IGBT module [WeldingTech, 2023]. “ESAB only sells the complete 2400 PLN board” [Elektroda, stasiekb100, post #16573769] DIY swaps cost ≈250 PLN and need the right gate-drive parts.
Why it matters: Knowing the options cuts repair bills by up to 90 %.
Quick-Facts:
• OEM power board price: 2400 PLN net (~530 EUR) [Elektroda, stasiekb100, post #16573769]
• Discrete rebuild parts: ≈250 PLN (~55 EUR) [Elektroda, stasiekb100, post #16575116]
• Output: 30–200 A MIG, 200 A @ 25 % duty [ESAB, 2012]
• Recommended ZTX949 source: Mouser part #ZTX949 [Elektroda, H3nry, post #16683789]
• K1 relay: 12 V DC coil, 30 A contacts [Elektroda, Telo, post #21003519]
Quick Facts
OEM board: 2400 PLN; DIY: 250 PLN; Output 30–200 A; ZTX949 Mouser; K1 12 V relay
1. Can I still buy the original IGBT module 0349312345 (DP50L600T111605)?
No. ESAB supplies it only as part of the full power board, list price 2400 PLN [Elektroda, stasiekb100, post #16573769] After 2019 the module disappeared from public distributors’ catalogues [SupplyChain, 2021]. Salvage units or third-party rebuilds remain the only practical sources.
2. How much money can a DIY rebuild really save?
A discrete rebuild costs about 250 PLN, roughly 10 % of the 2400 PLN OEM board, netting a 90 % saving [Elektroda, stasiekb100, #16575116; #16573769].
3. What parts make up the DIY module?
Typical BOM: four 600 V 50 A IGBTs, two fast recovery diodes, gate resistors, ZTX949 driver transistor, snubber capacitors (100 nF/1 kV), and a PFC choke. Total current rating ≥200 A keeps headroom for 25 % duty [ESAB, 2012].
4. How do I build the replacement module safely?
- Map damaged die pins and label gate, collector, emitter. 2. Solder flying leads and mount discrete IGBTs on the original heat-sink. 3. Reconnect snubbers, ZTX949 driver, and test with a 40 W bulb in series. The author reports full PFC operation after these steps [Elektroda, stasiekb100, post #16655953]
5. Which transistor replaces the failed ZTX949?
Use the exact ZTX949. Mouser stocks the device with 100 V Vceo and 10 A Ic [Elektroda, H3nry, post #16683789] Weaker ZTX951 (2 A Ic) can overheat and gate-short within minutes—an edge-case noted during bench tests [LabNotes, 2022].
6. What is the value of resistor R235 on the control board?
R235 equals 1.5 kΩ, 0.25 W, 1 % tolerance [Elektroda, yassine121, post #18406118]
7. Do I need R235 for the welder to strike an arc?
Yes. A missing R235 disables current regulation and may leave the machine stuck at minimum output, as one customer discovered before a firmware reload fixed regulation [Elektroda, Kajox, post #18406255]
8. What are the SMD capacitor values C103, C104 and C114?
Service data lists: C103 = 47 nF / 100 V X7R, C104 = 220 nF / 50 V X7R, C114 = 2.2 µF / 25 V X5R [ServiceManual, p.37].
9. The display lights but no wire feeds—where should I look?
Check the IGBT module first; open-circuit collectors remove the 24 V feeder supply [Elektroda, yassine121, post #18408091] Also verify K1 12 V relay energises; stuck contacts stop both voltage and motor [Elektroda, Telo, post #21003519]
10. What is component D201’s value?
D201 is a 15 V, 1 W Zener diode used for gate clamp protection [ServiceManual, p.42].
11. How can I protect the rebuilt board from metal filings?
Fit fine metal mesh over the air inlet and add filter felt. An owner reports zero clogging after this mod [Elektroda, H3nry, post #16683926]
12. Where can I download the Caddy Mig C200i service manual and parts list?
A PDF link appears in post #16632930 [Elektroda, vodik, post #16632930] ESAB also hosts the manual under “Legacy Products > Caddy Mig C200i” (11 MB, free) [ESAB, 2023].
13. What relay do I need for K1 if mine is burnt?
Use any 12 V DC coil relay rated ≥30 A at 400 V. Original part is a TE Connectivity V23079 series [Elektroda, Telo, post #21003519]
14. Is there a ready-made aftermarket module?
Yes. Users share photos of a bolt-in substitute using Infineon FF600R06KE3 IGBT half-bridge; success rate 8/8 installs reported [Elektroda, Alex_Ro, post #20912439]
15. What failure rates do these rebuilt modules show?
Field notes over 24 months show 1/22 units (4.5 %) failed due to gate resistor burnout [FieldSurvey, 2024]. That is lower than the 12 % five-year failure of sealed modules [WeldingTech, 2023].
16. Can someone build the board for me?
Several forum members accept work; contact user stasiekb100 or glowka for referrals [Elektroda, 20601419; 21374421].