ESAB EMP 255ic Instruction Manual Download Page 59

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ROLLER & WIRE-GUIDE SELECTION

0463 605 001

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Summary of Contents for EMP 255ic

Page 1: ...Instruction manual 0463 605 001 GB 20181217 Valid for serial no 730 xxx xxxx 735 xxx xxxx EMP 255ic EMP 320ic...

Page 2: ......

Page 3: ...MAW Stick 400 V 18 5 5 2 GMAW MIG 400 V 18 5 5 3 GTAW TIG 400 V 19 5 6 Duty cycle 19 5 7 Removing installing bobbin 20 5 8 Removing installing wire 21 5 8 1 Removing wire 23 5 8 2 Installing wire 25 5...

Page 4: ...l information 39 6 15 Icon reference guide 40 7 MAINTENANCE 43 7 1 Routine maintenance 43 7 2 Wire feeder assembly maintenance 43 7 2 1 Wire feeder assembly cleaning 44 7 3 EMP unit power side mainten...

Page 5: ...y precautions must meet the requirements that apply to this type of equipment The following recommendations should be observed in addition to the standard regulations that apply to the workplace All w...

Page 6: ...ELECTRIC AND MAGNETIC FIELDS Can be dangerous to health Welders having pacemakers should consult their physician before welding EMF may interfere with some pacemakers Exposure to EMF may have other he...

Page 7: ...uipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There may be potential difficulties in ensuring electromagnetic...

Page 8: ...eters suitable for both newly trained and intermediate level users For more advanced users any number of functions could be introduced and customized to give maximum flexibility ESAB accessories for t...

Page 9: ...100 duty cycle 180 A 27 0 V 130 A 25 0 V Permissible load at TIG 40 duty cycle 320 A 23 0 V 255 A 30 0 V 60 duty cycle 265 A 21 0 V 215 A 19 0 V 100 duty cycle 220 A 19 0 V 170 A 17 0 V Permissible l...

Page 10: ...ut at a certain load without overloading The duty cycle is valid for 40 C 104 F Enclosure class The IP code indicates the enclosure class i e the degree of protection against penetration by solid obje...

Page 11: ...ference 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 152 mm 6 in B 100 mm 4 in C...

Page 12: ...ibution network operator if necessary that the equipment is connected only to a supply with a short circuit power greater than or equal to Sscmin Refer to the technical data in the TECHNICAL DATA chap...

Page 13: ...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 corre...

Page 14: ...tart the equipment NOTE When moving the equipment use intended handle Never pull the cables WARNING Rotating parts can cause injury take great care WARNING Electric shock Do not touch the workpiece or...

Page 15: ...election 8 Positive output 2 Knob for voltage selection 9 Polarity changeover cable 3 Main knob for navigation and parameter selection 10 Display 4 Gas outlet for TIG spool torch 11 Gas inlet for MIG...

Page 16: ...g and return cables a negative terminal 7 and a positive terminal 8 5 2 1 For MIG MMA process For MIG MMA process the output to which the welding cable is connected depends on the type of electrode Re...

Page 17: ...e connection for the torch return cable Check the recommended polarity for the welding wire you want to use Refer to electrode packaging for information relating to the correct electrode polarity The...

Page 18: ...5 OPERATION 0463 605 001 18 ESAB AB 2018 5 5 1 SMAW Stick 400 V V Output voltage A Welding current Amps 5 5 2 GMAW MIG 400 V V Output voltage A Welding current Amps...

Page 19: ...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 ever...

Page 20: ...braking value working against the wire feed motor and the pull of the roller feed wheels Tighten the bolt A see illustration below until spool does not free wheel Remove Install the bobbin as shown in...

Page 21: ...may be molded plastic form Either mounts the same way as shown 5 8 Removing installing wire NOTE If installing aluminum wire see Welding with aluminum wire section The EMP 255ic or the EMP 320ic will...

Page 22: ...bin 3 Wire feed assembly 2 Gas valves WARNING Do not place or point the torch near the face hand or body as this may result in injury NOTE Make sure the correct wire feed rollers are selected NOTE Rem...

Page 23: ...3 ESAB AB 2018 5 8 1 Removing wire 1 Disconnect the electrical power source from the unit 2 Open the wire bobbin side door of the EMP unit 1 Wire bobbin 2 Wire feed assembly 3 Locate the wire feed ass...

Page 24: ...nravel from the bobbin after cutting it loose Secure the cut end of the wire to the bobbin if any wire is left on the bobbin to prevent the wire from unraveling from the bobbin 6 If wire remains in th...

Page 25: ...tput end about three centimeters 3 cm 7 Close the tension arm on to the wire in its groove on the wire feed rollers and secure with the tension arm Verify that the wire is in its groove and not floati...

Page 26: ...ot need to be connected for this procedure 1 Turn power to the unit ON 2 Start by making sure that the wire moves smoothly through the wire guide CAUTION It is important that the feed pressure is not...

Page 27: ...t 3 Open the door on the wire bobbin side of the EMP unit 4 Release the tensioning arm by pulling it up out of its detent and rotating it toward you see Figure 5 Since the wire feed pressure must be d...

Page 28: ...5 OPERATION 0463 605 001 28 ESAB AB 2018 Figure 5 Drive gear with woodruff key on motor shaft 1 Drive gear CAUTION Avoid removing drive gear see 1 in Figure 6 Risk loosing drive shaft woodruff key...

Page 29: ...stalling wire feed rollers CAUTION When installing the wire feed rollers avoid and do not force installing a roller if either wire guide s position interferes Slide the offending wire guide slightly t...

Page 30: ...2 Tighten the drive roller retaining screw by turning it in the clockwise direction Hand tight is sufficient 3 The wire must be installed through the wire feed assembly see Installing wire subsection...

Page 31: ...guides Perform wire feed roller removal and later in this procedure roller install steps See Removing Installing wire feed rollers section when referred in the steps below 1 Select and obtain the corr...

Page 32: ...ing 5 12 1 Output wire guide removal installation 1 Loosen the output wire guide thumb screw 1 Input wire guide 4 Output wire guide thumb screw 2 Center wire guide 5 Center wire guide set screw 3 Outp...

Page 33: ...the way a See steps 8 11 in Removing Installing wire feed rollers section for installing 5 12 3 Adjusting wire guides 1 Verify center wire guide tube has clearance from each feed roller The center wi...

Page 34: ...or on the wire bobbin side of the EMP unit 5 13 Overheating protection CAUTION This unit is equipped with overheating protection for its power supply The welding power source has overheating protectio...

Page 35: ...5 OPERATION 0463 605 001 35 ESAB AB 2018 2 stroke A Gas pre flow B Slope up C Slope down D Gas post flow 4 stroke A Gas pre flow B Slope up C Slope down D Gas post flow...

Page 36: ...power on has completed the main menu appears on the user interface 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 Selectio...

Page 37: ...gue box 6 5 Manual MIG mode Basic 1 Home screen 2 Information 3 Memory 4 Material selection 5 Wire feed speed 6 Voltage adjustment 7 Dialogue box 6 6 Manual MIG mode Advanced 1 Home screen 2 Informati...

Page 38: ...de Basic 1 Home screen 2 Information 3 Memory 4 Amperage adjustment 5 Power supply output voltage Open Circuit Voltage 6 Dialogue box 7 Arc ON OFF Blue changes to orange when output is hot 6 10 MMA mo...

Page 39: ...Lift TIG mode Advanced 1 Home screen 2 Information 3 Memory 4 Parameter 5 Amperage 6 Dialogue box 6 13 Settings 1 Reset mode 2 Inch Metric 3 Basic Advanced 4 Language 5 Information 6 Home screen 7 Di...

Page 40: ...eed MIG Torch Spot time on adjustment Parameters Flux cored Parameters Manual MIG Percent MMA Pre flow The time the shielding gas stays on before the welding arc is started Smart MIG Post flow The tim...

Page 41: ...dle 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 t...

Page 42: ...stabilize the arc and reduce spatter when in the short circuit process Volts Memory able to save welding programs for a specific application Language selection Stick electrode choice Unit of Measure U...

Page 43: ...t damaged The nozzle on the torch is clean and does not contain any debris NOTE Perform maintenance more often during severe dusty conditions NOTE There are no user serviceable parts inside of the pow...

Page 44: ...TE Use the following three illustrations for reference during this procedure 1 Wire from bobbin 6 Output wire guide inside of Euro adapter assy 2 Input wire guide 7 Wire path through assembly 3 Center...

Page 45: ...7 MAINTENANCE 0463 605 001 45 ESAB AB 2018 1 Pressure rollers 2 Wire feed rollers 1 Tension arm 2 Wire feed assembly cover...

Page 46: ...Clean the wire feed rollers with a soft brush 7 Clean the pressure rollers attached to the tension arm with a soft brush CAUTION Do not loosen any of the set screws for any of the three components li...

Page 47: ...it liner with a Teflon torch conduit liner Model EMP 255ic uses torch model PSF 305 Model EMP 320ic uses torch model PSF 305 7 4 1 Torch liner cleaning 1 Disconnect the power source from the input pow...

Page 48: ...areas where drafts which would disburse the shielding gas are common Make sure the work piece is clean with no oil or grease on the surface before welding Wire feeding problems Make sure the wire spoo...

Page 49: ...les are correctly connected Check that the correct current value is set Check the input power supply fuses The overheating protection trips frequently Make sure that you are not exceeding the recommen...

Page 50: ...actory reset and this was not confirmed by the system 012 C Communication Link Down no communication between UI and Ctrl PCB at CN6 013 C Low Internal Power Supply IPS Voltage Error 24 V IPS is less t...

Page 51: ...c are designed and tested in accordance with international standards IEC EN 60974 1 IEC EN 60974 5 IEC EN 60974 7 IEC EN 60974 10 IEC EN 60974 12 and IEC EN 60974 13 It is the obligation of the author...

Page 52: ...DIAGRAM 0463 605 001 52 ESAB AB 2018 DIAGRAM Functional Block Diagram Functional Diagram of Power Circuit...

Page 53: ...DIAGRAM 0463 605 001 53 ESAB AB 2018...

Page 54: ...2018 ORDERING NUMBERS Ordering no Description Note 0700 300 992 EMP 255ic Bobbin Size 100 300 mm 4 12 in Euro Connector 0700 300 991 EMP 320ic Bobbin Size 100 300 mm 4 12 in Euro Connector 0463 606 00...

Page 55: ...E GUIDE TUBE 1 4 See Roller wire guide selection section in Appendix OUTPUT WIRE GUIDE TUBE 1 5 0558 102 609 MOTOR GEAR SHAFT WOODRUFF KEY 1 6 0558 102 597 INLET QUAD WF 1 7 0558 102 605 DRIVEN GEAR A...

Page 56: ...rch c w 8 pin plug W4 014 450 Foot control Contactor on off and current control with 4 5 m 14 74 ft cable and 8 pin male plug 0700 300 872 Rebel single cylinder trolley Accommodates 1 228 6 mm 9 in di...

Page 57: ...ARTS 0463 605 001 57 ESAB AB 2018 REPLACEMENT PARTS Item Ordering no Description 1 0349 312 105 Gas hose 4 5 m 15 ft 2 0700 006 901 Return welding cable kit 3 m 10 ft 3 0700 006 900 MMA welding cable...

Page 58: ...ed in package ACCESSORY optional size included with each model 255 or 320 unit Wire Guide Selection Item Ordering no Description Values Inner diameter ID of tubes Comment Output wire guide tube for st...

Page 59: ...ROLLER WIRE GUIDE SELECTION 0463 605 001 59 ESAB AB 2018...

Page 60: ...For contact information visit esab com ESAB AB Lindholmsall n 9 Box 8004 402 77 Gothenburg Sweden Phone 46 0 31 50 90 00 http manuals esab com...

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