ESAB EMP 215ic Service Manual Download Page 1

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Revision:

Issue Date:

December 20, 2016

Manual No.:

0463 413 001

esab.com

ESAB

EMP 215IC/EMS 215IC

MULTI PROCESS WELDER

Service

Manual

Summary of Contents for EMP 215ic

Page 1: ...Revision AA Issue Date December 20 2016 Manual No 0463 413 001 esab com ESAB EMP 215IC EMS 215IC MULTI PROCESS WELDER Service Manual...

Page 2: ...take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand...

Page 3: ...13 001 Published by ESAB Group Inc 2800 Airport Rd Denton Texas 76207 www esab com Copyright 2016 by ESAB All rights reserved Reproduction of this work in whole or in part without written permission o...

Page 4: ...ereof 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 period...

Page 5: ...77 G teborg Sweden Phone 46 31 50 90 00 Fax 46 584 411 924 The following harmonised standard in force within the EEA has been used in the design EN 60974 1 2012 Arc Welding Equipment Part 1 Welding P...

Page 6: ...ESAB EMS215C EMP215C 6 DECLARATION OF CONFORMITY Manual 0463 413 001 This Page Intentionally Blank...

Page 7: ...re Rollers 3 7 3 08 Shielding Gas 3 8 3 09 Volt Ampere Curves 3 8 3 10 Duty Cycle 3 10 3 11 Control Panel 3 11 4 SERVICE INSTRUCTIONS 4 1 4 01 What is ESD 4 1 5 POWER SUPPLY INTRODUCTION 5 1 5 01 Intr...

Page 8: ...ire Feeder Replacement Parts CSA Systems 8 6 8 07 Wire Feeder Replacement Parts CE Systems 8 7 9 DISASSEMBLY 9 1 9 01 Safety Precautions for Disassembly 9 1 9 02 User Interface TFT Display Assembly Re...

Page 9: ...l electrical hazards which could result in personal injury or loss of life CAUTION CAUTION Means hazards which could result in minor personal injury WARNING Read and understand the instruction manual...

Page 10: ...r personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 7 Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can fly far By...

Page 11: ...uses localized Electric and Magnetic Fields EMF Welding and cutting current creates EMF around welding cables and welding machines Therefore 1 Welders having pacemakers should consult their physician...

Page 12: ...trucks undercarriages benches wall post or racks Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit 4 When not in use keep cylinder valves closed Ha...

Page 13: ...sition and in good repair 6 Use equipment only for its intended purpose Do not modify it in any manner CAUTION ADDITIONAL SAFETY INFORMATION For more information on safe practices for electric arc wel...

Page 14: ...ment 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 safe...

Page 15: ...use fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noise can damage hearing Protect your ears Use earmuffs or other hearing protection MALFUNCTION Call for exp...

Page 16: ...ESAB EMS215C EMP215C 1 8 SAFETY INSTRUCTIONS Manual 0463 413 001 This Page Intentionally Blank...

Page 17: ...In a domestic environ ment this product may cause radio interference It is the user s responsibility to take adequate precautions 2 02 Lifting Instructions The Power Supply includes a series of handl...

Page 18: ...source must be Correctly installed if necessary by a qualified electrician Correctly earthed electrically in accordance with local regulations Connected to the correct size power point and fuse as tab...

Page 19: ...ker 110 A 19 5 V 40 duty cycle 150A 21 5 V 15A Breaker 100 A 19 V 25 duty cycle 205 A 24 25 V 20 duty cycle 20A Breaker 130 A 20 5 V Setting range DC 15 A 14 75 V 235 A 26 V 15 A 14 75 V 130 A 20 5 V...

Page 20: ...le 20 A Breaker 130 A 20 5 V Setting range DC 15 A 14 75 V 220 A 26 V 15 A 14 75 V 130 A 21 V Permissible load at SMAW Stick 100 duty cycle 100 A 24 V 65 A 22 6 V 60 duty cycle 125 A 25 V 80 A 23 2 V...

Page 21: ...0 60Hz single phase supply Supply voltage 230V AC 120V AC Input current at maximum output 30 Amps 30 Amps Maximum recommended fuse or circuit breaker rating Time delay fuse UL class RK5 Refer to UL 24...

Page 22: ...ESAB EMS215C EMP215C 2 6 INSTALLATION Manual 0463 413 001 208 230V 50A 120V 15A 120V 20A NEMA 6 50P 230VAC plug...

Page 23: ...andle 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 opera tion Icon Reference Guide Home...

Page 24: ...ngth 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 cur...

Page 25: ...e beginning of the weld cycle Bead profile concave Volts Bead profile convex Wire feed speed Wire diameter V 8 mm 030 Inductance The addition of inductance into the arc characteristics to stabilize th...

Page 26: ...nt or wire feed speed selection 2 Display 3 Knob for voltage selection 4 Main knob for menu navigation 5 Torch Remote control connection 6 Negative output 7 Polarity changeover cable and receptacle co...

Page 27: ...ease refer to electrode packaging for information relating to the correct electrode polarity Connect the work lead to the remaining welding terminal on the power source Secure the work lead s contact...

Page 28: ...through the inlet guide 3 between the rollers through the outlet guide and into the MIG torch 5 Re secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Remov...

Page 29: ...torch approximately 2 50 mm from the piece of wood the wire should be fed out and bend illustration B 3 07 Changing the Feed Pressure Rollers A dual groove feed roller is supplied as standard It can...

Page 30: ...mixed gas Ar CO2 or Trimix He Ar CO2 Aluminium and silicon bronze use pure argon gas Ar In the sMIG mode see section sMIG mode in the CONTROL PANEL chapter the optimal welding arc with the gas you use...

Page 31: ...ESAB EMS215IC EMP215IC Manual 0463 413 001 OPERATION 3 9...

Page 32: ...and welding current can be selected Use the graphs below to determine the correct duty cycle for a given welding current 0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100 110 120 130...

Page 33: ...are similar If a welding process has a blue indication then a remote trigger devise needs to be used when that process is selected If the process has Red Orange color then it will be live hot as soon...

Page 34: ...3 Material thickness 4 Wire feed speed 5 Voltage trim 6 Dialogue box 7 Weld bead shape Must be in Advanced Settings 1 2 3 4 5 6 7 NOTE When a parameter setting is being changed the background and tex...

Page 35: ...on 3 Wire feed speed 4 Voltage 5 Dialogue box 1 2 3 4 5 3 11 6 Stick mode SMAW EMP 215ic only 1 Home screen 2 Information 3 Amperage 4 Voltage OCV or arc 6 Dialogue box 1 2 3 5 6 5 Stick mode ON OFF 4...

Page 36: ...11 8 Settings 1 Language 2 Inch Metric 3 Basic Advanced 4 Reset mode 5 Information 6 Dialog box Home screen 7 1 2 3 4 5 6 7 3 11 9 User Manual Information 1 Operation information 2 Maintenance inform...

Page 37: ...age ESD damage can be prevented by awareness If static electricity is prevented from building up on you or on anything at your work station then there cannot be any static discharges Nonconductive mat...

Page 38: ...ESAB EMS215IC EMP215IC 4 2 SERVICE INSTRUCTIONS Manual 0463 413 001 This Page Intentionally Blank...

Page 39: ...ection auxiliary power supply full bridge inverter main transformer secondary inductor and secondary diode modules Control module The control board with a microprocessor that monitors and controls the...

Page 40: ...R BR1 BR2 BOOST PFC INVERTER Q3 Q4 Q6 Q7 INDUCTOR L1 POWER BOARD PCB2 15AP1 INTERNAL POWERSUPPLY CIRCUIT BREAKER ON OFF SWITCH CB1 SW1 120Vac 230Vac 10 50 60Hz FERRITE RINGS L3 L4 L5 L6 DMA SECONDARY...

Page 41: ...ESAB EMS215IC EMP215IC Manual 0463 413 001 POWER SUPPLY INTRODUCTION 5 3 This Page Intentionally Blank...

Page 42: ...ESAB EMS215IC EMP215IC 5 4 POWER SUPPLY INTRODUCTION Manual 0463 413 001 A 12892_AA 5 04 System Schematic for CSA Systems...

Page 43: ...ESAB EMS215IC EMP215IC Manual 0463 413 001 POWER SUPPLY INTRODUCTION 5 5 A 12892_AA...

Page 44: ...ESAB EMS215IC EMP215IC 5 6 POWER SUPPLY INTRODUCTION Manual 0463 413 001 5 05 System Schematic for CE Systems A 13146_AA...

Page 45: ...ESAB EMS215IC EMP215IC Manual 0463 413 001 POWER SUPPLY INTRODUCTION 5 7 A 13146_AA...

Page 46: ...7 8 9 10 7 11 Item Description Designator 1 Control PCB PCB 20AP1 2 Circuit Breaker CB1 3 On Off Switch SW 1 4 Fan 1 and Fan 2 M1 and M2 5 PFC Inductor L1 6 Output Diode PCB PCB4 7 Main Transformer T...

Page 47: ...pcb CN5 CN6 CN7 CN8 Check Optical sensor power pcb U12 Operate the system at the specified duty cycle 2 Err 002 Warning TEMPERA TURE FAULT Output diode Temperature fault Analog tempera ture sensor UI...

Page 48: ...y resets and this was not confirmed by the system Possible software bug or communication protocol error UI Display CN8 Ctrl PCB Should not experience this error in the field Causes are poor communi ca...

Page 49: ...ower ON If fails 2 times reading from valid sector 1 15 then Display this for 3 sec UI Display Check if the SPI IC gone bad Console errors 1 N A N A Flash CRC Error Internal to U15 MCU processor the b...

Page 50: ...Q7 Collector Q6 Collector Q3 Collector D49 D50 Cathode Q19 Collector A series of quick checks can be done to verify Main Power components are not shorted Remove the right side panel to access this are...

Page 51: ...ow a reading other than as indicated above then the ten components will have to be checked to identify the failed component s The following images show the previous steps listed In the oval you will s...

Page 52: ...all three leads b Check for short between Line 1 and Line 2 c Check for short between both Line 1 and Line 2 leads to GROUND lead Replace MAINS POWER CABLE PLUG if fault is found The following image s...

Page 53: ...e oval you will see the step number and below that the meter reading you should see 2b ON Shorted OFF Open 2c Open Infinity 2b ON Shorted OFF Open 2c Open Infinity 3 CB1 CIRCUIT BREAKER a If breaker i...

Page 54: ...iode Check on both Bridge rectifiers If either one has open or shorted diode replace both BR1 BR2 The following image shows the previous step listed In the oval you will see the step number and below...

Page 55: ...e continuity between BR1 or BR2 Positive Terminals and BUS terminals on POWER PCB2 for 23 ohms If open or shorted replace POWER PCB2 The following image shows the previous step listed In the oval you...

Page 56: ...d on BR2 terminal for forward biased diode 0 30 00 7VDC If open or shorted replace POWER PCB2 See following illustration 9 C35 38 Disconnect wire from POWER PCB2 from PFC terminal a With meter in resi...

Page 57: ...iode reading between Heatsink Terminals Q7 and BR2 terminal d With meter in diode setting check for diode reading between Heatsink Terminal Q6 and either end of R88 or R89 on Power PCB2 If open or sho...

Page 58: ...ad on WELD OUT PUT terminal check for forward biased diode drop reading 2 With positive meter lead on OUTPUT WELD terminal and with negative meter lead on WELD OUTPUT terminal check for reverse biased...

Page 59: ...04 Initial Power Up Test Using Generators or Extension cords If a problem is encountered while running on a generator or while using an extension cord note the problem and then plug the unit directly...

Page 60: ...D44 UI COM Flashing D45 uP OK ON D85 10 3_VB OK ON D86 5V_10 OK ON D87 MIG SOL ON OFF D88 TRIGGER ON OFF D89 TIG SOL OFF D90 FAN ON OFF If the unit does not perform as indicated proceed to subsection...

Page 61: ...D40 24V_1 LOW OFF D43 BUS V ERR OFF D44 UI COM ON D45 uP OK ON D85 10 3_VB OK ON D86 5V_10 OK ON D88 TRIGGER ON OFF D89 TIG SOL OFF D90 FAN ON OFF 1 Use EN3 ENCODER to select GTAW LIFT TIG process 2...

Page 62: ...RR OFF D44 UI COM ON D45 uP OK ON D85 10 3_VB OK ON D86 5V_10 OK ON D87 MIG SOL ON OFF D88 TRIGGER ON OFF D89 TIG SOL OFF D90 FAN ON OFF 1 With gun in position activate MIG gun trigger On CONTROL PCB3...

Page 63: ...lem Open fuse tripped breaker Measure voltage at mains outlet b Defective MAINS POWER CABLE PLUG Measure voltage to SW1 Replace if defective c Defective SW1 ON OFF SWITCH Measure voltage from SW1 Repl...

Page 64: ...for the PFC Transistor the other on the heatsink for the switching transistors Q3 4 6 7 The Third is located on the Main Transformer T1 The forth is on the heatsink on the OUTPUT DIODE PCB4 When thes...

Page 65: ...413 001 TROUBLESHOOTING 6 19 The following image shows the previous steps 4a and 4b listed In the oval you will see the step number and below that the meter reading you should see 4a Approximately 12...

Page 66: ...5VDC If both of these measurements are correct replace CONTROL PCB3 d Defective POWER PCB2 1 On the CONTROL PCB3 Connector CN17 Measure from pin 6 to pin 4 The voltage should be approx 1 8VDC If volta...

Page 67: ...ESAB EMS215IC EMP215IC Manual 0463 413 001 TROUBLESHOOTING 6 21 4c 1 Approximately 1 8VDC 4c 2 0 25 VDC CN17 CN19 3 4 6 3 4 6 4d 1 Approximately 1 8VDC 4d 2 0 25 VDC...

Page 68: ...PCB Test see subsection 6 06 b Defective CS1 Current Sensor Perform CS 1 Test see subsection 6 06 c Defective CONTROL PCB3 d Defective USER INTERFACE PCB1 5 ERROR MESSAGE VOLTAGE FEEDBACK FAULT a Open...

Page 69: ...on b Control PCB3 Check that LED D87 turns on when trigger is activated If it is not on replace PCB3 c Defective GS1 GAS SOLENOID Gas valve supply voltage is 24vdc but if you measure it with true RMS...

Page 70: ...UBLESHOOTING Manual 0463 413 001 The following image shows the previous steps 2c 3a and 3b listed In the oval you will see the step number and below that the meter reading you should see CN10 2c 5 VDC...

Page 71: ...18VDC_PRI OK ON 3 Measure for 400VDC buss voltage between terminals LINE to LINE If problem is found remove power disconnect the harness connectors from CONTROL PCB3 connectors CN1 CN2 and CN4 Retest...

Page 72: ...1 Connector CN10 ENCODER PCB6 to PCB1 Connector CN11 ENCODER PCB7 to PCB1 Connector CN12 1 For the ENCODER PCB under test disconnect the harness connector from PCB1 At the mating con nector at PCB1 me...

Page 73: ...ce OUTPUT DIODE PCB4 The following image shows the previous steps listed In the oval you will see the step number and below that the meter reading you should see 2 0 3 0 7 VDC 3 Open Infinity CURRENT...

Page 74: ...G Manual 0463 413 001 The following image shows the previous steps listed In the oval you will see the step number and below that the meter reading you should see 4c 1 0 5VDC 100A with load 4c 2 0 0 V...

Page 75: ...e sockets are damaged or retracted into the connector body preventing a good electrical connection a If LED D88 does turn on and no arc will ignite in GTAW process when the torch electrode is touched...

Page 76: ...63 413 001 Control PCB D90 FAN ON D86 5V_1 OK D35 PS_OK D88 TRIGGER D40 24V_1 LOW D43 BUSS V ERROR D44 UI COM D45 P OK D33 PWM D89 TIG SOL ON D87 MIG SOL ON D85 10 3_VB OK R642 WIRE FEED SPEED CALIBRA...

Page 77: ...ESAB EMS215IC EMP215IC Manual 0463 413 001 TROUBLESHOOTING 6 31 Main PCB D42 24V_SEC OK D53 18V_PRI OK PFC Bus R89 R88 TRANSF2 TRANSF1 Line 1 Line 2 Line Line CN2 CN4 CN1 CN8 CN7 CN9 Output Diode PCB...

Page 78: ...ESAB EMS215IC EMP215IC 6 32 TROUBLESHOOTING Manual 0463 413 001 This Page Intentionally Blank...

Page 79: ...out repair work by non authorized service centers will invalidate the warranty WARNING Disconnect power before performing maintenance NOTE Perform maintenance more often during severe dusty conditions...

Page 80: ...outlet 5 Inspect if the inlet wire guide 4 outlet wire outlet 2 or the feeder roller 3 are worn and need replace ment See appendix WEAR PARTS for ordering numbers of parts 6 Remove and clean the feede...

Page 81: ...CEMENT PARTS 8 01 Introduction System Replacement numbers Ordering no Model Note 0558 102 239 EM 215ic Wire Reel Size 4 8 100 200 mm CSA Bayonet 0558 102 240 EMP 215ic Wire Reel Size 4 8 100 200 mm CS...

Page 82: ...Hinge 4 1 Nut M4 0 7 mm 5 1 0558 102 407 Hinge pin 6 1 0558 102 398 Side frame Left 7 1 Nut M6 1 mm 8 1 0558 102 399 Handle 9 2 0558 102 400 Top handle 10 1 0558 102 397 Side frame right 11 4 Screw M6...

Page 83: ...8 1 0558 102 437 Lens assembly kit 9 2 0558 102 438 Lens bezel Including decal 10 1 0558 102 440 Small knob 11 1 0558 102 441 Large knob 12 1 0558 102 418 50mm female Dinse 13 1 0558 102 419 Polarity...

Page 84: ...8 102 437 Lens assembly kit 9 2 0558 102 438 Lens bezel Including decal 10 1 0558 102 440 Small knob 11 1 0558 102 441 Large knob 12 1 0558 102 418 50mm female Dinse 13 1 0558 102 419 Polarity changeo...

Page 85: ...n Notes 1 1 0558 102 416 Circuit Breaker CB1 2 1 0558 102 415 ON OFF Switch SW1 3 1 0558 102 427 Control PCB PCB3 20AP1 4 1 0558 102 426 Power PCB Assembly PCB2 15AP1 5 1 0558 102 420 Fan 1 2 M1 M2 EV...

Page 86: ...guide MS SS Flux Cored 0 024 0 6 mm 2 0558 102 328 Wire inlet guide MS SS Flux Cored 0 024 0 030 0 035 0 045 0 6 mm 0 8 mm 0 9 mm 1 2 mm 3 0558 102 334 Key drive shaft N A N A 4 7977036 Feed roll V gr...

Page 87: ...Cored 0 6 mm 0 8 mm 0 9 mm 1 2 mm 0 023 0 030 0 035 0 045 3 0558 102 457 Key drive shaft N A N A 4 0367 556 001 Feed roll V groove Fe SS Flux Cored 0 6 mm 0 8 mm 0 023 0 030 0367 556 002 Feed roll V...

Page 88: ...ESAB EMS215IC EMP215IC 8 8 REPLACEMENT PARTS Manual 0463 413 001 This Page Intentionally Blank...

Page 89: ...t is on Wait 40 seconds after removing power before handling 9 02 User Interface TFT Display Assembly Removal Read and follow safety information in Section 1 before proceeding with disassembly Follow...

Page 90: ...e Control PCB Not shown 3 Remove the four 4 screws on the inside of the unit that secure the User Interface TFT Display in place You will need to access these from both sides of the unit 4 4 Remove th...

Page 91: ...rcuit Board Unplug the unit before beginning disassembly procedure 1 Remove eight 8 screws securing the power side cover and frame to the power supply 8 2 Take photos or notes on all the harness conne...

Page 92: ...ormer and PFC Inductor connections along the bottom of the Power PCB Assembly 3 Disconnect each of these from the Power PCB Assembly Not shown CAUTION Keep these 4 screws connecting the wires from alo...

Page 93: ...IFIER BR1 BR2 BOOST PFC INVERTER Q3 Q4 Q6 Q7 INDUCTOR L1 POWER BOARD PCB2 15AP1 INTERNAL POWERSUPPLY CIRCUIT BREAKER ON OFF SWITCH CB1 SW1 120Vac 230Vac 10 50 60Hz FERRITE RINGS L3 L4 L5 L6 DMA SECOND...

Page 94: ...ESAB EMS215IC EMP215IC A 2 APPENDIX Manual 0463 413 001 APPENDIX 2 CSA SYSTEM SCHEMATIC 115 230V UNITS A 12892_AA...

Page 95: ...ESAB EMS215IC EMP215IC Manual 0463 413 001 APPENDIX A 3 A 12892_AA...

Page 96: ...ESAB EMS215IC EMP215IC A 4 APPENDIX Manual 0463 413 001 APPENDIX 3 CE SYSTEM SCHEMATIC 115 230V UNITS A 13146_AA...

Page 97: ...ESAB EMS215IC EMP215IC Manual 0463 413 001 APPENDIX A 5 A 13146_AA...

Page 98: ...clamp on ammeter read the actual output amperage on the positive output cable Adjust Trimpot R34 on the Control PCB3 until the measured output amperage on the clamp on meter reads 180A 3A 0A Next set...

Page 99: ...ESAB EMS215IC EMP215IC Manual 0463 413 001 APPENDIX A 7 This Page Intentionally Blank...

Page 100: ...ESAB EMS215IC EMP215IC A 8 APPENDIX Manual 0463 413 001 Revision History Date Rev Description Dec 20 2016 AA Manual release...

Page 101: ...This Page Intentionally Blank...

Page 102: ...1 50 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 Te...

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