ESAB | EMP235IC | Service manual | ESAB EMP235IC User manual

ESAB EMP235IC User manual
ESAB
EMP235IC
MULTI PROCESS WELDER
Service
Manual
®
Revision: AA
Issue Date: May 20, 2019
Manual No.: 0463 644 001
esab.com
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 EMP235ic Service Manual Number 0463 644 001
Published by:
ESAB Group Inc
2800 Airport Rd.
Denton, Texas 76207
www.esab.com
Copyright © 2016 by ESAB
All rights reserved.
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: May 20, 2019
i
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!
TABLE OF CONTENTS
1
SAFETY PRECAUTIONS.............................................................................. 1-1
1.01
1.02
2
SYSTEM INSTALLATION............................................................................. 2-1
2.01
2.02
2.03
2.04
2.05
2.06
3
Introduction .................................................................................................... 5-1
Working Principle............................................................................................ 5-1
Diagram for both CSA and CE.......................................................................... 5-2
System Schematic for CSA Systems............................................................... 5-4
System Schematic for CE Systems.................................................................. 5-6
Component Location........................................................................................ 5-8
TROUBLESHOOTING................................................................................. 6-1
6.01
6.02
6.03
6.04
6.05
6.06
6.07
7
What is ESD..................................................................................................... 4-1
POWER SUPPLY INTRODUCTION................................................................... 5-1
5.01.
5.02.
5.03
5.04
5.05
5.06
6
General............................................................................................................ 3-1
Controls and Connections................................................................................ 3-5
Connection of Welding and Work leads........................................................... 3-6
Polarity Change................................................................................................ 3-6
Inserting and Replacing Wire........................................................................... 3-7
Setting the Wire Feed Pressure........................................................................ 3-8
Changing the Feed/Pressure Rollers................................................................ 3-8
Shielding Gas................................................................................................... 3-9
Volt Ampere Curves....................................................................................... 3-10
Duty Cycle...................................................................................................... 3-12
Control Panel................................................................................................. 3-13
SERVICE INSTRUCTIONS............................................................................ 4-1
4.01
5
Installation....................................................................................................... 2-1
Lifting Instructions.......................................................................................... 2-1
Location........................................................................................................... 2-1
Mains Supply................................................................................................... 2-2
Technical Data.................................................................................................. 2-3
Connecting the Power Source to Input Supply................................................ 2-4
OPERATION............................................................................................ 3-1
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.08
3.09
3.10
3.11
4
Safety precautions........................................................................................... 1-1
User responsibility........................................................................................... 1-6
Error Codes...................................................................................................... 6-1
Pre Power-up Checks...................................................................................... 6-3
LED Diagnostics............................................................................................ 6-12
Initial Power Up Test...................................................................................... 6-12
Initial Power Up Test Problems...................................................................... 6-16
Test Procedure/troubleshooting..................................................................... 6-24
PCB Layout.................................................................................................... 6-28
MAINTENANCE........................................................................................ 7-1
7.01
7.02
7.03
7.04
Routine Maintenance....................................................................................... 7-1
Power Source and Wire Feeder Maintenance................................................... 7-2
Torch and Liner Maintenance........................................................................... 7-2
Periodic Inspection and Testing....................................................................... 7-2
TABLE OF CONTENTS
8
DISASSEMBLY......................................................................................... 8-1
8.01
8.02
8.03
8.04
Safety Precautions for Disassembly................................................................ 8-1
User Interface TFT Display Assembly Removal................................................ 8-1
Control PCB Removal...................................................................................... 8-3
Power PCB Assembly Removal........................................................................ 8-4
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 EMP235IC
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.
Manual 0463 644 001
SAFETY INSTRUCTIONS
1-1
ESAB EMP235IC
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, cuff 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 cuffs, 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.
1-2
SAFETY INSTRUCTIONS
Manual 0463 644 001
ESAB EMP235IC
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 off 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 effects 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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SAFETY INSTRUCTIONS
1-3
ESAB EMP235IC
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 Jefferson 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.
1-4
SAFETY INSTRUCTIONS
Manual 0463 644 001
ESAB EMP235IC
!
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"
Manual 0463 644 001
SAFETY INSTRUCTIONS
1-5
ESAB EMP235IC
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
1-6
SAFETY INSTRUCTIONS
Manual 0463 644 001
ESAB EMP235IC
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 earmuffs 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.
Manual 0463 644 001
SAFETY INSTRUCTIONS
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ESAB EMP235IC
This Page Intentionally Blank
1-8
SAFETY INSTRUCTIONS
Manual 0463 644 001
ESAB EMP235IC
2
SYSTEM INSTALLATION
2.01
Installation
If you are not experienced seek help from a professional before installing.
!
2.02
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.
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)
A
B
B - 4” (100 mm)
Secure the equipment - particularly if the ground is uneven or sloping.
Manual 0463 644 001
INSTALLATION
2-1
ESAB EMP235IC
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 snuffing 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
32 Amps
30 Amps
Maximum recommended fuse* or circuit breaker rating
*Time delay fuse UL class RK5. Refer to UL 248
32 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
10 AWG (4 mm2)
12 AWG (4 mm2)
Maximum recommended extension cord length
50 ft (15m)
25 ft (8m)
Minimum recommended grounding conductor size
2-2
INSTALLATION
10 AWG (4
mm2 )
12 AWG (4 mm2)
Manual 0463 644 001
ESAB EMP235IC
Supply from power generators
The power source can be supplied from different types of generators. However, some generators may not
provide sufficient 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
EMP235ic
230 V,1 ~ 50/60 Hz
120 V, 1 ~ 50/60 Hz
Imax. GMAW - MIG
31.7 A
20 A Breaker: 28.6 A
15 A Breaker: 20.3 A
Imax. GTAW - TIG
24.9 A
15 A Breaker: 20.8 A
Imax. SMAW - Stick
31.2 A
15 A Breaker: 20.8 A
Ieff. GMAW - MIG
15.9 A
20 A Breaker: 13 A
15 A Breaker: 14.6 A
Ieff. GTAW - TIG
15.8 A
15 A Breaker: 14.7 A
Ieff. SMAW - Stick
15.9 A
15 A Breaker: 14.7 A
100% duty cycle
140 A / 21.0 V
15A Breaker: 75 A / 17.75 V
20A Breaker: 90 A / 18.5 V
60% duty cycle
170A / 22.5 V
15A Breaker: 90 A / 18.5 V
20A Breaker: 110 A / 19.5 V
40% duty cycle
195A / 23.75 V
15A Breaker: 100 A / 19 V
25% duty cycle
230A / 25.50 V
-
20% duty cycle
-
20A Breaker: 130 A / 20.5 V
Setting range (DC)
15A / 14.75V - 235A / 26.0V
15 A / 14.75 V - 130 A / 20.5 V
100% duty cycle
170 A / 16.8 V
100 A / 14 V
60% duty cycle
200 A / 18.0 V
120 A / 14.8 V
40% duty cycle
235 A / 19.4 V
130 A / 15.2 V
30% duty cycle
-
Setting range (DC)
5 A / 10.2 V – 240 A / 19.6 V
5 A / 10.2 V - 200 A / 18.0 V
100% duty cycle
120 A / 24.8 V
65 A / 22.6 V
60% duty cycle
150 A / 26.0 V
80 A / 23.2 V
40% duty cycle
175 A / 27.0 V
85 A / 23.4V
25% duty cycle
210 A / 28.4 V
-
Setting range (DC)
16 A / 20.6 V – 210 A / 28.4 V
16 A / 20.6 V - 130 A / 25.2 V
VRD Deactivated
68 V
68 V
VRD Activated
35V
35V
Efficiency
85%
84%
Power factor
0.98
0.99
Wire feed speed
80-700 in./min
(2.0-17.89 m/min)
80-700 in./min
(2.0-17.89 m/min)
Mild steel solid wire
.023” (0.6 mm) - .045”
(1.2 mm)
. 023” (0.6 mm) - .045”
(1.2 mm)
Stainless steel solid wire
.030” (0.8 mm) - .045”
(1.2 mm)
.030” (0.8 mm) - .045”
(1.2 mm)
Flux cored wire
.030” (0.8 mm) - .045”
(1.2 mm)
.030” (0.8 mm) - .045”
(1.2 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”- 12” (100-300 mm)
Ø 4”- 12” (100-300 mm)
Voltage
Primary current
Permissible load in GMAW - MIG
Permissible load in GTAW - TIG
Permissible load in SMAW - Stick
Open circuit voltage (OCV)
Wire diameter
Manual 0463 644 001
INSTALLATION
2-3
ESAB EMP235IC
Dimensions L×W×H
686 × 292 × 495 mm
(27.0 × 11.5 × 19.5 in.)
686 × 292 × 495 mm
(27.0 × 11.5 × 19.5 in.)
Weight
53 lbs. (24 kg)
53 lbs. (24 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
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
40 Amps
30 Amps
Maximum recommended fuse* or circuit breaker rating
*Time delay fuse UL class RK5. Refer to UL 248
40 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
10 AWG (5.2 mm2)
12 AWG (4 mm2)
Maximum recommended extension cord length
50 ft (15m)
25 ft (8m)
Minimum recommended grounding conductor size
10 AWG (5.2
mm2 )
12 AWG (4 mm2)
Supply From Power Generators
The power source can be supplied from different types of generators. However, some generators may not
provide sufficient 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 10kW, are recommended.
Use one of the supplied adapters to connect the power source to mains.
2-4
INSTALLATION
Manual 0463 644 001
ESAB EMP235IC
120V, 20A
120V, 15A
208/230V, 50A
NEMA 6-50P 230VAC plug
Manual 0463 644 001
INSTALLATION
2-5
ESAB EMP235IC
This Page Intentionally Blank
2-6
INSTALLATION
Manual 0463 644 001
ESAB EMP235IC
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!
NOTE:
SCT – Short Circuit Termination is a method of automatic burn back at the end of the weld to electrically cut
the wire by pulsing high current in a controlled process. The result is a nice clean wire end with no balling or
sticking to the weld pool or tip. This allows exceptional restarting of subsequent welds. This feature is primarily for Mild and Stainless steel short-arc welding. For spray and flux core welding, traditional burn back
is recommended. When burn back time is set to zero, SCT automatically is enabled. A non-zero burn back
setting will disable SCT
Icon Reference Guide
ICON
MEANING
ICON
Home
Spot time on/off
selection
(use navigation knob
and push to select from
display)
Burn back Adjusting
the time when the
voltage stays on
after the wire feed is
stopped to keep the
wire from freezing in
the weld puddle
Short Circuit
Termination (SCT: see
NOTE above):
ON: burnback set to
zero
OFF: burnback set to
non-zero
(See SCT Selection
on display)
Information
Manual 0463 644 001
MEANING
Wire feed speed
OPERATION
3-1
ESAB EMP235IC
ICON
MEANING
ICON
MEANING
MIG Torch
Spot time on
adjustment
Parameters
Flux cored
Parameters
Manual MIG
Percent
STICK
Pre-flow
The time the
shielding gas
stays on before
the welding arc is
started
Smart MIG
Post-flow
The time the shielding
gas stays on after
the welding arc is
stopped
3-2
Lift-TIG
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
2T, Trigger On/OFF
Volts
OPERATION
Manual 0463 644 001
ESAB EMP235IC
ICON
MEANING
ICON
MEANING
4T, Trigger Hold/Lock
User manual on main
menu
Amps
Plate thickness
at sMIG mode
Arc force
On stick weldingincreasing amps
when the arc
length is shortened
to reduce or
eliminate the freezing
of the stick electrode in
the weld puddle
Downslope Sloping
the current down
over a period of time
at the end of the weld
cycle
Hot start
The increase of amps
when striking the
electrode to reduce
sticking
Inductance
The addition of
inductance into the
arc characteristics to
stabilize the arc and
reduce spatter when
in the short circuit
process
Memory
Ability to save
welding programs
for a specific
application
Trim bar Changing the
weld bead profile from
flat to convex or flat to
concave
Advanced Settings
EN
Basic Settings
Language selection
Stick electrode
choice
Upslope
Sloping the current up
over a period of time
at the beginning of
the weld cycle
Manual 0463 644 001
OPERATION
Unit of Measure
3-3
ESAB EMP235IC
ICON
MEANING
ICON
Wire diameter
MEANING
Bead profile,
concave
Bead profile, convex
3-4
OPERATION
Manual 0463 644 001
ESAB EMP235IC
3.02
Controls and Connections
Front and rear:
12
11
2
1
10
3
4
9
5
6
7
8
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 Tig
12. Gas valve inlet Mig
Manual 0463 644 001
OPERATION
3-5
ESAB EMP235IC
Drive System Diagram
3
4
2
1
5
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 off the power source and disconnect the mains cable.
2. Move the polarity changeover cable from positive to negative terminal.
3-6
OPERATION
Manual 0463 644 001
ESAB EMP235IC
3.05
Inserting and Replacing Wire
The EMP235ic will handle wire spool sizes of 4” (100 mm), 8” (200 mm) and 12” (300 mm).
1. Open the side door on the spool side.
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 door.
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.
Manual 0463 644 001
OPERATION
3-7
ESAB EMP235IC
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.
3-8
OPERATION
Manual 0463 644 001
ESAB EMP235IC
CE
Active Groove
3.08
CSA
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.
Manual 0463 644 001
OPERATION
3-9
ESAB EMP235IC
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.
3-10
OPERATION
Manual 0463 644 001
ESAB EMP235IC
Manual 0463 644 001
OPERATION
3-11
ESAB EMP235IC
3.10
Duty Cycle
The EMP235ic have a maximum welding current output of 220A at 10% duty cycle. A self-resetting thermostat
will protect the power source if the duty cycle is exceeded.
A different combination of duty cycle and welding current can be selected. Use the graphs below to determine
the correct duty cycle for a given welding current.
Duty cycle on 120V AC
100
90
80
70
%
60
MIG@20A
50
MIG@15A
40
MMA
TIG
30
20
10
0
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
Welding Current (Amps)
Welding current (AMPS)
Duty cycle on 230V AC
100
90
80
70
%
60
50
TIG
MMA
40
MIG
30
20
10
0
0
10
20
30
40
50
60
70
80
90
100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
Welding Current (Amps)
Welding current (AMPS)
3-12
OPERATION
Manual 0463 644 001
ESAB EMP235IC
3.11
Control Panel
After power on has completed the main menu appears on the control panel.
NOTE!
System output status will be indicated by the screen background color. Red/Orange means the torch is live/hot. No trigger needed. Blue means a trigger has to
be used and Green means system is in Set Up mode and not able to be activated.
Process selection colors are similar. If a welding process has a blue indication
then a remote trigger devise needs to be used when that process is selected. If
the process has Red/Orange color, then it will be live/hot as soon as it is selected.
Green means system is in Set Up mode and the torch cannot be activated..
3.11.1 How to Navigate
235ic
1
1.
2.
3.
Current / Wire feed speed selection
Voltage selection
Menu navigation. Rotate and push to
select menu option.
2
3
3.11.2 Main Menu
EMP235ic
3
5
4
6
2
7
1
8
Manual 0463 644 001
OPERATION
1.
sMIG mode
2.
Manual MIG mode
3.
Flux cored wire mode
4.
Stick/MMA mode
5.
Lift-TIG mode
6.
7.
Settings
User manual information
8.
Dialogue box
3-13
ESAB EMP235IC
3.11.3 sMIG mode
3
4
5
2
1
7
1.
Home screen
2.
Information
3.
Wire feed speed
4.
Material thickness
5.
Weld bead shape
6.
Voltage trim
Must be in
“Advanced Settings”
7.
Dialogue box
6
NOTE!
When a parameter/setting is being changed the background and text will reverse
colors. Once the change is complete and the change has been accepted the
colors will revert back to black text on white background..
3.11.4 Manual MIG mode
3
1.
Home screen
2.
Information
3.
Wire feed speed
4.
5.
Voltage
Dialogue box
2
1
5
3-14
4
OPERATION
Manual 0463 644 001
ESAB EMP235IC
3.11.5 Flux cored wire mode
3
1.
Home screen
2.
Information
3.
Wire feed speed
4.
5.
Voltage
Dialogue box
2
1
4
5
3.11.6 Stick mode SMAW
3
1. Home screen
2. Information
3. Amperage
4. Voltage (OCV or arc)
2
4
5. Stick mode ON/OFF
6. Dialogue box
1
5
6
3.11.7 TIG-Lift mode
3
2
1.
Home screen
2.
Information
3.
Amperage
4.
5.
Voltage
Dialogue box
1
5
Manual 0463 644 001
4
OPERATION
3-15
ESAB EMP235IC
3.11.8 Settings
1
2
3
4
5
6
1.
Reset mode
2.
Inch/Metric
3.
Basic/Advanced
4.
Language
5.
Information
6.
Home screen
7.
Dialog box
7
3.11.9 User Manual Information
1
1.
Maintenance information
2.
Spare parts
3.
Operation information
2
4.
Home screen
3
5.
Di alogue box
4
5
3-16
OPERATION
Manual 0463 644 001
ESAB EMP235IC
4
SERVICE INSTRUCTIONS
DANGER
Only qualified workers who are knowledgeable and have been trained to work safely with test instruments and equipment on energized circuits shall be permitted to perform testing work on electrical
circuits or equipment where there is danger of injury from accidental contact with energized parts or
improper use of the test instruments and equipment.
!
4.01
What is ESD
!
CAUTION
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostaticsensitive devices.
• Use proper static-proof bags and boxes.
What is ESD?
A sudden transfer or
discharge of static
electricity from one
object to another. ESD
stands for Electrostatic
Discharge.
How does ESD damage occur?
ESD can cause damage to sensitive electrical components, but is not dangerous to people. ESD damage occurs
when an ungrounded person or object with a static charge comes into contact with a component or assembly
that is grounded. A rapid discharge can occur, causing damage. This damage can take the form of immediate
failure, but it is more likely that system performance will be affected and the component will fail prematurely.
How do we prevent ESD damage?
ESD damage can be prevented by awareness. If static electricity is prevented from building up on you or on
anything at your work station, then there cannot be any static discharges. Nonconductive materials (e.g. fabrics),
or insulators (e.g. plastics) generate and hold static charge, so you should not bring unnecessary nonconductive items into the work area. It is obviously difficult to avoid all such items, so various means are used to drain
off any static discharge from persons to prevent the risk of ESD damage. This is done by simple devices: wrist
straps, connected to ground, and conductive shoes.
Work surfaces, carts and containers must be conductive and grounded. Use only antistatic packaging materials. Overall, handling of ESD-sensitive devices should be minimized to prevent damage.
Service aid
ESAB can offer a number of service tools that will simplify
the service.
Antistatic service kit
Ordering no. 0740 511 001
The kit makes it easier to protect sensitive components from
electrostatic discharge.
Contents:
•
A conductive mat (size 610 x 610 mm)
•
A 1.5 meter long ground cable with a crocodile clip
Antistatic Service Kit
• An adjustable wrist strap and cable with an inbuilt protective resistor
Manual 0463 644 001
SERVICE INSTRUCTIONS
4-1
ESAB EMP235IC
This Page Intentionally Blank
4-2
SERVICE INSTRUCTIONS
Manual 0463 644 001
ESAB EMP235IC
5
POWER SUPPLY INTRODUCTION
5.01. Introduction
Design structure of the power source
The EMP235ic power source is operating on the inverter principle. It consists of a number of function modules.
Each module has a module number, which is always included as the first part of the name/identification of
components in the module.
The modules have the following main functions:
• User Interface module - The user interface is a 4.3 inch TFT display with 3 encoders attached to it.
• Power module - Power board includes primary rectifier, pre-charger, main PFC section, auxiliary power
supply, full bridge inverter, main transformer, secondary inductor and secondary diode modules.
• Control module - The control board, with a microprocessor, that monitors and controls the welding process.
• Main switch and thermal breaker section (this is connected to enclosure).
5.02. Working Principle
The mains input voltage range is single-phase 120 VAC ±10% and 230 VAC ±10% at rated load.
The primary rectifier, rectifies the input AC voltage. Main PFC section boosts this voltage to 400 VDC with
0.99 power factor.
The main inverter of the power source is a 4-transistor IGBT full bridge, operating at a switching frequency of
47 kHz.
The primary inverter output is connected to a main transformer with a 4:1 turns ratio
The main transformer output is connected to a secondary rectifier which contains four diode modules.
Manual 0463 644 001
POWER SUPPLY INTRODUCTION
5-1
ESAB EMP235IC
5.03
5-2
Diagram for both CSA and CE
POWER SUPPLY INTRODUCTION
Manual 0463 644 001
ESAB EMP235IC
Manual 0463 644 001
POWER SUPPLY INTRODUCTION
5-3
ESAB EMP235IC
This Page Intentionally Blank
5.04
System Schematic for CSA Systems
A-12892_AA
5-4
POWER SUPPLY INTRODUCTION
Manual 0463 644 001
ESAB EMP235IC
A-12892_AA
Manual 0463 644 001
POWER SUPPLY INTRODUCTION
5-5
ESAB EMP235IC
5.05
System Schematic for CE Systems
A-13146_AA
5-6
POWER SUPPLY INTRODUCTION
Manual 0463 644 001
ESAB EMP235IC
A-13146_AA
Manual 0463 644 001
POWER SUPPLY INTRODUCTION
5-7
ESAB EMP235IC
5.06
Component Location
1
2
3
11
10
4
9
8
Item #
1
2
3
4
5
6
7
8
9
10
11
5-8
7
Description
Control PCB
Circuit Breaker
On / Off Switch
Fan 1 and Fan 2
PFC Inductor
Output Diode PCB
Main Transformer
Current Sensor
Output Inductor
Power PCB
User Interface TFT Display
5
6
Designator
PCB / (20AP1)
CB1
SW 1
M1 and M2
L1
PCB4
T1
CS 1
L2
PCB2 / (15AP1)
PCB1 / (1AP1)
POWER SUPPLY INTRODUCTION
Manual 0463 644 001
ESAB EMP235IC
6
TROUBLESHOOTING
6.01
Error Codes
Serverity Levels
Critical
Service Required - Unit not functional or locked, not recoverable
NonCritical
Service may be desired - unit functional with limit performance
Warning
Unit functional and will recover on its own
Error
Code
Severity
Level
Possible Cause or Repair Action
001
W
PFC Heatsink, IGBT Heatsink or Main
transformer has overheated > 85 C
Check Fan operates by inspection when D90 is on,
during output cur­rent load condition, Check CN19
pin 6 is low when system is cool. Check temp sensor
connectors on power board CN5, CN6, CN7 & CN8.
Check Optical coupler on power board U12. Operate
the system at the specified duty cycle.
002
W
Output diode Temperature fault, Analog
tempera­ture sensor.
Check across C64 at room tempera­ture it should be
~1.0 vdc. When system is hot it will reduce to a trip
point of 157mV. Input from power board is CN19 pin 3.
Check power board CN9 or Output Diode on CN3 for
connection
003
C
DC Bus (400V) fault, PFC not supplying
400 to inverter
Faulty Power board, Bad PFC. Less likely but also
possible bad PFC inductor or Main Transformer.
004
C
Output voltage is above VRD levels
when VRD switch is active
CN1 connection on Ctrl board, Bad OKC connection
internally between OKC and Control board, Faulty
control board.
Functional Circuit Failure
Explanation
(005 – 007 are reserved)
008
C
Open circuit Voltage error, OKC voltage
signal not sensed at Control Board CN1
as expected
009
C
Low Voltage Error, ac mains voltage is
less than 108 VAC.
We start sensing this voltage only when weld activity
is expected to be occurring. If this failure happens
check control board connectors CN1 to OKC and CN18
to current sensor for continuity. Check control board
for pres­ence of +/- 15v, D35 is on. If D35 or either 15V
is not to specified values replace control board.
(010 is reserved)
011
C
User has attempted to reset parameter
or factory resets, and this was not
confirmed by the system. Possible
software bug or communication
protocol error.
Should not experience this error in the field, Causes
are poor communi­cation with the control (which
should cause err 012), unknown software bug, UI
panel NVRAM not responding correctly. Check UI panel
and control is latest sw. Test by plugging in a spare UI
panel and perform factory reset, if fails replace control
board if passes replace UI board.
012
C
Communication Link Down, no
communication between UI and Ctrl
PCB at CN6
Possible bad connection at CN6 on Control board,
bad connection at CN3 UI board, bad/broken cable
between these boards, or one of these boards are bad.
Manual 0463 644 001
TROUBLESHOOTING
6-1
ESAB EMP235IC
013
C
Low Internal Power Supply (IPS)
Voltage Error, +24V IPS is less than
22VDC
Possible IPS is bad. Pos­sible faulty detection circuit on
control board. Measure for >23.4 VDC on both sides of
D51 on the control board. Check input source of +24
from the IPS.
014
C
Secondary Current Sensor CN18 not
being read
Bad Current Sensor, poor cable con­nection on Control
board CN18 or the sen­sor. Faulty Control board - R34
bad.
(015 – 019 are reserved)
020
C
No Image found in Flash
021
C
The image read from the flash is
corrupted
Re-Load the SPI (Serial Peripheral Interface) Flash with
correct “image.bin” file. Still bad, replace the display
board.
022
NC
While saving user memory (into sectors
1-15) the system makes two attempts
to correctly store the data into SPI
flash. If both times it fails, then displays
this message for 3 seconds
Non-critical error. Corrected by replacing the UI board.
023
NC
During Power ON If fails 2 times
reading from valid sector (1-15), then
Display this for 3 seconds
Check if the SPI (Serial Peripheral Interface) IC gone
bad. Replace either (or both UI board or Control Board).
6-2
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
6.02
Pre Power-up Checks
WARNING
Buss voltage of 400 VDC will be present on the heatsinks of POWER PCB2
while unit is on. Wait 40 seconds after removing power before handling.
Examine unit for any visible signs of damage.
In order to prevent tripping wall fuses and/or causing damage to the unit when power is applied, it is recommended that the following components be checked prior to connecting unit to mains power:
1 MAINS POWER CABLE
INPUT POWER CABLE/PLUG
2 SW1 ON/OFF SWITCH
3 CB1CIRCUIT BREAKER
4 VR1
VARISTOR on POWER PCB2
5 BR1/BR2
BRIDGE RECTIFIERS on POWER PCB2
6 PTC1/RY1 PTC1 (R79) & INRUSH RELAY (RY1) contacts in parallel on POWER
PCB2
7 D49 & D50
DIODES on POWER PCB2
8 Q19 & Q21
PFC TRANSISTORS on POWER PCB2
9 C35-3
WORKING CAPACITORS on POWER PCB2
10 Q3,4,6,7
SWITCHING TRANSISTORS on POWER PCB2
Q7 Collector
Q4 Collector
Q3 Collector
Q6 Collector
D49 & D50 Cathode
Q19 Collector
A series of quick checks can be done to verify Main Power components are not shorted. (Remove the right
side panel to access this area.)
Using a meter set to resistance and with the unitSW1 set to ON position:
1. Measure resistance between MAINS CABLE plug blade terminals 1 & 2 for approx.. 1.6K ohms.
Using a meter set to diode test and with the unit SW1 set to ON position:
2. Place positive meter lead on MAINS CABLE blade terminal 1 and negative meter lead on Bridge Rectifier BR1 + terminal. Check for forward bias drop (0.3- 0.7v).
3. Place positive meter lead on BR1(+) terminal and negative meter lead on Q4 terminal. Check for forward
bias drop (0.3- 0.7v).
4. Place negative meter lead on terminal Q4 and positive meter lead on Q7 terminal. Check for forward
biased diode (0.3 – 0.7V)
5. Place negative lead on Q7 Terminal and positive probe on BR2(-) terminal. Check for forward bias diode
(0.3 – 0.7v)
6. Place positive meter led on BR2 (-) terminal and negative meter lead on MAINS CABLE plug blade Line
1. Check for forward bias diode (0.3 – 0.7v)
7. Place positive meter led on BR2 (-) terminal and negative meter lead on MAINS CABLE plug blade Line
2. Check for forward bias diode (0.3 – 0.7v)
Manual 0463 644 001
TROUBLESHOOTING
6-3
ESAB EMP235IC
If any of the checks show a reading other than as indicated above, then the ten components will have to be
checked to identify the failed component(s).
The following images show the previous steps listed. In the oval you will see the step number and below that
the meter reading you should see.
1
1.6k ohm
Ground
Line 2
Line 1
-
7
0.3 - 0.7 V
6
0.3 - 0.7 V
+
+
2
0.3 - 0.7 V
-
+
BR1(+)
BR2(-)
Q7 Collector
Q4 Collector
6-4
Q3 Collector
Q6 Collector
TROUBLESHOOTING
D49 & D50 Cathode
Q19 Collector
Manual 0463 644 001
ESAB EMP235IC
4
0.3 - 0.7 V
-
+
Q7 Collector
Q4 Collector
-
5
0.3 - 0.7 V
-
+
3
0.3 - 0.7 V
+
BR2(-)
1 MAINS POWER CABLE/PLUG
a. Check continuity of cable from end to end on all three leads.
b. Check for short between Line 1 and Line 2.
c. Check for short between both Line 1 and Line 2 leads to GROUND lead
Replace MAINS POWER CABLE/ PLUG if fault is found
The following image shows the previous steps listed. In the oval you will see the step number and below that
the meter reading you should see.
1a
< 1 ohm
Ground
Line 1
Green
Black
Line 2
White
Manual 0463 644 001
1c
Open /Infinity
TROUBLESHOOTING
1b
Open /Infinity
6-5
ESAB EMP235IC
2 SW1 ON/OFF SWITCH
a. Check that mechanical switch action is crisp and positive.
b. Check both halves of switch for continuity when ON and open when OFF
c. Check for short between each half of switch
Replace SW1 if fault is found
The following image shows the previous steps listed. In the oval you will see the step number and below that
the meter reading you should see.
2c
Open /Infinity
2b
ON=Shorted
OFF=Open
2b
ON=Shorted
OFF=Open
2c
Open /Infinity
3 CB1 CIRCUIT BREAKER
a. If breaker is tripped, reset. Located on the wire feed side in the upper left.
b. Check for continuity to insure breaker is not open
Replace CB1 if fault is found
4 VR1
a. Visually Check.
If burned/blown, the problem was caused from an over voltage from the Mains Power and further damage to the unit's power components is likely and is not eligible for warranty.
VR1
6-6
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
5 BR1/BR2
a. Perform Diode Check on both Bridge rectifiers
If either one has open or shorted diode, replace both BR1 & BR2
The following image shows the previous step listed. In the oval you will see the step number and below that
the meter reading you should see.
5a
0.3-0.7VDC
+
-
AC
+
BR1
and
BR2
AC
+
-
5a
0.3-0.7VDC
Manual 0463 644 001
TROUBLESHOOTING
6-7
ESAB EMP235IC
6 PTC1/RY1
a. Measure continuity between BR1 or BR2 Positive Terminals and BUS terminals on POWER PCB2
for 23 ohms.
If open or shorted replace POWER PCB2.
6-8
TROUBLESHOOTING
6a
23 ohm
+
-
The following image shows the previous step listed. In the oval you will see the step number and below that
the meter reading you should see.
Manual 0463 644 001
ESAB EMP235IC
7 D49/D50
a. With Meter in Diode Check setting check for diode reading between Heatsink Terminal D50 and PFC
Terminal on Power PCB2..
If open or shorted replace POWER PCB2.
See following illustration
8 Q19/Q21
a. With Meter in Diode Check setting, place negative meter lead on PFC terminal on POWER PCB 2
and positive lead on BR2(–) terminal for forward biased diode (0.30-00.7VDC).
If open or shorted replace POWER PCB2.
See following illustration
9 C35-38
Disconnect wire from POWER PCB2 from PFC terminal.
a) With meter in resistance setting, Place positive meter lead on Heatsink Terminal D50 and negative
meter lead on BR2 (-). Meter will show charging of capacitors
If shorted replace POWER PCB2
The following image shows the previous steps (7,8 and 9) listed. In the oval you will see the step number and
below that the meter reading you should see.
D50 Cathode
9a
CAP Charging
+
7a
0.3 - 0.7 V
+
+
BR2(-)
8a
0.3 - 0.7 V
PFC
Manual 0463 644 001
TROUBLESHOOTING
6-9
ESAB EMP235IC
10 Q3, 4, 6, 7
Re-install wire into POWER PCB2 PFC terminal. Disconnect wire from POWER PCB2 TRANS2 terminal.
a) With meter in diode setting, check for diode reading between Heatsink Terminals Q4 and Q7.
b) With meter in diode setting, check for diode reading between Heatsink Terminals Q3 and Q6.
c) With meter in diode setting, check for diode reading between Heatsink Terminals Q7 and BR2 (-)
terminal.
d) With meter in diode setting, check for diode reading between Heatsink Terminal Q6 and either end
of R88 or R89 on Power PCB2.
If open or short is found in steps b-e, replace POWER PCB2.
Re-install wire into POWER PCB2 TRANS 2 terminal.
If open or shorted replace POWER PCB2.
The following image shows the previous steps listed. In the oval you will see the step number and below that
the meter reading you should see.
10a
0.3 - 0.7 VDC
+
+
10b
0.3 - 0.7 VDC
-
-
Q3 Collector
Q4 Collector
-
Q6 Collector
10d
0.3 - 0.7 VDC
Q7 Collector
-
10c
0.3 - 0.7 VDC
+
+
BR2(-)
6-10
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
An additional Pre Power-up check for the Output Diodes D66 – D69 should be performed. Using a meter set
in the DIODE TEST setting do the following:
1 With positive meter lead on – OUTPUT WELD terminal and with negative meter lead on + WELD OUTPUT terminal, check for forward biased diode drop reading.
2 With positive meter lead on + OUTPUT WELD terminal and with negative meter lead on - WELD OUTPUT
terminal, check for reverse biased diode drop reading.
If an open or short is found, Replace OUTPUT DIODE PCB4.
The following image shows the previous steps listed. In the oval you will see the step number and below that
the meter reading you should see.
-
+
1
0.3 - 0.7 VDC
+
-
2
Open /Infinity
This concludes the Pre Power-up Checks.
Manual 0463 644 001
TROUBLESHOOTING
6-11
ESAB EMP235IC
6.03
LED Diagnostics
The unit has several LEDs that can assist in diagnosing problems.
POWER PCB2 / (15AP1) D42
+24V_SEC OK
+24VDC Supply on this pcb is present
D53
+18V_PRI OK
+18VDC Supply on this pcb is present
CONTROL PCB3 / (20AP1)
D33
PWM IGBT Gate signals are enabled (Brightness depends on PWM demand)
D35
PS_OK
+15VDC & -15VDC Supply on this PCB is present.
D36
3,3V_1 OK
+3.3VDC Supply on this PCB is present
D40
+24V_1 LOW
Problem: +24VDC Supply on this PCB is low
D43
BUS V ERROR
Problem: Buss Voltage from PCB3 is less than 350VDC
D44
UI COM
Communication from PCB1 is established
D45
uP OK
If flashing, u processor. On this pcb is active
D85
10.3V_VB OK
+10.3 VDC Supply on this PCB is present
D86
+5V_1 OK
+5VDC Supply on this PCB is present
D87
MIG SOL ON
Signal is active to turn on MIG gas solinoid
D88
TRIGGER ON
Remote trigger is closed
D89
TIG SOL ON
Signal is active to turn on TIG Solenoid (IF INSTALLED)
D90
FAN ON
Fan control signal is on, fans should be running
6.04
Initial Power Up Test
Using Generators or Extension cords
If a problem is encountered while running on a generator or while using an extension cord, note the problem
and then plug the unit directly into a Mains Power Outlet. If the problem is no longer found, there is a problem
with the power from the generator or the extension cable is too long or wire gauge is too small to adequately
power the unit. Measure the incoming voltage at the units Mains Power Cable/Plug both before and while the
unit is under load to verify voltage does not drop under load conditions, especially when connecting to 120VAC.
Interconnections
When performing tests to determine failed component, check for open wires or poor connection between
components, pcbs, connectors, etc.
Wire Feed-ability Problems
Many welding problems, gun and consumable issues can be caused by improper wire feed set up, incorrect
or worn parts. Pay close attention to the following items:
Wire spool – Wire feeds smoothly off spool – no friction or wire cross over
Wire Spool Hub Brake Tension
Drive Roll - Size, style and condition
Wire Guides – Size and condition
Wire Tension Adjustment
Wire Liner (Conduit) - Size and condition
Contact Tip – Size and condition
Wire type
Gun Polarity
6-12
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
Initial Set up conditions
SW1- OFF
J1 – No remote device installed
Connect unit to 120VAC Mains Power.
Polarity Cable not connected.
1) Power-Up Test
a) Turn SW1 to ON position and observe the following
The unit will come up in whichever process that the unit was in when the unit was last turned off.
PCB LEDs Status
POWER PCB3
D42 & D53 ON
CONTROL PCB2
D35
PS OKON
D36
3.3V_1 OK
ON
D40
+24V_1 LOW OFF
D43
BUS V ERR
OFF
D44
UI COM
Flashing
D45
uP OKON
D85
10.3_VB OK
ON
D86
+5V_10 OK
ON
D87
MIG SOL ON
OFF
D88
TRIGGER ON
OFF
D89
TIG SOL
OFF
D90
FAN ON
OFF
If the unit does not perform as indicated, proceed to subsection 6.05
SMAW Process Test
1) If unit is not in SMAW process, use MAIN ENCODER to select SMAW (STICK) process. Approx. 54
VDC present between +/- weld output connectors.
PCB LEDs Status
CONTROL PCB2
D33
PWM
ON
(Dim but ON)
2) Connect weld cables to unit.
3) Strike welding arc. D90 on PCB3 turns on and Fans run.
4) Vary Current/WFS Encoder to adjust current from min to max. D33 will increase brightness as current
is increased.
If the unit does not perform as indicated, proceed to subsection 6.05
Manual 0463 644 001
TROUBLESHOOTING
6-13
ESAB EMP235IC
GTAW LIFT TIG Process Test
1) Turn SW1 to Off Position.
2) Connect TIG torch power cable to negative weld output connector and work cable to positive weld
output connector.
3) Connect gas hose to flow meter regulator. And turn regulator on and set flow.
4) Connect either Torch mounted control cable or foot pedal to 8 pin connector J1 on front of unit.
5) Turn SW1 to ON position. Using Main Encoder, go to SETTINGS and select BASIC mode then go to
and select LIFT TIG process.
PCB LEDs Status
POWER PCB3
D42 & D53 ON
CONTROL PCB2
D35
PS OKON
D36
3.3V_1 OK
ON
D40
+24V_1 LOW OFF
D43
BUS V ERR
OFF
D44
UI COM
ON
D45
uP OKON
D85
10.3_VB OK
ON
D86
+5V_10 OK
ON
D88
TRIGGER ON
OFF
D89
TIG SOL
OFF
D90
FAN ON
OFF
1) Use EN3 ENCODER to select GTAW (LIFT TIG) process.
2) Touch electrode to the work piece, Activate start signal ( Torch mounted trigger or foot Pedal) D88
on CONTROL PCB3 comes on, then lift the torch off the plate, starting the welding arc. Vary current
control from Min to Max . Remove Start signal. Arc shuts off
If the unit does not perform as indicated, proceed to subsection 6.05
GMAW MIG Process Test
1) Turn SW1 to Off Position. Remove TIG torch. Connect MIG gun, connect polarity cable to + weld
output connector and work cable to – weld output connector. Connect appropriate gas supply inlet to
rear panel gas inlet fitting.
2) Turn SW1 to ON. Main menu screen will be displayed.
6-14
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
PCB LEDs Status
POWER PCB3
D42 & D53 ON
CONTROL PCB2
D35
PS OKON
D36
3.3V_1 OK
ON
D40
+24V_1 LOW OFF
D43
BUS V ERR
OFF
D44
UI COM
ON
D45
uP OKON
D85
10.3_VB OK
ON
D86
+5V_10 OK
ON
D87
MIG SOL ON
OFF
D88
TRIGGER ON
OFF
D89
TIG SOL
OFF
D90
FAN ON
OFF
1) With gun in position, activate MIG gun trigger. On CONTROL PCB3, D87 D88 will come on, gas will
flow and wire will feed and arc will establish. D90 turns on and fans run.
2) If the unit does not perform as indicated, proceed to subsection 6.05
Manual 0463 644 001
TROUBLESHOOTING
6-15
ESAB EMP235IC
6.05
Initial Power Up Test Problems
1) Mains Power fuses blow/ breaker trips when SW1 is turned on.
a) Faulty Mains Power Cable and/or Plug
Check continuity – Replace if faulty
b) Shorted BR1 or BR2 rectifiers.
Check continuity- See sub-section 6.02 BR1/ BR2.
c) Shorted components on MAIN POWER PCB2.
Replace
2) Unit is completely inactive, Front panel display is off, no output voltage.
a) Mains Power problem. Open fuse/ tripped breaker
Measure voltage at mains outlet.
b) Defective MAINS POWER CABLE /PLUG
Measure voltage to SW1. Replace if defective.
c) Defective SW1 ON/OFF SWITCH
Measure voltage from SW1. Replace if defective.
d) CB1 Circuit Breaker Tripped.
Reset breaker.
Replace if defective.
e) Defective POWER PCB2
Perform POWER PCB2 Test, see subsection 6.06
f) Defective CONTROL PCB3
Perform POWER PCB2 Test, see subsection 6.06
g) Defective USER INTERFACE PCB1
Check for LED D44 UI COM on CONTROL PCB3.
If D44 is OFF then replace USER INTERFACE PCB1
h) Defective connection from CN6 on PCB3 to CN3 on PCB1.
Check continuity
If no problem is found, replace CONTROL PCB3
6-16
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
The following image shows the previous steps listed. In the oval you will see the step number and below that
the meter reading you should see.
2c
120VAC +/- 10%
OR
2c
208/230VAC +/- 10%
2b
120VAC +/- 10%
OR
2b
208/230VAC +/- 10%
3. Front Panel Display is off, but OCV is present on output weld terminals.
a) Connector unplugged from either CN3 on USER INTERFACE PCB1 or CN6 on CONTROL PCB3 or
there is an open wire between them.
b) Defective USER INTERFACE PCB1
4) OVER TEMPERATURE symbol displayed on panel
There are four (4) NTC Thermal Devices in the unit. If the unit is experiencing an overheating issue, the
NTCs will prevent damage to the unit. Two are part of the POWER PCB2; one located on the heatsink
for the PFC Transistor, the other on the heatsink for the switching transistors Q3,4,6,7. The Third is
located on the Main Transformer T1. The forth is on the heatsink on the OUTPUT DIODE PCB4.
When these devices are heated they will enable the OVERTEMP Protection to disable the output of the
unit. The OVER TEMPERATURE symbol will appear on the TFT Display and the Fan will turn on. When
the error is displayed, the unit should remain powered on allowing the fans to run, properly cooling the
unit components.
If the unit OVER TEMPERATURE error remains active when the unit has been allowed to cool, then the
unit has a failure.
a) Defective NTC3
Disconnect harness plug from CN7 from POWER PCB2. Measure for approx.. 12K Ohms on the harness plug. Replace if defective.
b) Defective NTC4
Disconnect the harness plug from CN3 connector on OUTPUT DIODE PCB4. Measure for approx. 12K
Ohms on the CN3 connector on the pcb. Replace OUTPUT DIODE PCB4 if defective.
Manual 0463 644 001
TROUBLESHOOTING
6-17
ESAB EMP235IC
CN7
4b
Approximately 12k ohm
4a
Approximately 12k ohm
The following image shows the previous steps (4a and 4b) listed. In the oval you will see the step number and
below that the meter reading you should see.
6-18
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
c) Defective CONTROL PCB3 (This step requires the unit be connected to power and turned on)
1) On the CONTROL PCB3 Connector CN19, Measure from pin 6 to pin 4. The voltage should be
approx 1.8VDC.
2) On the Control PCB3 Connector CN19, Measure from Pin 3 to pin 4. The voltage should be less
than 0.25VDC.
If both of these measurements are correct, replace CONTROL PCB3
d) Defective POWER PCB2
1) On the CONTROL PCB3 Connector CN17, Measure from pin 6 to pin 4. The voltage should be
approx. 1.8VDC. If voltage is less than 0.5VDC, Replace POWER PCB2.
2) On the Control PCB3 Connector CN17, Measure from Pin 3 to pin 4. The voltage should be less
than 0.25VDC. If the voltage is greater than 0.3VDC, Replace Power PCB2
The following image shows the previous steps (4c and 4d) listed. In the oval you will see the step number and
below that the meter reading you should see.
Manual 0463 644 001
TROUBLESHOOTING
6-19
ESAB EMP235IC
CN17
4d 2
< 0.25 VDC
3
4
6
4d 1
Approximately 1.8VDC
4c 2
< 0.25 VDC
3
4
6
4c 1
Approximately 1.8VDC
CN19
SMAW Process Test Problems
1) Cannot change weld process
a) Defective ENCODER PCB7
6-20
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
Perform ENCODER PCB Test subsection 6.06
2) No voltage between +/- Weld Output Connectors
a) Defective CONTROL PCB3
D33 should be on (Very dim). If it is not on, replace Control PCB3
b) Defective OUTPUT DIODE PCB4
Perform OUTPUT DIODE PCB4 Test, see subsection 6.06
c) Defective POWER PCB2
Replace POWER PCB2
3) No output current flows when connected to load.
a) Open work cable or electrode holder cable
Replace if open
b) Poor work cable connection to table or work piece
Clean connection
4) Cannot change output current setting
a) Defective ENCODER PCB5
Perform ENCODER PCB Test, see subsection 6.06
b) Defective CS1 Current Sensor
Perform CS-1 Test, see subsection 6.06
c) Defective CONTROL PCB3
d) Defective USER INTERFACE PCB1
5) ERROR MESSAGE : VOLTAGE FEEDBACK FAULT
a) Open connection from output terminals to CN1 connector on Control PCB1
Check that connector is securely installed and check continuity of wires and replace if open
b) Defective CONTROL PCB3
Replace PCB3
GTAW (Lift TIG) Process Test Problems
1) Cannot change weld process from SMAW to GTAW
a) Defective ENCODER PCB7
Perform ENCODER PCB Test subsection 6.06
2) No output voltage from unit when remote device trigger is closed
a) Defective Remote Device
Check LED88 on Control pcb. If it is not coming on when trigger is closed.
Perform REMOTE CONTROL START (TRIGGER) Test, see subsection 6.06
b) Defective CONTROL PCB3
D45 & D89 should turn on, at least momentarily when trigger is depressed. If not, Replace CONTROL PCB3
Manual 0463 644 001
TROUBLESHOOTING
6-21
ESAB EMP235IC
3) No welding arc is established when electrode is touched /lifted off the work piece.
a) Open or poor work cable connection
b) Open TIG Torch lead
c) Problem in the remote control start (Trigger) circuit.
Perform REMOTE CONTROL START (TRIGGER) Test, see subsection 6.06
d) Defective Control PCB3
Check LED D33 is on (Very dim) when trigger is active. If it does not turn on replace PCB3.
GMAW (MIG) Process Test Problems
1) Gas does not flow, Wire feed motor does not turn when trigger is depressed.
a) Defective MIG gun trigger or leads.
Perform REMOTE CONTROL START (TRIGGER) Test, see subsection 6.06
2) Wire Feeds but gas does not flow when trigger is active.
a) Gas supply to unit is not on
b) Control PCB3
Check that LED D87 turns on when trigger is activated. If it is not on, replace PCB3.
c) Defective GS1 GAS SOLENOID.
Gas valve supply voltage is 24vdc but if you measure it with true RMS you will receive a value approx.
5vdc Measure at CN10 on PCB3 between pins 1 & 2 when trigger is active.
If voltage is present, replace GS1
3) Gas flows but M1 Wire Feed Motor does not turn when trigger is active
a) Defective M1 motor.
Open wire tension adjustment arm. Depress trigger and measure for DCV at PCB3 connector CN13 between pins 1 & 2. If voltage is present replace M1.
b) Defective CONTROL PCB3.
Depress trigger and measure for DCV at PCB3 connector CN13 between pins 1 & 2. If voltage is not
present replace PCB3.
4) Gas Flows, Wire feeds but no arc established
a) Polarity cable not connected or open
b) Open lead in MIG gun.
5) Cannot change output voltage setting
a) Defective ENCODER PCB6
Perform ENCODER PCB Test, see subsection 6.06
6-22
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
The following image shows the previous steps (2c , 3a and 3b) listed. In the oval you will see the step number
and below that the meter reading you should see.
CN10
2c
5 VDC
-
+
-
+
3a
1-24 VDC
OR
3b
0.0 VDC
CN13
Manual 0463 644 001
TROUBLESHOOTING
6-23
ESAB EMP235IC
6.06
Test Procedure/troubleshooting
POWER PCB2 - Power Supply Test
1) Measure for Mains voltage on POWER PCB2 between terminals LINE1 to LINE2.
2) Check LEDs Status
D42
+24V_SEC OK
ON
D53
+18VDC_PRI OK
ON
3) Measure for 400VDC buss voltage between terminals LINE+ to LINE-.
If problem is found, remove power, disconnect the harness connectors from CONTROL PCB3 connectors CN1,
CN2 and CN4. Retest POWER PCB2.
If findings are still incorrect replace POWER PCB2.
BR2(-)
1a
120VAC +/- 10%
OR
208/230VAC +/- 10%
BR1(+)
The following image shows the previous steps (1a) listed. In the oval you will see the step number and below
that the meter reading you should see.
6-24
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
CONTROL PCB3 - Power Supply Test
1) Check PCB LEDs status as follows
D35
PS OKON
D36
3.3V_1 OK
ON
D40
+24V_1 LOW OFF
D85
10.3_VB OK
ON
D86
+5V_10 OK
ON
If problem is found, remove power, disconnect the harness connectors from CONTROL PCB3 connector CN6.
Recheck CONTROL PCB3 LED status.
If findings are still incorrect replace CONTROL PCB3.
ENCODER PCB5-7 Test
The three encoder PCBs with harness and connector receive power from the USER INTERFACE PCB1 as follows:
ENCODER PCB5 to PCB1 Connector CN10
ENCODER PCB6 to PCB1 Connector CN11
ENCODER PCB7 to PCB1 Connector CN12
1) For the ENCODER PCB under test, disconnect the harness connector from PCB1. At the mating connector at PCB1, measure from common pin 4, to pins 1, 2 & 3. All three should measure +3.3VDC. If
voltage is low or missing, replace USER INTERFACE PCB1.
2) Reconnect the harness connector back into the mating connector on PCB1
With the connector now installed, Measure from common pin 4, to both pin 1 and pin 2. As the encoder
is turned, the voltage will toggle between 0vdc and +3.3VDC
3) [For PCB7 only] Measure from common pin 4 to pin 3. When the encoder knob is depressed, the voltage will go from +3.3VDC to 0VDC and when encoder knob is released, will return to +3.3VDC.
Manual 0463 644 001
TROUBLESHOOTING
6-25
ESAB EMP235IC
OUTPUT DIODE PCB4 Test
1) Disconnect and isolate T1 transformer wires from Terminals SEC1 & SEC2.
2) With negative meter lead on + Welding Output Connector, place positive meter lead on SEC1, then
SEC2 terminal. Check for forward biased diode drop reading.
3) With positive meter lead on + Welding Output Connector place negative meter lead on SEC1, then
SEC2 terminal. Check for reverse biased diode drop reading.
If an open or short is found, Replace OUTPUT DIODE PCB4.
The following image shows the previous steps listed. In the oval you will see the step number and below that
the meter reading you should see.
2
0.3 - 0.7 VDC
+
-
+
3
Open /Infinity
CURRENT SENSOR CS1 Test
1) At CN18 connector on PCB3, use Pin 4 as a common and measure for +15VDC on Pin 1 and measure
for -15VDC on Pin 2.
If either voltage is low or missing, replace CONTROL PCB2
2) Measure voltage from Pin 4 to Pin 3. Voltage with no current flow should measure 0VDC.
3) Measure voltage from Pin 4 to Pin 3. When weld current is flowing, the voltage measured should be
approx. 0.5VDC / 100A output. Use an external ammeter to verify actual current flow as a reference.
If problem is found replace CS1.
6-26
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
The following image shows the previous steps listed. In the oval you will see the step number and below that
the meter reading you should see.
+
1
+15 VDC
-
+
CN18
1
2
3
4
+
-
4c 2
0.0 VDC
No load
-
4c 1
0.5VDC / 100A
(with load)
+
Manual 0463 644 001
1
-15 VDC
TROUBLESHOOTING
6-27
ESAB EMP235IC
REMOTE CONTROL START (TRIGGER) Test
LED D88 (TRIGGER ON), located on CONTROL PCB3, is normally OFF. PCB3 applies either a 12VAC (230VAC
line voltage) or 6vac (115vac line voltage) to CN5 Pins 3 &4 which connects to the front panel Remote Control
Connector J1, Pins 2&3. When a Remote Device is connected to J1 and a switch (trigger) closure is applied
between Pins 2 & 3, the voltage at PCB3 CN5 Pins 3 & 4 will drop to 0VAC and LED D88 will turn ON and weld
output will be enabled.
For any problem encountered with remote device, examine the J1 connector to make sure that none of the
sockets are damaged or retracted into the connector body preventing a good electrical connection
a) If LED D88 does turn on and no arc will ignite in GTAW process when the torch electrode is touched
to the work piece then lifted off, or if there is no output voltage at weld terminals in MIG process, replace
the Control PCB3.
b) If LED D88 does not turn ON when the Remote trigger signal is active, disconnect the Remote Control
Device from J1. Install a jumper into J1 connector between pins 2 & 3. If LED D88 turns on, then remote
device is defective.
c) If LED D88 does not turn ON when a jumper is installed into J1 connector between pins 2 & 3, connect a jumper at CN5 connector between pins 3 & 4. If LED D88 turns on then replace the Remote Control
Connector J1 with harness.
6.07
PCB Layout
Display PCB
Display PCB Test Point Layout
6-28
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
Control PCB
D87 MIG SOL ON
D89 TIG SOL ON
D33 PWM
R34 CURRENT
CALIBRATION POT
D36 3.3V_1 OK
D45 uP OK
D44 UI COM
D43 BUSS V ERROR
D40 +24V_1 LOW
D88 TRIGGER
R642 WIRE FEED
SPEED CALIBRATION
POT
D35 PS_OK
D86 +5V_1 OK
D90 FAN ON
D85 +10.3_VB OK
Manual 0463 644 001
TROUBLESHOOTING
6-29
ESAB EMP235IC
Main PCB
Line Line +
Line 2
R89
Line 1
R88
Bus
PFC
D42 +24V_SEC OK
CN2
D53 +18V_PRI OK
CN4
CN1
CN9
TRANSF1
TRANSF2
CN7
CN8
Output Diode PCB
RFI filter PCB
6-30
TROUBLESHOOTING
Manual 0463 644 001
ESAB EMP235IC
7
MAINTENANCE
NOTE!
Regular maintenance is important for safe, reliable operation
!
CAUTION
Only persons with the appropriate electrical knowledge (authorized personnel) may
remove the cover of the product to connect or carry out service, maintenance or repair
work on the welding equipment.
!
CAUTION
The product is covered by manufacturer’s warranty. Any attempt to carry out repair work
by non-authorized service centers will invalidate the warranty.
WARNING
Disconnect power before performing maintenance!
NOTE!
Perform maintenance more often during severe dusty conditions.
Before each use - make sure that:
• The torch body and torch cable and leads are not damaged.
• The contact tip on the torch is not damaged.
• The nozzle on the torch is clean and does not contain any debris.
7.01
Routine Maintenance
Maintenance schedule during normal conditions.
Interval
Area to maintain
Every 3 month
Clean or replace
unreadable labels.
Clean weld
terminals.
Check or replace weld cables.
Every 6 month
Clean inside
equipment.
Manual 0463 644 001
ROUTINE MAINTENANCE
7-1
ESAB EMP235IC
7.02
Power Source and Wire Feeder Maintenance
Perform a power source cleaning each time you replace a Ø4” (100 mm) or Ø8” (200 mm) wire bobbin.
Power source and wire feeder cleaning procedure
NOTE!
Always were safety gloves during cleaning.
1. Disconnect the power source from the mains receptacle.
2. Open the lid and release the tension from the pressure roller by turning the tension screw (1) counterclockwise and then pull it toward you.
3. Remove the wire and the wire spool.
4. Remove the torch and use a low pressure airline, taking care not to let the wire consumable unravel, to
clean the power source interior and power source air inlet and outlet.
5. Inspect if the inlet wire guide (4), outlet wire outlet (2) or the feeder roller (3) are worn and need replacement. See appendix WEAR PARTS for ordering numbers of parts.
6. Remove and clean the feeder roller with a soft brush. Clean the pressure roller attached to the wire
feeder mechanism with a soft brush.
7.03
Torch and Liner Maintenance
Torch and liner cleaning procedure
1. Disconnect the power source from the mains socket.
2. Open the lid and release the tension from the pressure roller by turning the tension screw (1) counterclockwise and then pull it toward you.
3. Remove the wire and the wire spool.
4. Turn Mig gun locking screw counter-clockwise to allow Mig gun to be removed from feed plate.
5. Remove the liner from the torch and inspect it. Clean the liner by blowing compressed air (max 5 bar)
through the end of the liner that was mounted closest to the power source.
6. Re-install the liner.
7.04
Periodic Inspection and Testing
EMP235IC is designed to meet the Periodic Inspection and Test requirements in IEC60974-4 2010 section 4.4
without complimentary instructions. There are no special instructions from the manufacturer for the tests in
Table 1.
7-2
ROUTINE MAINTENANCE
Manual 0463 644 001
ESAB EMP235IC
8
DISASSEMBLY
8.01
Safety Precautions for Disassembly
!
!
WARNING
Read and follow safety information in Section 1 before proceeding. Follow
anti static precautions when handling any PCB (Printed Circuit Board).
WARNING
Buss voltage of 400 VDC will be present on the heatsinks of POWER PCB2
while unit is on. Wait 40 seconds after removing power before handling.
8.02
User Interface TFT Display Assembly Removal
Read and follow safety information in Section 1 before proceeding with
disassembly. Follow anti static precautions when handling any PCB (Printed Circuit Board).
Unplug the unit before beginning disassembly procedure.
NOTE!
There is a ground wire attached to the inside, bottom of the power-side cover..
Be careful not to pull on the wire when removing the cover.
1. Remove eight (8) screws securing the power-side cover and frame to the power supply.
8
Manual 0463 644 001
DISASSEMBLY
8-1
ESAB EMP235IC
2. Unplug the small multi wire harness from CN6 on the bottom of the Control PCB. (Not shown)
3. Remove the four (4) screws on the inside of the unit that secure the User Interface TFT Display in place.
You will need to access these from both sides of the unit.
4
4. Remove the Display being careful to feed the harness through the oblong slot in the sheet metal.
Reverse this process for installation.
8-2
DISASSEMBLY
Manual 0463 644 001
ESAB EMP235IC
8.03
Control PCB Removal
Read and follow safety information in Section 1 before proceeding with
disassembly. Follow anti static precautions when handling any PCB (Printed Circuit Board).
Unplug the unit before beginning disassembly procedure.
1. Remove eleven (11) screws securing the power-side cover and frame to the power supply.
8
2. Take photos or notes on all the harness connections to the Control PCB which is the upper most board.
3. Disconnect all harnesses from the Control PCB. (Not shown)
4. Remove the five (5) screws securing the board in place and remove the board.
5
Reverse this process for installation.
Manual 0463 644 001
DISASSEMBLY
8-3
ESAB EMP235IC
8.04
Power PCB Assembly Removal
!
WARNING
Read and follow safety information in Section 1 before proceeding. Follow
anti static precautions when handling any PCB (Printed Circuit Board).
NOTE!
The Control PCB must be removed before you can remove the Power PCB Assembly..
1. First remove the Control PCB by following the previous process.
2. Take photos and or notes on all the harness connections along the top and the four (4) transformer and
PFC Inductor connections along the bottom of the Power PCB Assembly.
3. Disconnect each of these from the Power PCB Assembly. (Not shown)
!
CAUTION
Keep these 4 screws connecting the wires from along the bottom of the board
separate as they are shorter and must be used in the same locations again.
The longer screws from all other locations will damage the board if used reconnecting these wires.
4. Remove the 9 screws and washers that secure the board to the Center Wall structure. Remove the 4
from the wire spool side first and then the 3 from this side. The 2 screws are for the PFC and are M4x8.
3
4
2 PFC
5. Carefully remove the assembly.
Reverse this process for installation.
8-4
DISASSEMBLY
Manual 0463 644 001
ESAB EMP235IC
APPENDIX 1: WORKING PRINCIPLE
(BLOCK DIAGRAM)
Manual 0463 644 001
APPENDIX
A-1
ESAB EMP235IC
APPENDIX 2: CSA SYSTEM SCHEMATIC, 115/230V UNITS
A-12892_AA
A-2
APPENDIX
Manual 0463 644 001
ESAB EMP235IC
A-12892_AA
Manual 0463 644 001
APPENDIX
A-3
ESAB EMP235IC
APPENDIX 3: CE SYSTEM SCHEMATIC, 115/230V UNITS
A-13146_AA
A-4
APPENDIX
Manual 0463 644 001
ESAB EMP235IC
A-13146_AA
Manual 0463 644 001
APPENDIX
A-5
ESAB EMP235IC
Calibration
This section provides qualified service personnel detailed instructions to calibrate the Rebel control PCB when
in an assembled unit. The control PCB will require calibration when:
1. The Control PCB, PCB3 has been replaced,
2. The Wire Feed Mechanism M1 has been replaced,
3. The Output current sensor CS1 has been replaced.
Required Tools:
True RMS Volt Meter:
Fluke Model 179 or equivalent
True RMS Current Clamp:
Fluke Model 376 or equivalent
Hand Held Tachometer:
Extech Instruments Model 461891 or equivalent
Load Bank:
Capable of 200A continuous load
NOTE!
See CONTROL PCB 3 Layout for Trimpot locations
Output Amperage Calibration:
With unit connected to 230VAC primary line voltage, connect the output terminals of the power supply to a load
bank. The calibration will be checked at both Maximum and Minimum output current settings. Turn unit on and
set the machine into STICK (SMAW) Process and adjust for 210A (max) at 28.4VDC. Using a clamp on ammeter
read the actual output amperage on the positive output cable. Adjust Trimpot R34 on the Control PCB3 until
the measured output amperage on the clamp on meter reads 210A (+3A/- 0A). Next set the unit and load bank
up for 15A (min) @20.6VDC. The reading on the clamp on meter should be 15A (+0A/-1A). If necessary, adjust
R34 until both the max and min readings are both within the specified tolerances listed above.
Wire Feed Speed Calibration:
Set the power supply to MIG (GMAW) process and adjust Wire Feed Speed for 700 ipm on the power supply
display. The calibration will be checked at both Maximum and Minimum Wire Feed Speed settings. Using the
tachometer to measure the speed of the drive roll, trigger the unit and get actual speed measurement from
tachometer. Adjust the trimpot R642 on the Control PCB3 until the actual measured speed is 700 (max) ipm
(+/- 10 ipm). Then set Wire Feed Speed to 100 ipm and trigger the power supply. Actual measured speed
should be within +/- 8 ipm of power supply display reading. If necessary adjust R642 until both max and min
Wire Feed Speed measurements are within the specified tolerances listed above.
Voltmeter specification across the entire output range is +/- 0.5VDC.
A-6
APPENDIX
Manual 0463 644 001
ESAB EMP235IC
This Page Intentionally Blank
Manual 0463 644 001
APPENDIX
A-7
ESAB EMP235IC
Revision History
Date
Dec. 20, 2016
A-8
Rev
Description
AA
Manual release
APPENDIX
Manual 0463 644 001
This Page Intentionally Blank
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Distributors
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