ESAB EMP 205ic AC/DC Instruction Manual Download Page 18

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4 INSTALLATION

0463 703 001

-18-

4.4

High frequency interference

WARNING!

The high frequency section of this machine has an output like a radio transmitter.
The power source should NOT be used near blasting operations due to the danger of

premature firing.

WARNING!

Operation close to computer installations may cause computer malfunction.

WARNING!

HIGH FREQUENCY FIELDS CAN BE DANGEROUS TO HEALTH. Extra precautions may be

required when this welding power source is used in a domestic situation. Welders with

medical pacemakers should consult their doctor before welding. EMF may interfere with

some pacemakers.

WARNING!

Equipotential bonding:
Bonding of all metallic components in the welding installation and adjacent to it might

be considered. However, metallic components bonded to the work piece will increase the

risk that the operator could receive a shock by touching the metallic components and the

electrode at the same time. The operator should be insulated from all such bonded metallic

components.

WARNING!

Earthing/grounding of the work place:
Care should be taken to prevent the earthing of the work piece increasing the risk of injury

to users, or damage to other electrical equipment. Changing the earthing arrangements

should only be authorized by a person who is competent to assess whether the changes will

increase the risk of injury.

WARNING!

The importance of correct installation of high frequency welding equipment cannot be

overemphasized. Interference due to high frequency initiated or stabilized arc is almost

invariably traced to improper installation. A duly authorized person such as a properly

licensed electrician should perform the installation to avoid injury, death, or any equipment

damage.

Summary of Contents for EMP 205ic AC/DC

Page 1: ...0463 703 001GB 20190927 Valid for serial no 937 xxx xxxx EMP 205ic AC DC Instruction manual ...

Page 2: ...rk in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Original Publication Date 09 27 2019 Revision Date Record the following information for Warranty pur...

Page 3: ...mity with the description thereof contained in this manual and accompanying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked periodi cally Malfunctioning or poorly maintained equipment should not be used Parts that are broken missing worn distorted or contaminated should be replaced immediately Should ...

Page 4: ......

Page 5: ... controls 22 5 2 Connection of welding and return cables 23 5 2 1 For MIG MMA process 23 5 2 2 For TIG process 23 5 3 Polarity change 23 5 4 Shielding gas 24 5 5 Volt ampere curves 24 5 5 1 SMAW Stick 120 V 24 5 5 2 SMAW Stick 230 V 24 5 5 3 GMAW MIG 120 V 25 5 5 4 GMAW MIG 230 V 25 5 5 5 GTAW DC TIG 120 V 26 5 5 6 GTAW DC TIG 230 V 26 5 5 7 GTAW AC TIG 120 V 27 5 5 8 GTAW AC TIG 230 V 27 5 5 9 Du...

Page 6: ...ual Current 51 7 2 AC TIG Welding 53 7 3 DC TIG Lift Arc and 2 stroke 4 stroke Illustration 57 7 4 Selection and Preparation of Tungsten Electrodes 58 8 MAINTENANCE 59 8 1 Routine maintenance 59 8 2 Power source and wire feeder maintenance 60 8 2 1 Wire feeder assembly cleaning 61 8 3 EMP unit power side maintenance 62 8 4 Torch liner maintenance 62 8 4 1 Torch liner cleaning 62 9 TROUBLESHOOTING ...

Page 7: ...D OTHERS Somewelding cuttingandgougingprocessesarenoisyandrequireearprotection Thearc likethe sun emits ultraviolet UV and other radiation and can injure skin and eyes Hot metal can cause burns Training in the proper use of the processes and equipment is essential to prevent accidents Therefore 1 Wear a welding helmet fitted with a proper shade of filter to protect you face and eyes when welding o...

Page 8: ...vere injury or death DO NOT use AC welding current in damp areas if movement is confined or if there is danger of falling Therefore 1 Be sure the power source frame chassis is connected to the ground system of the input power 2 Connect the workpiece to a good electrical ground 3 Connect the work cable to the workpiece A poor or missing connection can expose you or others to a fatal shock 4 Use wel...

Page 9: ... Never strike an arc on a cylinder 2 Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder Do not use adaptors Maintain hoses and fittings in good condition Follow manufacturer s operating instructions for mounting regulator to a compressed gas cylinder 3 Always secure cylinders in an upright position by chain or stra...

Page 10: ...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 equip ment ask your supplier for a copy of Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 The following publications are recommended to you 1 ANSI ASC Z49 1 Safety in Welding and Cutt...

Page 11: ...nprotected when the arc is struck 3 The workplace must be suitable for the purpose be free from drafts 4 Personal safety equipment Always wear recommended personal safety equipment such as safety glasses flame proof clothing safety gloves Do not wear loose fitting items such as scarves bracelets rings etc which could become trapped or cause burns 5 General precautions Make sure the return cable is...

Page 12: ...cloth ing Protect bystanders with suitable screens or curtains FIRE HAZARD Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noise can damage hearing Protect your ears Use earmuffs or other hearing protection Warn bystanders of the risk MALFUNCTION Call for expert assistance in the event of malfunction READ AND UNDERSTAND THE INSTRUCTI...

Page 13: ...5 m 14 8 ft Quick connector MMA welding cable kit 3 m 10 ft Return cable kit 3 m 10 ft Drive roll 0 6 0 8 mm 0 023 in 0 030 in Cored Steel and Stainless wire installed on drive system 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 0 6 mm 0 8 mm 0 023 in 0 030 in in accessory box Mains cable 3 m 10 ft...

Page 14: ...0 duty cycle Breaker 20 A 115 A Vout 19 75 V Setting range DC 15 A Vout 14 75 V 235 A Vout 26 0 V 15 A Vout 14 75 V 130 A Vout 20 5 V Permissible load in GTAW DC TIG 100 duty cycle 110 A Vout 14 4 V Breaker 15 A 80 A Vout 13 2 V 60 duty cycle 125 A Vout 15 0 V Breaker 15 A 100 A Vout 14 0 V 40 duty cycle Breaker 15 A 110 A Vout 14 4 V 25 duty cycle 205 A Vout 18 2 V Setting range DC 5 A Vout 10 2 ...

Page 15: ... can weld or cut at a certain load without overloading The duty cycle is valid for 40 C 104 F or below 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 S This symbol indicates that the po...

Page 16: ...etected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer This remedial action may be as simple as earthing the welding circuit In other cases it could involve constructing an electromagnetic screen enclosing the welding power source and the work complete with associated input filters In all cases ele...

Page 17: ...erference may be transmitted by a high frequency initiated or stabilized arc welding power source in the following ways Direct radiation Radiation from the equipment can occur if the case is metal and is not properly grounded It can occur through apertures such as open access panels The shielding of the high frequency unit in the power source will prevent direct radiation if the equipment is prope...

Page 18: ...ents bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components WARNING Earthing grounding of the work place Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users or damage to ot...

Page 19: ...se poor welding perfor mance Too high 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 accordan...

Page 20: ...me 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 Minimum recommended cord size 2 5 mm2 13 AWG 2 5 mm2 13 AWG Maximum recommended extension cord length 15 m 50 ft 8 m 25 ft Minimum recommended grounding conductor size 2 5 mm2 13 AWG 2 5 mm2 13 AWG 4 7 Supply from power generators The power ...

Page 21: ...ts 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 covers are closed during operation WARNING Tighten the bobbin bolt to prevent it from sliding off the hub CAUTION Before each use make sure The torch body and torch cable and leads are not damaged The contact tip on the torch is not damaged The noz...

Page 22: ...remote control connection 13 Main power switch ON OFF 6 Torch connection 14 Main power cable 7 Negative output 15 Labels 8 Positive output 1 U 2 L 3 M Figure 2 Function of user interface control dials 1 U Upper control knob a Set current output value b Set wire feed speed 3 M Menu navigation Push to select 2 L Lower control knob a MIG voltage selection b SMIG voltage trim c MMA mode Arc ON OFF NOT...

Page 23: ...art for initial selection of welding controls This is intended as a guide for setting parameters on this equipment 5 2 2 For TIG process For TIG process connect the TIG torch power cable to the negative terminal 7 see illustration Connect the gas inlet nut on the TIG torch to the gas outlet connector 4 located on the front of the power source Connect the gas inlet quick connect 12 on rear panel to...

Page 24: ... mode see sMIG mode section in the CONTROL PANEL chapter the optimal welding arc with the gas used will be automatically set 5 5 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 5 5 1 SMAW S...

Page 25: ...5 OPERATION 25 5 5 3 GMAW MIG 120 V Figure 6 GMAW MIG 120 V Duty cycle 5 5 4 GMAW MIG 230 V Figure 7 GMAW MIG 230 V Duty cycle ...

Page 26: ...5 OPERATION 26 5 5 5 GTAW DC TIG 120 V Figure 8 GTAW DC TIG 120 V Duty cycle 5 5 6 GTAW DC TIG 230 V Figure 9 GTAW DC TIG 230 V Duty cycle ...

Page 27: ...5 OPERATION 27 5 5 7 GTAW AC TIG 120 V Figure 10 GTAW AC TIG 120 V Duty cycle 5 5 8 GTAW AC TIG 230 V Figure 11 GTAW AC TIG 230 V Duty cycle ...

Page 28: ...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 Figure 12 Example of 25 duty cycle 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 Figure 13 Plotting du...

Page 29: ...ing the bobbin locking nut for 100 mm 4 in 5 7 Liner selection Refer to the torch user s guide on the USB stick to select the proper replacement liner for the wire type and diameter in use 5 8 Installing Removing wire NOTE If installing aluminium wire see Welding with aluminium wire section The EMP 205ic AC DC will handle the two smaller bobbin sizes of 100 mm 4 in and 200 mm 8 in See TECHNICAL DA...

Page 30: ... fitted in the torch is recommended for welding with Fe and SS wires 5 8 1 Installing wire 1 Turn power to the unit OFF 2 Open the side cover 3 Release the pressure roller arm by pushing the tension screw toward you 1 4 Lift the pressure roller arm up 2 CAUTION Hold MIG welding wire tightly to prevent it from unraveling 5 With the MIG welding wire feeding from the bottom of the spool pass the elec...

Page 31: ...lose the side cover 5 9 Welding with aluminum wire NOTE After completing the instructions in this section return to 5 8 Installing removing wire section To weld aluminum using the standard supplied torch refer to MIG torch instruction manual for replacing standard steel torch conduit liner with a Teflon torch conduit liner Model EMP 205ic AC DC uses torch model MXL 270 A MIG torch with 3 m 10 ft c...

Page 32: ...ece of wood 4 Adjusting for minimum roller pressure When you hold the welding torch approximately 6 mm in from the piece of wood see Figure 12 the wire feed roll ers should slip If they don t reduce the tension on the wire by adjusting the tension knob on the wire feed assembly 6 mm Figure 18 Check feed roller for slip indicating no over pressure 5 Adjusting for correct roller pressure If you hold...

Page 33: ...of wire feed rollers The pressure rollers are not replaced 1 2 3 Figure 20 Location of wire feed rollers and pressure rollers 1 Pressure roller 3 Locking knob 2 Wire feed rollerr NOTE The visual label stamped on the side of a wire feed roller and facing you designates the wire groove size on the opposite inner side of the roller The selected groove should match the wire size being used Each roller...

Page 34: ... to be re adjusted at the end of this procedure Recording the undisturbed scale number in the previous step facilitates the process at the end of the procedure to accurately set the tension 5 Release the tensioning arm by loosening the tension knob pulling it up out of its detent and rotating it toward you see 1 in Figure 10 Since the wire feed pressure adjustment must be disturbed to release this...

Page 35: ...NOTE Label on roller side matches with the groove on the opposite side of the roller 2 Tighten the drive roller locking knob by turning it in the clockwise direction Hand tight is sufficient 3 Lay the wire into the inside groove of the Wire Feed roller NOTE If the wire was removed not just lifted from the groove in the roller then the wire will have to be re installed see Installing wire subsectio...

Page 36: ... the control panel 6 1 How to navigate 1 Upper control knob a Set current output value b Set wire feed speed 2 Lower control knob a MIG Voltage Selection b sMIG Voltage Trim c MMA Mode ARC ON OFF d DC TIG Set PPS e AC TIG Set Balance 3 Menu navigation Push to select 6 2 EMP 205ic AC DC Home screen 1 sMIG mode 2 Manual MIG mode 3 Gasless flux cored wire mode 4 MMA mode 5 DC TIG mode 6 AC TIG mode 7...

Page 37: ...reen 2 Information 3 Memory 4 Material selection 5 Wire feed speed 6 Voltage adjustment 7 Dialogue box Advanced 1 Home screen 2 Information 3 Memory 4 Material selection 5 Parameter selection 6 Wire feed speed 7 Voltage adjustment 8 Dialogue box 6 2 3 Gasless flux cored wire mode Basic 1 Home screen 2 Information 3 Memory 4 Wire feed speed 5 Voltage adjustment 6 Dialogue box 4 5 3 2 1 6 6 7 3 2 5 ...

Page 38: ...pen Circuit Voltage or Arc 6 Dialogue box 7 Arc ON OFF Blue changes to orange when output is hot Advanced 1 Home screen 2 Information 3 Memory 4 Parameter selection 5 Amperage 6 Weld output voltage Open Circuit Voltage or Arc 7 Arc ON OFF 8 Dialogue box Blue changes to orange when output is hot 6 2 5 DC TIG mode Basic 1 Home screen 2 Information 3 Memory 4 Pulse 5 Amperage 6 Dialogue box 5 6 3 4 2...

Page 39: ...se ON 1 Home screen 2 Information 3 Memory 4 Pulse 5 Parameter selection 6 Amperage 7 Dialogue box 8 Peak time 6 2 6 AC TIG mode Basic 1 Home screen 2 Information 3 Memory 4 Amperage 5 Dialogue box Advanced 1 Home screen 2 Information 3 Memory 4 Parameter selection 5 Amperage 6 Balance 7 Dialogue box 4 3 2 1 5 5 6 3 2 4 1 7 6 3 4 2 1 7 5 6 3 4 2 1 7 5 8 ...

Page 40: ...to the weld pool or tip This allows exceptional restarting of subsequent welds This feature is primarily for Mild and Stainless steel short arc welding For spray and flux core welding traditional burn back is recommended When burn back time is set to zero SCT automatically is enabled A non zero burn back setting will disable SCT ICON MEANING ICON MEANING Home Spot time ON OFF selection use navigat...

Page 41: ...er manual menu Cancel Spool torch Not all markets Remote Settings Foot control 2T Trigger ON OFF Volts 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 ...

Page 42: ...Ability to save welding programs for a specific application Stick electrode choice Up Slope Sloping the current up over a period of time at the beginning of the weld cycle Unit of Measure Wire diameter Bead profile concave DC TIG Bead profile convex AC TIG Pulse Up Slope Down Slope Pulse ON OFF Hz Back Current Peak Time Balance Offset Frequency Retrieve Erase Dual Current Amin HF Start Lift Arc Pr...

Page 43: ...OPERATION 43 7 TIG WELDING OPERATION 7 1 DC TIG Welding Below illustration shows the navigation setup of DC TIG Welding in advanced mode A B C D E F G H I J K L M N O P Q R S T A B C D E F G H I J K L M N O P Q R S T ...

Page 44: ... user has the ability to adjust the DC Pulse TIG settings as explained below 1 Pulse ON OFF 2 Back Current 3 Peak Time 4 Peak Set Current A 5 Hz PPS Pulses Per Second BackCurrent BackgroundCurrentistheamountofthecurrentatwhichtheDCTIGPulsewaveformisinthebackground time The back ground current is adjusted in percentage of peak current in the pulse menu Can be adjusted between 1 and 99 Peak Time The...

Page 45: ...7 TIG WELDING OPERATION 45 Below illustration shows the navigation setup of DC TIG Pulse in advanced mode A B C D E F G H I J A B C D E F G H I J ...

Page 46: ...CK 50A IPEAK 100A User Settings IPEAK 100A Default Settings Background 50 Peak Time 50 Hz PPS 2 0 Dual Current Mode OFF BASIC MODE WELDING STATE 50 BACK 50 PEAK 50 BACK 70 PEAK 70 PEAK 30 BACK 30 BACK IBACK 50A IPEAK 100A User Settings IPEAK 100A Background 50 Peak Time 70 Hz PPS 3 0 Dual Current Mode OFF ADVANCED MODE WELDING STATE 70 PEAK 30 BACK ...

Page 47: ...ger Without Remote controller the background current value is the set percentage times the user set current but with Remote controller it is the set percentage times the Remote controller set current Example Basic Mode If user sets current as Ipeak A 100 The default settings for other parameters in basic mode are Background 50 Peak Time 50 Hz PPS Pulses Per Second 2 0 Imin A 5 The calculated value...

Page 48: ... WITH REMOTE SET TO ALL THE WAY 50 BACK IBACK 25A IPEAK 50A User Settings IPEAK 100A Default Settings Background 50 Peak Time 50 Hz PPS 2 0 Dual Current Mode OFF BASIC MODE WELDING STATE WITH REMOTE SET TO HALF WAY IBACK 37A IPEAK 75A User Settings IPEAK 100A Default Settings Background 50 Peak Time 50 Hz PPS 2 0 Dual Current Mode OFF BASIC MODE WELDING STATE WITH REMOTE SET TO THREE FOURTH WAY 50...

Page 49: ...f Iback A 80A Ipeak 80 100 0 8 This means if the Remote controller set to all the way then Ipeak 100A Iback 80A but if user sets the Remote controller to half way then Ipeak 50A Iback 40A and if user sets the Remote controller to three fourth way then Ipeak 75A Iback 60A Below illustration shows the above example in terms of output current waveforms in advanced mode ...

Page 50: ...30 BACK 70 PEAK 70 PEAK 30 BACK 30 BACK I BACK 40A IPEAK 50A User Settings IPEAK 100A Background 80 Peak Time 70 Hz PPS 3 0 Dual Current Mode OFF ADVANCED MODE WELDING STATE WITH REMOTE SET TO HALF WAY 70 PEAK 30 BACK 70 PEAK 70 PEAK 30 BACK 30 BACK IBACK 60A IPEAK 75A User Settings IPEAK 100A Background 80 Peak Time 70 Hz PPS 3 0 Dual Current Mode OFF ADVANCED MODE WELDING STATE WITH REMOTE SET T...

Page 51: ...urrent mode is enabled it can be activated by quick trigger tap action during welding One quick tap on trig ger push and release will switch the output weld current from Current A to Current B another quick tap on trigger will switch the current from Current B to Current A See below picture Current A Current B Settings 4 Stroke Enabled Torch Selected in Remote Dual Current Mode Enabled Trigger Pre...

Page 52: ...d current times 0 85 See below pictures Quick Trigger Tap 100ms and 250ms Current B 55A Current A 100A User Settings ISET 100A Current A 2T 4T 4T Mode Dual Current Mode ON Dual Current 55 ADVANCED MODE WELDING STATE WITH DUAL CURRENT ENABLED Quick Trigger Tap 100ms and 250ms Current B peak 56A Current A 100A User Settings ISET 100A Current A 2T 4T 4T Mode Dual Current Mode ON Dual Current 55 Backg...

Page 53: ...er set weld current to establish the lower limit Up Slope and Down Slope settings are adjustable only in non remote non foot pedal mode Frequency Hz Frequency is the number of times the AC TIG Arc switches between EP and EN in one second Frequency in Rebel 205 AC DC machine varies from 25 400 Hz with a default value of 120 Hz Frequency helps in narrowing the weld bead and focus the arc in special ...

Page 54: ...leaning or better penetration respectively without adjusting the balance duty and or user set current Offset gives the user ability to have a narrower bead with deeper penetration and no visible cleaning action or wider bead with less penetration and clear visible cleaning action based on which direction the Offset is adjusted In advanced AC TIG mode the user can adjust the Offset parameter which ...

Page 55: ...7 TIG WELDING OPERATION 55 Below illustration shows the navigation setup of AC TIG Welding in advanced mode A B C D E F G H I J K A B C D E F G H I J K ...

Page 56: ...60A User Settings I 100A Balance 75 Frequency 180Hz Offset 20A ADVANCED MODE WELDING STATE WITH 20A OFFSET WITH REMOTE SET HALF WAY 25 EP 75 EN 25 EP EP EN 75 EN Remote Set to Half Way Offset 20 x 50 10A IEN with Offset 60A IEP with Offset 40A 75 EN 25 EP EP EP EN EN IEP 120A IEN 80A User Settings I 100A Balance 75 Frequency 180Hz Offset 20A ADVANCED MODE WELDING STATE WITH 20A OFFSET 25 EP 75 EN ...

Page 57: ...minate the arc The shielding gas will continue to flow in order to protect the weld and the tungsten electrode Gas pre flow Gas post flow Slope up Slope down 4 Stroke In 4 stroke mode press the TIG torch trigger switch 1 to start shielding gas flow and initiate the arc at a pilot level Release the trigger switch 2 to slope up the current to the set current value To stop the welding press the trigg...

Page 58: ...reen pure tungsten DC only Shipped with Rebel EMP 205ic AC DC machines Tungsten Electrode Grinding Techniques The shape of the tungsten electrode tip plays an important role in TIG welding So care must be taken when grinding the tungsten electrode Below are some recommendations on how to grind the tungsten electrode for Rebel 205 machine use HOW TO PREPARE TUNGSTEN ELECTRODES Point for arc of alum...

Page 59: ...by unauthorized service centers will invalidate the warranty NOTE Additional maintenance should be performed if you operate in severe dusty condition NOTE There are no user serviceable parts inside of the power supply side of the EMP unit Any need for service on the power supply side should be referred to the nearest ESAB service center 8 1 Routine maintenance Maintenance schedule during normal co...

Page 60: ... you 3 Remove the wire and the wire bobbin 4 Remove the torch and use a low pressure airline taking care not to let the wire consumable unravel to clean the power source interior and power source air inlet and outlet 5 Inspect if the inlet wire guide 4 outlet wire guide 2 or the feeder roller 3 are worn and need replacement See WEAR PARTS for ordering numbers of parts 6 Remove and clean the feeder...

Page 61: ...or use a forced air source by blowing compressed air max 5 bar to remove all debris which may have accumulated in this space WEAR EYE PROTECTION 6 Inspect if the input wire feed guides and the feed rollers for wear and need replacement See WEAR PARTS section for ordering wear part numbers See Removing wire feed roller subsection in Removing Installing wire feed roller section in the OPERATION chap...

Page 62: ...the electrical power source from the unit 2 Unlock tension knob rotate spool clockwise while holding the wire until wire is no longer in the torch Re secure the wire between tensor knob and roller 3 Disconnect the torch assembly from the unit 4 Remove the liner from the torch hose and inspect it for damage or kinks Clean the liner by blowing compressed air max 5 bar through the end of the liner th...

Page 63: ...ure the proper direction of motion is set based on the wire type into the weld pool for aluminum Make sure the correct contact tip is used and it is not worn Make sure liner is the right size and type for wire Refer Section 3 1 EMP 205ic AC DC specifications 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 to...

Page 64: ... Level Functional Circuit Failure Explanation 001 W PFC Heatsink IGBT Heatsink or Main transformer has overheated 85 C 185 F 002 W Output diode Temperature fault 003 W C Warning If occurred during load arc start cause is due to low input AC volts ERR009 Critical If occurred at power up under no load condition DC Bus 400 V fault droop under load PFC not supplying 400 V to inverter 004 C Output volt...

Page 65: ...N 60974 7 IEC EN 60974 10 IEC EN 60974 11 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 Spare parts and wear parts can be ordered through your nearest ESAB dealer see the back cover of this document When ordering please state product type ser...

Page 66: ...DIAGRAM 66 DIAGRAM Functional block diagram Schematic ...

Page 67: ...ORDERING NUMBERS 67 ORDERING NUMBERS Ordering number Denomination Notes 0700 300 998 EMP 205ic AC DC Bobbin size 100 200 mm 4 8 in 0463 704 001 Spare parts list ...

Page 68: ...0 8 mm 0 9 mm 1 2 mm 0 023 in 0 030 in 0 035 in 0 045 in 3 0191 496 114 Key drive shaft crescent N A N A 4 0367 556 001 Feed roll V groove Fe SS Flux Cored 0 6 mm 0 8 mm 0 023 in 0 030 in 0367 556 002 Feed roll V groove Fe SS Flux Cored 0 8 mm 1 0 mm 0 030 in 0 040 in 0367 556 003 Feed roll V groove Fe SS Flux Cored 1 0 mm 1 2 mm 0 040 in 0 045 in 0367 556 004 Feed roll U groove Aluminium 1 0 mm 1...

Page 69: ...700 025 557 TIG Torch TIG torch 4 m 200A flexible head 0700 200 004 MIG Torch MXLTM 270 3 m for FCW 1 2 mm 0459 366 887 Trolley W4014450 Foot control Contactor ON OFF and current control with 4 6 m 15 ft cable and 8 pin male plug ...

Page 70: ...rdering no Denomination 1 0700 200 002 MIG Torch MXL 201 3 m 10 ft 2 0700 025 556 ESAB SR B 26 TIG Torch 4 m 200 A 3 0349 312 105 Gas hose 4 5 m 14 8 ft 4 0700 006 900 MMA welding cable kit 3 m 10 ft 5 0700 006 901 Return welding cable kit 3 m 10 ft ...

Page 71: ...0 95 00 Fax 46 31 50 92 22 ESAB international AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 UKRAINE ESAB Ukraine LLC Kiev Tel 38 044 501 23 24 Fax 38 044 575 21 88 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 444...

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