ESAB | EM 235ic | Instruction manual | ESAB EM 235ic User manual

ESAB EM 235ic User manual
EMP 235ic, EM 235ic
Instruction manual
0463 479 101 US 20171110
Valid for: serial no. EMP 235ic: 636-, 716-xxx-xxxx,
EM 235ic: 640-, 733-xxx-xxxx
TABLE OF CONTENTS
SAFETY PRECAUTIONS ............................................................................
4
1.1
Meaning of symbols ...............................................................................
4
1.2
Safety guidance and information..........................................................
4
1.3
User responsibility .................................................................................
9
INTRODUCTION ..........................................................................................
11
2.1
Equipment ...............................................................................................
11
3
TECHNICAL DATA ......................................................................................
13
4
INSTALLATION............................................................................................
16
4.1
Location...................................................................................................
16
4.2
Lifting instructions .................................................................................
16
4.3
Mains supply...........................................................................................
17
4.3.1
Recommended fuse sizes and minimum cable area............................
17
4.3.2
Connecting the power source to input supply ......................................
18
OPERATION ................................................................................................
19
5.1
Connections............................................................................................
20
5.2
Connecting welding and return cables ................................................
20
5.3
Polarity change.......................................................................................
21
5.4
Inserting and replacing wire..................................................................
21
5.5
Setting the wire feed pressure ..............................................................
23
5.6
Changing the feed/pressure rollers ......................................................
23
5.7
Shielding gas ..........................................................................................
24
5.8
Volt-Ampere curves................................................................................
25
5.9
Duty cycle ...............................................................................................
27
5.10
Overheating protection ..........................................................................
28
CONTROL PANEL.......................................................................................
29
6.1
How to navigate - EMP 235ic .................................................................
29
6.1.1
Main menu............................................................................................
29
6.1.2
sMIG mode ...........................................................................................
29
6.1.3
Manual MIG mode ................................................................................
30
6.1.4
Flux cored wire mode ...........................................................................
30
6.1.5
Stick mode............................................................................................
30
6.1.6
LIFT-TIG mode (EMP 235ic only).........................................................
31
6.1.7
Settings ................................................................................................
31
6.1.8
User manual information ......................................................................
31
6.1.9
Icon reference guide.............................................................................
31
How to navigate - EM 235ic ...................................................................
34
Symbol reference EM 235ic .................................................................
34
MAINTENANCE ...........................................................................................
36
7.1
Routine maintenance .............................................................................
36
7.2
Power source and wire feeder maintenance .......................................
36
1
2
5
6
6.2
6.2.1
7
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© ESAB AB 2017
TABLE OF CONTENTS
7.3
Torch and liner maintenance.................................................................
37
8
TROUBLESHOOTING .................................................................................
38
9
ORDERING SPARE PARTS ........................................................................
40
MIG WELD PARAMETER CHART .......................................................................
41
FRACTION TO DECIMAL CONVERSION ...........................................................
43
DIAGRAM .............................................................................................................
44
ORDERING NUMBERS ........................................................................................
45
WEAR PARTS.......................................................................................................
46
ACCESSORIES ....................................................................................................
48
REPLACEMENTS PARTS....................................................................................
49
Rights reserved to alter specifications without notice.
0463 479 101
© ESAB AB 2017
1 SAFETY PRECAUTIONS
1
SAFETY PRECAUTIONS
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.
1.2
Safety guidance and information
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer's safety practices and Safety
Data Sheets (SDSs).
WARNING!
These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in the 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 the Safety Precautions could
result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require
hearing protection. The arc, like the sun, emits ultraviolet (UV) and
other radiation and can injure the 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.
2.
3.
Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching.
Always wear safety glasses with side shields in any work area, even if welding
helmets, face shields and/or goggles are also required.
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 look at the arc and not to expose themselves to
the rays of the electric-arc or hot metal.
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1 SAFETY PRECAUTIONS
4.
5.
6.
7.
Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants,
high-topped shoes, and a welding helmet or cap for personal protection; in order to
protect against arc rays and hot sparks or hot metal. A flameproof apron may also be
desirable as additional protection against radiated heat and sparks.
Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned (closed) and open pockets should be eliminated
from the front of the clothing.
Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains. Post warning signs advising others not to watch the welding arc
or be in direct exposure to the active arc without proper protection.
Use goggles or face shields over safety glasses when chipping slag or grinding.
Chipped slag may be hot and can fly for long distances. Bystanders should also wear
goggles over safety glasses.
FIRES AND EXPLOSIONS
The heat from flames and arcs can start fires. Hot slag or sparks can
also cause fires and explosions. Therefore:
1.
2.
3.
4.
5.
6.
7.
8.
Protect yourself and others from flying sparks and hot metal.
Remove all combustible materials well away from the work area or cover the materials
with an approved protective non-flammable covering. Combustible materials include
wood, cloth, sawdust, liquid and gas fuels, solvents, paints, and coating paper, etc.
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.
Follow the "hot work" procedures for the location. This can include a fire watch person
who monitors the sparks during the work, the requirement for a formal work permit and
the surveillance of the scene for an extended period of time to ensure no smoldering
fires are developing.
Do not weld, cut, or perform other hot work until the work piece has been completely
cleaned so that there are no substances on or in the work piece which might produce
flammable or toxic vapors. Do not perform hot work on closed containers, they may
explode.
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.
Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.
After completing work, inspect the work area to make sure there are no hot sparks or
hot metal that could cause a fire later. Use fire watchers when necessary.
ELECTRICAL SHOCK
Contact between live electrical parts and earth 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.
2.
3.
4.
5.
Be sure the power source frame (chassis) is connected to the earth system of the
input power. All ground points should be verified with periodic testing by an electrician.
Connect the workpiece to a good electrical earth.
Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.
Use well-maintained equipment. Replace worn or damaged cables.
Keep everything dry, including clothing, work area, cables, torch/electrode holder and
power source.
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1 SAFETY PRECAUTIONS
6.
Make sure that all parts of your body are insulated from both the work piece and from
the ground.
7. Do not stand directly on metal or the ground while working in tight quarters or a damp
area; stand on an effective insulation layer, such as dry boards, 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 for specific grounding recommendations. Do not
mistake the work lead for a earth 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.
2.
3.
Welders with medical pacemakers fitted should consult their doctor 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:
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
together 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 the 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. Therefore:
1.
2.
3.
4.
5.
Keep your head out of the fumes, smoke, and vapors. Do not breathe the smoke,
fumes, and gases that are generated by welding processes.
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 in the fumes from these materials.
Orient the ventilation to draw smoke, fumes, and vapors in a direction away from the
welding operator. Position ventilation suction to pull welding fumes and smoke from
the far side of the work area if possible
Provide general ventilation for the surrounding work area if there is a risk of workers or
other persons beyond the immediate work area getting exposed to significant welding
fumes. Monitor the fugitive fumes and smoke for potential collateral exposures. Install
appropriate ventilation controls or cease surrounding activity if fumes become an
exposure issue outside of the immediate work area
Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors or liquids to form phosgene, a highly toxic gas,
and other irritant gases.
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1 SAFETY PRECAUTIONS
6.
7.
8.
9.
If you develop momentary eye, nose or throat irritation while operating, this is an
indication that the ventilation is not adequate. Stop work and take the necessary steps
to improve ventilation in the work area. Do not continue to operate if physical
discomfort persists.
Respiratory protection is required if worker respiratory exposures to fumes exceed
recommended thresholds. Those thresholds can only be accurately measured through
standardized industrial hygiene sampling protocols. Seek the assistance of specialists
if your work causes respiratory exposures or you have other exposure concerns.
Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
WARNING: This product when used for welding or cutting, typically produces fumes or
gases which contain chemicals known to the State of California that can 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. A
sudden rupture of the cylinder valve or relief device can injure or kill.
Therefore:
1.
2.
3.
4.
5.
6.
7.
Locate cylinders away from heat, sparks and flames.
Inspect all connections before use to detect and correct any leaks or system defects.
Use soapy water as a test if you suspect a leak but have difficulty confirming its
location or existence.
Never strike an arc on a cylinder. Handle cylinders with care and avoid jolts and
impacts to cylinders; regardless of if they are empty, partial, or full.
Secure all cylinders in a way that prevents them from falling and potentially doing
damage to the valve, regulator, or attachments. Typically, this requires the use of a
secure strap or chain at an appropriate height that helps to prevent the cylinder from
falling over.
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 adapters. Maintain
hoses and fittings in good condition. Follow the manufacturer's operating instructions
for mounting a regulator to a compressed gas cylinder.
Never secure cylinders to work tables or fixtures where they may become part of an
electrical circuit.
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.
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause injury.
Therefore:
1.
2.
3.
4.
5.
6.
Keep all doors, panels, guards, and covers closed and securely in place.
Stop the engine or drive systems before installing or connecting a unit.
Have only qualified people remove covers for maintenance and troubleshooting as
necessary
To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery. Monitor the battery to prevent accidental reconnection
before the work is done and the area is clear for restarting.
Keep hands, hair, loose clothing and tools away from moving parts. Do not use gloves
near moving parts.
Reinstall panels or covers and close doors when service is finished and before starting
engine.
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1 SAFETY PRECAUTIONS
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 and moving
equipment when working from an aerial location.
WARNING!
EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death.
Therefore:
1.
2.
3.
4.
5.
6.
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.
Before performing any maintenance work inside a power source,
disconnect the power source from the incoming electrical power.
Maintain cables, earthing wire, connections, power cord and power
supply in safe working order. Do not operate any equipment in faulty
condition.
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.
Keep all safety devices and cabinet covers in position and in good repair.
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.
2.
3.
4.
5.
6.
7.
8.
9.
1
0.
0463 479 101
ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding"
AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"
AWS SP - "Safe Practices" - Reprint, Welding Handbook
ANSI/AWS F4.1 - "Recommended Safe Practices for Welding and
Cutting of Containers That Have Held Hazardous Substances"
OSHA 29 CFR 1910 - "Safety and Health Standards"
CSA W117.2 - "Code for Safety in Welding and Cutting"
NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and
Other Hot Work"
CGA Standard P-1, “Precautions for Safe Handling of Compressed
Gases in Cylinders”
ANSI Z87.1, "Occupational and Educational Personal Eye and Face
Protection Devices"
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© ESAB AB 2017
1 SAFETY PRECAUTIONS
1.3
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 or exceed the standard 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
could result in injury to the operator and damage to the equipment.
1.
2.
3.
4.
5.
Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops and safety features
○ its function
○ the relevant safety precautions
○ welding and cutting methods or other applicable operations of the equipment
The operator must ensure that:
○ no unauthorized person is 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 to the extent possible, in order to maintain effective
ventilation and the control of welding fumes and work byproducts
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 may cause injury to yourself and others. Take
precautions when welding and cutting. Ask for your employer's safety practices,
which should be based on the manufacturer's hazard data.
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1 SAFETY PRECAUTIONS
ELECTRIC SHOCK - Can kill
• Install and ground 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 the ground and the workpiece
• Ensure your working position is safe
FUMES AND GASES - Can be dangerous to your 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 darkening
screen and filter lens, and wear protective clothing
• Protect bystanders with suitable screens or curtains
FIRE HAZARD
• Sparks (spatter) can cause a fire. Therefore, make sure that there are
no flammable/combustible materials nearby
• Take steps to monitor the work area for fugitive sparks that could
cause a fire, either immediately or after smoldering over time
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection with the
appropriate level of noise reduction/hearing protection.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
This product is solely intended for arc welding.
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.
0463 479 101
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© ESAB AB 2017
2 INTRODUCTION
2
INTRODUCTION
The ESAB EM and EMP product family is a new generation of MIG and multi-process
(MIG/Stick/TIG) welding power sources.
All Rebel power sources are designed to match the needs of the user. They are tough,
durable and portable, providing excellent arc performance across a variety of welding
applications.
The EMP features a 4.3 in. (11.0 cm) color 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 functions could be
introduced and customized to give maximum flexibility.
Exclusive to ESAB, sMIG provides users with excellent short circuit transfer arc
characteristics.
The EM and EMP family connects to 120 V – 230 V, 1 ~ 50/60 Hz input power supplies,
supplied by mains or generator power. Incorporating a PFC (Power Factor Correction) circuit
significantly increases power efficiency.
Key features:
•
•
•
•
•
•
•
•
Excellent MIG characteristics (EM)
Excellent multi-process, MIG/Stick and Lift/TIG (EMP) welding capabilities
Automatic recognition of input power with PFC (120 V – 230 V)
Large 4.3 in. (11 cm) high resolution customizable user interface (EMP)
Rugged case design and internal hardware
Portable
High grade cast aluminum wire drive system provides excellent control of drive roll
geometry ensuring smooth, precise wire feeding
Professional high grade accessories
2.1
Equipment
Package consists of the following:
EMP series
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
ESAB EMP 235ic power source
Tweco® Spray Master 250 A MIG gun with 15.0 ft (4.6 m) cable, 0.030 in., 0.035 in.,
0.045 in. (0.8 mm, 0.9 mm, 1.2 mm) contact tips and Allen key
Tweco® Classic Velocity™ No. 2 with 15.0 ft (4.6 m) cable (for 0558012702 MX)
Adapter cable 4 pin to 8 pin (for 0558012702 MX)
ESAB stick electrode holder, 12 ft (4 m), 200 A
Ground clamp, 10 ft (3 m), 250 A
Input cable 10 ft (3 m) with 230 V plug (part of power source)
Power adapter cable (230 V to 120 V, 15 A)
Victor® Flow Meter with 10 ft (3 m) gas hose
ESAB OK AristoRod™ premium solid wire 0.035 in. (0.9 mm) 11# spool
ESAB Atom Arc Acclaim 1/8 in. premium stick electrodes 1# sample pack
Drive roll, 0.023 in. / 0.030 in. / 0.035 in. / 0.045 in. (0.6 mm / 0.8 mm / 0.9 mm /
1.2 mm)
Guide tubes 0.023 in. – 0.045 in. (0.6 mm – 1.2 mm)
Thickness gauge tool
USB stick including manuals
Safety manual
Quick start guide
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2 INTRODUCTION
EM series
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
ESAB EM 235ic power source
Tweco® Spray Master 250 A MIG gun with 15 ft (4.6 m) cable, 0.030 in., 0.035 in.,
0.045 in. (0.8 mm, 0.9 mm, 1.2 mm) contact tips and Allen Key
Tweco® Classic Velocity™ No. 2 with 15.0 ft (4.6 m) cable (for 0558012700 MX)
Adapter cable 4 pin to 8 pin (for 0558012700 MX)
Ground clamp, 10 ft (3 m), 250 A
Input cable 10 ft (3 m) with 230 V plug (part of power source)
Power adapter cable (230 V to 120 V, 15 A)
Victor® Flow Meter with 10 ft (3 m) gas hose
ESAB OK AristoRod™ premium solid wire 0.035 in. (0.9 mm) 11# spool
ESAB Atom Arc Acclaim 1/8 in. premium stick electrodes 1# sample pack
Guide tubes 0.023 in. – 0.045 in. (0.6 mm – 1.2 mm)
Thickness gauge tool
USB stick including manuals
Safety manual
Quick start guide
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© ESAB AB 2017
3 TECHNICAL DATA
3
TECHNICAL DATA
EMP 235ic
Voltage
230 V, 1 ~ 50/60 Hz
120 V, 1 ~ 50/60 Hz
Primary current
Imax. GMAW - MIG
Breaker 20 A: 28.6 A
32.1 A
Breaker 15 A: 20.3 A
Imax. GTAW - TIG
26.1 A
Breaker 15 A: 20.8 A
Imax. SMAW - Stick
31.3 A
Breaker 15 A: 20.8 A
Ieff. GMAW - MIG
Breaker 20 A: 18.0 A
20.31 A
Breaker 15 A: 14.6 A
Ieff. GTAW - TIG
19.8 A
Breaker 15 A: 14.7 A
Ieff. SMAW - Stick
16.5 A
Breaker 15 A: 14.7 A
Permissible load at GMAW - MIG
100% duty cycle
160 A / 22.0 V
Breaker 15 A: 75 A / 17.75 V
Breaker 20 A: 90 A / 18.5 V
60% duty cycle
200 A / 24.0 V
Breaker 15 A: 90 A / 18.5 V
Breaker 20 A: 110 A / 19.5 V
40% duty cycle
235 A / 25.75 V
Breaker 15 A: 100 A / 19 V
20% duty cycle
–
Breaker 20 A: 130 A / 20.5 V
Setting range (DC)
15 A / 14.75 V –
250 A / 30.0 V
15 A / 14.75 V –
130 A / 20.5 V
Permissible load at GTAW - TIG
100% duty cycle
170 A / 16.8 V
100 A / 14 V
60% duty cycle
215 A / 18.6 V
120 A / 14.8 V
40% duty cycle
–
130 A / 15.2 V
30% duty cycle
240 A/19.6 V
–
Setting range (DC)
5 A / 10.2 V – 240 A / 19.6 V
5 A / 10.2 V – 200 A / 18.0 V
Permissible load at SMAW - Stick
100% duty cycle
130 A / 25.2 V
65 A / 22.6 V
60% duty cycle
170 A / 26.8 V
80 A / 23.2 V
40% duty cycle
–
85 A / 23.4 V
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
Open circuit voltage (OCV)
VRD deactivated
68 V
68 V
VRD activated
35 V
35 V
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)
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© ESAB AB 2017
3 TECHNICAL DATA
EMP 235ic
Wire diameter
Mild steel solid wire
0.023–0.045 in. (0.6–1.2 mm) 0.023–0.045 in. (0.6–1.2 mm)
Stainless steel solid wire
0.030–0.045 in. (0.8–1.2 mm) 0.030–0.045 in. (0.8–1.2 mm)
Flux cored wire
0.030-0.052 in. (0.8-1.3 mm)
Aluminum
0.030–0.045 in. (0.8–1.2 mm) 0.030–0.045 in. (0.8–1.2 mm)
Bobbin size
Ø 4–12 in. (100–300 mm)
Ø 4–12 in. (100–300 mm)
Dimensions l×w×h
27.0 × 11.5 × 19.5 in.
(686 × 292 × 495 mm)
27.0 × 11.5 × 19.5 in.
(686 × 292 × 495 mm)
Weight
63 lb (28.6 kg)
63 lb (28.6 kg)
Operating temperature
14 to 104 °F (-10 to +40 °C)
14 to 104 °F (-10 to +40 °C)
Enclosure class
IP23S
IP23S
0.030-0.052 in. (0.8-1.3 mm)
Application classification
EM 235ic
Voltage
230 V, 1 ~ 50/60 Hz
120 V, 1 ~ 50/60 Hz
Primary current
Imax. GMAW - MIG
Breaker 20 A: 28.6 A
32.1 A
Breaker 15 A: 20.3 A
Ieff. GMAW - MIG
Breaker 15 A: 14.6 A
20.31 A
Breaker 20 A: 18.0 A
Permissible load at GMAW - MIG
100% duty cycle
160 A / 22.0 V
Breaker 15 A: 75 A / 17.75 V
Breaker 20 A: 90 A / 18.5 V
60% duty cycle
200 A / 24.0 V
Breaker 15 A: 90 A / 18.5 V
Breaker 20 A: 110 A / 19.5 V
40% duty cycle
235 A / 25.75 V
Breaker 15 A: 100 A / 19 V
20% duty cycle
–
Breaker 20 A: 130 A / 20.5 V
Setting range (DC)
15 A / 14.75 V – 250 A / 30.0
V
15 A / 14.75 V – 130 A / 20.5
V
VRD deactivated
68 V
68 V
VRD activated
35 V
35 V
Efficiency
84%
84%
Power factor
0.98
0.99
Wire feed speed
60-700 in./min
(1.5-17.89 m/min)
60-700 in./min
(1.5-17.89 m/min)
Open circuit voltage (OCV)
Wire diameter
Mild steel solid wire
0.023–0.045 in. (0.6–1.2 mm) 0.023–0.045 in. (0.6–1.2 mm)
Stainless steel solid wire
0.030–0.045 in. (0.8–1.2 mm) 0.030–0.045 in. (0.8–1.2 mm)
Flux cored wire
0.030-0.052 in. (0.8-1.3 mm)
Aluminum
0.030–0.045 in. (0.8–1.2 mm) 0.030–0.045 in. (0.8–1.2 mm)
0463 479 101
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0.030-0.052 in. (0.8-1.3 mm)
© ESAB AB 2017
3 TECHNICAL DATA
EM 235ic
Bobbin size
Ø 4–12 in. (100–300 mm)
Ø 4–12 in. (100–300 mm)
Dimensions l×w×h
27.0 × 11.5 × 19.5 in.
(686 × 292 × 495 mm)
27.0 × 11.5 × 19.5 in.
(686 × 292 × 495 mm)
Weight
63 lb (28.6 kg)
63 lb (28.6 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.
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© ESAB AB 2017
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. 4 in. (100 mm)
B. 4 in. (100 mm)
4.2
Lifting instructions
The power source can be lifted using any of the handles.
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4 INSTALLATION
Secure the equipment - particularly if the ground is
uneven or sloping.
4.3
Mains supply
The supply voltage should be 230 V AC ±10% or 120 V ±10%. Too low supply voltage may
cause poor welding performance. Too high of 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 grounded (electrically) in accordance with local regulations.
Connected to the correct size power point and fuse as indicated in table below.
WARNING!
Do not connect an input (WHITE or BLACK) conductor to the ground terminal.
Do not connect the ground (GREEN) conductor to an input line terminal.
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.
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.
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© ESAB AB 2017
4 INSTALLATION
120 – 230 V, 1 ~ 50/60 Hz
Supply voltage
230 V AC
120 V AC
Input current at maximum output
48 A
30 A
Maximum recommended fuse* or circuit breaker rating
*Time delay fuse UL class RK5, refer to UL 248
40 A
30 A
Maximum recommended fuse* or circuit breaker rating
*Normal operating UL class K5, refer to UL 248
50 A
50 A
10 AWG
(5.3 mm2)
12 AWG
(4 mm2)
50 ft (15 m)
25 ft (8 m)
10 AWG
(5.3 mm2)
12 AWG
(4 mm2)
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 10 kW rated power, are recommended.
4.3.2
Connecting the power source to input supply
Use one of the supplied adapters to connect the power source to mains.
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5 OPERATION
5
OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY
PRECAUTIONS" chapter of this manual. Read it through before you start using the
equipment!
NOTE!
When moving the equipment, use the 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!
WARNING!
Make sure that the side covers are closed during operation.
WARNING!
Ensure spool retaining cotter pin is in place to prevent the spool from sliding off
the hub.
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© ESAB AB 2017
5 OPERATION
5.1
Connections
Front and rear:
1. Knob for current or wire feed speed
selection (EMP)
2. Display (EMP)
3. Knob for voltage selection (EMP)
4. Main knob for menu navigation (EMP)
5. Gas valve output for TIG/Spool-gun
6. Torch/Remote control connection
7. Negative output [-]
8. Polarity changeover cable
9. Positive output [+]
5.2
10. Torch connection
11. Mains cable
12. Mains supply switch ON/OFF
13. Gas valve inlet for TIG/Spool-gun
14. Gas valve inlet for MIG/MAG
15. Knob for voltage selection (EM)
16. Display LED - Volt/Ampere (EM)
17. Knob for wire feed (EM)
18. Knob for process selection (EM)
Connecting welding and return cables
The power source has two outputs for connecting welding and return cables: A negative [-]
terminal (7) and a positive [+] terminal (9); see front illustration.
For the TIG process, connect the TIG torch trigger remote or foot control to the remote
receptacle (6); see front illustration. Connect the TIG torch gas connector to the gas outlet
receptacle (5). Connect gas input supply from a regulated shielding gas supply to the gas
inlet connector (13) located on the rear of the machine.
For MIG/Stick 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.
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5 OPERATION
Secure the return cable's contact clamp to the workpiece and ensure that there is good
contact.
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.
Drive system diagram
1. Spool hub
2. Circuit breaker
3. Opening side cover
5.4
4. Gas valves
5. Wire feed mechanism
Inserting and replacing wire
EMP 235ic and EM 235ic will handle bobbin sizes of 4 in. (100 mm), 8 in. (200 mm) and
12 in. (300 mm). See TECHNICAL DATA chapter for suitable wire dimensions for each wire
type.
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 or pinching when replacing the wire spool! Do not use safety
gloves when inserting the welding wire between the feed rollers.
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5 OPERATION
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 0.030 in. (0.8 mm) wire. If you use
another diameter you must change the contact tip and drive roll. 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 side cover.
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 and adjust the
pressure if necessary. Remove the velocity nozzle and contact tip from the MIG torch.
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.
Close the side cover.
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.
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© ESAB AB 2017
5 OPERATION
5.5
Setting the wire feed pressure
Piece of wood
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 in. (6 mm) from the piece of wood
(Illustration A) the feed rollers should slip.
If you hold the welding torch approximately 2 in. (50 mm) from the piece of wood, the wire
should be fed out and bend (Illustration B).
5.6
Changing the feed/pressure rollers
Three dual groove feed rollers are 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 groove for proper operation.
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© ESAB AB 2017
5 OPERATION
1.
2.
3.
4.
5.
Open the side cover.
Remove the feed roll retaining screw by turning it in a counter-clockwise direction.
Change the feed roll.
Tighten the feed roll retaining screw by turning it to clockwise position.
Close the side cover.
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). Aluminum 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.
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5 OPERATION
5.8
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.
A=Welding current (AMPS), V=Output voltage
SMAW (Stick) 230 V
SMAW (Stick) 120 V
GMAW (MIG) 230 V
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5 OPERATION
GMAW (MIG) 120 V
GTAW (TIG) 230 V
GTAW (TIG) 120 V
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© ESAB AB 2017
5 OPERATION
5.9
Duty cycle
The EMP 235ic and EM 235ic both have a welding current output of 235 A at 40% 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 40% duty cycle, it will provide the rated
amperage for a maximum of 4 minutes out of every 10 minute period. The remaining time,
6 minutes, the power source must be allowed to cool down.
4 minutes
6 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 (AMPS)
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© ESAB AB 2017
5 OPERATION
Duty cycle on 230 V AC
Welding current (AMPS)
5.10
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 in the display
(EMP), or the overtemperature indicator is illuminated (EM).
The overheating protection resets automatically when the temperature has
returned to normal working temperature.
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© ESAB AB 2017
6 CONTROL PANEL
6
CONTROL PANEL
General safety regulations for handling the equipment can be found in the "SAFETY
PRECAUTIONS" 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!
6.1
How to navigate - EMP 235ic
After power on has completed the main menu appears on the control panel.
6.1.1
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
Stick/MMA mode
Lift-TIG mode
Settings
User manual information
Dialogue box
1.
2.
3.
4.
5.
6.
7.
8.
9.
Home screen
Information
Memory
MIG/Spool gun selection
Parameter
Wire feed speed
Material thickness
Trim box
Dialogue box
Main menu
EMP 235ic
6.1.2
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sMIG mode
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© ESAB AB 2017
6 CONTROL PANEL
6.1.3
6.1.4
6.1.5
Manual MIG mode
1.
2.
3.
4.
5.
6.
7.
8.
Home screen
Information
Memory
MIG/Spool gun selection
Parameter
Wire feed speed
Voltage
Dialogue box
1.
2.
3.
4.
5.
6.
7.
Home screen
Information
Memory
Parameter
Wire feed speed
Voltage
Dialogue box
1.
2.
3.
4.
5.
6.
7.
Home screen
Information
Memory
Parameter
Amperage
Voltage (OCV or arc)
Dialogue box
Flux cored wire mode
Stick mode
The user must select the ON position to
have output voltage and weld current.
Also the background color indicates the
output state, where blue indicates an
"off" state and orange indicates an "on"
state.
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6 CONTROL PANEL
6.1.6
6.1.7
6.1.8
6.1.9
LIFT-TIG mode (EMP 235ic only)
1.
2.
3.
4.
5.
6.
Home screen
Information
Memory
Parameter
Amperage
Dialogue box
1.
2.
3.
4.
5.
6.
7.
Home screen
Information
Language
Basic/Advanced
Inch/Metric
Reset mode
Dialogue box
1.
2.
3.
4.
5.
Home screen
Operation information
Wear & Spare parts
Maintenance information
Dialogue box
Settings
User manual information
Icon reference guide
Home
Spot time on/off selection
Information
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6 CONTROL PANEL
0463 479 101
MIG Gun
Spot time on adjustment
Parameters
Flux cored
Parameters
Manual MIG
Percent
Settings
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
Cancel
Seconds
Saving welding programs for
a specific application when in
the Memory Mode
Settings on user manual
menu
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
Spool Gun
Stick
2T, Trigger On/OFF
Lift-TIG
4T, Trigger Hold/Lock
User Manual on main menu
Amps
Plate thickness at sMIG
mode
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© ESAB AB 2017
6 CONTROL PANEL
0463 479 101
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
Bead profile, concave
Hot start The increase of
amps when striking the
electrode to reduce sticking
Bead profile, convex
Inductance The addition of
inductance into the arc
characteristics to stabilize
the arc and reduce spatter
when in the short circuit
process
Advanced Settings
Memory, able to save
welding programs for a
specific application
Basic Settings
Stick electrode choice
Diagnostics
Upslope, Sloping the
current up over a period of
time at the beginning of the
weld cycle
Language selection
Volts
Unit of Measure
Wire feed speed
Wire diameter
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© ESAB AB 2017
6 CONTROL PANEL
6.2
How to navigate - EM 235ic
1.
2.
3.
4.
5.
6.
Spool gun indication: Symbol
illuminates when spool gun is
connected.
Over temperature indication:
Symbol illuminates when product is
overheated.
Volt/Amp display: LED displays the
Volts and Amps values during
welding. It holds the last used
parameter.
In sMIG "V" displays the wire
diameter while idle "A" displays the
set wire feed speed.
Voltage knob: Adjust the voltage
value (in sMIG not functional).
Knob for plate thickness or wire
feed speed: in sMIG mode (outer
circle, in yellow) plate thickness can
be adjusted. Wire feed speed can
be adjusted when in manual
MIG/MAG or flux cored (inner circle,
in white).
Process selection knob: Enables
selection between sMIG mode (left,
in yellow) and manual MIG mode
(right, in white).
NOTE!
Third-party spool guns cannot be used with the EM 235ic. The EM 235ic only
operates with Rebel spool guns.
6.2.1
0463 479 101
Symbol reference EM 235ic
Overtemperature
Volts (manual MIG mode only)
Spool Gun
Amps
Smart MIG
Wire feed speed
- 34 -
© ESAB AB 2017
6 CONTROL PANEL
Wire diameter (sMIG mode
only)
Thickness gauge (sMIG
mode only)
Manual MIG
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© 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 centers 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:
•
•
•
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 months
Clean or replace
unreadable labels.
Clean weld
terminals.
Check or replace weld cables.
Every 6 months
Clean inside
equipment.
7.2
Power source and wire feeder maintenance
Perform a power source cleaning each time you replace a Ø4 in. (100 mm), Ø8 in. (200 mm)
or Ø12 in. (300 mm) wire bobbin.
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© ESAB AB 2017
7 MAINTENANCE
Power source and wire feeder cleaning procedure
NOTE!
Always were safety gloves during cleaning.
1.
2.
3.
4.
5.
6.
Disconnect the power source from the mains socket.
Open the lid and release the tension from the pressure roller by turning the tension
screw (1) counter-clockwise and then pull it toward you.
Remove the wire and the wire spool.
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
Torch and liner maintenance
Torch and liner cleaning procedure
1.
2.
3.
4.
5.
6.
Disconnect the power source from the mains socket.
Open the lid and release the tension from the pressure roller by turning the tension
screw (1) counter-clockwise and then pull it toward you.
Remove the wire and the wire spool.
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.
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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
• 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.
Wire feeding problems
•
•
•
•
•
See appendix WEAR
PARTS for correct sizes
and types.
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 the correct contact tip is used and it is not worn.
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.
STICK (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 is connected to the power source:
Connect the TIG torch to the negative [-] welding terminal.
Connect the welding ground cable to the positive [+]
welding terminal.
• Use only 100% Argon gas for TIG welding.
• Make sure the regulator/flow meter is connected to the gas
bottle.
• Make sure the gas pipe for the TIG torch is connected to
the gas outlet connector (M12) on the front of the power
source.
• Make sure the work clamp has proper contact with the
work piece.
• Make sure the gas bottle is opened and check the gas flow
rate on the regulator/flow meter. The flow rate should be
between 1.25–3.12 gpm (4.72–11.80 l/min).
• Make sure the power source is turned on and TIG welding
process is selected.
• Make sure all connections are tight and leak-free.
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8 TROUBLESHOOTING
Type of fault
No arc
Corrective action
• Check that the mains power supply switch is turned on.
• Check that the mains, welding and return cables are
correctly connected.
• Check that the correct current value is set.
• Check the mains 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.
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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 EM 235ic and EMP 235ic are designed and tested in accordance with international
standards IEC 60974-1, IEC 60974-5, Canadian and US standards CAN/CSA-E60974-1:12
and US standards ANSI/IEC 60974-1:2008. It is the obligation of the authorized service
center 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
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MIG WELD PARAMETER CHART
MIG WELD PARAMETER CHART
120 VAC / 30A Electrical outlet through 1/4 in.
120 VAC / 20A Electrical outlet through 3/16 in.
120 VAC / 15A Electrical outlet through 1/8 in.
120 VAC
Material Welding Shield
selection wire
gas
type
Material
thickness
Mild steel ER70S-6 75% Ar
Wire speed
0.023 in. 25% CO2 display
(0.6 mm)
Voltage
display
165
295
325
385
430
14.2
16.2
17
19.2
19.5
35%
35%
35%
35%
35%
86
129
153
232
15
17
17.5
19
35%
35%
35%
35%
95
118
129
224
15
15.5
16.5
18.5
Inductance
display
35%
35%
35%
35%
Wire speed
display
150
160
180
300
350
Voltage
display
16.5
17
18.5
20
25
Inductance
display
90%
90%
90%
90%
90%
Wire speed
display
70
90
173
Voltage
display
14
14
16
E71T-11
0.035 in.
(0.9 mm)
Inductance
display
0%
0%
0%
Wire speed
display
270
300
375
Voltage
display
14.5
15.5
20
Inductance
display
35%
35%
35%
Inductance
display
Mild steel ER70S-6 75% Ar
Wire speed
0.030 in. 25% CO2 display
(0.8 mm)
Voltage
display
Inductance
display
Mild steel ER70S-6 75% Ar
Wirespeed
2
0.035 in. 25% CO display
(0.9 mm)
Voltage
display
Stainless ER308L/ 90% He
steel
316L
7.5% Ar
0.030 in. 2.5% CO2
(0.8 mm)
Mild steel ER71T- No gas
11
required
0.030 in.
(0.8 mm)
Aluminum E4043
100% Ar
Use spool 0.035 in.
gun.
(0.9 mm)
22 ga. 18 ga. 16 ga. 1/8 in. 3/16 i 1/4 in.
n.
230 VAC
0463 479 101
- 41 -
© ESAB AB 2017
MIG WELD PARAMETER CHART
Material Welding Shield
selection wire
gas
type
Material
thickness
Mild steel ER70S-6 75% Ar
Wire speed
2
0.023 in. 25% CO display
(0.6 mm)
Voltage
display
22 ga. 18 ga. 16 ga. 1/8 in. 3/16 i 1/4 in.
n.
200
250
300
400
15
16
16
19
35%
35%
35%
35%
90
130
280
400
500
14
15
16
18
19
35%
35%
35%
35%
35%
85
120
24
320
360
15
15
17
18
19
35%
35%
35%
35%
35%
Wire speed
display
185
250
Voltage
display
19.5
21
Inductance
display
90%
90%
Wire speed
display
80
170
360
Voltage
display
15
17
17
Inductance
display
0%
0%
0%
Wire speed
display
200
275
300
Voltage
display
23
24
25
Inductance
display
35%
35%
35%
Inductance
display
Mild steel ER70S-6 75% Ar
Wire speed
2
0.030 in. 25% CO display
(0.8 mm)
Voltage
display
Inductance
display
Mild steel ER70S-6 75% Ar
Wire speed
2
0.035 in. 25% CO display
(0.9 mm)
Voltage
display
Inductance
display
Stainless ER308L/ 90% He
steel
316L
7.5% Ar
0.030 in. 2.5% CO2
(0.8 mm)
Mild steel ER71T- No gas
11
required
0.035 in.
(0.9 mm)
Aluminiu E4043
100% Ar
m
0.035 in.
Use spool (0.9 mm)
gun.
0463 479 101
- 42 -
© ESAB AB 2017
FRACTION TO DECIMAL CONVERSION
FRACTION TO DECIMAL CONVERSION
0463 479 101
- 43 -
© ESAB AB 2017
DIAGRAM
DIAGRAM
EM 235ic, EMP 235ic
0463 479 101
- 44 -
© ESAB AB 2017
ORDERING NUMBERS
ORDERING NUMBERS
Ordering no.
Denomination
0558 012 702
Rebel EMP 235ic
0558 012 704
Rebel EMP 235ic with cart
0558 012 700
Rebel EM 235ic
0558 012 701
Rebel EM 235ic with cart
0558 012 702MX
Rebel EMP 235ic MX
0558 012 700MX
Rebel EM 235ic MX
0463 485 001
Spare parts list
0463 479 101
Note
- 45 -
© ESAB AB 2017
WEAR PARTS
WEAR PARTS
Item Ordering no. Denomination
Wire type Wire dimensions
1
0558 102 515 Brass outlet
assembly
N/A
2
0558 102 516 Wire outlet guide
Fe/SS/Flux 0.024 in. / 0.030 in.
Cored
(0.6 mm / 0.8 mm)
0558 102 517 Wire outlet guide
Fe/SS/Flux 0.035 in. / 0.052 in.
Cored
(0.9 mm / 1.3 mm)
3
0558 102 328 Wire inlet guide
Fe/SS/Flux 0.024 in. / 0.030 in. / 0.035 in. /
Cored
0.045 in. (0.6 mm / 0.8 mm /
0.9 mm / 1.2 mm)
4
0558 102 457 Crescent Woodruff N/A
key
5
N/A
N/A
7977036
Feed roll “V”
groove
Fe/SS
0.024 in. / 0.030 in.
(0.6 mm / 0.8 mm)
W4014800
Feed roll “V”
groove
Fe/SS
0.024 in. / 0.035 in.
(0.6 mm / 0.9 mm)
7977732
Feed roll “V”
knurled
Flux Cored 0.030 in. / 0.035 in.
(0.8 mm / 0.9 mm)
0367 556 006 Feed roll "V"
knurled
Flux Cored 0.045 in. (1.1 mm)
7977731
Feed roll "U"
Alum
0.030 in. / 0.035 in.
(0.8 mm / 0.9 mm)
7977264
Feed roll "U"
Alum
0.040 in. / 3/64 in. (1.0 mm / 1.2 mm)
6
0558 102 518 Locking knob
N/A
N/A
7
0558 102 329 Wire tension knob
N/A
N/A
8
0558 102 331 Pressure arm
N/A
complete assembly
N/A
9
0558 102 550 Shoulder screw
N/A
N/A
10
0558 102 333 MIG torch locking
knob
N/A
N/A
0463 479 101
- 46 -
© ESAB AB 2017
WEAR PARTS
0463 479 101
- 47 -
© ESAB AB 2017
ACCESSORIES
ACCESSORIES
10271398
Spool gun (CSA only)
200 A, 12 ft (3.6 m), suits 4 in. (100 mm) spools
0558102493 TIG Torch (for EMP only)
TXH 201 5/8 in. npt 12.5 ft (3.5 m) TIG Torch
Outfit
0558102491 Rebel Single Cylinder Cart
Accommodates maximum 9 in. (228.6 mm)
diameter cylinder
0558102492 Rebel Dual Cylinder Cart
Accomodates 2 × 9 in. (228.6 mm) diameter
cylinders
W4014450
0463 479 101
Foot control
Contactor on/off and current control with 15 ft
(4.6 m) cable and 8-pin male plug
- 48 -
© ESAB AB 2017
REPLACEMENTS PARTS
REPLACEMENTS PARTS
EMP series
Item
Ordering no.
Denomination
1
10231140
2
WS200E13
ESAB Stick electrode holder, 12 ft (4 m), 200 A
3
WS200G10
Ground clamp, 10 ft (3 m), 250 A
4
W4014000
Power adapter cable 230 V to 120 V, 15 A
5
07812743
Victor® Flow Meter with 10 ft (3 m) gas hose
6
V215B4045
7
354TA8
Tweco® Spray Master 250 A MIG Gun 15 ft (4.5 m)
Tweco® Classic Velocity™ No. 2 with 15.0 ft (4.6 m) cable
Adapter cable 4 pin to 8 pin
EM series
Item
Ordering no.
1
10231140
2
WS200G10
Ground clamp, 10 ft (3 m), 250 A
3
W4014000
Power adapter cable 230 V to 120 V, 15 A
4
07812743
Victor® Flow Meter with 10 ft (3 m) gas hose
5
V215B4045
6
354TA8
0463 479 101
Denomination
Tweco® Spray Master 250 A MIG Gun 15 ft (4.5 m)
Tweco® Classic Velocity™ No. 2 with 15.0 ft (4.6 m) cable
Adapter cable 4 pin to 8 pin
- 49 -
© 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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