ESAB | EMP 215ic | Instruction manual | ESAB EMP 215ic User manual

ESAB EMP 215ic User manual
EMP 215ic
Instruction manual
0463 489 001 GB 20171115
Valid for: serial no. 719-xxx-xxxx
TABLE OF CONTENTS
SAFETY .......................................................................................................
5
1.1
Meaning of symbols ...............................................................................
5
1.2
Safety precautions .................................................................................
5
INTRODUCTION .........................................................................................
8
2.1
Equipment ...............................................................................................
8
3
TECHNICAL DATA ......................................................................................
9
4
INSTALLATION............................................................................................
11
4.1
Location...................................................................................................
11
4.2
Lifting instructions .................................................................................
11
4.3
Mains supply...........................................................................................
12
Recommended fuse sizes and minimum cable area............................
13
OPERATION ................................................................................................
14
5.1
Connections............................................................................................
15
5.2
Connection of welding and return cables ............................................
16
5.3
Polarity change.......................................................................................
16
5.4
Inserting and replacing wire..................................................................
16
5.5
Setting the wire feed pressure ..............................................................
18
5.6
Changing the feed/pressure rollers ......................................................
18
5.7
Shielding gas ..........................................................................................
19
5.8
Duty cycle ...............................................................................................
20
5.9
Overheating protection ..........................................................................
21
5.10
Voltage Reduction Device (VRD)...........................................................
21
CONTROL PANEL.......................................................................................
22
6.1
How to navigate ......................................................................................
22
6.1.1
Main menu............................................................................................
22
6.1.2
sMIG mode ...........................................................................................
22
6.1.3
Manual MIG mode ................................................................................
23
6.1.4
Flux cored wire mode ...........................................................................
23
6.1.5
MMA mode ...........................................................................................
23
6.1.6
LIFT-TIG mode .....................................................................................
23
6.1.7
Settings ................................................................................................
24
6.1.8
User manual information ......................................................................
24
6.1.9
Icon reference guide.............................................................................
24
MAINTENANCE ...........................................................................................
27
7.1
Routine maintenance .............................................................................
27
7.2
Power source and wire feeder maintenance .......................................
27
7.3
VRD periodic tests .................................................................................
28
7.4
Torch and liner maintenance.................................................................
29
8
TROUBLESHOOTING .................................................................................
30
9
ORDERING SPARE PARTS ........................................................................
32
1
2
4.3.1
5
6
7
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© ESAB AB 2017
TABLE OF CONTENTS
DIAGRAM .............................................................................................................
33
ORDERING NUMBERS ........................................................................................
34
WEAR PARTS.......................................................................................................
35
ACCESSORIES ....................................................................................................
37
REPLACEMENTS PARTS....................................................................................
38
Rights reserved to alter specifications without notice.
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© ESAB AB 2017
1 SAFETY
1
SAFETY
1.1
Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).
1.2
Safety precautions
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1.
2.
3.
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
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
The workplace must:
○ be suitable for the purpose
○ be free from drafts
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1 SAFETY
4.
5.
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
General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
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1 SAFETY
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation
in accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be
disposed of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.
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2 INTRODUCTION
2
INTRODUCTION
The ESAB EMP product family is a new generation of MIG and Multi-Process
(MIG/MMA/TIG) welding power sources.
The EMP 215ic power source is designed to match the needs of the light-medium fabrication
user. They are tough, durable and portable, providing excellent arc performance across a
variety of welding applications.
The EMP features a 11 cm (4.3 in.) colour TFT user interface display which provides quick
and easy selection of weld process and parameters, suitable for both newly trained and
intermediate level users. For more advanced users, a number of additional functions and
features can be introduced and customized to give maximum flexibility.
Exclusive to ESAB, sMIG provides users with an excellent 'Short circuit' arc characteristic.
The EMP family connects to an input power supply range between
120 V – 230 V, 1 ~ 50/60 Hz input power supplies. Input power can be supplied by mains or
generator. Incorporating a PFC (Power Factor Correction) circuit significantly increases
power efficiency.
Key features:
•
•
•
•
•
•
•
•
Excellent multi-process welding capabilities, MIG/MMA and Lift/TIG
Automatic recognition of input power with PFC (120 V – 230 V)
Large 11 cm (4.3 in.) high resolution, customizable user interface
Rugged case design and internal hardware
Portable, single person lift and carry design
High grade cast aluminium wire drive system provides excellent control of drive roll
geometry ensuring smooth, precise wire feeding
Professional high grade accessories
Voltage Reduction Device (VRD, Applicable in stick mode only)
2.1
Equipment
The package consists of the following:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
ESAB EMP 215ic power source
Tweco Fusion™ 250 MIG torch, 3 m (10 ft)
Contact tip M6 for 0.8 mm (0.030 in.) wire (qty 2)
Contact tip M6 for 1.0 mm (0.040 in.) wire (qty 2)
Gas hose, 4.5 m (14.8 ft), Quick connector, 5/8-18UNF
MMA welding cable kit 3 m (10 ft)
Return cable kit 3 m (10 ft)
OK 12.50 0.8 mm (0.030 in.) × 5 kg (11 lb) bobbin
Drive roll 0.6 / 0.8 mm (0.023 in. / 0.030 in.) cored, steel and stainless wire (installed
on drive system)
Drive roll 0.8 / 1.0 mm (0.030 in. / 0.040 in.) cored, steel and stainless wire (in
accessory box)
Guide tube 1.0 mm – 1.2 mm (0.040 in. – 0.045 in.) (installed on drive system)
Guide tube 0.6 mm – 0.8 mm (0.023 in. – 0.030 in.) (in accessory box)
Mains cable 3 m (10 ft), fixed with plug
Safety manual
USB with Instruction manual
Material thickness guide
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3 TECHNICAL DATA
3
TECHNICAL DATA
EMP 215ic
Voltage
230 V, 1 ~ 50/60 Hz
120 V, 1 ~ 50/60 Hz
Primary current
Imax. GMAW - MIG
Breaker 20 A: 28.6 A
30 A
Breaker 15 A: 20.3 A
Imax. GTAW - TIG
19 A
Breaker 15 A: 20.8 A
Imax. SMAW - MMA
25 A
Breaker 15 A: 20.8 A
Ieff. GMAW - MIG
Breaker 20 A: 13 A
14 A
Breaker 15 A: 13 A
Ieff. GTAW - TIG
10 A
Breaker 15 A: 14.7 A
Ieff. SMAW - MMA
13 A
Breaker 15 A: 14.7 A
Permissible load at GMAW - MIG
100% duty cycle
110 A / 19.5 V
Breaker 20 A: 90 A / 18.5 V
Breaker 15 A: 75 A / 17.75 V
60% duty cycle
125 A / 20.25 V
Breaker 20 A: 110 A / 19.5 V
Breaker 15 A: 90 A / 18.5 V
40% duty cycle
150 A / 21.5 V
Breaker 15 A: 100 A / 19 V
25% duty cycle
205 A / 24.25 V
-
20% duty cycle
-
Breaker 20 A: 130 A / 20.5 V
Setting range (DC)
15 A / 14.75 V –
230 A / 25.5 V
15 A / 14.75 V –
130 A / 20.5 V
Permissible load at GTAW - TIG
100% duty cycle
110 A / 14.4 V
100 A / 14 V
60% duty cycle
125 A / 15 V
120 A / 14.8 V
40% duty cycle
-
130 A / 15.2 V
30% duty cycle
180 A / 17.2 V
-
Setting range (DC)
5 A / 10.2 V – 200 A / 18 V
5 A / 10.2 V – 150 A / 16 V
Permissible load at SMAW - MMA
100% duty cycle
100 A / 24 V
65 A / 22.6 V
60% duty cycle
125 A / 25 V
80 A / 23.2 V
40% duty cycle
-
85A / 23.4V
25% duty cycle
180 A / 27.2 V
-
Setting range (DC)
16 A / 20.6 V – 180 A / 27.2 V 16 A / 20.6 V – 110 A / 24.4 V
Open circuit voltage (OCV)
VRD activated
<35 V DC
<35 V DC
VRD* deactivated, nominal
OCV (Boost OCV)
68 V / (90 V)
68 V / (90 V)
Efficiency
86%
84%
Power factor
0.98
0.99
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3 TECHNICAL DATA
EMP 215ic
Wire feed speed
1.5–12 m/min
(62–475 in./min)
1.5–12 m/min
(62–475 in./min)
Wire diameter
Mild steel solid wire
0.6–1.0 mm (0.023–0.040 in.) 0.6–1.0 mm (0.023–0.040 in.)
Stainless steel solid wire
0.8–1.0 mm (0.030–0.040 in.) 0.9–1.0 mm (0.035–0.040 in.)
Flux cored wire
0.8–1.1 mm (0.030–0.045 in.) 0.8–1.1 mm (0.030–0.045 in.)
Aluminium
0.8–1.2 mm (0.030–3/64 in.)
0.8–1.2 mm (0.030–3/64 in.)
Bobbin size
Ø 100–200 mm (4–8 in.)
Ø 100–200 mm (4–8 in.)
Dimensions l×w×h
548 × 229 × 406 mm
(23.0 × 9.0 × 16.0 in.)
548 × 229 × 406 mm
(23.0 × 9.0 × 16.0 in.)
Weight
18.2 kg (40 lb)
18.2 kg (40 lb)
Operating temperature
-10 to +40 °C (-14 to +104 °F) -10 to +40 °C (-14 to +104 °F)
Enclosure class
IP23S
IP23S
Application classification
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40 °C (104 °F).
For more information, see section "Duty cycle" in the "OPERATION" chapter.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP 23S is intended for indoor and outdoor use; however, should not be
operated in precipitation.
Application class
The symbol
indicates that the power source is designed for use in areas with increased
electrical hazard.
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4 INSTALLATION
4
INSTALLATION
The installation must be carried out by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment this product
may cause radio interference. It is the user's responsibility to take adequate
precautions.
4.1
Location
Position the power source so that its cooling air inlets and outlets are not obstructed.
A. 100 mm (4 in.)
B. 100 mm (4 in.)
4.2
Lifting instructions
The power source can be lifted using any of the handles.
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4 INSTALLATION
WARNING!
Secure the equipment - particularly if
the ground is uneven or sloping.
4.3
Mains supply
NOTE!
Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit
power is greater than or equal to 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 230 V AC ±10% or 120 V ±10%. Too low supply voltage may
cause poor welding performance. Too high welding supply voltage will cause components to
overheat and possibly fail. Contact the local electric utility for information about the type of
electrical service available, how proper connections should be made, and inspection
required.
The Welding power source must be:
•
•
•
Correctly installed, if necessary, by a qualified electrician.
Correctly earthed (electrically) in accordance with local regulations.
Connected to the correct size power point and fuse as table below.
NOTE!
Use the welding power source in accordance with the relevant national
regulations.
CAUTION!
Disconnect input power and secure employing ‘Lock-out’ / ‘Tagging’ procedures.
Ensure input power line disconnect switch is locked (lock-out/Tagging) in the
‘Open’ position BEFORE removing input power fuses. Connection/Disconnect
should be carried out by competent persons.
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4 INSTALLATION
1.
Rating plate with supply connection data
4.3.1
Recommended fuse sizes and minimum cable area
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.
120 – 230 V, 1 ~ 50/60 Hz
Supply voltage
230 V AC
120 V AC
Input current at maximum output
30 A
30 A
Maximum recommended fuse* or circuit breaker rating
*Time delay fuse
30 A
30 A
Maximum recommended fuse or circuit breaker rating
50 A
50 A
2.5 mm2
(13 AWG)
2.5 mm2
(13 AWG)
15 m (50 ft)
15 m (50 ft)
2.5 mm2
(13 AWG)
2.5 mm2
(13 AWG)
Minimum recommended cord size
Maximum recommended extension cord length
Minimum recommended grounding conductor size
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.
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5 OPERATION
5
OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
NOTE!
When moving the equipment use intended handle. Never pull 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!
WARNING!
Assure that the side panels are closed during operation.
WARNING!
Tighten the bobbin locking nut in order to prevent it from sliding off the hub.
100 mm (4 in.)
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200 mm (8 in.)
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© ESAB AB 2017
5 OPERATION
5.1
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 [-]
0463 489 001
7. Polarity changeover cable
8. Positive output [+]
9. Euro torch connection
10. Mains cable
11. Mains supply switch ON/OFF
12. Gas valve inlet female
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© ESAB AB 2017
5 OPERATION
Drive system diagram
1. Bobbin hub
2. EMC filter
3. Circuit breaker
5.2
4. Opening side panel
5. Gas valve
6. Wire feed mechanism
Connection of welding and return cables
The power source has two outputs for connecting welding and return cables: a negative [-]
terminal (6) and a positive [+] terminal (8), see front and rear illustration.
For MIG/MMA process, the output to which the welding cable is connected depends on the
type of electrode; refer to electrode packaging for information relating to the correct electrode
polarity. Connect the return cable to the remaining welding terminal on the power source.
Secure the return cable's contact clamp to the work piece and ensure that there is good
contact.
For TIG process (requires optional TIG accessories), connect the TIG torch power cable to
the negative [-] terminal (6), see front illustration. Connect gas inlet nut to a regulated
shielding gas supply. Connect the work return lead to the positive [+] terminal (8), see front
and rear illustration.
5.3
Polarity change
The power source is delivered with the polarity changeover cable connected to the positive
terminal. Some wires, e.g. self-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 return cable to the positive terminal. Check the recommended
polarity for the welding wire you want to use.
The polarity can be changed by moving the polarity changeover cable to suit the applicable
welding process.
5.4
Inserting and replacing wire
The EMP 215ic will handle bobbin sizes of 100 mm (4 in.) and 200 mm (8 in.). See
"TECHNICAL DATA" chapter for suitable wire dimensions for each wire type.
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5 OPERATION
WARNING!
Do not place or point the torch near the face, hand or body as this may result in
personal injury.
WARNING!
Risk of crushing when replacing the wire bobbin! Do not use safety gloves when
inserting the welding wire between the feed rollers.
NOTE!
Make sure the correct feed/pressure rollers are used. For more information, see
appendix "WEAR PARTS".
NOTE!
Remember to use the correct contact tip in the welding torch for the wire diameter
used. The torch is fitted with a contact tip for 0.8 mm (0.030 in.) wire. If another
diameter is used, the contact tip and drive roll must be changed. The wire liner
fitted in the torch is recommended for welding with Fe and SS wires.
1.
2.
3.
4.
5.
6.
7.
Open the right side panel.
Release the pressure roller arm by pushing the tension screw toward you (1).
Lift the pressure roller arm up (2).
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.
Re-secure the pressure roller arm and wire drive tension screw. Adjust the pressure if
necessary.
With the MIG torch lead reasonably straight, feed the wire through the MIG torch by
depressing the trigger switch.
Close the side panel.
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5 OPERATION
Welding with aluminium wire
In order to weld aluminium using the standard supplied MIG torch, refer to MIG torch
instruction manual for replacing standard, steel conduit liner with Teflon conduit liner.
Order the following accessories: 'U' groove drive roll 1.0 mm / 1.2 mm (0.040 in. / 0.045 in.)
and Teflon conduit liner (PTFE liner), 3 m (10 ft). See appendix "WEAR PARTS" in this
manual and appendix "WEAR PARTS" in Instruction manual for the MIG torch for ordering
numbers.
5.5
Setting the wire feed pressure
Illustration A
Illustration B
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 6 mm (¼ in.) from the piece of wood
(illustration A), the feed rollers should slip.
If you hold the welding torch approximately 50 mm (2 in.) from the piece of wood, the wire
should be fed out and bend (Illustration B).
5.6
Changing the feed/pressure rollers
One dual groove feed roller is supplied as standard. Change the feed roller to match the filler
metal.
NOTE!
Be sure not to lose the key that is located on the drive motor shaft. This key must
align with drive roll slot for proper operation.
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5 OPERATION
1.
2.
3.
4.
5.
Open the right side panel.
Remove the feed roll retaining screw by turning it counterclockwise.
Change the feed roll.
Tighten the feed roll retaining screw by turning it clockwise.
Close the side panel.
NOTE!
The visual wire stamp designates the wire diameter groove in use.
5.7
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 are used
with pure argon gas (Ar). IIn the sMIG mode (see section "sMIG mode" in the "CONTROL
PANEL" chapter), the optimal welding arc with the gas used will be automatically set.
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5 OPERATION
5.8
Duty cycle
The EMP 215ic has a welding current output of 205 A at 25% duty cycle (230 V). A
self-resetting thermostat will protect the power source if the duty cycle is exceeded.
Example: If the power source operates at a 25% duty cycle, it will provide the rated
amperage for a maximum of 2.5 minutes out of every 10 minute period. The remaining time,
7.5 minutes, the power source must be allowed to cool down.
2.5 minutes
7.5 minutes
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 120 V AC
Welding current (A)
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5 OPERATION
Duty cycle on 230 V AC
Welding current (A)
5.9
Overheating protection
The welding power source has overheating protection that operates if the
internal temperature becomes too high. When this occurs, the welding
current is interrupted and an overheating symbol appears on the display.
The overheating protection resets automatically when the temperature has
returned to normal working temperature.
5.10
Voltage Reduction Device (VRD)
A VRD (Voltage Reduction Device) is a hazard reducing device designed to reduce electric
shock hazards present on the output of the welding power source when operating in MMAW
(stick) mode. Note that the presence of VRD should not be used as a substitute for the use
of appropriate safety practices as indicated in the "SAFETY" chapter of this manual!
Both the green and the red indicators on the power source control panel only operate in
MMAW (stick) mode. The green VRD ON light illuminates (red light is off) when the VRD is
active. Under this condition the open circuit voltage of the unit is limited to below 35 V DC,
thus reducing the potential of serious electric shock (such as when changing electrodes).
The red VRD OFF light illuminates (green light is off) when the VRD is inactive. Under this
condition the output voltage of the unit will be at welding potential which in some cases may
exceed 35 V DC.
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6 CONTROL PANEL
6
CONTROL PANEL
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. General information about operation can be found in the
"OPERATION" chapter of this manual. Read both chapters thoroughly before you
start using the equipment!
After power on has completed, the main menu appears on the control panel.
6.1
6.1.1
6.1.2
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How to navigate
1.
2.
3.
Current / Wire feed speed selection
Voltage selection
Menu navigation. Rotate and push to
select menu option.
1.
2.
3.
4.
5.
6.
7.
8.
sMIG mode
Manual MIG mode
Flux cored wire mode
MMA mode
Lift-TIG mode
Settings
User manual information
Dialogue box
1.
2.
3.
4.
5.
6.
7.
Home screen
Information
Memory
Material selection
Wire feed speed
Material thickness
Dialogue box
Main menu
sMIG mode
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© ESAB AB 2017
6 CONTROL PANEL
6.1.3
6.1.4
6.1.5
6.1.6
0463 489 001
Manual MIG mode
1.
2.
3.
4.
5.
6.
7.
Home screen
Information
Memory
Material selection
Wire feed speed
Voltage
Dialogue box
1.
2.
3.
4.
5.
6.
Home screen
Information
Memory
Wire feed speed
Voltage
Dialogue box
1.
2.
3.
4.
5.
6.
7.
8.
Home screen
Information
Memory
Parameter
Amperage
Voltage (OCV or Arc)
VRD indicator (VRD ON or VRD OFF)
Dialogue box
1.
2.
3.
4.
5.
6.
Home screen
Information
Memory
Parameter
Amperage
Dialogue box
Flux cored wire mode
MMA mode
LIFT-TIG mode
- 23 -
© ESAB AB 2017
6 CONTROL PANEL
6.1.7
6.1.8
6.1.9
Settings
1.
2.
3.
4.
5.
6.
7.
Reset mode
Inch/Metric
Basic/Advanced
Language
Information
Home screen
Dialogue box
1.
2.
3.
4.
5.
Maintenance information
Wear & Spare parts
Operation information
Home screen
Dialogue box
User manual information
Icon reference guide
Home
Spot time on/off selection
Information
0463 489 001
MIG Torch
Spot time on adjustment
Parameters
Flux cored
Parameters
Manual MIG
Percent
MMA
- 24 -
© ESAB AB 2017
6 CONTROL PANEL
0463 489 001
Preflow The time the
shielding gas stays on
before the welding arc is
started
Smart MIG
Postflow The time the
shielding gas stays on after
the welding arc is stopped
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
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 over a period
of time at the end of the
weld cycle
Advanced Settings
- 25 -
© ESAB AB 2017
6 CONTROL PANEL
0463 489 001
Hot start The increase of
amps when striking the
electrode to reduce sticking
Basic Settings
Inductance The addition of
inductance into the arc
characteristics to stabilize
the arc and reduce spatter
when in the short circuit
process
Diagnostics
Memory Save welding
programs for a specific
application
Language selection
Stick electrode choice
Unit of Measure
Upslope Sloping the
current up over a period of
time at the beginning of the
weld cycle
Bead profile, concave
Volts
Bead profile, convex
Wire feed speed
VRD ON indicator
Voltage Reduction Device
active
Wire diameter
VRD OFF indicator
Voltage Reduction Device
inactive
- 26 -
© ESAB AB 2017
7 MAINTENANCE
7
MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
CAUTION!
Only persons with the appropriate electrical knowledge (authorized personnel)
may remove the cover of the product 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 centres will invalidate the warranty.
WARNING!
Disconnect power before performing maintenance. Maintain control and
awareness of the disconnected power connections when performing work. Detect
and prevent premature reconnection of the power.
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.
7.1
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.
7.2
Power source and wire feeder maintenance
Perform a power source cleaning each time you replace a Ø100 mm (4 in.) or Ø200 mm
(8 in.) wire bobbin.
0463 489 001
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© ESAB AB 2017
7 MAINTENANCE
Power source and wire feeder cleaning procedure
NOTE!
Always wear safety gloves and spectacle during cleaning.
1.
2.
3.
4.
5.
6.
Disconnect the power source from the input power socket.
Open the side panel and release the tension from the pressure roller by turning the
tension screw (1) counterlockwise and then pull it toward you.
Remove the wire and the wire bobbin.
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.
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.
Remove and clean the feeder roller with a soft brush. Clean the pressure roller
attached to the wire feeder mechanism with a soft brush.
7.3
VRD periodic tests
Units fitted with VRDs shall have the periodic tests outlined in the table below conducted by
an accredited CIGWELD service provider. Testing shall be conducted at intervals as outlined
below.
•
•
For transportable equipment, at least once every 3 months
For fixed equipment, at least once every 12 months
Description
Required parameters
VRD Open circuit voltage
Less than 35 V (at nominal input voltage)
VRD Turn on resistance
Less than 200 ohms
VRD Turn off time
Less than 0.3 seconds
0463 489 001
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© ESAB AB 2017
7 MAINTENANCE
7.4
Torch and liner maintenance
Torch and liner cleaning procedure
1.
2.
3.
4.
5.
6.
Disconnect the power source from the input power socket.
Open the side panel and release the tension from the pressure roller by turning the
tension screw (1) counterclockwise and then pull it toward you.
Remove the wire and the wire bobbin.
Remove the torch from the power source.
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.
Re-install the liner.
0463 489 001
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© ESAB AB 2017
8 TROUBLESHOOTING
8
TROUBLESHOOTING
Try these checks and inspections before sending for an authorized service technician.
Type of fault
Corrective action
Porosity within the weld
metal
•
•
•
•
Wire feeding problems
•
•
•
•
See appendix WEAR
PARTS for correct sizes
and types.
Check gas bottle is not empty.
Check gas regulator is not closed.
Check gas inlet hose for leaks or blockage.
Check that the correct gas is connected and the correct
gas flow is used.
• Keep the distance between the MIG torch nozzle and the
work piece to a minimum.
• Make sure the work piece is clean before welding.
Make sure the wire spool brake is adjusted correctly.
Make sure the feed roller is correct size and not worn.
Make sure the correct pressure on the feed rollers is set.
Make sure proper direction of motion based on wire type
(into the weld pool for aluminium away from the weld pool
for steel).
• Make sure the correct contact tip is used and it is not worn.
• Make sure liner is the right size and type for wire.
• Make sure the liner is not bent so that friction is caused
between the liner and the wire.
MIG (GMAW/FCAW)
welding problems
• Make sure the MIG torch is connected to correct polarity.
Refer to the electrode wire manufacturer for the correct
polarity.
• Replace contact tip if it has arc marks in the bore causing
excessive drag on the wire.
• Make sure the correct shielding gas, gas flow, voltage,
welding current, travel speed and MIG torch angle is used.
• Make sure the work lead has proper contact with the work
piece.
MMA (SMAW) basic
welding problems
• Make sure you are using correct polarity. The electrode
holder is usually connected to the positive polarity and the
work lead to the negative polarity. If in doubt consult the
electrode data sheet.
TIG (GTAW) welding
problems
• Make sure the TIG torch lead is connected to negative
welding terminal
• Make sure the correct shielding gas, gas flow, voltage,
welding current, travel speed, filler rod placement,
electrode diameter and welding mode on power source is
used.
• Make sure the work clamp has proper contact with the
work piece.
• Make sure the gas valve on the TIG torch is on.
0463 489 001
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© ESAB AB 2017
8 TROUBLESHOOTING
Type of fault
No power/No arc
Corrective action
•
•
•
•
Check that the input power supply switch is turned on.
Check if a temperature fault is shown on display.
Check if system breaker is tripped.
Check that the input power, welding and return cables are
correctly connected.
• Check that the correct current value is set.
• Check the input power supply fuses.
The overheating protection • Make sure that you are not exceeding the recommended
trips frequently.
duty cycle for the weld current you are using.
See section "Duty cycle" in the OPERATION chapter.
• Make sure the air inlets or outlets are not clogged.
0463 489 001
- 31 -
© ESAB AB 2017
9 ORDERING SPARE PARTS
9
ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
The EMP 215ic is designed and tested in accordance with international standards IEC-/EN
60974-1, IEC-/EN 60974-5, IEC-/EN 60974-7, IEC-/EN 60974-10, IEC-/EN 60974-12 and
IEC-/EN 60974-13. It is the obligation of the authorized service centre carrying out the
service or repair work to ensure that the product still conforms to the aforementioned
standards.
The spare parts list is published in a separate document that can be downloaded from the
Internet: www.esab.com
0463 489 001
- 32 -
© ESAB AB 2017
DIAGRAM
DIAGRAM
0463 489 001
- 33 -
© ESAB AB 2017
ORDERING NUMBERS
ORDERING NUMBERS
Ordering no.
Denomination
Note
0700 300 993
EMP 215ic
Bobbin Ø100–200 mm (4–8 in.) CE, euro
connection
0463 412 001
Spare parts list
0463 489 001
- 34 -
© ESAB AB 2017
WEAR PARTS
WEAR PARTS
Item Ordering no. Denomination
1
Wire type Wire dimensions
0558 102 460 Wire outlet guide
steel
Fe/SS/Flux 1.0 mm–1.2 mm (0.040 in.–0.045 in.)
Cored
0558 102 461 Wire outlet guide
steel
Fe/SS/Flux 0.6 mm–0.8 mm (0.023 in.–0.030 in.)
Cored
0464 598 880 Wire outlet guide
teflon
Aluminium 1.0 mm–1.2 mm (0.040 in.–0.045 in.)
2
0558 102 328 Wire inlet guide
Fe/SS/Flux 0.6 mm/0.8 mm/0.9 mm/1.2 mm
Cored
(0.023 in./0.030 in./0.035 in./0.045 in.)
3
0558 102 457 Key-drive shaft
crescent
N/A
N/A
4
7977036
Feed roll "V"
groove
Fe/SS
0.6 mm/0.8 mm (0.023 in./0.030 in.)
7977660
Feed roll "V"
groove
Fe/SS
0.9 mm/1.2 mm (0.035 in./0.045 in.)
7977732
Feed roll "V"
knurled
Flux Cored 0.8 mm/0.9 mm (0.030 in./0.035 in.)
704277
Feed roll "V"
knurled
Flux Cored 1.2 mm/1.6 mm (0.045 in./0.063 in.)
7977731
Feed roll "U"
groove
Aluminium 0.8 mm/0.9 mm (0.030 in./0.035 in.)
7977264
Feed roll "U"
groove
Aluminium 1.0 mm/1.2 mm (0.040 in./0.045 in.)
5
0558 102 518 Locking knob
N/A
N/A
6
0558 102 331 Pressure arm
N/A
complete assembly
N/A
7
0558 102 550 Shoulder screw
N/A
N/A
8
0558 102 459 Euro adapter
locating screw
N/A
N/A
0463 489 001
- 35 -
© ESAB AB 2017
WEAR PARTS
0463 489 001
- 36 -
© ESAB AB 2017
ACCESSORIES
ACCESSORIES
0700 300 869 TIG Torch
ET 17V 4 m TIG torch with 8-pin plug
0558 102 491 Rebel Single Cylinder Cart
Accommodates maximum 9 in. (228.6 mm)
diameter cylinder
Rebel 215 and Rebel 235 brackets included
W4014450
0463 489 001
Foot control
Contactor on/off and current control with 4.6 m
(15 ft) cable and 8-pin male plug
- 37 -
© ESAB AB 2017
REPLACEMENTS PARTS
REPLACEMENTS PARTS
Item
Ordering no.
1
W4013701
2
0349 312 105
Gas hose, 4.5 m (14.8 ft)
3
0700 006 900
MMA welding cable kit, 3 m (10 ft)
4
0700 006 901
Return welding cable kit, 3 m (10 ft)
5
OTW22/50
Nozzle 13 mm
OTW22/62
Nozzle 16 mm
OTW14/23
Contact tip 0.6 mm
OTW14/30
Contact tip 0.8 mm
OTW14/35
Contact tip 0.9 mm
OTW14/40
Contact tip 1.0 mm
OTW14/45
Contact tip 1.2 mm
6
Denomination
Tweco Fusion™ 250 MIG torch, 3 m (10 ft)
7
OTW32
Insulator
8
OTW52
Gas diffuser
9
62J-45S
Conductor tube, 45 degree
10
W7005001
Trigger assembly
11
W7005000
Handle mouldings
12
OTW42/3035
Liner 0.8-0.9 mm Hard wire
OTW42/4045
Liner 1.0-1.2 mm Hard wire
OTW42N/3545 Liner 0.9-1.2 mm Soft wire
0463 489 001
- 38 -
© ESAB AB 2017
REPLACEMENTS PARTS
0463 489 001
- 39 -
© ESAB AB 2017
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 15 25 79 30
Fax: +32 15 25 79 44
BULGARIA
ESAB Kft Representative Office
Sofia
Tel: +359 2 974 42 88
Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
USA
ESAB Welding & Cutting
Products
Florence, SC
Tel: +1 843 669 4411
Fax: +1 843 664 5748
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
GERMANY
ESAB Welding & Cutting GmbH
Langenfeld
Tel: +49 2173 3945-0
Fax: +49 2173 3945-218
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
SWITZERLAND
ESAB Europe GmbH
Baar
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
www.esab.com
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 0220
Fax: +1 905 670 4879
SPAIN
ESAB Ibérica S.A.
San Fernando de Henares
(MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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