ESAB EMP 215IC, EMS 215IC Service Manual

Revision: AA Issue Date: December 20, 2016 Manual No.: 0463 413 001

esab.com

ESAB EMP 215IC/EMS 215IC

MULTI PROCESS WELDER

Service Manual

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on the web at www.esab.com

This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

ESAB is a Global Brand of manual and automation Plasma Cutting Products.

We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.

WARNING

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Multi-Process Welding Power Supply ESAB EMP215ic/EMS215ic Service Manual Number 0463 413 001

Published by: ESAB Group Inc 2800 Airport Rd. Denton, Texas 76207

www.esab.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

For Printing Material Speciﬁcation refer to document 47x1914

Original Publication Date: December 20, 2016 Revision Date:

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

OPERATING.

PROTECT YOURSELF AND OTHERS!

ESAB EMS215C/EMP215C

Manual 0463 413 001 DECLARATION OF CONFORMITY 5

EU DECLARTION OF CONFORMITY

According to

The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016

The EMC Directive 2014/30/EU, entering into force 20 April 2016

The RoHS Directive 2011/65/EU, entering into force 2 January 2013

Type of equipment Welding power source

Type designation EMP 215ic, from serial number 615 xxx xxxx (2016 w/21)

Brand name or trade mark ESAB

Manufacturer or his authorised representative established within the EEA

Name, Address, and telephone No:

ESAB AB Lindholmsallén 9, Box 8004, SE-402 77 Göteborg, Sweden Phone: +46 31 50 90 00, Fax: +46 584 411 924

The following harmonised standard in force within the EEA has been used in the design:

EN 60974-1:2012, Arc Welding Equipment - Part 1: Welding Power Sources EN 60974-5:2013, Arc Welding Equipment - Part 5: Wire Feeders EN 60974-10:2014, Arc Welding Equipment - Part 10: Electromagnetic Compatibility (EMC) requirements

Additional Information: Restrictive use, Class A equipment, intended for use in location other than residential

By signing this document, the undersigned declares as manufacturer, or the manufacturer's authorised representative established within the EEA, that the equipment in question complies with the safety requirements stated above.

Date Signature Position

Gothenburg Global Director of Equipment

2016-04-20 Stephen Argo

2016

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6 DECLARATION OF CONFORMITY Manual 0463 413 001

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TABLE OF CONTENTS

1 SAFETY PRECAUTIONS ............................................................................. 1-1

1.01 Safety precautions .......................................................................................... 1-1

1.02 User responsibility .......................................................................................... 1-6

2 SYSTEM INSTALLATION ............................................................................ 2-1

2.01 Installation ...................................................................................................... 2-1

2.02 Lifting Instructions ......................................................................................... 2-1

2.03 Location .......................................................................................................... 2-1

2.04 Mains Supply .................................................................................................. 2-2

2.05 Technical Data ................................................................................................. 2-3

2.06 Connecting the Power Source to Input Supply ............................................... 2-5

3 OPERATION ........................................................................................... 3-1

3.01 General ........................................................................................................... 3-1

3.02 Controls and Connections ............................................................................... 3-4

3.03 Connection of Welding and Work leads .......................................................... 3-5

3.04 Polarity Change ............................................................................................... 3-5

3.05 Inserting and Replacing Wire .......................................................................... 3-6

3.06 Setting the Wire Feed Pressure ....................................................................... 3-7

3.07 Changing the Feed/Pressure Rollers ............................................................... 3-7

3.08 Shielding Gas .................................................................................................. 3-8

3.09 Volt Ampere Curves ........................................................................................ 3-8

3.10 Duty Cycle ..................................................................................................... 3-10

3.11 Control Panel ................................................................................................ 3-11

4 SERVICE INSTRUCTIONS ........................................................................... 4-1

4.01 What is ESD .................................................................................................... 4-1

5 POWER SUPPLY INTRODUCTION .................................................................. 5-1

5.01. Introduction ................................................................................................... 5-1

5.02. Working Principle ........................................................................................... 5-1

5.03 Block Diagram ................................................................................................ 5-2

5.04 System Schematic for CSA Systems .............................................................. 5-4

5.05 System Schematic for CE Systems ................................................................. 5-6

5.06 Component Location ....................................................................................... 5-8

6 TROUBLESHOOTING ................................................................................ 6-1

6.01 Error Codes ..................................................................................................... 6-1

6.02 Pre Power-up Checks...................................................................................... 6-4

6.03 LED Diagnostics ........................................................................................... 6-13

6.04 Initial Power Up Test ..................................................................................... 6-13

6.05 Initial Power Up Test Problems ..................................................................... 6-17

6.06 Test Procedure/troubleshooting .................................................................... 6-25

6.07 PCB Layout ................................................................................................... 6-29

7 MAINTENANCE ....................................................................................... 7-1

7.01 Routine Maintenance ...................................................................................... 7-1

7.02 Power Source and Wire Feeder Maintenance .................................................. 7-2

7.03 Torch and Liner Maintenance .......................................................................... 7-2

TABLE OF CONTENTS

8 REPLACEMENT PARTS .............................................................................. 8-1

8.01. Introduction ................................................................................................... 8-1

8.02. External Replacement Parts ............................................................................ 8-2

8.03 Internal Replacement Parts 1 CSA Systems ................................................... 8-3

8.04 Internal Replacement Parts 1 CE Systems ...................................................... 8-4

8.05 Internal Replacement Parts 2 .......................................................................... 8-5

8.06 Wire Feeder Replacement Parts CSA Systems ................................................ 8-6

8.07 Wire Feeder Replacement Parts CE Systems .................................................. 8-7

9 DISASSEMBLY ........................................................................................ 9-1

9.01 Safety Precautions for Disassembly ............................................................... 9-1

9.02 User Interface TFT Display Assembly Removal ............................................... 9-1

9.03 Control PCB Removal ..................................................................................... 9-3

9.04 Power PCB Assembly Removal ....................................................................... 9-4

APPENDIX 1: WORKING PRINCIPLE

(BLOCK DIAGRAM) .................................................................................. A-1

APPENDIX 2: CSA SYSTEM SCHEMATIC, 115/230V UNITS .......................................... A-2

APPENDIX 3: CE SYSTEM SCHEMATIC, 115/230V UNITS ........................................... A-4

Revision History ............................................................................................ A-8

ESAB EMS215C/EMP215C

Manual 0463 413 001 SAFETY INSTRUCTIONS 1-1

1 SAFETY PRECAUTIONS

1.01 Safety precautions

MEANING OF SYMBOLS As used throughout this manual: Means Attention! Be Alert!

DANGER!

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

injury or loss of life.

WARNING!

WARNING Means potential mechanical or non-electrical hazards which could result in personal injury or loss of life.

WARNING Means potential electrical hazards which could result in personal injury or loss of life.

CAUTION!

CAUTION Means hazards which could result in minor personal injury.

WARNING

Read and understand the instruction manual before installing or operating..

WARNING

These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

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1-2 SAFETY INSTRUCTIONS Manual 0463 413 001

PROTECT YOURSELF AND OTHERS

Some welding, cutting and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:

1. Wear a welding helmet ﬁtted with a proper shade of ﬁlter to protect you face and eyes when welding or watching.

2. Always wear safety glasses with side shields in any work area, even if welding helmets face shields and goggles are also required.

3. Use a face shield ﬁtted with the correct ﬁlter and cover plates to protect your eyes, face, neck and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

4. Wear ﬂameproof gauntlet type gloves, heavy long-sleeve shirt, cu less trousers, high-topped shoes and a welding helmet or cap for protection, to protect against arc rays and hot sparks or hot metal. A ﬂameproof apron may also be desirable as protection against radiated heat and sparks.

5. Hot sparks or metal can lodge in rolled up sleeves, trouser cus, or pockets. Sleeves and collars should be kept buttoned and open pockets eliminated from the front of clothing.

6. Protect other personnel from arc rays and hot sparks with a suitable non-ﬂammable partition or curtains.

7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can ﬂy far. Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS

Heat from ﬂames and arcs can start ﬁres. Hot slag or sparks can also cause ﬁres and explosions. Therefore:

1. Protect yourself and others from ﬂying sparks and hot metal.

2. Remove all combustible materials well away from the work area or cover the materials with a protective non-ﬂammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings paper, etc.

3. Hot sparks or hot metal can fall through cracks or crevices in ﬂoors or wall openings and cause a hidden smoldering ﬁre or ﬁres on the ﬂoor below. Make certain that such openings are protected from hot sparks and metal.

4. Do not weld, cut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce ﬂammable or toxic vapors. Do not do hot work on closed containers. They may explode.

5. Have ﬁre extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable ﬁre extinguisher. Be sure you are trained in its use.

6. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a ﬁre hazard.

7. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later ﬁre. Use ﬁre watchers when necessary.

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Manual 0463 413 001 SAFETY INSTRUCTIONS 1-3

ELECTRICAL SHOCK

Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is conﬁned, or if there is danger of falling. Therefore:

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for speciﬁc grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS

May be dangerous. Electric current ﬂowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

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

2. Exposure to EMF may have other health eects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF:

a) Route the electrode and work cables together. Secure them with tape when possible.

b) Never coil the torch or work cable around your body.

c) Do not place your body between the torch and work cables. Route cables on the same side of your

body.

d) Connect the work cable to the workpiece as close as possible to the area being welded.

e) Keep welding power source and cables as far away from your body as possible.

FUMES AND GASES

Fumes and gases, can cause discomfort or harm, particularly in conﬁned spaces. Shielding gases can cause asphyxiation. Therfore:

1. Keep your head out of the fumes. Do not breathe the fumes and gases.

2. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

3. Do not operate near degreasing and spraying operations. The heat or arc can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other irritant gases.

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1-4 SAFETY INSTRUCTIONS Manual 0463 413 001

4. If you develop momentary eye, nose or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.

5. Refer to ANSI/ASC Standard Z49.1 (see listing below) for speciﬁc ventilation recommendations.

6. WARNING: This product when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer (California Health & Safety Code §25249.5 et seq.)

CYLINDER HANDLING

Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder valve or relief device can injure or kill. Therefore:

1. Locate cylinders away from heat, sparks and ﬂames. Never strike an arc on a cylinder.

2. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and ﬁttings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.

3. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work tables or ﬁxtures where they may become part of an electrical circuit.

4. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks.

5. For additional information, refer to CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”, which is available from Compressed Gas Association, 1235 Jeerson Davis Highway, Arlington, VA 22202.

MOVING PARTS

Moving parts, such as fans, rotors and belts can cause injury. Therefore:

1. Keep all doors, panels and covers closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualiﬁed people remove covers for maintenance and troubleshooting as necessary

4. To prevent accidental starting of equipment during service, disconnect negative (-) battery cable from battery.

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

6. Reinstall panels or covers and close doors when service is ﬁnished and before starting engine.

WARNING

FALLING EQUIPMENT CAN INJURE

• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or any other accessories.

• Use equipment of adequate capacity to lift and support unit.

• If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

• Keep cables and cords away from moving vehicles when working from an aerial location.

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Manual 0463 413 001 SAFETY INSTRUCTIONS 1-5

WARNING

EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death. Therefore:

1. Always have qualiﬁed personnel perform the installation, troubleshooting and maintenance work. Do not perform any electrical work unless you are qualiﬁed to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

CAUTION

ADDITIONAL SAFETY INFORMATION For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding, Cutting and Gouging”, Form 52-529. The following publications are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”

2. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”

3. AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”

4. AWS SP - “Safe practices” - Reprint, Welding Handbook

5. ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances”

6. OSHA 29 CFR 1910 - “Safety and health standards”

7. CSA W117.2 - “Code for safety in welding and cutting”

8. NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other

Hot Work"

9. CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in

Cylinders”

10. ANSI Z87.1, "Occupational and Educational Personal Eye and Face

Protection Devices"

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1-6 SAFETY INSTRUCTIONS Manual 0463 413 001

1.02 User responsibility

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

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 extinquishing 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. Ask for your employer’s safety practices which should be based on manufacturers’ hazard data.

ELECTRIC SHOCK - Can kill

• Install and earth the unit in accordance with applicable standards

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

• Insulate yourself from earth and the work piece

• Ensure your working stance is safe

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

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Manual 0463 413 001 SAFETY INSTRUCTIONS 1-7

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

FIRE HAZARD

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

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmus or other hearing protection.

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

PROTECT YOURSELF AND OTHERS!

REFERENCE TO CAN/CSA-W117.2-06

WARNING

Do not use the power source for thawing frozen pipes.

CAUTION

This product is solely intended for arc welding.

ESAB can provide you with all necessary welding protection and accessories.

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1-8 SAFETY INSTRUCTIONS Manual 0463 413 001

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ESAB EMS215C/EMP215C

Manual 0463 413 001 INSTALLATION 2-1

2 SYSTEM INSTALLATION

2.01 Installation

If you are not experienced seek help from a professional before installing.

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.

2.02 Lifting Instructions

The Power Supply includes a series of handles for hand lifting only.

2.03 Location

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

A - 4” (100 mm)

B - 4” (100 mm)

Secure the equipment - particularly if the ground is uneven or sloping.

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2-2 INSTALLATION Manual 0463 413 001

2.04 Mains Supply

NOTE! Mains suppy requirments for CE version

This equipment complies with IEC 61000-3-12 provided that the short-circuit power is greater than or equal to Sscmin at the interface point between the user's supply and 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 Sscmin. Refer to the technical data in the TECHNICAL DATA chapter.

The supply voltage should be within 230VAC ± 10% or 120 V ± 10%. Too low a supply voltage may cause poor welding performance in Stick mode such as the arc snung out during welding. Too high a 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 line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit. If no disconnect switch is available then unplug the power cord from the wall.

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.

Do not connect the input (WHITE or BLACK) conductor to the ground terminal. Do not connect the ground (GREEN) conductor to an input line terminal.

WARNING

The power source must be electrically connected by a qualiﬁed electrical trades-person. Damage to the PCA (Power Control Assembly) could occur if 265 VAC or higher is applied to the primary power cable.

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts..

2.4.1 Recommended Fuse Sizes and Minimum Cable Size

WARNING

An electrical shock or ﬁre hazard is probable if the following electrical service guide recommendations are not followed. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

50/60Hz single phase supply

Supply voltage 230V AC 120V AC

Input current at maximum output 30 Amps 30 Amps

Maximum recommended fuse* or circuit breaker rating *Time delay fuse UL class RK5. Refer to UL 248

30 Amps 30 Amps

Maximum recommended fuse* or circuit breaker rating *Normal operating UL class K5. Refer to UL 248

50 Amps 50 Amps

Minimum recommended cord size 12 AWG (4 mm2) 12 AWG (4 mm2)

Maximum recommended extension cord length 50 ft (15m) 25 ft (8m)

Minimum recommended grounding conductor size 12 AWG (4 mm2 ) 12 AWG (4 mm2)

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Manual 0463 413 001 INSTALLATION 2-3

Supply from power generators

The power source can be supplied from dierent types of generators. However, some generators may not provide sucient power for the welding power source to operate correctly. Generators with Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with rated power 8 kW, are recommended.

2.05 Technical Data

EMP 215ic

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

Primary current

Imax. GMAW - MIG 30 A (27.6A @ 25% duty cycle)

20 A Breaker: 28.6 A 15 A Breaker: 20.3 A

Imax. GTAW - TIG 19 A 15 A Breaker: 20.8 A

Imax. SMAW - Stick 25 A 15 A Breaker: 20.8 A

Ie. GMAW - MIG 14 A

20 A Breaker: 13 A 15 A Breaker: 14.6 A

Ie. GTAW - TIG 10 A 15 A Breaker: 14.7 A

Ie. SMAW - Stick 13 A 15 A Breaker: 14.7 A

Permissible load in GMAW - MIG

100% duty cycle 110 A / 19.5 V

15A Breaker: 75 A / 17.75 V 20A Breaker: 90 A / 18.5 V

60% duty cycle 125 A / 20.25 V

15A Breaker: 90 A / 18.5 V 20A Breaker: 110 A / 19.5 V

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

25% duty cycle 205 A / 24.25 V

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

Setting range (DC) 15 A / 14.75 V - 235 A / 26 V 15 A / 14.75 V - 130 A / 20.5 V

Permissible load in 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 - 200 A / 18.0 V

Permissible load in SMAW - Stick

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 - 85 A / 23.4V

25% duty cycle 180A / 27.2 V -

Setting range (DC) 16 A / 20.6 V - 180 A / 27.2 V 16 A / 20.6 V - 130 A / 25.2 V

Open circuit voltage (OCV)

VRD Deactivated 68 V 68 V

VRD Activated 35V 35V

Eciency 86% 84%

Power factor 0.98 0.99

Wire feed speed

80-475 inch/min (2-12.1 m/min)

Wire diameter

Mild steel solid wire

.023” (0.6 mm) - .035” (0.9 mm)

Stainless steel solid wire

.030” (0.8 mm) - .035” (0.9 mm)

Flux cored wire

.030” (0.8 mm) - .045” (1.1 mm)

Aluminium

.030” (0.8 mm) - 3/64" (1.2 mm)

Wire Spool size Ø 4”- 8” (100-200 mm) Ø 4”- 8” (100-200 mm)

ESAB EMS215C/EMP215C

2-4 INSTALLATION Manual 0463 413 001

Dimensions L×W×H

23.0” (548 mm) × 9.0” (229 mm) × 16.0” (406 mm)

Weight 40 lbs (18.2 kg) 40 lbs (18.2 kg)

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

Enclosure class IP23S IP23S

Application classiﬁcation

EMS 215ic

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

Primary current

Imax. GMAW - MIG 30 A (27.6 A @ 25% duty cycle

20 A Breaker: 28.6 A 15 A Breaker: 20.3 A

Imax. SMAW - Stick 25 A 15 A Breaker: 20.8 A

Ie. GMAW - MIG 14A

20 A Breaker: 18 A 15 A Breaker: 14.6 A

Ie. SMAW - Stick 13 A 15 A Breaker: 14.7 A

Permissible load at GMAW - MIG

100% duty cycle 110 A / 19.5 V

20 A Breaker: 90 A / 18.5 V 15 A Breaker: 75 A / 17.75 V

60% duty cycle 125 A / 20.25 V

20 A Breaker: 110 A / 19.5 V 15 A Breaker: 90 A / 18.5 V

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

25% duty cycle 205 A / 24.25 V -

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

Setting range (DC) 15 A / 14.75 V - 220 A / 26 V 15 A / 14.75 V - 130 A / 21 V

Permissible load at SMAW - Stick

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 C 85 A / 23.4 V

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 - 130 A / 25.2 V

Open circuit voltage (OCV)

VRD Deactivated 68 V 68 V

VRD Activated 35V 35V

Eciency 86% 84%

Power factor 0.98 0.99

Wire feed speed 80-475 inch/min

(2-12.1 m/min)

80-475 inch/min (2-12.1 m/min)

Wire diameter

Mild steel solid wire .023” (0.6 mm) - .035” (0.9 mm) .023” (0.6 mm) - .035” (0.9 mm)

Stainless steel solid wire .030” (0.8 mm) - .035” (0.9 mm) .030” (0.8 mm) - .035” (0.9 mm)

Flux cored wire .030” (0.8 mm) - .045”

(1.1 mm)

.030” (0.8 mm) - .045” (1.1 mm)

Aluminium .030” (0.8 mm) - 3/64"

(1.2 mm)

.030” (0.8 mm) - 3/64" (1.2 mm)

Wire Spool size Ø 4”- 8” (100-200 mm) Ø 4”- 8” (100-200 mm)

Dimensions l×w×h 23.0” (548 mm) × 9.0”

(229 mm) × 16.0” (406 mm)

l×w×h 23.0” (548 mm) × 9.0” (229 mm) × 16.0” (406 mm)

Weight 40 lbs (18.2 kg) 40 lbs (18.2 kg)

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

Enclosure class IP23S IP23S

Application classiﬁcation

ESAB EMS215C/EMP215C

Manual 0463 413 001 INSTALLATION 2-5

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 104°F / 40°C.

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.

2.06 Connecting the Power Source to Input Supply

50/60Hz single phase supply

Supply voltage 230V AC 120V AC

Input current at maximum output 30 Amps 30 Amps

Maximum recommended fuse* or circuit breaker rating *Time delay fuse UL class RK5. Refer to UL 248

30 Amps 30 Amps

Maximum recommended fuse* or circuit breaker rating *Normal operating UL class K5. Refer to UL 248

50 Amps 50 Amps

Minimum recommended cord size 12 AWG (4 mm2) 12 AWG (4 mm2)

Maximum recommended extension cord length 50 ft (15m) 25 ft (8m)

Minimum recommended grounding conductor size 12 AWG (4 mm2 ) 12 AWG (4 mm2)

Supply From Power Generators

Use one of the supplied adapters to connect the power source to mains.

ESAB EMS215C/EMP215C

2-6 INSTALLATION Manual 0463 413 001

208/230V, 50A

120V, 15A

120V, 20A

NEMA 6-50P 230VAC plug

ESAB EMS215IC/EMP215IC

Manual 0463 413 001 OPERATION 3-1

3 OPERATION

3.01 General

General safety regulations for handling the equipment can be found in the "1 SAFETY PRECAUTIONS" chapter of this manual. Read it through before you start using the equipment!

NOTE!

When moving the equipment use intended handle. Never pull on the cables.

WARNING

Rotating parts can cause injury, take great care.

WARNING

Electric shock! Do not touch the workpiece or the welding head during operation!

Icon Reference Guide

Home

Spot time on/o selection

Information

MIG Gun Spot time on adjustment

Parameters

Flux cored

Parameters Manual MIG

Percent

MMA

Postﬂow The time the

shielding gas stays on after the welding arc is stopped

Smart MIG

Preﬂow The time the

shielding gas stays on before the welding arc is started

TIG

ESAB EMS215IC/EMP215IC

3-2 OPERATION Manual 0463 413 001

2T, Trigger On/OFF

Burnback Adjusting the time

when the voltage stays on after the wire feed is stopped to keep the wire from freezing in the weld puddle

4T, Trigger Hold/Lock User manual on main menu

Amps

Plate thickness at sMIG

mode

Arc force On stick welding-increasing amps when the arc length is shortened to reduce or eliminate the freezing of the stick electrode in the weld puddle

Trim bar Changing the weld bead profile from flat to convex or flat to concave

Downslope Sloping the current down overaperiod of time at the end of the weld cycle

Advanced Settings

Hot start The increase of

amps when striking the electrode to reduce sticking

Basic Settings

Seconds

Saving welding programs for

a speciﬁc application when in the Memory Mode

Settings on user manual menu

Cancel

Spool Gun

(Not all markets)

Remote

Settings Foot control

ESAB EMS215IC/EMP215IC

Manual 0463 413 001 OPERATION 3-3

Stick electrode choice Unit of Measure

Upslope, Sloping the

current up overaperiod of time at the beginning of the weld cycle

Bead proﬁle, concave

Volts

Bead proﬁle, convex

Wire feed speed Wire diameter

.8 mm

(.030”)

Inductance The addition of inductance into the arc characteristics to stabilize the arc and reduce spatter when in the short circuit process

Diagnostics

Memory, able to save

welding programs for a specific application

Language selection

ESAB EMS215IC/EMP215IC

3-4 OPERATION Manual 0463 413 001

3.02 Controls and Connections

Front and rear:

1. Knob for current or wire feed speed selection

2. Display

3. Knob for voltage selection

4. Main knob for menu navigation

5. Torch/Remote control connection

6. Negative output [-]

7. Polarity changeover cable and receptacle connected to positive output [+]

8. Torch connection. CE will have Euro Torch Connector

9. Mains cable

10. Mains supply switch ON/OFF

11. Gas valve inlet

ESAB EMS215IC/EMP215IC

Manual 0463 413 001 OPERATION 3-5

Drive System Diagram

1. Wire Spool Hub

2. Circuit breaker

3. Side Panel

4. Gas valve

5. Wire feeder mechanism

3.03 Connection of Welding and Work leads

The power source has two outputs for connecting welding and work leads (see front illustration), a negative [-] terminal (6) and a positive [+] terminal (7). For optional TIG process, connect the TIG torch power cable to the negative [-] terminal (6), see front illustration. Connect the shielded gas hose ﬁtting to the inlet on the rear panel from the Regulator/Flowmeter For Stick process the output to which the welding cable is connected depends on the type of electrode, please refer to electrode packaging for information relating to the correct electrode polarity. Connect the work lead to the remaining welding terminal on the power source. Secure the work lead's contact clamp to the work piece and ensure that there is good contact.

3.04 Polarity Change

The power source is delivered with the polarity changeover cable connected to the positive terminal. Some wires, e.g. shelf-shielded cored wires, are recommended to be welded with negative polarity. Negative polarity means that the polarity changeover cable is connected to the negative terminal and the work lead to the positive terminal. Check the recommended polarity for the welding wire you want to use.

The polarity can be changed as follows:

1. Switch o the power source and disconnect the mains cable.

2. Move the polarity changeover cable from positive to negative terminal.

ESAB EMS215IC/EMP215IC

3-6 OPERATION Manual 0463 413 001

3.05 Inserting and Replacing Wire

The EMS 215ic and EMP 215ic will handle wire spool sizes of 4” (100 mm) and 8” (200 mm).

1. Open the side panel.

2. Release the tension from the pressure roller by turning the adjustable wire drive tension knob in an counter-clockwise direction. To release the pressure roller arm push the tension screw toward you (1).

3. Lift the pressure roller arm up (2).

4. With the MIG welding wire feeding from the bottom of the spool pass the electrode wire through the inlet guide (3), between the rollers, through the outlet guide and into the MIG torch.

5. Re-secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly. Remove the velocity nozzle and contact tip from the MIG torch.

6. With the MIG torch lead reasonably straight, feed the wire through the MIG torch by depressing the trigger switch. Fit the appropriate velocity nozzle and contact tip.

7. Close the side panel.

Welding with aluminium wire

In order to weld with aluminium wire use optional Spool gun. Refer to Instruction manual for Spool gun for set up.

Welding with TIG (EMP-series only)

In order to weld with TIG use optional TIG-torch. Refer to Instruction manual for TIG-torch for set up.

ESAB EMS215IC/EMP215IC

Manual 0463 413 001 OPERATION 3-7

3.06 Setting the Wire Feed Pressure

Piece of wood

WARNING

Never point the torch toward you while depressing the trigger.

Start by making sure that the wire moves smoothly through the wire guide. Then set the pressure of the wire feeder's pressure rollers. It is important that the pressure is not too high.

To check that the feed pressure is set correctly, you can feed out the wire against an insulated object, e.g. a piece of wood.

When you hold the welding torch approximately ¼” (5 mm) from the piece of wood (illustration A) the feed rollers should slip.

If you hold the welding torch approximately 2” (50 mm) from the piece of wood, the wire should be fed out and bend (illustration B).

3.07 Changing the Feed/Pressure Rollers

A dual groove feed roller is supplied as standard. It can accommodate 0.030” (0.8 mm) / 0.035” (0.9 mm) diameter hard wires. It is delivered from the factory with 0.030” installed which is the groove furthest from you.

NOTE!

Be sure not to lose the key that is located on the drive motor shaft. This key must align with drive roll groove for proper operation.

1. Open the side panel.

2. Remove the feed roll retaining screw by turning it in counter-clockwise direction.

3. Change the feed roll. The far side of the feed roll is the groove in use when wire is traveling through the roller.

4. Tighten the feed roll retaining screw by turning it in clockwise position.

5. Close the side panel.

Active Groove

ESAB EMS215IC/EMP215IC

3-8 OPERATION Manual 0463 413 001

3.08 Shielding Gas

The choice of suitable shielding gas depends on the material. Typically mild steel is welded with mixed gas (Ar + CO2) or 100% carbon dioxide (CO2). Stainless Steel can be welded with mixed gas (Ar + CO2) or Trimix (He + Ar + CO2). Aluminium and silicon bronze use pure argon gas (Ar). In the sMIG mode (see section "sMIG mode" in the CONTROL PANEL chapter) the optimal welding arc with the gas you use will be automatically set.

3.09 Volt Ampere Curves

The curves below show the maximum voltage and amperage output capabilities of the power source for three common welding process settings. Other settings result in curves that fall between these curves.

+ 72 hidden pages

ESAB EMP 215IC, EMS 215IC Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual