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ESAB
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EMP235ic
Instruction Manual
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Instruction Manual
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Table of contents
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ESAB EMP 235ic Instruction Manual

EMP 235ic
Multi-Process Welding Inverter
Instruction manual
0463 641 001 GB 20181220
Valid for: serial no. 821-xxx-xxxx

TABLE OF CONTENTS

1
2
3
4
INSTALLATION............................................................................................ 12
4.1 Location................................................................................................... 12
4.2 Lifting instructions ................................................................................. 12
4.3 Mains supply........................................................................................... 13
4.3.1 Recommended fuse sizes and minimum cable area............................ 14
5
OPERATION ................................................................................................ 15
5.1 Connections............................................................................................ 16
5.2 Connection of welding and return cables ............................................ 17
5.3 Polarity change....................................................................................... 17
5.4 Inserting and replacing wire.................................................................. 18
5.5 Setting the wire feed pressure .............................................................. 19
5.6 Changing the feed/pressure rollers ...................................................... 20
5.7 Shielding gas .......................................................................................... 20
5.8 Duty cycle ............................................................................................... 21
5.9 Overheating protection .......................................................................... 22
5.10 Voltage Reduction Device (VRD)........................................................... 22
6
CONTROL PANEL ...................................................................................... 23
6.1 How to navigate ...................................................................................... 23
6.1.1 Main menu............................................................................................ 23
6.1.2 sMIG mode ........................................................................................... 23
6.1.3 Manual MIG mode ................................................................................ 24
6.1.4 Flux cored wire mode ........................................................................... 24
6.1.5 MMA mode ........................................................................................... 24
6.1.6 LIFT-TIG mode ..................................................................................... 24
6.1.7 Settings ................................................................................................ 25
6.1.8 User manual information ...................................................................... 25
6.1.9 How does sMIG work? ......................................................................... 25
6.1.10 Why is sMIG limited to 6 mm plate? ..................................................... 25
6.1.11 Icon reference guide............................................................................. 26
6.1.12 Lift TIG operation.................................................................................. 28
7
MAINTENANCE .......................................................................................... 29
7.1 Routine maintenance ............................................................................. 29
7.2 Power source and wire feeder maintenance ....................................... 29
7.3 VRD periodic tests ................................................................................. 30
0463 641 001 © ESAB AB 2018
TABLE OF CONTENTS
7.4 Torch and liner maintenance ................................................................. 31
8
TROUBLESHOOTING ................................................................................. 32
9
ORDERING SPARE PARTS........................................................................ 34
DIAGRAM ............................................................................................................ 35
ORDERING NUMBERS ...................................................................................... 36
WEAR PARTS ..................................................................................................... 37
ACCESSORIES .................................................................................................. 39
REPLACEMENTS PARTS .................................................................................. 40
Rights reserved to alter specifications without notice.
0463 641 001 © ESAB AB 2018

1 SAFETY

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
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1 SAFETY
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.
0463 641 001
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
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© ESAB AB 2018
1 SAFETY
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.
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© ESAB AB 2018

2 INTRODUCTION

2 INTRODUCTION
The ESAB EMP product family is a new generation of MIG and Multi-Process (MIG/MMA/TIG) welding power sources.
The EMP 235ic power source is designed to match the needs of the light-medium fabrication user. It is 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 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 multi-process welding capabilities, MIG/MMA and Lift/TIG
• Automatic recognition of input power with PFC (120V–230V)
• Large 11cm (4.3in.) high resolution, customizable user interface
• Rugged case design and internal hardware
• 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 235ic power source
• Tweco Fusion™ 250 MIG torch, 3 m (10ft) with 0.9mm (0.035in.) Contact Tip fitted
• OTW14/30 Contact tip for 0.8 mm (0.030in.) wire (qty 2)
• OTW14/35 Contact tip for 0.9 mm (0.035in.) wire (qty 2 - 1x spare and 1x fitted)
• OTW14/40 Contact tip for 1.0 mm (0.040in.) wire (qty 2)
• Comet Professional Argon Regulator/Flowmeter
• Gas hose, 4.5 m (15ft), Quick connector, 5/8-18UNF
• MMA welding cable kit 3 m (10ft)
• Return cable kit 3m (10ft)
• OK 12.50 0.9mm (0.035in.) × 5 kg (11lb) spool
• Drive roll 0.9 / 1.2mm (0.035in. / 0.045in.) V Groove (fitted)
• Drive roll 0.8 / 1.0mm (0.030in. / 0.040in.) V Groove (spare)
• Drive roll 0.8 / 0.9mm (0.030in. / 0.035in.) V Knurled (spare)
• Guide tube 1.0 mm – 1.2 mm (0.040in. / 0.045in.) (fitted)
• Guide tube 0.6 mm – 0.8 mm (0.023in. / 0.030in.) (spare)
• Key-drive shaft crescent x 2
• Mains cable 3 m (10ft) fixed with plug
• USB with Instruction manual
• Material thickness guide
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3 TECHNICAL DATA

3 TECHNICAL DATA
EMP 235ic, 230 V
Voltage 230 V, 1~ 50/60 Hz
Primary current
I
GMAW - MIG
max.
I
GTAW - TIG
max.
I
SMAW - MMA
max.
I
GMAW - MIG
eff.
I
GTAW - TIG
eff.
I
SMAW - MMA
eff.
Permissible load at GMAW - MIG
100% duty cycle 130 A / 20.50 V
50% duty cycle 170 A / 22.50 V
32.1 A
24.9 A
31.2 A
14.6 A
14.7 A
14.7 A
35% duty cycle 195 A / 23.75 V
20% duty cycle 235 A / 25.75 V
Setting range (DC) 15 A / 14.75 V – 235A/26.0V
Permissible load at GTAW - TIG
100% duty cycle 160 A / 16.4 V
50% duty cycle 200 A / 18.0 V
35% duty cycle 235A/19.4V
Setting range (DC) 5 A / 10.2 V – 240A/19.6V
Permissible load at SMAW - MMA
100% duty cycle 110 A / 24.4 V
50% duty cycle 150 A / 26.0 V
35% duty cycle 175A/27V
20% duty cycle 210 A / 28.4 V
Setting range (DC) 16 A / 20.6 V – 210A/28.4V
Open circuit voltage (OCV)
VRD activated <35 V DC
VRD deactivated, nominal OCV (Boost OCV) 68 V / (90 V)
Efficiency 86%
Power factor 0.98
Wire feed speed 2.0–17.8m/min (80–700in./min)
Wire diameter
Mild steel solid wire 0.6–1.0 mm (0.023–0.040in.)
Stainless steel solid wire 0.8–1.0 mm (0.030–0.040in.)
Flux cored wire 0.8–1.1mm (0.030–0.045in.)
Aluminium 0.8–1.2mm (0.030–3/64in.)
Bobbin size Ø 100–300 mm (4–12in.)
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© ESAB AB 2018
3 TECHNICAL DATA
EMP 235ic, 230 V
Dimensions l×w×h 686×292×495mm (27.0×11.5×19.5in.)
Weight 28.6 kg (63 lb)
Operating temperature -10to+40°C (+14 to +104°F)
Enclosure class IP23S
Application classification
EMP 235ic, 120 V
Voltage 120 V, 1~ 50/60 Hz
Primary current
I
GMAW - MIG Breaker 20 A: 28.6 A
max.
Breaker 15 A: 20.3 A
I
GTAW - TIG
max.
I
SMAW - MMA
max.
I
GMAW - MIG Breaker 20 A: 18.0 A
eff.
Breaker 15 A: 20.8 A
Breaker 15 A: 20.8 A
Breaker 15 A: 13.0 A
I
GTAW - TIG
eff.
I
SMAW - MMA
eff.
Breaker 15 A: 14.7 A
Breaker 15 A: 14.7 A
Permissible load at GMAW - MIG
100% duty cycle Breaker 20 A: 90 A / 18.5 V
Breaker 15 A: 75 A / 17.75 V
60% duty cycle Breaker 20 A: 110 A / 19.5 V
Breaker 15 A: 90 A / 18.5 V
40% duty cycle Breaker 15 A: 100 A / 19.0 V
25% duty cycle -
20% duty cycle Breaker 20 A: 130 A / 20.5 V
Setting range (DC) 15 A / 14.75 V – 130A/20.5V
Permissible load at GTAW - TIG
100% duty cycle 100 A / 14.0 V
60% duty cycle 120 A / 14.8 V
40% duty cycle 130 A / 15.2 V
30% duty cycle -
Setting range (DC) 5 A / 10.2 V – 200A/18.0V
Permissible load at SMAW - MMA
100% duty cycle 65 A / 22.6 V
60% duty cycle 80 A / 23.2 V
40% duty cycle 85A / 23.4V
25% duty cycle -
Setting range (DC) 16 A / 20.6 V – 130A/25.2V
Open circuit voltage (OCV)
VRD activated <35 V DC
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3 TECHNICAL DATA
EMP 235ic, 120 V
VRD deactivated, nominal OCV (Boost OCV) 68 V / (90 V)
Efficiency 84%
Power factor 0.99
Wire feed speed 2.0–17.8m/min (80–700in./min)
Wire diameter
Mild steel solid wire 0.6–1.0 mm (0.023–0.040in.)
Stainless steel solid wire 0.9–1.0 mm (0.035–0.040in.)
Flux cored wire 0.8–1.2mm (0.030–0.045in.)
Aluminium 0.8–1.2mm (0.030–3/64in.)
Bobbin size Ø 100–300 mm (4–12in.)
Dimensions l×w×h 686×292×495mm (27.0×11.5×19.5in.)
Weight 28.6 kg (63 lb)
Operating temperature -10to+40°C (+14 to +104°F)
Enclosure class IP23S
Application classification
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a certain load without overloading. 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.
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© ESAB AB 2018

4 INSTALLATION

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.
0463 641 001
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© ESAB AB 2018
4 INSTALLATION
WARNING!
Secure the equipment - particularly if the ground is uneven or sloping.

4.3 Mains supply

NOTE! Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit power is greater than or equal to S
the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power greater than or equal to S
. Refer to the technical data in the TECHNICAL DATA chapter.
scmin
at the interface point between the user's supply and
scmin
The supply voltage should be 230VAC±10% or 120V±10%. Too low supply voltage may cause poor welding performance. Too high welding supply voltage will cause components to overheat and possibly fail. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required.
The welding power source must be:
• Correctly installed, if necessary, by a qualified electrician.
• Correctly earthed (electrically) in accordance with local regulations.
• Connected to the correct size power point and fuse as table below.
NOTE!
Use the welding power source in accordance with the relevant national regulations.
CAUTION!
Disconnect input power and secure employing ‘Lock-out’ / ‘Tagging’ procedures. Ensure input power line disconnect switch is locked (lock-out/Tagging) in the ‘Open’ position BEFORE removing input power fuses. Connection/Disconnect should be carried out by competent persons.
1. Rating plate with supply connection data
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© ESAB AB 2018
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