ESAB EM 215ic, EMP 215ic Instruction Manual

Instruction manual

0463 408 001 GB 20170228

Valid for: serial no. EMP: 615-xxx-xxxx, EM: 627-xxx-xxxx

EMP 215ic, EM 215ic

TABLE OF CONTENTS

0463 408 001 © ESAB AB 2017

1

SAFETY .........................................................................................................

5

1.1 Meaning of symbols .................................................................................

5

1.2 Safety precautions ...................................................................................

5

2

INTRODUCTION............................................................................................

8

2.1 Equipment .................................................................................................

8

3

TECHNICAL DATA ........................................................................................

10

4

INSTALLATION..............................................................................................

13

4.1 Location.....................................................................................................

13

4.2 Lifting instructions ...................................................................................

13

4.3 Mains supply.............................................................................................

14

4.3.1 Recommended fuse sizes and minimum cable area.............................. 15

5

OPERATION ..................................................................................................

16

5.1 Connections..............................................................................................

17

5.2 Connection of welding and return cables ..............................................

18

5.3 Polarity change.........................................................................................

18

5.4 Inserting and replacing wire....................................................................

18

5.5 Setting the wire feed pressure ................................................................

20

5.6 Changing the feed/pressure rollers ........................................................

20

5.7 Shielding gas ............................................................................................

21

5.8 Duty cycle .................................................................................................

22

5.9 Overheating protection ............................................................................

23

6

CONTROL PANEL.........................................................................................

24

6.1 How to navigate - EMP 215ic ...................................................................

24

6.1.1 Main menu.............................................................................................. 24

6.1.2 sMIG mode ............................................................................................. 24

6.1.3 Manual MIG mode .................................................................................. 25

6.1.4 Flux cored wire mode ............................................................................. 25

6.1.5 MMA mode ............................................................................................. 25

6.1.6 LIFT-TIG mode ....................................................................................... 25

6.1.7 Settings .................................................................................................. 26

6.1.8 User manual information ........................................................................ 26

6.1.9 Icon reference guide............................................................................... 26

6.2 How to navigate - EM 215ic .....................................................................

29

6.2.1 Symbol reference EM 215ic ................................................................... 29

7

MAINTENANCE.............................................................................................

30

7.1 Routine maintenance ...............................................................................

30

7.2 Power source and wire feeder maintenance .........................................

30

7.3 Torch and liner maintenance ...................................................................

31

8

TROUBLESHOOTING ...................................................................................

32

9

ORDERING SPARE PARTS..........................................................................

34

DIAGRAM ............................................................................................................. 35

TABLE OF CONTENTS

0463 408 001 © ESAB AB 2017

ORDERING NUMBERS ....................................................................................... 36

WEAR PARTS....................................................................................................... 37

ACCESSORIES .................................................................................................... 39

REPLACEMENTS PARTS.................................................................................... 40

Rights reserved to alter specifications without notice.

1 SAFETY

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1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!
Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!
Means potential hazards which could result in personal injury or loss of

life.

CAUTION!
Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB 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 equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY

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4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to
EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY

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MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.

NOTE!
Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation
in accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be
disposed of at a recycling facility.

As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION

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2 INTRODUCTION

The ESAB EM and EMP product family is a new generation of MIG and Multi-Process
(MIG/MMA/TIG) welding power sources.

The EMP 215ic and EM 215ic power sources are designed to match the needs of the
light-medium fabrication user. They are tough, durable and portable, providing excellent arc
performance across a variety of welding applications.

The EMP features a 11cm (4.3in.) colour TFT user interface display which provides quick
and easy selection of weld process and parameters, suitable for both newly trained and
intermediate level users. For more advanced users, a number of additional functions and
features can be introduced and customized to give maximum flexibility.

Exclusive to ESAB, sMIG provides users with an excellent 'Short circuit' arc characteristic.

The EM and EMP family connects to an input power supply range between
120V–230V,1~50/60Hz input power supplies. Input power can be supplied by mains or
generator. Incorporating a PFC (Power Factor Correction) circuit significantly increases
power efficiency.

Key features:

• Excellent MIG characteristics (EM)

• Excellent multi-process welding capabilities , MIG/MMA and Lift/TIG (EMP)

• Automatic recognition of input power with PFC (120V–230V)

• Large 11cm (4.3in.) high resolution, customizable user interface (EMP)

• Rugged case design and internal hardware

• Portable, single person lift and carry design

• High grade cast aluminium wire drive system provides excellent control of drive roll
geometry ensuring smooth, precise wire feeding

• Professional high grade accessories

2.1 Equipment

Package consists of the following:

EMP series

• ESAB EMP 215ic power source

• ESAB MXL 200 MIG torch, 3m (10ft)

• Contact tip M6 for 0.8mm (0.030in.) wire (qty 2)

• Contact tip M6 for 1.0mm (0.040in.) wire (qty 2)

• Gas hose, 4.5m (14.8ft), Quick connector

• MMA welding cable kit 3m (10ft)

• Return cable kit 3m (10ft)

• OK 12.50 0.8mm(0.030in.) ×5kg (11lb) bobbin

• Drive roll: 0.6 / 0.8 mm (0.023in. / 0.030in.) Cored, Steel and Stainless wire
(installed on drive system)

• Drive roll: 0.8/1.0mm (0.030in. / 0.040in.) Cored, Steel and Stainless wire (in
accessory box)

• Guide tube 1.0mm – 1.2mm (0.040in. – 0.045in.) (installed on drive system)

• Guide tube 0.6mm – 0.8mm (0.023in. – 0.030in.) (in accessory box)

• Mains cable 3m (10ft), fixed with plug

• Safety manual

• USB with Operator's Manual

• Material thickness guide

2 INTRODUCTION

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EM series

• ESAB EM 215ic power source

• ESAB MXL 200 MIG torch, 3m (10ft)

• Contact tip M6 for 0.8mm (0.030in.) wire (qty 2)

• Contact tip M6 for 1.0mm (0.040in.) wire (qty 2)

• Gas hose, 4.5m (14.8ft), Quick connector

• Return cable kit 3m (10ft)

• OK 12.50 0.8mm(0.030in.) ×5kg (11lb) bobbin

• Drive roll: 0.6 / 0.8 mm (0.023in. / 0.030in.) Cored, Steel and Stainless wire
(installed on drive system)

• Drive roll: 0.8/1.0mm (0.030in. / 0.040in.) Cored, Steel and Stainless wire (in
accessory box)

• Guide tube 1.0mm – 1.2mm (0.040in. – 0.045in.) (installed on drive system)

• Guide tube 0.6mm – 0.8mm (0.023in. – 0.030in.) (in accessory box)

• Mains cable 3m (10ft), fixed with plug

• Safety manual

• USB with Operator's Manual

• Material thickness guide

3 TECHNICAL DATA

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3 TECHNICAL DATA

EMP 215ic

Voltage 230 V, 1 ~ 50/60 Hz 120 V, 1 ~ 50/60 Hz

Primary current

I

max.

GMAW - MIG

30 A

Breaker 20 A: 28.6 A

Breaker 15 A: 20.3 A

I

max.

GTAW - TIG

19 A Breaker 15 A: 20.8 A

I

max.

SMAW - MMA

25 A Breaker 15 A: 20.8 A

I

eff.

GMAW - MIG

14 A

Breaker 20 A: 13 A

Breaker 15 A: 13 A

I

eff.

GTAW - TIG

10 A Breaker 15 A: 14.7 A

I

eff.

SMAW - MMA

13 A Breaker 15 A: 14.7 A

Permissible load at GMAW - MIG

100% duty cycle 110 A / 19.5 V Breaker 20 A: 90 A / 18.5 V

Breaker 15 A: 75 A / 17.75 V

60% duty cycle 125 A / 20.25 V Breaker 20 A: 110 A / 19.5 V

Breaker 15 A: 90 A / 18.5 V

40% duty cycle 150 A / 21.5 V Breaker 15 A: 100 A / 19 V

25% duty cycle 205 A / 24.25 V -

20% duty cycle - Breaker 20 A: 130 A / 20.5 V

Setting range (DC) 15 A / 14.75 V –

230A/25.5V

15 A / 14.75 V –
130A/20.5V

Permissible load at GTAW - TIG

100% duty cycle 110 A / 14.4 V 100 A / 14 V

60% duty cycle 125 A / 15 V 120 A / 14.8 V

40% duty cycle - 130 A / 15.2 V

30% duty cycle 180 A / 17.2 V -

Setting range (DC) 5 A / 10.2 V – 200A/18V 5 A / 10.2 V – 150A/16V

Permissible load at SMAW - MMA

100% duty cycle 100 A / 24 V 65 A / 22.6 V

60% duty cycle 125 A / 25 V 80 A / 23.2 V

40% duty cycle - 85A / 23.4V

25% duty cycle 180 A / 27.2 V -

Setting range (DC) 16 A / 20.6 V – 180A/27.2V 16 A / 20.6 V – 110A/24.4V

Open circuit voltage (OCV)

VRD deactivated, nominal
OCV (Boost OCV)

68 V / (90 V) 68 V / (90 V)

Efficiency 86% 84%

Power factor 0.98 0.99

3 TECHNICAL DATA

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EMP 215ic

Wire feed speed 1.5–12m/min

(62–475in./min)

1.5–12m/min
(62–475in./min)

Wire diameter

Mild steel solid wire 0.6–1.0 mm (0.023–0.040in.) 0.6–1.0 mm (0.023–0.040in.)

Stainless steel solid wire 0.8–1.0 mm (0.030–0.040in.) 0.9–1.0 mm (0.035–0.040in.)

Flux cored wire 0.8–1.1mm (0.030–0.045in.) 0.8–1.1mm (0.030–0.045in.)

Aluminium 0.8–1.2mm (0.030–3/64in.) 0.8–1.2mm (0.030–3/64in.)

Bobbin size Ø 100–200 mm (4–8in.) Ø 100–200 mm (4–8in.)

Dimensions l×w×h 548×229×406mm

(23.0×9.0×16.0in.)

548×229×406mm
(23.0×9.0×16.0in.)

Weight 18.2 kg (40 lb) 18.2 kg (40 lb)

Operating temperature -10to+40°C (-14 to +104°F) -10to+40°C (-14 to +104°F)

Enclosure class IP23S IP23S

Application classification

EM 215ic

Voltage 230V, 1~50/60Hz 120V, 1~50/60Hz

Primary current

I

max.

GMAW - MIG

30A (27.6A at 25% duty
cycle)

Breaker 20A: 28.6A

Breaker 15A: 20.3A

I

eff.

GMAW - MIG

14A

Breaker 15A: 14.6A

Breaker 20A: 18.0A

Permissible load at GMAW - MIG

100% duty cycle 110A / 19.5V Breaker 15A: 75A / 17.75V

Breaker 20A: 90A / 18.5V

60% duty cycle 125A / 20.25V Breaker 15A: 90A / 18.5V

Breaker 20A: 110A / 19.5V

40% duty cycle 150A / 21.5V Breaker 15A: 100A / 19V

25% duty cycle 205A / 24.25V -

20% duty cycle - Breaker 20A: 130A / 20.5V

Setting range (DC) 15A/14.75V–235A/26.0V15A/14.75V–130A/20.5

V

Open circuit voltage (OCV)

VRD deactivated 68V 68V

VRD activated 35V 35V

Efficiency 86% 84%

Power factor 0.98 0.99

Wire feed speed 2–12.1m/min

(80–475in./min)

2–12.1m/min
(80–475in./min)

Wire diameter

Mild steel solid wire 0.6–0.9 mm (0.023–0.035in.) 0.6–0.9 mm (0.023–0.035in.)

3 TECHNICAL DATA

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EM 215ic

Stainless steel solid wire 0.8–0.9 mm (0.030–0.035in.) 0.8–0.9 mm (0.030–0.035in.)

Flux cored wire 0.8–1.1mm (0.030–0.045in.) 0.8–1.1mm (0.030–0.045in.)

Aluminium 0.8–1.2mm (0.030–3/64in.) 0.8–1.2mm (0.030–3/64in.)

Bobbin size Ø 100–200 mm (4in.–8in.) Ø 100–200 mm (4in.–8in.)

Dimensions l×w×h 548×229×406mm

(23.0×9.0×16.0in.)

548×229×406mm
(23.0×9.0×16.0in.)

Weight 18.2kg (40lb) 18.2kg (40lb)

Operating temperature -10to+40°C (-14 to +104°F) -10to+40°C (-14 to +104°F)

Enclosure class IP23S IP23S

Application classification

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at
a certain current without overheating. The duty cycle is valid for 40°C / 104°F.

For more information see section "Duty cycle" in the OPERATION chapter.

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.

Equipment marked IP 23S is intended for indoor and outdoor use; however, should not be
operated in precipitation.

Application class

The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

4 INSTALLATION

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4 INSTALLATION

The installation must be carried out by a professional.

CAUTION!

This product is intended for industrial use. In a domestic environment this product
may cause radio interference. It is the user's responsibility to take adequate
precautions.

4.1 Location

Position the power source so that its cooling air inlets and outlets are not obstructed.

A. 100 mm (4in.)

B. 100 mm (4in.)

4.2 Lifting instructions

The power source can be lifted using any of the handles.